METHOD OF CONSTRUCTING AN INSULATED SHALLOW PIER FOUNDATION BUILDING

• US 20090202307A1
• Filed: 12/01/2008
• Published: 08/13/2009
• Est. Priority Date: 02/11/2008
• Status: Abandoned Application

• Current Assignee: Nova Chemicals Incorporated (Nova Chemicals)
• Original Assignee: Nova Chemicals Incorporated (Nova Chemicals)
• Inventors: Molke, Leslie, McLean, Bret, Stoffa, Robert, Rubb, Justin, Beaman, Jeffrey, Kovatch, Frank, Au, Ginawati
• Application Number:
  US12/325,611
• Publication Number:
  US 20090202307A1
• Time in Patent Office: Days
• US Class Current: 405/233
• CPC Class Codes: E02D 27/02 Flat foundations without substantial excavation E02D27/04, E02D27/08 take precedence

Abstract

A method of constructing a shallow pier foundation building that includes a) placing a plurality of insulating pier forms along a perimeter of the building; b) placing a plurality of insulating concrete forms between the insulating piers to form a continuous insulating surface to the surrounding soil and a continuous forming surface to provide a slab form; c) placing a concrete composition in the insulating piers and insulating concrete forms and allowing the concrete composition to cure and harden; and d) placing a concrete slab composition in the slab form and allowing the concrete composition to cure and harden.

Claims

1. A method of constructing a shallow pier foundation building comprising:

a) placing a plurality of insulating pier forms along a perimeter of the building;

b) placing a plurality of insulating concrete forms between the insulating piers to form a continuous insulating surface to the surrounding soil and a continuous forming surface to provide a slab form;

c) placing a concrete composition in the insulating piers and insulating concrete forms and allowing the concrete composition to cure and harden; and

d) placing a concrete slab composition in the slab form and allowing the concrete composition to cure and harden.

2. The method according to claim 1, wherein the insulating pier form comprises

(A) a first panel member comprising a first end and a second end:

(B) a second panel member comprising a first end and a second end, wherein the first end is connected to the second end of the first panel;

(C) a third panel member comprising a first end and a second end, wherein the first end is connected to the second end of the second panel; and

(D) a fourth panel member comprising a first end and a second end, wherein the first end is connected to the second end of the third panel and the second end is connected to the first end of the first panel;

wherein the first, second, third and forth panels maintain a spatial distance therebetween for defining a molding chamber generally having a rectangular cross section.

3. The method according to claim 1, wherein the insulating concrete form comprises

(A) a first panel member comprising:

(1) a first outer panel side including a first wall surface area extending generally vertically thereon;

(2) a first inner panel side positioned oppositely from said first outer panel side; and

(3) at least two first slots in the first inner panel side adapted to accept a connecting member;

(B) a second panel member comprising;

(1) a second outer panel side including a second wall surface area extending generally vertically thereon and facing oppositely from said first panel member;

(2) a second inner panel side positioned oppositely from said second outer panel side and facing said first inner panel side of said first panel member; and

(3) at least two second slots in the second inner panel side adapted to accept a connecting member; and

(C) at least two connecting members detachable and securable with respect to said first panel member and said second panel member adapted to maintain a spatial distance therebetween for defining a molding chamber therebetween, the connecting members comprising;

(1) a first flange detachably and securably extending within said first slot of said first panel member;

(2) a second flange detachably and securably extending within said second slot of said second panel member; and

(3) a mid-section portion.

4. The method according to claim 1, wherein the insulating pier form and the insulating concrete form comprise an expanded polymer matrix.

5. The method according to claim 4, wherein the expanded polymer matrix comprises one or more polymers selected from the group consisting of homopolymers of vinyl aromatic monomers;

copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride;

polyolefins;

polycarbonates;

an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers; and

combinations thereof.

6. The method according to claim 4, wherein the polymer matrix comprises carbon black, graphite or a combination thereof.

7. The method according to claim 3, wherein the first panel member and the second panel member each have a male end comprising a tongue edge and a female end comprising a female groove edge that facilitates a tongue and groove union between corresponding members.

8. The method according to claim 3, wherein the connecting member comprises a material selected from the group consisting of plastics, metal, construction grade plastics, composite materials, ceramics, and the like.

9. The method according to claim 1, wherein the concrete comprises one or more cements selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.

10. The method according to claim 1, wherein the concrete is light weight concrete.

11. The method according to claim 9, wherein the concrete comprises

8-20 volume percent cement,

11-50 volume percent sand,

10-31 volume percent expanded thermoplastic particles,

9-40 volume percent coarse aggregate, and

10-22 volume percent water;

wherein the expanded thermoplastic particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3.

12. The method according to claim 2, wherein rebar is placed in the molding chamber prior to placing the concrete.

13. The method according to claim 3, wherein rebar is placed in the molding chamber prior to placing the concrete.

14. The method according to claim 11, wherein the expanded thermoplastic particles comprise polymers containing polymerized residues from one or more monomers selected from the group consisting of styrene, ethylene, propylene, and methyl(meth)acrylate;

an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers; and

combinations thereof.

15. The method according to claim 1, wherein a water impervious fabric is placed over the outward facing continuous insulating surface.

16. The method according to claim 15, wherein a top edge of the water impervious fabric is above grade.

17. A building constructed according to the method of claim 1.