This application claims the benefit of U.S. Pi owsional Patent Application Seπal

Number 60/015598 filed April 1 8. 1996

Field The present invention pertains to fiber-reinforced concrete, more particularly, the

present invention peπains to fiber-reinforced concrete used in the construction of buildings

or residences

Background The search for low-cost housing has been a problem that has plagued builders and

governments for many years The beneficial effects associated with home ownership are

well recognized. Early in the 20th centun . Thomas Edison indicated that "I am going to live

to see the day when a working man's home can be built of concrete in a week if I

succeed, it will take from the city's slums everybody who is worth taking " Unfortunateh .

Thomas Edison's dream was never realized and the dreams of others to erect low-cost

housing are often not realized because of strict building code requirements and the

complexity of construction techniques

While fiber-reinforced concrete has been in use for many years, it has been difficult

to obtain a fiber-reinforced concrete where the fibers ai e uniformly distributed throughout

the concrete mixture This is because a relativeh liquid or wateπ mixture is needed to

assure distribution of the reinforcing fibers throughout the concrete Unfortunateh . such

liquid or water.' concrete mixture allows the fibers to migrate through the concrete mixture

and settle on one side, thus creating a non-unirorm distribution of fibers One attempt to solve this problem has been to spray concrete and reinforcing fibers together This spraying

causes the concrete and the fibers to mix during the spraving process Unfortunately, the spray-mixing system produces un-predictable results, non-uniform strength propemes in the

sprayed concrete and massive clean-up problems for the operator

Another attempt to strengthen fiber-reinforced concrete has been to add a variety of

different additives to the mixture of water, cement and sand For example, either sodium silicate or plasticizers. sometimes called water-reducers, have been used Examples of such

fiber-reinforced concrete mixtures ma\ be found in U S Patent 2.623.828

U.S Patent 4.406.703

U S Patent 4.482.385

U S Patent 5.082.181

U.S Patent 5.167.710

A mixture of sodium silicate and a plasticizer appears in the non-fiber reinforced

concrete descπbed in U S Patent 5.482.549

Despite the man> attempts to make a low cost concrete usable concrete to build

homes there remains a need in the art to provide a fiber-remforced concrete which can be

used to manufacture and erect low-cost homes Such low-cost, fiber-reinforced concrete

homes should be durable, easy to construct and environmentally fπendh

Summary of the Invention

The fiber-remforced concrete of the present invention provides tor the manufacture

ol residences and buildings which are durable. eas\ to construct and environmental h

fπendh

The fiber-reinforced concrete of the present invention includes a unique mixture of components which provides strong, durable, impact resistant and water-proof, fiber-reinforced concrete which can be used to build a vaπet\ of products from which low- cost buildings and residences may be built. The low -cost fiber-reinforced concrete of the present invention includes Poπland Type i or 1 ype II cement, sand and water. Added to the mixture of cement, sand and water is liquid sodium silicate and plasticizer. This mixture is fuπher strengthened by the addition of hydrophobic fibers. Because the concrete provides for the uniform distπbution and the random orientation of the hydrophobic fibers, the hydrophobic fibers serve to control the growth of cracks in the concrete and to act as energ\ absorbers should the concrete become cracked

Brief Description of the Figures

A better understanding of the fiber-reinforced concrete building mateπal of the present invention may be had by reference to the drawing figures wherein:

Figure 1 is a flow chaπ of the mixing process for the fiber-reinforced concrete building material of the present invention:

Figure 2 is a perspective view of the fiber-reinforced concrete of the present invention being formed into a wall panel in a mold.

Figure 3 is a perspective view in paπial section of a poπion of a wall panel. Figure 4 is a perspective view of a section of a wall panel showing the positioning of a metal weld plate:

Figure 4A is a perspective view of a panel w ith a lifting fixture attached. Figure 5 is a perspective view in paπial section showing the installation of a wall board:

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Figure 6 is a perspective view in paπial section of the installation of a roof panel.

Figure 7 is a perspective view of the installation of a wall panel havmg an outer skin utilizing the fiber-reinforced concrete of the present invention and 5 backing beams.

Figure 8 is a front elevational view of a fust alternate embodiment of a wall panel:

Figure 8 A is a left side elevational view of the wall panel shown in Figure 8: ] o Figure 9 is a front elevational view ol a first alternate embodiment ot a root panel:

Figure 9A is a top plan view of the rool panel illustrated in Figure 9. Figure 10 is a perspective view of siding shingles or shakes installed on a building or residence: 15 Figure 1 1 is a perspective view of roof shingles or shakes.

Figure 1 1 A is a perspective view of a roof having shingles or shakes formed of the concrete of the present invention installed thereon.

Figure 12 is a perspective view of a roof covered with roofing panels using the fiber-reinforced concrete of the present invention: 20 Figure 12A is a perspective view of the roof tiles shown in Figure 12.

Figure 12B is a perspective view of the installation of the roof tiles shown

in Figure 12A:

Figure 13 is a front elevational view of a wall panel including a door cutout and a brick outer surface.

Figures 14A-F are front elevauonai views ot wall panels having a variety ot different outer surfaces and configurations.

Figure 15 is a perspective view illustrating the assembh of a dwelling using the wall and roof panels shown in Figures 5 and 6. Figure 15A is a perspective view of the installation of the bottom of a wall panel onto a foundation.

Figure 16 is a perspective view of an alternate method of installing wall panels to a foundation.

Figure 16A is a perspective view ot a fixture used in a foundation for () mounting wall panels thereto.

Figure 16B is an alternate embodiment ot the fixture illustrated in Figure 16A. but usable at the corner of a foundation.

Figure 17 is a perspective view of an alignment tool. Figure 17A is a top plan view of the alignment tool shown in Figure 17. 5 Figure 18 is a perspective view of a corner alignment tool.

Figure 18A is a top plan view of the corner alignment tool shown in Figure 18.

Figure 19 is a side elevational view of a wall panel mounted on a foundation according to the pour-in-place method. 0 Figure 19A is a top plan view of the pour-in-place method of mounting of a wall panel on a foundation as shown in Figure 19.

Figure 19B is a top plan view of the poui-in-place method of construction onlv at a corner.

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Figure 20 is a top plan view of the installation of a roof panel bv the pour-in-place method.

Figure 21 is a top plan view ol a typical floor plan for a dwelling using the construction panels made of the fiber-reinforced concrete of the present invention Figure 22 is a perspective view oi a modular house made of the fiber-reinforced concrete of the present invention.

Figure 22A is a left side module of the house shown in Figure 22. Figure 22B is a center module of the house shown in Figure 22. and Figure 22C is a side module of the house shown in Figure 22 Description of the Embodiments

This section is divided into tour subsections. Components. Method of Manufacture. Products and Construction Methods While the drawing figures are referenced throughout all four sections, the drawing figures are organized to generally track with the descπptions m the Products and Construction Methods subsections

Components

The structural concrete of the present invention is a fiber-reinforced concrete In addition to the fiber component, the concrete also includes a dn component and a wet component The dry component includes sand and cement While equal quantities of sand and cement are used in the preferred embodiment, it has been found that the ratio ol sand to cement is not paπicularly cπtical For example, cement to sand ratios from about 3 1 to about 1 3 have proven satisfacton As the amount of sand with respect to cement is increased, the compressn e strength ot the fiber-reinforced concrete decreases while its tensile strength increases The preferred type oi cement is Type I oi I ype II Portland

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cement. The preferred type of sand is fine silica masonry grade sand. Such sand should be clean and essentially salt-free.

The wet component of the invention includes approximately 0.33 weight units of water when compared to the weight units of cement. In actual practice it has been found

5 that about 0.28 to about 0.40 weight units of water w ill also work. The water should be clean and salt-free. In the preferred embodiment, it has been found that de-mineralized or distilled water provides the best results. The wet component also includes approximately

0.01 weight units of liquid sodium silicate: however, the liquid sodium silicate may be reduced or increased by about 25% without a significant change in the propeπies of the

] () fiber-reinforced concrete. Liquid sodium silicate is often referred to as "liquid glass" or

"water glass." In the preferred embodiments, the liquid sodium silicate is marketed under the trademark "Crystal Lok" sold by Corroseal. Inc. Fuπher. the wet component includes preferably about 0.005 weight units of a plasticizer or a high range water reducer: however. the plasticizer may be reduced by as much as about 50% or increased by as much as about

] 5 300% without a significant change in the propeπies ofthe fiber-reinforced concrete. In the preferred embodiment, the plasticizer used is marketed under the trademark "Supercizer 7" sold by Fritz Industries. Inc. This plasticizer is funher described in U.S. Patent 4.961.790 and 5.120.367.

The third component of the structural concrete of the present invention is a fiber

20 component. The fibers in the fiber component may be selected from any number of commonly available fibers. The essential quality of the fibers is that they be resistant to absorbing water or hydrophobic. Specifically, fiberglass fibers may be used. If fiberglass fibers are used, approximately 0.10 weight units of fiberglass fibers are used with respect

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to 1 weight unit of cement. Nylon fibers may also be used If nylon fibers are used, it has been found that approximately 0.03 weight units of nvlon to 1 weight unit of cement will provide satisfactory results If the selected fiber is polypropylene, it has been found that approximately 0.01 weight units of polypropylene fibers to 1 weight unit of cement will provide satisfactory results Fuπher. the fiber component may be steel fibers. Such steel fibers are sold under the brand name "DRAMIX" by the Bekaeπ Corporation While mam lengths and diameters of steel fibers may be used, it has been found that in the preferred embodiment a steel fiber having a length of 30 millimeters and a diameter of 0.5 millimeters provides satisfactory results

If desired, different types of fibers mav be mixed For example, steel fibers may be mixed with polypropylene fibers. It has been found that when such mixture is used. approximately 0 1 weight units of steel fiber and about 0.0075 weight units of polypropylene fibers will provide satisfactory results When mixed properly, the fibers within the structural concrete ofthe present invention will be found to be oriented in random directions and distributed substantially uniformly within the fiber-reinforced structural concrete after the structural fiber-reinforced concrete has cured

As cement and sand are normally available in 94 lb bags, it has been found that the structural concrete of the present invention may be made by mixing one 94 lb bag of Poπland Type I or Type II cement with one 94 lb. bag of salt-free clean masonry sand The water required for such an amount of sand and cement is about 31 lbs To this mixture, approximately 16 ounces of liquid sodium silicate are used with about 8 ounces of plasticizer If a polypropylene fiber is used. 1 lb of polypropylene fiber is added to the mixture. If a steel fiber is used, approximate!) 13 lbs ol steel fiber are added to the mixture

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and if a combination of steel fiber and polypropylene fiber is used, approximate!} 10 lbs of steel fiber and approximately 0.75 lbs of polypropylene fiber are added to the mixture. As there is almost no waste, and none of the materials are toxic, the fiber- reinforced concrete of the present invention is environmentally fπendh Test Results

A test of the fiber-reinforced structural concrete of the present invention produced the followme results:

Method of Manufacture

The fiber-reinforced structural concrete of the present invention is made accordmg to the steps illustrated in the flow chaπ at Figure 1 First, water, preferabh clean, salt-free water, is mixed together with the liquid sodium silicate and the plasticizer for about 30 seconds in the following propomons.

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about 0 33 weight units of water about 0 01 weight units of liquid sodium silicate about 0 005 weight units of plasticizer

Once the water, the liquid sodium silicate and the plasticizer have been mixed together for about 30 seconds, about one weight unit of Portland Type 1 or Type II cement and about one weight unit of clean, masonry grade, preferabh salt-free sand is added to the mixture of water, liquid sodium silicate and plasticizer while it is still being mixed The cement, sand and the mixture of water, liquid sodium silicate and plasticizer is then mixed for about seven minutes Once the cement, the sand and the mixture ot watei liquid sodium silicate and plasticizer have been mixed together for about seven minutes, a hydrophobic fiber is added This hvdrophobic fiber is then stirred into the mixture for about one minute

As previously indicated, the hydrophobic fiber may be about 0 10 weight unit of a fiberglass fiber, about 0 03 weight units of a nylon fiber, about 0 01 weight units of a polypropylene fiber or about 0 20 weight units of a steel fiber If desired, about 0 10 weight units of a steel fiber may be mixed together with about 0 0075 weight units of a poh propylene fiber in the structural concrete

Once the fiber-remforced structural concrete 10 has been mixed together, it may be formed into a wide vaπety of shapes and products by pouring it into a mold 30 as shown in Figure 2 Preferably the structural concrete 10 is allowed to cure in the mold 30 m an atmosphere of about 90° Fahrenheit having a 50% relative humiditv

The resulting hardened concrete 10 is shown in Figure 3 Note that the fibers 10 are substantialh uniformh distributed and randomh oriented

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The wide flexibility of the fiber-reinforced structural concrete of the present invention 10 may be illustrated by indicating that the mold 30 may have a textured surface on its bottom 32 Thus, after the fiber-reinforced structural concrete 10 is poured on the textured surface, the molded fiber-remforced structural concrete 10 w ill have a similarh textured outer surface 104 The top side 106 of the poured fiber-reinforced structural concrete 10 may be smoothed with a vibrating screed to assure that the exposed back surface 102 of the poured fiber-remforced structural concrete 10 is smooth

It will be well understood by those of ordinal v skill in the an that numerous additions may be made to the mold 30 to produce a wide vaπetv of different products For example, flanged beams 126 as shown in Figure 7 mav be placed on the exposed surface 10" of a laver ofthe poured fiber-remforced structural concrete 10 and then attached thereto pouring additional fiber-reinforced structural concrete 128 over the flange 127 of the flanged beam 126 and onto the exposed back surface 103 of the poured fiber-reinforced structural concrete 10 Another example of a product is a wall board 100 as shown in the mold 30 in

Figure 2. Such wall boards 100 may have a foam core 1 10 made of styrofoam or urethane foam If desired, the foam core 1 10 may be entireh encapsulated with a top 106. a bottom 108 and side walls 1 12 The core material may be another type of non- fiber-reinforced concrete or cement In addition to forming wall boards 100. or alternative!} roofing boards 100 as shown in Figure 6. the fiber-remforced structural concrete 10 mav be molded into the shape of a structural beam, such as an I-beam, a box beam or a double bo\ beam If desired, the fiber-reinforced structural concrete mav also be molded into more complex structures, such as a roofing suppoπ truss

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It has also been found that the fiber-reinforced structural concrete of the present invention 10 may be formed in relatively thin sections as shown in Figures 10 and 1 1 and that such thm sections may be used as a siding shake or a shingle 200 on the wall W of a building or a roofing shake or shingle 204 over the ratters R of a building. By inseπing various different structures into the mold 30 shown in Figure 2. it is possible to increase the utility of the molded items. For example, an outer window frame or an outer door frame may be placed into the mold so that a wall panel may be formed with an opening and a frame already molded therein. A panel 100D with a door opening D is shown in Figure 13 and a panel 100E with a window poπal P is shown in Figure 14F When such wall panel 100 is erected, it remains for the builder to only inseπ a framed door or a framed window within the opening created in the wall panel 100.

Devices may also be added to the mold which will be exposed when the molded fiber-reinforced structural concrete is removed from the mold. For example, such devices may include a metal plate 42 which is exposed when the poured fiber-reinforced structural concrete 10 is removed from the mold 30 as shown in Figure 4 The exposed metal plate 42 may be used at a later time for welding the poured fiber-reinforced structural concrete wall panels 100 together or attaching the fiber-reinforced structural concrete wail panels 100 to a foundation F as shown in Figure 15.

In another embodiment, a threaded fastener, either a female threaded fastener 48 or

a combination of a male 48 and female threaded fastener 46. may be placed near the edge ofthe poured fiber-reinforced structural concrete wall panel 100 as shown in Figure 4 so that the male fastener 48 extends through any one of the surfaces of the wall panel 100 after it is removed from the mold 30 Optional!) , a threaded male fastener 48 may extend

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downwardly from female threaded fastener 46 into the fiber-reinforced structural concrete to provide for greater lifting capacity such as shown in Figure 5

To fuπher increase the utilization of the formed fiber-reinforced structural concrete panels, a tunnel or passage 140 may be formed in a wall panel 100 as shown in Figure 15 for a later utilization as a passageway for utilities such as plumbing, electπcal wires or ventilation

In situations where the poured fiber-reinforced structural concrete 10 is to be used in high load situations, or where large panels are required it is possible to add one or more steel reinforcing bars 120 to the poured fiber- reinforced concrete 10 before it cures as shown in Figures 9. 19. 19A. 19B and 20

It has also been found that because ofthe nature of the mixture of ingredients in the poured fiber-reinforced structural concrete of the present invention, the outer surface of the poured structural fiber-reinforced concrete may be polished

If it is desired to use slabs of molded fiber-reinforced structural concrete 10 on a roof, it is found that the slabs 300 of poured fiber-reinforced structural concrete 10. once cured, may be coated with a ceramic layer 302 as shown in Figure 12

In the preferred embodiment, it has been found that the following detailed steps mav be used to mold a sandwich panel 100. 100B. 100C as shown in Figures 5. 6. 8. 8A. 9 and 9A having an outer surface of structural concrete 10 and an inner foam core 1 10 Step ! The mold is coated lightly with oil or a smooth material

Step 2 Randomlv placed pourings of the fiber-reinforced structural concrete mixture to are placed on the bottom 32 of the mold 30 and spread out bv hand or bv a

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mechanical method so that all areas of the mold bottom 32 are covered This step is continued until the desired thickness of fiber-iemtorced concrete 10 is obtained

Step 3 A v ibrating screed 40 is calibrated to the required thickness of the fiber-reinforced structural concrete 10 Step 4 The vibrating screed 40 is placed on the open top 38 of the mold 40 at one

end 34

Step 5 The vibrating screed 40 is then slow h moved from one end 34 of the mold 30 to the other end 34 of the mold 30 across the open top 38 of the mold 30 and anv excess fiber-reinforced concrete 10 is removed or added as required Step 6 The vibrating screed 40 is then returned to the opposite end of the mold 34 to achieve a uniform thickness of fiber-remforced concrete 10

Step ⁷ A pre-cut foam core 1 10 is laid ov er the smoothed fiber- reinforced concrete 10. taking care not to press the core material 1 10 into the bottom layer 108 of the _j ust poured and smoothed fiber-reinforced concrete 10 Step 8 Fiber-reinforced concrete mix 10 is also poured into any surfaces ties 1 14 as shown in Figure 8 and formed in the rigid foam core 1 10 Optionalh concrete ribs 1 18 as shown in Figure 8. may be used in large panels

Step 9 Randomlv placed patties of fiber-reinforced concrete 10 are then poured over the top of the foam core 1 10 and spread by hand so that all areas are covered Step 10 The vibrating screed 40 is again calibrated to the necessary thickness

Step 1 1 The vibrating screed 40 is placed at one end 34 of the mold 30

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Step 12 The vibrating screed 40 is moved from one end 34 of the mold 30 to the

other end 34 of the mold 30 and fiber-reinforced concrete 10 is removed or added as

required

Step 13 The vibrating screed 40 is returned to the opposite end 34 of the mold 30

to achieve a uniform thickness of fiber-remforced concrete 10

If desired, the top surface 104 of the fiber-reinforced concrete may be either textured

or troweled to a smooth finish It is recommended that the curing fiber-reinforced

concrete 10 not be exposed to direct sunlight To achieve maximum strength, the mold 30 should be covered with a moisture resistant material ( not shown) to retain moisture w ithin

the fiber-reinforced concrete 10

To de-mold the fiber-reinforced concrete, the following steps are followed

Step 1 Check the outer surface 104 of the fiber-reinforced concrete 10 after 72 hours If the outer surface 104 of the fiber-reinforced concrete 10 has hardened after 72

hours, proceed with the following steps'

Step 2 Carefully remove the mold edges Great care should be exercised as if the

fiber-reinforced concrete is still green or soft, it may break if excess force is used In some situations, the layer of fiber-remforced concrete 10 at the bottom of the mold 30 may be paπicularly soft.

Step 3 The molded fiber-remforced concrete form 100 is then lifted off the mold

bottoms 32 The molded fiber-reinforced concrete forms 100 may be then stacked with a

sheet therebetween or stood on their long edges w ith approximate!} 1 inch separation

between each molded fiber-reinforced concrete form 100 to allow proper hvdration If

required, a shade cover (not shown) should be placed over the molded pieces 100 to prevent their exposure to direct sunlight.

Step 4: After the pieces 100 have cured for a full seven days, they may be used in construction.

Testing of building panels having a foam core as previously described have resulted

in compression strengths of greater than 5,800 PSI and moisture resistance of about 45 PSI.

Additionally, such structural panels will have an impact resistance of 55 x 10 inch lbs. per square inch.

Products

The strength and flexibility of the fiber-reinforced structural concrete of the present invention 10 lends itself to the manufacturer of a wide variety of products as shown, for example, in Figures 5, 6, 10, 1 1 which may be used to erect buildings or residences as shown in Figures 15 and 21.

The most basic of these products is a structural wall or roof panel 100 as shown in Figures 5 and 6 which includes an outer layer formed of the fiber-reinforced structural concrete 10 ofthe present invention. Such outer layer may include a back surface 102, front

surface 104, a top 106, a bottom 108, and one or more side walls 1 12. Within the outer

layer ofthe fiber-reinforced structural concrete is an inner foam core 1 10. It has been found

that such inner foam cores 1 10 may be formed using a styrofoam core or a urethane foam core. Those of ordinary skill in the art will understand that additional types of foam or cores 1 10 may be used without departing from the scope ofthe present invention. As shown in Figure 3, the fiber-reinforced structural concrete of the present invention 10 is

16 SUBSTTTUTE SHEET (RULE 26),

characterized by having a plurality of fibers 10F dispersed substantially uniformly and at

random angles. There is no bonding between the concrete and the fibers.

To facilitate the construction of a building or residence using the wall panel 100 previously described, it has been found that it is possible to mold in a metallic piece 42 on

one ofthe surfaces as shown in Figure 4, preferably at a corner, of the structural panel 100.

When this metallic piece 42 comes in contact with a metallic piece 42 on another wall

panel 100 or on the foundation F, the metallic pieces 42 may be welded together, thus facilitating the construction of a welded together building or residence.

If welding is difficult, it is also possible to erect a building or a residence using threaded fasteners which are molded into the building panel 100 as shown in Figure 4.

Specifically, the female end of a threaded fastener 46 is molded into the building panel 100 and the male end of a threaded fastener 48 extends therefrom. When it is desired to mount

the building panels 100 to a foundation F or connect the building panels 100 one to another, the threaded fasteners may be used to connect and align the building panels 100 as shown

in Figure 16. The basic construction of a wall panel 100 with connectors molded therein is

shown in Figure 4 where a metal plate 42 is connected to a female threaded fastener 46 by

a connector rod 44. Those of ordinary skill in the art will understand that the plate 42 or

threaded connectors 46, 48 may be used alone. Alternatively, the threaded connectors 46, 48 may be used to lift the panels 100 into place as shown in Figure 5. Therein a plate 50

having a lifting plate 52 is attached to the end of the panel 100 so that a hook 54 may be used. If desired, plate 50 and lifting plate 52 may be eliminated by placing eye bolts into

the female threaded connectors 46. Alternatively, the panel 100 may be lifted with a fork lift truck.

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As shown in Figure 5. the wall panel 100 ofthe present invention 100. once having

been lifted into place, is placed on a foundation F. If the wall panels 100 are properly

molded so that the mounting surfaces arc true, one with respect to another, there will be a close fit between the wall panels 100 when they are placed on a foundation F. To assure a

solid wall, filler material 124 may be placed in the space between two adjacent wall panels

100.

If desired, structural steel or wooden studs may be placed inside the wall panel 100 to serve as a mounting surface for interior wall board.

In Figure 6, the panel 100 ofthe present invention is used as a roof panel instead of as a wall panel. Therein, it may be seen that the panel 100 rests on and is attached by conventional methods to rafters R.

In Figure 7, a different type of wall panel 100Λ is shown. Specifically, the wall

panel 100A docs not include a foam core. Rather, it consists only of a bottom 108 which is poured on the bottom 32 of the mold 30 shown in Figure 2. Placed on the back surface 103 of the bottom 108 are a plurality of wall studs or beams 126. Such beams may be

formed of wood, steel or fiber-reinforced concrete 10. Once the beams 126 have been

placed on the back surface 103 ofthe bottom 108, additional deposits of cement 128 may

be poured onto the back surface 103 ofthe back skin 102 such that they overlap a flange or a surface 127 on the beam 126 which allows the beam 126 to be affixed to the skin 102

when the fiber-reinforced concrete dries. The beams 126 may then be used for the

attachment of commonly available interior wall board on the inside ofthe panel 100A. As

the fiber-reinforced concrete 10 does not adhere to the flanged portion 127 of the beams

126. there is no danger of the panel 100A cracking in response to temperature changes.

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In Figure 8, a first alternate embodiment of a wall panel 100B is shown. Note that

it has open sides but a solid foot 1 16. Also shown are surface ties 1 14 through the foam core 1 10 which may be used to connect the bottom 108 to the top 106. If the wall panel 100B is of a large size, it may be desired to add an optional rib 1 18 formed of the

fiber-reinforced concrete ofthe present invention. Such panels 100B are particularly useful

with the pour-in-place method of construction as described in Figures 19, 19A and 19B.

A first alternate embodiment of a roof panel 100C is shown in Figures 9 and 9A.

Note that the bottom 108 is smaller than the top 106 and that reinforcing bars 1 14 pass

through the foam core 1 10 at the surface ties 1 14. If desired, a solid panel end 122 may be formed at the lower end of the panel 100C. The installation of such panels 100C to form

a poured-in-place roof is illustrated in Figure 20.

The flexibility ofthe staictural concrete 10 of the present invention also allows for

the molding into a building panel 100 a wooden or metal frame. The wooden or metal frame may later be used as a support or an outer frame of a window or a door assembly. If desired, tunnels or passageways 140 (Figure 15) may be formed in the building panels 100. Such

tunnels or passageways 140 are extremely helpful for tieing together utility services, such

as plumbing, electricity or ventilation.

As previously indicated, the building panels may have any width x and height y and may have any type of outer surface desired as shown in Figures 14A through F. In

Figure 14A of simulated stucco and wood surface 132 is shown. Figure 14B illustrates a

simulated plane stucco surface 134. A simulated wood surface 136 appears in Figure 14C. Figure 14D shows a simulated limestone shingle surface 138. A simulated brick surface 130 appears in Figures 14E and 14F. The desired outer surface is placed in the bottom 32 ofthe

mold 30 and once the fiber-reinforced structural concrete of the present invention is poured thereon, the outer surface of the building panel will pick up the features found on the

bottom 32 of the mold 30. If desired a colorizer may be added to the fiber-reinforced structural concrete 10 to accent its surface appearance.

In larger panels, it may be necessary to assure that the structural concrete top 106 and bottom 108 of the building panel 100 are properly supported. This is accomplished by

assuring that surface ties 1 14 are formed through the foam core 1 10 and that structural fiber-reinforced concrete 10 connects the top 106 and the bottom 108 of the building panel,

one to another, by forming a passageway 1 14 which is filled with fiber-reinforced concrete through the foam core 1 10. In extremely large panels, it may be necessary to include

reinforcing bar 120 in the structural panel or possibly form concrete ribs 1 18 between sections of the foam core 1 10.

Further, it has been shown that if the fiber-reinforced structural concrete 10 of the

present invention is extruded, it may be formed into concrete shingles or shakes. Such

shingles or shakes may be used as siding 200 on a wall W as shown in Figure 10 or as roofing 204 as shown in Figure 1 1. The concrete shingles or shakes may have any desired

color by adding a colorizer to the mixture of the structural concrete of the present

invention 10 and any desired surface may be placed in the outer surface of the concrete shingles or shakes 200, 204. Typically, such concrete shingles or shakes 200, 204 are made

not by molding the fiber-reinforced concrete 10 of the present invention, but rather by extruding it. To facilitate the attachment of such concrete shingles or shakes 200, 204 to a residence or building, the fiber-reinforced concrete shingles or shakes 200, 204 are typically provided with one or more holes 202 formed therein through which a fastener 206 may be

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passed. Alternately, thin fiber-reinforced concrete panels may be molded or extruded which are larger than a single shake but may be used to give a wall a decorative appearance such

as a brick veneer 130.

The fiber-reinforced structural concrete ofthe present invention 10 may also be used without a foam core 1 10 for roofing panels as shown in Figures 12, 12A and 12B.

Specifically, if a slab of fiber-reinforced structural concrete according to the present

invention is molded into a convenient size as shown by the dimensions x and y in

Figure 12A, it may later be coated with a ceramic 302. One example of a ceramic elastomeric coating is marketed under the trademark "Uniflex" by Kool Seal Inc. As roof panels do not need the amount of structural strength that is required of load-

bearing wall panels, it is possible to form roof panels by a combination of a cement backing

with an outer skin of the fiber-reinforced structural concrete of the present invention. Attachment of roof panels 300 may be over sheeting S placed over rafters R as shown in Figure 12 and 12B. If desired, the roof panels 300 may then have a covering C as shown

in Figure 12 or left exposed.

It has also been found that the fiber-reinforced structural concrete of the present

invention 10 may be used to mold structural members. Such structural members may

include box beams, double box beams, I-beams, channel beams or combinations thereof. In applications where wood or steel beams may not be available, roof trusses may be molded using the structural concrete ofthe present invention.

Construction Methods

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Residences or buildings utilizing wall panels or structural members 100 employing

the fiber- reinforced concrete of the present invention 10 may be put together in several ways.

The first method of construction is to weld the wall panels 100 in place as shown in

Figure 15A. Such mcthoc' of construction involves embedding metal plates 56 in a poured

concrete foundation F as shown in Figure 15. Compatible weld plates 42 are set into the surface ofthe molded wall panel 100. When the molded wall panels are put in place on a poured concrete foundation F. the metal plates 42 in the wall panels 100 are positioned to

abut the metal plates 56 in the poured concrete foundation F. Such plates 56 may be positioned by times 64 which extend downwardly from the plate 56 into the foundation F

as shown in Figures 16A and 16B. With the metal plates abutting, it is then possible weld the metal plates together. Alternatively an angle iron 58 may be used to tie the metal

surfaces together. Similarly, at the top ofthe molded wall panels, it is also possible to use metal plates 42 at the corners as shown in Figure 15. When wall panels 100 are in position,

the metal plates 42 are put together so as to abut one another or be connected by a small

metal tie plate. Once again, the metal plates 42 are welded together and the wall panels are held securely in place, one with respect to another. Utility services, generally K, may be molded into the wall panels 100 to facilitate construction.

An alternate method of construction involves utilizing threaded fasteners as shown

in Figure 16. Typically, a female threaded fastener 46 is molded into the wall panel 100 so

that its opening is coplanar with a surface of the wall panel 100. When the surface of the wall panel 100 is placed against a plate or an angle iron 58 which is positioned in the foundation, it is possible to pass a male threaded fastener 48 through a hole 60 in the

plate 58 and into the female threaded fastener 46 located in the wall panel 100. A corner plate 62 is shown in Figure 16B. It will be well understand by those of ordinary skill in the

art that is possible to juxtapose the position of the male and female threaded fasteners

without departing from the scope ofthe present invention. Additional threaded fasteners may be used at other locations on the molded wall panel to tie the wall panels 100 one to

another. If a female threaded fastener 46 is placed coplanar with the bottom edge of the molded wall panel 100 and a male fastener 48 is inserted therein, it is possible to adjust the

position of the male fastener with respect to the female threaded fastener 46 to adjust or align the bottom ofthe wall panel so that it fits properly with respect to the adjacent wall panel 100 and to the foundation F.

Alignment ofthe top ofthe wall panels 100 is facilitated by utilization of a straight

alignment tool 66 as shown in Figures 17 and 17A or a 90° corner alignment tool 76 as

shown in Figures 18 and 18A.

The straight alignment tool 66 includes a flat bar 68. Attached to the flat bar 68 are

a plurality of C-clamps 70. Once the flat bar 68 is placed on the outside ofthe wall panel

100, the knobs 74 are turned such that the foot 72 on a C-clamp 70 contacts the opposite

surface ofthe wall panel 100. Once the tops of adjacent wall panels 100 have been properly aligned, the bottoms ofthe adjacent wall panels 100 may be welded in place, bolted in place or poured-in-place as previously discussed. A similar operation exists at the corner of a structure. Specifically as shown in

Figure 18 a 90° corner bai" 78 is placed on the outside surface of adjacent wall panels 100. C-clamps 70 are placed such that the foot 72 ofthe C-clamps 70 contacts the inner wall of

the wall panel 100 when knobs 74 are turned. Similarly, once the tops of adjacent panels

SUBSTTTUTE SHEET (RULE 26)

100 have been aligned, the bottoms of the adjacent panels 100 may be affixed in place by

welding, bolting or pouring-in-place as previously discussed.

Still another method of erecting a building or a residence using wall panels formulated from the fiber-reinforced concrete of the present invention involves placing the molded wall panels 100B (Figures 8 and 8A) on a foundation F with a space therebetween

as shown in Figures 19, 19A, and 19B. In this method of construction, each molded panel 100B has metal reinforcing bars 120 extending from its edges so that when the panels

are placed on a foundation F a void 90 exists therebetween. The metal reinforcing bar 120 extends into the void 90 between the panels 100B. With the panels 100B held in position, it is possible to fill up the void 90 between the panels with concrete so that the metal reinforcing bars 120 extending outwardly from the panels 100B are in the void 90 which is

filled with concrete. If desired, a substantially vertical metal reinforcing bar 84 may be placed in the void 90 between the adjacent panels 100B. This metal reinforcing bar 84 may be tied to a wall anchor 80 extending upwardly out of the foundation F by using a wire

tie 82.

It is recommended that in this method of erecting a house by pouring concrete

between the adjacent wall panels 100, the construction begin at one corner of the building. The panels 100 are formed so that a corner column void 90 is formed as shown in Figure 19B. It is also recommended that a horizontal metal reinforcing bar 88 in the

lintels 86 poured on top of the wall panels 100 be attached to the substantially vertical reinforcing bar 84. Additional wall panels 100 are then put in place along the foundation F

so that they are level and secure.

24

SUBSTTTUTE SHEET (RULE 26)

A poured-in-place roof is shown in Figure 20. An opening or void 90 between the panels 100C is shown on the right side of the figure. On the left side of the figure the void 90 has been filled with a poured beam 94 strengthened by two reinforcing rods 92.

A typical floor plan for a low cost dwelling 450 is shown in Figure 21 . Therein it

may be seen that an entrance or porch area 400 is formed at the front of the dwelling 450.

This area opens into a living area 402. Behind the living area 402 is a dining area 404 which opens into a kitchen 406. Adjacent to the kitchen 406 is a bath 408 which is adjacent to a bedroom 410. This entire structure 450 may be erected pursuant to the method illustrated

in Figure 15. It has also been found that a modular house 500 such as shown in Figure 22 may also be constructed in a factory using the fiber-reinforced concrete of the present invention 10

and erected on site. Such a modular house 500 may include a left side module 502 as shown

in Figure 22A, a center module 504 as shown in Figure 22B and a right side module 504 as shown in Figure 22C. To facilitate the construction a utilities pod 508 may be placed on one

of the modules.

There has now been disclosed by the foregoing specification a low cost, durable, environmentally friendly, fiber-reinforced concrete formulation which may be utilized to formulate a variety of different products to erect residences or buildings. While the

invention has been disclosed by reference to its preferred and alternate embodiments, those

of ordinary skill will understand that numerous other embodiments are possible by reference to the foregoing disclosure. Such other embodiments shall be included within the scope and meaning of the appended claims.

FΛA I 1229\CON046\58000\FIB-PA I APP