Systems and methods for manufacture of modular concrete building blocks and modular buildings

Abstract

Modular concrete building blocks can be manufactured using an apparatus comprising an expandable and collapsible inner form, a deconfigurable outer form, and a transport platform. The outer form can surround the inner form to form a cavity between the outer form and the expanded inner form, with the transport platform providing a floor of the cavity. Reinforcements and utility conduits may be placed in the cavity. Concrete is poured into the cavity and cured to form a modular concrete building block. Upper and lower connector channels are formed in order to secure building blocks together to form a building.

Description

SYSTEMS AND METHODS FOR MANUFACTURE OF MODULAR CONCRETE BUILDING BLOCKS AND MODULAR BUILDINGSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority Canadian Patent Application No. 3,245,236 filed on May 31, 2024 and to Canadian Patent Application No. 3,260,979 filed on December 30, 2024.TECHNICAL FIELD

[0002] The present disclosure relates to concrete fabrication, and in particular to concrete fabrication for use in modular construction.BACKGROUND

[0003] “Buy land, they’re not making it anymore.” This quotation, attributed to Mark Twain, still rings true today. In both Canada and the United States, housing affordability presents a serious problem. For example, the National Bank of Canada released a Housing Affordability Monitor for the fourth quarter of 2023, showing that an annual household income of more than $260,000 would be required to afford a representative (noncondominium) home in Toronto. According to the same report, an annual household income of nearly $180,000 would be required to afford a representative (noncondominium) home in Ottawa / Gatineau. These income requirements would place a home out of reach for many middle-class families.SUMMARY

[0004] In one aspect, an apparatus for casting a hollow concrete block is provided. The apparatus comprises an inner form, wherein the inner form has an inner form casting configuration and an inner form demold configuration, a movable transport platform having an opening configured to be arranged in registration with the inner form, and an outer form, wherein the outer form comprises at least one outer form wall and has an outer form casting configuration in which the outer form wall(s) form an open-topped enclosure. When the transport platform is positioned with the opening arranged in registration with the inner form, when the inner form is in the inner form casting configuration, the inner form is extended to form a roofed column extending upwardly through the inner form opening of the transport platform, and when the inner form is in the inner form demoldconfiguration, the inner form is retracted whereby the transport platform is movable past the retracted inner form in at least a first direction. When the transport platform is positioned with the opening arranged in registration with the inner form and the outer form is in the outer form casting configuration and the inner form is in the inner form casting configuration, the outer form wall(s) extend upwardly beyond a roof of the inner form, wherein the outer form wall(s) surround and are spaced from the inner form and the outer form wall(s), the inner form and the transport platform cooperate to define a cavity between the outer form and the inner form with the floor of the cavity formed by the transport platform, such that the cavity is adapted to receive and contain concrete surrounding the inner form. The outer form can be deconfigured from the outer form casting configuration so that the outer form wall(s) are clear of the transport platform and permit movement of the transport platform in at least the first direction.

[0005] In some embodiments, the inner form is an erectable superstructure having a superstructure roof and first and second sets of opposed substantially parallel superstructure walls, where the inner form casting configuration is an erected configuration in which the superstructure walls are upwardly extended and the inner form demold configuration is a collapsed configuration in which the superstructure walls are downwardly collapsed such that the superstructure walls and the superstructure roof are non-obstructing to movement of the transport platform in the first direction. The first set of opposed superstructure walls may be a set of opposed collapsible concertina walls coupled to the superstructure roof, and the second set of opposed superstructure walls may be a set of opposed substantially rigid non-collapsing panel walls each being movable between a recumbent position and an upright position. In such an embodiment, when the inner form is in the erected configuration, the concertina walls are extended into a substantially planar configuration and the panel walls are in the upright position and extend substantially orthogonal to the concertina walls, and when the inner form is in the collapsed configuration, the concertina walls are collapsed upon themselves beneath the superstructure roof and the panel walls are in the recumbent position to overlie the superstructure roof.

[0006] In some embodiments, at least one scissor lift is disposed beneath the superstructure roof and configured to selectively raise and lower the superstructure roof. In some such embodiments, raising the superstructure roof extends the concertina wallsinto the substantially planar configuration, and lowering the superstructure roof collapses the concertina walls upon themselves beneath the superstructure roof. In particular instances of such embodiments, the panel walls are pivotably movable between the recumbent position and the upright position, and a respective piston-cylinder assembly acts between an inner form base and each of the panel walls to selectively pivot the panel walls between the recumbent position and the upright position. The superstructure roof may have a pair of opposed piston-cylinder apertures at edges thereof adjacent the panel walls to enable the superstructure roof to move past the piston-cylinder assemblies.

[0007] The transport platform may be a wheeled transport platform.

[0008] In another aspect, a method for casting a hollow concrete block is described. The method comprises placing an inner form into an inner form casting configuration, wherein the inner form is surrounded by a movable transport platform having an opening arranged in registration with the inner form, and wherein in the inner form casting configuration the inner form defines a roofed column extending upwardly through the inner form opening. The method further comprises placing reinforcements around the inner form, placing an outer form comprising at least one outer form wall into an outer form casting configuration in which the outer form wall(s) form an open-topped enclosure disposed roundabout the transport platform. When the inner form is in the inner form casting configuration and the outer form is in the outer form casting configuration, the outer form wall(s) extend upwardly beyond the roofed column and surround and are spaced from the roofed column, and the outer form wall(s), the roofed column and the transport platform cooperate to define a cavity between the outer form and the inner form, with a floor of the cavity formed by the transport platform and the reinforcements disposed within the cavity. The method further comprises pouring concrete into the cavity so that the concrete surrounds the roofed column while being contained by the outer form and the floor, and curing the concrete to form the hollow concrete block, which rests upon the transport platform, wherein the curing is sufficient for the concrete to have set so that the concrete can be transported without damage. The method further comprises retracting the inner form into an inner form demold configuration wherein the transport platform and the hollow concrete block resting thereon are movable past the retracted inner form in at least a first direction, and deconfiguring the outer form from the outer form casting configuration so that the outer form wall(s) are clear of the transport platform and thehollow concrete block resting thereon and permit movement of the transport platform and the hollow concrete block resting thereon in at least the first direction. The method yet further comprises moving the transport platform with the hollow concrete block thereon past the inner form.

[0009] In some preferred embodiments, the method further comprises, before pouring the concrete into the cavity, installing reinforcements in the cavity.

[0010] In some embodiments, the inner form is an erectable superstructure having a superstructure roof and first and second sets of opposed substantially parallel superstructure walls, the inner form casting configuration is an erected configuration in which the superstructure walls are upwardly extended, and the inner form demold configuration is a collapsed configuration in which the superstructure walls are downwardly collapsed such that the superstructure walls and the superstructure roof are non-obstructing to movement of the transport platform in the first direction. In some such embodiments, the first set of opposed superstructure walls is a set of opposed collapsible concertina walls coupled to the superstructure roof, and the second set of opposed superstructure walls is a set of opposed substantially rigid non-collapsing panel walls each being movable between a recumbent position and an upright position. When the inner form is in the erected configuration, the concertina walls are extended into a substantially planar configuration, and the panel walls are in the upright position and extend substantially orthogonal to the concertina walls. When the inner form is in the collapsed configuration, the concertina walls are collapsed upon themselves beneath the superstructure roof and the panel walls are in the recumbent position to overlie the superstructure roof.

[0011] In some embodiments, at least one scissor lift is disposed beneath the superstructure roof and configured to selectively raise and lower the superstructure roof.

[0012] In some embodiments, the concertina walls are coupled to the superstructure roof whereby raising the superstructure roof extends the concertina walls into the substantially planar configuration, and lowering the superstructure roof collapses the concertina walls upon themselves beneath the superstructure roof. In particular embodiments, the panel walls are pivotably movable between the recumbent position and the upright position, and a respective piston-cylinder assembly acts between an inner form base and each of thepanel walls to selectively pivot the panel walls between the recumbent position and the upright position. The superstructure roof may have a pair of opposed piston-cylinder apertures at edges thereof adjacent the panel walls to enable the superstructure roof to move past the piston-cylinder assemblies.

[0013] In another aspect, an erectable and collapsible superstructure is described. The superstructure comprises a superstructure roof, a set of opposed collapsible concertina walls coupled to the superstructure roof, and a set of opposed substantially rigid noncollapsing panel walls each being movable between a recumbent position and an upright position. The superstructure has an erected configuration and a collapsed configuration. When the superstructure is in the erected configuration, the concertina walls are extended into a substantially planar configuration, and the panel walls are in the upright position and extend substantially orthogonal to the concertina walls. When the inner form is in the collapsed configuration, the concertina walls are collapsed upon themselves beneath the superstructure roof, and the panel walls are in the recumbent position and overlie the superstructure roof. In some embodiments, at least one scissor lift may be disposed beneath the superstructure roof and configured to selectively raise and lower the superstructure roof.

[0014] In some embodiments, the concertina walls are coupled to the superstructure roof whereby raising the superstructure roof extends the concertina walls into the substantially planar configuration, and lowering the superstructure roof collapses the concertina walls upon themselves beneath the superstructure roof.

[0015] In some embodiments, the panel walls are pivotably movable between the recumbent position and the upright position, and a respective piston-cylinder assembly acts between an inner form base and each of the panel walls to selectively pivot the panel walls between the recumbent position and the upright position.

[0016] The superstructure roof may have a pair of opposed piston-cylinder apertures at edges thereof adjacent the panel walls to enable the superstructure roof to move past the piston-cylinder assemblies.

[0017] In yet another aspect, a precast modular concrete building block is described. The modular concrete building block comprises an internally reinforced monolithic concreteenclosure defining an interior volume and having at least one internally reinforced concrete wall at least partially circumvallating the interior volume, and an internally reinforced concrete roof coupled to the concrete wall(s). An underside of the concrete enclosure opposite the concrete roof is open into the interior volume. At least one utility conduit is embedded within the at least one concrete wall. At least one interior connection for the at least one utility conduit is accessible from within the interior volume, and at least one exterior connection for the at least one utility conduit is accessible from outside of the interior volume. The utility conduit(s) may be comprised of one or more of at least one HVAC duct, at least one ventilation duct, at least one electrical conduit, at least one plumbing supply pipe, at least one plumbing drain pipe, and at least one drain vent pipe. Utility conduit(s) may also be embedded within the concrete roof.

[0018] In preferred embodiments, there is at least one opening through the internally reinforced concrete wall(s) into the interior volume. In some embodiments, the opening(s) through the internally reinforced concrete wall(s) may comprise at least one doorway aperture formed in the internally reinforced concrete wall(s). In some embodiments, the opening(s) through the concrete wall(s) may comprise at least one window aperture formed in the internally reinforced concrete wall(s). In some embodiments, the opening(s) through the internally reinforced concrete wall(s) may comprise a discontinuity in the at least one internally reinforced concrete wall, and in some such embodiments a building may comprise at least two such building blocks arranged adjacent to one another with their respective discontinuities arranged in registration with one another.

[0019] In some embodiments, a building comprising at least two modular concrete building blocks, each as described above, wherein an upper one of the two modular concrete building blocks is secured atop a lower one of the two modular concrete building blocks, and at least one respective exterior connection for the utility conduit(s) embedded within the internally reinforced concrete wall(s) of the upper one of the two modular concrete building blocks is in registration with and coupled to a corresponding at least one respective exterior connection for the utility conduit(s) embedded within the at least one internally reinforced concrete wall of the lower one of the two modular concrete building blocks. In such a building, the upper one of the two modular concrete building blocks may be secured atop the lower one of the two modular concrete building blocks by aplurality of anti-slip connectors fitted into upper connector channels formed in the internally reinforced concrete roof of the lower one of the modular concrete building blocks and further fitted into lower connector channels formed in the distal edge of the at least one internally reinforced concrete wall of the upper one of the modular concrete building blocks, with the lower connector channels in registration with the upper connector channels.

[0020] In some embodiments, a height of the concrete enclosure, measured from the underside of the concrete enclosure to an interior surface of the internally reinforced concrete roof, is about 2.3 meters and the interior surface of the roof is about 7 square meters.

[0021] In some embodiments, the modular concrete building block has at least one of lower connector channels formed in a distal edge of the at least one concrete wall, and upper connector channels formed in an outwardly facing surface of the roof. In preferred embodiments, the modular concrete building block has both of the lower connector channels formed in the distal edge of the at least one internally reinforced concrete wall and the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete roof, and the lower connector channels and the upper connector channels are substantially in registration with one another.

[0022] A modular building system may comprise a plurality of the modular concrete building blocks as described above.

[0023] In still a further aspect, a precast modular concrete building block comprises an internally reinforced monolithic concrete enclosure defining an interior volume and having at least one internally reinforced concrete wall at least partially circumvallating the interior volume, and an internally reinforced concrete roof coupled to the internally reinforced concrete wall(s). An underside of the concrete enclosure opposite the internally reinforced concrete roof is open into the interior volume, and the concrete wall(s) include at least one opening through the concrete wall(s) into the interior volume. The modular concrete building block has at least one of lower connector channels formed in a distal edge of the at least one internally reinforced concrete wall, and upper connector channels formed in an outwardly facing surface of the internally reinforced concrete roof.

[0024] In preferred embodiments, there is at least one opening through the internally reinforced concrete wall(s) into the interior volume. In some embodiments, the opening(s) through the internally reinforced concrete wall(s) may comprise at least one doorway aperture formed in the internally reinforced concrete wall(s). In some embodiments, the opening(s) through the concrete wall(s) may comprise at least one window aperture formed in the internally reinforced concrete wall(s).

[0025] In some embodiments, the modular concrete building block has both the lower connector channels formed in the distal edge of the at least one internally reinforced concrete wall and also the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete roof. The lower connector channels and the upper connector channels of each block are substantially in registration with one another.

[0026] While a single one of the modular concrete building blocks may form a building on its own, in some embodiments, a building may comprise at least two of the modular concrete building blocks described above, with an upper one of the two modular concrete building blocks secured atop a lower one of the two modular concrete building blocks, where the upper one of the two modular concrete building blocks has at least the lower connector channels and the lower one of the two modular concrete building blocks has at least the upper connector channels, the upper one of the two modular concrete building blocks is secured atop the lower one of the two modular concrete building blocks by a plurality of anti-slip connectors fitted into the lower connector channels of the upper one of the two modular concrete building blocks and into the upper connector channels of the lower one of the two modular concrete building blocks.

[0027] In some embodiments, the opening(s) through the concrete wall(s) may comprise a discontinuity in the internally reinforced concrete wall(s). A building may comprise at least two such building blocks arranged adjacent to one another with their respective discontinuities arranged in registration with one another.

[0028] A modular building system may comprise a plurality of the modular concrete building blocks as described above.

[0029] In still another aspect, the present disclosure is directed to a precast modular concrete building block comprising an internally reinforced monolithic concrete bodyhaving an internally reinforced concrete spanning panel and a perimeter skirt depending from the internally reinforced concrete spanning panel. The perimeter skirt comprises at least one internally reinforced concrete ambit panel, and the internally reinforced concrete spanning panel extends transverse to the perimeter skirt and spans the perimeter skirt. The internally reinforced concrete ambit panel(s) and the internally reinforced concrete spanning panel cooperate to define an interior volume between the internally reinforced concrete ambit panel(s) and the internally reinforced concrete spanning panel. The internally reinforced monolithic concrete body is open into the interior volume opposite the internally reinforced concrete spanning panel. At least one utility conduit is embedded within at least one of the internally reinforced concrete ambit panel(s) and the internally reinforced concrete spanning panel. At least one interior connection for the utility conduit(s) is accessible from within the interior volume, and at least one exterior connection for the utility conduit(s) is accessible from outside of the interior volume.

[0030] In some embodiments, there is a single internally reinforced concrete ambit panel. In some such embodiments, the perimeter skirt further comprises a pair of spaced-apart reinforced concrete columns opposite the single internally reinforced concrete ambit panel. At least one support pocket may be formed in an interior surface of the single internally reinforced concrete ambit panel adjacent the internally reinforced concrete spanning panel.

[0031] In some embodiments, the internally reinforced concrete ambit panel(s) may consist of two adjacent substantially orthogonal internally reinforced concrete ambit panels(s). In such embodiments, the perimeter skirt may further comprise a single internally reinforced concrete column opposite the internally reinforced concrete ambit panels. In some embodiments, at least one support pocket is formed in an interior surface of one of the internally reinforced concrete ambit panels adjacent the internally reinforced concrete spanning panel.

[0032] In some embodiments, the internally reinforced concrete ambit panel(s) comprise two opposed substantially parallel ones of the internally reinforced concrete ambit panels. In particular embodiments, the internally reinforced concrete ambit panel(s) further comprise a third internally reinforced concrete ambit panel extending between and substantially orthogonal to the two opposed substantially parallel ones of the internally reinforced concrete ambit panels.

[0033] In some embodiments, the utility conduit(s) may be comprised of one or more of at least one HVAC duct, at least one ventilation duct, at least one electrical conduit, at least one plumbing supply pipe, at least one plumbing drain pipe, and at least one drain vent pipe.

[0034] In some embodiments, the internally reinforced concrete ambit panel(s) may include at least one opening through the internally reinforced concrete ambit panel(s).

[0035] In some embodiments, the modular concrete building block has at least one of lower connector channels formed in a distal edge of the at least one internally reinforced concrete ambit panels, and upper connector channels formed in an outwardly facing surface of the internally reinforced concrete spanning panel. In preferred embodiments, the modular concrete building block has both the lower connector channels formed in the distal edge of the at least one internally reinforced concrete ambit panel and the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete spanning panel, and the lower connector channels and the upper connector channels are substantially in registration with one another.

[0036] A building comprising at least two modular concrete building blocks as described above may comprise a first one of the two modular concrete building blocks disposed adjacent a second one of the two modular concrete building blocks, and the respective exterior connection(s) for the utility conduit(s) embedded within the internally reinforced concrete ambit panel(s) of the first one of the two modular concrete building blocks is in registration with and coupled to corresponding respective exterior connection(s) for the utility conduit(s) embedded within the internally reinforced concrete ambit panel(s) of the second one of the two modular concrete building blocks. In some embodiments, the first one of the two modular concrete building blocks is disposed atop the second one of the two modular concrete building blocks. In some such embodiments, the first one of the two modular concrete building blocks is secured atop the second one of the two modular concrete building blocks by a plurality of anti-slip connectors fitted into lower connector channels of the first one of the two modular concrete building blocks and into upper connector channels of the second one of the two modular concrete building blocks. In some embodiments, the first one of the two modular concrete building blocks is disposed beside the second one of the two modular concrete building blocks.

[0037] In yet a further aspect, the present disclosure is directed to a precast modular concrete building block comprising an internally reinforced monolithic concrete body having an internally reinforced concrete spanning panel and a perimeter skirt depending from the internally reinforced concrete spanning panel. The perimeter skirt comprises at least one internally reinforced concrete ambit panel, and the internally reinforced concrete spanning panel extends transverse to the perimeter skirt and spans the perimeter skirt. The internally reinforced concrete ambit panel(s) and the internally reinforced concrete spanning panel cooperate to define an interior volume between the internally reinforced concrete ambit panel(s) and the internally reinforced concrete spanning panel. The internally reinforced monolithic concrete body is open into the interior volume opposite the internally reinforced concrete spanning panel. The modular concrete building block has at least one of lower connector channels formed in a distal edge of the at least one internally reinforced concrete ambit panel, and upper connector channels formed in an outwardly facing surface of the internally reinforced concrete spanning panel.

[0038] In some embodiments, the internally reinforced concrete wall includes at least one opening through the at least one concrete ambit panel. In some embodiments, the opening(s) through the internally reinforced concrete ambit panel(s) may comprise at least one doorway aperture formed in the at least one concrete ambit panel and / or at least one window aperture formed in the internally reinforced concrete ambit panel(s).

[0039] In preferred embodiments, the modular concrete building block has both the lower connector channels formed in the distal edge of the at least one internally reinforced concrete ambit panel and the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete spanning panel, and the lower connector channels and the upper connector channels are substantially in registration with one another.

[0040] A building may comprise at least two of the modular concrete building blocks, wherein an upper one of the two modular concrete building blocks is secured atop a lower one of the two modular concrete building blocks. The upper one of the two modular concrete building blocks has at least the lower connector channels, the lower one of the two modular concrete building blocks has at least the upper connector channels, and the upper one of the two modular concrete building blocks is secured atop the lower one of thetwo modular concrete building blocks by a plurality of anti-slip connectors fitted into the lower connector channels of the upper one of the two modular concrete building blocks and into the upper connector channels of the lower one of the two modular concrete building blocks.

[0041] In some embodiments, the opening(s) through the internally reinforced concrete ambit panel(s) may comprise a discontinuity in the internally reinforced concrete ambit panel(s), and a building may comprise at least two such modular concrete building blocks arranged adjacent to one another with their respective discontinuities arranged in registration with one another.

[0042] In preferred embodiments, at least one utility conduit is embedded within at least one of the internally reinforced concrete ambit panel(s) and the internally reinforced concrete spanning panel, at least one interior connection for the utility conduit(s) is accessible from within the interior volume and at least one exterior connection for the utility conduit(s) is accessible from outside of the interior volume. In some embodiments, the utility conduit(s) may be comprised of one or more of at least one HVAC duct, at least one ventilation duct, at least one electrical conduit, at least one plumbing supply pipe, at least one plumbing drain pipe, and at least one drain vent pipe.

[0043] In some embodiments, there is a single internally reinforced concrete ambit panel. In some such embodiments, the perimeter skirt further comprises a pair of spaced-apart reinforced concrete columns opposite the single internally reinforced concrete ambit panel. In some such embodiments, at least one support pocket may be formed in an interior surface of the single internally reinforced concrete ambit panel adjacent the internally reinforced concrete spanning panel.

[0044] In some embodiments, the internally reinforced concrete ambit panel(s) may consist of two adjacent substantially orthogonal internally reinforced concrete ambit panels. In some such embodiments, the perimeter skirt may further comprise a single internally reinforced concrete column opposite the internally reinforced concrete ambit panels. In some such embodiments, at least one support pocket is formed in an interior surface of one of the internally reinforced concrete ambit panels adjacent the internally reinforced concrete spanning panel.

[0045] In some embodiments, the internally reinforced concrete ambit panel(s) may comprise two opposed substantially parallel ones of the internally reinforced concrete ambit panels. In some such embodiments, the internally reinforced concrete ambit panel(s) may further comprise a third internally reinforced concrete ambit panel extending between and substantially orthogonal to the two opposed substantially parallel ones of the internally reinforced concrete ambit panels.

[0046] A modular building system may comprise a plurality of the aforementioned modular concrete building blocks.BRIEF DESCRIPTION OF THE DRAWINGS

[0047] These and other features will become more apparent from the following description in which reference is made to the appended drawings wherein:FIGURE 1 is a partially transparent perspective view of an illustrative erectable and collapsible superstructure according to an aspect of the present disclosure, shown in an erected configuration in association with a transport platform;FIGURE 1 A shows detail views of a first illustrative embodiment of a portion of the superstructure of Figure 1 ;FIGURE IB shows detail views of a second illustrative embodiment of a portion of the superstructure of Figure 1 ;FIGURE 2A is a perspective view of the superstructure of Figure 1, shown in an erected configuration;FIGURE 2B is a side elevation view of the superstructure of Figure 1, shown in an erected configuration;FIGURE 2C is a side cross-sectional view of the superstructure of Figure 1, shown in an erected configuration;FIGURE 3 A is a perspective view of the superstructure of Figure 1, showing lowering of a superstructure roof thereof to collapse concertina walls upon themselves beneath the superstructure roof;FIGURE 3B is a side elevation view of the superstructure of Figure 1, showing lowering of the superstructure roof thereof to collapse concertina walls upon themselves beneath the superstructure roof;FIGURE 3C is a side cross-sectional view of the superstructure of Figure 1, showing lowering of the superstructure roof thereof to collapse concertina walls upon themselves beneath the superstructure roof;FIGURE 4A is a perspective view of the superstructure of Figure 1, showing the superstructure roof thereof fully lowered and the concertina walls collapsed upon themselves beneath the superstructure roof;FIGURE 4B is a side elevation view of the superstructure of Figure 1, showing the superstructure roof thereof fully lowered and the concertina walls collapsed upon themselves beneath the superstructure roof;FIGURE 4C is a side cross-sectional view of the superstructure of Figure 1, showing the superstructure roof thereof fully lowered and the concertina walls collapsed upon themselves beneath the superstructure roof;FIGURE 5 A is a perspective view of the superstructure of Figure 1, showing panel walls thereof pivoting from an upright position toward a recumbent position;FIGURE 5B is a side elevation view of the superstructure of Figure 1, showing the panel walls thereof pivoting from the upright position toward the recumbent position;FIGURE 5C is a side cross-sectional view of the superstructure of Figure 1, showing the panel walls thereof pivoting from the upright position toward the recumbent position;FIGURE 6A is a perspective view of the superstructure of Figure 1, showing the superstructure in a collapsed configuration;FIGURE 6B is a side elevation view of the superstructure of Figure 1, showing the superstructure in the collapsed configuration;FIGURE 6C is a side cross-sectional view of the superstructure of Figure 1, showing the superstructure in the collapsed configuration;FIGURE 7 is a top perspective view of an apparatus for casting a hollow concrete block according to an aspect of the present disclosure, with an inner form thereof in an inner form casting configuration, an outer form thereof in an outer form casting configuration and a transport platform thereof arranged with its inner form opening in registration with the inner form;FIGURE 8 is a side cross-sectional view of the apparatus of Figure 7, with the inner form thereof in the inner form casting configuration and with a cavity thereof empty;FIGURE 9 is a side cross-sectional view of the apparatus of Figure 7, with the inner form thereof in the inner form casting configuration and with the cavity thereof being filled with concrete;FIGURE 9A is a side cross-sectional view of the apparatus of Figure 7, with the inner form thereof in the inner form casting configuration and with the cavity thereof filled with concrete;FIGURE 9B is a side cross-sectional view of a portion of the apparatus of Figure 7 in the configuration shown in Figure 9;FIGURE 9C is a top perspective view of an illustrative spacer template for use in forming an upper connector channel;FIGURE 9D is a bottom perspective view of the spacer template of Figure 9C;FIGURE 9E shows an upper region of the side cross-sectional view shown in Figure 9B, while the concrete is still wet, awaiting application of the spacer template of Figure 9C;FIGURE 9F shows the upper region of the side cross-sectional view shown in Figure 9B during initial application of the spacer template of Figure 9C;FIGURE 9G shows the upper region of the side cross-sectional view shown in Figure 9B with the spacer template of Figure 9C applied;FIGURE 9H shows the upper region of the side cross-sectional view shown in Figure 9B during removal of the spacer template of Figure 9C after the concrete has cured;FIGURE 91 is a partially transparent perspective view of a portion of an illustrative embodiment of the apparatus of Figure 7 in which the transport platform thereof is configured to accommodate lower channel spacers;FIGURE 9J is a detail view of a portion of the apparatus of Figure 91;FIGURE 9K shows installation of a lower channel spacer using positioning grooves formed in the transport platform of the apparatus of Figure 91;FIGURE 9L shows the lower channel spacer of Figure 9K installed in the transport platform of the apparatus of Figure 91;FIGURE 9M is a detail view of a lower region of the side cross-sectional view shown in Figure 9B;FIGURE 9N is perspective view of an illustrative embodiment of the apparatus of Figure 7 that includes scaffolding for the spacer template(s) of Figure 9C;FIGURE 10 is a side cross-sectional view of the apparatus of Figure 7, with a first illustrative embodiment of a modular concrete building block formed therein;FIGURE 10A is atop perspective view of the apparatus of Figure 7, with the modular concrete building block of Figure 10 formed therein;FIGURE 11 is a side cross-sectional view of the apparatus of Figure 7 after formation of the modular concrete building block of Figure 10, with the inner form thereof still in the inner form casting configuration and the outer form being deconfigured from the outer form casting configuration;FIGURE 11 A is a partially transparent perspective view of the modular concrete building block of Figure 10 resting on the transport platform of Figure 7, after deconfiguring the outer form from the outer form casting configuration and prior to retracting the inner form;FIGURE 12 is a side cross-sectional view of the modular concrete building block of Figure 10 resting on the transport platform of Figure 7 after deconfiguring the outer form from the outer form casting configuration, with the inner form collapsing from the inner form casting configuration into the inner form demold configuration;FIGURE 13 is a side cross-sectional view of the modular concrete building block of Figure 10 resting on the transport platform of Figure 7 after deconfiguring the outer form from the outer form casting configuration, with the inner form in the inner form demold configuration;FIGURE 14 is a side cross-sectional view of the modular concrete building block of Figure 10 resting on the transport platform of Figure 7 after deconfiguring the outer form from the outer form casting configuration and collapsing the inner form into the inner form demold configuration, showing movement of the transport platform with the modular concrete building block thereon past the collapsed inner form;FIGURE 14A is a partially transparent perspective view of the modular concrete building block of Figure 10 resting on the transport platform of Figure 7 after deconfiguring the outer form from the outer form casting configuration and collapsing the inner form into the inner form demold configuration, showing movement of the transport platform with the modular concrete building block thereon past the collapsed inner form;FIGURES 15A to 15F show loading of the modular concrete building block of Figure 10 onto a flatbed tractor trailer;FIGURE 16A is a top perspective view of the modular concrete building block of Figure 10;FIGURE 16B is a bottom perspective view of the modular concrete building block of Figure 10;FIGURE 16C is a first side elevation view of the modular concrete building block of Figure 10;FIGURE 16D is a first end elevation view of the modular concrete building block of Figure 10;FIGURE 16E is a second side elevation view of the modular concrete building block of Figure 10;FIGURE 16F is a second end elevation view of the modular concrete building block of Figure 10;FIGURE 16G is a top plan view of the modular concrete building block of Figure 10;FIGURE 16H is a bottom plan view of the modular concrete building block of Figure 10;FIGURE 161 is a cross-sectional view of the modular concrete building block of Figure 10 taken along the line 161- 161 in Figure 16G;FIGURE 16J is a cross-sectional view of the modular concrete building block of Figure 10 taken along the line 16J-16J in Figure 16G;FIGURE 16K is a cross-sectional view of the modular concrete building block of Figure 10 taken along the line 161-161 in Figure 16G, showing optional additional thickness of the walls;FIGURE 17A is a perspective view showing how two of the modular concrete building blocks of Figure 10 can be stacked together using a first illustrative anti-slip connector;FIGURE 17B is a perspective view showing how two of the modular concrete building blocks of Figure 10 can be stacked together using a second illustrative anti-slip connector;FIGURE 17C is a perspective view showing how two of the modular concrete building blocks of Figure 10 can be stacked together using a third illustrative anti-slip connector;FIGURE 17D is a perspective view showing how two of the modular concrete building blocks of Figure 10 can be stacked together using a fourth illustrative anti-slip connector;FIGURE 17E is a cross-sectional view showing an upper connector channel of one of the modular concrete building blocks of Figure 10;FIGURE 17F is an enlargement of the view shown in Figure 17E, showing installation of an instance of the anti-slip connector of Figure 17DFIGURE 18 is a perspective view showing a stack of the modular concrete building blocks of Figure 10;FIGURES 19A, 19B and 19C are elevation, perspective and perspective views, respectively, showing how multiple stacks of the modular concrete building blocks of Figure 10 may be combined to form a larger structure.FIGURE 20 is a partially transparent perspective view of an illustrative modular concrete building block according to an aspect of the present disclosure, showing utility conduits embedded therein, including HVAC ducts, ventilation duct, electrical conduits, plumbing supply pipes, plumbing drain pipe, and drain vent pipe;FIGURE 20A is a perspective view of the modular concrete building block of Figure 20, showing the embedded utility conduits, including HVAC ducts, ventilation duct, electrical conduits, plumbing supply pipes, plumbing drain pipe, and drain vent pipe, with dashed lines;FIGURE 20B is a partially transparent perspective view of the modular concrete building block of Figure 20 showing plumbing supply pipes in isolation;FIGURE 20C is a partially transparent perspective view of the modular concrete building block of Figure 20 showing plumbing drain pipes in isolation;FIGURE 20D is a partially transparent perspective view of the modular concrete building block of Figure 20 showing electrical conduits in isolation;FIGURE 20E is a partially transparent perspective view of the modular concrete building block of Figure 20 showing HVAC ducts in isolation;FIGURE 20F is a partially transparent perspective view of the modular concrete building block of Figure 20 showing a ventilation duct in isolation;FIGURE 20G is a partially transparent perspective view of the modular concrete building block of Figure 20 showing internal reinforcement in walls thereof;FIGURE 20H is a partially transparent perspective view of the modular concrete building block of Figure 20 showing internal reinforcement in walls and a roof thereof;FIGURES 21 A through 21C show schematically an illustrative method for replacing wiring;FIGURES 22A through 22D show aspects of a first illustrative method for manufacturing the modular concrete building block of Figure 10 with an embedded utility conduit;FIGURE 23 A is a top perspective view of the modular concrete building block of Figure 10 having a vertical utility conduit arranged at the junctions of one of the longer walls and one of the shorter walls;FIGURES 23B and 23 C show an illustrative method for forming the vertical utility conduit of Figure 23 A;FIGURE 24A shows a first variant of a second illustrative embodiment of a modular concrete building block;FIGURE 24B shows a second variant of the modular concrete building block of Figure 24A;FIGURE 24C shows a third variant of the modular concrete building block of Figure 24 A;FIGURE 24D shows the modular concrete building block of Figure 24C in cooperation with anti-slip connectors;FIGURE 25 A shows a first variant of a third illustrative embodiment of a modular concrete building block;FIGURE 25B shows a second variant of the modular concrete building block of Figure 25 A;FIGURE 25C shows a third variant of the modular concrete building block of Figure 25 A;FIGURE 25D shows the modular concrete building block of Figure 25C in cooperation with anti-slip connectors;FIGURE 26A shows a first variant of a fourth illustrative embodiment of a modular concrete building block;FIGURE 26B shows a second variant of the modular concrete building block of Figure 26A;FIGURE 26C shows a third variant of the modular concrete building block of Figure 26 A;FIGURE 26D shows the modular concrete building block of Figure 26C in cooperation with anti-slip connectors;FIGURE 27 A shows a first variant of a fifth illustrative embodiment of a modular concrete building block;FIGURE 27B shows a second variant of the modular concrete building block of Figure 27A;FIGURE 27C shows a third variant of the modular concrete building block of Figure 27 A;FIGURE 27D shows the modular concrete building block of Figure 27C in cooperation with anti-slip connectors;FIGURE 28A shows a first variant of a sixth illustrative embodiment of a modular concrete building block;FIGURE 28B shows a second variant of the modular concrete building block of Figure 28A;FIGURE 28C shows a third variant of the modular concrete building block of Figure 28 A;FIGURE 28D shows the modular concrete building block of Figure 28C in cooperation with anti-slip connectors;FIGURE 29A shows a first variant of a seventh illustrative embodiment of a modular concrete building block;FIGURE 29B shows a second variant of the modular concrete building block of Figure 29A;FIGURE 29C shows a third variant of the modular concrete building block of Figure 29 A;FIGURES 30 and 30A show construction of a first embodiment of a larger room from a plurality of modular concrete building blocks;FIGURE 30B shows two layers of the arrangement shown in Figure 30A;FIGURE 30C shows how a foundation layer may be assembled;FIGURE 30D shows a multi-storey building formed from two layers of the arrangement shown in Figure 30A, as well as a third, below-grade foundation layer as shown in Figure 30C;FIGURES 31A through 3 IL show construction of a second embodiment of a larger room from a plurality of modular concrete building blocks;FIGURE 32 shows an eighth illustrative embodiment of a modular concrete building block, for use in constructing the larger room of Figures 31 A through 3 IL;FIGURE 33 shows a ninth illustrative embodiment of a modular concrete building block, for use in constructing the larger room of Figures 31 A through 3 IL;FIGURE 36 is a top perspective view of a first variant of the modular concrete building block of Figure 10;FIGURE 37 is a top perspective view of a second variant of the modular concrete building block of Figure 10;FIGURE 38 is a top perspective view of a third variant of the modular concrete building block of Figure 10;FIGURE 39A shows a crane lifting the modular concrete building block of Figure 24A, modified with lifting loops; andFIGURE 39B shows how the lifting loops of Figure 39A may be cut away after positioning.DETAILED DESCRIPTION

[0048] Broadly speaking, the present disclosure describes systems and methods for manufacturing hollow concreate blocks that can be used in modular construction, that is, modular concrete building blocks, and the use of these modular concrete building blocks to assemble various structures. The modular concrete building blocks can be mass produced, and then transported by a conventional flatbed tractor trailer to a construction site for deployment and assembly.

[0049] Reference is now made to Figures 1, 2A, 2B and 2C, which illustrate an embodiment of an erectable and collapsible superstructure 100 according to an aspect of the present disclosure, shown in an erected configuration. Figure 1 is a partially transparent perspective view showing interior components of the superstructure 100, and Figure 2A is a solid perspective view. The superstructure 100 may be used as an inner form for an apparatus for casting a hollow concrete block having an open face for use as a modular concrete building block, although an erectable superstructure according to the present disclosure has other applications as well.

[0050] The superstructure 100 comprises a superstructure roof 102 and first and second sets of opposed substantially parallel superstructure walls. In the illustrated embodiment, the first set of superstructure walls is a set of opposed collapsible concertina walls 104, and the second set of superstructure walls is a set of opposed substantially rigid noncollapsing panel walls 106. The concertina walls 104 are formed from a plurality of longitudinally-extending segments 108 that are hinged to one another by concertina wall hinges 108H, and an upper end 104U of each concertina wall 104 is pivotally coupled to a respective edge of the superstructure roof 102 by support hinges 102H. Where an erectable superstructure is to be used in applications other than forming concrete blocks, the concertina walls may be omitted, or may be replaced by other materials, such as curtains or flexible sheeting (which may serve as a surface for a projection), for example.

[0051] The panel walls 106 are each movable between a recumbent position and an upright position. In Figures 1 and 2A to 2C, the panel walls 106 are in the upright position. As can be seen in Figure 1, a respective hydraulic piston-cylinder assembly 110 acts between a superstructure base 112 and each of the panel walls 106 to selectively pivot the panel walls 106 between the recumbent position and the upright position. In the illustrated embodiment, the superstructure base is formed by the floor 112 of a pit 114 into which the superstructure 100 can collapse; in other embodiments the superstructure base may be a discrete (single-part or multi-part) component that can be moved with the superstructure.

[0052] In the illustrated embodiment, as best seen in Figures 3C, 4C, 6C, and 10, the lower ends of the panel walls 106 are pivotally coupled to hinge posts 116 secured in the pit 114 at the comers thereof. The hinge posts 116 preferably each have a respective hingeslot 118 at their upper ends, in which respective pivot shafts 120 coupled to the lower ends of the panel walls 106 can both slide and rotate. The pivot shafts 120 may be provided with bushings, bearings or other friction-reducing elements. The lower end of each piston-cylinder assembly 110 pivots within a respective lower bracket 122 that is secured upon the floor 112 of the pit 114, and the upper end of each piston-cylinder assembly 110 pivots within a respective upper bracket 124 that is secured to the inner side 1061 of the respective panel walls 106.

[0053] In alternate embodiments (not shown), the hinge posts and pivot shafts may be omitted, and servomotors may be coupled to the upper and lower ends of the pistoncylinder assemblies to pivot the piston-cylinder assemblies relative to the upper and lower brackets. By selectively controlling the servomotors and the piston-cylinder assemblies, the panel walls can be moved between the recumbent position and the upright position.

[0054] Where an erectable superstructure is to be used in applications other than forming concrete blocks, the panel walls may be omitted, or may be replaced by other materials, such as curtains or flexible sheeting, for example.

[0055] A hydraulic scissor lift 126 is disposed beneath the superstructure roof 102, and is configured to selectively raise and lower the superstructure roof 102. The various hydraulic components of the scissor lift 126 are omitted from the drawings for clarity of illustration; these will be understood by one of ordinary skill in the art. While the illustrated embodiment shows only a single scissor lift 126 disposed centrally relative to the superstructure roof 102, other embodiments may have two or more scissor lifts. The superstructure roof 102 has a pair of opposed piston-cylinder apertures 128 at edges thereof adjacent the panel walls 106 to enable the superstructure roof 102 to move past the piston-cylinder assemblies 110. The piston-cylinder apertures 128 may be covered by respective piston-cylinder aperture flaps 130 when the superstructure roof 102 is fully raised; Figure 1 shows the piston-cylinder flaps 130 in a closed position covering the piston-cylinder apertures 128. In the illustrated embodiment the piston-cylinder aperture flaps 130 are coupled to the superstructure roof 102 by hinges 132, which may be spring- loaded hinges to bias the piston-cylinder aperture flaps 130 into the closed position, although other configurations are also contemplated. From the closed position, the pistoncylinder aperture flaps 130 are pushed aside by the piston-cylinder assemblies 110 as thesuperstructure roof 102 is lowered, as shown in Figures 3A to 3C. In alternate embodiments, the piston-cylinder aperture flaps may be manually installed or removed.

[0056] The scissor lift 126 is merely one illustrative apparatus for raising and lowering superstructure roof 102. In other embodiments, for example, a piston-cylinder assembly may be used, with the cylinder fitted into a receptacle below the pit so that the cylinder can raise and lower the superstructure roof. Any suitable hoisting mechanism may be used to raise and lower the superstructure roof.

[0057] As noted above, the concertina walls 104 are pivotally coupled to the edges of the superstructure roof 102. Accordingly, raising the superstructure roof 102 extends the concertina walls 104 into the substantially planar configuration shown in Figures 1, 2A, 2B and 2C, and lowering the superstructure roof 102 collapses the concertina walls 104 upon themselves beneath the superstructure roof 102, as shown in Figures 3 A, 3B and 3C. Figures 4A, 4B and 4C and 5A, 5B and 5C show the concertina walls 104 fully collapsed beneath the superstructure roof 102.

[0058] In some embodiments, the ends of the concertina walls 104 include track followers 134 that ride within guide tracks on the inner sides 1061 of the panel walls 106. Figure 1A shows an embodiment in which the guide tracks 136 are set into the panel walls 106, and Figure IB shows an embodiment in which the guide tracks 138 are formed by a pair of opposed guide rails 140 projecting inwardly from the inner sides 1061 of the panel walls 106. In some embodiments, the track followers 134 may be integrated into specialized ones of the concertina wall hinges 108H and the support hinges 102H. The relevant support hinges 102H are omitted from Figure 1A and Figure IB for clarity of illustration, to avoid obscuring the track followers 134.

[0059] In the embodiment shown in Figure 1 A where the guide tracks 136 are set into the panel walls 106, the panel walls 106 may be hollow core walls formed by two sheets of metal, and a portion of each of the track followers 134 may be trapped between the two sheets.

[0060] In the embodiment shown in Figure IB, the superstructure roof 102 may include rail apertures 142 covered by rail aperture flaps 144 arranged in registration with the guide rails 140 to enable the superstructure roof 102 to move past the guide rails 140 when beinglowered, while covering the rail apertures 142 when the superstructure roof 102 is fully raised. The rail apertures 142 and rail flaps 144, which may optionally be spring-loaded, function similarly to the piston-cylinder apertures 128 and piston-cylinder aperture flaps 130 described above.

[0061] In either case (Figure 1 A or Figure IB), the track followers 134 may be or comprise bearings or other friction-reducing elements, and bearings or other frictionreducing elements may also be disposed in the guide tracks 136, 138.

[0062] When the superstructure 100 is in the erected configuration, as shown in Figures 1, 2A, 2B and 2C, the concertina walls 104 are extended into a substantially planar configuration and the panel walls 106 are in the upright position and extend substantially orthogonal to the concertina walls 104. In some embodiments, the lower ends of the concertina walls 104 may be coupled directly or indirectly to the superstructure base (e.g. the floor 112 of the pit 114) to maintain the substantially planar configuration when the superstructure 100 is in the erected configuration. In other embodiments, the lower ends of the concertina walls may be weighted to maintain the substantially planar configuration when the superstructure 100 is in the erected configuration.

[0063] Movement of the superstructure 100 from the erected configuration to the collapsed configuration will now be described.

[0064] Referring now to Figures 3A, 3B and 3C, the scissor lift 126 begins to lower the superstructure roof 102, which causes the concertina walls 104 to begin to collapse. The upper ends of the piston-cylinder assemblies 110 move through the piston-cylinder apertures 128 and push the piston-cylinder aperture flaps 130 out of the closed position, allowing the superstructure roof 102 to move past the piston-cylinder assemblies 110 into a fully lowered position.

[0065] Figures 4A, 4B and 4C show the superstructure 100 with the superstructure roof 102 fully lowered, with the panel walls 106 remaining in the upright position. The pistoncylinder aperture flaps 130 are in an open position, and the piston-cylinder assemblies 110 project upwardly through the piston-cylinder apertures 128. Although in the illustrated embodiment the superstructure roof 102 is disposed slightly above the top of the pit 114 when fully lowered (see Figure 4C), in other embodiments the superstructure roof may bedisposed inside the pit when fully lowered. Also, as noted above, in other embodiments the superstructure base may be a discrete single- or multi-part component that can be moved with the superstructure.

[0066] Referring now to Figures 5 A, 5B and 5C, the piston-cylinder assemblies 110 begin to retract, which causes the panel walls 106 to begin to pivot from the upright position (Figures 4A, 4B and 4C) toward the recumbent position.

[0067] Reference is now made to Figures 6A, 6B and 6C, which show the superstructure 100 in the collapsed configuration. When the superstructure 100 is in the collapsed configuration, the scissor lift 126 is collapsed and the superstructure roof 102 is in the lowered position, the concertina walls 104 are collapsed upon themselves beneath the superstructure roof 102, the piston-cylinder assemblies 110 are fully retracted and the panel walls 106 are inwardly pivoted into the recumbent position to overlie the superstructure roof 102.

[0068] Referring now to Figure 7, in one particularly advantageous embodiment, the superstructure 100 serves as an inner form that is part of a casting apparatus for casting a hollow concrete block having an open face, which may be used as a modular concrete building block. An illustrative such casting apparatus is indicated generally by reference 150. The casting apparatus 150 further comprises a movable transport platform 152 (see Figure 6A) and an outer form 154 as shown in Figure 7.

[0069] Where the superstructure 100 serves as the inner form of the casting apparatus 150, the superstructure 100 has an inner form casting configuration, namely the erected configuration shown in Figures 1, 2A, 2B and 2C, and an inner form demold configuration (which may also be referred to as a bypass configuration), namely the collapsed configuration shown in Figures 6A, 6B and 6C. Where the superstructure 100 serves as an inner form for a casting apparatus 150, the embodiment shown in Figure 1A, in which the guide tracks 136 are set into the panel walls 106, is preferred as it avoids the use of rail flaps 144 which can cause problems during demolding.

[0070] In the illustrated embodiment, as best seen in Figure 6A, the transport platform 152 takes the form of a hollow rectangular frame having an inner form opening 156 configured to be arranged in registration with the superstructure 100 that serves as the inner form.

[0071] Moreover, in the illustrated embodiment the transport platform 152 is a wheeled transport platform. More particularly, in the illustrated embodiment, a plurality of wheeled skates 158 are disposed beneath the longer sides 160 of the transport platform 152, which straddle the pit 114 when the inner form opening 156 is in registration with the superstructure 100. The longer sides 160 of the transport platform 152 are connected by crossbars 162 that form the shorter sides of the rectangular transport platform 152. This is merely an illustrative embodiment, and is not limiting.

[0072] In some embodiments, the lower ends of the concertina walls 104 may be directly or indirectly braced against the transport platform 152, using the transport platform as an anchor to maintain the substantially planar configuration of the concertina walls 104 when the superstructure 100 is in the erected configuration.

[0073] The illustrative transport platform 152 shown in the Figures is a separate component from the superstructure 100, but this is merely one illustrative embodiment and is not limiting.

[0074] With reference in particular to Figure 7, the outer form 154 comprises a plurality of outer form walls, which in the illustrated embodiment include two opposed parallel side walls 164 and two opposed end walls 166. The side walls 164 and end walls 166 may be separate pieces or one or more of them may be hinged together. The outer form 154 has an outer form casting configuration, as shown in Figure 7, in which the outer form walls 164, 166 form an open-topped enclosure. In the illustrated embodiment, the two end walls 166 include upper outcroppings 168. The upper outcroppings 168 include an outcropping floor 170 and an upturned U-shaped retainer wall 172 whose ends mate with the side walls 164, so as to form an overhanging trough 174 extending outwardly at each longitudinal end of the outer form 154. These overhanging troughs 174 form part of the open-topped enclosure. The overhanging trough 174 is optional, and in other embodiments the overhanging trough may be omitted. In yet further embodiments, an overhanging trough may extend outwardly at each transverse end of the outer form (i.e. from the side walls). Moreover, the shape of the outer form 154 shown in the drawings, with or without the overhanging trough 174, is merely illustrative and not limiting. Other suitable shapes for the outer form are also contemplated. For example, all or part of the outer form may be curved.

[0075] Figures 1, 2A, 2B and 2C show the transport platform 152 positioned with the inner form opening 156 arranged in registration with the superstructure 100, with the superstructure 100 in the inner form casting configuration. As can be seen in Figures 1, 2A, 2B and 2C, when the superstructure 100 is in the inner form casting configuration, the superstructure 100 is extended to form a roofed column extending upwardly through the inner form opening 156 of the transport platform 152. Thus, the inner form casting configuration is an erected configuration in which the superstructure walls 104, 106 are upwardly extended.

[0076] Figures 6 A, 6B and 6C show the transport platform 152 positioned with the inner form opening 156 arranged in registration with the superstructure 100, with the superstructure 100 in the inner form demold configuration. With reference to Figures 6A to 6C, in particular, the superstructure 100 is retracted so that the transport platform 152 is movable past the retracted superstructure 100 in at least a first direction D (Figure 6A). The inner form demold configuration is a collapsed configuration in which the superstructure walls 104, 106 are downwardly collapsed such that the superstructure walls 104, 106 and the superstructure roof 102 are non-obstructing to movement of the transport platform 152 in the first direction D. Thus, the inner form demold configuration may also be described as an inner mold bypass configuration since it allows the transport platform 152 to bypass the superstructure 100. As shown in the illustrated embodiment, with particular reference to Figure 6C, it is not necessary that the superstructure 100 be retracted entirely below the transport platform 152, i.e. below the wheeled skates 158. It is only necessary that the superstructure 100 be retracted low enough to enable the transport platform 152 to be rolled past the superstructure 100. In particular, in the illustrated embodiment, since the longer sides 160 of the transport platform 152 with the wheeled skates 158 straddle the pit 114, it is only necessary for the superstructure 100 to be retracted below the crossbars 162 to enable the transport platform 152 to be rolled past the superstructure 100 as shown in Figure 14. In other embodiments, the erectable superstructure may be retracted completely below the transport platform. Equivalently, in yet further embodiments the transport platform is movable past the retracted erectable superstructure by way of a movable crossbar that can be pivoted out of the way, or by way of one or both crossbars being removable, or by other adaptations of the transport platform to allow the transport platform to bypass the superstructure.

[0077] Figure 8 shows the transport platform 152 positioned with the inner form opening 156 (see Figure 11 A) arranged in registration with the superstructure 100 that serves as the inner form, with the outer form 154 in the outer form casting configuration and the superstructure 100 in the inner form casting configuration (i.e. erected). As best seen in Figure 8, the outer form walls 164, 166 extend upwardly beyond the superstructure roof 102, and the outer form walls 164, 166 surround and are spaced from the concertina walls 104 and the panel walls 106 of the superstructure 100 that serves as the inner form. More particularly, in the illustrated embodiment the side walls 164 of the outer form 154 are arranged opposite to and spaced from the respective concertina walls 104 of the superstructure 100, and the end walls 166 of the outer form 154 are arranged opposite to and spaced from the respective panel walls 106 of the superstructure 100.

[0078] Continuing to refer to Figure 8, the outer form walls 164, 166, the superstructure walls 104, 106 and the transport platform 152 cooperate to define a cavity 176 between the outer form 154 and the superstructure 100 that serves as the inner form, with the floor 178 of the cavity 176 formed by the upper surface of the transport platform 152. As will be described further below, the cavity 176 is adapted to receive and contain concrete surrounding the superstructure walls (concertina walls 104 and panel walls 106) and the superstructure roof 102.

[0079] The outer form 154 can be deconfigured from the outer form casting configuration so that the outer form walls 164, 166 are clear of the transport platform 152 and permit movement of the transport platform 152 in at least the first direction D. In some embodiments, the outer form is composed of multiple pieces that can be assembled to place the outer form in the outer form casting configuration, and then disassembled to deconfigure the outer form from the outer form casting configuration. In the illustrated embodiment, each of the side walls 164 and the end walls 166 is a separate part, such that the side walls 164 and the end walls 166 can be assembled and fastened together, and then unfastened and disassembled.

[0080] In other embodiments, the outer form may be constructed as a single part, which may be lowered into the outer form casting configuration from above, and then deconfigured by being lifted away. In such embodiments, the overhanging troughs would be omitted.

[0081] With reference now to Figures 8 through 14, an illustrative method for casting a hollow concrete block having an open face, which may be used as a modular concrete building block, will now be described. The method makes use of the components described above, namely the superstructure 100 (which is used as an inner form), the transport platform 152 and the outer form 154.

[0082] Reference is first made to Figure 8. The transport platform 152 is moved into a position in which the inner form opening 156 (see Figure 11 A) is in registration with the superstructure 100, and then the superstructure 100 is placed into the inner form casting configuration so that the superstructure 100 defines a roofed column extending upwardly through the inner form opening 156. In some alternate embodiments, such as where the transport platform 152 has removable or pivotable crossbars 162, the superstructure 100 may be placed into the inner form casting configuration first and then the transport platform 152 is moved into position without the crossbars 162, and the crossbars 162 are then placed in position. The outer form 154 is placed into the outer form casting configuration by securing the side walls 164 and the end walls 166 of the outer form together, so that the outer form walls 164, 166 form an open-topped enclosure disposed roundabout the transport platform 152. The outer form 154 may be placed into the outer form casting configuration either before or after the superstructure 100 is placed into the inner form casting configuration. However, it is preferable to place the outer form 154 in the outer form casting configuration after the superstructure 100 is placed into the inner form casting configuration, especially where reinforcements or other components are to be embedded within the modular concrete building block. With the outer form 154 in the outer form casting configuration and the superstructure 100 in the inner form casting configuration, the outer form walls 164, 166 extend upwardly beyond the roofed column formed by the superstructure 100 and surround and are spaced from the roofed column formed by the superstructure 100. As noted above, the outer form walls 164, 166, the roofed column formed by the superstructure 100, and the transport platform 152 cooperate to define a cavity 176 between the outer form 154 and the superstructure 100, with the floor 178 of the cavity 176 formed by the upper surface of the transport platform 152. Optionally, sealing tape or another sealant may be applied at the various junctions. These include the junctions between the outer form walls 164, 166 and the transport platform 152, the junctions between the superstructure walls 104, 106 and the transport platform152, the junctions between the side walls 164 and the end walls 166 of the outer form 154, the junctions between the concertina walls 104 and the panel walls 106, and between the segments 108 of the concertina walls 104. Preferably, all inner surfaces of the cavity 176 are coated with a suitable separating oil or other release agent.

[0083] Preferably, to ensure adequate resistance to bending, shear, and axial loads, internal reinforcements 180, such as steel rebar, is positioned in the cavity 176 before pouring any concrete (see Figure 9). Reinforcement may be required either for technical (e.g. modular multistory construction) or regulatory reasons, for example. Although only a single element of reinforcement 180 is shown in Figure 9 to avoid cluttered illustration, in practice the reinforcements 180 would be distributed throughout the cavity 176 in accordance with appropriate civil and / or structural engineering specifications. Placement of suitable reinforcement is within the capability of one of ordinary skill in the art, now informed by the present disclosure, and may include, for example, rebar mesh with starter bars and rebar lapping, J-hooks, U-hooks and / or truss bars, as appropriate. Depending upon the application, a structural engineer will calculate and specify all the details for the rebar, including the size of the bars, the type of hooks used to connect them, and how they should be tied together. Such reinforcement may be used to reinforce both the walls 1006, 1008 and the roof 1010 of the modular concrete building blocks 1000 so that the walls 1006, 1008 and the roof 1010 have internal reinforcement. In addition, other components may be positioned in the cavity 176 before pouring concrete. For example, electrical wiring, junction boxes, HVAC ducts (including for heat pumps), plumbing pipes, fire protection (e.g. sprinklers), gas lines, telecommunication wiring, with externally accessible connections may be installed in the cavity 176 to facilitate modular construction.

[0084] Optionally, spacers may be placed between the transport platform 152 and the outer form walls 164, 166, and wall extenders may be coupled to the outer form walls 164, 166, or different sizes of outer form walls 164, 166 may be used, to vary the size of the cavity 176. Varying the size of the cavity 176 allows elements like wiring, conduits and insulation to be accommodated while ensuring sufficient thickness of concrete, and also allows for modular concrete building blocks having thicker walls, for use in constructing foundations. Suitable sizing is within the capability of one of ordinary skill in the art, now informed by the present disclosure.

[0085] Components such as utility conduits, junction boxes, wiring, removable door, window and stairway spacers, retained doorposts / lintels / doorframes, window frames and stairway frames may be positioned in the cavity 176 before pouring concrete and supported by attaching these components to the reinforcement 180, or by using separate supports, such as support legs.

[0086] Insulation may also be installed in the cavity 176. Moreover, in some embodiments, thermal insulation, for example rigid insulation sheets, may also be positioned in the cavity 176 before pouring concrete.

[0087] In some embodiments for use in the construction of medical or laboratory facilities, radiation shielding can be placed in the cavity 176.

[0088] A wide range of additional elements can be placed in the cavity 176, or above the superstructure 100, so as to be embedded in the resulting modular concrete building block 1000. These include, for example, and without limitation, anchor plates or bolts for structural connections, steel or aluminum fixtures for curtain, wall or facade attachments, seating supports, seismic restraints, light fixtures or housings (including for outside lighting and emergency lighting), electrical boxes for outlets and switches, cross-linked polyethylene (PEX) tubing for radiant heating or cooling, grounding plates or rods, embedded sensors (e.g. temperature, humidity, or structural monitoring) or mountings therefor, fixtures and conduits for smoke detectors, carbon monoxide detectors and gas detectors, sprinkler head fixtures and pipes, safe or vault components, soundproofing or acoustic barrier materials, vibration isolators, pipe sleeves for industrial systems, embedded rails or tracks for machinery, chemical resistant liners, waterproofing / water resistance membranes, water filtration systems or components thereof, embedded magnets or plates for crane systems, load-bearing plates and / or anchor bolts for connecting beams and floor systems, integrated wall braces for earthquake resistance, solar panel mountings and related electrical connections, housings for batteries or other energy storage, energy meters / monitors or fixtures therefor, heat exchanger plates or other components for geothermal systems, thermal mass panels for passive heating and cooling, heat recovery ventilation (HRV) ducts, irrigation and / or drainage conduits (e.g. for outdoor or green roof applications), mountings for signage (or signage itself), electric fireplaces and / or wiring therefor, and decorative elements.

[0089] Elements associated with electrical and communication systems, in addition to electrical conduits, light fixtures or housings, and electrical boxes for outlets and switches, can be placed in the cavity 176, or above the superstructure 100, to be embedded in the resulting modular concrete building block 1000. Examples include, but are not limited to, smart home sensors or sensor fixtures (e.g., temperature, motion, or air quality sensors), wireless charging pads, recessed housings and connections for audio or audio / video systems, intercom or doorbell wiring, as well as empty cable conduits to provide for additional cabling to accommodate future developments.

[0090] Anchors or brackets for pergolas and canopies may also be embedded within the modular concrete building blocks, for example in the in the roof overhangs 1012.

[0091] Also optionally, lower channel spacers 182 may be positioned atop the transport platform 152 to form lower connector channels as described further below; the lower channel spacers 182 are preferably secured in position on the transport platform 152, as described further below. In the illustrated embodiment the lower channel spacers 182 are elongate triangular members that form elongate triangular or trapezoidal connector channels although other suitable shapes are also contemplated. In some preferred embodiments, the lower channel spacers 182 may be permanently affixed to the transport platform 152 to provide for consistent placement. In other preferred embodiments, the lower channel spacers 182 may be retained by and incorporated into the modular concrete building block 1000.

[0092] Where reinforcements 180 and / or other components such as utility conduits, door spacers, window spacers, insulation or other elements are to be incorporated, the superstructure 100 may be placed into the inner form casting configuration and the transport platform 152 is moved into position, and then the reinforcements 180 and / or other components are positioned around the superstructure 100 with suitable support. The lower channel spacers 182 are also installed at this time.

[0093] In a particularly preferred embodiment, a first set of reinforcements (e.g. rebar mesh) is supported against the erected superstructure 100, atop the transport platform 152, along with any door frames, with the reinforcement configured to provide appropriate support. Window frames may be supported within the first set of reinforcements, again with appropriately configured support by the surrounding reinforcement. Anycomponents that provide an interior connection for the utility conduit(s) may then be secured to the first set of reinforcements. The desired utility conduits are then run, and secured (e.g. with tie wire) to the first set of reinforcements. A second set of reinforcements (e.g. rebar mesh) is placed against the utility conduits, so that the utility conduits are “sandwiched” between the first set of reinforcements and the second set of reinforcements. The first set of reinforcements and the second set of reinforcements are then connected together (e.g. using pre-bent pieces of rebar). Any components that provide an interior connection for the utility conduit(s) may be secured to the second set of reinforcements. At this stage, quality control, plumbing, electrical, HVAC and other inspections of the relevant utility conduits may be performed and, where permitted by applicable law, such inspections may be signed off. Once all of the reinforcements 180 and / or other components are in position, and any inspections have been performed, the outer form 154 may be placed into the outer form casting configuration and secured, and then the concrete 184 can be poured.

[0094] Referring now to Figure 9, concrete 184 is poured into the cavity 176 so that the concrete surrounds the roofed column formed by the superstructure 100 while being contained by the outer form 154. For example, and without limitation, the concrete 184 may be made using Type I Ordinary Portland Cement (OPC), Grade 43 or Grade 53; this is merely an illustrative example. One of ordinary skill in the art, now informed by the present disclosure, may select an appropriate cement type based upon the type and purpose of the modular concrete building block(s) being made. As can be seen in Figure 10, the concrete 184 not only fills the space between superstructure walls 104, 106 and the outer form walls 164, 166 but also covers the superstructure roof 102 and fills the overhanging troughs 174. Of note, the track followers 134 and the guide tracks 136, 138 (Figures 1A, IB respectively) provide reinforcement of the concertina walls 104 to inhibit the concertina walls 104 from being pushed inwardly by the concrete 184; additional reinforcements may also be used. Figure 9A shows the cavity 176 filled with concrete 184.

[0095] Where reinforcements 180 and / or other components such as utility conduits, door frames, window frames, insulation or other elements are used, after the cavity 176 is filled with concrete, vibrator rods are used to help drive the concrete 184 to fully surround thereinforcements 180 and other components. After the outer form 152 is removed, any external areas where the concrete 184 did not penetrate can be manually patched.

[0096] Lifting loops (see Figures 39A and 39B) may be installed in the concrete 184 at the upper surface thereof to facilitate lifting by crane. Optionally, after the upper surface 188 of the concrete 184 is smoothed, upper channel spacers 186 may be inserted into the upper surface 188 of the concrete 184, preferably coated with separating oil, to form upper connector channels as described further below. As shown, in the illustrated embodiment the upper channel spacers 186 are generally triangular in cross-section. The upper channel spacers 186 should be in registration with the lower channel spacers 182.

[0097] Reference is now made to Figures 9B through 9N.

[0098] Figures 9B through 9D show an illustrative embodiment of a spacer template 902. The spacer template 902 comprises the upper channel spacer 186, as well as a template body 904 and an optional longitudinally extending positioning strip 906 disposed adjacent an outer edge of the template body 904. The upper channel spacer 186 is secured on the respective spacer template body 904 and extends longitudinally parallel to the positioning strip 906. The upper channel spacer 186 may be monolithically formed with the template body 904 and the positioning strip 906 may also be monolithically formed with the template body 904. The positioning strip 906 can be braced against the side wall 164 and the distal portion of the retainer wall 172 to enable consistent placement of the upper channel spacer 186 relative to the superstructure walls 104, 106 and the side walls 164 and the end walls 166 of the outer form 154. The spacer templates 902 may be reusable. The spacer template 902 is shown in Figures 9B in use with the longer side 144 of the outer form 154. The structure would be similar, but with different dimensions, for use with the retainer wall 172 associated with the end walls 166 of the outer form 154.

[0099] Figures 9E through 9H show how the upper channel spacer 186 carried by the template body 904 can be placed in the still-wet concrete 184 (Figures 9E to 9G) after the upper surface 188 of the concrete 184 has been smoothed. Once the concrete 184 is sufficiently cured, the spacer template 902 can be removed, and the cavities resulting from removal of the upper channel spacer 186 form upper connector channels 1024. Figures 9E through 9H show a spacer template 902 for use with the retainer wall 172 associated with the end wall 166 of the outer form 154.

[0100] Figures 91 to 9M show an embodiment in which the transport platform 152 is specifically configured to accommodate the lower channel spacers 182. More particularly, as shown in Figure 91, the upper surfaces of the longer sides 160 and the crossbars 162 of the transport platform 152 include respective longitudinally extending spaced-apart shallow positioning grooves 160 A, 162A. Figures 9J to 9L show the arrangement for the longer sides 160 of the transport platform 152 in more detail; the arrangement for the crossbars 162 is similar. Figure 9J shows the longer sides 160 of the transport platform 152 and the respective positioning grooves 160A in more detail. As can be seen in Figures 9K and 9L, in a preferred embodiment the lower channel spacers 182 each comprise an elongate hollow V-shaped insert 910 having a slightly flattened vertex 912 and two-spaced apart distal ends 914 opposite the vertex 912. The inserts may be made from any suitable material, including without limitation acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), or high-density polyethylene (HDPE), among others. For a disposable insert of the type shown, HDPE is presently preferred as providing a good balance of strength, cost and availability. The distal ends 914 are received in the positioning grooves 160 A, 162A formed in the transport platform 152 to enable consistent placement of the insert 910 and maintain position during pouring of the concrete 184. The inserts 910 may adhere to the concrete 184 and be incorporated into the modular concrete building block 1000 (Figure 10) to form the lower connector channels 1026, as shown in Figure 9M.

[0101] Where present, the positioning strips 906 on the spacer templates 902 cooperate with the grooves 160A, 162A formed in the transport platform 152 so that the upper channel spacers 186 are in registration with the lower channel spacers 182.

[0102] Figure 9N shows an illustrative embodiment of a mechanism for positioning the spacer templates 902 on the upper surface 188 of the concrete 184. The illustrative mechanism comprises two spaced-apart parallel uprights 920 carried by a respective one of the side walls 164. The uprights 920 extend vertically beyond the side wall 164, above the upper surface 188 of the concrete 184. The upper portions of the uprights 920 include respective guide slots 922. The guide slots 922 are parallel to one another. A spacer template 902 for the upper connector channel 1024 that will be nearest to and parallel to the side wall 164 is supported from above by a pair of followers 924 that are slidably received within the guide slots 922. This allows the spacer template 902 toslide vertically relative to the uprights 920. By sliding vertically relative to the uprights 920, the spacer template 902 can be lowered to place the upper channel spacer 186 thereof in the concrete 184 to form the upper connector channel 1024, and then raised to remove the upper spacer channel 186 after the concrete 184 has cured. The upper channel spacer 186 is coated with separating oil or another suitable release agent, as noted above. While the arrangement for only one of the side walls 164 is shown in Figure 9N, it will be appreciated that a similar arrangement may be used for the other side wall 164. The spacer templates 902 for the upper guide channels 1024 that will be parallel to the end walls 166 (and perpendicular to the side walls 164) may be supported by a scaffolding mechanism similar to that described above in respect of the side walls 164. Alternatively, the spacer templates 902 for the upper guide channels 1024 that will be parallel to the end walls 166 can be secured to the ends of the spacer templates 902 for the upper guide channels 1024 that will be parallel to the side walls 164. In the further alternative, the spacer templates 902 for the upper guide channels 1024 that will be parallel to the end walls 166 may be positioned manually. In this case, the ends of the spacer templates 902 associated with the side walls 164 may be used as positioning guides for placing the spacer templates 902 for the upper guide channels 1024 that will be parallel to the end walls 166. The foregoing merely describes some illustrative examples of mechanisms for positioning the spacer templates 902, and is not intended to be limiting.

[0103] After the concrete 184 has been poured and the vibrator rods have been deployed, and after the spacer templates 902 have been moved into position, the concrete 184 is cured. Preferably, the concrete 184 is steam cured at a suitable temperature with controlled humidity. In a preferred embodiment, for modular concrete building blocks of the dimensions described below, the concrete 184 is steam cured at a temperature between about 60°C to about 90°C with humidity of about 95% for a period of about 3 hours to about 5 hours. For example, a tent or other containment may be placed around the outer form 154 to maintain a controlled environment for curing. Suitable temperatures, humidity and related cure times for modular concrete building blocks of other sizes will be known to one of ordinary skill in the art, now informed by the present disclosure, and are not discussed further. While full curing will not occur during the initial period of about 3 hours to about 5 hours, sufficient hydration and early strength gain will have occurred during this time for the concrete to have hardened enough to be moved. Thus, the terms“cure”, “cured” and “curing”, as used herein without the modifier “full” refer to a curing sufficient for the concrete to have set so that it can be transported without damage. Full curing may occur, for example, during transport and / or storage.

[0104] Where steam curing is used, after about 3 to 5 hours, concrete typically achieves about 30-50% of its design strength, depending on the mix design, curing temperature, and cement type. For transportation, the modular concrete building block must have enough strength to resist handling stresses like stacking, and vibrations during transit and lifting during installation. In preferred embodiments, a minimum compressive strength of about 15-20 MPa (about 2175-2900 psi) is appropriate for safe handling. If the mix design and curing conditions result in sufficient early strength (e.g., rapid hardening cement or supplementary materials like silica fume) then transport after about 3 to 5 hours of steam curing will be feasible. For modular concrete building blocks that will be subjected to heavy handling or transport over rough terrain, additional curing time or precautions (e.g., protective packaging or careful handling) may be needed.

[0105] Full curing, when concrete reaches its maximum designed strength, typically occurs over a longer period. In some embodiments, after initial steam curing, concrete will (depending on the mix design and cement type) achieve about 70% of design strength after about 7 days, and about 90% to 100% of the design strength after about 28 days. After about 28 days, strength gain continues at a slower rate, depending on the mix design and environment. Some high-strength cements achieve full curing faster, while others take longer. Environmental conditions also play a role; high humidity and moderate temperatures promote curing while dry or cold conditions slow the process. Additives, such as accelerators and supplementary cementitious materials can alter the curing timeline.

[0106] In preferred embodiments, to facilitate transportability after steam curing, the mix design should be optimized for early strength (e.g., low water-cement ratio, high- strength cement, or accelerators), and early compressive strength should be tested to confirm adequacy before transport. The transport methods will preferably limit stress on the modular concrete building block; an illustrative method for transferring modular concrete building blocks onto a transport trailer is described further below. Followingtransportation, proper curing methods (e.g. continued hydration via moist curing or covering the modular concrete building blocks).

[0107] As noted above, full curing generally requires about 28 days. In some embodiments, full curing may occur during the construction process. For example, if the modular concrete building blocks are used to construct a single-family home (typically ranging from 3,000 to 5,000 square feet), it may take about 8 hours to assemble the structure from the modular concrete building blocks. The interior and exterior finishing work may require an additional three to four weeks. By the time the home is prepared for occupancy (e.g. an occupancy permit is obtained), the concrete can be cured before movein.

[0108] Similarly, if the modular concrete building blocks are used to construct a five-story, 80-unit multi-family apartment building, the structural assembly of the modular concrete building blocks may be completed in under 10 days, and the interior and exterior finishing may be completed in less than 30 days. In this case, too, the concrete will be fully cured by the time the building is ready for occupancy.

[0109] After initial steam curing, the concrete 184 will form a hollow concrete block, that is, a modular concrete building block 1000, resting upon the transport platform 152, as shown in Figures 10 and 10A. At this stage, the outer form 154 still surrounds the hollow modular concrete building block 1000 and the roofed column formed by the superstructure 100 remains inside the interior volume 1002 (Figures 11 to 14) of the hollow modular concrete building block 1000. The upper channel spacers 186 may then be removed from the hollow modular concrete building block 1000; this may be done later as well.

[0110] With reference now to Figures 11 to 13, after the concrete 184 is cured, the outer form 154 is deconfigured from the outer form casting configuration and the superstructure 100 serving as the inner form is retracted into the inner form demold configuration. In the illustrated embodiment, the outer form 154 is deconfigured first, and then the superstructure 100 is retracted; in other embodiments this may be done in the reverse order or substantially simultaneously. At this stage, the exterior of the modular concrete building block 1000 may be thoroughly inspected, and any discontinuities may be filled.

[0111] As shown in Figure 11, in the illustrated embodiment deconfiguring the outer form 154 from the outer form casting configuration comprises separating the side walls 164 and the end walls 166 from one another and then moving them away from the modular concrete building block 1000 so that the side walls 164 and the end walls 166 are clear of the transport platform 152 and the modular concrete building block 1000 resting thereon and therefore (subject to retraction of the superstructure 100) permit movement of the transport platform 152 and the modular concrete building block 1000 resting thereon in at least the first direction D (Figures 13 and 14). Figure 11 A shows a transparent view of the modular concrete building block 1000 resting on the transport platform 152 after deconfiguring the outer firm 154 and prior to retracting the superstructure 100.

[0112] As shown in Figures 12 and 13, in the illustrated embodiment retracting the superstructure 100 serving as the inner form into the inner form demold configuration comprises moving the superstructure 100 into the collapsed configuration in which the superstructure walls 104, 106 are downwardly collapsed such that the superstructure walls 104, 106 and the superstructure roof 102 are non-obstructing to movement of the transport platform 152 in the first direction D (Figures 13 and 14). This also results in the superstructure walls 104, 106 and the superstructure roof 102 being withdrawn from the interior volume 1002 of the modular concrete building block 1000 and positioned below the modular concrete building block 1000, so that the transport platform 152 and the modular concrete building block 1000 resting thereon are movable past the retracted superstructure 100 in at least the first direction D (Figures 13 and 14). This avoids needing to lift the modular concrete building block 1000 clear of the superstructure 100, allowing the modular concrete building block 1000 to instead be moved laterally, as described below in the context of Figures 14 and 14A.

[0113] Figure 13 shows the result after the outer form 154 has been deconfigured from the outer form casting configuration and the superstructure 100 serving as the inner form has been retracted into the inner form demold configuration. The resulting modular concrete building block 1000 can be used in modular construction, for example modular housing.

[0114] The superstructure 100 is merely one illustrative embodiment for an inner form, and is not limiting. For example, in other embodiments the inner form may not becollapsible, but may instead comprise a rigid roofed column that can be extended from and retracted into a cavity.

[0115] Figures 14 and 14A illustrate moving the transport platform 152 with the hollow modular concrete building block 1000 thereon past the superstructure 100 serving as the inner form. As noted above, in the illustrated embodiment, a plurality of wheeled skates 158 are disposed beneath the longer sides 160 of the transport platform 152, which straddle the pit 114 when the inner form opening 156 is in registration with the superstructure 100. This allows the transport platform 152 with the hollow modular concrete building block 1000 to be rolled past the collapsed superstructure, without requiring lifting of the modular concrete building block 1000. Either or both of the crossbars 162 may be configured with a tow hitch to facilitate movement of the transport platform 152, or the transport platform 152 may be motorized and may be controlled remotely. In other embodiments, the transport platform may be mounted on rails.

[0116] Preferably, the transport platform 152 with the hollow modular concrete building block 1000 is rolled over a person-accessible depression, narrower than the transport platform 152 and straddled thereby, to facilitate an inspection of the interior volume 1002 of the modular concrete building block 1000. At this stage, any concrete 184 that may have entered or obstructed the interior connections for the utility conduits may be removed, and any discontinuities may be patched. The transport platform 152 with the hollow modular concrete building block 1000 may then be rolled to a loading dock.

[0117] Reference is now made to Figures 15A through 15F, which illustrate how the transport platform 152 can be used to transfer the hollow modular concrete building block 1000 to a flatbed tractor trailer 1500 comprising a flatbed trailer 1502 towed by a tractor unit 1504. Although not shown, the tractor unit 1504 may have a driver, or the tractor unit 1504 may be autonomous. As seen in Figure 15A, the tractor trailer 1500 is maneuvered so that the flatbed trailer 1502 is positioned on an inclined ramp 1506 so that the aft end 1508 of the flatbed trailer 1502 is lower than the forward end 1510 of the flatbed trailer 1502. The inclined ramp 1506 descends below the substantially level floor 1512 of the loading dock, so that a region of the substantially level floor 1512 is disposed on either side of the inclined ramp 1506 (see Figure 15F). A plurality of chocks 1514 is disposed on the flatbed trailer 1502, with the chocks 1514 spaced apart along the length ofthe flatbed trailer 1502. The transport platform 152 with the hollow modular concrete building block 1000 is rolled toward the tractor unit 1504, with the wheeled skates 158 beneath the longer sides 160 of the transport platform 152 rolling along the regions of the substantially level floor 1512 on either side of the inclined ramp 1506. Thus, the transport platform 152 straddles the inclined ramp 1506 and also straddles the flatbed trailer 1502. The transport platform 152 with the hollow modular concrete building block 1000 is rolled toward the tractor unit 1504 until the modular concrete building block 1000 is in registration with the bed 1516 of the flatbed trailer 1502, as shown in Figures 15B and 15F. The crossbar 162 of the transport platform 152 closest to the tractor unit 1504 is removed or swung aside, either before or after the modular concrete building block 1000 is in registration with the bed 1516 of the flatbed trailer 1502.

[0118] Referring now to Figure 15C, the tractor unit 1504 begins to move forward, pulling the flatbed trailer 1502 forward with it, which also causes the flatbed trailer 1502 to rise as it ascends the inclined ramp 1506. As the flatbed trailer 1502 rises, the chocks 1514 sequentially engage the underside 1004 of the modular concrete building block 1000, lifting the modular concrete building block 1000 off the transport platform 152 until the modular concrete building block 1000 is fully supported by the chocks 1514 on the bed 1516 of the flatbed trailer 1502 and clear of the transport platform 152, as shown in Figure 15D. The tractor unit 1504 continues to move forward, pulling the flatbed trailer 1502 forward with it, until both the tractor unit 1504 and the flatbed trailer 1502 are on a substantially level surface, as shown in Figure 15E. Preferably, straps or other suitable fasteners may then be deployed to secure the modular concrete building block 1000 on the bed 1516 of the flatbed trailer 1502 before tractor trailer 1500 departs onto a roadway. Thus, the modular concrete building block 1000 may be transported to a construction site by a conventional flatbed tractor trailer 1500. Of course, all relevant transport laws should be complied with, for example the provision of “wide load” escort vehicles.

[0119] The hollow modular concrete building block 1000 may be used for modular construction. Reference is now made to Figures 16A through 16J, which depict aspects of the illustrative hollow modular concrete building block 1000. As will be evident from the foregoing description, the modular concrete building block 1000 is precast, and comprises a monolithic concrete enclosure defining an interior volume 1002. The term “monolithic”, as used in reference to the modular concrete building block 1000, means that the concrete184 of the modular concrete building block 1000 is a single continuous piece of concrete rather than two or more individual pieces of concrete joined together. The term “monolithic” does not preclude the presence of reinforcements, utility conduits, door frames, window frames, channel spacers, and / or other elements embedded within that single continuous piece of concrete. The term “monolithic” also does not preclude the presence of patches to fdl discontinuities in the modular concrete building block 1000. The concrete enclosure comprises at least one concrete wall (e.g. walls 1006, 1008) that at least partially circumvallates the interior volume 1002, and a concrete roof 1010 coupled to the concrete wall(s) (e.g. walls 1006, 1008). Preferably, both the concrete walls 1006, 1008 and the concrete roof 1010 are internally reinforced. The concrete walls 1006, 1008 and the concrete roof 1010 are part of an internally reinforced monolithic concrete body of the modular concrete building block 1000. Each of the concrete walls 1006, 1008 is an internally reinforced concrete ambit panel 1006, 1008 that defines the ambit of the interior volume 1002, and together they form a perimeter skirt depending from the roof 1010. The term “perimeter”, as used in this context, refers to the perimeter of the interior volume 1002 and not the perimeter of the roof 1010, as the roof 1010 (e.g. the roof overhangs 1012) may extend beyond the interior volume 1002. The roof 1010 is an internally reinforced concrete spanning panel 1010 that extends transverse to the perimeter skirt formed by the ambit panels 1006, 1008 and spans the perimeter skirt formed by the ambit panels 1006, 1008. The ambit panels 1006, 1008 and the spanning panel 1010 cooperate to define the interior volume 1002 between the ambit panels 1006, 1008 and the spanning panel 1010, and the internally reinforced monolithic concrete body of the modular concrete building block 1000 is open into the interior volume 1002 opposite the spanning panel 1010.

[0120] In the illustrated embodiment, the modular concrete building block 1000 has, apart from the roof overhangs 1012, a generally rectangular parallel epipedic shape formed by two substantially parallel longer walls 1006, two substantially parallel shorter walls 1008 and the roof 1010, which spans the walls 1006, 1008. (Figure 33 shows an embodiment omitting the roof overhangs.) As can be seen in the figures, the walls 1006, 1008 are joined to one another and hence circumvallate the interior volume 1002. The roof 1010 includes projecting roof overhangs 1012 extending beyond the shorter walls 1008; the projecting roof overhangs 1012 are formed by the overhanging troughs 174extending outwardly at each longitudinal end of the outer form 154, as described above. The roof overhangs 1012 may be used to form balconies and / or hallways in a multi-storey structure, as described below. The balconies may be enclosed by glass or other suitable material so as to form a solarium, which can increase the living space associated with the structure. The above-described modular concrete building block 1000 is merely an illustrative embodiment, and is not limiting. For example, there may be one or more walls with a curved outer surface, or one or more walls may be omitted or truncated as described further below.

[0121] In preferred embodiments, at least one of the concrete walls 1006, 1008 includes at least one opening through the respective wall 1006, 1008 into the interior volume 1002. As noted above, removable spacers or retained frames for doorways, windows and / or other large or small openings may be installed in the cavity 176 before pouring concrete, which will result in openings in one or more of the walls, 1006, 1008 into which a door (or door frame), window (or window frame) or other appurtenance may be installed, as appropriate. Thus, the opening(s) through the wall(s) 1006, 1008 may comprise one or more doorway apertures 1014 and / or one or more window apertures 1016 formed in the wall(s) 1006, 1008.

[0122] Figures 16A, 16C and 16D show, with dashed lines, non-limiting illustrative positions for two doorway apertures 1014 and a window aperture 1016. Although not shown, one or more openings may also be formed through the roof 1010 for accommodating utilities, such as a sanitary drain, which may include embedded conduits, or for staircases, elevators and / or other elements, as described further below. Without promising any particular utility, by fabricating a modular concrete building block 1000 with pre-formed openings (or embedded frames) for doors, windows, and other appurtenances, the need for additional cutting or modification on site may be reduced.

[0123] The underside 1004 of the modular concrete building block 1000 is formed by the respective edge faces 1018, 1020 of the longer walls 1006 and the shorter walls 1008 that are distal from the roof 1010; these edge faces 1018, 1020 frame a rectangular opening 1022 (see Figures 161 and 16J) into the interior volume 1002. Thus, the underside 1004 of the concrete enclosure opposite the roof 1010 is formed by the distaledges of the walls 1006, 1008, relative to the roof 1010, and the underside 1004 is open into the interior volume 1002.

[0124] In some preferred embodiments, the longer walls 1006 may have a length of about 7.2 meters (about 24 feet), excluding the roof overhangs 1012, which may have a length of about 1.5 meters (about 5 feet), and the shorter walls 1008 may have a length of about 3.6 meters (about 12 feet). The modular concrete building block 1000 may have a height of about 3.2 meters (about 10 feet, 7 inches). The thickness of the walls 1006, 1008 and the roof 1010 may generally be about 15 centimeters (about 6 inches) except that where a modular concrete building block 1000 is to form a lowermost floor or foundation of a building, the walls 1006, 1008 preferably have a thickness of about 25 centimeters (about 10 inches). Note that the foregoing metric to imperial length conversions are based on a conversion of 1 foot = 30 centimeters and 1 inch = 2.5 centimeters based on ruler convention rather than precise scientific conversion. Figure 16K is a view similar to that of Figure 161, and shows the thickened roof 1010 and optional additional thickness of one of the shorter walls 1008 with dashed lines on the right; the longer walls 1006 may be similarly thickened where the modular concrete building block 1000 is to be used as part of a foundation. In one preferred embodiment, a height of the concrete enclosure, measured from the underside (edge faces 1018, 1020 of the concrete enclosure) to an interior surface of the roof 1010, is about 2.3 meters (about 7 feet, 8 inches) and the interior surface of the roof is about 7 square meters (about 75 square feet) so as to provide a suitable volume for human habitation. Note that the foregoing metric to imperial length conversions are based on a conversion of 1 foot = 30 centimeters and 1 inch = 2.5 centimeters based on ruler convention rather than precise scientific conversion. The weight of the modular concrete building block 1000 may be, in some embodiments, up to 38 tons (about 76,000 lbs. or about 34,500 kg) depending on the number and extent of doorway apertures 1014, window apertures 1016 and roof openings. For a modular concrete building block 1000 that is to form a lowermost floor of a building and therefore has thicker walls 1006, 1008, the weight of the modular concrete building block 1000 may be, in some embodiments, up to about 49 tons (about 98,000 lbs. or about 44,500 kg) depending on the number and extent of doorway apertures 1014, window apertures 1016 and roof openings. All of the foregoing dimensions and weights are merely illustrative, and are not limiting. Systems and methods according to aspects of the present disclosurecan be used to manufacture hollow modular concrete building blocks in a wide range of shapes and sizes. In each case, the dimensions and other aspects will of course be subject to any applicable local building code, as well as any applicable transport regulations in respect of moving the modular concrete building blocks 1000 to a building site.

[0125] Any suitable finish may be applied to the interior surfaces of the walls 1006, 1008 and roof 1010, including for example painting, stucco, dry wall or paneling, or the interior surfaces may be left “raw”. Alternatively, electrical wiring (including telecommunication), HVAC, plumbing conduits, fire protection (e.g. sprinklers), gas lines, telecommunication, and / or insulation may be installed after manufacturing the modular concrete building block 1000 (e.g. at a construction site), rather than being embedded in the walls 1006, 1008 and / or roof 1010, and then concealed behind dry wall or another suitable covering. Additionally, interior walls may be installed within the interior volume 1002 of the modular concrete building block 1000 to divide the interior volume 1002 into individual rooms. The exterior surfaces of the walls 1006, 1008 and roof 1010 may also have any suitable finish applied, for example stucco, vinyl, metal, wood or composite cladding or siding, stone or brick, stone or brick veneer, an anti-corrosion finish, or may be left “raw”. This supports a wide range of architectural styles.

[0126] As best seen in Figures 16A and 16G, horizontal upper connector channels 1024 of triangular cross-section are formed in the roof 1010 (spanning panel 1010), resulting from the upper channel spacers 186 having been inserted into the upper surface 188 of the concrete 184. Similarly, as best seen in Figures 16B and 16H, horizontal lower connector channels 1026 of triangular cross-section are formed in the respective edge faces 1018, 1020 of the longer walls 1006 and the shorter walls 1008 (ambit panels 1006, 1008) that are distal from the roof 1010. The upper connector channels 1024 and the lower connector channels 1026 are disconnected from one another. These are merely illustrative embodiments and are not limiting.

[0127] As best seen in the cross-sectional views in Figures 161 and 16J, respective ones of the upper connector channels 1024 are in registration with corresponding respective ones of the lower connector channels 1026. The upper connector channels 1024 and the lower connector channels 1026 are further in registration with respective ones of the longer walls 1006 and the shorter walls 1008. The upper connector channels1024 and the lower connector channels 1026 can facilitate stacking of one instance of the modular concrete building block 1000 atop another instance of the modular concrete building block 1000, as described further below. In preferred embodiments, the upper connector channels 1024 and the lower connector channels 1026 each have a depth of at least six inches (about 15 cm) and more preferably a depth of at least ten inches (about 24 cm). Again, these are ruler convention conversions, rather than scientific. Preferably, the depths of the upper connector channels 1024 and the lower connector channels 1026 are equal.

[0128] Figure 17A shows an arrangement for a building comprising two of the modular concrete building blocks 1000, wherein an upper one of the two modular concrete building blocks 1000 is secured atop a lower one of the two modular concrete building blocks 1000. Suitably sized anti-slip connectors in the form of anti-slip plates 1700A, which may be made, for example, from metal tread plate (e.g. steel or aluminum) are fitted into the upper connector channels 1024 formed in the roof 1010 of a lower one of the modular concrete building blocks 1000. An upper one of the modular concrete building blocks 1000 is then lifted into place and lowered (e.g. via a crane) onto the lower one of the modular concrete building blocks 1000, with the lower connector channels 1026 of the upper one of the modular concrete building blocks 1000 in registration with the upper connector channels 1024 of the lower one of the modular concrete building blocks 1000, and therefore also in registration with the anti-slip plates 1700A. The height of the antislip plates 1700A should be about equal to the combined depth of the upper connector channels 1024 and the lower connector channels 1026. In preferred embodiments, before placing the upper one of the modular concrete building blocks 1000, cement (e.g. rubberized hydraulic cement) is applied around the perimeter of the roof 1010 (other than the roof overhangs 1012) of the lower one of the modular concrete building blocks 1000, outwardly of the upper connector channels 1024 thereof. After the upper one of the modular concrete building blocks 1000 has been placed, cement board tape (e.g. PVC mesh tape) may be applied along the joint between the upper one of the modular concrete building blocks 1000 and the lower one of the modular concrete building blocks 1000. A cement or mortar compound can then be applied over the tape to finish the joint.

[0129] The anti-slip plates 1700A secure the upper one of the modular concrete building blocks 1000 to the lower one of the modular concrete building blocks 1000, andinhibit the upper one of the modular concrete building blocks 1000 from shifting relative to the lower one of the modular concrete building blocks 1000. This enables multiple ones of the modular concrete building blocks 1000 to be stacked upon one another to form multiple stories of a building, with the floor of each upper storey of the building being formed by the roof(s) 1010 of the modular concrete building block(s) 1000 immediately below. For example, Figure 18 shows three modular concrete building blocks 1000 stacked one atop the other to form a stack 1800. The floor of the lowermost storey may be formed by a footing, which may be formed at the building site, and which may also include connector channels for receiving anti-slip connectors, such as anti-slip plates 1700 A. A specialized foundation block formed using the methods described above, but with thicker walls (e.g. about 20 cm to 25 cm, or about 8 to 10 inches using ruler convention conversion; see Figure 16K) will then be supported on the footing.Waterproof tar may be applied to the junction of the modular concrete building block 1000 and the footing, with additional protection provided by a layer of rubber or plastic matting. A foundation may be located at or below ground level. During manufacture of the uppermost modular concrete building block 1000 in a vertical series, the installation of the upper channel spacers 186 may be omitted so that the roof 1010 of the uppermost modular concrete building block 1000 lacks any upper connector channels, as shown in Figure 18. In some embodiments, buildings of several floors may be constructed by stacking the modular concrete building blocks 1000 one atop another to form multiple tiers or layers. Preferably, the number of tiers should not exceed seven. The buildings may comprise, for example, apartment buildings, townhomes, fourplex, triplex or duplex homes, or singlefamily homes.

[0130] Figures 17B and 17C show arrangements similar to that shown in Figure 17A, but where the anti-slip connectors take the form of a plurality of serpentine or sinusoidal anti-slip rods 1700B, 1700C. The anti-slip rods 1700B, 1700C may be formed by bending rebar into the desired shape, for example. In Figure 17B, a plurality of distinct individual anti-slip rods 1700B are fitted into each of the upper connector channels 1024 of the lower one of the modular concrete building blocks 1000. In Figure 17C, a single elongate anti-slip rod 1700C is fitted into each of the upper connector channels 1024 of the lower one of the modular concrete building blocks 1000. In the illustrated embodiments, the troughs of the anti-slip rods 1700B, 1700C are received in the upperconnector channels 1024 and the crests of the anti-slip rods 1700B, 1700C are received in the tower connector channels 1026. For the anti-slip rods 1700B, 1700C, the height (peak-to-peak amplitude) should be about equal to the combined depth of the upper connector channels 1024 and the tower connector channels 1026. For example, if the upper connector channels 1024 and the tower connector channels 1026 each have a depth of about six inches (about 15 cm), the height of the anti-slip rods 1700B, 1700C should be about twelve inches (about 30 cm). If the upper connector channels 1024 and the tower connector channels 1026 each have a depth of about ten inches (about 25 cm), the height of the anti-slip rods 1700B, 1700C should be about 20 inches (about 50 cm). Conversion is again based on ruler convention.

[0131] Figure 17D also shows an arrangement similar to that shown in Figure 17A, using a different kind of anti-slip plate 1700D. The anti-slip plates 1700D in Figure 17D have parallel centering cylinders 1704D disposed at each end. The centering cylinders 1704D may be formed, for example, by welding rebar onto opposite ends of a metal plate. As shown in Figures 17E and 17F, the centering cylinders 1704D assist in aligning the anti-slip plates 1700D within the upper connector channels 1024 and within the tower connector channels 1026 as the upper one of the modular concrete building blocks 1000 is towered into position. The height of the anti-slip plates 1700D in Figure 17D, including the centering cylinders 1704D, should be about double the combined depth of the upper connector channels 1024 and the tower connector channels 1026.

[0132] Optionally, strips of waterproofing material (e.g. PVC or rubber) may be placed in the upper connector channels 1024 and the lower connector channels 1026, inwardly of the anti-slip connectors 1700 A, 1700B, 1700C, 1700D, so as to vertically span the depth of the upper connector channels 1024 and the tower connector channels 1026. Preferably, waterproofing is applied to at least the lowermost above grade modular concrete building block 1000, as well as any below grade modular concrete building blocks 1000. Such waterproofing may include waterproof coating of the concrete walls 1006, 1008, roof 1010 and roof overhangs 1012, as well as waterproofing of any doors and windows.

[0133] Thus, as shown in each of Figures 17A to 17D and in Figure 18, the upper one of the two modular concrete building blocks 1000 is secured atop the tower one of thetwo modular concrete building blocks 1000 by a plurality of anti-slip connectors 1700 A, 1700B, 1700C, 1700D fitted into upper connector channels 1024 formed in the roof 1010 of the lower one of the modular concrete building blocks 1000 and further fitted into lower connector channels 1026 formed in the distal edges (edge faces 1018, 1020) of the concrete walls 1006, 1008 of the upper one of the modular concrete building blocks 1000, with the lower connector channels 1026 in registration with the upper connector channels 1024.

[0134] Additionally, concrete, mortar and / or sealant may be applied on site to junctions between adjacent modular concrete building blocks 1000.

[0135] As indicated previously, one or more openings may also be formed through the roofs 1010 of one or more of the modular concrete building blocks 1000. For example, such openings may be formed through the roofs 1010 of lower ones of the modular concrete building blocks 1000 to accommodate staircases to allow ascent and descent between the various modular concrete building blocks 1000 forming the multiple stories of the building. In particular embodiments, specialized modular concrete building blocks may be formed with enlarged roof openings. These specialized blocks may be stacked in the same way as shown in Figures 17 and 18 to form vertical shafts to accommodate elevators and / or plumbing, gas and electrical risers; such specialized blocks may omit any overhangs. Such specialized blocks may be formed by providing a second (further) extended configuration for the superstructure 100 where the superstructure roof 102 is level with the upper edges of the outer form 154, or by placing an additional form atop the superstructure roof 102.

[0136] Figures 19A and 19B show how multiple stacks 1800 of the modular concrete building blocks 1000 may be combined to form a larger structure 1900. The inner ones of the roof overhangs 1012 are arranged in abutting relationship so that the opposed shorter walls 1008 of each pair of modular concrete building blocks 1000 are spaced from one another to form a respective hallway 1902 between the opposed shorter walls 1008. Although not shown, an exterior elevator or a staircase may be provided in registration with the hallways 1902 and thereby enclose the ends of the hallways 1902. Alternatively, another one of the modular concrete building blocks 1000 may be used to enclose the ends of the hallways 1902 while also increasing the size of one of the endunits. The outer ones of the roof overhangs 1012 form balconies 1904 for the modular concrete building blocks 1000 that form the upper tiers of the structure 1900. Although not shown, a railing or enclosure may be provided for the balconies 1904, and mounting fixtures for such railing or enclosure may be embedded in the roof overhangs 1012 when the modular concrete building blocks 1000 are manufactured.

[0137] Figure 19C shows how multiple stacks 1800 of the modular concrete building blocks 1000 can be arranged not only with their roof overhangs 1012 in abutting relationship but with additional stacks 1800C arranged with the longer walls 1006 of adjacent pairs of modular concrete building blocks 1000 arranged in abutting relationship, to produce rows of stacked modular concrete building blocks 1000 of any desired length. Moreover, while Figure 19C shows only two rows of stacked modular concrete building blocks 1000, additional rows of stacked modular concrete building blocks 1000 may be provided with their respective roof overhangs 1012 in abutting relationship with those of the adjacent row, to thereby provide any desired number of rows. As noted above, thermal insulation, for example rigid insulation sheets, may be positioned in the cavity 176 before pouring concrete so that the resulting modular concrete building block 1000 includes integral insulation; such insulation need only be installed in the specific walls 1006, 1008 that will be exterior walls. Whether to install insulation, and the type and amount of such insulation, will depend upon the climatic conditions in which the modular concrete building block 1000 is to be deployed. In addition, the thermal mass of the modular concrete building blocks 1000 can help regulate indoor temperatures by absorbing and releasing heat.

[0138] Junctions between individual ones of the modular concrete building blocks 1000 may be patched or sealed. In some embodiments, a gasket seal may be placed between vertically adjacent blocks to inhibit infdtration of moisture / water and air and provide further insulation; such a gasket seal could be held in place merely by the weight of the upper one of the modular concrete building blocks 1000 although this would present a visible gap between the modular concrete building blocks absent additional exterior finishing. If a gasket seal alone is used, this will facilitate the rapid repair, because if an individual one of the modular concrete building blocks 1000 suffers damage, it can be removed and replaced.

[0139] In an embodiment of the type shown in Figure 19C, each modular concrete building block 1000 may form an individual dwelling, or two or more modular concrete building blocks with enlarged openings in, or entirely omitting, one or both of the longer walls 1006 (e.g. the modular concrete building blocks 2800 A, 2800B in Figures 28A and 29 A, respectively) may be combined so that an individual dwelling consists of multiple modular concrete building blocks. Internal partitions (e.g. framing and dry wall) can be used to create individual rooms within one or more of the modular concrete building blocks described herein.

[0140] As noted above, elements such as electrical wiring, HVAC, plumbing conduits, fire protection (e.g. sprinklers), gas lines, telecommunication wiring and the like may be placed in the cavity 176 before the concrete 184 is poured. In some cases, elements such as insulated electrical wiring and / or insulated telecommunication wiring may be directly embedded in the concrete. However, this arrangement is less preferred, as it may impede later servicing / repair / upgrading of the wiring. More preferably, utility conduit structures are placed within the cavity 176 before the concrete 184 is poured, with the result that the completed modular concrete building blocks 1000 will include one or more integrated utility conduits embedded within one or more of the walls 1006, 1008 and / or the roof 1010. The utility conduit(s) may be, for example, any one or more of electrical wiring conduit(s), telecommunication wiring conduit(s), heating, ventilation and air conditioning (HVAC) ducting, ventilation ducting, gas ducting (e.g. for a barbecue or gas range), plumbing pipe(s) (e.g. a drain pipe or supply pipe). For electrical wiring conduits or telecommunication conduits, suitable tubing may be used, and the wiring can be fed through the tubing, rather than being directly embedded in the concrete. The utility conduit(s) will have at least one interior connection that is accessible from within the interior volume 1002, which may form all or part of a living quarters. Suitable fixtures, such as electrical outlets, lighting, smoke and fire alarms, telecommunications connections, toilets, drains, faucets, showerheads, sprinklers and the like can be coupled to the embedded conduits. The utility conduit(s) will also have at least one exterior connection that is accessible from outside of the interior volume 1002. For example, the exterior connections may be located on an outer surface of one of the walls 1006, 1008, including the edge faces 1018, 1020 (or side edges of the walls if one or more walls are omitted, e.g. as shown in Figures 25 A to 29C), or on an outer surface of the roof 1010.From these exterior connections, the respective wiring conduits and fluid conduits of various vertical tiers and / or horizontal assemblies of the modular concrete building blocks 1000 can be coupled in electrical and fluid communication, for example to one another, to risers in the specialized blocks described above, and / or to external municipal services, or even to wells and / or septic systems in relatively remote locations. HVAC components, such as boiler(s) and chiller(s) for example, can be disposed on a building roof formed by the roofs 1010 of the uppermost modular concrete building blocks. Such utility connections are within the capability of one of ordinary skill in the art, now informed by the present disclosure. Since it may be difficult to inspect and certify embedded utility conduits at a building site, depending on legal requirements, inspection and certification (with optional labeling) may be carried out at the manufacturing facility where the modular concrete building blocks 1000 are made. Further inspection and certification may take place at the building site, with the prior inspection, certification and optional labeling providing assurance to on-site inspectors (again, subject to local legal requirements).

[0141] Figures 20 through 20F show a non-limiting, illustrative configuration of embedded utility conduits within the modular concrete building block 1000. As noted above, the modular concrete building block 1000 is precast to form a monolithic concrete enclosure defining an interior volume 1002, including at least one concrete wall 1006, 1008 that at least partially circumvallates the interior volume 1002, and a concrete roof 1010 coupled to the concrete wall(s) 1006, 1008. Each of the concrete walls 1006, 1008 is an internally reinforced concrete ambit panel 1006, 1008 that, together with the roof 1010, defines the ambit of the interior volume 1002, and together they form a perimeter skirt depending from the roof 1010. The roof 1010 is an internally reinforced concrete spanning panel 1010 that extends transverse to the perimeter skirt formed by the ambit panels 1006, 1008 and spans the perimeter skirt formed by the ambit panels 1006, 1008. The ambit panels 1006, 1008 and the spanning panel 1010 cooperate to define the interior volume 1002 between the ambit panels 1006, 1008 and the spanning panel 1010, and the internally reinforced monolithic concrete body of the modular concrete building block 1000 is open into the interior volume 1002 opposite the spanning panel 1010.

[0142] In the illustrated embodiment, the modular concrete building block 1000 has a generally rectangular parallelepipedic shape formed by two substantially parallel longer walls 1006, two substantially parallel shorter walls 1008 and the roof 1010 spansthe walls 1006, 1008. As can be seen in the figures, the walls 1006, 1008 are joined to one another and hence substantially completely circumvallate the interior volume 1002; in other embodiments the interior volume may be only partially circumvallated, as described further below in the context of Figures 24A through 29C; the modular concrete building blocks shown in those figures may also include embedded utility conduits. The underside 1004 of the concrete enclosure opposite the roof 1010 is formed by the distal edges of the walls 1006, 1008, relative to the roof 1010, and the underside 1004 is open into the interior volume 1002. There are openings through one of the longer walls 1006 in the form of a doorway aperture 1014 and a window aperture 1016. While two openings are shown in Figures 20 through 20F, this is merely illustrative and in other embodiments there may be only a single opening, or more openings, and the openings may be formed through more than one wall 1006, 1008. Moreover, while Figures 20 through 20F show only the upper connector channels 1024 formed in the outwardly facing surface of the roof 1010, lower connector channels 1026 are also present in the distal edges of the walls 1006, 1008.

[0143] Preformed conduit passages for various utilities may be embedded in the concrete 184 forming the modular concrete building blocks 1000. As shown in Figures 20 and 20A, a plurality of utility conduits is embedded in the concrete walls 1006, 1008 (ambit panels 1006, 1008) and the roof 1010 (spanning panel 1010), including HVAC ducts 2010, a ventilation duct 2012, electrical conduits 2014, plumbing supply pipes 2016, plumbing drain pipes 2018, and drain vent pipes 2020. Figures 20 and 20A show all the conduits together, and Figures 20B to 20F show certain of the conduits in isolation. Figure 20 shows the modular concrete building block 1000 with transparency to expose the utility conduits, and Figure 20A shows a solid view of the modular concrete building block 1000, with the utility conduits depicted using dashed lines. The arrangement and positioning of the utility conduits shown in Figures 20 through 20F is merely illustrative and not limiting; a wide range of utility conduit arrangements and positions are contemplated. Some modular concrete building blocks may include only some types of utility conduits, or none of them, depending on the configuration. Others may include additional utility conduits not specifically illustrated. As noted above, the utility conduits may be supported in the cavity 176 before pouring the concrete 184 by attaching these utility conduits to the reinforcement, or by using separate supports, such as support legs.Preferably this is done before moving the outer form 154 into the outer form casting configuration. The portions of the conduits that protrude beyond the walls 1006, 1008 and the roof 1010 show those that would be installed after casting of the modular concrete building block 1000.

[0144] Figure 20B shows the illustrative plumbing supply pipes 2016 embedded within the concrete walls 1006, 1008, in isolation. The plumbing supply pipes 2016 supply hot and cold water, and have interior connections 2024 that are accessible from within the interior volume 1002, and exterior connections 2026 that are accessible from outside the exterior volume 1002, that is, from an outer side of the wall 1006. The interior connections 2024 for the plumbing supply pipes 2016 can be coupled to plumbing fixtures such as faucets (for sinks and bathtubs), showers, toilets and bidets to supply water thereto. Preferably a suitable shutoff valve or stop valve is interposed between the interior connections 2024 for the plumbing supply pipes 2016 and the plumbing fixtures. The plumbing fixtures need not be directly adjacent interior connections 2024, as piping disposed inside the interior volume 1002 can be used to couple the interior connections 2024 to the plumbing fixtures. The exterior connections 2026 for the plumbing supply pipes 2016 can be connected in fluid communication with external water supply lines, for example a metered water supply in a building mechanical room.

[0145] Figure 20C shows the illustrative plumbing drain pipes 2018 and illustrative drain vent pipes 2020 embedded within the concrete walls 1006, 1008, in isolation.

[0146] The plumbing drain pipes 2018 have interior connections 2028 that are accessible from within the interior volume 1002 and can be coupled to plumbing fixtures such as sinks, bathtubs, showers, toilets and bidets to drain water therefrom. The plumbing drain pipes 2018 include drain branches 2030 and a main drainpipe 2032. The drain branches 2030 extend between respective ones of the interior connections 2028 and the main drainpipe 2032 whereby the interior connections 2028 are in fluid communication with the main drainpipe 2032. The plumbing fixtures need not be directly adjacent interior connections 2028, as piping disposed inside the interior volume 1002 can be used to couple the interior connections 2024 to the plumbing fixtures. The main drainpipe 2032 has exterior connections 2034, 2036 that are accessible from outside theexterior volume 1002, including an upper exterior connection 2034 of the main drainpipe 2032 that is accessible from an outer side of the roof 1010, and a lower exterior connection 2036 of the main drainpipe 2032 that is accessible from the underside 1004 of the modular concrete building block 1000. The lower exterior connection 2036 of the main drainpipe 2032 can be connected to the upper exterior connection 2034 of the main drainpipe 2032 of an underlying modular concrete building block 1000, such as in the one of the multi-storey arrangements shown in Figures 18 through 19C, so as to form a connected series of main drainpipes 2032. The lower exterior connection 2036 of the main drainpipe 2032 of a single or lowermost modular concrete building block 1000 can also be connected to a sewer line. The main drainpipe 2032 may also be configured for connection to a graywater processing system.

[0147] The drain vent pipes 2020 include drain vent branches 2038 and a main drain vent pipe 2040. The drain vent branches 2038 extend between the drain branches 2030 and the main drain vent pipe 2040, and also extend between the main drainpipe 2032 and the main drain vent pipe 2040. The main drain vent pipe 2040 has exterior connections 2042, 2044 that are accessible from outside the exterior volume 1002, including an upper exterior connection 2042 of the main drain vent pipe 2040 that is accessible from an outer side of the roof 1010, and a lower exterior connection 2044 of the main drain vent pipe 2040 that is accessible from the underside 1004 of the modular concrete building block 1000. The lower exterior connection 2044 of the main drain vent pipe 2040 can be connected to the upper exterior connection 2042 of the main drain vent pipe 2040 of an underlying modular concrete building block 1000, such as in the one of the multi-storey arrangements shown in Figures 18 through 19C so as to form a connected series of main drain vent pipes 2040. The upper exterior connection 2042 of the main drain vent pipe 2040 of a single or uppermost modular concrete building block 1000 may also vent to ambient.

[0148] Figure 20D shows the illustrative electrical conduits 2014 embedded within the concrete walls 1006, 1008, and within the concrete roof 1010, in isolation. Interior connections for the electrical conduits 2014, including electrical outlet boxes 2050, lighting junction boxes 2052, and a breaker box 2054 are embedded in the concrete walls 1006, 1008 and accessible from within the interior volume 1002. Exterior connections 2056 for the electrical conduits 2014 are accessible from outside of the interior volume1002. The exterior connections 2056 for the electrical conduits 2014 may be coupled in electrical communication with an electrical supply, for example a metered supply from a building electrical room. The exterior connections 2056 for the electrical conduits 2014 may also be coupled in electrical communication with an exterior connection for the electrical conduits of another modular concrete building block. In a preferred embodiment, rather than directly embedding wiring, the electrical conduits 2014 are formed from pipe of suitable material (e.g. PVC) so that wiring (e.g. Romex wiring) can be run through the pipes, which facilitates replacement and / or upgrading of the wiring. Figure 20D also shows an electrical heating element 2058 embedded in one of the roof overhangs 1012; this is an optional embodiment which may be advantageous if one or both of the roof overhangs is to be incorporated into an enclosed space, such as an enclosed balcony or solarium, for example.

[0149] Figure 20E shows the HVAC ducts 2010 embedded within the concrete walls 1006, 1008, in isolation. The HVAC ducts 2010 include interior connections in the form of vent openings 2060, as well as additional interior connections in the form of a fan coil connection 2062 which can be coupled to a fan coil unit 2064 embedded within the interior volume 1002. Of note, the fan coil unit is not embedded within the concrete wall 1006 but rather is disposed interiorly of. The fan coil unit 2064 may be conventional, and the embedded utility conduits may include electrical, water supply and drain connections for the fan coil unit 2064. The exterior connection 2066 for the HVAC ducts 2010 may be coupled to the exterior connection for another set of HVAC ducts in an adjacent modular concrete building block, or may be covered by an external vent.

[0150] Figure 20F shows the ventilation duct 2012 in isolation. The main portion 2070 of the ventilation duct 2012 is embedded in the concrete roof 1010 and a terminal portion 2072 of the ventilation duct 2012 jogs outwardly and downwardly into one of the shorter concrete walls 1008. The outward jog allows the terminal portion 2072 of the ventilation duct 2012 to pass through the comer gap between the upper connector channels 1024 into the shorter concrete wall 1008, and also circumvent reinforcement (e.g. rebar) in the shorter concrete wall 1008. The terminal portion 2072 of the ventilation duct 2012 communicates with an outlet 2074 embedded in the shorter concrete wall 1008 so as to provide an exterior connection for the ventilation duct 2012. The interior connections 2078 of the ventilation duct 2012 may be coupled to, for example, a range hood forstovetop, a bathroom fan or a dryer vent fan for a clothes dryer, for example, to vent from within the interior volume 1002 to ambient.

[0151] Figures 20G and 20H show illustrative internal reinforcement within the modular concrete building block 1000. Figure 20G shows internal reinforcement 180 in the walls (ambit panels) 1006, 1008 with internal reinforcement in the roof (spanning panel) 1010 omitted from the Figure for purposes of illustration. Figure 20H shows internal reinforcement 180 in the walls (ambit panels) 1006, 1008 as well as internal reinforcement 2080 in the roof (spanning panel) 1010. The internal reinforcement 180, 2080 may be formed from steel rebar, which may be cut to accommodate smaller elements such as junction boxes, electrical connections and water connections. For larger openings, additional reinforcement should be used, which may include header beams, side beams, perimeter reinforcement, diagonal bars and stirrups. Suitable reinforcement is within the capability of one of ordinary skill in the art, now informed by the present disclosure. Figures 20G and 20H show a single layer of internal reinforcement 180, 2080 to avoid unduly cluttered illustration; in practice there would typically be an inner and outer layer of internal reinforcement 180, 2080 in the walls (ambit panels) 1006, 1008 and the roof (spanning panel) 1010. The utility conduits would typically be disposed between the inner and outer layer of internal reinforcement 180, 2080. Lifting loops 3902 are also shown in Figures 20G and 20H.

[0152] Although not shown explicitly in the Figures, other examples of utility conduits include, without limitation, telecommunication wiring conduits (e.g. for telephone and Internet connectivity), fire suppression conduits (e.g. sprinklers) and gas conduits (e.g. for natural gas), a heating, ventilation and air conditioning (HVAC) duct, a gas duct, and a plumbing pipe. Utility conduits can be configured for integration of various “smart” building technologies, such as sensors, wiring for Internet of Things (loT) devices, and other modem building automation systems.

[0153] As noted above, in some embodiments, the utility conduits may be formed by placing rigid tubing, for example PVC or metal ducts or piping, or flexible tubing, for example PVC, TPE or HDPE tubing in the appropriate positions and configurations within the cavity 176 before pouring the concrete 184, so that the utility conduits are embedded within one or more of the walls 1006, 1008 and / or the roof 1010. The use of tubing allowsutility wiring such as electrical wiring or telecommunication wiring to be replaced or installed on site, although it may also be installed at a factory producing the modular concrete building blocks 1000. The materials used for the utility conduits should be approved by the appropriate governing body for each utility, to ensure compliance with applicable codes, including electrical codes, plumbing codes, fire codes, HVAC codes and any applicable laws and regulations.

[0154] Figures 21A through 21C show schematically how wiring can be replaced, for example to upgrade telecommunication wiring based on improvements in technology, or to upgrade electrical wiring based on changes in requirements or changes in relevant safety codes. In Figure 21 A, original wiring 2102 extends through a tubular utility conduit 2104 which is embedded in a modular concrete building block 1000 (not shown in Figures 21A to 21C). The lead end 2106 of the replacement wiring 2108 is fastened to the tail end 2110 of the original wiring 2102 and then the lead end 2112 of the original wiring 2102 is pulled, as shown in Figure 21B. This draws the original wiring 2102 out of the utility conduit 2104 while drawing the replacement wiring 2108 into the utility conduit 2104, as shown in Figure 21C. Once the lead end 2106 of the replacement wiring 2108 has emerged from the utility conduit 2104, the lead end 2106 of the replacement wiring 2108 can be detached from the tail end 2110 of the original wiring 2102. The original wiring 2102 can then be discarded (e.g. sent for recycling). The embodiment shown in Figures 21 A through 21C is relatively trivial, this is merely for purposes of illustration. Where there are multiple electrical conduits 2104 and multiple electrical wires (for example as shown in Figure 20D), the approach shown in Figures 21A through 21C allows for replacement of individual wires without impacting the structural integrity of the modular concrete building block 1000 by removing concrete to access the electrical conduits 2014 or electrical wiring. An approach similar to that shown in Figures 21A through 21C can be used where utility wiring such as electrical wiring or telecommunication wiring is to be replaced or installed on site, except that a dummy cable or rope may be installed at the factory instead of original wiring, and used to pull the original wiring into the utility conduit.

[0155] As noted above, the utility conduits may be supported in the cavity 176 before pouring the concrete 184 by attaching these utility conduits to the internalreinforcement 180, or by using separate supports, such as support legs, preferably before moving the outer form 154 into the outer form casting configuration.

[0156] Figures 22A through 22D show aspects of a first illustrative method for manufacturing a modular concrete building block 1000 including an embedded conduit. For purposes of illustration, the method is shown in Figures 22A through 22D in respect of the ventilation duct 2012 but may be applied, mutatis mutandis, in respect of any suitable utility conduit or other appurtenance, such as a door frame or window frame.

[0157] As shown in Figure 22A, the terminal portion 2072 of the ventilation duct 2012 and the outlet 2074 for the ventilation duct 2012 are positioned in the cavity 176 between the panel walls 106 of the superstructure 100 and the end wall 166 of the outer form 154. Reinforcements 180 are also disposed in the cavity 176. The terminal portion 2072 of the ventilation duct 2012 and the outlet 2074 for the ventilation duct 2012 are supported by the reinforcements 180. In Figure 22B, concrete 184 is poured into the cavity 176, so that the concrete 184 generally surrounds the terminal portion 2072 of the ventilation duct 2012, the outlet 2074 for the ventilation duct 2012, and the internal reinforcements 180. Figure 22C shows the cavity 176 fdled with concrete 184. At this stage, vibrator rods are inserted into the concrete 184 to drive the concrete 184 to substantially fully surround the internal reinforcements 180. Of note, an outer face 2076 of the outlet 2074 abuts the inner face of the end wall 166 of the outer form 154, so that the outer face 2076, which will form an exterior connection for the ventilation duct 2012, will remain substantially free of the concrete 184. After use of the vibrator rods, the spacer template 902 may be placed onto the upper surface 188 of the concrete 184, pushing the upper channel spacer 186 into the concrete 184 to form the respective upper connector channel 1024.

[0158] Reference is now made to Figures 23A through 23C. Figure 23 A is a top perspective view of the illustrative modular concrete building block 1000 surrounded by the outer form 154, showing a vertical conduit 2302 arranged at the junctions of one of the longer walls 1006 of the modular concrete building block 1000 and one of the shorter walls 1008 of the modular concrete building block 1000. The vertical conduit 2302 shown in Figure 23A is merely illustrative and not limiting. In some embodiments, as shown in other drawings above, vertical conduits may be disposed at all four junctions of the longerwalls 1006 and the shorter walls 1008. In other embodiments, vertical conduits may be disposed at only some of the junctions.

[0159] Figures 23B and 23C show an illustrative method for forming the vertical conduit 2302. An inflatable tube 2304 formed from a suitable flexible material, such as thermoplastic polyurethane (TPU) reinforced with synthetic fibers or wires, for example, is used to form the conduit 2302. A first end of the inflatable tube 2304 is secured on the transport platform 152. As shown in Figure 23B, the inflatable tube 2304 extends upwardly through the cavity 176 and beyond, and the second end 2306 of the inflatable tube 2304 is connected to a compressor 2308 that inflates the inflatable tube 2304 until it the portion disposed in the cavity 176 is effectively rigid. The concrete 184 can then be poured into the cavity 176 and cured while the compressor 2308 continues to maintain the rigidity of the inflatable tube, so that the inflatable tube 2304 will form the vertical conduit 2302. Then, as shown in Figure 23C, at least a portion of the inflatable tube 2304 is separated from the modular concrete building block 1000. In one embodiment, the inflatable tube 2304 may be coated with a suitable release agent before the concrete 184 is poured, and the inflatable tube 2304 is withdrawn from the vertical conduit 2302 after the concrete 184 has cured. In another embodiment, the inflatable tube 2304 remains embedded in the modular concrete building block 1000 so as to form a liner for the vertical conduit 2302. In an embodiment where the inflatable tube 2304 forms a liner for the vertical conduit 2302, the portion of the inflatable tube 2304 extending beyond the modular concrete building block 1000 is cut or otherwise separated from the portion of the inflatable tube 2304 that remains embedded in the modular concrete building block 1000. In either case, the inflatable tube 2304 may include reinforcement, for example a metallic helical reinforcement. In addition, a suitable fitting may be provided at either end of the vertical conduit 2302 to facilitate interconnection of the vertical conduits 2302 of vertically adjacent modular concrete building blocks 1000, for example as shown in Figures 17A through 17D. Where the inflatable tube 2304 forms a liner for the vertical conduit 2302 and remains embedded in the modular concrete building block 1000, the fittings may be disposed at either end of the portion of the inflatable tube 2304 that remains in the modular concrete building block 1000, and a mating fitting can be used to temporarily connect an additional portion of inflatable tube 2304 between the upper fitting and the compressor 2308. A conduit formed by an inflatable tube may be used as, or aspart of, a raceway or duct between two or more points, such as for a bathroom, kitchen, or dryer vent. Optionally, whether the inflatable tube forms a liner for the conduit and remains embedded in the modular concrete building block 1000, or is removed, a (further) sleeve (e.g. PVC pipe) may be fitted into the conduit to make the conduit suitable for running electrical wiring (e.g. Romex wiring).

[0160] The utility conduits described above are merely illustrative, and not limiting. Modular concrete building blocks according to an aspect of the present disclosure may be configured to support and integrate with a wide range of residential and commercial building technology and features, including smart lighting, smart switches, smart locks, motion sensors, smart doorbells, security cameras, various security sensors, smart thermostats, smart ceiling fans, smart air conditions, smart outlets, solar panel integration (e.g. on the roof 1010 of an uppermost one of the modular concrete building blocks 1000), energy monitoring systems, smart appliances, and automated window coverings. The foregoing are merely illustrative examples and are not limiting.

[0161] In some embodiments, a drop ceiling (e.g. a dry wall ceiling) may be provided below the roof 1010, and in addition to being embedded within the walls 1006, 1008 and / or roof 1010, utility conduits and other components may be disposed between the drop ceiling and the roof 1010.

[0162] The utility conduits must be configured so that they do not affect the loadbearing capacity and fire resistance of the modular concrete building blocks. The specific requirements will vary depending on the type of building, the load conditions, and the types of utility conduit(s) being installed. Moreover, the utility conduits should be configured to comply with relevant building and construction codes. Suitable configuration is within the capability of one of ordinary skill in the art, now informed by the present disclosure.

[0163] Rooms larger than the size of a single modular concrete building block 1000 may be formed by manufacturing two or more modular concrete building blocks with enlarged openings in one or both of the walls 1006, 1008 or omitting one or more walls entirely. These specialized modular concrete building blocks 1000 can then be arranged in abutting relation with these larger openings in registration with one another so that two or more modular concrete building blocks form a single room. For example, inaddition (or alternatively) to doorway apertures 1014 and / or window apertures 1016, an opening may comprise one or more discontinuities in the arrangement of the walls 1006, 1008 that substantially circumvallate the interior volume 1002. In one such embodiment, all or substantially all of one of the longer walls may be omitted, such that the omitted portion forms the discontinuity, and a building may be formed that comprises two such “three-wall” blocks (e.g. the modular concrete building blocks 2900 A, 2900B, 2900C in Figures 29A, 29B, 29C respectively) secured adjacent to one another with their respective discontinuities arranged in registration with one another to form a larger room. In another embodiment, a third block may have all or substantially all of both longer walls omitted (e.g. the modular concrete building block may have only the shorter walls) so as to have two opposed discontinuities. One or more of these “two-wall” blocks (e.g. the modular concrete building blocks 2800 A, 2800B, 2800C in Figures 28A, 28B, 28C respectively) may be interposed between a pair of the “three-wall” blocks, with one “three-wall” block at each end of the series, to form a yet larger room. For example, and without limitation, a single modular concrete building block 1000 might be used for a bachelor unit, two “three-wall” modular concrete building blocks might be used for a one-bedroom unit and two “three-wall” modular concrete building blocks and one “two-wall” modular concrete building blocks 1000 might be used for a two or three-bedroom unit. In yet another embodiment, a modular concrete building block according to an aspect of the present disclosure may have neither shorter walls nor longer walls, and instead have a roof (which may omit any roof overhangs) with columns at the comers thereof so as to resemble a table (e.g. the modular concrete building blocks 2400 A, 2400B, 2400C in Figures 24A, 24B, 24C respectively). Other embodiments of the modular concrete building blocks may have one longer wall with no shorter walls and two columns opposite the longer wall (e.g. the modular concrete building blocks 2500 A, 2500B, 2500C in Figures 25A, 25B, 25C respectively), or one shorter wall with no longer walls and two columns opposite the shorter wall (e.g. the modular concrete building blocks 2600A, 2600B, 2600C in Figures 26 A, 26B, 26C respectively). Other configurations may have one shorter wall adjacent one longer wall, with a column opposite the comer (e.g. the modular concrete building blocks 2700A, 2700B, 2700C in Figures 27 A, 27B, 27C respectively). Modular concrete building blocks according to these constructions may be used in combination with the “two-wall” and “three-wall” blocks to create rooms of various sizes and configurations. Other combinations may be used to construct a detached single-family home, for example.

[0164] Various illustrative embodiments will now be described with reference to Figures 24A through 29C.

[0165] Figure 24A shows an illustrative modular concrete building block 2400A in which the roof 2410A, including roof overhangs 2412A, is supported by load-bearing internally reinforced concrete columns 2428A. In this embodiment, reinforcements within the roof 2410A will preferably include crank bars. The columns 2428A define an interior volume 2402A of the modular concrete building block 2400A, with openings in the form of discontinuities 2430A between the columns 2428A. The columns 2428A may be considered a special case of a wall or ambit panel. The underside 2404A of the modular concrete building block 2400A opposite the roof 2410A is open into the interior volume 2402A (the space bounded by the columns 2428A). The modular concrete building block 2400A shown in Figure 24A can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in the roof 2410 A, which may include upper connector channels 2424A. In some embodiments, utility conduits can be embedded in the columns 2428A. Figure 24B shows a variant of the modular concrete building block 2400A shown in Figure 24A, with like reference numerals denoting like features but with the suffix “B” instead of “A”, having only a single roof overhang 2412B. Figure 24C shows a variant of the modular concrete building block 2400A shown in Figure 24A, with like reference numerals denoting like features but with the suffix “C” instead of “A”, which does not include any roof overhangs. Figure 24D shows a variant of the modular concrete building block 2400C shown in Figure 24C which is adapted for use as part of a foundation, with like reference numerals denoting like features but with the prefix “D” instead of “C” Figure 24D shows how the modular concrete building block 2400D (or one of the modular concrete building blocks 2400 A, 2400B, 2400C) may, as an upper one of two modular concrete building blocks 1000, be secured atop the lower one of the two modular concrete building blocks. A centered pocket 2432D is disposed at the lower end 2434D of each of the columns 2428D and is adapted to receive one end of an anti-slip connector in the form of a billet 2436. The other end of the billet 2436 can be received in a corresponding pocket formed in the roof of the lower one of the two modular concrete building blocks. The centered pockets 2432D can be provided by placing suitable hollow forms on the transport platform 152. The corresponding pockets in the roof can be formed as a truncated vertical conduit 2302, using a shortened inflatable tube2304, as shown in Figures 23B and 23C. Where the modular concrete building block 2400D is to be used as a foundation, the billets 2436 may extend into a hole in the underlying concrete footing, and in such cases the billets 2436 may be longer than twelve inches to provide for improved anchoring. Similar arrangements may be applied, mutatis mutandis, in respect of the modular concrete building blocks 2400B and 2400C shown in Figures 24B and 24C, respectively. In the illustrated embodiment, each of the pockets 2432D the columns 2428D and the pockets in the roofs of the underlying block is generally cylindrical and has a depth of approximately six inches (approximately 15 cm based on ruler convention conversion). This is merely an illustrative example and is not limiting. In the illustrated embodiment, the billet 2436 comprise a bundle of three 12-inch (approximately 30 cm based on ruler convention conversion) lengths of rebar bound together with rebar tie wire; this is merely a non-limiting illustrative example of a billet that can serve as an anti-slip connector and other configurations are also contemplated.

[0166] Figure 25A shows an illustrative modular concrete building block 2500A which has only a single wall 2506 A, corresponding to one of the longer walls 1006 in the modular concrete building block 1000 described above. The roof 2510A, including roof overhangs 2512A, is further supported by two internally reinforced load-bearing concrete columns 2528A opposite the wall 2506A. The roof 2510A, wall 2506A and columns 2528A define an interior volume 2502A within the modular concrete building block 2500 A, with openings in the form of discontinuities 2530A between the wall 2506A and the columns 2528A and between the two columns 2528A. The underside 2504A of the modular concrete building block 2500 opposite the roof 2510A is open into the interior volume 2502 A. The single wall 2506A is an ambit panel 2506 A which, along with the columns 2528A, forms the perimeter skirt defining the perimeter of interior volume 2502A. The roof 2510A is an internally reinforced concrete spanning panel 2510A that extends transverse to the perimeter skirt formed by the ambit panel 2506 A and the columns 2528A and spans the perimeter skirt formed by the ambit panel 2506A and the columns 2528A. The ambit panel 2506A and the columns 2528A and the spanning panel 2510A cooperate to define the interior volume 2502A therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 2500A is open into the interior volume 2502A opposite the spanning panel 2510A. Thus, in the embodiment shown in Figure 25 A, there is a single ambit panel 2506A and the perimeterskirt further comprises a pair of spaced-apart columns 2528A opposite the single internally reinforced concrete ambit panel 2506A.

[0167] The modular concrete building block 2500A shown in Figure 25A can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in the single wall 2506A and / or in the roof 2510A, which may include upper connector channels 2524A. In some embodiments, utility conduits can be embedded in the columns 2528A. Lower connector channels may be formed in the lower edge of the single wall 2506A. Figure 25B shows a variant of the modular concrete building block 2500A shown in Figure 25 A, with like reference numerals denoting like features but with the suffix “B” instead of “A”, having only a single roof overhang 2512B. Figure 25C shows a variant of the modular concrete building block 2500A shown in Figure 25 A, with like reference numerals denoting like features but with the suffix “C” instead of “A”, which does not include any roof overhangs. A mirror-image variant of the modular concrete building block 2500B shown in Figure 25B is also contemplated. Each of the modular concrete building blocks 2500 A, 2500B, 2500C shown in Figures 25 A, 25B and 25C, respectively, may have a centered pocket disposed at the lower end of each of the columns 2528A, 2528B, 2528C, similar to the arrangement described in respect of Figure 24D. Figure 25D shows a variant of the modular concrete building block 2500C shown in Figure 25C which is adapted for use as part of a foundation, with like reference numerals denoting like features but with the prefix “D” instead of “C”. Figure 25D shows explicitly how a centered pocket 2532D is disposed at the lower end 2534D of each of the two columns 2528D and is adapted to receive one end of an anti-slip connector in the form of a billet 2436. The upright edges of the wall 2506D include vertical edge connector channels 2540D, which may be formed by adapting the technique used for the lower connector channels 1026. For example, channel spacers may be mounted on the relevant parts of the outer form, for example. In one embodiment, expanded polystyrene (EPS) can be used to construct a disposable channel spacer. A suitably sized anti-slip connector may be fitted into the edge connector channels 2540D and into the correspondingly positioned edge connector channels of a horizontally adjacent block. In the illustrated embodiment, the anti-slip connector is of the same general type shown in Figure 17D, and comprises an anti-slip plate 2542 with centering cylinders at each end. Other types of anti-slip connectors, such as those of the types shown in Figures 17A to 17C, may also be used. Ina preferred embodiment, the edge connector channels may be used only for those modular concrete building blocks that will form the outer perimeter of a foundation (as described further below), although in other embodiments they may be used for all perimeter modular concrete building blocks.

[0168] Figure 26A shows an illustrative modular concrete building block 2600A which has only a single wall 2608 A, corresponding to one of the shorter walls 1008 in the modular concrete building block 1000 described above. The roof 2610A, including roof overhangs 2612A, is further supported by two internally reinforced load-bearing concrete columns 2628A opposite the wall 2606A. The roof 2610A, wall 2608A and columns 2528A define an interior volume 2602A within the modular concrete building block 2600 A, with openings in the form of discontinuities 2630A between the wall 2608A and the columns 2628A and between the columns 2628A. The underside 2604A of the modular concrete building block 2600 opposite the roof 2610A is open into the interior volume 2602A. The single wall 2608A is an ambit panel 2608A which, along with the columns 2628A, forms the perimeter skirt defining the perimeter of interior volume 2602A. The roof 2610A is an internally reinforced concrete spanning panel 2610A extending transverse to the perimeter skirt formed by the ambit panel 2608A and the columns 2628A and spans the perimeter skirt formed by the ambit panel 2608A and the columns 2628A. The ambit panel 2608A and the columns 2628A and the spanning panel 2610A cooperate to define the interior volume 2602A between these components, and the internally reinforced monolithic concrete body of the modular concrete building block 2600A is open into the interior volume 2602A opposite the spanning panel 2610A. Thus, in the embodiment shown in Figure 26A, there is a single ambit panel 2606A, with the perimeter skirt further comprising a pair of spaced-apart columns 2628A opposite the single internally reinforced concrete ambit panel 2606 A.

[0169] The modular concrete building block 2600A shown in Figure 26A can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in the single wall 2608A and / or in the roof 2610A, which may include upper connector channels 2624A. In some embodiments, utility conduits can be embedded in the columns 2628A. Lower connector channels may be formed in the lower edge of the single wall 2608A. Figure 26B shows a variant of the modular concrete building block 2600A shown in Figure 26A, with like reference numerals denoting likefeatures but with the suffix “B” instead of “A”, having only a single roof overhang 2612B. Figure 26C shows a variant of the modular concrete building block 2600A shown in Figure 26 A, with like reference numerals denoting like features but with the suffix “C” instead of “A”, which does not include any roof overhangs. Each of the modular concrete building blocks 2600A, 2600B, 2600C shown in Figures 26A, 26B and 26C, respectively, may have a centered pocket disposed at the lower end of each of the columns 2628A, 2628B, 2628C, similar to the arrangement described in respect of Figure 24D. Figure 26D shows a variant of the modular concrete building block 2600C shown in Figure 26C which is adapted for use as part of a foundation, with like reference numerals denoting like features but with the prefix “D” instead of “C” Edge connector channels 2640D are formed in the upright edges of the wall 2606D and adapted to receive an anti-slip connector, such as the anti-slip plate 2542. Figure 26D also shows the centered pockets 2632D at the lower ends 2634D of each of the columns 2628D adapted to receive one end of a billet 2436. Variants of the modular concrete building block 2600D shown in Figure 26D which include one or two roof overhangs, similar to the modular concrete building blocks 2600A and 2600B shown in Figures 26A and 26B, respectively, are also contemplated.

[0170] Figure 27A shows an illustrative modular concrete building block 2700A which has two adjacent walls 2706 A, 2708A, corresponding respectively to one of the longer walls 1006 and one of the shorter walls 1008 in the modular concrete building block 1000 described above. The roof 2710A, including roof overhangs 2712A, is further supported by a single column 2728A opposite the comer joining the walls 2706A, 2708A. The roof 2710A, walls 2706A, 2708A and column 2728A define an enclosure and the walls 2706 A, 2708A and column 2728A partially circumvallate an interior volume 2702A of the enclosure formed by the modular concrete building block 2700A, with openings in the form of discontinuities 2730A between the walls 2706 A, 2708A and the column 2728 A. The underside 2704A of the modular concrete building block 2700 opposite the roof 2710A is open into the interior volume 2702A. The walls 2706A, 2708A are ambit panels 2706A, 2708A which, along with the column 2728A, form the perimeter skirt defining the perimeter of interior volume 2702A. The roof 2710A is an internally reinforced concrete spanning panel 2710A that extends transverse to the perimeter skirt formed by the ambit panels 2706 A, 2708A and the column 2728A and spans the perimeterskirt formed by the ambit panels 2706A, 2708A and the column 2728A. The ambit panels 2706 A, 2708A and the column 2728A and the spanning panel 2710A cooperate to define the interior volume 2702 A therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 2700A is open into the interior volume 2702A opposite the spanning panel 2710A. Thus, in the embodiment shown in Figure 27 A, there are two adjacent substantially orthogonal ambit panels 2706A, 2708A and the perimeter skirt further comprises a single column 2728 A opposite the ambit panels 2706A, 2708A.

[0171] The modular concrete building block 2700A shown in Figure 27A can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in either or both walls 2706 A, 2708A and / or in the roof 2710A, which may include upper connector channels 2724A. In some embodiments, utility conduits can be embedded in the columns 2728 A. Lower connector channels may be formed in the lower edges of the walls 2706 A, 2708A. Figure 27B shows a variant of the modular concrete building block 2700A shown in Figure 1 , with like reference numerals denoting like features but with the suffix “B” instead of “A”, having only a single roof overhang 2712B. Figure 27C shows a variant of the modular concrete building block 2700A shown in Figure 27A, with like reference numerals denoting like features but with the suffix “C” instead of “A”, which does not include any roof overhangs. Mirror image variants of the modular concrete building blocks 2700 A, 2700B and 2700C shown in Figures 27A, 27B, 27C are also contemplated. Figure 30 shows a modular concrete building block 2700BM that is a mirror image of the modular block 2700B shown in Figure 27B. The lower end of the respective columns 2728A, 2728B, 2728C of each of the modular concrete building blocks 2700 A, 2700B, 2700C shown in Figures 27A, 27B, 27C may have a centered pocket disposed therein, similar to the arrangement described in respect of Figure 24D. Figure 27D shows a variant of the modular concrete building block 2700C shown in Figure 27C which is adapted for use as part of a foundation, with like reference numerals denoting like features but with the prefix “D” instead of “C” The upright edges (free ends) of the walls 2706D, 2708D have edge connector channels 2740D formed therein and adapted to receive an anti-slip connector, such as the anti-slip plate 2542. Figure 27D also shows the centered pockets 2732D at the lower ends 2734D of each of the columns 2728D, which can receive one end of a billet 2436. Also withincontemplation are variants of the modular concrete building block 2700D shown in Figure 27D which include one or two roof overhangs, similar to the modular concrete building blocks 2700A and 2700B shown in Figures 27A and 27B.

[0172] Figure 28A shows an illustrative modular concrete building block 2800A which has two opposed walls 2808 A, corresponding to the shorter walls 1006 in the modular concrete building block 1000 described above. The roof 2810A, including roof overhangs 2812A, is fully supported by the walls 2808 A. The roof 2810A and walls 2808A define an enclosure and the walls 2808A partially circumvallate an interior volume 2802A of the enclosure formed by the modular concrete building block 2800 A, with openings in the form of discontinuities 2830A between the walls 2808A. The underside 2804A of the modular concrete building block 2800 opposite the roof 2810A is open into the interior volume 2802A. The walls 2808A are ambit panels 2808A forming the perimeter skirt defining the perimeter of the interior volume 2802A. The roof 2810A is an internally reinforced concrete spanning panel 2810A that extends transverse to the perimeter skirt formed by the ambit panels 2808A and spans the perimeter skirt formed by the ambit panels 2808 A. The ambit panels 2808 A and the spanning panel 2810A cooperate to define the interior volume 2802A therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 2800A is open into the interior volume 2802A opposite the spanning panel 2810A. Thus, in the embodiment shown in Figure 28A, there are two opposed substantially parallel ambit panels 2808A.

[0173] The modular concrete building block 2800A shown in Figure 28A can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in either or both walls 2808A and / or in the roof 2810A, which may include upper connector channels 2824A. Lower connector channels may be formed in the lower edges of the walls 2808A. Figure 28B shows a variant of the modular concrete building block 2800A shown in Figure 28A, with like reference numerals denoting like features but with the suffix “B” instead of “A”, having only a single roof overhang 2812B. Figure 28C shows a variant of the modular concrete building block 2800A shown in Figure 28A, with like reference numerals denoting like features but with the suffix “C” instead of “A”, which does not include any roof overhangs. Although not shown, other variants may have two opposed walls corresponding to the longer walls 1006 in the modular concrete building block 1000 described above. Variants of the modular concretebuilding blocks 2800A, 2800B, 2800C shown in Figures 28A, 28B and 28C adapted for use as foundation blocks, and including edge connector channels in the upright edges of the walls, are also contemplated.

[0174] Figure 29A shows an illustrative modular concrete building block 2900A which has three adjacent walls 2906A, 2908 A, corresponding respectively to one of the longer walls 1006 and two of the shorter walls 1008 in the modular concrete building block 1000 described above. The roof 2910A, including roof overhangs 2912 A, is fully supported by the walls 2906A, 2908A. The roof 2910A and the walls 2906A, 2908A define an enclosure and the walls 2906A, 2908A partially circumvallate an interior volume 2902A of the enclosure formed by the modular concrete building block 2900 A, with an opening in the form of a discontinuity 2930A between the shorter walls 2908A. The underside 2904A of the modular concrete building block 2900 opposite the roof 2910A is open into the interior volume 2902 A. The walls 2906 A, 2908 A are ambit panels 2906 A, 2908A forming the perimeter skirt defining the perimeter of the interior volume 2902A. The roof 2610A is an internally reinforced concrete spanning panel 2610A that extends transverse to the perimeter skirt formed by the ambit panels 2906A, 2908A and spans the perimeter skirt formed by the ambit panels 2906A, 2908A. The ambit panels 2906 A, 2908A and the spanning panel 2910A cooperate to define the interior volume 2902A therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 2900A is open into the interior volume 2902A opposite the spanning panel 2910A. Thus, in the embodiment shown in Figure 29 A, there are two opposed substantially parallel ambit panels 2908A and a third ambit panel 2906A extending between and substantially orthogonal to the two opposed substantially ambit panels 2908A.

[0175] The modular concrete building block 2900A shown in Figure 29A can be formed by placing a suitable spacer within the cavity 176. One or more utility conduits may be embedded in one or more of the walls 2906A, 2908A and / or in the roof 2910A, which may include upper connector channels 2924A. Lower connector channels may be formed in the lower edges of the walls 2906 A, 2908A. Figure 29B shows a variant of the modular concrete building block 2900A shown in Figure 29 A, with like reference numerals denoting like features but with the suffix “B” instead of “A”, having only a single roof overhang 2912B. Figure 29C shows a variant of the modular concrete buildingblock 2900A shown in Figure 29A, with like reference numerals denoting like features but with the suffix “C” instead of “A”, which does not include any roof overhangs. Although not shown, other variants may have three adjacent walls corresponding to two of the longer walls 1006 and one of the longer walls 1008 in the modular concrete building block 1000 described above. A mirror-image variant of the modular concrete building block 2900B shown in Figure 29B is also contemplated. It is also contemplated that variants of the modular concrete building blocks 2800 A, 2800B, 2800C shown in Figures 28A, 28B and 28C may be adapted for use as foundation blocks, with edge connector channels being provided in the upright edges (free ends) of the shorter walls.

[0176] Although not shown in Figures 25 A through 29C, any of the modular concrete building blocks 2500 A, 2500B, 2500C, 2600 A, 2600B, 2600C, 2700A, 2700B, 2700C, 2800 A, 2800B, 2800C, 2900A, 2900B, 2900C shown therein may include doorway aperture(s) and / or window aperture(s). Moreover, as noted above any of the modular concrete building blocks 2500A, 2500B, 2500C, 2600 A, 2600B, 2600C, 2700A, 2700B, 2700C, 2800 A, 2800B, 2800C, 2900 A, 2900B, 2900C may include embedded utility conduits in a manner analogous to that described in respect of Figures 20 to 20F. The modular concrete building blocks 2500A, 2500B, 2500C, 2600 A, 2600B, 2600C, 2700 A, 2700B, 2700C, 2800A, 2800B, 2800C, 2900A, 2900B, 2900C preferably include internal reinforcement in a matter analogous to that described in respect of Figures 20G and 20H.

[0177] Figures 30 and 30A show construction of a larger room 3000 from a plurality of the modular concrete building blocks arranged horizontally adjacent to one another with their respective discontinuities arranged in registration with one another. In the particular embodiment shown in Figures 30 and 30A, the larger room is constructed from one of the modular concrete building blocks 2400C shown in Figure 24C, two of the modular concrete building blocks 2500C shown in Figure 25C, two of the modular concrete building blocks 2600B shown in Figure 26B, two of the modular concrete building blocks 2700B shown in Figure 27B, and two blocks 2700BM that are mirror images of the modular concrete building blocks 2700B shown in Figure 27B. In the illustrative embodiment, the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM are arranged in a 3x3 matrix, although this is merely illustrative and not limiting. The modular concrete building block 2400C with four columns occupies thecentral position in the matrix. The modular concrete building blocks 2700B, 2700BM having two adjacent walls form the comers of the matrix, and the modular concrete building blocks 2500C, 2600B having a single wall occupy the position between the comers in each outer row of the matrix. This is merely a non-limiting illustration, and a wide array of configurations are possible. Where utility conduits are embedded in the walls and / or roofs, the external connections of the utility conduits of adjacent blocks may be coupled to one another. Doorway apertures and or window apertures may be provided.

[0178] Figure 30B shows two layers of the arrangement shown in Figure 30A, namely a lower layer 3008 and an upper layer 3010. Within each layer 3008, 3010 the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM are arranged horizontally adjacent to one another with their respective discontinuities arranged in registration with one another. Each of the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the upper layer 3010 is secured atop a respective one of the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the lower layer 3008, in registration therewith. The modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the upper layer 3010 may be secured atop the respective modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the lower layer 3008 using anti-slip connectors such as the anti-slip plates 1700A, 1700D and / or anti-slip rods 1700B, 1700C in the manner shown in Figures 17A through 17D. Figures 17A to 17D also illustrate how, for each pair of respective upper and lower modular concrete building blocks 1000, utility conduits 1702 embedded within the concrete walls of the upper one of the modular concrete building blocks 1000 are in registration with a corresponding utility conduit 1702 embedded within the concrete walls of the corresponding lower one of the modular concrete building blocks 1000. A similar arrangement may be applied in respect of the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the upper layer 3010 is secured atop a respective one of the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the lower layer 3008. As can be seen, doorway apertures 3014 and window apertures 3016 may be provided. Analogous to the process described above in the context of Figure 17, before placing the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the upper layer 3010, cement is applied around the perimeter (other than the roof overhangs) of the modular concrete building blocks 2400C, 2500C, 2600B, 2700B,2700BM in the lower layer 3008. After the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM in the upper layer 3010 have been placed, cement board tape (e.g. PVC mesh tape) may be applied along the joints between the upper layer 3010 and the lower layer 3008, and along the joints between the respective ones of the modular concrete building blocks 2400C, 2500C, 2600B, 2700B, 2700BM. A cement or mortar compound can then be applied over the tape to finish the joints.

[0179] As noted above, in preferred embodiments a building constructed from modular concrete building blocks according to aspects of the present disclosure may have up to seven floors (i.e. seven layers). In some embodiments, all of the floors are constructed above grade (above ground), although they may rest upon a foundation that is entirely or partially below grade. In other embodiments, some or all of the floors may be below grade.

[0180] Figure 30C shows how a foundation layer 3006 may be assembled. Similarly to the lower layer 3008 and the upper layer 3010, the foundation layer 3006 comprises a larger room formed from a plurality of the modular concrete building blocks arranged horizontally adjacent to one another with their respective discontinuities arranged in registration with one another. The modular concrete building blocks used for the foundation layer 3006 are those which omit any roof overhangs, and which are specialized foundation blocks formed using the methods described above, but with thicker walls and columns (e.g. 8 to 10 inches or 20 to 25 cm using ruler convention conversion), resting upon an underlying concrete footing with suitable connector channels. Thus, in the particular embodiment shown in Figure 30C, the foundation layer 3006 is constructed from one of the modular concrete building blocks 2400D shown in Figure 24D, two of the modular concrete building blocks 2500D shown in Figure 25D, two of the modular concrete building blocks 2600D shown in Figure 26D, two of the modular concrete building blocks 2700D shown in Figure 27D, and two blocks 2700DM that are mirror images of the modular concrete building blocks 2700D shown in Figure 27D. The upright edges of the walls 2506D, 2608D, 2706D, 2708D of the modular concrete building blocks 2500D, 2600D, 2700D that will form the exterior of the foundation layer 3006 may be coupled to one another by fitting anti-slip connectors into the edge connector channels 2540D, 2640D, 2740D. Figure 30C shows the use of both anti-slip plates 2542 (similar to the anti-slip plates 1700A in Figure 17A) and anti-slip rods 2544 (similar to the anti-sliprods 1700B in Figure 17B) to illustrate that different kinds of connectors may be used; in practice a single type of anti-slip connector would typically be used for a particular project. For the larger room 3100 shown in Figures 31A through 31L, cement may be used in association with the anti-slip plates 2542 and / or anti-slip rods 2544. Cement may be applied to the anti-slip plates 2542 and / or anti-slip rods 2544 before they are inserted into the edge connector channels 2540D, 2640D, 2740D or cement can be injected into the edge connector channels 2540D, 2640D, 2740D after the anti-slip plates 2542 and / or antislip rods 2544 are inserted.

[0181] The billets 2436 would also be used but are omitted from Figure 30C to avoid unduly cluttering the illustration.

[0182] Figure 30D shows a multi-storey building 3004 formed from two layers of the arrangement shown in Figure 30A, namely a lower layer 3008 and an upper layer 3010, as well as a third, below-grade foundation layer 3006 as shown in Figure 30C. The foundation layer 3006 forms part of the foundation for the building 3004, and comprise foundation modular concrete building blocks 2400D, 2500D, 2600D, 2700D and 2700DM as described above, supported on an underlying concrete footing. The below-grade foundation layer 3006 is disposed under the ground 3012, and the lower layer 3008 is secured atop the foundation layer 3006, for example in the manner shown in Figures 17A through 17D. The upper layer 3010 may be likewise secured atop the lower layer 3008, with joints finished as described above.

[0183] A crane can be used to move the modular concrete building blocks into position. Reference is now made to Figures 39A and 39B. Figure 39A shows a crane 3900 lifting the modular concrete building block 2400A from Figure 24A. During casting of the modular concrete building block 2400A, lifting loops 3902 may be embedded in the roof 2410A. The crane 3900 supports a rectangular lifting frame 3904 via crane cables 3906, and frame cables 3908 depend from the lifting frame 3904 and are coupled to the lifting loops 3902, enabling the crane 3900 to lift the modular concrete building block 2400A while maintaining balance. After the modular concrete building block 2400A has been positioned, the lifting loops 3902 may be cut away, as shown in Figure 39B. The use of the modular concrete building block 2400A is merely illustrative, and a similarapproach can be taken to facilitate the positioning by crane of any of the modular concrete building blocks described herein.

[0184] Figures 31 A to 3 IL show construction of a larger room 3100 from a plurality of the modular concrete building blocks arranged horizontally adjacent to one another with their respective discontinuities arranged in registration with one another. The larger room 3100 is constructed from modular concrete building blocks that are similar to the modular concrete building blocks 2500D, 2600D, 2700D, 2700DM used for the arrangement shown in Figure 30A, but without any columns, and denoted by reference numerals 3500, 3200, 3300 and 3300M, respectively. In addition, an internally reinforced concrete slab 3400 is used in place of the modular concrete building block 2400 shown in Figure 24A and used for the arrangement shown in Figure 30A. With the columns omitted, internal support will be provided instead by steel beams 3128.

[0185] Details of the modular concrete building blocks 3200, 3300 and 3300M, and 3500, and the concrete slab 3400, will now be provided.

[0186] Figure 32 shows an illustrative modular concrete building block 3200 which is similar in construction to the illustrative modular concrete building block 2600D shown in Figure 26D, but without any columns. The modular concrete building block 3200 in Figure 32 has a roof 3210 with no overhangs, and a single wall 3208 corresponding to one of the shorter walls 1008 in the modular concrete building block 1000 described above. The roof 3210 and wall 3208 define an interior volume 3202 of the modular concrete building block 3200. The underside 3204 of the modular concrete building block 3200 opposite the roof 3210 is open into the interior volume 3202. The single wall 3208 is an ambit panel 3208 forming the perimeter skirt defining a portion of the perimeter of the interior volume 3202. The roof 3210 is an internally reinforced concrete spanning panel 3210 extending transverse to the perimeter skirt formed by the ambit panel 3208 and spans the perimeter skirt formed by the ambit panel 3208. The ambit panel 3208 and the spanning panel 3210 cooperate to define the interior volume 3202 therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 3200 is open into the interior volume 3202 opposite the spanning panel 3210. Thus, in the embodiment shown in Figure 32, there is a single ambit panel 3208, without any columns. The modular concrete building block 3200 shown in Figure32 can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in the single wall 3208 and / or in the roof 3210, which may include upper connector channels 3224. Lower connector channels may be formed in the lower edge of the single wall 3208. The upright edges of the wall 3208 include edge connector channels 3240, which may be formed by adapting the technique used for the lower connector channels 1026. For example, channel spacers may be mounted on the relevant parts of the outer form. The edge connector channels 3240 extend past the junction between the wall 3208 and the roof 3210 and through the roof 3210 to enable an anti-slip plate 2542 to be inserted either from the side as shown, or from above through the roof 3210.

[0187] Figure 33 shows an illustrative modular concrete building block 3300 which is similar in construction to the illustrative modular concrete building block 2700D shown in Figure 27D, but without a column. Figure 33 shows an illustrative modular concrete building block 3300 which has two adjacent walls 3306, 3308, corresponding respectively to one of the longer walls 1006 and one of the shorter walls 1008 in the modular concrete building block 1000 described above. The roof 3310 and walls 3306, 3308 define an enclosure and the walls 3306, 3308 partially circumvallate an interior volume 3302 of the enclosure formed by the modular concrete building block 3300, with an opening in the form of the discontinuity 3330 between the walls 3306, 3308. The underside 3304 of the modular concrete building block 3300 opposite the roof 3310 is open into the interior volume 3302. The walls 3306, 3308 are ambit panels 3306, 3308 which form the perimeter skirt defining the perimeter of the interior volume 3302. The roof 3310 is an internally reinforced concrete spanning panel 3310 that extends transverse to the perimeter skirt formed by the ambit panels 3306, 3308 and spans the perimeter skirt formed by the ambit panels 3306, 3308. The ambit panels 3306, 3308 and the spanning panel 3310 cooperate to define the interior volume 3302 therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 3300 is open into the interior volume 3302 opposite the spanning panel 3310. Thus, in the embodiment shown in Figure 33, there are two adjacent substantially orthogonal ambit panels 3306, 3308. The modular concrete building block 3300 shown in Figure 33 can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in either or both walls 3306, 3308 and / or in the roof 3310, which may includeupper connector channels 3324. Lower connector channels may be formed in the lower edges of the walls 3306, 3308. The edge connector channels 3340 extend past the junctions between the walls 3306, 3308 and the roof 3310 and through the roof 3310 to enable anti-slip plates 2542 to be inserted either from the side as shown, or from above through the roof 3310. A support pocket 3350 is formed in an interior surface of the longer wall (ambit panel) 3306 toward an outer edge thereof adjacent the roof (spanning panel) 3310. A mirror image version of the modular concrete building block 3300 shown in Figure 33 is denoted by reference 3300M.

[0188] Figure 34 shows an illustrative internally reinforced concrete slab 3400 which includes upper connector channels 3424 formed in the generally planar upper surface 3410 thereof.

[0189] Figure 35 shows an illustrative modular concrete building block 3500 which is similar in construction to the illustrative modular concrete building block 2500D shown in Figure 25D, but without any columns. The illustrative modular concrete building block 3500 has only a single wall 3506, corresponding to one of the longer walls 1006 in the modular concrete building block 1000 described above. The roof 3510 and wall 3506 define an interior volume 3502 and the underside 3504 of the modular concrete building block 3500 opposite the roof 3510 is open into the interior volume 3502. The single wall 3506 is an ambit panel 3506 which forms the perimeter skirt defining the perimeter of the interior volume 3502. The roof 3510 is an internally reinforced concrete spanning panel 3510 that extends transverse to and spans the perimeter skirt formed by the ambit panel 3506. The ambit panel 3506 and the spanning panel 3510 cooperate to define the interior volume 3502 therebetween, and the internally reinforced monolithic concrete body of the modular concrete building block 3500 is open into the interior volume 3502 opposite the spanning panel 3510. Thus, in the embodiment shown in Figure 35, there is a single ambit panel 3506 forming the perimeter skirt. Support pockets 3550 are formed in the interior surface of the wall (ambit panel) 3506 toward the outer edges thereof, adjacent the roof (spanning panel) 3510. The modular concrete building block 3500 shown in Figure 35 can be formed by placing suitable spacers within the cavity 176. One or more utility conduits may be embedded in the single wall 3506 and / or in the roof 3510, which may include upper connector channels 3524. Lower connector channels may be formed in the lower edge of the single wall 3506. The edge connector channels 3540 extend past thejunctions between the wall 3506 and the roof 3510 and through the roof 3510 to enable anti-slip plates 2542 to be inserted either from the side as shown, or from above through the roof 3510.

[0190] Reference is again made to Figures 31A to 3 IL, which show construction of a larger room 3100 from the modular concrete building blocks 3500, 3200, 3300 and 3300M and the internally reinforced concrete slab 3400, with support provided by steel beams 3128. Figure 31 A is an exploded view of the room 3100. In the illustrated embodiment, the modular concrete building blocks 3500, 3200, 3300, 3300M and the slab 3400 are arranged in a 3x3 matrix, although this is merely illustrative and not limiting. The slab 3400 occupies the central position in the matrix. The modular concrete building blocks 3300, 3300M having two adjacent walls 3306,3308 form the comers of the matrix, and the modular concrete building blocks 3200, 3500 having a single wall 3208, 3506 occupy the positions between the comers in each outer row of the matrix. This is merely a non-limiting illustration, and a wide array of configurations are possible. Where utility conduits are embedded in the walls and / or roofs, the external connections of the utility conduits of adjacent blocks may be coupled to one another. Doorway apertures and or window apertures may be provided.

[0191] In Figures 31B to 31K, the modular concrete building blocks 3500, 3200, 3300 and 3300M, slab 3400, steel beams 3128, anti-slip plates 2542 and anti-slip rods 2544 “floating” near their eventual positions for purposes of illustration; in practice these components (other than the anti-slip plates 2542 and anti-slip rods 2544) would be located elsewhere and moved by crane into the appropriate position as needed. The lifting loops are omitted for clarity of illustration. Figures 31A to 31L show the use of both anti-slip plates 2542 and anti-slip rods 2544 to illustrate that different kinds of connectors may be used; in practice a single type of anti-slip connector would typically be used for a particular project. The modular concrete building blocks 3500, 3200, 3300 and 3300M may be disposed upon a footing, for example as a foundation layer, or atop another layer of modular concrete building blocks, using anti-slip connectors as described above.

[0192] Reference is first made specifically to Figure 31B. One of the modular concrete building blocks 3300M forming a first comer of the matrix is moved into position, and then one of the steel beams 3128 is maneuvered so that the end of the steelbeam 3128 is received in the support pocket 3350 in the interior surface of the wall 3306.The other end of the steel beam 3128 is temporarily supported by an adjustable support stand 3160.

[0193] Referring now to Figure 31C, another one of the modular concrete building blocks 3300 forming a second comer of the matrix is moved into position, so that the end of the steel beam 3128 that was supported by the support stand 3160 (Figure 31B) is received in the support pocket 3350 in the interior surface of the wall 3306. The support stand 3160 can then be removed. At this point, the modular concrete building blocks 3300, 3300M are coupled to one another by the steel beam 3128 received in the respective support pockets 3350 to form a self-supporting structure.

[0194] Turning to Figure 31D, one of the modular concrete building blocks 3200 having a shorter wall 3208 is lowered onto the steel beam 3128 coupling the modular concrete building blocks 3300, 3300M, between the modular concrete building blocks 3300, 3300M forming the first and second comers of the matrix and in registration therewith. The structure continues to be self-supporting, with the modular concrete building block 3200 having the shorter wall 3208 supported by the steel beam 3128 extending between the modular concrete building blocks 3300, 3300M. The edge connector channels 3340 on the shorter walls 3308 of the modular concrete building blocks 3300, 3300M that form the first and second comers of the matrix are in registration with the edge connector channels 3240 on the single wall of the modular concrete building block 3200 disposed between them. Then the anti-slip plates 2542 and / or anti-slip rods 2544 can be slid into the edge connector channels 3240, 3340 from above, resulting in the configuration shown in Figure 31E.

[0195] Next, as shown in Figure 3 IF, one of the modular concrete building blocks 3500 having a single longer wall 3506 is moved into position adjacent one of the modular concrete building blocks 3300M forming a comer of the matrix, and an anti-slip plate 2542 is placed in the respective edge connector channels 3340, 3540. Two steel beams 3128 are maneuvered so that their ends are received in respective support pockets 3550 in the interior surface of the wall 3506, with the other ends of the steel beams 3128 being temporarily supported by respective adjustable support stands 3160.

[0196] Referring now to Figure 31G, another one of the modular concrete building blocks 3500 having a single longer wall 3506 is moved into position opposite the first such modular concrete building block 3500 and adjacent to the modular concrete building block 3300 forming the other comer of the matrix. The ends of the steel beams 3128 that are supported by the support stands 3160 are received in the support pockets 3550 in the interior surface of the wall 3506. An anti-slip rod 2544 is placed into the respective edge connector channels 3340, 3540 of the modular concrete building blocks 3300, 3500.

[0197] Next, as shown in Figure 31H, the slab 3400 is lowered into position between the modular concrete building blocks 3500 having the single longer wall 3506, and adjacent to the modular concrete building block 3200 having a single shorter wall 3206. The slab 3400 is supported by the steel beams 3128 extending between the modular concrete building blocks 3500 having the single longer wall 3506.

[0198] Then, as shown in Figure 311, another one of the modular concrete building blocks 3300 is moved into position adjacent to one of the modular concrete building blocks 3500 having the single longer wall 3506, so that this modular concrete building block 3300 forms a third comer of the matrix. An anti-slip rod 2544 is placed into the respective edge connector channels 3340, 3540 of the modular concrete building blocks 3300, 3500. Then, one of the steel beams 3128 is maneuvered so that the end of the steel beam 3128 is received in the support pocket 3350 in the interior surface of the wall 3306 of the modular concrete building block 3300 forming the third comer of the matrix. The other end of the steel beam 3128 is temporarily supported by an adjustable support stand 3160.

[0199] Referring now to Figure 31 J, another one of the modular concrete building blocks 3300M forming a fourth comer of the matrix is moved into position, so that the end of the steel beam 3128 that is supported by the support stand 3160 is received in the support pocket 3350 in the interior surface of the wall 3306. The support stand 3160 can then be removed and an anti-slip plate 2542 can be placed into the respective edge connector channels 3340, 3540 (see Figure 311) of the modular concrete building blocks 3300M, 3500.

[0200] Next, as shown in Figure 3 IK, another one of the modular concrete building blocks 3200 having a shorter wall 3208 is towered onto the steel beam 3128coupling the modular concrete building blocks 3300, 3300M forming the third and fourth comers of the matrix, between these modular concrete building blocks 3300, 3300M and in registration therewith. The modular concrete building block 3200 having the shorter wall 3208 is supported by the steel beam 3128 extending between the modular concrete building blocks 3300, 3300M forming the third and fourth comers. The edge connector channels 3340 (Figure 31 J) on the shorter walls 3308 of the modular concrete building blocks 3300, 3300M that form the third and fourth comers of the matrix are in registration with the edge connector channels 3240 (Figure 31 J) on the single wall 3208 of the modular concrete building block 3200 disposed between them. Then the anti-slip plates 2542 and / or anti-slip rods 2544 can be slid into the edge connector channels 3240, 3340 (see Figure 31J) from above, resulting in the configuration shown in Figure 31L. Cement board tape (e.g. PVC mesh tape) may be applied along the joints between the respective ones of the modular concrete building blocks 3200, 3300, 3500 and the slab 3400. A cement or mortar compound can then be applied over the tape to finish the joints. The arrangement shown in Figure 3 IL may be an above-ground layer or an underground layer, and may be used, for example, as or as part of a parking structure. A similar arrangement, but omitting the steel beams, may be inverted to form a larger swimming pool.

[0201] For the larger room 3100 shown in Figures 31 A through 31L, cement may be used in association with the anti-slip plates 2542 and / or anti-slip rods 2544. Cement may be applied to the anti-slip plates 2542 and / or anti-slip rods 2544 before they are inserted into the edge connector channels 3240, 3340, 3540 or cement can be injected into the edge connector channels 3240, 3340, 3540 after the anti-slip plates 2542 and / or antislip rods 2544 are inserted.

[0202] Figure 36 shows a first variant 1000A of the modular concrete building block 1000, with like reference numerals denoting like features but with the suffix “A”, which includes roof overhangs 1032A along the longer walls 1006A in addition to the roof overhangs 1012A along the shorter walls 1008A, as well as a vertical conduit 2302A. Figure 37 shows a second variant 1000B of the modular concrete building block 1000, with like reference numerals denoting like features but with the suffix “B”, which includes roof overhangs 1032B only along the longer walls 1006B, without any roof overhangs along the shorter walls 1008B. The variants 1000 A, 1000B of the modular concrete building block 1000 shown in Figures 36 and 37 may be manufactured using side walls164 of the outer form 154 which have overhanging troughs similar to the overhanging troughs 174 of the end walls 166 of the outer form 154. Figure 38 shows a third variant 1000C, with like reference numerals denoting like features but with the suffix “C”, of the modular concrete building block 1000 which does not include any roof overhangs. This latter variant may be manufactured by omitting the overhanging troughs 174 from the end walls 166 of the outer form 154, or blocking them. It is also contemplated that there may be variants in which only one of the longer walls 1006 has a roof overhang 1032 and / or only one of the shorter walls 1008 has a roof overhang 1012, and this may be applied, mutatis mutandis, to any of the modular concrete building blocks 2500 A, 2500B, 2500C, 2600 A, 2600B, 2600C, 2700A, 2700B, 2700C, 2800A, 2800B, 2800C, 2900 A, 2900B, 2900C shown in Figures 25A to 25C, 26A to 26C, 27A to 27C, 28A to 28C and / or 29A to 29C.

[0203] As can be seen from the above description, the modular concrete building blocks 1000, 1000 A, 1000B, 1000C, 2400 A, 2400B, 2400C, 2400D, 2500 A, 2500B, 2500C, 2500D, 2600A, 2600B, 2600C, 2600D, 2700 A, 2700B, 2700C, 2700D, 2800 A, 2800B, 2800C, 2900 A, 2900B, 2900C, 3200, 3300, 3500 or suitable sub-combinations of these, or variants thereof, may form a modular building system. In a preferred embodiment, as can be seen in Figures 30A through 3 IL, each of the modular concrete building blocks 1000, 1000 A, 1000B, 1000C, 2400A, 2400B, 2400C, 2400D, 2500 A, 2500B, 2500C, 2500D, 2600A, 2600B, 2600C, 2600D, 2700A, 2700B, 2700C, 2700D, 2800 A, 2800B, 2800C, 2900A, 2900B, 2900C, 3200, 3300, 3500 have a uniform footprint, excluding the roof overhangs. The modular building system can be used to build single-family homes, townhomes, and mid-rise buildings for residential, industrial or commercial use, using only the anti-slip connectors without additional structural support such as steel beams.

[0204] Thus, the modular concrete building blocks described herein may be used as part of a modular building system to support flexible and customizable layouts. Depending on the context, the modular concrete building blocks described herein may facilitate expansion (e.g. adding one or more blocks) or modification with limited reconstruction as compared to conventional buildings. Thus, buildings constructed using modular concrete building blocks according to aspects of the present disclosure provide for scalability. Without being limited by theory, and without promising any particularutility, modular concrete building blocks according to aspects of the present disclosure can be mass-produced to meet large scale construction needs, and transported to a building site, where the assembly procedure may reduce the construction timeline, allowing for faster project completion than conventional construction, with less on-site construction activity, reducing noise, dust, and disruption to the surrounding area during the building process. Moreover, the standardized nature of the modular concrete building blocks allows for better predictability in construction costs.

[0205] One or more modular concrete building blocks according to an aspect of the present disclosure can also be formed with suitable utility conduits for filtration and water supply / circulation / drainage and the interior volume sealed, so that the modular concrete building block(s) can be inverted to form a swimming pool, or a reservoir or water collection system, or, if formed with large, embedded windows of suitable material, an aquarium. Further, one or more modular concrete building blocks according to an aspect of the present disclosure can also be positioned to form a bridge for traversing, for example, a road or a waterway such as a river.

[0206] In addition, modular concrete building blocks according to aspects of the present disclosure may be used in the construction of tunnels. For example, modular concrete building blocks 2800C of the type shown in Figure 28C may be arranged end-to- end to form a tunnel. Similarly, opposing pairs of the modular concrete building blocks 3500 shown in Figure 35 with supporting steel beams may be arranged end-to-end to form a tunnel.

[0207] In addition, various ones of the modular concrete building blocks described herein may be deployed in a position in which the roof (spanning panel) forms a wall or a floor and / or in which one of the walls (ambit panels) forms a roof.

[0208] Modular concrete building blocks which comprise four connected walls (ambit panels) and which omit any roof (spanning panel) are also contemplated. These may be used, for example, for elevator shafts and / or utility shafts or risers.

[0209] While the illustrated embodiments have included planar roofs (spanning panels), sloped roofs (spanning panels) are also contemplated. Such may be produced using additional outer forms.

[0210] Methods according to aspects of the present disclosure may also be adapted to construct ramps.

[0211] The modular nature of the modular concrete building blocks described herein allows for relatively rapid assembly and disassembly, making them well-suited for temporary structures or situations where rapid deployment is necessary. Depending on the context, when a larger structure formed from individual modular concrete building blocks is no longer needed, it can be disassembled into individual modular concrete building blocks, which can then be transported elsewhere for reuse. For example, an athlete’s village for a large international sporting event could be constructed in the manner described above and, after the event, be dissembled and the individual modular concrete building blocks could be reused in other structures. The same could be done for temporary housing for asylum-seekers or refugees, or other instances where housing or other structures are needed on a temporary basis.

[0212] Modular concrete building blocks according to aspects of the present disclosure can be made compatible with other prefabricated components. For example, the plumbing supply pipes, plumbing drain pipes and electrical conduits can be configured for compatibility with prefabricated modular kitchen pods and bathroom pods, such as those offered by (for example and without limitation) ModularPods, having an address at 180 West Beaver Creek Rd, Richmond Hill, ON L4B 1B4 Canada. In one embodiment, the kitchen pod and / or bathroom pod may be provided with one or more hinged or removable panels to provide access for connecting the interior connections of the utility conduits to the pod fixtures, and one or more of the walls of the modular concrete building block may be formed with niche(s) to accommodate the pod(s), or to provide storage space. Mirrors with backlighting connections for bathrooms and closets may be embedded in the concrete wall(s). In addition, one of the walls can be provided with a recess to accommodate a pivoting / tilt-away wall bed, such as a so called “Murphy Bed” offered by Murphy Wall Beds Hardware Inc. having an address at 107-3170 194th Street, Surrey, BC Canada V3Z 9V2, or the roof may have a recess to accommodate an elevator bed that can retract into the ceiling.

[0213] In preferred embodiments, materials used for internal aspects of the modular concrete building blocks are selected to emit low levels of volatile organic compounds (VOCs), contributing to healthier indoor air quality.

[0214] Modular concrete building blocks according to aspects of the present disclosure can also incorporate a wide array of extant components and features in the construction and building industry. For example, and without limitation, modular concrete building blocks according to aspects of the present disclosure may incorporate drainage channels to manage water runoff efficiently, inhibiting water accumulation and damage, and outer surfaces can be treated to resist graffiti, making it easier to maintain the building’s appearance in urban environments. The modular concrete building blocks can also be integrated with seismic isolation systems, or other features to provide resistance to natural disasters. In addition, the modular nature of the modular concrete building blocks can support fire compartmentalization within a structure.

[0215] One or more currently preferred embodiments have been described by way of example. It will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the claims.Listing of Reference Numerals

[0216] The following listing of reference numerals is provided for convenience only, and no limitation is implied; the list is not necessarily exhaustive and may not be complete.100 Superstructure (generally)102 Superstructure roof102H Support hinges104 Concertina walls104U Upper ends of concertina walls106 Panel walls1061 Inner sides of panel walls108 Segments of concertina walls108H Concertina wall hinges110 Piston-cylinder assemblies112 Superstructure base / floor of pit114 Pit116 Hinge posts118 Hinge slots120 Pivot shafts122 Lower bracket124 Upper bracket126 Scissor lift128 Piston-cylinder apertures130 Piston-cylinder aperture flaps132 Hinges (for piston-cylinder aperture flaps)134 Track followers136 Guide tracks (set into panel walls)138 Guide tracks (formed by guide rails)140 Guide rails142 Rail apertures144 Rail flaps150 Casting apparatus (generally)152 Transport platform154 Outer form156 Inner form opening158 Wheeled skates160 Longer sides of transport platform160A Positioning grooves in longer sides of transport platform162 Crossbars of transport platform162A Positioning groove in crossbar of transport platform164 Side walls of outer form166 End walls of outer form168 Upper outcroppings170 Outcropping floors172 Retainer walls174 Overhanging trough176 Cavity178 Floor of cavity180 Internal reinforcements182 Lower channel spacers184 Concrete186 Upper channel spacers188 Upper surface of concrete902 Spacer template904 Template body906 Positioning strip910 V-shaped insert912 Vertex of V-shaped insert914 Distal ends of V-shaped insert920 Uprights922 Guide slots in uprights924 Followers1000 Hollow concrete block (modular concrete building block)1002 Interior volume of modular concrete building block1004 Underside of modular concrete building block1006 Longer walls of modular concrete building block (ambit panel)1008 Shorter walls of modular concrete building block (ambit panel)1010 Roof of modular concrete building block (spanning panel)1012 Projecting roof overhangs of modular concrete building block1014 Doorway apertures1016 Window apertures1018 Edge faces of longer walls1020 Edge faces of shorter walls1022 Opening into interior volume1024 Upper connector channels1026 Lower connector channels1000A Hollow concrete block (modular concrete building block)1004 A Underside of modular concrete building block1006 A Longer walls of modular concrete building block1008 A Shorter walls of modular concrete building block1010A Roof of modular concrete building block1012A Projecting roof overhangs (shorter walls) of modular concrete building block1014A Doorway aperture1016A Window aperture1024A Upper connector channels1032A Projecting roof overhangs (longer walls) of modular concrete building block1000B Hollow concrete block (modular concrete building block)1004B Underside of modular concrete building block1006B Longer walls of modular concrete building block1008B Shorter walls of modular concrete building block1010B Roof of modular concrete building block1014B Doorway aperture1016B Window aperture1024B Upper connector channels1032B Projecting roof overhangs (longer walls) of modular concrete building block1000C Hollow concrete block (modular concrete building block)1004C Underside of modular concrete building block1006C Longer walls of modular concrete building block1008C Shorter walls of modular concrete building block1010C Roof of modular concrete building block1014C Doorway apertures1016C Window apertures1024C Upper connector channels1500 Flatbed tractor trailer1502 Flatbed trailer1504 Tractor unit1506 Inclined ramp1508 Aft end of flatbed trailer1510 Forward end of flatbed trailer1512 Substantially level floor1514 Chocks1516 Bed of flatbed trailer1700A Anti-slip plates1700B Anti-slip rods1700C Anti-slip rods1700D Anti-slip plates1702 Utility conduits1704D Centering cylinders1800 Stack of modular concrete building blocks1900 Larger structure1902 Hallways1904 Balconies2010 HVAC ducts2012 Ventilation duct2014 Electrical conduits2016 Plumbing supply pipes2018 Plumbing drain pipes2020 Drain vent pipes2024 Interior connections of plumbing supply pipes2026 Exterior connections of plumbing supply pipes2028 Interior connections of plumbing drain pipes2030 Drain branches2032 Main drainpipe2034 Upper exterior connection of main drainpipe2036 Lower exterior connection of main drainpipe2038 Drain vent branches2040 Main drain vent pipe2042 Upper exterior connection of the main drain vent pipe2044 Lower exterior connection of the main drain vent pipe2050 Electrical outlet boxes2052 Lighting junction boxes2054 Breaker box2056 Exterior connections for electrical conduits2058 Electrical heating element2060 HVAC vent openings2062 HVAC fan coil connections2064 Fan coil unit2066 Exterior connection for HVAC ducts2070 Main portion of ventilation duct2072 Terminal portion of ventilation duct2074 Outlet for ventilation duct2076 Outer face of outlet2078 Interior connections for ventilation duct2080 Internal reinforcements2102 Original wiring2104 Utility conduit2106 Lead end of replacement wiring2108 Replacement wiring2110 Tail end of replacement wiring2112 Lead end of original wiring2302 Vertical conduit2302 A Vertical conduit2302B Vertical conduit2302C Vertical conduit2304 Inflatable tube2306 Second end of inflatable tube2308 Compressor2400A Modular concrete building block (two roof overhangs)2402A Interior volume of modular concrete building block2404A Underside of modular concrete building block2410A Roof of modular concrete building block2412A Roof overhang of modular concrete building block2424A Upper connector channels of modular concrete building block2428A Columns of modular concrete building block2430A Discontinuity2400B Modular concrete building block (one roof overhang)2402B Interior volume of modular concrete building block2404B Underside of modular concrete building block241 OB Roof of modular concrete building block2412B Roof overhang of modular concrete building block2424B Upper connector channels of modular concrete building block2428B Columns of modular concrete building block2430B Discontinuity2400C Modular concrete building block (no roof overhangs)2402C Interior volume of modular concrete building block2404C Underside of modular concrete building block2410C Roof of modular concrete building block2424C Upper connector channels of modular concrete building block2428C Columns of modular concrete building block2430C Discontinuity2400D Modular concrete building block (foundation)2402D Interior volume of modular concrete building block2404D Underside of modular concrete building block2410D Roof of modular concrete building block2424D Upper connector channels of modular concrete building block2428D Columns of modular concrete building block2430D Discontinuity2432D Centered pockets at lower ends of columns2434D Lower ends of columns2436 Billets2500A Modular concrete building block (two roof overhangs)2502A Interior volume of modular concrete building block2504 A Underside of modular concrete building block2506A Wall of modular concrete building block2510A Roof of modular concrete building block2512A Roof overhang of modular concrete building block2524A Upper connector channels of modular concrete building block2528A Columns of modular concrete building block2530A Discontinuity2500B Modular concrete building block (one roof overhang)2502B Interior volume of modular concrete building block2504B Underside of modular concrete building block2506B Wall of modular concrete building block2510B Roof of modular concrete building block2512B Roof overhang of modular concrete building block2524B Upper connector channels of modular concrete building block2528B Columns of modular concrete building block2530B Discontinuity2500C Modular concrete building block (no roof overhangs)2502C Interior volume of modular concrete building block2504C Underside of modular concrete building block2506C Wall of modular concrete building block2510C Roof of modular concrete building block2524C Upper connector channels of modular concrete building block2528C Columns of modular concrete building block2530C Discontinuity2500D Modular concrete building block (foundation)2502D Interior volume of modular concrete building block2504D Underside of modular concrete building block2506D Wall of modular concrete building block2510D Roof of modular concrete building block2524D Upper connector channels of modular concrete building block2528D Columns of modular concrete building block2530D Discontinuity2532D Centered pockets at lower ends of columns2434D Lower ends of columns2540D Edge connector channels2542 Anti-slip plate2544 Anti-slip rod2600A Modular concrete building block (two roof overhangs)2602A Interior volume of modular concrete building block2604A Underside of modular concrete building block2606A Wall of modular concrete building block2610A Roof of modular concrete building block2612A Roof overhang of modular concrete building block2624A Upper connector channels of modular concrete building block2628A Columns of modular concrete building block2630A Discontinuity2600B Modular concrete building block (one roof overhang)2602B Interior volume of modular concrete building block2604B Underside of modular concrete building block2606B Wall of modular concrete building block261 OB Roof of modular concrete building block2612B Roof overhang of modular concrete building block2624B Upper connector channels of modular concrete building block2628B Columns of modular concrete building block2630B Discontinuity2600C Modular concrete building block (no roof overhangs)2602C Interior volume of modular concrete building block2604C Underside of modular concrete building block2606C Wall of modular concrete building block26 IOC Roof of modular concrete building block2624C Upper connector channels of modular concrete building block2628C Columns of modular concrete building block2630C Discontinuity2600D Modular concrete building block (foundation)2602D Interior volume of modular concrete building block2604D Underside of modular concrete building block2606D Wall of modular concrete building block2610D Roof of modular concrete building block2624D Upper connector channels of modular concrete building block2628D Columns of modular concrete building block2630D Discontinuity2632D Centered pockets at lower ends of columns2634D Lower ends of columns2640D Edge connector channels2700A Modular concrete building block (two roof overhangs)2702A Interior volume of modular concrete building block2704 A Underside of modular concrete building block2706 A Longer wall of modular concrete building block2708 A Shorter wall of modular concrete building block2710A Roof of modular concrete building block2712A Roof overhang of modular concrete building block2724A Upper connector channels of modular concrete building block2728 A Columns of modular concrete building block2730A Discontinuity2700B Modular concrete building block (one roof overhang)2700BM Modular concrete building block (one roof overhang) (mirror image)2702B Interior volume of modular concrete building block2704B Underside of modular concrete building block2706B Longer wall of modular concrete building block2708B Shorter wall of modular concrete building block271 OB Roof of modular concrete building block2712B Roof overhang of modular concrete building block2724B Upper connector channels of modular concrete building block2728B Column of modular concrete building block2730B Discontinuity2700C Modular concrete building block (no roof overhangs)2702C Interior volume of modular concrete building block2704C Underside of modular concrete building block2706C Longer wall of modular concrete building block2708C Shorter wall of modular concrete building block27 IOC Roof of modular concrete building block2724C Upper connector channels of modular concrete building block2728C Column of modular concrete building block2730C Discontinuity2700D Modular concrete building block (foundation)2702D Interior volume of modular concrete building block2704D Underside of modular concrete building block2706D Longer wall of modular concrete building block2708D Shorter wall of modular concrete building block2710D Roof of modular concrete building block2724D Upper connector channels of modular concrete building block2728D Column of modular concrete building block2730D Discontinuity2732D Centered pockets at lower ends of columns2734D Lower ends of columns2740D Edge connector channels2800A Modular concrete building block (two roof overhangs)2802A Interior volume of modular concrete building block2804A Underside of modular concrete building block2808A Walls of modular concrete building block2810A Roof of modular concrete building block2812A Roof overhang of modular concrete building block2824A Upper connector channels of modular concrete building block2830A Discontinuity2800B Modular concrete building block (one roof overhang)2802B Interior volume of modular concrete building block2804B Underside of modular concrete building block2808B Walls of modular concrete building block281 OB Roof of modular concrete building block2812B Roof overhang of modular concrete building block2824B Upper connector channels of modular concrete building block2830B Discontinuity2800C Modular concrete building block (no roof overhangs)2802C Interior volume of modular concrete building block2804C Underside of modular concrete building block2808C Walls of modular concrete building block28 IOC Roof of modular concrete building block2824C Upper connector channels of modular concrete building block2830C Discontinuity2900A Modular concrete building block (two roof overhangs)2902A Interior volume of modular concrete building block2904A Underside of modular concrete building block2906A Longer wall of modular concrete building block2908A Shorter walls of modular concrete building block2910A Roof of modular concrete building block2912A Roof overhang of modular concrete building block2924A Upper connector channels of modular concrete building block2930A Discontinuity2900B Modular concrete building block (one roof overhang)2902B Interior volume of modular concrete building block2904B Underside of modular concrete building block2906B Longer wall of modular concrete building block2908B Shorter walls of modular concrete building block291 OB Roof of modular concrete building block2912B Roof overhang of modular concrete building block2924B Upper connector channels of modular concrete building block2930B Discontinuity2900C Modular concrete building block (no roof overhangs)2902C Interior volume of modular concrete building block2904C Underside of modular concrete building block2906C Longer wall of modular concrete building block2908C Shorter walls of modular concrete building block29 IOC Roof of modular concrete building block2924C Upper connector channels of modular concrete building block2930C Discontinuity3004 Multi-storey building3006 Foundation layer3008 Lower layer of modular concrete building blocks3010 Upper layer of modular concrete building blocks3012 Ground3014 Doorway apertures3016 Window apertures3100 Larger room3128 Steel beams3160 Stand3200 Modular concrete building block (no columns)3202 Interior volume of modular concrete building block3204 Underside of modular concrete building block3208 Wall of modular concrete building block3210 Roof of modular concrete building block3224 Upper connector channels of modular concrete building block3240 Edge connector channels3300 Modular concrete building block (no columns)3302 Interior volume of modular concrete building block3304 Underside of modular concrete building block3306 Longer wall of modular concrete building block3308 Shorter wall of modular concrete building block3310 Roof of modular concrete building block3324 Upper connector channels of modular concrete building block3340 Edge connector channels3350 Support pocket3400 Slab3410 Upper surface of slab3424 Upper connector channels of slab3500 Modular concrete building block (no columns)3502 Interior volume of modular concrete building block3504 Underside of modular concrete building block3506 Wall of modular concrete building block3510 Roof of modular concrete building block3524 Upper connector channels of modular concrete building block3540 Edge connector channels3550 Support pocket3900 Crane3902 Lifting loop3904 Lifting frame3906 Crane cables3908 Frame cablesD First direction

Claims

1. WHAT IS CLAIMED IS:

1. A precast modular concrete building block, comprising: an internally reinforced monolithic concrete body having: an internally reinforced concrete spanning panel; and a perimeter skirt depending from the internally reinforced concrete spanning panel, the perimeter skirt comprising at least one internally reinforced concrete ambit panel; wherein the internally reinforced concrete spanning panel extends transverse to the perimeter skirt and spans the perimeter skirt; wherein: the at least one internally reinforced concrete ambit panel and the internally reinforced concrete spanning panel cooperate to define an interior volume between the at least one internally reinforced concrete ambit panel and the internally reinforced concrete spanning panel; the internally reinforced monolithic concrete body is open into the interior volume opposite the internally reinforced concrete spanning panel; wherein the modular concrete building block has at least one of: lower connector channels formed in a distal edge of the at least one internally reinforced concrete ambit panel; and upper connector channels formed in an outwardly facing surface of the internally reinforced concrete spanning panel.

2. The modular concrete building block of claim 1, wherein the at least one internally reinforced concrete ambit panel includes at least one opening through the at least one internally reinforced concrete ambit panel.

3. The modular concrete building block of claim 2, wherein the at least one opening through the at least one internally reinforced concrete ambit panel comprises at least one of: at least one doorway aperture formed in the at least one internally reinforced concrete ambit panel; and at least one window aperture formed in the at least one internally reinforced concrete ambit panel.

4. The modular concrete building block of any one of claims 1, 2 or 3 wherein: the modular concrete building block has both of: the lower connector channels formed in the distal edge of the at least one internally reinforced concrete ambit panel; the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete spanning panel; and wherein the lower connector channels and the upper connector channels are substantially in registration with one another.

5. A building comprising at least two of the modular concrete building blocks according to any one of claims 1 to 4, wherein: an upper one of the two modular concrete building blocks is secured atop a lower one of the two modular concrete building blocks; the upper one of the two modular concrete building blocks has at least the lower connector channels; the lower one of the two modular concrete building blocks has at least the upper connector channels; andthe upper one of the two modular concrete building blocks is secured atop the lower one of the two modular concrete building blocks by a plurality of anti-slip connectors fitted into the lower connector channels of the upper one of the two modular concrete building blocks and into the upper connector channels of the lower one of the two modular concrete building blocks.

6. The modular concrete building block of to any one of claims 2 or 3, wherein the at least one opening through the at least one internally reinforced concrete ambit panel comprises a discontinuity in the at least one internally reinforced concrete ambit panel.

7. A building comprising at least two modular concrete building blocks according to claim 6 arranged adjacent to one another with their respective discontinuities arranged in registration with one another.

8. The modular concrete building block of any one of claims 1 to 4 or 6, wherein at least one utility conduit is embedded within at least one of the at least one internally reinforced concrete ambit panel and the internally reinforced concrete spanning panel; at least one interior connection for the at least one utility conduit is accessible from within the interior volume; and at least one exterior connection for the at least one utility conduit is accessible from outside of the interior volume.

9. The modular concrete building block of claim 8, wherein the at least one utility conduit comprises at least one HVAC duct, at least one ventilation duct, at least one electrical conduit, at least one plumbing supply pipe, at least one plumbing drain pipe, and at least one drain vent pipe.

10. The modular concrete building block of any one of claims 1 to 4, 6, 8 or 9, wherein the at least one internally reinforced concrete ambit panel consists of a single internally reinforced concrete ambit panel.

11. The modular concrete building block of claim 10, wherein the perimeter skirt further comprises a pair of spaced-apart reinforced concrete columns opposite the single internally reinforced concrete ambit panel.

12. The modular concrete building block of claim 10, wherein at least one support pocket is formed in an interior surface of the single internally reinforced concrete ambit panel adjacent the internally reinforced concrete spanning panel.

13. The modular concrete building block of any one of claims 1 to 4, 6, 8 or 9, wherein the at least one internally reinforced concrete ambit panel consists of two adjacent substantially orthogonal internally reinforced concrete ambit panels.

14. The modular concrete building block of claim 13, wherein the perimeter skirt further comprises a single internally reinforced concrete column opposite the internally reinforced concrete ambit panels.

15. The modular concrete building block of claim 13, wherein at least one support pocket is formed in an interior surface of one of the internally reinforced concrete ambit panels adjacent the internally reinforced concrete spanning panel.

16. The modular concrete building block of any one of claims 1 to 4, 6, 8 or 9, wherein the at least one internally reinforced concrete ambit panel comprises two opposed substantially parallel ones of the internally reinforced concrete ambit panels.

17. A modular building system comprising a plurality of the modular concrete building blocks of any one of claims 1 to 4, 6, 8 or 9.

18. A precast modular concrete building block, comprising: an internally reinforced monolithic concrete body having: an internally reinforced concrete spanning panel; and a perimeter skirt depending from the internally reinforced concrete spanning panel, the perimeter skirt comprising at least one internally reinforced concrete ambit panel; wherein the internally reinforced concrete spanning panel extends transverse to the perimeter skirt and spans the perimeter skirt; wherein: the at least one internally reinforced concrete ambit panel and the internally reinforced concrete spanning panel cooperate to define an interior volume between the at least one internally reinforced concrete ambit panel and the internally reinforced concrete spanning panel; the internally reinforced monolithic concrete body is open into the interior volume opposite the internally reinforced concrete spanning panel; at least one utility conduit is embedded within at least one of the at least one internally reinforced concrete ambit panel and the internally reinforced concrete spanning panel;at least one interior connection for the at least one utility conduit is accessible from within the interior volume; and at least one exterior connection for the at least one utility conduit is accessible from outside of the interior volume.

19. The modular concrete building block of claim 18, wherein the at least one internally reinforced concrete ambit panel consists of a single internally reinforced concrete ambit panel.

20. The modular concrete building block of claim 19, wherein the perimeter skirt further comprises a pair of spaced-apart reinforced concrete columns opposite the single internally reinforced concrete ambit panel.

21. The modular concrete building block of claim 19, wherein at least one support pocket is formed in an interior surface of the single internally reinforced concrete ambit panel adjacent the internally reinforced concrete spanning panel.

22. The modular concrete building block of claim 18, wherein the at least one internally reinforced concrete ambit panel consists of two adjacent substantially orthogonal internally reinforced concrete ambit panels.

23. The modular concrete building block of claim 22, wherein the perimeter skirt further comprises a single internally reinforced concrete column opposite the internally reinforced concrete ambit panels.

24. The modular concrete building block of claim 22, wherein at least one support pocket is formed in an interior surface of one of the internally reinforced concrete ambit panels and adjacent the internally reinforced concrete spanning panel.

25. The modular concrete building block of claim 18, wherein the at least one internally reinforced concrete ambit panel comprises two opposed substantially parallel ones of the internally reinforced concrete ambit panels.

26. The modular concrete building block of claim 25, wherein the at least one internally reinforced concrete ambit panel further comprises a third internally reinforced concrete ambit panel extending between and substantially orthogonal to the two opposed substantially parallel ones of the internally reinforced concrete ambit panels.

27. The modular concrete building block of claim 18, wherein the at least one internally reinforced concrete ambit panel comprises four internally reinforced concrete ambit panels joined to one another such that the internally reinforced concrete ambit panels completely circumvallate the interior volume.

28. The modular concrete building block of any one of claims 18 to 27, wherein the at least one utility conduit comprises at least one HVAC duct, at least one ventilation duct, at least one electrical conduit, at least one plumbing supply pipe, at least one plumbing drain pipe, and at least one drain vent pipe.

29. The modular concrete building block of any one of claims 18 to 27, wherein the at least one internally reinforced concrete ambit panel includes at least one opening through the at least one internally reinforced concrete ambit panel.

30. The modular concrete building block of any one of claims 18 to 29, wherein the modular concrete building block has at least one of: lower connector channels formed in a distal edge of the at least one internally reinforced concrete ambit panels; and upper connector channels formed in an outwardly facing surface of the internally reinforced concrete spanning panel.

31. The modular concrete building block of claim 30, wherein the modular concrete building block has both of: the lower connector channels formed in the distal edge of the at least one internally reinforced concrete ambit panel; the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete spanning panel; and wherein the lower connector channels and the upper connector channels are substantially in registration with one another.

32. A building comprising at least two modular concrete building blocks, each according to any one of claims 18 to 31, wherein: a first one of the two modular concrete building blocks is disposed atop a second one of the two modular concrete building blocks; and the at least one respective exterior connection for the at least one utility conduit embedded within the at least one internally reinforced concrete ambit panel of the first one of the two modular concrete building blocks is in registration with and coupled to a corresponding at least one respective exterior connection for the at least one utility conduit embedded within the at least one internally reinforced concrete ambit panel of the second one of the two modular concrete building blocks.

33. The building of claim 32, wherein the first one of the two modular concrete building blocks is disposed atop the second one of the two modular concrete building blocks.

34. The building of claim 33, wherein the first one of the two modular concrete building blocks is secured atop the second one of the two modular concrete building blocks by a plurality of anti-slip connectors fitted into lower connector channels of the first one of the two modular concrete building blocks and into upper connector channels of the second one of the two modular concrete building blocks.

35. The building of claim 32, wherein the first one of the two modular concrete building blocks is disposed beside the second one of the two modular concrete building blocks.

36. The modular concrete building block of claim 25, wherein the at least one internally reinforced concrete ambit panel further comprises a third internally reinforced concrete ambit panel extending between and substantially orthogonal to the two opposed substantially parallel ones of the internally reinforced concrete ambit panels.

37. The modular concrete building block of claim 27, wherein: the at least one utility conduit provides at least one of filtration, water supply, circulation and drainage; and the building block is oriented with its interior volume open upwardly to form one of a swimming pool, a reservoir and an aquarium.

38. A precast modular concrete building block, comprising: an internally reinforced monolithic concrete enclosure defining an interior volume and having: at least one internally reinforced concrete wall at least partially circumvallating the interior volume; an internally reinforced concrete roof coupled to the at least one concrete wall; wherein: an underside of the concrete enclosure opposite the concrete roof is open into the interior volume; wherein the modular concrete building block has at least one of: lower connector channels formed in a distal edge of the at least one concrete wall; and upper connector channels formed in an outwardly facing surface of the roof.

39. The modular concrete building block of claim 38, wherein the at least one internally reinforced concrete wall includes at least one opening through the at least one concrete wall into the interior volume.

40. The modular concrete building block of claim 39, wherein the at least one opening through the at least one internally reinforced concrete wall comprises at least one of: at least one doorway aperture formed in the at least one concrete wall; and at least one window aperture formed in the at least one internally reinforced concrete wall.

41. The modular concrete building block of any one of claims 38, 39 or 40 wherein: the modular concrete building block has both of: the lower connector channels formed in the distal edge of the at least one internally reinforced concrete wall; the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete roof; and the lower connector channels and the upper connector channels are substantially in registration with one another.

42. A building comprising at least two of the modular concrete building blocks according to any one of claims 38 to 41, wherein: an upper one of the two modular concrete building blocks is secured atop a lower one of the two modular concrete building blocks; the upper one of the two modular concrete building blocks has at least the lower connector channels; the lower one of the two modular concrete building blocks has at least the upper connector channels; and the upper one of the two modular concrete building blocks is secured atop the lower one of the two modular concrete building blocks by a plurality of anti-slip connectors fitted into the lower connector channels of the upper one of the two modular concrete building blocks and into the upper connector channels of the lower one of the two modular concrete building blocks.

43. The modular concrete building block of any one of claims 39 to 42, wherein the at least one opening through the at least one internally reinforced concrete wall comprises a discontinuity in the at least one internally reinforced concrete wall.

44. A building comprising at least two modular concrete building blocks according to claim 43 arranged adjacent to one another with their respective discontinuities arranged in registration with one another.

45. A modular building system comprising a plurality of the modular concrete building blocks of any one of claims 38 to 44.

46. A precast modular concrete building block, comprising: an internally reinforced monolithic concrete enclosure defining an interior volume and having: at least one internally reinforced concrete wall at least partially circumvallating the interior volume; an internally reinforced concrete roof coupled to the at least one internally reinforced concrete wall; wherein: an underside of the concrete enclosure opposite the concrete roof is open into the interior volume; at least one utility conduit is embedded within the at least one concrete wall; at least one interior connection for the at least one utility conduit is accessible from within the interior volume; and at least one exterior connection for the at least one utility conduit is accessible from outside of the interior volume.

47. The modular concrete building block of claim 46, wherein the at least one internally reinforced concrete wall includes at least one opening through the at least one concrete wall into the interior volume.

48. The modular concrete building block of claim 46 or 47, wherein the at least one utility conduit comprises at least one HVAC duct, at least one ventilation duct, at least one electrical conduit, at least one plumbing supply pipe, at least one plumbing drain pipe, and at least one drain vent pipe.

49. The modular concrete building block of claim 46, 47 or 48, further comprising the at least one utility conduit embedded within the internally reinforced concrete roof.

50. The modular concrete building block of any one of claims 46 to 49, wherein the at least one internally reinforced concrete wall comprises four internally reinforced concrete walls joined to one another such that the internally reinforced concrete walls completely circumvallate the interior volume.

51. The modular concrete building block of claim 47, wherein the at least one opening through the at least one internally reinforced concrete wall comprises at least one of: at least one doorway aperture formed in the at least one internally reinforced concrete wall and at least one window aperture formed in the at least one internally reinforced concrete wall.

52. The modular concrete building block of any one of claims 47 to 50, wherein the at least one opening through the at least one internally reinforced concrete wall comprises a discontinuity in the at least one internally reinforced concrete wall.

53. A building comprising at least two modular concrete building blocks according to claim 52 arranged adjacent to one another with their respective discontinuities arranged in registration with one another.

54. A building comprising at least two modular concrete building blocks, each according to any one of claims 46 to 53, wherein: an upper one of the two modular concrete building blocks is secured atop a lower one of the two modular concrete building blocks; and the at least one respective exterior connection for the at least one utility conduit embedded within the at least one internally reinforced concrete wall of the upper one of the two modular concrete building blocks is in registration with and coupled to a corresponding at least one respective exterior connection for the at least one utility conduit embedded within the at least one internally reinforced concrete wall of the lower one of the two modular concrete building blocks.

55. The building according to claim 54, wherein the upper one of the two modular concrete building blocks is secured atop the lower one of the two modular concrete building blocks by a plurality of anti-slip connectors fitted into upper connector channels formed in the internally reinforced concrete roof of the lower one of the modular concrete building blocks and further fitted into lower connector channels formed in the distal edge of the at least one internally reinforced concrete wall of the upper one of the modular concrete building blocks, with the lower connector channels in registration with the upper connector channels.

56. The modular concrete building block of any one of claims 46 to 52, wherein: a height of the concrete enclosure, measured from the underside of the concrete enclosure to an interior surface of the roof, is about 2.3 meters; andthe interior surface of the internally reinforced concrete roof is about 7 square meters.

57. The modular concrete building block of any one of claims 46 to 52 or 56, wherein the modular concrete building block has at least one of: lower connector channels formed in a distal edge of the at least one concrete wall; and upper connector channels formed in an outwardly facing surface of the roof.

58. The modular concrete building block of claim 57, wherein the modular concrete building block has both of: the lower connector channels formed in the distal edge of the at least one internally reinforced concrete wall; the upper connector channels formed in the outwardly facing surface of the internally reinforced concrete roof; and the lower connector channels and the upper connector channels are substantially in registration with one another.

59. A modular building system comprising a plurality of the modular concrete building blocks according to any one of claims 46 to 52 or 57 or 58.

60. A method for casting a hollow concrete block, the method comprising: placing an inner form into an inner form casting configuration, wherein the inner form is surrounded by a movable transport platform having an opening arranged in registration with the inner form, wherein in the inner form casting configuration the inner form defines a roofed column extending upwardly through the inner form opening;placing reinforcements around the inner form; placing an outer form comprising at least one outer form wall into an outer form casting configuration in which the at least one outer form wall forms an open-topped enclosure disposed roundabout the transport platform; wherein, when the inner form is in the inner form casting configuration and the outer form is in the outer form casting configuration: the at least one outer form wall extends upwardly beyond the roofed column and surround and are spaced from the roofed column; and the at least one outer form wall, the roofed column and the transport platform cooperate to define a cavity between the outer form and the inner form, with a floor of the cavity formed by the transport platform; the reinforcements are disposed within the cavity; pouring concrete into the cavity so that the concrete surrounds the roofed column while being contained by the outer form and the floor; curing the concrete to form the hollow concrete block, which rests upon the transport platform, wherein the curing is sufficient for the concrete to have set so that the concrete can be transported without damage; retracting the inner form into an inner form demold configuration wherein the transport platform and the hollow concrete block resting thereon are movable past the retracted inner form in at least a first direction; deconfiguring the outer form from the outer form casting configuration so that the at least one outer form wall is clear of the transport platform and the hollow concrete block resting thereon and permit movement of the transport platform and the hollow concrete block resting thereon in at least the first direction; and moving the transport platform with the hollow concrete block thereon past the inner form.

61. The method of claim 60, further comprising: before pouring the concrete into the cavity, installing reinforcements in the cavity.

62. The method of claim 60 or 61, wherein: the inner form is an erectable superstructure having a superstructure roof and first and second sets of opposed substantially parallel superstructure walls; the inner form casting configuration is an erected configuration in which the superstructure walls are upwardly extended; and the inner form demold configuration is a collapsed configuration in which the superstructure walls are downwardly collapsed such that the superstructure walls and the superstructure roof are non-obstructing to movement of the transport platform in the first direction.

63. The method of claim 62, wherein: the first set of opposed superstructure walls is a set of opposed collapsible concertina walls coupled to the superstructure roof; and the second set of opposed superstructure walls is a set of opposed substantially rigid non-collapsing panel walls each being movable between a recumbent position and an upright position; wherein: when the inner form is in the erected configuration: the concertina walls are extended into a substantially planar configuration; and the panel walls are in the upright position and extend substantially orthogonal to the concertina walls; andwhen the inner form is in the collapsed configuration: the concertina walls are collapsed upon themselves beneath the superstructure roof; and the panel walls are in the recumbent position to overlie the superstructure roof.

64. The method of claim 63, wherein: at least one scissor lift is disposed beneath the superstructure roof and configured to selectively raise and lower the superstructure roof.

65. The method of claim 64, wherein the concertina walls are coupled to the superstructure roof whereby: raising the superstructure roof extends the concertina walls into the substantially planar configuration; and lowering the superstructure roof collapses the concertina walls upon themselves beneath the superstructure roof.

66. The method of claim 65, wherein: the panel walls are pivotably movable between the recumbent position and the upright position; and a respective piston-cylinder assembly acts between an inner form base and each of the panel walls to selectively pivot the panel walls between the recumbent position and the upright position.

67. The apparatus of claim 66, wherein the superstructure roof has a pair of opposed piston-cylinder apertures at edges thereof adjacent the panel walls to enable the superstructure roof to move past the piston-cylinder assemblies.

68. An apparatus for casting a hollow concrete block, the apparatus comprising: an inner form, wherein the inner form has an inner form casting configuration and an inner form demold configuration; a movable transport platform having an opening configured to be arranged in registration with the inner form; an outer form, wherein the outer form comprises at least one outer form wall and has an outer form casting configuration in which the at least one outer form wall forms an opentopped enclosure; wherein, when the transport platform is positioned with the opening arranged in registration with the inner form: when the inner form is in the inner form casting configuration, the inner form is extended to form a roofed column extending upwardly through the inner form opening of the transport platform; and when the inner form is in the inner form demold configuration, the inner form is retracted whereby the transport platform is movable past the retracted inner form in at least a first direction; and wherein, when the transport platform is positioned with the opening arranged in registration with the inner form and the outer form is in the outer form casting configuration and the inner form is in the inner form casting configuration: the at least one outer form wall extends upwardly beyond a roof of the inner form, wherein the at least one outer form wall surrounds and is spaced from the inner form;the at least one outer form wall, the inner form and the transport platform cooperate to define a cavity between the outer form and the inner form with the floor of the cavity formed by the transport platform, which cavity is adapted to receive and contain concrete surrounding the inner form; and the outer form can be deconfigured from the outer form casting configuration so that the at least one outer form wall is clear of the transport platform and permit movement of the transport platform in at least the first direction.

69. The apparatus of claim 68, wherein: the inner form is an erectable superstructure having a superstructure roof and first and second sets of opposed substantially parallel superstructure walls; the inner form casting configuration is an erected configuration in which the superstructure walls are upwardly extended; and the inner form demold configuration is a collapsed configuration in which the superstructure walls are downwardly collapsed such that the superstructure walls and the superstructure roof are non-obstructing to movement of the transport platform in the first direction.

70. The apparatus of claim 69, wherein: the first set of opposed superstructure walls is a set of opposed collapsible concertina coupled to the superstructure roof; and the second set of opposed superstructure walls is a set of opposed substantially rigid non-collapsing panel walls each being movable between a recumbent position and an upright position; and wherein: when the inner form is in the erected configuration:the concertina walls are extended into a substantially planar configuration; and the panel walls are in the upright position and extend substantially orthogonal to the concertina walls; and when the inner form is in the collapsed configuration: the concertina walls are collapsed upon themselves beneath the superstructure roof; and the panel walls are in the recumbent position to overlie the superstructure roof.

71. The apparatus of claim 70, wherein: at least one scissor lift is disposed beneath the superstructure roof and configured to selectively raise and lower the superstructure roof.

72. The apparatus of claim 71, wherein: raising the superstructure roof extends the concertina walls into the substantially planar configuration; and lowering the superstructure roof collapses the concertina walls upon themselves beneath the superstructure roof.

73. The apparatus of claim 72, wherein: the panel walls are pivotably movable between the recumbent position and the upright position; anda respective piston-cylinder assembly acts between an inner form base and each of the panel walls to selectively pivot the panel walls between the recumbent position and the upright position.

74. The apparatus of claim 73, wherein the superstructure roof has a pair of opposed piston-cylinder apertures at edges thereof adjacent the panel walls to enable the superstructure roof to move past the piston-cylinder assemblies.

75. The apparatus of any one of claims 68 to 74, wherein the transport platform is a wheeled transport platform.

76. An erectable and collapsible superstructure, comprising: a superstructure roof; a set of opposed collapsible concertina walls coupled to the superstructure roof; and a set of opposed substantially rigid non-collapsing panel walls each being movable between a recumbent position and an upright position; wherein the superstructure has an erected configuration and a collapsed configuration and wherein: when the superstructure is in the erected configuration: the concertina walls are extended into a substantially planar configuration; and the panel walls are in the upright position and extend substantially orthogonal to the concertina walls; and when the inner form is in the collapsed configuration:the concertina walls are collapsed upon themselves beneath the superstructure roof; and the panel walls are in the recumbent position and overlie the superstructure roof.

77. The superstructure of claim 76, wherein: at least one scissor lift is disposed beneath the superstructure roof and configured to selectively raise and lower the superstructure roof.

78. The superstructure of claim 77, wherein the concertina walls are coupled to the superstructure roof whereby: raising the superstructure roof extends the concertina walls into the substantially planar configuration; and lowering the superstructure roof collapses the concertina walls upon themselves beneath the superstructure roof.

79. The superstructure of claim 78, wherein: the panel walls are pivotably movable between the recumbent position and the upright position; and a respective piston-cylinder assembly acts between an inner form base and each of the panel walls to selectively pivot the panel walls between the recumbent position and the upright position.

80. The superstructure of claim 79, wherein the superstructure roof has a pair of opposed piston-cylinder apertures at edges thereof adjacent the panel walls to enable the superstructure roof to move past the piston-cylinder assemblies.

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