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Method of making a building element, an apparatus for making the building element, and a building element made by the method

  • US 10,239,228 B2
  • Filed: 06/03/2014
  • Issued: 03/26/2019
  • Est. Priority Date: 06/04/2013
  • Status: Active Grant
First Claim
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1. A method of casting a reinforced slab-shaped building element (E) having a length (L), a width (W) and a thickness, said slab-shaped building element (E) comprising:

  • an upper concrete plate (20) anchored to a lower concrete plate (10) with a top surface and a bottom surface,said lower concrete plate (10) being of a first type concrete,said upper concrete plate (20) being cast from higher strength concrete than the first type concrete, the higher strength concrete laid out upon said top surface,said lower concrete plate (10) including a base (11) contiguous with a plurality of raised portions (14) integral therewith,said raised portions (14) being spaced apart in the direction of said length (L) and said width (W),said element (E) including reinforcing bars (R) laid out between at least some of said raised portion (14),said raised portions (14) defining said top surface,said method comprising the steps of;

    i) providing a first mold (100, 1000) configured to define a support for said lower plate (10) and at least one second mold (120, 1200) having an internal shape corresponding to a respective one of said raised portions (14),ii) preparing a first type concrete,iii) filling said at least one second mold (120, 1200) with said first type concrete and discharging said first type concrete from said at least one second mold (120, 1200) into said first mold (100, 1000) to form said lower plate (10) by said first type concrete bonding to first type concrete previously discharged into said first mold (100, 1000),iv) repeating step iii) by successively relocating said at least one second mold (120, 1200) to neighboring positions relative to previously discharged first type concrete,v) at least partially curing said first type concrete discharged into said first mold (100, 1000),vi) laying out said reinforcing bars (R) between at least some of said raised portion (14),vii) preparing a higher-strength type concrete stronger than said first type concrete, andviii) using said lower plate (10) as a third mold to cast said upper plate (20) by applying said higher-strength type concrete upon said top surface of said lower plate (10).

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