FOAM POD FOUNDATION SYSTEM AND METHOD OF ASSEMBLY

A building foundation that includes a plurality of foam pods disposed on a graded surface and a concrete structure disposed around the plurality of foam pods.

TECHNICAL FIELD

The present disclosure relates generally to foundation systems, and more specifically to a foam pod foundation system and method of assembly.

BACKGROUND OF THE INVENTION

Foundation systems typically use post-tensioned slabs or piers and beams.

SUMMARY OF THE INVENTION

A building foundation is disclosed that includes a plurality of foam pods disposed on a graded surface and a concrete structure disposed around the plurality of foam pods.

DETAILED DESCRIPTION OF THE INVENTION

FIG.1is a diagram of a system100that uses foam pods for a foundation, in accordance with an example embodiment of the present disclosure. System100includes foam pods102, spacers104, post tension cable106, form108and staple110, which can be fabricated as discussed below.

Foam pods102can be fabricated from polymers, elastomers, rubbers, other suitable materials or a suitable combination of materials. In one example embodiment, foam pods102can be fabricated from partially recycled polystyrene that is molded into quadrilateral pods, such as square pods having dimensions of 36″ by 36″ and a suitable height, such as 12″, or other suitable dimensions. Foam pods102can have a density of 1.3 lb/cf or other suitable densities. Foam pods102can be disposed on a graded surface that has been treated with a vapor barrier or in other suitable manners.

Spacers104can be fabricated from polymers, elastomers, rubbers, other suitable materials or a suitable combination of materials. In one example embodiment, spacers104can be circular disc spacers having a predetermined radius (such as 6 inches) and a predetermined thickness (such as 2 inches) and that are made using plastic injection molding or other suitable processes.

Post tension cable106can be formed from plastic, steel, galvanized steel or other suitable material, and is disposed between foam pods or in other suitable locations. In one example embodiment, post tension cable106can be installed at a first level that is located at a point along the height of foam pods102, and at a second level above the height of foam pods102, as further described below. Spacers104can be disposed on the post tension cable106between foam pods102at the lower level to maintain even and consistent spacing. Staples110can be used to support the post tension cable106at the second level.

Form108can be fabricated from steel or other suitable materials, and can be used to align post tension cables106, such as by temporarily attaching post tension cables106to form108or in other suitable manners. Form108can be configured for removal after concrete has been poured and has set or in other suitable manners.

Staples110can be fabricated from plastic, steel, galvanized steel or other suitable materials, and can be used to provide proper spacing between foam pods102, to support post tension cables106and for other suitable purposes. In one example embodiment, staples110can be installed in series, so as to ensure that proper spacing is provided and to avoid the inadvertent creation of offsets or discontinuities.

In operation, system100can be used to provide a foundation for a building that is easy to install, that can be installed quickly and that can be installed at a substantially lower cost than prior art foundations. System100allows multiple workers to install components of system100such as foam pods102, spacers104and staples110in parallel, so as to decrease the amount of time required for installation. Foam pods102can be pre-fabricated and delivered to the job site just in time for construction, which decreases fabrication and material storage costs. For example, for pier and beam foundations, it is often necessary to dig holes for each pier using specialized equipment, then to construct each pier, which is time consuming and which requires specialized skills. Foam pods102eliminate the need for such construction activities.

FIG.2is a diagram200of an elevation view of a system that uses foam pods for a foundation, in accordance with an example embodiment of the present disclosure. Elevation view200includes foam pods102, spacers104, form108, staples110, vapor barrier202, concrete204and finished floor206, which can be fabricated as discussed below.

In addition to the components of system100as discussed above, diagram200shows a vapor barrier202, which can be installed after the site has been graded but prior to the installation of foam pods102. After all foam pods102have been installed and properly placed using spacers104and staples110, concrete204can be poured until the finished floor206level has been reached. Post-pour treatment of concrete204can then be performed, such as leveling, smoothing, sealing and so forth. Form108can be removed after concrete104has set, and post tensioning of the post tension cables106(not explicitly shown) can then be performed.

FIG.3is a diagram of an algorithm300for fabricating a foundation that uses foam pods, in accordance with an example embodiment of the present disclosure. Algorithm300can be performed by one or more processors to track the status of associated manual activities or in other suitable manners.

Algorithm300begins at302, where a site is fine graded. In one example embodiment, a system can be used to generate a user interface that includes a status notice for scheduling grading, to schedule equipment or workers or for other suitable purposes, including one or more controls for updating status, rescheduling or other suitable functions. In this example embodiment, the site can be graded to a suitable depth below the finished floor level, such as 17″ for installations where the foam pods are 12″ in height and a 5″ over layer of concrete is to be installed, but other suitable dimensions can also or alternatively be used. The present disclosure thus avoids the need for slab undercutting, moisture injection of expansive soils or other treatments. Prior to grading, the surface can be compacted where needed, forms can be installed, underground plumbing and electrical facilities can be installed, trenches and pads can be compacted and other suitable processes or activities can also or alternatively be performed, and suitable notifications and user controls can be generated to manage progress and to report any delays or interruptions, such as by generating an alert. The user interface can also or alternatively include status indicators and controls for one or more of these additional activities. The algorithm then proceeds to304.

At304, a status notice and controls are generated for activities associated with installing a concrete vapor barrier, such as polyethylene plastic sheeting, resin implanted plastic sheeting or other suitable materials. In one example embodiment, the vapor barrier can be installed on an entire slab footprint, on predetermined portions of the slab footprint or in other suitable manners. The algorithm then proceeds to306.

At306, a status notice and controls are generated for activities associated with installing post tension cables or other suitable tensioning equipment, and the post tension cables are then installed. In one example embodiment, a pour strip can be provided, such as where the available post tension cable length is shorter than the pad dimensions or in other suitable embodiments. The algorithm then proceeds to308.

At308, a status notice and controls are generated for activities associated with installing spacers at each side of the locations where the foam pods will be installed. In one example embodiment the spacers can be 6″ circular disc structures, but other suitable shapes and configurations of spacers can also or alternatively be used. The spacers can be configured to connect to and support post tension cables, such as to maintain their height over the grade at 3″ or other suitable distances. The algorithm then proceeds to310.

At310, a status notice and controls are generated for activities associated with installing foam pods. In one example embodiment, the foam pods can be delivered “just in time” to reduce or eliminate storage requirements. In this embodiment, the number of workers available to install the pods and the installation rate can be used to schedule deliveries of the foam pods, where suitable notices and controls for reporting the installation rate, the number of installed foam pods, the number of remaining foam pods, a number of foam pods to be delivered on a predetermined day or within a predetermined time, completion of installation, interruption of installation, alerts for any status, the number of workers, the number of available foam pods or other suitable data and functions can be generated to assist with scheduling activities. The algorithm then proceeds to312.

At312, a status notice and controls are generated for activities associated with installing staples at foam pod. In one example embodiment, one or more staples can be installed at each foam pod, such as to serve as an additional 6″ spacer, to support an upper post tension cable into the 5″ thick slab by a suitable amount such as 2″ for additional strength of the slab, or for other suitable purposes. The use of these staples can eliminate the need for rebar in the slab or other strengthening components. The algorithm then proceeds to314.

At314, a status notice and controls are generated for activities associated with installing final system components. In one example embodiment, additional reinforcing can be provided for walls, such as concrete masonry wall blocks and vertical rebar, tilt wall, cutting penetrations for plumbing and electrical facilities and other suitable activities. The algorithm then proceeds to316.

At316, a status notice and controls are generated for activities associated with pouring concrete. In one example embodiment, a single-ended concrete delivery hose and boom can be used to provide concrete at the top of each pod, to allow the concrete to flow into grade beams, followed by vibration of the concrete into place, or other suitable processes can also or alternatively be used. Notifications and controls can be generated when installation of concrete is completed, if installation of concrete has been interrupted, or for other suitable purposes. The algorithm then proceeds to318.

At318, a status notice and controls are generated for activities associated with stripping the concrete forms to expose the post tension cables. In one example embodiment, the notice and controls can be modified based on an engineer's recommendation, the concrete mix design for the site, to allow for proper cure times or for other suitable purposes. The algorithm then proceeds to320.

At320, a status notice and controls are generated for activities associated with applying tension to the post-tensioning cables. In one example embodiment, the cables can be tensions one or more days after the pour, and then after the concrete has met its design strength after curing, the cables can be further tensioned to comply with a cable supplier's recommendations, such as from 7-10% elongated length of original cable length to reach desired strength. Scheduling notices can be generated for a third party testing company to document the elongation, submit their findings to the engineer of record, to verify that the elongation meets the specified standards and for other suitable purposes. Once it is determined that the elongation is sufficient, the post tension cable is cut, and the pockets are grouted.

In general, a software system is a system that operates on a processor to perform predetermined functions in response to predetermined data fields. A software system is typically created as an algorithmic source code by a human programmer, and the source code algorithm is then compiled into a machine language algorithm with the source code algorithm functions, and linked to the specific input/output devices, dynamic link libraries and other specific hardware and software components of a processor, which converts the processor from a general purpose processor into a specific purpose processor. This well-known process for implementing an algorithm using a processor should require no explanation for one of even rudimentary skill in the art. For example, a system can be defined by the function it performs and the data fields that it performs the function on. As used herein, a NAME system, where NAME is typically the name of the general function that is performed by the system, refers to a software system that is configured to operate on a processor and to perform the disclosed function on the disclosed data fields. A system can receive one or more data inputs, such as data fields, user-entered data, control data in response to a user prompt or other suitable data, and can determine an action to take based on an algorithm, such as to proceed to a next algorithmic step if data is received, to repeat a prompt if data is not received, to perform a mathematical operation on two data fields, to sort or display data fields or to perform other suitable well-known algorithmic functions. Unless a specific algorithm is disclosed, then any suitable algorithm that would be known to one of skill in the art for performing the function using the associated data fields is contemplated as falling within the scope of the disclosure. For example, a message system that generates a message that includes a sender address field, a recipient address field and a message field would encompass software operating on a processor that can obtain the sender address field, recipient address field and message field from a suitable system or device of the processor, such as a buffer device or buffer system, can assemble the sender address field, recipient address field and message field into a suitable electronic message format (such as an electronic mail message, a TCP/IP message or any other suitable message format that has a sender address field, a recipient address field and message field), and can transmit the electronic message using electronic messaging systems and devices of the processor over a communications medium, such as a network. One of ordinary skill in the art would be able to provide the specific coding for a specific application based on the foregoing disclosure, which is intended to set forth exemplary embodiments of the present disclosure, and not to provide a tutorial for someone having less than ordinary skill in the art, such as someone who is unfamiliar with programming or processors in a suitable programming language. A specific algorithm for performing a function can be provided in a flow chart form or in other suitable formats, where the data fields and associated functions can be set forth in an exemplary order of operations, where the order can be rearranged as suitable and is not intended to be limiting unless explicitly stated to be limiting.