Cozycrete

Unsurpassed Security,Value, and Comfort

Interesting oxymoron, hard cold concrete being cozy. Yet, when its 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 and thermostat setback. Occupants report never having felt so "cozy". The infrared comes from the floor, all four walls, and the ceiling for full immersion.

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.

AI analysis says: "You have a phenomenal system here!"

Cozycrete Technical Manual

Precast concrete panels serve as a stay in place form for cast in place concrete with the wall face being a finished architectural cut stone aesthetic

Cast in place forming is free, puts mass where is should be in home's interior structure. Can you conceptualize that huge mass absorbing warmth from a heated floor slab?

Invented by Walt DeVore

Industrial Engineer

Georgia Tech, 1973

Idaho Springs, CO

walt.devore@cozycrete.com

Cell and WhatsApp: 720 227 4524

Patent No. 5,802,793

Executive Summary

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

Quick Summary of Why This is the Inevitable Best Choice

Glass smooth beveled wall faces for timeless cut stone aesthetic.
Completely fireproof.
Wall faces couple together for the widest and most efficient structural stiffness footprint.
System a "container" or "cavity wall" amenable to any appropriate bulk fill.
Tongue and grooved joints provide sealing, alignment, reinforcement, and unequaled ductility for maximum surviveability.
Easily and economically buildable to survive the most powerful servings of Nature.
Easy jobs for anyone to make profound contribution from precasting the panels and installing them.
Stretches concrete to maximum efficacy, only 14.7 pounds per square foot.
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.

System eliminates framing, sheathing, wrap,siding, and drywall. Walls fireproof, supports post tensioned concrete roof slabs

Precast concrete wall face units with embedded steel that overlap and fasten, in tandem with groove and spline (tongue and slot) for alignment, reinforcing, and sealing with a pvc strip. Characterized by AI as "Fortress Construction". Surprisingly low cost.

Projects with the Concrete Building System LLC

Note the mosaic patterns artfully created combining different panel sizes

Fastening

To have a quarter inch cover at each wall face on a 12” wide wall, the steel combination is 11 ½” which creates this overlap. Very easy for tack welding.

Forming

Couplers align vertically and horizontally. They support a formboard however one wishes. The cavity is easily partitioned so bulk fill such as crusher fines can be filled first and adjacent to it cast in place concrete. This gives the ability to use cast in place concrete around door and window frames to maximize strength against tornados, etc. Threaded inserts can be added to bolt opening protection such as expanded steel.

Column formed by dropping osb board down cavity braced by vertical couplers

If wall removed, columns and beams can be formed judiciously within cavity

Encasement of columns and beams within cavity. Bottom of beams supported by top of fill

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.

Getting the first row in is huge. That's assuming one had a high quality flat slab in lieu of grinding and shimming. One meticulously lays out the wall panel slots for a quarter inch deep slot to define the wall alignments for the rest of the project.

The first layer of horizontal rebar, if any, is tied into place along with the vertical rebars. Then a one layer course of concrete is deposited to lock it all in, Then one is ready to be off to the races.

Each wall is mapped out so panel placement is easy and straight forward. Electric boxes and conduit paths are specified. Any plumbing penetrations are sleeved during precasting.

Mold precision and resultant panel precision lets everything fit quickly. Descrepancies are identified and solved to not get thrown off.

Cast in place columns and beams within wall cavity

The wall cavity is filled with chosen material to within specified inches from the top. The fill then supports cast in place concrete for the bond/spandrel beam which ties all the walls together in monolithic fashion.

Design Example

Design phase tedious but can pinpoint function of every panel. Recording the number and size of each panel for each wall generates a materials list for the totality of panels required. Any special requirements for panel inlays are specified in the part number of the panel.

Basement wall layout

Attached South wall greenhouse

A timeless enduring concept, increasing strength by decreasing the dead load of concrete. The Pantheon has survived natural calamities since 128 AD. Concrete in compression can't be beat.

Two ways to displace concrete below:

Strategic voids displace 40% of concrete

Therefore, 40% of weight and cost and carbon footprint

1-1/2" R Tech foam board R 5.78

Insulates half of the surface area for a net panel R value of 2.89. Polyiso added to the backside brings it up to any desired value.

The embedment extends to a quarter inch of the face for a depth of 1 ¾”, pull out strength 700 pounds, more or less depending on mix design, admixtures, fiber type and amount. That is over an area of 16" tall and 12" wide, or 1.33 sq ft. The pull out per sq ft is 700/1.33 =

2-1/2 Diamond and 2 diamond length of 12" wall, 8" cavity, insulation placed against longer coupler

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.