Concrete void form and method of modular construction therewith
The present specification relates generally to modular construction and more specifically to a sacrificial concrete void form and method of modular construction therewith. The concrete void form includes a steel frame having a top face, a bottom face, and four side faces, wherein at least one of the four side faces and the top face are covered with at least one sheet of corrugated steel decking. The method of modular construction includes constructing at least one concrete void form, the at least one concrete void form comprising a steel frame having a top face, bottom face and four side faces, wherein at least one of the four side faces and the top face are covered with at least one sheet of corrugated steel decking, installing the at least one concrete void form at a construction site, and pouring concrete over or adjacent to the at least one concrete void form.
1. A method of modular construction comprising:
constructing a first concrete void form, the first concrete void form comprising a vertically extending first bent steel plate and a first steel frame having a top face, bottom face and four side faces, wherein a first side face of the four side faces and the top face of the first steel frame are covered with a first sheet of corrugated steel decking, the vertically extending first bent steel plate extending inwardly with respect to the first side face of the first concrete void form;
installing the first concrete void form at a construction site;
constructing a second concrete void form, the second concrete void form comprising a vertically extending second bent steel plate and a second steel frame having a top face, bottom face and four side faces, wherein a first side face of the four side faces and the top face of the second steel frame are covered with a second sheet of corrugated steel decking, the vertically extending second bent steel plate extending inwardly with respect to the first side face of the second concrete void form;
installing the second concrete void form at the construction site adjacent to the first side face of the first steel frame and aligning the first bent steel plate with the second bent steel plate to form a rectangular columnar gap, the first side face of the second steel frame being on a proximal side of the second concrete void form with respect to the first side face of the first steel frame;
providing a rebar mat between the first concrete void form and the second concrete void form such that the rebar mat is positioned immediately between the first sheet of corrugated steel decking on the first side face of the first steel frame and the second sheet of corrugated steel decking on the first side face of the second steel frame; and
pouring concrete between the first concrete void form and the second concrete void form to allow the concrete to fill a gap between the first sheet of corrugated steel decking and the second sheet of corrugated steel decking enveloping the rebar mat and forming a rectangular concrete column between the first concrete void form and the second concrete void form with a thickness greater than a thickness of a cast-in-place concrete wall formed by pouring concrete between the first concrete void form and the second concrete void form.
2. The method of claim 1 , wherein the first and second sheets of corrugated steel decking are each formed of at least one of 16-gauge composite steel decking and 20-gauge composite steel decking.
3. The method of claim 1 , further comprising installing at least one upper concrete void form on top of the first concrete void form before the poured concrete cures.
4. The method of claim 1 , wherein the construction of the first and second concrete void forms is completed off-site of the construction site.
5. The method of claim 4 , wherein the step of constructing the first and second concrete void forms is completed in an at least one of a temperature-controlled environment and a humidity-controlled environment that is not the construction site.
6. The method of claim 1 , wherein the step of installing the second concrete void form includes affixing the second concrete void form to the first concrete void form by at least one of welding and bolting.
7. The method of claim 1 , wherein the step of installing the second concrete void form includes affixing the second concrete void form to the first concrete void form with threaded rod ties.
8. The method of claim 1 , further comprising finishing an interior of the first and second concrete void forms with at least one of steel studs, insulation, doors and trim, electrical, plumbing, HVAC, drywall, millwork, flooring, lighting and plumbing fixtures, finishes and furnishings.
9. The method of claim 1 , wherein the first steel frame and the second steel frame are each composed of at least two steel tubes and two steel beams.