Abstract:
A building form that uses two building panels made of a rigid board and a form filler and supported by light gauge framing members and integrating two adjacent building panel molds forming a ribbed chamber into which concrete can be poured. The building panels when jointed together form a depression within the mold panel for a concrete rib when concrete is poured over the building panels. In addition, each of the building panels when separated by another fire resistant board thereby forming a space between the panel molds forming a wider forming mold which becomes an integral part of the building panel. The separated building panels also allow for mechanical mean to be distributed. Additional forming means can be added for a wider and deeper forming structure. Several different transverse support beams can be used to increase the panel mold structural strength.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    A provisional patent application No. 61/065,236 was filed on Feb. 11, 2008 by LeBlang and this date should be used as the filling date for this application. In addition a patent pending application US 2007/0044392 was filed on Nov. 12, 2004 by LeBlang. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    (1) Field of the Invention 
         [0003]    The present invention relates to an improved poured concrete floor, wall or roof form system where the size of the concrete rib can easily vary in size plus the panel system has a fire rating assembly built into the forming system. Different types of materials can be used interchangeably without changing the integrity of the concrete structure as well as the method to fabricate a building panel and transverse beam. 
         [0004]    2. Background of the Invention 
         [0005]    It is well known in the industry that light gauge metal framing is used to support floors, more typically by attaching plywood to the top flange of the metal framing channel. Then if a concrete floor was desired, a thin concrete topping was installed over the plywood. 
         [0006]    Another method to create a concrete floor was to install portable forms using temporary bracing to support the portable forms. The concrete hardens then the temporary forms and shoring are removed thereby creating a concrete floor and an exposed concrete ceiling below the floor. 
         [0007]    There are several floor forming systems that are presently on the market that are made of polystyrene and metal channels. These panels are a polystyrene mold used to support a concrete floor or concrete wall panel until the concrete has cured. The concrete material and its structural steel reinforcing is the structural result of using the polystyrene forms. The forms are made so that a ribbed concrete configuration will result. These existing panels are basically manufactured where a metal support channel is embedded in the thicker middle section of the polystyrene or in some cases two metal supports are installed within the panel. The metal channels support the expanded polystyrene and the concrete until the concrete has cured. 
         [0008]    In some cases the metal channel is molded into the polystyrene, other times the metal channel is slid into the polystyrene at the thicker interior section of the panel. In another case the polystyrene fits over the metal channels again at the thicker polystyrene section of the panel. 
         [0009]    Initially LeBlang in U.S. Pat. No. 6,041,561 showed a floor or wall constructed on metal channels and rigid insulation with intermediate crossing beams within the wall/floor structures using rigid insulation or rigid board as additional support until the concrete has cured. In addition isolated beams and columns are shown using light gauge metal framing and other beams are shown using steel bar joists as a forming structure. 
         [0010]    Later PCT/EP97/05671 was converted to U.S. Pat. No. 6,298,622, by Cretti has embedded metal channels within expanded plastic material to support a concrete floor until the concrete has cured. The expanded plastic material is extruded with the steel studs embedded therein. The panels are interconnected to form a floor upon which concrete is cast. In addition lath is installed to the flange of the metal channels and plaster material is installed over the metal lath to create a fire resistant underside of the floor construction. 
         [0011]    Soon thereafter Boeshart in U.S. Pat. No. 6,817,150 improved on Plastedil patent by adding layer of expanded polystyrene material to increase the depth of the concrete ribs without having to remake a panel as well as used oblique sidewalls to better secure the expanded polystyrene to the concrete ribs. 
         [0012]    Later LeBlang in US 2007/0044392 shows a floor system supported by two light gauge metal channels back to back or an H channel. The flanges of the channels support a rigid board or an expanded polystyrene material. An additional layer of expanded polystyrene is then added on top of the rigid board forming the ribbed concrete flooring mold. The metal channels penetrate the rigid insulation, allowing the light gauge metal support channels to support a flooring system until the concrete has cured. 
         [0013]    Two years later US 2006/0251851 by Bowman embeds a portion of the light gauge metal framing into the expanded polymer with the metal framing exposed above and/or below the expanded polymer. Later that same year in US 2008/0041004 by Gibbar, shows metal channels supporting polymer foam to form a concrete ribbed system. Then later that same year Amend in US 2007/0074804 embeds a brace within the polymer foam to give strength to the expanded polymer. The light gauge metal channels support the embedded brace within the foam adding additional support to the foam. 
         [0014]    One thing all these panels have in common is that the metal channels support the polystyrene and the polystyrene supports a floor rib by the narrow polystyrene support of the panel. The weight of the concrete at the rib section of the panel is the thickest and therefore the heaviest. All of these existing panels support the heaviest portion or the rib section with only the polystyrene and not the metal channel. 
         [0015]    Typically the existing polystyrene panels are not protected from fire. The polystyrene and the metal channels are exposed to any type of fire or explosions within the building. Polystyrene is flammable and does melt until extreme heat or fire. The building codes require that the polystyrene molds be protected, that is add drywall or spray on fireproofing to reduce smoke and fire within a building. In other words, the existing patents require additional materials to be added to within a building to reduce the public health and safety issues within our building codes. 
         [0016]    In addition to the floor/wall panel mold, these various floor panel molds can be supported by the light gauge framing beams or the steel bar joists as shown in the LeBlang patent U.S. Pat. No. 6,041,561. The depth of the beam can be extended when using light gauge framing or bar joists as an extension of the floor forming system. Not all molds panels use polystyrene as the molding structure. For example, inventor Marschke has developed many machines to make cardboard. Later in a pending patent, Marschke in US 2008/0010943 uses an open core element made of fluted paper and an upper and lower sheet as a forming structure for concrete overlayment. A post tension system is used to support the floor as well as wood embedded within the core element. Other structural steel elements are used to support the fluted paper structure. A foam core can also be applied to the open cores of the fluted paper. 
         [0017]    Another wood-based product is shown in U.S. Pat. No. 6,541,097 by Lynch for Masonite Corporation developed a ribbed high density fibreboard product that can be used as decking or packaging. The product is structurally support by exposed wood beams. Later in U.S. Pat. No. 7,255,765 by Ruggle shows the ribbed high density fibreboard installed with a layer above and below, therefore making a more rigid cardboard. 
         [0018]    Another application using fiberboard in a panel application is in U.S. Pat. No. 6,737,115 by Griesbach uses a slurry to produce diagonal bands in the panel to stiffen and reinforce the panel. On the other hand U.S. Pat. No. 6,584,742 by Kilgier uses metal channels and strand board at the interior with inner and outer facing layers. 
         [0019]    The materials being produced today are getting more sophisticated for example U.S. Pat. No. 7,232,605 by Burgueno is a hybrid natural-fiber composite panel with cellular skeleton tubular openings. The hybrid natural-fiber panel also has a greater strength than other types of products. 
       BRIEF SUMMARY OF THE INVENTION 
       [0020]    The general object of the present invention is to provide a better ribbed concrete floor, wall or roof structure by using a stronger and more fire resistant forming system. A further object is to provide a more versatile form allowing for more flexibility in the field and one allowing ease in installing other utilities within the building system as well as a broader range of materials used to create a better forming system. The system also allows for reduced shoring below the floor system, since the metal framing members are directly adjacent to the concrete rib within the floor. Another object is to provide a stay-in-place beam forming system connecting the ribbed concrete flooring sections. 
         [0021]    From a structural aspect, in a ribbed concrete floor, the most concrete is at the ribbed area of the concrete floor and therefore the heaviest load is located at the concrete rib. Therefore by placing the metal support channel at the concrete rib section of the panel, the polystyrene insulation and rigid board below will not deflect and therefore support a greater load and therefore fewer temporary braces are required below the flooring system. 
         [0022]    A typical panel has two metal C channels that are parallel to each other with a polystyrene core between the channels. The web of each of the C channels is the outer edge of the longitudinal side of the panel. The flanges of each of the C channels faces inwardly toward each other forming a ledge to support a rigid board between the C channels. Polystyrene is then installed between the C channels and above the rigid board. The polystyrene is molded to the desired thickness of the panel and notched out above the C channel. The notch can either be obtained by molding the polystyrene into the desire shape or cutting the polystyrene to the desire shape after the panel is molded. The rigid board can be a concrete board or drywall material or other fire resistant materials. The rigid board also becomes a form mold for forming the polystyrene shape as well as the fire resistant material on the bottom of the forming panel. 
         [0023]    Since light gauge metal and the rigid board are the structural supporting members of the panel molds, a non-structural foam or corrugated paper can be used as form filler support of the panel mold. In fact a material like straw could even be used as a filler in lieu of the rigid insulation described below to support the concrete ribbed floor. Many different types of rigid board can be used like drywall, concrete board, fiber cement board, ribbed fiber board as well as forming a panel using a fiber cement skin. This skin would be poured in place at a factory and the foam core or other product would be added prior to the concrete curing. The rigid board doesn&#39;t really have to be a rigid board, but a light gauge ribbed metal decking. Based on the type of panel construction, different building materials can be used interchangeably based on the panel requirements. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0024]      FIG. 1  shows a typical floor section between floor braces showing the cross section of the concrete rib. 
           [0025]      FIG. 2  shows the typical floor section with a space between the floor braces allowing for a wider concrete rib and utility distribution area. 
           [0026]      FIG. 3  shows the typical floor section with a space between the floor braces, however an H brace is used and a concrete is deeper. 
           [0027]      FIG. 4  shows a deeper ribbed concrete floor using two different size braces and still maintain the utility distribution under the concrete rib. 
           [0028]      FIG. 5  shows an even deeper ribbed concrete floor using two different size braces, but eliminating the utility distribution under the concrete rib. 
           [0029]      FIG. 6  shows a transverse concrete beam between two ribbed concrete floor sections. 
           [0030]      FIG. 7  shows a different transverse concrete beam between two ribbed concrete floor sections, however the supporting transverse beam supports are deeper. 
           [0031]      FIG. 8  shows a transverse concrete support where a bar joist is used rather than light gauge metal framing. 
           [0032]      FIG. 9  shows an isometric drawing of the typical concrete ribbed floor and the transverse beam using light gauge metal framing. 
           [0033]      FIG. 10  shows an isometric drawing of the typical concrete ribbed floor where a steel bar joist is used at the transverse beam area. 
           [0034]      FIG. 11  shows an isometric drawing of the typical concrete ribbed floor and the transverse beam using C channels and different panel mold materials. 
           [0035]      FIG. 12  shows and enlarged drawing area of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0036]    After review of the existing and pending patents, one can immediately see the differences in this patent application. In  FIG. 1  the drawings show a ribbed panel mold  10  and two partial panel molds  10 ′ and  10 ″. The panel molds when joined together form a continuous surface onto which concrete  40  can be poured to form a floor or a wall. The size of a concrete rib depends on the structural requirements of the floor span required or the height or wind load of a wall. 
         [0037]      FIG. 1  shows a panel mold  10  consisting of a C channel  21  on the left side and another C channel  22  on the right side of the panel mold. Each of the C channels  21  &amp;  22  consists of a web  21   a  &amp;  22   a  and a lower flange  21   b  &amp;  22   b  plus an upper flange  21   c  &amp;  22   c.  The C channels  21  &amp;  22  are turned so that the lower flange  21   b  and  22   b  support a rigid board  17  between the channels  21  and  22  therefore the webs  21   a  &amp;  22   a  are the outer edges of the panel mold  10 . A form filler of rigid insulation  18  is installed between on the rigid board  17  between the C channel webs  21   a  and  22   a  and extend above the upper flanges  21   c  and  22   c  to the desire depth of a concrete rib. 
         [0038]    A concrete rib  40  is formed when panel mold  10  and  10 ′ are placed adjacent to one another, that is, when the C channel  22 ′ of panel mold  10 ′ abuts the C channel  21  of panel mold  10 . Since the C channels  21  &amp;  22 ′ do abut each other, their webs  22   a ′ and  22   a  are touching. The width of a concrete rib  40  is determined by adding the width of the upper flange  22   c ′ and  21   c  together and the height is determined by the thickness of the rigid insulation  18 . Utility distribution can be installed within the holes  16  of the rigid insulation  18 . The holes  18  can be cut adjacent to the rigid board  17  for ease of manufacturing and parallel to the C channels  22  and  23  within panel mold  10 . The holes  16  can be located adjacent to the rigid board  17  since the rigid board  17  is the main support for supporting the concrete  39  until the concrete  39  cures. Additional steel reinforcing bars  14  are added within the concrete rib  40 . Additional reinforcing steel  14 ′ can be added perpendicular to the reinforcing steel  14  in the concrete rib. The size of the C channels  21  &amp;  22  is dependent on the gauge and size of the metal channels  21  &amp;  22  as well as the distance they are required to span. Additional temporary bracing (not shown) is required below the panel mold  10  if the size of the C channels  21  &amp;  22  are not strong enough to support the weight of the wet concrete  39 . After the temporary bracing and steel reinforcing is installed, concrete  39  is ready to be installed within the panel molds  10 ,  10 ′ &amp;  10 ″.  FIG. 1   a  shows an enlarged section of the left concrete rib  40  shown between the panel mold  10  &amp;  10 ′. 
         [0039]    The configuration of panel molds  10 ,  10 ′ &amp;  10 ″ are exactly the same in  FIG. 2 , except the panel molds  10  &amp;  10 ′ plus  10  &amp;  10 ″ are separated leaving a utility chase located between the C channel  22 ′ &amp;  21  and between C channel  22  &amp;  21 ″. The concrete rib  40 ′ is the same size on both the left side and right side of the drawing. The concrete rib  40 ′ on the right side is supported by the rib board  19  and the upper flanges of  22   c  and  21   c ″ of the C channels  22  &amp;  21 ″ respectively. The rib board  19  between each panel is the bottom of the mold of the concrete rib  40 ′. Since the rib board  19  is totally independent of the panel molds  10  and  10 ″ the width of the concrete rib  40 ′ can be an size depending on the structural requirements of the concrete rib  40 ′. The left concrete rib  40 ′ shows a cover plate  13  can be installed under the lower flanges  22   b ′ &amp;  21   b  as shown at left as a utility chase  38  and also shown in  FIG. 2   a.  Since each of the panel molds are separated by the utility chase  38 , the opening between the C channel  22 ′ &amp;  21  plus between C channels  22  &amp;  22 ″ can have electricity, plumbing, telephone, i.e. distributed as well as accessible but yet concealed between panel molds without being exposed under the panel molds. 
         [0040]      FIG. 3  is similar to  FIG. 2 , except here H channels  23  &amp;  24  are used as the panel mold support members on both the left side and right side of the panel mold  11 . The left concrete rib  40 ′ is the same as in  FIG. 2  except here a rib board  19  rests upon the top flange  24   c ′ &amp;  23   c  of the H channels  24 ′ &amp;  23 . Because the support members are H channels, the lower flange  24   b ′ supports a hard board  17  of panel mold  11 ′ and a smaller rib support  19 ′ between the opposite lower flange  23   a  and the hard board  17  of panel mold  11 . The right concrete rib  40 ″ has a greater depth because the concrete rib  40 ″ is supported on the smaller rib support  19 ′.  FIG. 3  does show the H channels as described above, however two back to back U channels (not shown) could also be used to serve the same supporting function. 
         [0041]    The flanges of any of the C channels or H channels allows for the hard board or rib supports to be attached by gravity or glue if desired to create the panels. 
         [0042]      FIG. 4  shows a larger concrete rib  40 ″ ′ than the previous figures discussed. The panel mold  12  has two deeper C channels  25  &amp;  26 , which are installed at the sides of the panel mold  12  where the webs  25   a  &amp;  26   a  define the edge of the panel mold  12 . The lower flanges  25   b  &amp;  26   a  support the hard board  17  and the rigid insulation  18  above is also thicker. The upper flange  25   c  &amp;  26   c  of the C channels  25  &amp;  26  are embedded into the rigid insulation  18 . A large concrete rib  40 ′″ is formed when panel mold  12  and panel mold  12 ′ &amp;  12 ″ are placed near panel mold  12 . Additional C channels  27  &amp;  28  are installed between panel mold  12 ′ and panel mold  12  as well as between panel mold  12  and panel mold  12 ″. The web  27   a  is adjacent to web  26   a  at the right larger concrete rib  40 ′″ and web  28   a  is adjacent to  25   a ″. The top flanges of  27   c  &amp;  28   c  support the rib board  19 , which is the bottom of the concrete rib  40 ′″. Another rib board  19 ″ can be installed between the lower flange  27   b  &amp;  28   b  creating a utility chase  38  below the large concrete rib  40 ′″. The C channel  27  can be attached to panel mold  12  and C channel  28  can be attached to panel mold  12 ″ or can be installed loosed at the construction site. The rib boards  19  &amp;  19 ″ are installed after the panels  12 ,  12 ′ &amp;  12 ″ are installed. By installing the rib boards  19  &amp;  19 ″ at the job site, the size of the concrete rib  40 ″ can be flexible in size. 
         [0043]    The  FIG. 5  panels  13 ,  13 ′ &amp;  13 ″ are made similar to  FIG. 4 , however U channels  29  &amp;  30  encase the sides of panel mold  13 . The lower flange  29   b  and  30   b  supports the rigid board  17  and the webs  29   a  &amp;  30   a  define the sides of panel mold  13 . The rigid insulation  18  is installed above the rigid board  17  to the height of the upper flange  29   c  &amp;  30   c  of the U channels  29  &amp;  30 . Once the height and width of a rib concrete beam is determined, C channels  31  &amp;  32  can be attached to the sides of mold  13 . Therefore web  31   a  of C channel  31  is attached to the web  29   a  of U channel  29  and set to the desire height of the concrete rib  40 ′″ plus the web  32   a  of C channel  32  is attached to the web  30   a  of U channel  30 . The width of the concrete rib  40 ′″ can be any dimension depending on the structural requirements required to support a floor or the height of any wall. The lower flange  31   b  and  32   b  form a shelf where the  19 ′″ rib board rests form the lower edge of the concrete rib  40 ″″. 
         [0044]    The different configuration of the floor system also requires transverse beams which are formed when the flooring system intersects a crossing beam known as a transverse beam. The transverse beams are usually larger in size than a typical rib beam with the flooring system. The floor system had several different types of panel support members. These panel support members for example are shown in  FIG. 1 &amp; 2  was C channel  23  &amp;  24 . In  FIG. 3  the panel support members were the H channels  23  &amp;  24  and in  FIG. 4  the C channels  25 ,  26 ,  27  &amp;  28 . 
         [0045]      FIG. 6  shows two C channels  33  &amp;  34  separated by a rib board  19 ″″ that rests on the lower flange  33   b  of channel  33  and the lower flange  34   b  of C channel  34 . The web  33   a  and  34   a  define the width of the transverse beam  41 . The transverse beam  41  is also formed when panel molds  10 ′, when the floor mold  10 ′ is supported by framing C channels  21 ′ &amp;  22 ′ and rest on the upper flange  33   c  of the transverse beam, plus the floor panel mold  10  is supported by framing C channels  21  &amp;  22  and rest on the upper flange  34   c  of the transverse beam. The rigid insulation  18  and the rigid board  17  of both floor panel molds  10  &amp;  10 ′ are trimmed to align with the webs of the C channels  33  &amp;  34  forming the transverse beam. Additional reinforcing steel  14  is installed in the transverse beam  41  and in the concrete  39  of the rib panel  10  &amp;  10 ′. Temporary bracing is installed below panel molds  10  &amp;  10 ′ and the transverse beam (bracing not shown) prior to installing concrete  39  over the molds  10  &amp;  10 ′ and into the transverse beam  41 . 
         [0046]    The transverse beam  43  in  FIG. 7  is similar to the transverse beam  41  in  FIG. 6  except here the transverse support channels  35  &amp;  36  are similar but since their configuration is different the C channels  33  &amp;  34  have a greater structural capacity.  FIG. 7   a  shows an enlarged drawing of the transverse support channel  35 , where the top flange  35   c  supports the framing member C channels  21 ′ &amp;  22 ′ of panel mold  10 ′ rest on this top flange  35   c.  The web  35   a ′ extends above the top flange  35   c  and the web  35   a  extends downward to the lower flange  35   b  which defines the bottom of the transverse beam  43 . The web  35   a  also extends above the top flange  35   c  in order to increase the structural capabilities of the support channels  33  &amp;  34  in  FIG. 6 . The web  35   a ′ has holes  15 ′ and are aligned with the holes  15 ′ of the web  35   a.  The transverse support channel  36  is a mirror image of transverse support channel  35 . The C channels  21  &amp;  22  of panel mold  10  rest on the upper flange  36   c  of the transverse support channel  36 . The rib board  19 ″″ rests on the lower flange of  35   b  &amp;  36   b.  To increase strength of the transverse beam  43  additional reinforcing steel  14  is added to the interior of the transverse beam  43 . The rigid board  17  of both the panel mold  10 ′ &amp;  10  extend to the transverse support channels  35  &amp;  36  while the rigid insulation is shown 
         [0047]    A smaller transverse beam  44  is installed in  FIG. 8 , where a steel bar joist  37  is used as a support member between the panel mold  10  &amp;  10 ′. The panel supports  21 ′ &amp;  22 ′ of panel mold  10 ′ and the panel supports  21  &amp;  22  of panel mold  10  rest on the top chord  37   c  of the steel bar joist  37 . The space between the panel molds  10 ′ &amp;  10  and the top chord  37   c  of the steel bar joist  37  is the area of transverse beam  44 . Additional steel reinforcing bars  14  are installed parallel to the steel bar joist  37 . 
         [0048]      FIG. 9  shows an isometric view of the transverse beam  41  shown in  FIG. 7  and the intersecting panel molds  10 ′ &amp;  10 . The support C channels  21 ′ &amp;  22 ′ of panel molds  10 ′ and the support C channels  21  &amp;  22  of panel molds  10  rest on the transverse support channel  36  at the upper flange  36   c.  The panel molds  10 ′ &amp;  10  have the hard board  17  supported by the lower flanges  21   b ′ &amp;  22   b ′ plus  21   b  &amp;  22   b.  The rib beam  40  between the panel molds  10 ′ &amp;  10  are support by the rib board  19 . The same panel molds  10 ′ &amp;  10  rest on the upper flange  35   c  of the transverse channel  35 . When the two transverse support channels  35  &amp;  36  are set in place the rib board  19 ″″ is installed on the lower flanges  35   b  &amp;  36   b  of the transverse channels  35  &amp;  36 . Holes  15 ′ are located in the transverse support channels  35  &amp;  36  which allow the steel reinforcing  14  and concrete  39  to pass through. Additional reinforcing steel  14  in the transverse beam  44  is installed and connected to the reinforcing steel  14  in the rib beam. 
         [0049]    The same panel molds  10 ′ &amp;  10  from  FIG. 9  is used in  FIG. 10  except here the C channels  21 ′ &amp;  22 ′ of the panel mold  10 ′ and the C channels  21  &amp;  22  of panel mold  10  (panel mold view cut short) are resting on the top chord  37   c  of the bar joist  37 . The mechanical chase below the concrete rib  44 , allow the any utilities installed within the mechanical chase to pass through the bar joist  37 . 
         [0050]      FIG. 11  &amp; FIG.  12 is similar to  FIG. 2  except the same panel mold  10  uses C channels  21  &amp;  22  support a ribbed fiberboard  50  which is a paper based product rather than a rigid board like drywall or plywood. Above the vertically ribbed fiberboard  51  is a treated fluted skin paper known as corrugated paper. The vertically ribbed corrugated paper  51  is orientated vertically to support the weight of the wet concrete  39  until it cures. The vertical orientation of the ribbed corrugated paper  51  requires the ribbed fiberboard  50  to be stronger. In panel mold  10 ′ the C channels  21 ′ &amp;  22 ′ uses metal corrugated decking  53  to span greater distances in lieu of the fiberboard  41  as described in  FIG. 2 . Also in panel mold  10 ″ the C channel  21 ″ &amp;  22 ″ has a hybrid natural-fiber composite panel  54  with cellular skeleton tubular openings  55  between the C channels  21 ″ &amp;  22 ″. In lieu of the vertically oriented ribbed fiberboard  51  as shown in panel mold  10 , a horizontally oriented ribbed fiberboard  56  is shown in panel mold  10 ″. A rib beam  40 ′ also uses the ribbed fiberboard  50  between the C channels  22 ′ &amp;  21 . The transverse beam  41  shown as shaded and as shown in  FIG. 6  is supported by C channels  33  &amp;  34  also has the ribbed fiberboard  50  as the bottom of the transverse beam  41 . A transverse beam  45  shown as a ghost outline and highlighted in shading, is shown as a T shaped transverse beam. The top area of the T shape is supported by the ribbed fiberboard  50  on the right side and hybrid natural-fiber composite panel  54  on the left side. By not installing the vertically ribbed fiberboard  51  over the ribbed fiberboard  50 , then a T transverse beam can be installed. 
         [0051]    Even though these panel molds are shown for a concrete floor system, the molds can also be used as a precast wall system or a precast floor system (where the floor panels are cast in sections). The panel molds are described typically using a metal supports at the sides with rigid board and rigid insulation above. In lieu of the rigid insulation at the panel mold, a single or double faced fiberboard form spacer or even straw can be used to create a support means for the concrete to be installed over.