Construction of monolithic structures with air forms

Abstract

A method and system for constructing a monolithic structure with a moldable mixture including one or more rigid forms connected to form an inner rigid wall, an inner inflatable air form, wherein the inner inflatable air form extends from the inner rigid wall, one or more rigid forms connected together to form an outer rigid wall, and an outer inflatable air form, wherein the outer inflatable wall extends from the outer rigid wall.

1 . A method for building a monolithic structure, the method comprising:
 compacting and preparing a foundation on a site where the monolithic structure will reside;   erecting an inner vertical structural wall on the foundation;   securing the inner vertical structural wall to the foundation;   connecting an inner air form to a top of the inner vertical structural wall;   inflating the inner air form creating an inner mold;   erecting an outer vertical structural wall around the inner vertical structural wall, wherein the distance between the inner vertical structural wall and the outer vertical structural wall is a desired thickness of the monolithic structure;   securing the outer vertical structural wall to the foundation;   connecting an outer air form to a top of the outer vertical structural wall creating an outer mold;   pouring a moldable mixture in a space between the inner mold and the outer mold;   removing air pressure once the moldable mixture is solidified;   curing the moldable mixture;   detaching the outer air form from the outer vertical structural wall, and removing the outer air form and the outer vertical structural wall from the cured moldable mixture; and   detaching the inner air form from the inner vertical structural wall and removing the inner air form and the inner vertical structural wall from the moldable mixture.   
     
     
         2 . The method as recited in  claim 1 , wherein the inner vertical structural wall and the outer vertical structural wall comprise one or more rigid forms. 
     
     
         3 . The method as recited in  claim 1 , wherein the foundation is a poured concrete slab, a trench rubble foundation or a stem wall. 
     
     
         4 . The method as recited in  claim 1 , wherein inner structural wall and the outer structural wall are secured to the foundation using bolts, screws, concrete anchors, weights to hold the inner and outer structural walls down, straps to anchor the inner and outer structural walls in the ground or tied to rope cleats. 
     
     
         5 . The method as recited in  claim 2 , wherein the one or more rigid forms are a web of rebar, reinforcing mesh or basalt rebar. 
     
     
         6 . The method as recited in  claim 1 , wherein the inner and outer structural walls are secured to the foundation by screwing weld plates on the rigid forms into the foundation. 
     
     
         7 . The method as recited in  claim 1 , wherein the moldable mixture is poured in a hole in the outer mold. 
     
     
         8 . The method as recited in  claim 1 , further comprising cutting a doorway in the cured moldable mixture to detach and remove the inner air form and the inner structural wall. 
     
     
         9 . The method as recited in  claim 1 , wherein doorways, windows, utility connections and plumbing are cast in the inner and the outer vertical structural walls. 
     
     
         10 . The method as recited in  claim 2 , wherein the one or more rigid forms and the inner and outer air forms are reusable for another monolithic structure. 
     
     
         11 . The method as recited in  claim 1 , further comprising sealing the monolithic structure. 
     
     
         12 . A system for constructing a monolithic structure with a moldable mixture comprising:
 one or more rigid forms connected to form an inner rigid wall;   an inner inflatable air form, wherein the inner inflatable air form extends from the inner rigid wall;   one or more rigid forms connected together to form an outer rigid wall; and   an outer inflatable air form, wherein the outer inflatable wall extends from the outer rigid wall.   
     
     
         13 . The system as recited in  claim 11 , wherein the moldable mixture is a foam cement. 
     
     
         14 . The system as recited in  claim 12 , wherein the moldable mixture is hempcrete or a mixture infused with fiberglass, polymers, epoxies, plastics, or curable liquid insulators. 
     
     
         15 . The method as recited in  claim 1 , further comprising inflating the air form before air form before pouring the moldable mixture.