US 12,421,711 B2
Method for using aerated autoclaved concrete in residential and commercial construction
James Atterstrom, Flower Mound, TX (US)
Assigned to The PAAC-Tech Response, LLC, Plano, TX (US)
Filed by The PAAC-Tech Response, LLC, Plano, TX (US)
Filed on Jun. 20, 2022, as Appl. No. 17/807,746.
Claims priority of provisional application 63/202,683, filed on Jun. 21, 2021.
Prior Publication US 2022/0403641 A1, Dec. 22, 2022
Int. Cl. E04B 1/04 (2006.01); E04B 1/16 (2006.01); E04B 2/00 (2006.01); E04B 5/02 (2006.01); E04C 2/04 (2006.01); E04G 13/02 (2006.01); E04G 13/04 (2006.01); E04G 17/065 (2006.01); E04G 21/16 (2006.01)
CPC E04B 1/043 (2013.01) [E04B 1/165 (2013.01); E04C 2/044 (2013.01); E04C 2/46 (2013.01); E04C 2/50 (2013.01); E04G 13/02 (2013.01); E04G 13/04 (2013.01); E04G 17/0655 (2013.01); E04B 2103/02 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A method for creating a building having an integral monolithic superstructure, the method comprising:
placing a foundation having a plurality of predetermined horizontally spaced apart column locations having a width;
setting a first set of vertically oriented shoring having a width adjacent to an interior side of the horizontally spaced apart column locations, the width being sufficiently wide to cover the interior side of each respective space for the vertical supporting columns to be formed in the horizontally spaced apart column locations and having a width, and a portion of the ends of the first set of construction material on either side of each of the horizontally spaced apart column locations;
placing a first set of vertically oriented construction materials that include planks, panels, or planks and panels comprising a foam material and having a length, width, ends, a thickness and lower and upper edges, the first set of construction materials being supported by the foundation on a construction site to form one or more vertical walls of the integral monolithic superstructure, the ends of the first set of construction materials being spaced apart horizontally and endwise on the foundation at the predetermined horizontally spaced apart column locations to leave a sufficient space for the vertical supporting columns but sufficiently close together that the first set of vertically oriented shoring covers a portion of the ends of the first set of construction material on either side of each of the horizontally spaced apart column locations;
setting a second set of vertically oriented shoring having a width adjacent to an exterior side of the horizontally spaced apart column locations, the width being sufficiently wide to cover the exterior side of the space for the vertical supporting columns and a portion of the ends of the first set of construction material on either side of each of the horizontally spaced apart column locations such that the space for each of the vertical supporting columns is substantially enclosed on all vertical sides;
placing a second set of construction materials that include planks, panels, or planks and panels on an inner portion of a topmost edge of the first set of construction materials to form a horizontal surface of the integral monolithic superstructure while leaving an outer portion of the top edge of the first set of construction materials uncovered by the horizontal surface, the horizontal surface having a thickness and an upper surface having a height greater than the height of the topmost horizontal edge of the first set of construction material;
placing a perimeter vertically oriented and horizontally elongated form around the topmost portion of the exterior perimeter of the upper portion of the first set of construction materials, the form having a top edge higher than the upper surface of the horizontal surface, the form in combination with the topmost horizontal edge of the first set of construction materials uncovered by the horizontal surface of the second set of construction materials, the adjacent edge of the horizontal surface, and the second set of vertically oriented shoring, forming an open-at-the-top generally circumferential space, the bottom portion of which is in communication with the upper ends of each of the horizontally spaced apart column locations;
pouring mortar, concrete or a mix thereof into the open-at-the-top generally circumferential space to substantially fill it and each of the horizontally spaced apart column locations, and to cover at least a portion of an upper surface of the horizontal surface of the second set of construction materials with a predetermined thickness of the mortar, concrete or a mix thereof;
allowing the mortar, concrete or a mix thereof to cure to a predetermined strength to form an integral monolithic portion of the superstructure comprising vertically oriented concrete columns in the horizontally spaced apart column locations, an interconnected circumferential ring beam in the open-at-the-top generally circumferential space, and a horizontal floor, ceiling or roof of predetermined thickness in the portion of the upper surface of the horizontal surface of the second set of construction material covered by the mortar, concrete or a mix thereof; and
removing the first set of vertically oriented shoring and the second set of vertically oriented shoring while permanently retaining the foam material as part of the completed building having an integral monolithic superstructure.