WO2003021056A2

WO2003021056A2 - Construction system and method for its use

Info

Publication number: WO2003021056A2
Application number: PCT/IL2002/000732
Authority: WO
Inventors: Dani Shlezinger
Original assignee: Dani Shlezinger
Priority date: 2001-09-04
Filing date: 2002-09-04
Publication date: 2003-03-13
Also published as: AU2002330727A1; WO2003021056A3

Abstract

The present invention is a method of fabricating construction forms that become part of the finish wall or ceiling they are forming. The construction forms also include the finished surface of the wall or ceiling when construction is complete. The present invention, as described herein by example only, includes three wall form panels (exterior-façade (2), interior load bearing (30) and partition wall form panels (50)) and one ceiling panel (90), methods for their fabrication and method for their use in forming walls and ceiling/floors. While of the panels of the present invention may be used individually in conjunction with corresponding construction forms of prior art, optimum use is best achieved by using panels of the present invention as a system for constructing walls, ceilings and floors of a building.

Description

CONSTRUCTION SYSTEM AND METHOD FOR ITS USE

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to construction forms for use with fluid concrete and, in particular, it concerns forms that become part of the finish wall and also include a finished surface of the wall when construction is complete.

There are numerous ways known in the construction arts to produce forms into which fluid concrete is deployed in order to create walls, ceilings and floors for buildings. These include planks or panels made from wood, various metals, or plastic materials. In some cases, all of the form material is removed after in concrete has set and the resultant concrete surfaces are then covered with a finish material such as plaster before the wall in painted.

In other cases, some of the form material is integrated into the finished λvall and may provide some or all of the finished surface of the wall. In these cases, however, the size and shape of the pre-foπned form modules may limit the design possibilities of the wall and therefore the building of which the wall is a part.

There is therefore a need for construction forms for use with fluid concrete for creating walls, ceilings and floors, such that the form becomes part of an end product wall, ceiling or floor and provides the pre-fϊnished surface of an end product wall or ceiling. It would be advantageous if at least some the construction forms did not require any support superstructure when deployed for use in constructing a wall or ceilins. SUMMARY OF THE INVENTION

The present invention is a method of fabricating construction forms that become part of the finish wall or ceiling they are forming, the construction forms also include the finished surface of the wall or ceiling when construction is complete. According to the teachings of the present invention there is provided, a method for construction of an exterior wall, the method comprising: (a)fabricating at least one exterior-facade form panel by: (i)fabricating at least one horizontal exterior- panel-support-frame, the exterior-panel-support-frame having at least one horizontal exterior-panel suppou surface configured to support an exterior facing material, the exterior-panel-support- frame further including vertical sides substantially circumscribing horizontal exterior-panel support surface, the vertical sides extending up from the horizontal exterior-panel support surface to a vertical height greater than a thickness of the exterior facing material; (ii)placing the exterior facing material into the exterior-panel-support-frame such that the exterior facing material substantially covers the horizontal exterior-panel support surface, the exterior facing material being deployed such that a finished exterior surface of the exterior facing material abuts the horizontal exterior-panel support surface; (iii)deploying a first amount of fluid concrete into the exterior-panel-support-frame so as to substantially cover the exterior facing material with a depth of the concrete; and (iv)allowing the first amount of concrete to set; (b)providing at least one interior load bearing wall form panel; (c)creating at least a first volume for receiving a second amount of fluid concrete by deploying at least one the exterior-facade form panel and the at least one interior load bearing wall foπn panel, the exterior-facade form panel and the interior load bearing wall foπn panel being spaced a distance apart such that at least two sides of the at least a first volume are defined by at least one the exterior- facade form panel and the at least a first the interior load bearing wall panel, the exterior-facade foπri panel and the interior load bearing wall form panel being deployed such that the exterior facing material and the interior facing material are facing away from the at least a first volume; (d)substantially filling at least the first volume with the second amount of concrete; (e)al lowing the second amount of concrete to set, thereby interconnecting at least the exterior-facade form panel and the second amount of concrete so as to creating the exterior wall; and (f)removing the horizontal exterior- panel-support-frame from the exterior-facade foπn panel, thereby exposing the exterior facing material which is now a finished exterior-facade surface. According to a further teaching of the present invention, the interior load bearing wall form panel is implemented by: (a)fabricating at least one ihterior-load- bearing-panel-support-frame, the interior-load-bearing-panel-support-frame having an interior-facing-material support surface configured to support an interior facing material in a substantially vertical deployment; (b)placing the interior facing material onto the interior- facing-material support surface and securing the interior facing material in place.

There is also provided according to the teachings of the present invention, removing the interior-load-bearing-panel-support-frame from the interior facing material w<fιich is now a substantially finished wall surface. According to a further teaching of the present invention, the fabricating at least one exterior-facade foπτι panel further comprises foπning window openings and doorway openings during the placing of the exterior facing material into the exterior- panel-support-frame by, deploying an appropriate opening support form onto the horizontal exterior-panel support surface and using vertical surfaces of the opening support foπn to support an amount of exterior facing material so as to extended vertically from the horizontal exterior-panel support surface to a vertical height substantially equal to a required thickness of the exterior wall minus a combined thickness of the exterior- facade form panel and the interior load bearing wall foπn panel so as to define: (a)for windows, a top, a bottom and sides of the window opening; (b)for doorways, a top and sides of the doorway opening.

There is also provided according to the teachings of the present invention, removing the interior facing material from the area of the window openings and the doorway openings.

According to a further teaching of the present invention, the at least one horizontal exterior-panel support surface is implemented as a plurality of spaced apart support surface elements deployed so as to support the exterior facing material by coming into contact with only a portion of the exterior facing material.

According to a further teaching of the present invention, the exterior facing material is implemented as panels chosen from a group including stone, wood, glass, metal, and textured pre-cast concrete.

According to a further teaching of the present invention, the interior facing material is implemented as panel chosen from a group including gypsum board, wood, and composite board.

According to a further teaching of the present invention, the deploying a first amount of fluid concrete into the exterior-panel-support-frame further includes foπning at least two concrete spacers, the spacers being foπried to a vertical height substantially corresponding to a thickness of the wall minus a combined thickness of the exterior-facade foπn panel and the interior load bearing wall form panel.

There is also provided according to the teachings of the present invention, foπning the concrete spacers with attachment points so as the accommodate attachment to a hoisting mechanism.

There is also provided according to the teachings of the present i 'ention, vibrating the exterior-panel-support-frame after the first amount of concrete is deployed so as to settle the first amount of concrete. According to a further teaching of the present invention, the fabricating at least one exterior-facade foπτι panel further comprises removing the exterior-facade foπn panel from the exterior-panel-support-frame, thereby exposing the finished exterior- facade surface.

There is also provided according to the teachings of the present invention, hingedly connecting the exterior-panel-support-frame to a support structure such that the exterior-panel-support-frame is rotatable between a horizontal position and a vertical position.

According to a further teaching of the present invention, the removing the exterior-facade form panel is accomplished by rotating the exterior-panel-support- frame from the horizontal position to the vertical position and attaching the exterior- facade fomi panel to a hoisting mechanism. The method of claim 1, wherein the fabricating at least one exterior- facade foπn panel further comprises affixing a plurality of nuts to the exterior-facade fomi panel so as to be unseen from the finished exterior-facade surface.

According to a further teaching of the present invention, the creating at least a first volume further comprises passing a plurality of bolts through the interior load bearing wall fomi panel such that each of the plurality of bolts^' engages a corresponding one of the plurality of nuts, thereby interconnecting the interior load bearing wall fom panel and the exterior-facade form panel.

According to a further teaching of the present invention, the fabricating at least one exterior-facade foπn panel further comprises forming an outside comer as an integral part of a single the exterior- facade foπn panel.

According to a further teaching of the present invention, the fabricating the horizontal exterior-panel-support-frame further comprises interconnecting a combination of at least one standardized exterior-panel-support-frame member and at least one custom fabricated exterior-panel-support-frame member.

According to a further teaching of the present invention, the fabricating the exterior-facade foπn panel and the interior load bearing wall form panel is accomplish at a building site.

According to a further teaching of the present invention, dimensions of the exterior-facade foπn pane and the interior load bearing wall form panel are established by architectural plans.

According to a further teaching of the present invention, there is also provided a method for construction of an exterior wall, the method comprising: (a)providing at least one exterior foπn panel by; (b)fabricating at least one interior load bearing wall form panel by: (i)fabricating at least one interior-load-bearing-panel-support-frame, the interior-load-bearing-panel-support-frame having at least one interior- facing- material support surface configured to support an interior facing material in a substantially vertical deployment; (ii)placing the interior facing material onto the interior-facing-material support surface and securing the interior facing material in place; (c)creating at least a first volume for receiving a first amount of fluid concrete by deploying at least one the exterior form panel and at least one the interior load bearing wall form panel, the exterior form panel and the interior load bearing wall form panel being spaced a distance apart such that at least two sides of the at least a first volume are defined by at least one the exterior foπn panel and the at least a first the interior load bearing wall panel, the interior load bearing wall forcn panel being deployed such that the interior facing material are facing away from the at least a first volume; (d)substantially filling at least the first volume with the first^' amount of concrete; (e)allowing the first amount of concrete to set, thereby interconnecting at least the interior load bearing wall form panel and the second amount of concrete so as to creating the exterior wall; and (f)removing the interior-load-bearing-panel- support- frame from the interior facing material which is now a substantially finished wall surface.

According to a further teaching of the present invention, the exterior form panel is implemented by fabricating at least one exterior-facade form panel by: (a)fabricating at least one horizontal exterior-panel-support-frame, the exterior-panel- support- frame having at least one horizontal exterior-panel support surface configured to support an exterior facing material, the exterior-panel-support-frame further including vertical sides substantially circumscribing horizontal exterior-panel support surface, the vertical sides extending up from the horizontal exterior-panel support surface to a vertical height greater than a thickness of the exterior facing material; (b)placing the exterior facing material into the exterior-panel-support-frame such that the exterior facing material substantially covers the horizontal exterior- panel support surface, the exterior facing material being deployed such that a finished exterior surface of the exterior facing material abuts the horizontal exterior-panel support surface; (c)deploying a first amount of fluid concrete into the exterior-panel- support-frame so as to substantially cover the exterior facing material with a depth of the concrete; and (d)allowing the first amount of concrete to set.

According to a further teaching of the present invention, the at least one interior- facing-material support surface is implemented as a plurality of spaced apart support surface elements deployed so as to support the interior facing material by coming into contact with only a portion of the interior facing material. According to a further teaching of the present invention, the interior facing material is implemented as panel chosen from a group including gypsum board, wood, and composite board.

According to a further teaching of the present invention, the fabricating at least one exterior- facade foπn panel further comprises affixing a plurality of nuts to the exterior-facade foπxi panel so as to be unseen from the finished exterior-facade surface.

According to a further teaching of the present invention, the creating at least a first volume further comprises passing a plurality of bolts through the interior load bearing wall fom panel such that each of the plurality of bolts engages a coπesponding one of the plurality of nuts, thereby interconnecting the interior load bearing wall form panel and the exterior- facade fomi panel.

According to a further teaching of the present invention, the fabricating at least one interior-load-bearing-panel-support-frame further comprises interconnecting a combination of at least one standardized interior-load-bearing- panel-support-frame member and at least one custom fabricated interior-load- bearing-panel-support-frame member.

According to a further teaching of the present invention, the fabricating the interior load bearing wall form panel is accomplish at a building site. According to a further teaching of the present invention, dimensions of the exterior- facade form pane and the interior load bearing - wall form panel are established by architectural plans.

According to a further teaching of the present invention, there is also provided a method for construction of an interior load bearing wall, the method comprising: (a)fabricating at least one interior load bearing wall fom panel by: (i)fabricating at least an interior-load-bearing-panel-support-frame, the interior-load-bearing-panel- support-frame having an interior-facing-material support surface configured to support an interior facing material in a substantially vertical deployment; (ii)placing the interior facing material onto the interior-facing-material support surface and securing the interior facing material in place; (b)providing at least a second wall foπn panel; (c)creating at least a first volume for receiving an amount of fluid concrete by deploying at least one the interior load bearing wall foπn panels so as to be spaced a distance apart from the at least a second w-all fomi panel such that at least two sides of the at least a first volume are defined by at least one the interior load bearing wall panels and the at least a second wall foπn panel, the interior load bearing wall fomi panel being deployed such that the interior facing material is facing away from the at least a first volume; (d)substantially filling at least the first volume with the amount of concrete; (e)allowing the concrete to set, thereby interconnecting at least the at least one interior load bearing wall foπn panels and the amount of concrete so as to creating the interior load bearing wall; and (f)removing of the at least one interior- load-bearing-panel-support- frame from the interior facing material of the at least one interior load bearing wall foπn panel such that the interior facing material is now substantially a finished wall surface of the interior load bearing wall.

According to a further teaching of the present invention, the at least one interior-facing-material support surface is implemented as a plurality of spaced apart support surface elements deployed so as to support the interior facing material by coming into contact with only a portion of the interior facing material.

According to a further teaching of the present invention, the fabricating at least one interior load bearing wall foπn panel further comprises foπning window openings by affixing suitable foπn material to either one of the at least one interior load bearing wall fomi panels and the at least a second wall foπn panel before the at least a first volume is created so as to define a top, a bottom and sides of the window opening, the foπn material extending from the either one of the at least one interior load bearing wall foπn panel and the at least a second wall foπn panel toward a corresponding other of the at least one interior load bearing wall foπn panel and the at least a second wall foπn panel to a distances great enough to close a gap between the at least one interior load bearing wall form panel and the at least a second wall form panel such that when the at least a first volume is created, a sealed cavity into which substantially no fluid concrete may flow is also created, thereby defining the window opening. There is also

according to the teachings of the present invention, removing the interior facing material from the cavity after the concrete is set, thereby exposing the window opening.

According to a further teaching of the present invention, the fabricating at least one interior load bearing wall foπn panel further comprises foπning doorway openings by affixing suitable form material to either one of the at least one interior load bearing wall foπn panel and the at least a second wall foπn panel before the at least a first volume is created so as to define a top and sides of the doorway opening, the form material extending from the either one of the at least one interior load bearing wall foπn panel and the at least a second wall form panel tow^rard a corresponding other of the at least one interior load bearing λvall foπn panel and the at least a second wall foπn panel to a distances great enough to close a gap between the at least one interior load bearing wall foπn panel and the at least a second wall foπn panel such that when the at least a first volume is created, a sealed cavity into which substantially no fluid concrete may flow is also created, thereby defining the doorway opening.

There is also provided according to the teachings of the present invention, removing the interior facing material from the cavity after the concrete is set, thereby exposing the doorway opening. According to a further teaching of the present i -ention, the fabricating at least one interior-load-bearing-panel-support-frame further comprises interconnecting a combination of at least one standardized interior-load-bearing- panel-support-frame member and at least one custom fabricated interior-load- bearing-panel-support- frame member. According to a further teaching of the present invention, the fabricating the at least two interior load bearing wall fomi panels is accomplish at a building site.

There is also provided according to the teachings of the present invention, establishing dimensions of the at least two interior load bearing wall foπri panels from architectural plans. According to a further teaching of the present invention, there is also provided a method for construction of an interior partition wall, the method comprising: (a)fabricating at least one interior partition wall form panel by: (i)fabricating at least one horizontal interior-partition-panel support frame, the interior-partition-panel support frame having a at least one horizontal interior-partition-panel support surface configured to support an interior facing material, the interior-partition-panel support frame further including vertical sides substantially circumscribing horizontal interior- partition-panel support surface, the vertical sides extending up from the horizontal interior-partition-panel support surface to a vertical height greater than a thickness of the interior facing material; (ii)placing the interior facing material into the interior- partition-panel-support-frame such that the interior facing material substantially covers the horizontal interior-partition-panel support surface, the interior facing material being deployed such that a finished exterior surface of the interior facing material abuts the horizontal interior-partition-panel support surface; (iii)deploying a first amount of fluid concrete into the interior-partition-panel-support-frame so as to substantially cover the interior facing material with a depth of the concrete; and (iv)allowing the first amount of concrete to set; (b)creating at least a first volume for receiving a second amount of fluid concrete by deploying at least one the interior partition wall foπn panel and at least a second w^?all foπn panel so as to be spaced a distance apart such that at least two sides of the at least a first volume are defined by at least one the interior partition wall panel and the second wall foπn panel, the interior partition wall form panels being deployed such that the interior facing material of the interior partition wall foπn panels is facing away from the at least a first volume; (c)substantially filling at least the first volume with the second amount of concrete; (d)allowing the concrete to set, thereby interconnecting at least the one interior partition wall foπn panels and the second amount of concrete so as to creating the interior partition wall; and (e)removing the interior-partition-panel support frame from the interior facing material which is now substantially finished wall surface on the interior partition wall.

There is also provided according to the teachings of the present invention: (a)deploying non-load bearing construction material onto a surface of the first amount of concrete, before the concrete is set, the non-load bearing construction material substantially covering an area to a depth, the area and the depth being established by architectural plans; and (b)allowing set first amount of concrete to set, thereby affixing the non-load bearing construction material to the surface of the first amount of concrete.

According to a further teaching of the present invention, the fabricating at least one interior-partition-panel support frame further comprises Interconnecting a combination of at least one standardized interior-partition-panel support frame member and at least one custom fabricated interior-partition-panel support frame member.

The method of claim 39, wherein the fabricating the at least two interior partition wall fomi panels is accomplish at a building site.

There is also provided according to the teachings of the present invention, establishing dimensions of the at least two interior partition wall foπn panels from architectural plans.

According to a further teaching of the present invention, there is also provided a method for constructing a ceiling and floor, the method comprising: (a)fabricating at least one ceiling panel by; (i)fabricating at least one horizontal ceiling-panel support frame, the ceiling-panel support frame having a horizontal ceiling-panel support surface configured to support the ceiling panel, the ceiling-panel support frame further including vertical sides substantially circumscribing horizontal ceiling- panel support surface, the vertical sides extending up from the horizontal ceiling- panel support surface to a vertical height equal to or greater than a thickness of the ceiling panel; (ii)deploying a first amount of fluid concrete into the interior-partition- panel-support-frame so as to substantially cover the horizontal ceiling-panel support surface with a depth of the concrete; and (iii)allowing the first amount of concrete to set; (iv)removing the ceiling panel from the horizontal ceiling-panel support frame thereby exposing a finished ceiling surface; (b)deploying at least one the ceiling panel so as to substantially cover an area requiring a ceiling, each of the at least one ceiling panels being deployed with the finished ceiling surface facing substantially- downward, each of the at least one ceiling panels being supported by at least one wall such that each the at least one ceiling panels extends over at least a part of at least one room; (c)erecting a border around a periphery of the at least one ceiling panel, the border extending vertically to a height equal to or greater than a required thickness of the floor; (d)deploying at least a second amount of fluid concrete so as to substantially fill the area within the border to the required thickness; and (e)allowing the concrete to set, thereby creating the floor. There is also provided according to the teachings of the present invention:

(a)placing interior facing material into the ceiling-panel support frame such that the interior facing material substantially covers areas of the ceiling-panel that will exposed when the ceiling-panel is deployed and leaving uncovered areas that will adjoin the support walls, the interior facing material being deployed such that a finished exterior surface of the interior facing material abuts the horizontal ceiling- panel support surface; (b)deploying a third amount of fluid concrete into the ceiling- panel-support-frame so as to substantially cover the interior facing material with a depth of the concrete; and (c)allθλving the third amount of concrete to set.

There is also provided according to the teachings of the present invention, deployment of at least one re-enforcement member such that a first portion of the re- enforcement member is encased in the first amount of concrete and a second portion of the re-enforcement member is encased in the second amount of concrete.

According to a further teaching of the present invention, the at least one re- enforcement member is implemented as a plurality of substantially parallel spaced apart re-enforcement members.

According to a further teaching of the present invention, there is also provided an exterior-facade foπn panel for construction of an exterior wall, the exterior- facade form panel comprising: (a)a first, outward facing, layer consisting of at least one exterior facing material element; and (b)a second layer consisting of rigid material configured to secure the first layer and add rigidity and strength to the panel; wherein the panel is used as a fom as fluid concrete is pour to construct the exterior wall, and becomes the finish exterior facade when the concrete sets.

According to a further teaching of the present invention, the second layer is concrete that is deployed onto the first layer in a fluid state and allowed to set. According to a further teaching of the present invention, there is also provided an interior load bearing wall form panel for constructing load bearing walls, the interior load bearing wall form pane comprising: (a)an interior-load-bearing-panel- support-frame; and (b)a layer of interior facing material releasably attached to the frame in a substantially vertical deployment; wherein the panel is used as a form as fluid concrete is pour to construct the load bearing wall, and when the concrete sets and the frame is removed the interior facing material becomes a finish surface of the wall.

According to a further teaching of the present invention, there is also provided an interior partition wall foπn panel for constructing an interior partition wall, the panel comprising: (a)an interior-partition-panel support frame: (b)a first layer consisting of interior facing material: and (c)a second layer consisting of rigid material configured to add rigidity and strength to the panel: wherein the panel is used as a form as fluid concrete is pour to construct the load bearing wall, and when the concrete sets and the frame is removed the interior facing material becomes a finish surface of the wall. There is also provided according to the teachings of the present invention, a third layer of non-load bearing construction material.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein: FIG. 1 is side elevation of a horizontal exterior-panel-support-frame constructed and operative according to the teachings of the present invention, shown here supported by a construction table;

FIG. 2 is a cross-sectional top view of an exterior-facade foπn panel constructed and operative according to the teachings of the present invention; FIG. 3 is a cross-sectional top view of an outside comer of an exterior-facade form panel constructed and operative according to the teachings of the present invention;

FIG. 4 is a cross-sectional side view of an exterior-facade form panel constructed and operative according to the teachings of the present invention; FIGs. 5-7a are perspective views and corresponding cross-sectional side views of three alternative methods of finishing the seam between two vertically adjoining exterior-facade foπn panels constructed and operative according to the teachings of the present invention; FIG. 8 is a side elevation of interior-load-bearing-panel-sυpport-frame constructed and operative according to the teachings of the present Invention;

FIG. 9 is a cross-sectional side detail of two corresponding interior partition Λvall form panels constructed and operative according to the teachings of the present invention; FIG. 10 is a side elevation of an interior-load-bearing-panel-support-frame deployed for constructive use;

FIG. 1 1 is a cross-sectional side view of a ceiling-panel shown here supporting a floor;

FIG. 12 is a detail of FIG. 11 , showing ceiling support elements constructed and operative according to the teachings of the present invention;

FIG. 13 is a top elevation of a ceiling panel constmcted and operative according to the teachings of the present invention;

FIG. 14 is a partial top elevation of an alternative ceiling panel constmcted and operative according to the teachings of the present invention; FIG. 15 is an illustration of a ceiling panel constructed and operative according to the teachings of the present invention being hoisted into position;

FIG. 16 is a cross-sectional side detail of the joint between and exterior wall and a ceiling/floor constmcted and operative according to the teachings of the present invention; FIG. 17 is a cross-sectional side detail of the joint between and interior wall and a ceiling/floor constmcted and operative according to the teachings of the present invention; and

FIG. 18 is a top elevation of a plurality of foπn panels constructed and operative according to the teachings of the present invention, deployed for use in constructing the walls of a building. DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is a method of fabricating construction foπns that become part of the finish wall or ceiling they are forming, the construction foπns also include the finished surface of the w^rall or ceiling when construction is complete. The principles and operation of fabricating construction forans according to the present invention may be better understood with reference to the drawings and the accompanying description.

By λvay of introduction, the present invention, as described herein by example only, includes three wall foπn panels (exterior-facade, interior load bearing and partition wall form panels) and one ceiling panel, methods for their fabrication and method for their use in foπriing walls and ceiling/floors. While of the panels of the present invention may be used individually in conjunction with corresponding construction foπns of prior art, optimum use is best achieved by using panels of the present invention in conjunction with the corresponding panels of the present invention as a system for constructing walls, ceilings and floors of a building, as Illustrated in Figure 18.

Referring now to the exterior-facade foπn panel (Fig. 2) 2, its fabrication and use as a construction form. The exterior-facade foπn panel 2 is fabricated by first fabricating an exterior-panel-support-frame 4 that defines the exterior dimensions of the panel as per architectural plans and requirements. It should be noted that all of the support frames described herein, but non-limiting example, may be fabricated from pre-configured standardized frame elements 80 used in conjunction with any custom configured frame elements 82 needed to meet the requirements of the foπn panel being fabricated. Further, all of the support frames may be constmcted of welded together square tubular materials. The exterior-panel-support-frame 4 is configured for use in a horizontal attitude with a horizontal support surface 6 configured to support the desired exterior facing material. The choices of exterior facing material may include, but not limited to, elements or panels made of stone, wood, metal, glass, and textured pre-cast concrete. The support surface 6 may be a single contiguous surface or more preferably, as in the preferred embodiment described herein. configured as a plurality of spaced apart support elements. The support elements are spaced apart at intervals appropriate for the choice of exterior facing material. In the case of rectangular stone panels all of substantially equal size, for example, the support elements might be spaced so as to support the stone panels along two opposite edges. The exterior facing material is placed on the support surface with the finish exterior surface against the support surface. Once the exterior facing material is placed on the horizontal support surface 6, vertical side foπns 8 are attached to the support frame 4 so as to substantially circumscribe the area cover by the exterior facing material. Abutment joints between exterior facing material panel are sealed by any known method such as chalking or tape. Any required constmction elements such as attachment nuts 20 (Figures 2 and 3) may be deployed, and concrete spacers 22 (Figures 2 and 4) any be foπned. When a window or doorway opening is required, an appropriately shaped form blank is deployed on the support surface instead of exterior facing material. Exterior facing material is then supported by vertical surfaces of the form blank such that the exterior facing material extend upward to a height substantially equal to the distance between the exterior-facade foπn panel and the corresponding interior load bearing wall foπxi panel which will be used later in foπning the exterior wall. Fluid concrete is then poured onto the exterior facing material so as to substantially cover the entire area of exterior facing material to a desired depth, preferably 4 cm. The frame is the vibrated using any appropriate device in order to settle and solidify the fluid concrete. The concrete is then allowed to set.

Once the concrete in hard, the exterior-facade form panel in removed from the support frame. As illustrated in Figure 1, this is accomplished by tilting the support frame 4, or alternatively the support table top, to a substantially vertical attitude 12 . The exterior-facade foπn panel is attached to a hoisting mechanism and lifted out of the support frame, thereby exposing the finished exterior surface of the exterior- facade. It should be noted that the support frame may alternative be left in place on the foπn panel until after completion of the exterior wall. An illustration of a hoist mechanism being used in conjunction with a ceiling panel 90 is shown in Figure 15. Turning now to the fabrication of interior wall form panels of the present invention, λvhich include interior load bearing wall fom panels 30 and interior partition wall panels 50. Both type of interior wall form panels, may be configured with interior facing material chosen foπn, by non-limiting example, panels made of wood, gypsum board (as in the preferred embodiment described herein), composite or pressed board, or plywood.

In the case of an interior load bearing wall foπn panel 30, the interior facing material 32 is deployed onto a support frame 40 such as the one illustrated, by non- limiting example, in Figure 8. The support frame has exterior dimension as per the architectural plans and requirements. Spaced along the bottom edge of the support frame 40 are leveling feet 42 used to compensate for any un-levelness in the surface on which the support frame is deployed. The interior facing material is anchored to the frame and further re-enforced by the attachment of spaced apart re-enforcement ribs 34, some of the attachment screws of which past through the support frame 40 and the interior facing material 30 so as to sandwich the interior facing material 30 between the support frame 40 and the re-enforcement ribs 34. The substantially vertical surface of the support frame may be configured as a single contiguous surface or more preferably, as in the preferred embodiment described herein, as a plurality of, preferably parallel, spaced apart support surface elements 44, thereby exposing a portion of the finished surface 30' of the interior facing material 30. This open configuration allows access to the surface of the facing- material for placement of, by non-limiting example, electrical and telephone jack boxes and the like.

Interior partition fomi panels 50, as seen in Figure 9, are fabricated with a layered combination of interior facing material 52 and concrete 54, so they are fabricated on a support frame similar to the support frame of figure 8, however there is a step of deploying the support frame in a horizontal attitude. With the support frame positioned horizontally, the interior facing material in place in the frame and a border in erected around the periphery of the support frame. A layer, preferably 4 cm., of concrete is applied to the facing material. While the concrete is still in a fluid state, any required non-load bearing constmction material 56, such as but not limited to, rigid foam panels, cinder or porous concrete blocks, or "Itung", may be placed as required on the concrete layer 54, becoming fixed to the panel 50 when the concrete 54 sets.

When deployed for constructive use, both types of interior wall foπn panels are supported in a vertical attitude by any known style of adjustable support bar 70, as illustrated in Figure 10.

Ceiling panels 90 may be fabricated with or without integral interior facing material 92 configured so as to provide a finished ceiling surface in any room over which the ceiling panel is deployed.

In the case of a ceiling panel fabricated without interior facing material, Fluid concrete is poured into a form frame to a predeteπnined depth, preferably 2 cm.. Support trusses 100 configured to span one dimension of the ceiling panel 90 are placed into the fluid concrete 94 at spaced apart intervals, such that a portion of each truss is encased in the concrete so as to become fixed when the concrete sets. Figure 12 shows a cross section of a non-limiting example of a t ss, part of which is encased in the concrete layer 94 of the ceiling panel 90. The three bars 102, 104, and 106 run the length of the tmss and support bar 108 is one of a plurality of such support bars interconnecting the three bars 102, 104, and 106 along their length. Bars 102 and 104 are encased in the concrete layer 94 of the ceiling panel 90.

Figure 14 illustrates a top view of a ceiling panel 120 with integral interior facing material 92. Here, additional support ribs 122 are shown alternating with support trusses 100 along the length of the ceiling panel 120.- In this case the ceiling panel is fabricated by first placing the interior facing material into a form frame, and abutment seams are sealed. Support ribs 122 are attached and support trusses 100 deployed as per architectural plans. A layer of concrete 94 is poured into the foπn frame so as to cover the interior facing material92 , preferably to a depth of 2 cm.

In both cases, once the concrete is set, the ceiling panel 90 is ready to be hoisted into position as illustrated in Figure 15.

To construct an exterior wall 150 using the exterior facade from panels 2 and interior load bearing wall foπn panels 30 of the present invention, either of the foπn panels may be deployed first, however, for the ease of discussion here in, the interior load bearing wall form panel 30 is placed first. The interior panel 30 may be supported by adjustable support bars 70 as discussed with regard to Figure 10. Any required electrical, plumbing, or air conditioning elements necessary may be attached to the backside of the interior foπn panel 30 along with any required re-enforcing bars or netting. The exterior-facade foπn panel 2 is hoisted into position and it may be attached to the interior foπn panel 30 by. as a non-limiting example, bolts 152 which pass through the interior load bearing wall foπn panel 30 and interior support frame 40 and screw into bolts 20 (Figures 2, 3, and 4). Once all necessary foπn panels are in place, fluid concrete is pour into the volume 154 between the foπn panels and allowed to set. At this point, the finished exterior facade is already exposed. Once the concrete hardens, the interior support frame 40 is removed from the interior side of the wall, thereby revealing the finish interior wall surface, which requires little if any substantially labor intensive finish work, as is require with poured concrete walls of prior art.

Figure 3 illustrates that outside comers 160 may be formed as an integral part of a single form panel, as shown here with regard to an exterior- facade foπn panel 2.

As shown in Figure 4, the exterior-facade form panels 2 and 2' of successive stories of a build are stacked one on the other leaving a seam gap 170. Figures 5-7a illustrate three design alternatives for this gap of, for example, 1 cm. in height.

Figures 5 and 5a suggest leaving the seam gap 170 untouched. Figures 6 and 6a suggest including the seam gap 170 as part of a decorative recess 172, and Figures 7 and 7a suggest a decorative protruding rim 174 that helps to camouflage the seam gap- Figure 16 illustrates a preferred deployment of a ceiling panel 90 on an exterior wall 180 such that the interior facing material 92 of the ceiling panel 90 overlaps the interior facing material 182 of the wall 180. Figure 17 illustrates a preferred deployment of a ceiling panel 90 on an interior wall 186. It should be noted here, that the w^rall illustrated in Figure 17 is formed using an interior partition wall foπn panel 50 in conjunction with an interior load bearing wall form panel 30, thereby showing the versatility afforded by the uses of all of the form panels of the present invention when constructing a building. Figures 4 and 11 show substantially finished floors constructed by pouring fluid concrete onto the top surface 190 of the ceiling panels 90 to a required depth. Both Figures show the support trasses 100 fully encased in the concrete used to fabricate the ceiling panel and the concrete used to construct the floor 200. Figure 4 also illustrates an alternative comer cornice 210 that may be added as part of the wall or as a separated piece add after constmction is finished if it is desired at all.

It will be appreciated that the above descriptions are intended only to serve as examples, and that many other embodiments are possible within the spirit and the scope of the present invention.

Claims

WHAT IS CLAIMED IS:

1. A method for constmction of an exterior wall, the method comprising:

(a) fabricating at least one exterior- facade fom panel by:

(i) fabricating at least one horizontal exterior-panel-support- frame, said exterior-panel-support-frame having at least one horizontal exterior-panel support surface configured to support an exterior facing material, said exterior-panel- support-frame further including vertical sides substantially circumscribing horizontal exterior-panel support surface, said vertical sides extending up from said horizontal exterior-panel support surface to a vertical height greater than a thickness of said exterior facing material;

(ii) placing said exterior facing material into said exterior- panel-support-fraine such that said exterior facing material substantially covers said horizontal exterior-panel support surface, said exterior facing material being deployed such that a finished exterior surface of said exterior facing material abuts said horizontal exterior-panel support surface;

(iii) deploying a first amount of fluid concrete into said exterior-panel-support-frame so as to substantially cover said exterior facing material with a depth of said concrete; and

(iv) allowing said first amount of concrete to set;

(b) providing at least one interior load bearing wall form panel;

(c) creating at least a first volume for receiving a second amount of fluid concrete by deploying at least one said exterior-facade form panel and said at least one interior load bearing wall form panel, said exterior-facade foπn panel and said interior load bearing wall foπn panel being spaced a distance apart such that at least two sides of said at least a first volume are defined by at least one said exterior-facade foπn panel and said at least a first said interior load bearing wall panel, said exterior-facade foπn panel and said interior load bearing λvall form panel being deployed such that said exterior facing material and said interior facing material are facing away from said at least a first volume;

(d) substantially filling at least said first volume with said second amount of concrete;

(e) alloλving said second amount of concrete to set, thereby interconnecting at least said exterior-facade form panel and said second amount of concrete so as to creating the exterior wall; and

(f) removing said horizontal exterior-panel-support-frame from said exterior-facade foπn panel, thereby exposing said exterior facing material which is now a finished exterior- facade surface.

2. The method of claim 1, wherein said interior load bearing wall form panel is implemented by:

(a) fabricating at least one interior-load-bearing-panel-support-frame, said interior-load-bearing-panel-support- frame having an interior- facing-material support surface configured to^" support an interior facing material in a substantially vertical deployment;

(b) placing said interior facing material onto said interior-facing- material support surface and securing said interior facing material in place;

3. The method of claim 2, further comprising removing said interior- load-bearing-panel-support-frame from said interior facing material which is now a substantiallv finished wall surface.

4. The method of claim 1, wherein said fabricating at least one exterior- facade foπn panel further comprises foπning window openings and doorway openings during said placing of said exterior facing material into said exterior- panel-support-frame by, deploying an appropriate opening support form onto said horizontal exterior-panel support surface and using vertical surfaces of said opening support foπn to support an amount of exterior facing material so as to extended vertically from said horizontal exterior-panel support surface to a vertical height substantially equal to a required thickness of the exterior wall minus a combined thickness of said exterior- facade foπn panel and said interior load bearing wall foπn panel so as to define:

(a) for windows, a top, a bottom and sides of said window opening;

(b) for doorways, a top and sides of said doorway opening;

5. The method of claim 4, further comprising removing said interior facing material from the area of said window openings and said doorway openings.

6. The method of claim 1, wherein said at least one horizontal exterior- panel support surface is implemented as a plurality of spaced apart support surface elements deployed so as to support said exterior facing material by coming into contact with only a portion of said exterior facing material.

7. The method of claim 1, wherein said exterior facing material is implemented as panels chosen from a group including stone, wood, glass, metal, and textured pre-cast concrete.

8. The method of claim 2, wherein said interior facing material is implemented as panel chosen from a group including gypsum board, wood, and composite board.

9. The method of claim 1, wherein said deploying a first amount of fluid concrete into said exterior-panel-support-frame further includes foπning at least two concrete spacers, said spacers being foπned to a vertical height substantially corresponding to a thickness of the wall minus a combined thickness of said exterior- facade foπn panel and said interior load bearing wall foπn panel.

10. The method of claim 9, further including forming said concrete spacers with attachment points so as the accommodate attachment to a hoisting mechanism.

11. The method of claim 1, further comprising vibrating said exterior- panel-support-frame after said first amount of concrete is deployed so as to settle said first amount of concrete.

12. The method of claim 1, wherein said fabricating at least one exterior- facade foπn panel further comprises removing said exterior- facade foπn panel from said exterior-panel-support-frame, thereby exposing said finished exterior-facade surface.

13. The method of claim 12, further including hingedly connecting said exterior-panel-support-frame to a support structure such that said exterior- panel-support-frame is rotatable between a horizontal position and a vertical position.

14. The method of claim 13, wherein said removing said exterior- facade foπn panel is accomplished by rotating said exterior-panel-support-frame from said horizontal position to said vertical position and attaching said exterior- facade foπn panel to a hoisting mechanism.

15. The method of claim 1, wherein said fabricating at least one exterior- facade foπn panel further comprises affixing a plurality' of nuts to said exterior- facade foπn panel so as to be unseen from said finished exterior-facade surface.

16. The method of claim 15, wherein said creating at least a first volume further comprises passing a plurality of bolts through said interior load bearing wall foπn panel such that each of said plurality of bolts engages a corresponding one of said plurality of nuts, thereby interconnecting said interior load bearing wall foπn panel and said exterior-facade foπn panel.

17. The method of claim 1 , wherein said fabricating at least one exterior- facade foπn panel further comprises forming an outside comer as an integral part of a single said exterior- facade form panel.

18. The method of claim 1 , wherein said fabricating said horizontal exterior-panel-support-frame further comprises interconnecting a combination of at least one standardized exterior-panel-support-frame member and at least one custom fabricated exterior-panel-support-frame member.

19. The method of claim 18, wherein said fabricating said exterior- facade foπn panel and said interior load bearing wall foπn panel is accomplish at a building site.

20. The method of claim 1. wherein dimensions of said exterior- facade foπn pane and said interior load bearing wall foπn panel are established by architectural plans.

21. A method for constmction of an exterior wall, the method comprising:

(a) providing at least one exterior form panel by; (b) fabricating at least one interior load bearing wall form panel by (i) fabricating at least one interior-load-bearing-panel- support-frame, said interior-load-bearing-panel-support- frame having at least one Interior- facing-material support surface configured to support an interior facing material in a substantially vertical deployment;

(ii) placing said interior facing material onto said interior- facing-material support surface and securing said interior facing material in place;

(c) creating at least a first volume for receiving a first amount of fluid concrete by deploying at least one said exterior foπn panel and at least one said interior load bearing wall foπn panel, said exterior form panel and said interior load bearing wall foπn panel being spaced a distance apart such that at least two sides of said at least a first volume are defined by at least one said exterior foπn panel and said at least a first said interior load bearing wall panel, said interior load bearing w^rall foπn panel being deployed such that said interior facing material are facing away from said at least a first volume;

(d) substantially filling at least said first volume with said first amount of concrete; and

(e) allowing said first amount of concrete to set, thereby interconnecting at least said interior load bearing wall form panel and said second amount of concrete so as to creating the exterior wall;

(f) removing said interior-load-bearing-panel-support-frame from said interior facing material which is now a substantially finished wall surface.

22. The method of claim 21, wherein said exterior foπn panel is implemented by fabricating at least one exterior-facade form panel by: (a) fabricating at least one horizontal exterior-panel-support-frame, said exterior-panel-support-frame having at least one horizontal exterior-panel support surface configured to support an exterior facing material, said exterior-panel-support-frame further including vertical sides substantially circumscribing horizontal exterior-panel support surface, said vertical sides extending up from said horizontal exterior-panel support surface to a vertical height greater than a thickness of said exterior facing material;

(b) placing said exterior facing material into said exterior-panel- support-frame such that said exterior facing material substantially coλ'ers said horizontal exterior-panel support surface, said exterior facing material being deployed such that a finished exterior surface of said exterior facing material abuts said horizontal exterior-panel support surface;

(c) deploying a first amount of fluid concrete into said exterior- panel-support-frame so as to substantially cover said exterior facing material with a depth of said concrete; and

(d) allowing said first amount of concrete to set.

23. The method of claim 21, wherein said at least one interior-facing- material support surface is implemented as a plurality' of spaced apart support surface elements deployed so as to support said interior facing material by- coming into contact with only a portion of said interior facing material.

24. The method of claim 21 , wherein said interior facing material is implemented as panel chosen from a group including gypsum board, λvood, and composite board.

25. The method of claim 22, wherein said fabricating at least one exterior- facade form panel further comprises affixing a plurality of nuts to said exterior-facade form panel so as to be unseen from said finished exterior- facade surface.

26. The method of claim 23, wherein said creating at least a first volume further comprises passing a plurality of bolts through said interior load bearing wall form panel such that each of said plurality of bolts engages a corresponding one of said plurality of nuts, thereby interconnecting said interior load bearing wall foπn panel and said exterior-facade foπn panel.

27. The method of claim 21, wherein said fabricating at least one interior-load-bearing-panel-support-frame further comprises interconnecting a combination of at least one standardized interior-load-bearing-panel-support- frame member and at least one custom fabricated interior-load-bearing-panel- support-frame member.

28. The method of claim 27, wherein said fabricating said interior load bearing wall foπn panel is accomplish at a building site.

29. The method of claim 21, wherein dimensions of said exterior- facade form pane and said interior load bearing wall form panel are established by architectural plans.

30. A method for constmction of an interior load bearing wall, the method comprising:

(a) fabricating at least one interior load bearing wall foπn panel by:

(i) fabricating at least an interior-load-bearing-panel-support- frame, said interior-load-bearing-panel-support-frame having an interior-facing-material support surface configured to support an interior facing material in a substantially vertical deployment; (ii) placing said interior facing material onto said interior- facing-material support surface and securing said interior facing material in place;

(b) providing at least a second wall foπn panel;

(c) creating at least a first volume for receiving an amount of fluid concrete by deploying at least one said interior load bearing wall foπn panels so as to be spaced a distance apart from said at least a second wall foπn panel such that at least two sides of said at least a first volume are defined by at least one said interior load bearing wall panels and said at least a second wall foπn panel, said interior load bearing wall foπn panel being deployed such that said interior facing material is facing away from said at least a first volume;

(d) substantially filling at least said first volume with said amount of concrete; and

(e) allowing said concrete to set, thereby interconnecting at least said at least one interior load bearing wall foπn panels and said amount of concrete so as to creating the interior load bearing wall;

(f) removing of said at least one interior-load-bearing-panel-support- frame from said interior facing material of said at least one interior load bearing wall foπn panel such that said interior facing material is now substantially a finished wall surface of the interior load bearing wall.

31. The method of claim 30, wherein said at least one interior-facing- material support surface is implemented as a plurality of spaced apart support surface elements deployed so as to support said interior facing material by coming into contact with only a portion of said interior facing material.

32. The method of claim 30, wherein said fabricating at least one interior load bearing wall form panel further comprises foπning window openings by affixing suitable foπn material to either one of said at least one interior load bearing wall form panels and said at least a second wall foπn panel before said at least a first volume is created so as to define a top, a bottom and sides of said window opening, said form material extending from said either one of said at least one interior load bearing wall form panel and said at least a second wall foπn panel toward a corresponding other of said at least one interior load bearing wall foπn panel and said at least a second wall form panel to a distances great enough to close a gap between said at least one interior load bearing wall form panel and said at least a second wall foπn panel such that when said at least a first volume is created, a sealed cavity into which substantially no fluid concrete may flow is also created, thereby defining said window opening.

33. The method of claim 31, further comprising removing said interior facing material from said cavity after said concrete is set, thereby exposing said window opening.

34. The method of claim 30, wherein said fabricating at least one interior load bearing wall form panel further comprises foπning doorway openings by- affixing suitable form material to either one of said at least one interior load bearing λvall foπn panel and said at least a second wall foπn panel before said at least a first volume is created so as to define a top and sides of said doorway opening, said foπn material extending from said either one of said at least one interior load bearing wall foπn panel and said at least a second wall form panel toward a corresponding other of said at least one interior load bearing wall form panel and said at least a second wall foπn panel to a distances great enough to close a gap between said at least one interior load bearing wall form panel and said at least a second wall form panel such that when said at least a first volume is created, a sealed cavity into which substantially no fluid concrete may flow is also created, thereby defining said doorway opening.

35. The method of claim 33, further comprising removing said interior facing material from said cavity after said concrete is set, thereby exposing said doorway opening.

36. The method of claim 30, λvherein said fabricating at least one interior-load-bearing-panel-support-frame further comprises interconnecting a combination of at least one standardized interior-load-bearing-panel-support- frame member and at least one custom fabricated interior-load-bearing-panel- support-frame member.

37. The method of claim 36, wherein said fabricating said at least two interior load bearing wall foπn panels is accomplish at a building site.

38. The method of claim 30, further comprising establishing dimensions of said at least two interior load bearing wall form panels from architectural plans.

39. A method for constmction of an interior partition wall, the method comprising:

(a) fabricating at least one interior partition wall form panel by:

(i) fabricating at least one horizontal interior-partition-panel support frame, said interior-partition-panel support frame having a at least one horizontal interior-partition-panel support surface configured to support an interior facing material, said interior-partition-panel support frame further including vertical sides substantially circumscribing horizontal interior-partition-panel support surface, said vertical sides extending up from said horizontal interior- partition-panel support surface to a vertical height greater than a thickness of said interior facing material;

(ii) placing said interior facing material into said interior- partition-panel-support-frame such that said interior facing material substantially covers said horizontal interior- partition-panel support surface, said interior facing material being deployed such that a finished exterior surface of said interior facing material abuts said horizontal interior-partition-panel support surface;

(iii) deploying a first amount of fluid concrete into said interior-partition-panel-support-frame so as to substantially cover said interior facing material with a depth of said concrete; and

(iv) allowing said first amount of concrete to set;

(b) creating at least a first volume for receiving a second amount of . fluid concrete by deploying at least one said interior partition wall foπn panel and at least a second wall foπn panel so as to be spaced a distance apart such that at least two sides of said at least a first volume are defined by at least one said interior partition wall panel and said second wall form panel, said interior partition wall foπn panels being deployed such that said interior facing material of said interior partition wall foπn panels is facing away from said at least a first volume;

(c) substantially filling at least said first volume with said second amount of concrete; and

(d) allowing said concrete to set, thereby interconnecting at least said one interior partition wall foπn panels and said second amount of concrete so as to creating the interior partition wall; (e) removing said interior-partition-panel support frame from said interior facing material which is now substantially finished wall surface on the interior partition wall.

40. The method of claim 39, further comprising:

(a) deploying non-load bearing construction material onto a surface of said first amount of concrete, before said concrete is set, said non-load bearing construction material substantially covering an area to a depth, said area and said depth being established by architectural plans; and

(b) allowing set first amount of concrete to set. thereby affixing said non-load bearing constmction material to said surface of said first amount of concrete.

41. The method of claim 39, wherein said fabricating at least one interior-partition-panel support frame further comprises interconnecting a combination of at least one standardized interior-partition-pane] support frame member and at least one custom fabricated interior-partition-panel support frame member.

42. The method of claim 39, wherein said fabricating said at least two interior partition w-all foπn panels is accomplish at a building site.

43. The method of claim 39, further comprising establishing dimensions of said at least two interior partition wall form panels from architectural plans.

44. A method for constructing a ceiling and floor, the method comprising:

(a) fabricating at least one ceiling panel by; (i) fabricating at least one horizontal ceiling-panel support frame, said ceiling-panel support frame having a horizontal ceiling-panel support surface configured to support said ceiling panel, said ceiling-panel support frame further including vertical sides substantially circumscribing horizontal ceiling-panel support surface, said vertical sides extending up from said horizontal ceiling-panel support surface to a vertical height equal to or greater than a thickness of said ceiling panel;

(ii) deploying a first amount of fluid concrete into said interior-partition-panel-support-frame so as to substantially cover said horizontal ceiling-panel support surface with a depth of said concrete; and

(iii) allowing said first amount of concrete to set;

(iv) removing said ceiling panel from said horizontal ceiling- panel support frame thereby exposing a finished ceiling surface;

(b) deploying at least one said ceiling panel so as to substantially cover an area requiring a ceiling, each of said at least one ceiling panels being deployed with said finished ceiling surface facing substantially downward, each of said at least one ceiling panels being supported by at least one wall such that each said at least one ceiling panels extends over at least a part of at least one room.

(c) erecting a border around a periphery of said at least one ceiling panel, said border extending vertically to a height equal to or greater than a required thickness of the floor;

(d) deploying at least a second amount of fluid concrete so as to substantially fill said area within said border to said required thickness; and

(e) allowing said concrete to set, thereby creating the floor.

45. The method of claim 44, further comprising:

(a) placing interior facing material Into said ceiling-panel support frame such that said interior facing material substantially covers areas of said ceiling-panel that will exposed when said ceiling- panel is deployed and leaving uncovered areas that will adjoin said support walls, said interior facing material being deployed such that a finished exterior surface of said interior facing material abuts said horizontal ceiling-panel support surface;

(b) deploying a third amount of fluid concrete into said ceiling-panel- support-frame so as to substantially cover said interior facing material with a depth of said concrete; and

(c) allowing said third amount of concrete to set.

46. The method of claim 44, further comprising deployment of at least one re-enforcement member such that a first portion of said re-enforcement member is encased in said first amount of concrete and a second portion of said re-enforcement member is encased in said second amount of concrete.

47. The method of claim 46, wherein said at least one re-enforcement member is implemented as a plurality of substantially parallel spaced apart re- enforcement members.

48. An exterior- facade foπn panel for constmction of an exterior wall, the exterior-facade foπn panel comprising:

(a) a first, outward facing, layer consisting of at least one exterior facing material element;

(b) a second layer consisting of rigid material configured to secure said first layer and add rigidity and strength to the panel; wherein the panel is used as a foπn as fluid concrete is pour to construct the exterior wall, and becomes the finish exterior facade when said concrete sets.

49. The exterior-facade foπn panel of claim 48, wherein said second layer is concrete that is deployed onto said first layer in a fluid state and allowed to set.

50. An interior load bearing wall foπn panel for constructing load bearing walls, the interior load bearing wall form pane comprising:

(a) an interior-load-bearing-panel-support-frame;

(b) a layer of interior facing material releasably attached to said frame in a substantially vertical deployment; wherein the panel is used as a foπn as fluid concrete is pour to construct the load bearing wall, and when said concrete sets and said frame is removed said interior facing material becomes a finish surface of the wall.

51. An interior partition wall foπn panel for constructing an interior partition wall, the panel comprising:

(a) an interior-partition-panel support frame;

(b) a first layer consisting of interior facing material

(c) a second layer consisting of rigid material configured to add rigidity and strength to the panel; wherein the panel is used as a foπn as fluid concrete is pour to constmct the load bearing wall, and when said concrete sets and said frame is removed said interior facing material becomes a finish surface of the wall.

52. The interior partition wall foπn panel of claimS l, further comprising a third layer of non-load bearing construction material.