Following is an overview and technical treatise as part of an application towards a government program on alternative energy
Abstract for Patent Application No.: 15/460,002 - Now Posted
OVERVIEW
In the world of construction, concrete is the most used resource in the world. It is versatile, moldable, and sturdy. Creating an aggregate solution of cement, sand, a uniform size of rock/gravel added for strengthening, and water makes up your essential concrete recipe. The basic ingredients for making concrete can be found in abundance the world over. Seems the ideal building material yet there are downsides to this miracle product. First, it has no insulation value of its own – it’s basically a rock so if it is cold outside then the concrete is cold outside and in. The same goes for heat. Secondly, although sturdy, concrete needs the benefit of strengthening solutions to keep larger sections from cracking and crumbling. Thirdly, concrete weighs a lot – let’s face it, it is heavy and adding any of the conventional strengthening solutions adds even more weight.
Wouldn’t it be great if someone came up with an aggregate solution that addressed these concrete shortcomings?
INVENTION DISCLOSURE FORM
1. PodCasts – PodCasts 3D Geometric Shapes Aggregate Replacement Solution
2. In the use of concrete for construction this product solves the three main drawbacks of the medium:
A. Increase Insulation
B. Reduce Weight
C. Add Strength
3. PodCasts is an aggregate substitute in the batching of concrete. PodCasts are hollow injection molded three-dimensional geometric shapes. Currently we are utilizing the plastic tetrapod form to replace the gravel aggregate component of the concrete mix. The size of the PodCasts is equivalent to the aggregate it is substituting, i.e. ¾” rock is replaced with ¾” PodCasts. The size is also scalable to meet any mix needs from sand grain up to several inch rocks. One of the great features of PodCasts is that it mixes in truck as opposed to entrainment. Since we are replacing volume for volume at significant weight reduction because of the hollow design and materials used, we already achieve one of our goals, current estimates are at about 50% reduction in weight - although that number could increase significantly with more rigorous testing. The fact that they are hollow means that they are an air pocket, which creates an insulation value – another goal met. That their unique shapes naturally cause them to interweave or intertwine creates the additional strengthening and energy disbursement qualities we are aiming for – PodCasts scores again. In addition PodCasts will be enthusiastically embraced by the concrete industry as it will integrate easily into current concrete mix and delivery systems without any supplementary infrastructure, handling, or disruption to the standard chain of process. In fact it will greatly increase productivity of delivery as larger quantities of lightweight PodCasts infused concrete will now be deliverable without exceeding current road weight limits, which equates to fewer truck transports to the jobsite. PodCasts can be utilized to great benefit in any current building solution as well as creating opportunities for as yet unimagined construction possibilities.
4. In the current environment of concrete aggregates the two products that come closest to PodCasts are foam and micro-rebar – each with their own set of drawbacks. Foam, a version of Styrofoam injected into the concrete mix, adds insulation value while reducing weight yet strength is greatly compromised – to the point where you can push your finger through the surface of a foam injected concrete wall. Micro-rebar, small metal rods mixed into the concrete solution, adds strength but does nothing for increasing insulation or reducing weight. And mixing those two products together will still come nowhere near achieving the results that one can realize with PodCasts. Only PodCasts is able to tackle all three challenges with one easy solution.
5. Aside from the products mentioned in answer #4 there are no known similar products currently being used in this field.
6. Concrete has been utilized in the building process for over two thousand years. In all of that time things have not changed very much – until now. PodCasts are a Geometric Shapes Aggregate Replacement Solution that utilizes manmade products of diverse material, i.e. plastic, paper, etc., and formed into hollow three-dimensional geometric shapes that are naturally prone to interweave or intertwine to create a hybrid aggregate substitute. The shapes interweave characteristics and hollow displacement are the underlying technology values that create the weight reduction, enhanced insulation characteristics, and added strength.
7. The skyscraper’s no longer the limit for potential application of the PodCasts. We see the potential for Podcasts in the application of current building practices as revolutionary and for the creation of next generation building practices as evolutionary. In this brave new PodCasts world engineers will need to rewrite their technical specifications manuals to conform to the advancements that PodCasts makes.
8. The PodCasts invention has not been publicly discussed. The idea development and the initial prototyping and testing have been done in a private shop utilizing our own 3D printer to create the first batch of PodCasts.
Are there any potential downsides to the PodCasts Aggregate Solution?
The only downside from the use of PodCasts is the additional cost to a yard of concrete – which we conservatively estimate at around double the current price. Although this cost increase should scale down as manufacture processes scale up and per unit costs decrease. But that price increase is superficial and negated by the savings in overall construction process – in reality the cost of building a structure will decrease with the use of PodCasts infused concrete. Current practice has it that a concrete wall is cast in place and then wood framing is constructed on both the interior and exterior walls for the addition of insulation and siding. This work could all be eliminated along with those material costs. Secondly, the structural integrity of the building would be greatly increased and as such would allow for the decrease in wall thickness while maintaining engineered specifications – less concrete means more cost savings. Thirdly, the time needed to construct a typical wood frame home is around ninety days, this timeline would decrease exponentially to around thirty days with a PodCasts concrete home. How much is that time worth? When you are sitting on a construction loan, quite a bit.
Now before you accuse us of advocating the building of drab soviet style block housing let me add that, with the current methods of concrete stamping and molding, a concrete structure can be made to look like it was built of anything from river rock to rough hewn logs to normal board siding on the exterior and drywall to plaster to tile on the interior – or whatever you can imagine to express your unique personal style. And this to such a degree that it would fool most of the people all of the time. Add to all of this the fact that the current wood frame housing has a thirty to fifty year lifespan verses a one hundred, two hundred, even five hundred year lifespan for a concrete home and the savings multiply. Plus, as concrete doesn’t burn, doesn’t get blown away in a hurricane, and is not conducive to mold growth you’ve got a formula for cheaper and better and safer and more easily insured housing that everyone can afford.
As to the use of PodCasts in the construction of commercial buildings like hi-rises the savings would be huge. Upper floor concrete decking would be thinner and lighter allowing for the use of less and lighter steel infrastructure to hold the building together. This goes for concrete exterior walls as well. The added insulation factor would also reduce the costs of heating and air-conditioning. The reduced weight would also allow for bigger and taller structures as well as unique design executions.
Environmentally, building more concrete homes and structures would greatly reduce the depletion of our forests for lumber - more trees, better air.
Overall we see the integration of PodCasts into the construction stream as a huge benefit for civilization and we are very excited to see this evolution in building become a reality.
In the world of construction, concrete is the most used resource in the world. It is versatile, moldable, and sturdy. Creating an aggregate solution of cement, sand, a uniform size of rock/gravel added for strengthening, and water makes up your essential concrete recipe. The basic ingredients for making concrete can be found in abundance the world over. Seems the ideal building material yet there are downsides to this miracle product. First, it has no insulation value of its own – it’s basically a rock so if it is cold outside then the concrete is cold outside and in. The same goes for heat. Secondly, although sturdy, concrete needs the benefit of strengthening solutions to keep larger sections from cracking and crumbling. Thirdly, concrete weighs a lot – let’s face it, it is heavy and adding any of the conventional strengthening solutions adds even more weight.
Wouldn’t it be great if someone came up with an aggregate solution that addressed these concrete shortcomings?
INVENTION DISCLOSURE FORM
1. PodCasts – PodCasts 3D Geometric Shapes Aggregate Replacement Solution
2. In the use of concrete for construction this product solves the three main drawbacks of the medium:
A. Increase Insulation
B. Reduce Weight
C. Add Strength
3. PodCasts is an aggregate substitute in the batching of concrete. PodCasts are hollow injection molded three-dimensional geometric shapes. Currently we are utilizing the plastic tetrapod form to replace the gravel aggregate component of the concrete mix. The size of the PodCasts is equivalent to the aggregate it is substituting, i.e. ¾” rock is replaced with ¾” PodCasts. The size is also scalable to meet any mix needs from sand grain up to several inch rocks. One of the great features of PodCasts is that it mixes in truck as opposed to entrainment. Since we are replacing volume for volume at significant weight reduction because of the hollow design and materials used, we already achieve one of our goals, current estimates are at about 50% reduction in weight - although that number could increase significantly with more rigorous testing. The fact that they are hollow means that they are an air pocket, which creates an insulation value – another goal met. That their unique shapes naturally cause them to interweave or intertwine creates the additional strengthening and energy disbursement qualities we are aiming for – PodCasts scores again. In addition PodCasts will be enthusiastically embraced by the concrete industry as it will integrate easily into current concrete mix and delivery systems without any supplementary infrastructure, handling, or disruption to the standard chain of process. In fact it will greatly increase productivity of delivery as larger quantities of lightweight PodCasts infused concrete will now be deliverable without exceeding current road weight limits, which equates to fewer truck transports to the jobsite. PodCasts can be utilized to great benefit in any current building solution as well as creating opportunities for as yet unimagined construction possibilities.
4. In the current environment of concrete aggregates the two products that come closest to PodCasts are foam and micro-rebar – each with their own set of drawbacks. Foam, a version of Styrofoam injected into the concrete mix, adds insulation value while reducing weight yet strength is greatly compromised – to the point where you can push your finger through the surface of a foam injected concrete wall. Micro-rebar, small metal rods mixed into the concrete solution, adds strength but does nothing for increasing insulation or reducing weight. And mixing those two products together will still come nowhere near achieving the results that one can realize with PodCasts. Only PodCasts is able to tackle all three challenges with one easy solution.
5. Aside from the products mentioned in answer #4 there are no known similar products currently being used in this field.
6. Concrete has been utilized in the building process for over two thousand years. In all of that time things have not changed very much – until now. PodCasts are a Geometric Shapes Aggregate Replacement Solution that utilizes manmade products of diverse material, i.e. plastic, paper, etc., and formed into hollow three-dimensional geometric shapes that are naturally prone to interweave or intertwine to create a hybrid aggregate substitute. The shapes interweave characteristics and hollow displacement are the underlying technology values that create the weight reduction, enhanced insulation characteristics, and added strength.
7. The skyscraper’s no longer the limit for potential application of the PodCasts. We see the potential for Podcasts in the application of current building practices as revolutionary and for the creation of next generation building practices as evolutionary. In this brave new PodCasts world engineers will need to rewrite their technical specifications manuals to conform to the advancements that PodCasts makes.
8. The PodCasts invention has not been publicly discussed. The idea development and the initial prototyping and testing have been done in a private shop utilizing our own 3D printer to create the first batch of PodCasts.
Are there any potential downsides to the PodCasts Aggregate Solution?
The only downside from the use of PodCasts is the additional cost to a yard of concrete – which we conservatively estimate at around double the current price. Although this cost increase should scale down as manufacture processes scale up and per unit costs decrease. But that price increase is superficial and negated by the savings in overall construction process – in reality the cost of building a structure will decrease with the use of PodCasts infused concrete. Current practice has it that a concrete wall is cast in place and then wood framing is constructed on both the interior and exterior walls for the addition of insulation and siding. This work could all be eliminated along with those material costs. Secondly, the structural integrity of the building would be greatly increased and as such would allow for the decrease in wall thickness while maintaining engineered specifications – less concrete means more cost savings. Thirdly, the time needed to construct a typical wood frame home is around ninety days, this timeline would decrease exponentially to around thirty days with a PodCasts concrete home. How much is that time worth? When you are sitting on a construction loan, quite a bit.
Now before you accuse us of advocating the building of drab soviet style block housing let me add that, with the current methods of concrete stamping and molding, a concrete structure can be made to look like it was built of anything from river rock to rough hewn logs to normal board siding on the exterior and drywall to plaster to tile on the interior – or whatever you can imagine to express your unique personal style. And this to such a degree that it would fool most of the people all of the time. Add to all of this the fact that the current wood frame housing has a thirty to fifty year lifespan verses a one hundred, two hundred, even five hundred year lifespan for a concrete home and the savings multiply. Plus, as concrete doesn’t burn, doesn’t get blown away in a hurricane, and is not conducive to mold growth you’ve got a formula for cheaper and better and safer and more easily insured housing that everyone can afford.
As to the use of PodCasts in the construction of commercial buildings like hi-rises the savings would be huge. Upper floor concrete decking would be thinner and lighter allowing for the use of less and lighter steel infrastructure to hold the building together. This goes for concrete exterior walls as well. The added insulation factor would also reduce the costs of heating and air-conditioning. The reduced weight would also allow for bigger and taller structures as well as unique design executions.
Environmentally, building more concrete homes and structures would greatly reduce the depletion of our forests for lumber - more trees, better air.
Overall we see the integration of PodCasts into the construction stream as a huge benefit for civilization and we are very excited to see this evolution in building become a reality.