NZ808221B2 - Foam filled structural plank building foundation with laminated reinforcement - Google Patents
Foam filled structural plank building foundation with laminated reinforcementInfo
- Publication number
- NZ808221B2 NZ808221B2 NZ808221A NZ80822122A NZ808221B2 NZ 808221 B2 NZ808221 B2 NZ 808221B2 NZ 808221 A NZ808221 A NZ 808221A NZ 80822122 A NZ80822122 A NZ 80822122A NZ 808221 B2 NZ808221 B2 NZ 808221B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- structural
- plank
- building
- foam
- enclosure
- Prior art date
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/386—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of unreconstituted or laminated wood
Abstract
foam filled concrete and cement free structure plank made from a plurality of structural beams (20, 30) assembled together to form a structure capable of supporting the weight of a building thereon. The plurality of structural beams (20, 30) define an enclosure (40) therebetween and an outer perimeter (20A, 30A) therearound; a bottom wall (60) on the enclosure; and a top wall (70) on the enclosure. The bottom and top walls are connected to the plurality of structural beams (20, 30). A structural building foam (50) such as expanded polystyrene foam having a density from 1.5 to 3.0 PFC fills the enclosure, such that the structural building foam is in direct contact with the plurality of structural beams and the top and bottom walls. The structural plank also includes at least one of a bottom laminate panel (204) covering and being in direct contact with the bottom wall (60), or a top laminate panel (202) covering and being in direct contact with the top wall (70). Traditionally, many building foundations were made with concrete slabs or mountings. A disadvantage of using concrete in building foundations is its high amount of embodied carbon. The invention provides a lightweight pre-fabricated concrete free building foundation panel which is easily transportable.
Claims (21)
1. A concrete and cement free foam filled structural plank load bearing building foundation, comprising: a plurality of structural beams connected together to define a structural plank building foundation, the structural plank building foundation being capable of supporting the weight of a building thereon, wherein the plurality of structural beams define an enclosure therebetween and an outer perimeter therearound; a bottom wall on the enclosure, wherein the bottom wall is connected to the plurality of structural beams; a top wall on the enclosure, wherein the top wall is connected to the plurality of structural beams; a structural building foam filling the enclosure, wherein the structural building foam is on top of the bottom wall and wherein the structural building foam is in direct contact with the plurality of structural beams and with the bottom wall and with the top wall; and at least one of: a bottom laminate panel covering and being in direct contact with the bottom wall; or a top laminate panel covering and being in direct contact with the top wall.
2. The structural plank of claim 1, wherein the building foundation further comprises: a plurality of laminate panels extending at least partially through an inner portion of the structural plank building foundation.
3. The structural plank of claims 1 or 2, wherein at least one of the top or bottom laminate panels comprise at least one of the following: (a) a fabric mesh, (b) a fossil fuel mesh including, Rayon, Polypropylene or Nylon, having a weight from 1.5 to 16 oz / square yard (50.86 to 542.49 grams / square meter), (c) a carbon-based mesh including graphene or Kevlar, having a density from 170 g/m to 300 g/m , (d) a plant-based mesh, including but not limited to hemp or burlap, (e) a synthetic acrylic or cementious composites, (f) a product made by a pultrusion process including fiberglass, graphene, carbon, glass fiber reinforced carbon, or fiberglass based, or (g) wood-based panel products including, cellulosic panels; plywood, Medium Density Fiberboard, Medium Density Overlay, Oriented Strand Board, plywood panels, bamboo board, hempboard, flaxboard, particleboard, or strawboard.
4. The structural plank of claim 2, wherein a plurality of the laminate panels are positioned parallel to one another.
5. The structural plank of claims 1 or 2, wherein the structural building foam is an expanded polystyrene foam having a density from 1.5 to 3.0 pound-force per cubic foot (235.63 to 471.26 Newton per cubic meter).
6. The structural plank of any one of the preceding claims, wherein the bottom wall is made of metal and the top wall is made of wood.
7. The structural plank of any one of the preceding claims, wherein some of the plurality of structural beams form the outer perimeter of the structural plank and others of the plurality of structural beams pass across interior mid-sections of the structural plank.
8. The structural plank of claim 7, wherein all of the plurality of structural beams have the same heights such that all of the plurality of structural beams are in direct contact with the top and bottom walls to provide load sharing and distribution through the structural plank.
9. The structural plank of any one of the preceding claims, wherein the structural building foam has a plurality of openings cut therein to permit electrical wiring or HVAC air conduits to pass therethrough.
10. The structural plank of any one of the preceding claims, wherein the plurality of structural beams are made of steel or aluminum.
11. A concrete and cement free foam filled structural plank load bearing building foundation, comprising: a plurality of structural beams connected together to define a structural plank building foundation, the structural plank building foundation being capable of supporting the weight of a building thereon, wherein the plurality of structural beams define an enclosure therebetween and an outer perimeter therearound; a bottom wall on the enclosure, wherein the bottom wall is connected to the plurality of structural beams; a top wall on the enclosure, wherein the top wall is connected to the plurality of structural beams; a structural building foam filling the enclosure, wherein the structural building foam is poured on top of the bottom wall prior to the structural building foam setting in place and wherein the structural building foam is in direct contact with the plurality of structural beams and with the bottom wall and with the top wall; and an array of piers, wherein interior structural members of the structural plank are positioned on top of the piers with a top edge of each pier supporting a bottom edge of the bottom wall of the structural plank, and wherein placement of the interior structural members of the structural plank define openings through the structural plank through which the piers are received.
12. The structural plank of any one of claims 1 to 10, wherein the structural plank is a horizontally oriented building foundation capable of supporting the weight of a building thereon.
13. A method of forming a concrete and cement free foam filled structural plank load bearing building foundation, comprising: assembling a plurality of structural beams together to form a structural plank, wherein the plurality of structural beams define an enclosure therebetween and an outer perimeter therearound; assembling a bottom wall onto the enclosure, wherein the bottom wall is connected to the plurality of structural beams; and then filling the enclosure with a structural building foam by pouring the structural building foam onto the bottom wall; assembling a top wall onto the enclosure, wherein the structural building foam is in direct contact with the top wall; attaching at least one of: a bottom laminate panel onto the bottom wall, or a top laminate panel onto the top wall; while permitting the structural building foam to set prior to transporting the structural plank to a building jobsite.
14. The method of claim 13, further comprising: assembling a plurality of laminate panels extending across an inner portion of the structural plank prior to filling the enclosure with the structural building foam.
15. The method of claims 13 or 14, further comprising: cutting openings into the structural building foam after the structural building foam has set within the enclosure, wherein the openings are dimensioned to permit electrical wiring or HVAC air to pass therethrough.
16. The structural plank of claim 11, wherein each pier comprises: a helical screw inserted into a hole in the ground wherein a bottom end of the helical screw extends down below the bottom of the hole in the ground, and a concrete mixture filling the hole around the helical screw, thereby resulting in a concrete topped structure that projects above ground level.
17. The structural plank of claims 11 or 16, further comprising: a waterproofing membrane, wherein: the structural plank is positioned directly on top of the waterproofing membrane, and the waterproofing membrane is positioned directly on top of the ground.
18. The structural plank of claim 16, wherein the structural plank is supported above the ground by the concrete topped structure on each of the piers.
19. The structural plank of any one of claims 11 or 16 to 18, further comprising: an inner shear wall connected to the structural plank, wherein the inner shear wall is supported by at least one of the piers being positioned directly thereunder.
20. The structural plank of any one of claims 11 or 16 to 19, further comprising: an exterior foam wall connected to the structural plank, wherein the exterior foam wall is supported cantilevered from at least one of the piers, and wherein coupling mechanisms used to attach the exterior foam wall that is connected to the structural plank are disposed within the structural plank and are covered by the structural building foam.
21. The structural plank of any one of claims 1 to 10 or 12, further comprising: a plurality of mechanical connectors on a side of the structural plank, the mechanical connectors permitting a plurality of structural planks to be assembled together side-by-side.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202163232425P | 2021-08-12 | 2021-08-12 | |
| US202163289816P | 2021-12-15 | 2021-12-15 | |
| PCT/US2022/039962 WO2023018804A1 (en) | 2021-08-12 | 2022-08-10 | Foam filled structural plank building foundation with laminated reinforcement |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| NZ808221A NZ808221A (en) | 2025-02-28 |
| NZ808221B2 true NZ808221B2 (en) | 2025-06-04 |
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