| |
| United States Patent
|
5,845,441 |
| Swartz |
December 8, 1998 |
Premanufactured portable concrete house
Abstract
This invention provides a premanufactured portable concrete house
and efficient systems for making such a house and for providing
portability to a housing site. Floor, roof, and wall components are
made by casting concrete in molds with features such as electrical
and water conduits being concrete-embedded during the casting. Also
concrete-embedded in the various house components are steel plates
used for welding to secure the components to each other during
assembly of a portable house. Spaced core holes for holding lift
rods are cast into the periphery of the floor/foundation component;
and these are used as lift points in lifting the house onto a truck
for transport to a housing site.
| Inventors: |
Swartz; Paul D.
(Phoenix, AZ) |
| Appl. No.:
|
08/675,230 |
| Filed: |
July 1, 1996 |
| Current U.S.
Class: |
52/250 ;
52/251; 52/79.1 |
| Current
International Class: |
E04B
1/04 (20060101); E04B 1/02 (20060101); E04B 001/00 () |
| Field of
Search: |
52/250,251,253,258,259,122.1,125.1,220.1,220.2,220.3,79.1,79.9,79.11,295,293.3
|
References Cited
[Referenced By]
U.S. Patent
Documents
Primary Examiner: Smith; Creighton
Attorney, Agent or Firm:
Stoneman; Martin L.
Claims
What is claimed is:
1. A premanufactured portable concrete housing structure comprising,
in combination:
a. first concrete means for providing a floor member;
b. multiple second concrete means for providing wall members;
c. third concrete means for providing a roof member; and
d. said first concrete means comprising multiple spaced means for
assisting lifting and deposit of said premanufactured portable
concrete housing structure;
e. wherein each of said multiple spaced means for assisting lifting
and deposit of said premanufactured portable concrete housing
structure comprises core means adjacent a side of said first
concrete means;
f. wherein said core means comprises a horizontal hole substantially
perpendicular to said side of said first concrete means; and
g. wherein said core means comprises a substantially-cylindrical
hole, in a socket beam, adapted for holding a substantially
cylindrical rod member adapted for jacking.
2. A premanufactured portable concrete housing structure comprising,
in combination:
a. first concrete means for providing a floor member;
b. multiple second concrete means for providing wall members;
c. third concrete means for providing a roof member; and
d. said first concrete means comprising multiple spaced means for
assisting lifting and deposit of said premanufactured portable
concrete housing structure;
e. wherein said first and second concrete means comprise
concrete-embedded first attachment means for attaching said first
concrete means to each of said second concrete means; and
f. wherein each said first attachment means comprises first steel
plate means for welding to an other said first attachment means.
3. A premanufactured portable concrete housing structure comprising,
in combination:
a. first concrete means for providing a floor member;
b. multiple second concrete means for providing wall members;
c. third concrete means for providing a roof member; and
d. said first concrete means comprising multiple spaced means for
assisting lifting and deposit of said premanufactured portable
concrete housing structure;
e. wherein said third concrete means comprises a pair of said roof
members connected at a selected pitch by connection means comprising
concrete-embedded second steel-plate means for welding to an other
said connection means.
4. A premanufactured portable concrete housing structure according
to claim 3 wherein said third concrete means comprises second
attachment means comprising concrete-embedded third steel-plate
means for welding to a roof-member-supporting said second concrete
means.
5. A premanufactured portable concrete housing structure system,
using housing structure members formed as floor members, roof
members, and wall members for connection to provide a
premanufactured portable concrete housing structure, comprising the
steps of:
a. preparing a horizontal concrete-casting mold for casting a
concrete means for providing a said housing structure member;
b. placing into said mold internal steel rebar elements for said
concrete means and surface steel plate elements for said concrete
means, each said surface steel plate element being supported by
dowel means supported by a said steel rebar element;
c. placing concrete into said mold and curing said concrete to
provide a solid said housing structure member;
d. removing said housing structure member from said mold;
e. from the above steps, using suitable said concrete-casting molds,
accumulating said housing structure members, formed as floor
members, roof members, and wall members;
f. from said accumulated said housing structure members, making a
premanufactured portable concrete housing structure by successively
i. placing each said housing structure member in suitable
juxtaposition to an other said housing structure member, and
ii. welding together contacting said surface steel plate elements of
said juxtaposed housing structure members;
g. transporting said premanufactured portable concrete housing
structure to a suitable site; and
h. depositing said premanufactured portable concrete housing
structure on said site.
6. A premanufactured portable concrete housing structure system
according to claim 5 further comprising the step of:
a. before placing concrete into said mold to make a said floor
member, configuring said mold to provide spaced socket beams each
including a cylindrical hole adjacent to and substantially
perpendicular to an edge of said floor member.
7. A premanufactured portable concrete housing structure system
according to claim 6 further comprising the step of:
a. after making a said premanufactured portable concrete housing
structure, placing a fitting cylindrical steel rod into each said
cylindrical hole in such manner that a portion of said steel rod
extending from said hole acts as a lift point for lifting said
premanufactured portable concrete housing structure.
8. A premanufactured portable concrete housing structure system
according to claim 7 further comprising the steps of:
a. after said placing of each said steel rod, placing lifting means
under each said steel rod portion extending from a said hole; and
b. lifting said premanufactured portable concrete housing structure.
9. A premanufactured portable concrete housing structure system
according to claim 8 wherein said transporting is by truck.
10. A premanufactured portable concrete housing structure system
according to claim 8 wherein said lifting comprises using four said
steel rods.
11. A premanufactured portable ready-to-use concrete house
comprising:
i. a precast concrete floor member comprising bottom portion
concrete beams for added support strength, said concrete beams
comprising both circumferential beams and internal beams;
j. four precast concrete exterior wall members;
k. two precast concrete roof members each supported by three of said
wall members at a pitch angle;
l. an interior bearing wall member further supporting said roof
members; and
m. concrete-embedded attachment means in each of said members (said
floor member, said exterior wall members, said roof members, and
said interior bearing wall member), attaching each said member to a
juxtaposed other member;
n. wherein each said attachment means in each said member comprises
a steel plate welded to an other said attachment means of an other
said member.
12. A premanufactured portable ready-to-use concrete house according
to claim 11 wherein said floor member is about 16 feet wide by about
28 feet long.
13. A premanufactured portable ready-to-use concrete house according
to claim 11 further comprising:
a. a second house substantially identical to said concrete house and
situate spaced from said concrete house about one house-width
distant; and
b. spanning roof member means for providing a roof spanning said
distance between said concrete house and said second house.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to premanufactured portable concrete housing
structures. More particularly, this invention concerns a system for
providing a premanufactured portable concrete house, for making such
a house, and for providing portability to a housing site.
2. Description of the Prior Art
Typically, a concrete house is manufactured or put together right on
the site of permanent use for such house. And although a concrete
house provides long life, low maintenance, high strength, good
insulation, and other advantages to a homeowner, the cost of
building such a concrete house on site is more than what low-income
families can afford.
Also, typically, mobile homes which are premanufactured of other
materials at a mass production location and then transported to and
placed on a home site are inexpensive and within the budget of many
low-income families. However, such mobile homes are usually of much
shorter life, higher maintenance, lower strength, poorer insulation,
etc., than what a concrete house would be. And there have been no
successful efforts to provide for the needs of such low-income
families an efficient and inexpensive system for premanufacturing in
a mass production manner a portable concrete house which may be
efficiently transported and installed at a home site.
OBJECTS OF THE INVENTION
A primary object of the present invention is to fulfill the
above-mentioned needs by the provision of a premanufactured portable
concrete house. A further primary object of the present invention is
to provide such a house which is efficient and inexpensive. In
addition, it is a primary object of this invention to provide a
system for making and for transporting for on-site use of such a
house. Other objects of this invention will become apparent with
reference to the following invention descriptions.
SUMMARY OF THE INVENTION
According to a preferred embodiment of the present invention, this
invention provides a premanufactured portable concrete housing
structure comprising, in combination: first concrete means for
providing a floor member; multiple second concrete means for
providing wall members; third concrete means for providing a roof
member; and such first concrete means comprising multiple spaced
means for assisting lifting and deposit of such premanufactured
portable housing structure. Also, it provides such a premanufactured
portable concrete housing structure wherein each of such multiple
spaced means for assisting lifting and deposit of such
premanufactured portable concrete housing structure comprises core
means adjacent a side of such first concrete means. And it provides
such a premanufactured portable concrete housing structure wherein
such core means comprises a horizontal hole substantially
perpendicular to such side of such first concrete means; and
further, wherein such core means comprises a
substantially-cylindrical hole, in a socket beam, adapted for
holding a substantially cylindrical rod member adapted for jacking.
Further, the present invention provides such a premanufactured
portable concrete housing structure wherein such second concrete
means comprises concrete-embedded electrical and water conduits. And
it provides such a premanufactured portable concrete housing
structure wherein such first concrete means comprises multiple
concrete beams strong enough to permanently support such
premanufactured portable concrete housing structure on footing
members. Additionally, it provides such a premanufactured portable
concrete housing structure wherein such first and second concrete
means comprise concrete-embedded first attachment means for
attaching such first concrete means to each of such second concrete
means; and, further, wherein each such first attachment means
comprises first steel plate means for welding to an other such first
attachment means.
Moreover, the present invention provides such a premanufactured
portable concrete housing structure wherein such third concrete
means comprises a pair of such roof members connected at a selected
pitch by connection means comprising concrete-embedded second
steel-plate means for welding to an other such connection means.
Also, it provides such a premanufactured portable concrete housing
structure wherein such third concrete means comprises second
attachment means comprising concrete-embedded third steel-plate
means for welding to a roof-member-supporting said second concrete
means.
Even further, the present invention provides, in accordance with a
preferred embodiment thereof a premanufactured portable concrete
housing structure system comprising the steps of: preparing a
horizontal concrete-casting mold for the casting of a concrete means
for providing a housing structure member; placing into such mold
internal steel rebar elements for such concrete means and surface
steel plate elements for such concrete means, each such surface
steel plate element being supported by dowel means supported by a
such steel rebar element; placing concrete into such mold and curing
such concrete to provide a solid such housing structure member;
removing such housing structure member from such mold; from the
above steps using suitable such concrete-casting molds, accumulating
such housing structure members in the form of floor members, roof
members, and wall members adapted to be connected to provide a
premanufactured portable concrete housing structure; from such
accumulated such housing structure members, making a premanufactured
portable concrete housing structure by successively placing each
such housing structure member in suitable juxtaposition to an other
such housing structure member and welding together contacting such
surface steel plate elements of such juxtaposed housing structure
members; transporting such premanufactured portable concrete housing
structure to a suitable site; and depositing such premanufactured
portable concrete housing structure on such site.
Also, this invention provides such a premanufactured portable
concrete housing structure system further comprising the step of,
before placing concrete into such mold to make a such floor member,
configuring such mold to provide spaced socket beams each including
a cylindrical hole adjacent to substantially perpendicular to an
edge of such floor member; and, further, comprising the step of,
after making a such premanufactured portable concrete housing
structure, placing a fitting cylindrical steel rod into each such
cylindrical hole in such manner that a portion of such steel rod
extending from such hole is adapted to act as a lift point for
lifting such premanufactured portable concrete housing structure. It
further provides such a premanufactured portable concrete housing
structure system further comprising the steps of: after such placing
of each such steel rod, placing lifting means under each such steel
rod portion extending from a such hole; and lifting such
premanufactured portable concrete housing structure; and, further,
wherein such transporting is by truck; and, further, wherein such
lifting comprises using four such steel rods.
Even additionally, the present invention provides, according to a
preferred embodiment thereof, a premanufactured portable
ready-to-use concrete house comprising: a precast concrete floor
member comprising bottom-portion concrete beams for added support
strength, such concrete beams comprising both circumferential beams
and internal beams; four precast concrete exterior wall members; two
precast concrete roof members each supported by three of such wall
members at a pitch angle; an interior bearing wall member further
supporting such roof members; and concrete-embedded attachment means
in each of such members (such floor member, such exterior wall
members, such roof members, and such interior bearing wall member)
for attaching each such member to a juxtaposed other member.
Still further, this invention provides such a premanufactured
portable ready-to-use concrete house wherein each such attachment
means in each such member comprises a steel plate for welding to an
other such attachment means of an other such member; and, further,
wherein the floor dimensions of such concrete house are about 16
feet by about 28 feet. And it also provides such a premanufactured
portable ready-to-use concrete house further comprising: a second
house substantially identical to such concrete house and situate
spaced from such concrete house about one house-width distant; and
spanning roof member means for providing a roof spanning such
distance between such concrete house and such second house.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the
premanufactured concrete house of the present invention.
FIG. 2 is a floor plan view of a premanufactured concrete house.
FIG. 3 is a perspective view of the underside of the
floor/foundation.
FIG. 4 is a perspective view of typical floor/foundation and wall
construction.
FIG. 5 is a cross-section elevation view of floor/foundation and
exterior wall construction.
FIG. 6 is a cross-section elevation view of floor/foundation and
interior wall construction.
FIG. 7 is a perspective view of the underside of a roof/ceiling
section.
FIG. 8 is a cross-section elevation view of roof/ceiling and
interior bearing wall construction including showing the attachment
means.
FIG. 9 is a cross-section elevation view of a roof/ceiling and
exterior wall construction including showing the attachment means.
FIG. 10 is cross-section elevation view of typical integral plumbing
and electrical.
FIG. 11 is a perspective view of a lifting bar and socket.
FIG. 12 is a cross-section elevation view of a lifting bar and
socket.
FIG. 13 is a perspective view of the concrete house components prior
to assembly.
FIG. 14 is a perspective view of an alternate method of the concrete
house's use.
FIG. 15 is a perspective view of a second alternate method of the
concrete house's use.
FIG. 16 (FIGS. 16A through 16G) is a series of perspective views
showing essentially a preferred system or method of making the
concrete house's concrete components or structures.
FIG. 17 (FIGS. 17A through 17D) is a series of perspective views
showing essentially a preferred system or method of assembling the
concrete components or structures into a concrete house.
FIG. 18 is a perspective view illustrative of one of the final steps
in a preferred system for completing a concrete house of the present
invention.
FIG. 19 is a series of perspective views showing some steps in a
preferred system for lifting and transporting a concrete house for
deposit at a home site. FIG. 19A shows the insertion of a lift rod
into a cored hole at a lift point in a floor/foundation member. FIG.
19B and FIG. 19C show a jacking means operating for lifting at a
lift point. FIG. 19D shows a truck transporting a concrete house of
the present invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT AND THE BEST MODE OF
PRACTICE
Shown in perspective view in FIG. 1 is a preferred embodiment of a
premanufactured portable concrete housing structure, embodied by
concrete house 20, according to the present invention. Concrete
house 20 would have been previously manufactured at a factory site,
where this design of house is manufactured in quantity, and then
transported to, and installed at the location where it is to be
occupied as a residential dwelling. The concrete house 20 is a
completely assembled and ready to use dwelling with its component
structures 21 (constructed of steel reinforced concrete members)
consisting of first concrete means for providing a floor member,
embodied by floor/foundation 22, multiple second concrete means for
providing wall members, embodied by exterior walls 23 and interior
walls 24, and third concrete means for providing a roof member,
embodied by ceiling/roof sections 25 and 26. The assembled
structures 21 then preferably incorporate insulating materials and
coatings, roofing materials, and interior and exterior paint
coatings. Additionally the concrete house 20 preferably includes
factory installed windows 30, doors 31, interior cabinetry, hot and
cold water and sewer plumbing systems with plumbing fixtures,
electrical wiring with outlets, lighting and utility box, and a
heating and cooling system with heat pump 32.
The concrete house 20, in its ready to use state, and after being
transported to its set-up site, is installed and attached atop seven
footings 33 which rest upon an approved base 34. The approved base
34 may be either engineering certified compacted fill or 18 inches
below undisturbed soil. After the footings 33 and concrete house 20
are set, fill 35 is brought up to the natural grade 36. Installation
of the concrete house 20 is completed with the hook up of water,
sewer, electric, and gas if required. As the concrete house 20 will
commonly be used as a part of a planned community or defined
neighborhood, parking, landscaping, walkways, etc., might generally
be installed in conjunction with a group of other concrete houses.
The simplicity of set-up and installation of the concrete house 20,
as described, will allow for a minimum of time and labor required to
bring the concrete house 20 to a habitable state.
As the concrete house 20 has been designed for the goal of maximum
economy and longevity by being mass produced at a factory site and
then transported to an installation site, the overall size and
configuration is also directed towards this goal. As illustrated in
FIG. 2, the floor plan view of a preferred floor plan of the
concrete house 20 shows the simplicity of the concrete house 20,
while maintaining the necessary features of a single family
dwelling. The exterior dimensions are approximately 16'-4" by 28'-4"
excluding the roof overhang 37 which is a nominal 12" all around and
illustrated with dotted lines. This size provides a living area of
approximately 480 square feet, yet allows a practical method of
construction, and a size suitable for transporting the completed
unit to the installation site.
The floor plan of the concrete house 20 includes a living room 40,
kitchen/dining area 41, one bedroom 42 with a large closet 43,
bathroom 44, and utility area 45. Exterior walls 23 include windows
30 and doors 31. Four interior walls 24 define the rooms with the
interior bearing wall 46 located midway of the longitudinal
dimension of the concrete house 20, dividing it in half and
separating the living room 40 and kitchen/dining area 41 from the
bedroom 42, bathroom 44 and utility area 45. This interior bearing
wall 46 additionally supports the two ceiling/roof sections where
they connect at the roof peak. The remaining three interior walls 24
are non-bearing walls. Cabinets 47 are located in the kitchen/dining
area 41 and bathroom 44 and house sinks 50. Additional fixtures
include bathtub 51 and water closet 52. Appliances include stove and
oven 53, with locations for refrigerator 54, washer 55 and dryer 56.
Additionally, the floor plan illustrates the location of the seven
footings 33, on which the concrete house 20 will rest and to which
it will be attached at the installation site. A footing 33 will be
located at each of the four corners 60, two midway longitudinally
where the interior bearing wall 46 joins with the two opposing
exterior walls 23, and one located under the center of the concrete
house 20. Although not shown, electrical outlets and lighting
fixtures are appropriately located throughout the concrete house 20.
The underside 61 of the floor/foundation 22 of the concrete house 20
is shown in perspective in FIG. 3 with portions of an exterior wall
23 and left ceiling/roof section 26 included. The floor/foundation
22, manufactured as one piece of steel reinforced concrete,
incorporates (as further discussed just below) multiple concrete
beams strong enough to permanently support the premanufactured
portable concrete housing structure on footing members.
Floor/foundation 22 incorporates a floor slab 62 with integral
foundation beams 63 around its perimeter on all four sides and a
center foundation beam 64 located midway longitudinally and
interconnecting with two opposing foundation beams 63 on the
longitudinal sides of the floor. This center foundation beam 64 is
located under the location of the interior bearing wall 46.
Additionally, non-supporting foundation beams 65 are included under
the locations of the remaining interior walls 24. Also supporting
the floor slab 62, and integral with it, are support beams 66,
spanning the longitudinal length and interconnecting with the
foundation beams 63 on the opposing short sides of the floor. These
support beams 66 also interconnect with the center foundation beam
64. There are three support beams 66 under each half of the floor
slab 62, equally spaced, dividing the floor slab 62 into quarters.
Also shown are cored holes 67 through foundation beams 63 and center
foundation beam 64 at the locations where the concrete house 20 will
rest atop the seven footings 33. These cored holes 67 may be used to
attach the concrete house 20 to the footings 33 with mechanical
fasteners; but it is noted that, for most such connections, using an
angle iron clip (not shown) at each of the exterior footing
locations, in well known ways, may be preferable. Additionally
located on the underside 61 of the floor slab 62 are four socket
beams 70, further described in FIGS. 11 and 12, which contain cored
holes 71 for removable lifting rods used while moving the concrete
house 20. The cored holes 71 extend through opposing foundation
beams 63 and into the socket beams 70 preferably at two locations on
each longitudinal side of the floor/foundation 22.
Specific details of the features of the floor/foundation 22, along
with details of exterior walls 23 and interior walls 24, and
attachment of these components, are described in FIGS. 4 through 6.
As earlier stated, the floor/foundation 22, exterior walls 23,
interior walls 24, and right and left ceiling/roof sections 25 and
26 are manufactured of steel reinforced concrete. These component
structures 21 are cast horizontally in casting beds using necessary
forms; then, after curing, they are available for assembly and
attachment to each other. The casting process is similar to that
used for industrial building component construction and involves
preparing a casting bed with forms, preparing and positioning
reinforcing steel and fittings within the casting bed and forms, and
then pouring concrete within the bed and forms. Once poured, the top
surface of the concrete is leveled and finished. After the concrete
is sufficiently cured, forms are removed and the cast item is lifted
from the casting bed. For manufacture of the concrete house 20 in
production quantities, casting beds specifically made and provided
for each component to be cast and include shapes and forms for all
required features, and also provide ease of assembly and disassembly
as is necessitated for reuse. The floor/foundation 22 is cast in one
piece, with the casting bed and forms configured to produce the
foundation beams 63, center foundation beam 64, non-supporting
foundation beams 65, support beams 66, socket beams 70 and the
underside 61 of the floor slab 62.
The floor slab 62 incorporates a steel reinforcing rod grid 72, and
the foundation beams 63 located around the perimeter of the floor
slab 62 are reinforced by rebar with ties 73. Additionally, the
support beams 66 contain rebar 74. Around the perimeter of the
floor/foundation 22 is a recess 75 for positioning of exterior walls
23. As will be herein more particularly described, this invention
includes concrete-embedded first attachment means (preferably steel
plate means, weldable) for attaching the floor/foundation 22 to each
of the various wall elements and similar second attachment means for
attaching the roof (25 and 26) to its supporting wall elements.
Steel weld plates 76 with dowels 77 are cast into the foundation
beams 63 around the outer perimeter spaced approximately 48" apart
with their locations corresponding with like weld plates 78, with
dowels 79, cast into the outer surface 82 at the bottom edge of
exterior walls 23. When the exterior walls 23 are positioned in
their appropriate locations in the recess 75 of the foundation beams
63 of the floor/foundation 22, weld plates 76 are joined with weld
plates 78, with a weld bead 83, thus securing the exterior walls 23
to the floor/foundation 22.
Exterior walls 23 are cast in casting beds in the same manner as the
floor/foundation 22. A steel reinforcing rod grid 84 is again used
in the exterior walls 23 with additional rebar 85 around and just
inside the perimeter edges, and around door and window openings.
When the exterior walls 23 are cast, the outer surface 82 is faced
downward, and, prior to pouring the concrete, a layer of insulating
foam panels 86 are placed into the casting bed to provide for an
insulating barrier on the outer surface 82 of the exterior walls 23.
After the various structures 21 are assembled, wire mesh 87 (chicken
wire) is secured through the insulating foam panels 86 to the outer
surface 82 of the exterior walls 23, and then a layer of stucco 88
is applied. The surface of the stucco 88, along with the remaining
exterior of the concrete house 20, receives a final paint coat
system 91 with coloring as desired.
In FIG. 6, details of the attachment of the interior bearing wall 46
to the center foundation beam 64 of the floor/foundation 22 is
shown. Cast into the bottom surface 94 of the interior bearing wall
46 are weld plates 95, with dowels 96, which are spaced
approximately every 48", and mate with the center foundation beam 64
at weld plates 97 incorporating dowels 98. Upon assembly, weld
plates 95 and weld plates 97 are joined with weld bead 99 on both
sides of interior bearing wall 46. Attachment of other interior
walls 24, which are non-bearing, to the floor/foundation 22 at
non-supporting foundation beams 65, occurs in the same manner using
weld plates with dowels. The center foundation beam 64 with rebar
with ties 104 is shown resting atop a footing 33. Footings 33 also
incorporate a grid of reinforcing rod 105.
The underside of left/ceiling roof section 26 is shown in
perspective in FIG. 7. Right ceiling/roof section 25 is identical in
construction to left ceiling/roof section 26, with the exception of
the location of weld plates 106 and provisions (in the right
section) for beams to connect with non-bearing walls (using the
steel plate methods described herein), for lighting, for heat pump
32 and for other utilities. Typical for both left and right
ceiling/roof sections 26 and 25, is ceiling slab 107 with beams 108.
Joining surface 110 is appropriately angled (angle A, as shown) for
providing an interface with the opposing roof/ceiling section when
installed with an established roof pitch.
This interface between roof sections 26 and 25 is illustrated in
FIG. 8. Weld plates and dowels 111 are cast on the top surface 112
of both left and right ceiling/roof sections 25 and 26, with edges
flush with the joining surface 110. When both left and right
ceiling/roof sections 26 and 25 are in place and supported atop
interior bearing wall 46, weld beads 113 at weld plates and dowels
111 join these two sections. Thus, the roof concrete means comprises
a pair of roof members connected at a selected pitch by connection
means comprising concrete-embedded steel-plate means for welding to
an other similar steel-plate means. The left and right ceiling/roof
sections, 26 and 25 are cast with a steel reinforcing rod grid 116
within the ceiling slabs 107 and rebar 117 in the beams 108. Weld
plates 114 on the bottom surface 115 of the beams 108 are positioned
to mate with corresponding wall weld plates, as shown and discussed
below.
At the top of interior bearing wall 46, and extending its full
length, is beam 118, cast with rebar with ties 119, which
interconnect with a rebar grid 120 which is cast within the interior
bearing wall 46. The remaining interior walls within the structure
are non-bearing, and do not include beams at their top, but do
incorporate a rebar grid. Imbedded at the top of the interior
bearing wall 46, in the beam 118 are weld plates 125. When
assembled, weld plates 114 on the on the bottom surface 115 of the
left and right ceiling/roof sections 26 and 25, are welded to the
weld plates 125 with weld beads 126 on both sides of the interior
bearing wall 46. This connection means not only secures the left and
right ceiling/roof sections 26 and 25 to the interior bearing wall
46, but completes their tie to each other. Completing the roof is a
layer of foam insulation 127 and roof covering 128. The roof
covering 128 is of conventional materials such as concrete tile or
baked enamel metal sheeting, and is secured to the ceiling slabs 107
with mechanical fasteners extending through the foam insulation 127,
in well-known ways. In FIG. 9 is illustrated the typical attachment
of the left and right ceiling/roof sections, 26 and 25 to an
exterior wall 23. Weld plates 114 cast into beams 108 are welded
with weld beads 129 to weld plates 130 cast at the top of exterior
walls 23. It is noted that, for most applications, roof insulation
127 should be continuous with wall insulation 86, and stucco 87
should connect with the end of roof covering 128, for the best
thermal encapsulation and visual appeal. Thus, this invention
provides a premanufactured portable concrete housing structure
wherein the third concrete means (roof) comprises a second
attachment means comprising concrete-embedded third steel-plate
means for welding to a roof-member-supporting said second concrete
means (wall).
FIG. 10 shows an example of the common means that typifies the
inclusion of electrical, water and sewage lines within and
throughout the structure of the concrete house as concrete-embedded
electrical and water conduits. Electrical outlet boxes 133 and
interconnecting conduit 134 are cast into the interior and exterior
walls 23 and 24. Additionally, wall switch boxes, fixtures for
lighting, provisions for appliances, and related electrical conduit,
are also included. Where interconnecting conduits 134 join at
connecting walls, floor/foundation 22 or ceiling roof sections,
mechanical connectors 135 are used. After the concrete house 20 has
been assembled, the electrical wiring 136 is then pulled through the
interconnecting conduit 134. In the same manner, sewer lines 137 and
water lines are cast into the exterior walls 23, and
floor/foundation 22. Where sewer lines 137 or water lines pass
through walls or the floor slab 62, cored holes 138 are provided.
After the concrete house 20 is assembled, it requires raising and
lowering while being transported to the installation site by truck.
Multiple spaced means for assisting lifting and deposit of said
premanufactured portable housing structure, embodied by four lift
points 140 (see FIG. 11), are provided for this purpose. At each
lift point 140, a removable lift rod 141, of round steel, is
inserted into core means adjacent a side of floor/foundation 22,
embodied (as shown) by the substantially cylindrical cored hole 71,
a horizontal hole substantially perpendicular to such side of
floor/foundation 22. Lift rod 141 is a substantially cylindrical rod
member adapted for jacking, and the remaining extending portion
(from the cored hole) of the lift rod is an attachment location for
a jacking means. A socket beam 70 is cast on the underside 61 of the
floor slab 62 of the floor/foundation 22 at each of the lift points.
The socket beam 70 extends from the foundation beam 63 to a support
beam 66 providing maximum support. The cored hole 71 is slightly
larger in diameter than a lift rod 141 and passes through the
foundation beam 63 into the socket beam 70. A cross-section
elevation view through the section 12--12 of FIG. 11 is shown in
FIG. 12. A socket beam 70, on the underside 61 of the floor slab 62,
is shown, with a lift rod 141 in the cored hole 71.
In FIG. 13 is a perspective view of the steel reinforced concrete
components of the various components or structures 21 of the
concrete house 20 prior to assembly. Dotted lines shown on the
components indicate the locations where mating components are to be
attached. Secured to the floor/foundation 22 are the interior walls
24 and exterior walls 23. The interior wall 24 which supports the
roof weight is the interior bearing wall 46. Interior and exterior
walls 24 and 23 attach to the floor/foundation 22, on their bottom
edge 143. Left and right ceiling/roof sections 26 and 25 join at
their joining surfaces 111 and attach to all walls.
An alternate method of usage of the concrete house 20 is shown in a
perspective view in FIG. 14. Two concrete houses 20 are utilized
together with connecting sections 145 to produce a single enlarged
house with approximately triple the square footage. The new large
room 149 may be used as the living room or a family room. The use of
the other existing rooms may be redefined to best suit the needs of
the occupying family. The interior wall/floor plan is illustrated
with dotted lines. The connecting sections 145 required include two
ceiling/roof sections 146, two exterior wall sections 147, and a
floor/foundation 148. A second alternate method of the concrete
house's 20 use is shown in FIG. 15. Two concrete houses 20 are
located and spaced an appropriate distance apart to be joined at the
roofs with a supplemental roof span 155 to provide a breezeway 156.
This breezeway 156 may be used by the residents of the two concrete
houses 20 as a common utility or patio area. Thus, the present
invention provides, as shown, a premanufactured portable
ready-to-use concrete house comprising: a second house substantially
identical to such concrete house and situate spaced from such
concrete house about one house-width distant; and spanning roof
member means for providing a roof spanning such distance between
such concrete house and such second house.
Described in the views of FIG. 16 (i.e., FIGS. 16A through 16 G) is
the preferred common method of manufacturing a typical steel
reinforced concrete component 200 that will be used as one of the
various kinds of concrete structures 21 of the concrete house 20.
FIG. 16A shows a portion of a casting bed 201 used for the
manufacture of a typical steel reinforced concrete component 200 of
the concrete house 20. The casting bed 201, commonly made of
concrete, is used as a mold to reproduce a cast concrete component
with the features, shapes, and sizes desired. The casting bed shown
incorporates a base 202, recessed feature 203, and removable forms
204. Thus, a step in the system of the present invention is
preparing a horizontal concrete-casting mold for the casting of a
concrete means for providing a housing structure member. In FIG. 16B
the interior surfaces 206 of the casting bed 201 and removable forms
204 are sprayed with a mold release agent 205 to prevent the cast
concrete component from sticking to the interior surfaces 206 and
complicating removal after curing.
Shown in FIG. 16C is the casting bed 201 with typical steel
reinforcing bars 207, weld plate 210, and electrical conduit 208,
with each of these items positioned where they are required to be
located in the completed cast concrete component. Thus, another step
in the system of the present invention is placing into a such mold
internal steel rebar elements for such concrete means and surface
steel plate elements for such concrete means, each such surface
steel plate element being supported by dowel means supported by a
such steel rebar element. An important further step in making the
floor/foundation 22 is, before placing concrete into such mold to
make a such floor member, configuring such mold to provide spaced
socket beams each including a cylindrical hole adjacent to
substantially perpendicular to an edge of such floor member (for
holding the lifting-point rods, as hereinbefore described. In FIG.
16D, freshly mixed concrete 212 is poured into the prepared casting
bed 201, flowing into all recesses and around all features. The top
surface 213 of the freshly poured concrete 214 is leveled to the top
of the removable forms 204 and then smoothly finished as in FIG.
16E. Thus, another step in the system of the present invention is
placing concrete into such mold and curing such concrete to provide
a solid such housing structure member. As shown in FIG. 16F, the
removable forms 204 are removed after the concrete 214 has cured 1
to 2 days and the cast concrete component 200 is removed from the
casting bed 201. FIG. 16G shows the completed steel reinforced
concrete components 200 (i.e., the concrete structures 21) of the
concrete house 20, being stored until further needed. Thus, another
step in the system of the present invention is, from the above steps
using suitable such concrete-casting molds, accumulating such
housing structure members in the form of floor members, roof
members, and wall members adapted to be connected to provide a
premanufactured portable concrete housing structure.
As shown in the views of FIG. 17 (i.e., FIGS. 17A through 17D), the
steel reinforced concrete components 200 (structures 21) are
assembled, completing the essential assembly of the concrete house
20. Starting with FIG. 17A, assembly of the steel reinforced
concrete structures/components 21 begins with the positioning of the
interior walls 24 on the floor/foundation 22 and the subsequent
welding together (weld rod 211 forming a weld bead 99) of the weld
plates 210 of these components as illustrated in FIG. 17B. After the
interior walls 24 are installed, the exterior walls 23 are placed in
position and welded in place on the floor/foundation 22 as in FIG.
17C. As shown in FIG. 17D, after wall assembly is completed, the
right and left ceiling/roof sections 25 and 26 are positioned and
welded in place and to each other, completing essential assembly of
the concrete house 20. Thus, another step in the system of the
present invention is, from such accumulated such housing structure
members, making a premanufactured portable concrete housing
structure by successively (1) placing each such housing structure
member in suitable juxtaposition to an other such housing structure
member, and (2) welding together contacting such surface steel plate
elements of such juxtaposed housing structure members.
In FIG. 18, the concrete house 20 receives its electrical wiring,
plumbing fixtures, caulking of seams, stucco, paint coat system 91,
insulation and roof covering, utilities, cabinets 47, windows,
doors, and all items necessary to bring the concrete house 20 to a
completed state. The completed concrete house 20 will be transported
to the installation site where it will be mounted on footings and
connections to utility services rendering it ready for habitation.
As shown in the views of FIG. 19 (i.e., FIGS. 19A through 19D), the
concrete house 20, at its manufacturing site, is elevated for
placement upon a tractor trailer for transportation. At the
installation site it will be lowered to the preset footings. As
illustrated in FIG. 19A, a lift rod 141 is inserted into a cored
hole 71 at each of the four lift points 140 within the
floor/foundation 22. A jacking means 217 is connected to each of the
projecting lift rods 141. The jacking means 217 shown in FIGS. 19B
and 19C represents a device operated with hydraulic cylinders 218.
An identical jacking means is used at all four lift points 140. FIG.
19B shows the jacking means 217 at a lift point 140 with the
concrete house 20 resting on the ground 221. FIG. 19C shows the
concrete house 20 lifted up from the ground level. The concrete
house 20 is elevated sufficiently for a trailer 219 to be positioned
underneath. FIG. 19D illustrates the concrete house 20 resting upon
the trailer 219 being pulled by tractor 220.
At the installation site, the concrete house 20 is raised above the
trailer 219 with the jacking means 217 so that the trailer 219 can
be withdrawn. The concrete house 20 is then lowered to the footings
33 (see FIG. 1). It is noted that, in order to make the concrete
house of the present invention strong enough for unitary portability
without injury, each of the concrete structures 21 is very firmly
tied to the other such concrete structures in juxtaposition with it
using the described method and structure of juxtaposed
concrete-embedded weldable steel plates.
Thus, it is seen that the system of this invention includes the
steps of: transporting such premanufactured portable concrete
housing structure to a suitable site; and depositing such
premanufactured portable concrete housing structure on said site;
and, further, it includes the steps of, after placing of each steel
rod at the lifting points provided, placing lifting means under each
steel rod portion extending from a lifting-point hole; and lifting
such premanufactured portable concrete housing structure.
Although applicant has described applicant's preferred embodiments
of this invention, it will be understood that the broadest scope of
this invention includes such modifications as diverse shapes and
sizes and materials. Such scope is limited only by the below claims
as read in connection with the above specification.
Further, many other advantages of applicant's invention will be
apparent to those skilled in the art from the above descriptions and
the below claims.
* * * * *
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