Floor and roof construction

Abstract

A construction system for floors and/or roofs includes a foam form configured to engage one or more beams. When the form engages the beams, the form is further attached and secured by an attachment system. Other attachment and support components are added to the form and/or beam. Concrete is poured onto the form to create one distinct monolithic unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other aspects of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings are not drawn to scale. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1A shows a front view of a form;

FIG. 1B shows an isometric view of a form;

FIG. 2 shows an isometric view of a beam;

FIG. 3A shows anchor pins of an attachment system;

FIG. 3B shows attachment and support stands of an attachment system;

FIG. 4 shows a front view of a rebar support;

FIG. 5 shows a grade pin;

FIG. 6 shows an isometric view of a construction system for floors and/or roofs; and

FIG. 7 shows a method of construction a floor and/or roof system.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Embodiments of the present invention include floor and roof construction systems and methods. In one embodiment of the invention, a foam form is configured to include openings to engage beams, conduits for electrical or other utility lines, and cavities for ductworks. When the form engages the beams, an attachment system secures the form to the beams. Other components of the floor and roof system are attached to or otherwise placed in connection with the form for a variety of purposes. In one embodiment of the invention the system is completed when concrete is poured over the form and cooperating components to form one distinct monolithic unit. The floor and roof construction system of the present invention thereby provides an efficient construction system that in a floor and/or roof with minimal structural discontinuities.

With attention now to FIG. 1A, a front view of a form 100 is shown. In one embodiment of the invention form 100 is configured of a foam material, such as, for example, a cement-foam composite, polyurethane foam, polystyrene foam, expanded polystyrene, and extruded polystyrene. Form 100 includes a center portion 102, a first end 104 having a flange 106, and a second end 108 having a flange 110.

While FIG. 1A shows a front view of a form 100, it is to be appreciated t that embodiments of the present invention include configurations of multiple forms. As is shown in the description of form 100 below, certain features of form 100 are configured to allow two or more forms to be secured to each other when two or more forms are configured adjacent each other. The configuration of multiple forms is shown in further detail below with reference to FIGS. 1B and 6.

As mentioned previously, certain features of form 100 are, in one embodiment of the invention, configured to allow two or more forms to be secured to each other when the forms are positioned adjacent to each other. For example, in one embodiment of the invention flanges 106 and 110 include a protruding portion 112 and a receiving portion 114, respectively. When two forms are positioned adjacent each other in a side-by-side arrangement, receiving portion 114 of flange 110 engages protruding portion 112 of flange 106, thus securing a second end of a form, such as second end 108, to a first end, such as end 104, of another form. Configuring two forms adjacent each other in a side-by-side arrangement, as described above, creates a depression between the center portions of the forms where the flanges of the forms meet.

To further engage an adjacent form, form 100 also includes elongated protruding portion 116. Elongated protruding portion 116 extends from first end 104 through center portion 102 to second end 108. In one embodiment of the invention an opposite, or back, side of form 100 (not shown) includes an elongated receiving portion also extending from first end 104 through center portion 102 to second end 108, the receiving portion being configured to engage an elongated protruding portion, such as elongated protruding portion 116. When a second form is configured adjacent to form 100 in a front-to-back arrangement, elongated protruding portion 116 engages an t elongated receiving portion of the second form (not shown).

In addition to elongated protruding portion 116, form 100 also includes a cavity 118. In one embodiment of the invention cavity 118 is configured to house ductworks. Moreover, in another embodiment of the invention form 100 includes conduits 120 for utility lines. Also, form 100 includes openings 122 and 124 configured to engage beams (shown in FIG. 2) of a floor and roof construction system.

Finally, in yet another embodiment of the invention, form layer 126 is configured to engage center portion 102 of form 100 at the top of center portion 102. Form layer 126 may be configured of any height, and, when added to form 100, increases the overall height of form 100. In this way form 100 may be configured and designed to have any desirable height.

Directing attention now to FIG. 1B, an isometric view of a form system 150 is shown. Forms 152, 154, 156, and 158 are configured adjacent to each other, with forms 152, 154, and 156 configured in a side-by-side arrangement, and forms 154 and 158 configured in a front-to-back arrangement. As forms 152 and 154 are positioned adjacent to each other, receiving portion 160 of flange 162 of form 152 engages protruding portion 164 of flange 166 of form 154. Similarly, a receiving portion of a flange (not shown) of form 154 engages a protruding portion of a flange (not shown) of form 156. Moreover, an elongated protruding portion (not shown) of form 154 engages an elongated receiving portion (not shown) of form 158. The configuration of forms 152, 154, and 156 adjacent to each other in a side-by-side arrangement creates depressions 168.

Moving to FIG. 2, an isometric view of beam 200 is shown. In one embodiment of the invention beam 200 is made of metal, such as steel, galvanized steel, or any other metal or combination of metals. In another embodiment of the invention, beam 200 is made of plastic, such as acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), or any other plastic or combination of plastics. Beam 200 may also be made of wood. Beam 200 includes layers 202 and top 204, having openings 206 and 208. Openings 206 and 208 are configured to allow an attachment system to attach to beam 200, with the attachment system engaging one or more of the layers 202. The attachment system, not shown in FIG. 2, is discussed in more detail with reference to FIGS. 3A-3D below. In addition, the configuration of beam 200 with the attachment system is discussed in more detail below with reference to FIG. 6.

In operation, beam 200 is attached to temporary shoring. A foam form, such as form 100 described with reference to FIGS. 1A and 1B, is positioned such that an opening in the foam form engages beam 200. In one embodiment of the invention a form includes multiple openings to engage multiple beams. An attachment system may be inserted through the form to engage openings 206 and 208 of beam 200, thus helping to secure the form to the beam 200. Other construction components are added to the construction system that includes beam 200 and a form. Concrete is then poured onto the form. After the concrete has been poured, the temporary shoring can be removed and, in one embodiment of the invention, beam 200 then provides a permanent anchor for drywall or other finishing materials. Thus, beam 200 is one component of a construction system that creates a floor and/or roof, with concrete forming the floor surface, and finishing materials, such as drywall, capable of being mounted to beam 200 on the underside of the floor to form a ceiling. These and other aspects of beam 200 are discussed in further detail with reference to a floor and/or roof construction system, as shown in FIG. 6 below.

While FIG. 2 shows beam 200 having openings 206 and 208, FIGS. 3A and 3B show an attachment system 300. In FIG. 3A, anchor pins 302 and 304, which, in one embodiment of the invention, engage a form and beam, are shown. Anchor pins 302 and 304 are, in one embodiment of the invention, manufactured of one or more of ABS, PVC, or any other plastic or combination of plastics. In one embodiment of the invention, anchor pin 302 includes barbed section 306 that engages layers of a beam, such as layers 202 of beam 200 discussed above. Anchor pin 302 is inserted into the top of a beam, having first been inserted through a form engaging the beam. Also, anchor pin 302 may include disk 308 to further secure anchor pin 302 to the form and beam.

In another embodiment of the invention, anchor pin 304, like anchor pin 302, also engages a form and a beam. Unlike anchor pin 302, however, anchor pin 304 is inserted into a beam from the bottom, entering the form after passing through the beam. Anchor pin 304 includes flange 310, which secures anchor pin 304 at the bottom of a beam and prevents anchor pin 304 from passing through the beam and the form. In addition, anchor pin 304 includes a top portion 312, which, in one embodiment of the invention, may be threaded. A disk, such as disk 314, is configured to engage anchor pin 304 at top portion 312 with hole 316, thus further securing anchor pin 304 to a form and a beam. In one embodiment of the invention where top portion 312 is threaded, hole 316 is also threaded. In another embodiment of the invention hole 316 is configured to include a nut.

As suggested by the preceding discussion, anchor pins 300 include an exemplary structural implementation of a means for anchoring a form to a beam. Generally, such means serve to secure a form to a beam and to prevent movement of the form with respect to the beam. Yet other examples of a means for anchoring a form to a beam include any other part of, or attachment to a floor and/or roof construction system that anchor and secures a form to a beam.

Attachment and support stand 350, shown in side view FIG. 3B and top view in FIG. 3C, is configured to cooperate with anchor pins 302 and 304 to secure a form to a beam. In one embodiment of the invention, attachment and support stand 350 may be made of one or more of ABS, PVC, or any other plastic. In another embodiment of the invention attachment and support stand 350 may be made of one or more of steel, aluminum, or any other metal. Finally, in additional embodiments of the invention attachment and support stand 350 may be made of concrete or clay brick.

While attachment and support stand 350 may be made of made of different materials, it may also be configured in different ways. In one embodiment of the invention attachment and support stand 350 includes a top portion 352 having a depression 354, and a bottom portion 356. In one embodiment of the invention depression 354 is cross-shaped or x-shaped. Depression 354 is configured to engage rebar. In one embodiment of the invention two rebar may be positioned in depression 354, such that the first rebar is configured orthogonal to the second rebar. Extensions 360, shown in FIG. 3D, may be placed on top portion 352 of attachment and support stand 350 to increase the height of attachment and support stand 352 to any desirable height.

As shown by the discussion of attachment and support stand 350, attachment and support stand 350 is one exemplary structural implementation of a means for engaging an anchor pin or other structure that attaches a form to a beam. Generally, such means for engaging cooperate with a means for attaching to provide security and stability to a form configured to attach to a beam. Yet other examples of a means for engaging include any part of, or attachment to a floor and/or roof construction system that engages a means for attaching to further secure the means for attaching to the form and the beam.

In addition to top portion 352 and depression 354, attachment and support stand 350 includes hollow center portion 358 that extends from the center of top portion 352 through bottom portion 356. In one embodiment of the invention, center portion 358 is configured such that anchor pins 300 may be inserted through center portion 358. When attachment and support stand 350 is positioned on top of a form, one of anchor pins 300 may be inserted through center portion 358 and a form to engage a beam. Rebar may then be positioned in top portion 352 of attachment and support stand 350. Thus, attachment and support stand 350 cooperates with anchor pins 300 to secure a form to a beam, and further provides a system for supporting rebar. Embodiments of attachment system 300 are discussed in further detail below with reference to FIG. 6.

As suggested by the preceding discussion of FIGS. 3A-3D, attachment system 300 includes an exemplary structural implementation of a means for securing a form to a beam. Generally, such means serve to maintain the position of a form and a beam relative to each other, thus preventing movement either of the form or the beam with respect to the other. Yet other examples of a means for securing a form to a beam include any other part of, or attachment to a floor and roof construction system that secures and/or maintains the position of the form and beam with respect to each other.

In one embodiment of the invention, an anchor base plate (not shown) further secures a form to a base structure. In one embodiment of the invention the anchor base plate is configured of steel. Moreover, the anchor base plate may include multiple studs having different heights depending on design needs. The anchor base plate is configured alongside a beam to engage and secure a form coupled to one or more beams.

With attention now to FIG. 4, a front view of a rebar support 400 is shown. In one embodiment of the invention rebar support 400 is made of steel, galvanized steel, or any other metal. Rebar support 400 includes a first end 402 and a second end 404, with a center portion 406. Center portion 406 further includes a notch 408 configured to engage rebar. In operation, rebar support 400 is configured to engage a form, with first end 402 engaging the center portion of a first form, and second end 404 engaging the center portion of a second form positioned adjacent to the first form in a side-by-side arrangement. Thus, center portion 406 of rebar support 400 lies within the depression created when the two forms are positioned side-by-side. In this way rebar support 400 provides a way for rebar to be positioned in a stable arrangement within a construction system for floor and roofs. Embodiments of rebar support 400, and the operation of rebar support 400 in relation to a form, rebar, and other components of a construction system for floors and roofs, is shown in further detail below with reference to FIG. 6.

As suggested by the preceding discussion of FIG. 4, rebar support 400 is an exemplary structural implementation of a means for supporting rebar. Generally, such means serve to support rebar at a desired location and elevation with respect to a form. Yet other examples of a means for supporting rebar include any other part of, or attachment to a floor and roof construction system that supports and/or maintains the position of rebar within the form.

Directing attention now to FIG. 5, an embodiment of a grade pin 500 is shown. Grade pin 500 includes a center portion 502 and disks 504 positioned at different heights along center portion 502. In one embodiment of the invention, grade pin 500 may be configured within a form, such as form 100 shown in FIG. 1, in order to provide a depth gauge for concrete poured over the form and to ensure an even grade of concrete in a construction system for floors and roofs.

With attention now to FIG. 6, an isometric view of a construction system 600 for floors and roofs is shown. Forms 602 and 604, including flanges 606 and 608, respectively, are configured adjacent to each other in a side-by-side arrangement. Flange 606 engages flange 608 when a protruding portion (not shown) of flange 608 is coupled to a receiving portion (not shown) of flange 606. The side-by-side arrangement of forms 602 and 604 thus forms a depression 610 over flanges 606 and 608. Depression 612 is likewise created when flange 614 of form 602 is coupled to a flange of an additional form (not shown). Finally, in one embodiment of the invention forms 602 and 604 may include a top layer, such as layer 616 configured on top of form 602. Layer 616 may be of any thickness to increase the height of form 602 to any desirable height.

While each of forms 602 and 604 may include a top layer, such as layer 616, each of forms 602 and 604 may also include cavities 618, conduits 620, and openings 622. In one embodiment of the invention cavities 618 provide space for ductworks while conduits 620 are configured for utility lines. In another embodiment of the invention openings 622 are configured to engage beams 624 of form 602, and beams 626 and 628 of form 604. Form 604 also includes attachment systems 630 and 632, which include attachment and support stands 634 and 636, respectively. Attachment system 630 further includes anchor pin 638, while attachment system 632 includes anchor pin 640.

Embodiments of construction system 600 further include rebar support 642 positioned to engage a center portion of form 602 and a center portion of a form (not shown) that may be placed adjacent to form 602, with a center portion of rebar support 642, including notch 644, lying within depression 612. Finally, in one embodiment of the invention one or more grade pins (not shown) may also be attached to forms 602 and 604.

In operation, construction system 600 is configured as forms 602 and 604 are positioned adjacent to each other in a side-by-side arrangement, with flanges 606 and 608 engaging each other. Depression 610 is thus created between forms 602 and 604, over flanges 606 and 608. Forms 602 and 604 are further configured to engage beams 624, and beams 626 and 628, respectively. In one embodiment of the invention attachment systems, such as attachment systems 630 and 632, may further secure form 604 to beams 626 and 628.

Beams 626 and 628 are secured to form 604 as attachment and support stands 634 and 636 are positioned on top of form 604. Anchor pin 638 is inserted through attachment and support stand 634, passing through form 604 to engage beam 626. In one embodiment of the invention, a shown in FIG. 6, anchor pin 638 is a barbed anchor pin, or an anchor pin including a barbed section. In another embodiment of the invention, anchor pin 640 is a flanged anchor pin, engaging beam 628, form 604, and attachment and support stand 636. Configured as shown in FIG. 6, attachment systems 630 and 632 secure form 604 to beams 626 and 628 and ensure that the position of form 604 with respect to beams 626 and 628 is maintained.

Further, rebar 646 may be positioned in top portions of attachment and support stands 634 and 636. In one embodiment of the invention two rebar may be positioned at a 90° angle within a top portion of attachment and support stands 634 and 636. Rebar 648 may also be placed in notch 644 of rebar support 642, which maintains the position of rebar within the depression and ensures an even elevation of the rebar within depression 612. In one embodiment of the invention where layer 616 is configured on top of form 602, rebar support 642 is configured to engage form 602 beneath layer 616.

Finally, construction system 600 is completed as concrete is poured onto forms 602 and 604, with concrete covering attachment and support stands 634 and 636, and rebar 646 and 648. Concrete also fills depressions 610 and 612, located between adjacent forms. In one embodiment of the invention the concrete is poured onto forms 602 and 604 in a single event. The concrete of construction system 600 is, therefore, one distinct monolithic unit. Embodiments of the present invention thereby create a construction system for floors and roofs that is easy to assemble and efficiently designed. Moreover, embodiments of the present invention provide construction systems for floors and/or roofs in which the concrete of the system is one distinct monolithic unit, thus minimizing structural discontinuities in the floor and/or roof. Further, embodiments of the present invention may be used in conjunction with other construction systems to create structures wherein concrete deposited in the structures is one distinct monolithic unit having minimal structural discontinuities.

With attention now to FIG. 7, a method 700 for constructing a floor and/or roof system is shown. At stage 702, one or more form sections are configured to create a form having any length, width, and height. Next, at stage 704, the form is attached to beams. Attachment, support, and other components are then added to the form and/or beams, as shown at stage 706. Finally, concrete is poured onto the form to create a monolithic unit, as shown at stage 708.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A construction system for floors and roofs comprising: one or more form comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene;one or more beams engaged by the one or more forms;means for securing the one or more beams to the one or more forms; andconcrete, wherein the concrete is poured onto the one or more forms creating one distinct monolithic unit.

2. The construction system as recited in claim 1, wherein the one or more forms further comprise: a first end having a protruding portion; anda second end having a receiving portion, wherein the receiving portion is configured to engage the protruding portion.

3. The construction system as recited in claim 1, wherein the one or more forms includes openings to receive the one or more beams.

4. The construction system as recited in claim 1, wherein the one or more forms includes cavities for ductworks.

5. The construction system as recited in claim 1, wherein the one or more forms includes conduits.

6. The construction system as recited in claim 1, wherein the one or more forms includes one or more layers.

7. The construction system as recited in claim 1, wherein the beams include openings.

8. The construction system as recited in claim 1, wherein the beams are comprised of one or more of: steel, galvanized steel, and, any other metal; acrylonitrile butadiene styrene, polyvinyl chloride, and, any other plastic; and, wood.

9. The construction system described in claim 1, wherein the means for securing includes a means for anchoring and a means for engaging.

10. The construction system as recited in claim 1, further comprising means for supporting rebar.

11. The construction system as recited in claim 1, further comprising rebar.

12. The construction system as recited in claim 1, further comprising one or more grade pins.

13. The construction system as recited in claim 1, further comprising anchor base plates, wherein the anchor base plates are comprised of one or more of: steel; galvanized steel; and, any other metal.

14. A floor and roof construction system comprising: one or more beams;one or more forms comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene, wherein the one or more forms is configured to engage the one or more beams;an attachment system, wherein the attachment system secures the one or more beams for the one or more forms; andconcrete, wherein the concrete is poured onto the one or more forms to create one distinct monolithic unit.

15. The construction system as recited in claim 14, wherein the one or more forms includes one or more layers.

16. The construction system as recited in claim 14, wherein the one or more forms sections include protruding ends and receiving ends, wherein the receiving ends are configured to engage the protruding ends.

17. The construction system as recited in claim 14, wherein the one or more forms include cavities for ductworks.

18. The construction system as recited in claim 14, wherein the one or more forms include one or more conduits.

19. The construction system as recited in claim 14, further comprising: a rebar support configured to engage a center portion of the form; and,rebar positioned within the rebar support.

20. The construction system as recited in claim 14, wherein the attachment system further comprises: one or more attachment and support stands; andone or more anchor pins, wherein the one or more anchor pins is configured to be inserted through an opening in the one or more attachment and support stands to secure the one or more forms to the one or more beams.

21. The construction system as recited in claim 20, wherein the one or more attachment and support stands is configured to engage rebar.

22. The construction system as recited in claim 14, further comprising one or more grade pins attached to the one or more forms, wherein the one or more grade pins are comprised of: acrylonitrile butadiene styrene; polyvinyl chloride; and, any other plastic.

23. The construction system as recited in claim 14, wherein the attachment system is comprised of one or more of: acrylonitrile butadiene styrene; polyvinyl chloride; and, any other plastic.

24. The construction system as recited in claim 20, wherein the one or more attachment and support stands is comprised of one or more of: steel, galvanized steel, and, any other metal; concrete; and, clay brick.

25. The construction system as recited in claim 14, further comprising a rebar support attached to the one or more forms, wherein the rebar support is comprised of one or more of: steel; galvanized steel; and, any other metal.

26. The construction system as recited in claim 25, further comprising one or more rebar, wherein the rebar support and the attachment and support stands engage the one or more rebar.

27. A floor and roof construction system comprising: one or more beams, wherein the one or more beams include openings;one or more forms configured to engage the one or more beams, the one or more forms further configured to be positioned adjacent to each other with one or more receiving ends of the one or more forms configured to engage one or more protruding ends of the one or more forms, the one or more forms comprised of one or more of: a cement-foam composite; polyurethane foam; polystyrene foam; expanded polystyrene; and, extruded polystyrene, wherein the one or more forms further comprises: one or more cavities within the one or more forms for receiving ductworks;one or more conduits within the one or more forms for receiving utility lines;one or more layers configured to attach to a top center portion of the one or more forms; andan attachment system for attaching the one or more beams to the one or more forms, the attachment system comprising: one or more anchor pins; andone or more attachment and support stands; anda rebar support configured to engage the one or more forms and further configured to support rebar;rebar; andone or more grade pins attached to the one or more forms.

28. The construction system as recited in claim 27, further comprising concrete, wherein the concrete is poured onto the one or more forms to create a monolithic unit.

29. The construction system as recited in claim 27, wherein the one or more beams are comprised of one or more of: steel, galvanized steel, and, any other metal; and, wood.

30. The construction system as recited in claim 27, wherein the one or more beams, the one or more anchor pins, the one or more attachment and support stands, and the one or more grade pins are comprised of one or more of: acrylonitrile butadiene styrene; polyvinyl chloride; and, any other plastic.

31. The construction system as recited in claim 27, wherein the one or more anchor pins are one or more of: barbed; and, flanged.

32. The construction system as recited in claim 27, wherein the one or more anchor pins further comprise anchor disks configured to attach to a first end of the one or more anchor pins.

33. The construction system as recited in claim 27, wherein the one or more attachment and support stands engage a first end of the one or more anchor pins.

34. The construction system as recited in claim 27, wherein the one or more attachment and support stands engage the rebar.

35. The construction system as recited in claim 27, wherein the one or more attachment and support stands are comprised of one or more of: steel, galvanized steel, aluminum, and any other metal; concrete; and, clay brick.

36. A method for constructing floors and roofs comprising: configuring one or more one or more forms sections to create a one or more forms having any length

37. The method as recited in claim 36, wherein the attaching the one or more forms to beams further comprises: inserting a means for anchoring into the one or more forms and the beams; andcoupling a means for engaging to the means for anchoring.

38. The method as recited in claim 36, further comprising: gauging a depth of the concrete; andensuring a grade of the concrete is even.