WO2007145633A1

WO2007145633A1 - Affordable, modular concrete homes, condominiums, and apartments

Info

Publication number: WO2007145633A1
Application number: PCT/US2006/023545
Authority: WO
Inventors: Raul Z. Zamora
Original assignee: Zamora Raul Z
Priority date: 2006-06-15
Filing date: 2006-06-15
Publication date: 2007-12-21

Abstract

The present invention is directed toward building affordable modular homes, condominiums, apartments, and the like. The invention uses a variety of prefabricated machine compacted steel framed concrete walls which by virtue of their steel perimeters can be welded at the bottom to steel plates anchored in a concrete foundation and welded at the top to prefabricated steel trusses which span two or more walls. Welded to the top of the steel trusses are prefabricated steel framed concrete roof tiles to form a roof and ceiling. Prefabricated steel framed concrete walls are welded at predetermined points of contact to form the interior walls and rooms. It should be noted that the abstract is submitted with the understanding that it will not be used to interpret or limit the claims pursuant to 37 CFR Section 1.72 (b).

Description

Affordable Modular Concrete Homes, Condominiums,and Apartments

DETAILED DESCRIPTION Preferred Embodiment

Construction of an affordable concrete modular building begins with construction of a prefabricated steel framed concrete wall.

FIG. IA Illustrates a rectangular steel frame formed by welding the ends of four steel members at right angles to each other. The width of the steel frame is defined by top horizontal steel member 54 and bottom steel member 56. The height is defined by two vertical placed apart steel members 58. Openings for doors and windows are provided by welding two set apart vertical steel members 60 to top 54 and bottom 56 steel members then welding between vertical steel members 60, horizontal steel members 62 to define width and height of door and windows. Holes 64 on top of steel member 54 allows for insertion of electrical wires. Welded steel pipes 66 allows insertion of means to lift, move, and erect the steel framed concrete walls.

FIG.1B Shows a pre-assembled electrical conduct 68 with a single electric box 74 welded at perimeters of holes 64 to allow insertion of electrical wires. Pre- assembled double electrical conducts 70 with double electric boxes 74 are welded at perimeters of holes 64 to allow insertion of electrical wires. Grill sections are provided by welding a plurality of vertical reinforcing steel bars 76 and 78 perpendicular to opposite sides of steel frame members, and welding a plurality of horizontal reinforcing steel bars 80 perpendicular to opposite sides of steel frame members. By performing the steps mentioned above a steel framed skeleton for a concrete wall is achieved. The next step is to place and secure the steel framed skeleton on top of a prefabricated steel forklift pallet, which is placed and secured on top of a vibration acted machine. A formulation of fluid concrete 82 is poured into the grilled sections of the steel framed skeleton. After the desired compaction is achieved and excess concrete trimmed, the steel forklift pallet with the steel framed concrete wall is removed and stored leaving the compacting machine free to repeat the operation. Other method for achieving the same results when a machine is not available is to place the steel framed wall skeleton flat on a flat surface and pour a formulation of fluid concrete 82 in the grilled sections of the steel framed wall skeleton. After trimming excess concrete let it set until cured and dry enough to be removed for storage or for erection.

FIG.1C Shows a finished prefabricated steel framed concrete wall.

In the following descriptions, it should be understood that all walls from FIG.l to FIG.43 regardless of size and shape are fabricated with the method described above. Also, that all walls are steel framed concrete walls even if at times, the steel framed conprete walls are referred to as just walls.

FIG.l Represents an exterior steel framed concrete door entrance wall.

FIG.2 Represents an exterior steel framed concrete window wall.

FIG.3 Represents an interior between rooms; entrance steel framed concrete wall.

FIG.4 Represents a triangular steel framed concrete wall, which when welded on top of wall in FIG.2 forms the front and/or back wall of a small affordable house. It also, provides structure for roof and defines roof pitch.

FIG.5 Represents a prefabricated steel truss, which when welded serves to span the distance between two standing set apart parallel walls. It also serves to add stability to tiie wall to which it is welded, and provides structural support for roof and ceilings and helps to define roof pitch.

FIG.6 Represents exterior bathroom steel framed concrete wall.

FIG.7 Represents an interior bathroom and hall entrance steel framed concrete wall. A portion of this wall affords privacy to the bathroom and part of this wall affords access to hall and other rooms.

FIG.8 Represents interior bathroom steel framed concrete wall. This wall affords access to bathroom.

FIG.9 Represents exterior steel framed concrete wall. It serves to afford continuity to larger walls adjacent to it and helps to define hall boundaries.

FIG.10 Represents an interior steel framed concrete wall. Its main use is to afford structure and privacy between adjacent room and bedrooms.

FIG.ll Represents a steel framed triangular concrete wall used to form front and back walls by welding two opposite triangular walls on top of two adjacent FIG.2 walls to achieve a wall similar to wall illustrated in FIG.20. This welding arrangement provides front and back face walls for a building structure, provides structure for roof and defines roof pitch. This operation is done in order to clear freeway overpasses when transportation is necessary.

FIG.12 Represents a prefabricated steel truss, which when welded on top of two standing set apart parallel walls serves to span and stabilize them. It also provides structural support for roof and ceilings. FIG.13 Represents a prefabricated steel grilled skeleton to fabricate a steel framed concrete roof tile.

FIG.14 Represents a prefabricated steel framed concrete roof tile.

FIG.15 Represents a method to erect and join prefabricated steel framed concrete walls to concrete foundations at bottom and to prefabricated steel trusses at top by welding with welding filler material 55, the bottom of a prefabricated steel framed concrete wall 2 to a plurality of steel plates 57 anchored in a concrete foundation 61 with anchors 59 welded at bottom of steel plates 57, welding at top of the wall, a plurality of prefabricated steel trusses 12, which span the distance between two or three set apart parallel walls. Prefabricated steel framed concrete roof tiles 14 are welded at determined points of steel trusses 12 to provide roof to the structure.

FIG.16 Represents a front or rear prefabricated steel framed concrete wall built with one pouring operation. In order to avoid operations described on FIG.l 1, this wall is fabricated in places where underpasses on freeways are not obstacles.

FIG.17 Represents a front or rear steel framed concrete wall used in building a small affordable house. This wall is fabricated in one single concrete pouring operation. In order to avoid operations described on FIG.4, this wall is fabricated in places where freeway underpasses are not encountered.

FIG.18 Represents two FIG.l 1 triangular steel framed concrete walls welded opposite to each other and when welded on top of two welded adjacent FIG.2 walls form the front or rear walls illustrated on FIG.20.

FIG. 19 Represents two FIG.12 steel trusses welded opposite to each other and when welded on top of three upright parallel walls in a manner described on description of FIG.15 ^' spans two rooms. These trusses in cooperation with walls described on FIG.18 gives structural support to the roof, ceilings and defines roof pitch.

FIG.20 Represent the front and rear steel framed concrete wall of a two, three or more bedroom house. It is fabricated either as a one single wall unit with one single concrete pour or assembled by welding two FIG.11 walls on top of two FIG.2 walls or assembled by welding one FIG.18 wall on top of one FIG.23 wall. All these operations are done in order to solve the problems present or not present by transportation constrictions of freeway underpasses. The fabrication of this wall is also determined by the capacity of equipment used to move and erect these walls.

FIG.21 Represents a single steel framed concrete wall that embraces four exterior walls at once. This wall is fabricated with a single concrete pour. The lines defining the different shapes and sizes of the single walls that this embracing single wall supplants are put here merely to illustrate their positions and functions. Although this single wall is not used in the construction of the house illustrated in FIG.34 below, the position and usage of this wall can be better understood by looking at illustration represented in FIG.34 below.

FIG.22 Represents the same features as the wall described in FIG.21 above and the supposed position of this wall can be seen in illustration represented in FIG.34 below.

FIG.23 Represents a single steel framed concrete wall that embraces two FIG.2 exterior walls and is fabricated with a single concrete pour. The line defining the two walls is fictitious. This wall in cooperation with a wall represented in FIG.18 form a wall similar to the wall represented in FIG.20 and serves as the front and rear face of a house building. The assembled method of this wall is due to the limitation presented by freeway underpasses when transportation is required.

FIG.24 Represents a single interior steel framed concrete wall that embraces one FIG.10 interior wall and one FIG.3 interior wall. This wall is fabricated with a single concrete pour. Its fictitious position and use can be better understood by looking at illustration represented in FIG.34 below.

FIG.25 Represents an interior single steel framed concrete wall that embraces two opposite FIG.7 walls. This wall is fabricated with a single concrete pour and its fictitious position in a three bedroom house can be better appreciated by looking at illustration represented in FIG.34 below,

FIG.26,27,28 Are experimental steel framed concrete roof tiles, which manageability has not been tested. The purpose of these experimental roof tiles is to determine what are the thinnest weight factor and the largest surface factor that can be lifted and positioned without collapsing in on itself.

FIG.29 Represents concrete foundation 61, standard concrete floor slabs 107 and floor slab 109.

FIG.30 Represents a three room small house. This house is formed by welding the bottoms in a manner described on FIG.15 of steel framed concrete walls to steel plates 57 anchored in a concrete foundation 61 and welding exterior and interior wall at determined points of contact to each other. This house is shown without a roof in order to better understand the position and function of the different walls. The front room, which serves as kitchen and dining room is formed by welding three FIG.2 walls and one FIG.3 wall. The room behind serves as living room and bedroom and is formed by adding and welding one FIG.l entrance wall, one FIG.7 bathroom wall and one FIG.2 window wall. The room behind the middle room is formed by adding and welding one FIG.6 wall, one FIG.9 exterior wall and one FIG.7 wall. This room serves as privacy and storage room. This house is designed for very poor agricultural areas in third world countries where sewer facilities may or may not be available.

FIG.31 Represents the concrete foundation 61, standard concrete floor slabs 107, Bathroom concrete floor slab 109, and small hall concrete slab 111. This small affordable house is designed for young start up families, low wage earners, and low income retirees.

FIG.32 Represents a four room house and a small hall. This house is formed by welding the bottom of steel framed concrete walls to steel plates 57, anchored in a concrete foundation 61 in a manner described on FIG.15 and welding exterior and interior walls at determined places of contact to each other. This house is shown without roof in order to better understand the position and function of the different walls. The front room, which serves as kitchen and dining room is formed by welding three FIG.2 exterior window walls and one interior FIG.3 between rooms entrance wall. The next room is a living room formed by adding and welding one exterior FIG.l entrance wall, one exterior FIG.2 window wall and one interior FIG.7 bathroom wall. The next room is a bathroom and hall formed-by adding and welding one exterior FIG.6 bathroom wall, one interior FIG.7 bathroom wall, one interior FIG.8 bathroom entrance wall and one exterior FIG.9 wall. The following room is a bedroom formed by adding three FIG.2 exterior window walls. The roof is formed by welding on top of the walls prefabricated steel trusses 12, which form the structure that supports roof and ceiling. Prefabricated steel framed concrete tiles 14 are welded on top of steel trusses 12 to form the roof. These operations are illustrated in FIG.15 in drawing 3/9. FIG.33 Represents the concrete foundation 61 and standard room concrete slabs 107 with concrete bathroom slabs 109 and hall concrete slab 113.

FIG.34 Represents an eight room house and a hall and is designed for the general public. This house can be completed all at once or by modular additions, which will increase its size as economic conditions of the customer improve. The following disclosures will make apparent the full concept of modular additions intended by this invention. Starting at the front of illustration represented byFIG..34, the room at right is a dining room and is formed by welding the bottoms of two FIG.2 walls and two FIG.3 walls to steel plates 57 anchored in a concrete foundation 61 in a manner described on FIG.15 and also welded at determined points of contact to each other. The room behind the dining room is a living room and is formed by adding and welding one FIG.l exterior entrance wall, one FIG.10 interior privacy wall and one FIG.7 interior bathroom wall. The room behind the living room is a bathroom and a small hall formed by adding and welding one FIG.6 exterior bathroom wall, one FIG.7 interior bathroom wall and one FIG.8 interior bathroom wall. The room behind the bathroom is a bedroom formed by adding and welding two FIG.2 exterior window walls, and one FIG.10 privacy wall. Getting back to the front, the room to the left of the dining room is a kitchen room formed by adding and welding two FIG.2 exterior window walls and one FIG.10 interior privacy wall. Behind the kitchen room is a bedroom formed by adding and welding one FIG.2 exterior window wall, and one ulterior FIG.7 bathroom wall. Behind the bedroom is a bathroom and a small hall formed by adding and welding one exterior FIG.6 bathroom wall, one interior FIG.7 bathroom wall, and one interior FIG.8 bathroom entrance wall. Behind the bathroom is a bedroom formed by adding one FIG.1 entrance wall, and one FIG.2 wall.

FIG.35A (Cancelled). FIG.35B (Cancelled). FIG.36 (Cancelled). FIG.37 (Cancelled).

FIG.38 Illustrates a right hand side view of house shown in FIG.34 prior to finishing coats. It shows the position of the different walls with a roof.

FIG.39 Illustrates the front view of house shown in FIG.34 prior to finishing coats. It shows the position of the different walls with a roof.

FIG.40 Illustrates a cross section 5-5 of FIG.38. It shows at left a FIG.2 wall; at center shows a FIG.3 wall; at right shows a FIG.2 wall. Facing front at left is a FIG.10 wall facing front at right is a FIG.3 wall. These walls are welded at bottom to steel plates 57 anchored to a concrete foundation 61. At top, they are welded to a plurality of steel trusses 12 which serves as roof and ceiling support and defines roof pitch. Steel framed concrete roof tiles are welded to top of steel trusses to form a roof. A more detailed description and illustration of this procedure can be seen inFIG.15.

FIG.41 Shows a steel framed concrete wall plug wall which when welded to bottom of FIG.3 interior entrance wall converts it into a FIG.2 window wall and functions as such until it becomes necessary to add more rooms by removing FIG.41 wall plug. The wall reverts to FIG.3 entrance wall and gives access to added room.

FIG.42 Shows a steel framed concrete plug wall which when welded into window opening of a FIG.2 exterior window wall converts it into a FIG.10 privacy wall when a bedroom addition is required. FIG.43 Shows a steel framed concrete wall plug welded into door opening of a FIG.7 wall and removed when access to an additional room is required.

It should be understood that the modes, sequences, arrangement, qualities, sizes, filling materials referred to in this description are the best models I can think of to make it understandable and teach how to make and use this invention. The quantities, arrangement, and brevity of this description disclosure should not be understood or construed to limit the scope of this invention. Example, multi-level houses, condominiums, apartments, motels, rental storage buildings, etc. can be built with the basic components and principles of this invention.

Claims

1. ( Original) A method for fabricating a plurality of steel framed concrete walls to use in construction of affordable concrete modular buildings comprising the steps of;

(a) Joining at right angles the ends of four steel members to form a perimeter of a rectangular steel frame.

(b) Providing a plurality of reinforcing steel rebar's to form a grill to insert and secure inside said perimeter of said rectangular steel frame.

(c) Providing a plurality of prefabricated steel frames welded at interrupted point of said grill and at determined points of said rectangular steel frame to form openings for doors and windows.

(d) Providing means to insert electric, and telephone wires to serve electric boxes for electric switches, electric outlets, and telephone lines.

(e) Providing means to pour a formulation of fluid mixed concrete in the grilled sections of said rectangular steel frame where by completing steps l(a) through l(e) a steel framed concrete wall is formed.

2. (Cancelled)

3. (Original). The method of claim 1 further comprises erecting said steel framed concrete walls to form a building by means of welding the bottoms of said steel framed concrete walls to a plurality of steel plates anchored in a concrete foundation and welding the tops of said steel framed concrete walls to a plurality of prefabricated steel trusses, which span a distance between set apart parallel walls, said steel trusses serve to add stability to said set apart parallel walls and also serves as a structure to support roof and ceilings.

4. (Original).The method of claim 1 further comprises welding exterior and interior of said steel framed concrete walls at determined places of contact to each other.

5. ( Original) .The method of claim 1 further comprises attaching a plurality of prefabricated insulation panels to the exterior or interior of said erected steel framed concrete walls.

6. ( Original).The method of claim 1 further comprises constructing a roof by means of welding a plurality of prefabricated steel framed concrete roof tiles to roof trusses and to each other at determined points of contact.

7. (Original)The method of claim 1 further comprises increasing the size of smaller modular structure by means of adding more steel framed concrete walls and adding additional structural components to form additional rpoms.

8. (Cancelled)

9. (Cancelled).

10. (Cancelled)

11. (Cancelled)