Importance

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Abstract

In a method for forming a module having a floor, a roof and opposing sides, a concrete floor is first poured and, once solidified, moved into position between tilted wall molds. Inexpensive hollow masonry blocks are then dry-stacked in rows against the wall molds; that is, they are loosely stacked without mortar therebetween. Spaces with reinforcing rods therein are left along the outer wall molds at each end of the stacked blocks. Inner wall molds and, for some modules, a roof mold are then moved into place adjacent the stacked blocks. With the wall molds vertical, the blocks are pressed between the inner and outer wall molds. Concrete is poured into the spaces at each end of the stacks of blocks to form structural posts and over the tops of the stacks of blocks to form structural spandrel beams. Additional hollow blocks are laid across the roof mold and concrete is poured over those blocks to complete the roof. Once the concrete has cured, the outer wall molds are tilted away, and the molded structure is moved to another station. At the second station, the inner molds are removed and the blocks, held in compression by the weight of the spandrel, are coated with stucco to bind the blocks to each other. End walls are also constructed at this station. The resulting module includes a roof primarily supported by structural posts and spandrel beams. Stacked blocks forming the walls of the module are in compression to assure sufficient friction between the blocks for structural stability of the walls. Structural stability of the blocks is enhanced by the cementitious stucco coating.

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First Claim