Cozycrete

 AI analysis says: "You have a phenomenal system here!"  Masterful mosaic geometry with Cozycrete's standard panel sizes.

Finite Element Analysis Report

Note that the report is for a single panel.  The backing of polyiso, cast in place concete, and the interior panel are not factored in here.

I'm seeking architects, engineers, builders, and prospective home owners to say, "This is Great, I'll help you produce this to the maximum!"  

I need your help, your intervention, cooperation, and team play.  I've taken this as far as I can on my own.  I need to pass the baton to YOU!

The barrier has been the lack of a PE to embrace the system.  AI has validated all claimed features, but new innovation is a learning curve apparently very few wish to engage.  A dominant new criteria has come to rule the roost, called Finite Element Analysis, ultimately creating a "Revit" model to plug into construction design.  This system is now undergoing that analysis with results expected soon.

The system can be designed to any strength, including E5 tornado resistance.  With extreme weather always increasing, homes need to be secure and insurance expense needs to be held in check, if not eliminated.

This is made possible by the fact that precision molds can replicate their precision into concrete castings.  High performance features are simply replicated endlessly.  A perfect weight, variety, and maximum durability are done with a minimum of materials and expense.  Given the mold, anyone can do it.

The above approach having the massive concrete fill was due to the structural component of the system panels was completely ignored.  They were considered non performing cladding.

Credentials

An Industrial Engineer is a problem solver.  When something innovative needs to be implemented, a system solution is created particularly paying attention to the "devil in the details".

This geometry creates a wall stiffness of 9.25" using only 2-1/4" of concrete, thanks to the physical fact of "Moment of Inertia", same as stiffness structural engineering design.

Here is a step drawing of the smallest 12" x 16" complete with the embedded expanded steel and the concrete it would displace within its mounting rib removed.

Interesting oxymoron, hard cold concrete being cozy.  Yet, when the wall temperature is above room temperature, concrete emits a long wave infrared radiation which gently and penetratingly warms objects within a space.  In fact, the penetrating nature of it allows a four degree temperature warmer sensation with a corresponding thermostat setback.  Occupants report never having felt so "cozy".  The infrared comes from the floor, all four walls, and the ceiling for full immersion. 

I've been in suspense for thirtyfive years if another system could out perform this.  If there was one, I'd quit in an instant since any more work would be futility and foolish.  But there isn't, and I don't think there can be because of a fundamental law of physics.  That is that the structural stiffness of a wall increases with the cube of its thickness.  Put your strongest material as far as possible from the neutral axis, (where tensile force goes to zero and then transitions to compression).  As material approaches the middle of a wall, its contribution to stiffness (not bending) goes to zero.  This system has the 1 1/8" concrete wall faces, (average between 2" thick ribs and 1/2" thick webs) give a structural stiffness of 9-1/4" of regular cast in place concrete.

The concrete wall faces are an absolute bare minimum of concrete to be structurally sound.  The steel joinery of the faces converts the two wall faces into a monolithic unit.

With the increasing popularity of "bunkers", a common sense choice for protection in a dangerous world, this system is ideally suited.  For underground construction, the cavity wall air space shields moisture penetration.  

Executive Summary

Appropriate Housing for a Challenged Humanity

Built the coast of British Columbia to the Los Angeles and Tokyo Earthquake Codes, a Proven System

The devastation of people's homes from increasingly violent weather is a tragedy that we must confront and do better.  My initial forays into AI has it being called "Fortress" construction.  That sounds like it would be a hopelessly expensive and unattainable.  However, it's not, because of efficiencies and bulk materials inherent to the system.

The key is mega mass, streamlining construction processes, creating a precision product from bulk pea gravel concrete using molds developed over decades of evolution.  Installation uses a wall map indicating placement of what goes where, easy installation of electrical and plumbing, and versatility as to what systems, ideas, and innovations are possible within the cavity wall.  The product is lightweight enough to be handled and installed manually by unskilled labor.  The greatest skill required is flat level concrete finishing for the slab or footing which the wall will be erected.  There's a somewhat meticulous onus on the designer to specify everything, yet the performance of the system can be mind boggling.  One utilizes a post tensioned concrete roof supported on all four sides by spandrel beams, eliminating column line droop and simplifying calculations.  The overlaying concrete diaphragm ties it all together for a monolithic response and ductility.  One may grasp this instantly or one can give it time to reveal its efficacy.  

This is my singular creation and I'm looking for help and talent to turn this into a self turning wheel.The devastation of people's homes from increasingly violent weather is a tragedy that we must confront and do better.  My initial forays into AI has it being called "Fortress" construction.  That sounds like it would be a hopelessly expensive and unattainable.  However, it's not, because of efficiencies and bulk materials inherent to the system.

This is my singular creation and I'm looking for help and talent to turn this into a self turning wheel.

Quick Summary of Why This is the Inevitable Best Choice 

SWOT

1. Glass smooth beveled wall faces for timeless cut stone aesthetic.

2. Completely fireproof.

3. Wall faces couple together for the widest and most efficient structural stiffness footprint.

4. System a "container" or "cavity wall" amenable to any appropriate bulk fill.

5. Tongue and grooved joints provide sealing, alignment, reinforcement, and  unequaled ductility for maximum surviveability.

6. Easily and economically buildable to survive the most powerful servings  of Nature.

7. Easy jobs for anyone to make profound contribution from precasting the panels and installing them.

8. Stretches concrete to maximum efficacy, only 14.7 pounds per square foot.

9. Mega mass floor, walls, and ceiling all infrared radiators for cozy even heat with and a 4 degree lower thermostat setting.  Infrared radiance feels warmer with penetrating coziness.

Fundamentals of Concrete Building System

• Glass smooth surface

• Cut stone beveled edges timeless appeal

• Amenable to myriad decorative concrete finishes or left plain

• Scant use of concrete at 14.7 pounds per square foot

• Panels easy to make with highly evolved molds

• Easy to manually install with basic wall maps

• Wide wall footprint maximum rigidity (stiffness)

• Plumbing and electrical simple installation within cavity

• Trade labor minimal

• Framing, sheathing, paper wrap, siding, and drywall all eliminated 

It's the versatility that separates this from other options.  The open wall cavity is a cornucopia for applications.  It can be filled with everything from cast in place concrete, sand, gravel, crusher fines, or even plain dirt.  It's never been easier, cheaper, and greener to get critically important mass to resist the increasingly severe forces of Nature.  

Insulation is placed either against the interior panel or exterior panel.  It depends on what the smartest application is dependent on the function.  If against the exterior, then the cavity fill is part of the interior thermal mass.  This adds a lot more thermal storage to stay warm or cool longer.  But, it also requires a longer time to bring the interior mass up to temperature.

If against the interior panel then the exterior panel concrete becomes monolithic with the cast in place and one has a thick solid concrete exterior to withstand about anything.

Cost Estimating Spreadsheet

Approximate Rule of thumb is that 3.3 square feet of panel are required for each square foot of floor space.

Two ways to displace concrete below:

The steel overlap is tack welded.  The tack welding came along a little later as the bolt, nut, washer assembly would allow some slippage sliding apart of the panels due to the pressure of deposited concrete. Tack welding eliminated the problem.  However, if the panels are used in a temporary application, say blast protection in a war zone, the bolt nut method would be fine.  The cavity could be filled with sand and then later removed through access openings in the bottom of the wall.  The efficacy of sand for force absorption is evident on a runaway truck ramp outside Denver that is on a steep downhill grade.  Plastic barrels full of sand are deployed to somewhat gently bring a big rig to a halt that has burned up its brakes.

Splines align and seal the panel seams

Finished wall system from beginning giving a maintenance free, fireproof and waterproof home