AP534A

AP534A - Earthquake, wind resistant and fire resistant pre-fabricated building panels and structures formed therefrom.

Info

Publication number: AP534A
Application number: APAP/P/1994/000709A
Authority: AP
Inventors: Roger Georges Abou-Rached
Original assignee: R A R Consultants Ltd
Priority date: 1993-12-20
Filing date: 1994-12-19
Publication date: 1996-09-13
Also published as: DK1028207T3; DE69434694T2; HK1030644A1; ATE202609T1; UY23877A1; SV1994000079A; HRP941009B1; HU220484B1; NZ259493A; DZ1838A1; OA10300A; IL111974A0; HRP941009A2; IS2111B; FI962561A; CZ290196B6; AU5830694A; HK1030645A1; EP1028198B1; GEP20012521B

Abstract

An earthquake, fire and wind resistant

Description

BACKGROUND OFTIfE INVENTION

This inversion relates to an earthquake, fire and wind resistant pre-fabricated building panel for use in making a three-dimensional structure such as a house, apartment, office building or the like. A plurality of panels according to the invention is illustrated and described, a method of making such panels is described, examples of three dimensional structures according to the invention are described and a specially adapted shipping container for shipping components to build a three-dimensional structure is described.

Prefabricated Panels

I 15 Prefabricated building panels, in general, act as building components which can be quickly and easily fastened to a pre-erected frame structure. Many man-hours, however, are required to pre-erect the frame structure and prepare such structure for receipt of prefabricated panels. Dimension tolerances in both the pre-erected frame and the prefabricated panels can accumulate over large spans and ultimately, the panels may not properly ft on the pre-erected

0 frame.

In addition, conventional pre-fabricated panels are normally fastened to the exterior side of the pre-erected frame which enables such panels to withstand positive wind loading, however, negative wind loading such as created by hurricanes cannot be withstood.

Negative loading normally results in the exteriorally fastened panels being ripped off of the frame structure. This also occurs with conventional plywood board sheathing which is also fastened to the exterior side of the frame. Examples of such prior art prefabricated panels susceptible to negative wind loading are given in U.S. Patent No. 4,841,702 to Huettemann

0 and in U.S. Patent No. 4,937,993 to Hitchins. What is desirable therefore is a building panel or building system which can withstand both positive and negative dynamic loading.

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Three Dimensional $ tn ι / υ re

A consideration in most building designs is the susceptibility of the building to seismic forces such as created by earthquake activity. Many conventional building designs include a solid, unitary cast concrete foundation with engineered footings suitable for the soil upon which the building is to be erected. The building frame, in the form cf integral wall portions connected together, is built upon the solid unitary foundation and plywood board sheathing or prefabricated panels are fastened to the frame. (Of course the plywood board sheathing and prefabricated panels suffer from the disadvantages pointed out above).

The solid unitary foundation presents a problem under seismic forces because it is unitary' and f ' rigid. Although this permits such forces to be transmitted throughout the foundation, such a rigid foundation is unable to act sufficiently resiliency and elastically to absorb such forces (f ‘ without cracking or breaking. Cracks or breaks in the foundation are susceptible to water ingress which can have a tendency to cause the crack or break to propagate through the foundation resulting in degradation of the foundation.

In addition, the integral wall portions of the frame of the structure typically are formed of wood which is nailed together. Often seismic forces are sufficient to rip apart nailed walls resulting in localized failure of the frame leading to collapse of a wall and potential collapse of the building. While a wood frame of this type presents a relatively resilient elastic structure, typically the joints between frame portions are not sufficiently strong to hold the frame portions together under such loading and thus seismic forces cannot be properly

(. distributed to other portions of the frame to help share the load. What is desirable therefore is a sufficiently resilient elastic building foundation and a sufficiently resiliently elastic frame structure able to withstand and distribute seismic forces.

Hi-rise apartment or office buildings sometimes also suffer from a lack of a sufficiently resiliently elastic foundation and frame structure and, wall panels and partitions able to

0 withstand and distribute earthquake forces. Thus it is desirable to provide such ability in hirise apartment and office buildings or virtually in any structure exposed to such forces.

In addition to the need to withstand earthquake forces, there exists a need to provide prefabricated building structures capable of quick and easy erection with minimal labour

5 requirements. Presently, conventional easily erected building structures include prefabricated

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AP. Ο Ο 5 3 4 structures such as trailers, mobile homes etc., which are transported to the erection site. Transporting such structures is costly and requires an.enormous amount of space on a ship, for example. If it were possible to ship individual components of a structure and then erect the structure quickly and easily, shipping or transportation costs would be reduced, labour requirements for erecting the structure would be reduced and the cost of erecting the structure itself would be reduced. Thus it is desirable to provide building components which are capable of providing these advantages.

Transportation

Further to the transponation of conventional prefabricated building structures such as trailers, ( mobile homes and modular houses, such items are normally stacked one upon the other during shipping. Typically, however, these structures are designed only to bear their own ( weight and cannot bear the weight of other such structures, especially while the ship on which they are carried is travelling in rough seas. Thus, additional structural support is required to stack such prefabricated structures or stacking must be eliminated, resulting in inefficient use of cargo space on the ship.

What is desirable, therefore, is a prefabricated building system which can be shipped and

0 stacked without requiring additional structure, without damaging components of the building system and which makes efficient use of cargo space on a ship or other mode of transportation.

SUMMARY OF THE INVENTION 25

The above problems in the prior art are addressed by providing an earthquake-resistant, Fireresistant and wind-resistant pre-fabricated building panel comprising a plurality of frame members. The frame members are connected together to form a frame lying in a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior portion

0 of the panel. At least some of the frame members are biased inwardly, generally in the frame plane, towards the interior portion of the panel. A first solidified castable substance is cast in the interior portion of the frame, between the frame members.

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Preferably, the frame members are biased inwardly by a resiliently extendable tension link 3 5 extending between at least two of the frame members. More preferably, the flexible tension

bad ORIGINAL link has perpendicular portions lying in a firs: plane between the frame members and has diagonal portions lying in a second plane between the frame members, the second plane being spaced apart from the first plane. The castable substance is cast about the perpendicular and diagonal portions such that loads imposed on the castable substance, such as wind loads, are transferred to the tension link and hence are transferred to the frame members of the panel.

Also preferably, the pane! includes a layer of flexible mesh material extending between at least two frame members and tensioned therebetw'een to further bias the frame members inwardly. The castable substance is cast about the flexible mesh material to further distribute forces imposed on the castable substance to the frame members.

Also preferably, at least two opposite frame members are loosely connected to adjacent frame members of the same pane! such that the two opposite frame members are able to move relative to the adjacent frame members, at least in a direction parallel to the axes of the adjacent members.

A three-dimensional structure such as a house is formed by connecting panels, as described above, together. Connecting the panels together essentially connects together the individual frame members of each panel thereby forming a three-dimensional space-frame with the

0 castable substance of each pane! occupying the spaces between the frame members. The space frame is elastic and ductile and therefore is operable to distribute seismic and wind forces throughout the entire structure thus reducing the concentration of such forces at any given location and reducing the possibility of failure of any given member of the structure. In particular, the connections of the panels absorb and distribute seismic forces to the entire three-dimensional structure and the biased frame members act to absorb residual seismic forces reaching the cast portions of the individual panels. The castable substance, in cooperation with the biased frame members, permits the pane! to withstand both positive and negative dynamic loading. Yet only a minimal amount of castable substance is used, in strategic locations which enhance the structural integrity of the panel. The castable substance also provides a fire-resistant layer operable to protect the panel and provides 3n excellent base for any architectural finish.

Transportation of the panels and components necessary to form a three-dimensional structure such as a house is preferably accomplished by forming a container by connecting together a plurality of panels, ultimately destined for use in fabrication of the structure, to form a rigid

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-5container into winch the remaining panels and components necessary io form the structure may be placed. At least some of the panels of the structure therefore act as wall portions ot a container used to transport the remaining panels and components necessary to build the structure. Some panels of the structure thus can be used to fulfil two different purposes; forming a container and forming portions of a structure whose components are transported in the container so formed.

A first aspect of the invention provides a building panel comprising:

a) a plurality of frame members;

b) frame member connecting means for connecting together said frame members to torm a frame lying in a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior portion of the panel;

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c) biasing means for biasing at least one of said frame members inwardly, generally in said frame plane, towards said interior portion of the panel;

d) a firs: solidified castable substance cast in said interior portion of the frame, between said frame members and about said biasing means such that loads imposed on said solidified castable substance are transferred by said biasing means to said frame members.

A second aspect of the invention provides a method of making a building i panel, the method comprising the steps of:

a) connecting together frame members to form a frame lying in a frame plane;

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b) biasing at least some of said frame members inwardly generally in said frame plane towards an interior portion bounded by the frame members;

c) casting a first curable substance in said interior portion of the frame, between said frame members such that loads imposed on said first curable substance, when cured, are transferred to said frame members.

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A third aspect of the invention provides a building structure foundation member, the member comprising:

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a) a solidified castable material formed to me on the ground and a support portion for supporting a building structure;

b) a hollow conduit extending lengthwise in at least one of said footing portion and said support portion for holding utility service provisions;

c) openings in said support portion for permitting access to said hollow conduit and said utility service provisions; and

d) connecting means for connecting said member to an adjacent simitar member, the connecting means being operable to deform elastically when seismic forces are imposed on said member.

A fourth aspect of the invention pnovides a foundation fon a building stnuctune, the foundation including:

a) a plurality of foundation members each comprising:

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i) a hollow conduit extending lengthwise in at least one of said footing *·>

portion and said support portion for holding utility service ϊ provisions; m

-t ii) openings in said support portion for permitting access to said hollow conduit and said utility service provisions;

iii) connecting means for connecting said member to 3n adjacent similar member, the connecting means being operable to deform elastically when forces are imposed on said member; and

b) a plurality of connectors for co-operating with lespective connecting means on each member to secure adjacent members together.

A fifth aspect of the invention provides a method of securing an architectural finish element to a surface ultimately formed by a castable material cast about a mesh material, the method including the steps of:

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a) securing at least cne projection to a backing surface of said architectural finish element such that said projection extends generally away from said backing surface;

b) inserting said at least one projection into said castable material before said castable material has set, until said backing surface rests on a surface of said castable material, said at least one projection co-operating with said mesh material to engage therewith; and

c) permitting said castable material to set about said at least one projection, thereby firmly securing said projection in said castable material and securing said architectural finish element thereto.

A sixth aspect of the invention provides a three dimensional building structure comprising:

a) a plurality of building panels, each panel including:

i) a pluraii;’,’ of frame members;

ii) frame member connecting means for connecting together said frame members to form a frame lying in a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior portion of the panel;

( iii) biasing means for biasing at least one of said frame members

C. inwardly, generally in said frame plane, towards said interior portion of the panel;

iv) a first solidified castable substance cast in said interior portion of the frame, between said frame members;

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b) panel connecting means for connecting said building panels together, the panel connecting means being operable to deform elastically under forces imposed on said panel.

c) a plurality of connectors for co-operating with respective connecting means on each panel to secure adjacent panels together. ^AD ORIGINAL

A seventh aspect of tne invention provides a ni-rise building ctr-orising:

^a) ³ plurality ot spaced apart vertical members aligned to lie in spaced apart vertical planes;

b) a plurality of horizontal members connected to and extending between said vertical members to define a plurality of spaced apart horizontal planes intersecting said vertical members;

c) a plurality of building panels disposed between said spaced apart horizontal planes, each of said pane’s including:

i) a plurality of frame members;

iii) biasing means for biasing at least one of said frame members inwardly, generally in said frame plane, towards said interior portion of the panel;

iv) a firs; solidified castable substance cast in said interior portion of the frame, between said frame members and about said biasing means such that loads imposed on said solidified castable substance are transferred by said biasing means to said frame members; and

v) connecting means for connecting said each pane! to an adjacent panel, the connecting means being operable to deform elastically under force;

the panels being connected together to form a space frame defining an array of units between said spaced apart horizontal planes and said spaced apart vertical planes, the connecting means on panels adjacent the vertical and horizontal members connecting the space frame to the vertical members and horizontal members.

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An eighth aspect of tne invention provides a plurality of building panels for fanning a three dimensional structure, the panels including;

i) a plurality of frame members;

ii) frame member connecting means for connecting together said frame members to form a frame lying in a frame plane, the frame defining a perimeter of the pane!, the perimeter bounding an interior portion of the panel;

iv) a first solidified castable substance cast in said interior portion of the frame, between said frame members and about said biasing means such that loads imposed on said solidified castable substance are transferred by said biasing means to said frame members;

v) connecting means for connecting each of said panels to a co-operating connecting means of an adjacent said panel, the connecting means being operable to deform elastically under forces imposed on said panel, and vi) a plurality of connectors co-operating with said panel connecting means for connecting at leas: some of said panels together to form a transportation container capable of holding a sufficient number of panels and connectors to form a dwelling from said sufficient number of panels and said panels used to form said transportation container.

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BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a house including a foundation, and floor, exterior wall, interior wall and roof panels according to various embodiments of the invention;

Foundation

Figure 2 is a plan view of a foundation according to a first embodiment of the invention;

Figure 3 is a perspective view of a portion of the foundation shown in Figure 2;

Floor Panel

Figure 4 is an exploded view of frame members included in a floor panel according to a second embodiment of the invention;

Figure 5 is a side view of an end portion of a top frame member shown in Figure 4;

Figure 6 is a bottom view of the end portion shown in Figure 5;

Figure 7 is an end view of the end portion shown in Figure 5;

Figure S is a side view of an end portion of a side frame member shown in Figure 4;

Figure 9 is a face view of the end portion shown in Figure 8;

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Figure 10 is an end view of Lhe end portion shown in Figure 8;

Figure 11 is a plan, view of the floor pane! with insulation installed between die frame ncrr.bef s'

Figure 12 is a cross-sectional view taken along lines 12-12 of Figure 11;

Figure 13 is a cross-sectional view taken along lines 13-13 of Figure 11;

Figure 14 is a plan view of the door panel illustrating horizontal, vertical and diagonal tension wire portions;

Figure 15 is a cross-sectional view taken along lines 15-15 of Figure 14;

Figure 16 is a plan view of the floor panel with mesh portions covering the insulating material;

Figure 17 is a cross-sectional view taken along lines 17-17 of Figure 16;

0 Figure 18 is a cross-sectional view of a portion of the floor pane! illustrating the formation of a planar portion and a rib portion in cast concrete;

Figure 19 is a cross-sectional view of a portion of the floor panel illustrating first and second cast portions of concrete;

Figure 20 is a plan view of the completed floor panel;

Figure 21 is an exploded view illustrating a connection of the floor pane! shown in Figure 20 with interior and exterior panels according to the invention, and with the foundation shown in Figure 3;

Exterior Pane!

Figure 22 is a plan view of frame members included in an exterior panel according to a third embodiment of (he invention.'

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Figure 23

Figure 24

Figure 25

Figure 26

Figure 27

Figure 2S

Figure 29

Figure 30

Figure 31

Figure 32

Interior Panel

Figure 33

Figure 34

Figure 35 vz is a side view cf a portion of a side frame member shown in Figure 22;

is a race v:ew of the frame portion shown in Figure 23;

is a bottom vie* of the frame portion shown in Figure 23;

is a face view of a portion of a top frame member showm in Figure 22;

is a plan view' illustrating a firs; assembly step in assembling the exterior panel;

is a plan v:ew illustrating a second assembly step in which the frame members are placed upon an insulating portion;

is a plan view- illustrating a third assembly step in assembling the exterior panel, in which tension cables are routed between frame members;

is a plan view illustrating a fourth step in assembling the exterior panel, in which mesh portions are connected over pane! portions of the panel;

is a plan view of a completed exterior panel according to the third embodiment of the invention;

is a cross-sectional view of the completed exterior panel taken along lines 3232 of Figure 31.

is a plan view of frame members included in an interior panel according to a fourth embodiment of the invention;

is a side view of a portion of a side frame member shown in Figure 33;

is a face view of the frame portion shown in Figure 34,

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AP.00534

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Figure 36 is a face view of a frame portion of a top frame member shown in Figure 33;

Figure 37 is an end view of the frame portion shown in Figure 36;

Figure 3S is a plan view illustrating the connection of the frame portion of Figure 34 with the frame portion of Figure 36,

Figure 39 is a plan view of an assembly step in forming the interior panel, including the routing of tension cables between frame members;

Figure 40 is a plan view of an assembly step in forming the interior panel, including the connection of mesh material between the frame members;

Figure 41 is a plan view of a finished interior panel;

Figure 42 is a cross-sectional view taken along lines 42-42 cf the interior panel shown in Figure 41;

Roof Panels

Figure 43 is a plan view of frame members included in a roof panel according to a fifth embodiment of the invention;

Figure 44 is a side view of a frame portion of a top frame member shown in Figure 43;

Figure 45 is a face view of the frame portion shown in Figure 44;

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Figure 46 is a side view- of a connecting portion of the top frame member shown in Figure 43;

Figure 47 is a face view of the connecting portion shown in Figure 46;

Figure 4S is a side view cf a top end portion of a side frame member of Figure 43;

5 Figure 49 is a face view of the top end portion shown in Figure 4S;

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Figure 50 is a plan view of an assembly step in forming the roof panel, in which tl'.e frame members are placed on an insulating material;

Figure 51 is a plan view of an assembly step in forming the roof panel wherein tension 5 cables are connected between frame members;

Figure 52 is a plan view of an assembly step in forming the roof panel wherein a first layer of mesh material is connected between frame members;

Figure 53 Is a cross-sectional view of a completed roof panel according to the fifth embodiment ct the invention;

Figure 54 is a plan view of a completed roof pane: according to the fifth embodiment of the invention;

Assembly of Panels

Figure 55 is an exploded view illustrating the assembly of roof, Boor and wall panels according to the invention;

Figure 56 is a cross-sectional view t3ken along lines 56-56 of Figure 55;

Figure 57 is a cross-sectional view taken along line 57-57 of Figure 55;

5 Hi-Rise Structure

Figure 5S is a perspective view of a hi-rise structure, illustrating a use of panels according to the invention to form units of the structure;

0 Shipping Container

Figure 59 is a perspective view of 3 shipping container illustrating a further use of panels according to (he invention;

Figure 60a is a fragmented side view of a mid-portion Ct the container of Figure 59;

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IS

	Figure 60b	is a fragmented perspective view cf the mid-portion shown in Figure 60a;
c	Figure 60c	is a fragmented perspective view ot the mid-portion siiown in Figures 60a and 60b, in a partially assembled state;
	Figure 60d	is a fragmented perspective view of the mid-portion shown in Figures 60a, 60b, and 60c in a completed state;
	Figure 60e	is a fragmented perspective view of a corner portion of tine container shown
10		in Figure 59;
	Figure 60f	is a fragmented side view of the corner portion shown in Figure 60e;
	Figure 60g	is a fragmented perspective view of the corner portion shown in Figures 60e
15		and 60f, in a partially completed state;
	Figure 60h	is a fragmented perspective view of the corner portion shown in Figures 60e, 60f, and 60g shown in a completed state;
20	Figure 61	is a plan view of a house built from components shipped in the container shown in Figures 59 and 60;
	Figure 62	is a side view of the house of Figure 61;
25	Panel Finishing
30	Figure 63	is a layered view of an exterior panel according to the third embodiment of the invention, illustrating a method of securing an architectural finishing material to the panel;
	Panel Variations
	Figure 64	(a) - (x) illustrates a plurality of plan views of panel configurations having various dimensions;

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Curved Comporents

Figure 65

is a perspective vie* of a curved corner foundation nr ember according to a sixth embodiment of the invention;

Curved Floor Pane

Figure 66	is a plan view of frame members included in a floor pane! having a curved corner portion, according to a seventh embodiment of the invention;
Figure 67	is a plan view of an assembly step in forming the panel according to tire seventh embodiment, in which the frame members are placed on an insulating material;
Figure 6S	is a plan view of an assembly step in forming the panel according to the seventh embodiment wherein tension cables are connected between frame members;
Figure 69	is a plan view of an assembly step in forming the panel according to the seventh embodiment wherein a first layer of mesh material is connected between frame members;
Figure 70	is a plan view of a completed floor panel according to the seventh embodiment of the invention;

Curved Exterior Wall _P_3nel

Figure 71	is a plan view of frame members included in a curved exterior wall panel according to an eighth embodiment of the invention;
Figure 72	is a bottom view of a first curved frame member shown in Figure 71;
Figure 73	is a top view of a curved styrofoam slab according to the eighth embodiment of the invention;

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Figure 74 is a plan view of an assembly s:ep io forming the panel according to the eighth embodiment wherein the curved styrofoam slab of Figure 73 is placed upon a layer of mesh materia! and a water impermeable membrane;

Figure 75 is a plan view of an assembly step in forming the panel according to the eighth embodiment wherein a tension cable is routed between opposite curved frame members and wherein the mesh and water impermeable membrane are wrapped around edges of end frame members of the panel;

Figure 76 is a plan view of an assembly step in forming the panel according to the eighth embodiment wherein a second layer of mesh material is laid between the frame members to form a concave inner surface and wherein a concrete retaining edge form is secured to the frame members;

Figure 77

Figure 7S is a cross-sectional view of the pane! taken along lines 77-77 of Figure 76;

is a cross-sectional view of the curved wall panel;

Figure 79 is a plan view of the completed curved wall panel; and

Figure SO is a perspective view of a corner of a structure having a curved foundation portion, a floor panel with a curved portion and a curved exterior wall portion according to the sixth, seventh and eighth embodiments of the invention.

This application contains S7 drawing figures.

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DETAILED DESCRIPTION 30

Building structure 3nd pre-fabricated panels

Figure 1

Referring to Figure I. a pre-fabricated house formed of foundation members and panels 3 5 according to the invention is shown generally at 10 on a building site 12.

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-15 The house includes a foundation shown generally at 14, a first plurality of pre-fabricated firs; floor panels 20, a first plurality of pre-fabricated exterior wall panels 22, a first pluraJitv of pre-fabricated interior wa!, panels 24, a second piuraoty of p re-fabricated second floor panels 26 a second plurality of pre-fabricated exterior wall panels 2S, a second pluralitv of pre5 fabricated interior wall panels 20, a third plurality of pre-fabricated floor panels 32, a third plurality of pre-fabricated exterior panels 34, a third plural ity cf pre-fabricated interior panels 36 and a plurality of pre-fabricated roof panels 38.

Foundation

Figure 2

Referring to Figure 2, the foundation 14 is shown in accordance with a firs: embodiment cf the invention and includes, side, end and centre foundation members designated 40, 42 ar.d 44, respectively. Each foundation member is formed by casting concrete, to includea footing portion for resting on the ground and a support portion for supporting a building structure. The support portion is cast about a pre-assembled hollow' steel beam. Each foundation member is also formed such tha; the side, end and centre foundation members have engaging faces 41 which mate with each other and can be connected to each other.

0 Side foundation members

The side foundation members 40 have first and second opposite end portions 46 and 48 and a middle portion 50 disposed therebetween. The first and second end portions 46 and 4S have f rst and second short steel tubing portions 52 and 54, respectively while the middle portion has a relatively long steel tubing portion 56 which is welded to and extends between the frst and second end portions. The long portion 56 is in communication with the short portions such that a duct 58 is formed between the frst tubing portion 52 and the second tubing portion 54. As the tubing portions are welded together, a unitary length of structural tubing is formed. The duct is operable to hold utility service conduits for water, electricity, etc.

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0 Figure 3

Referring to Figure 3, the side foundation member 40 is formed with a concrete footing portion 60 and a concrete support portion 62 which encircle the steel tubing portions 52, 54, and 56 to form a structural support for the steel tubing portions. The steel tubing extends lengthwise in the support portion 62. A hollow conduit 64 is formed in the footing portion

5 60 and is filed with insulating material (not shown) such as styrofoam to provide insulating

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AP. Ο Ο 5 3 4 properties to the member and prevent ingress cf moisture in the event that the concrete becomes cracked. Tine insulating material also renders the foundation member lighter in weight.

Th.e first and second end portions 46 and 4S, only portion 4S being shown in Figure 3, have first and second vertically extending duct portions 66 and 68, respectively which are in immediate communication with the long steel tubing portion 56 and the second steel tubing portion 54, respectively. Tne first and second vertically extending duct portions have foundation connecting flanges 70 and 72, respectively which act as connecting means for connecting floor panels and wall panels to the foundation members. The middle portion 50 also has first and second vertically extending duct portions 74 and 76 which are disposed approximately midway between the first and second end portions and which are in immediate communication with the long steel tubing portion 56 and which have respective foundation ( connecting flanges 78 and SO. Each of the foundation connecting flanges 70, 72, 78 and SO has a respective opening S2 for permitting access to, and for communication with its respective vertical duct and each flange has a respective threaded opening S4 for permitting a fastening member to be received therein for use in connecting the floor panels to the foundation members.

0 Referring to Figures 2 and 3, the first and second end portions 46 and 4S also have first and second connecting flanges 86 and SS which are flush with respective end engaging faces of the side foundation member. The first and second connecting flanges 86 and 88 are used to connect the side foundation member to an adjacent end foundation member 42. The

C horizontal duct formed by the hollow tubing has end openings 89 and 91 which are accessible at respective engaging faces 41.

c

End foundation members

Referring to Figure 2, the end foundation members 42 are similar to the side foundation members in that they include a hollow steel tubing portion 90, have footing and support

0 portions 92 and 94, respectively and have an insulation filled conduit 96, shown best in

Figure 3. Referring back to Figure 2. the end foundation members also have Erst and second end portions 98 and 100 to which are rigidly connected first and second elastically deformable connecting flanges 102 and 104 which extend from the hollow steel tubing portion 90 for mating engagement with and bolting to co-operating connecting flanges of an adjacent

5 side foundation member (such as 86, SS and 142).

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Centre foundation member Still referring to Figure 2, firs: and second T'-shape. relatively long hollow' steel steel end members 114 and the centre foundation member 44 has a central portion 106 and d end portions IOS and 110. Toe central portion 106 includes 3 tubing portion 112 which is connected to firs: and second hollow 1 Ιό disposed at right angles to one long steel tubing portion 112 and connected so as to permit communication between me tirst and second hollow steel members 114 and 11 6.

Each end portion 10S and 110 has first, second and third vertically extending ducts IIS, 120 and 122, respectively. The first vertically extending duct 1 IS is in direct communication with the long steel tubing portion 1 12 while the second and third vertically extending ducts are in direct communication with the first (and second) steel end member 114. Each of die first, second and third ducts has a respective duct connecting fiar.ge 124 having an opening 126 in communication with its respective duct and a threaded opening 127 for receiving a threaded fastener for use in connecting an adjacent floor member to the centre foundation member.

The central portion 106 also has first and second vertically extending duct portions 128 and 130 which are disposed approximately midway between the first and second end portions 108 and 110 and which are in immediate communication with the long steel tubing portion 112.

0 These duct portions also have respective foundation connecting flanges 132 and 134. Each of the foundation connecting flanges has a respective opening 136 for communication wiuh its respective vertical duct and each flange has a respective threaded opening 138 for permitting a fastening member to be received therein for use in connecting the floor panels to the foundation members.

Tie centre foundation member further includes first and second connecting flanges 140 and 142 on opposite sides of the member for use in connecting the centre foundation member to adjacent end members 42.

In die preferred embodiment, all steel components of respective foundation members are welded to adjacent steel members of the same foundation member such that the steel components form a rigid structure within the foundation portion. The concrete footing portions and wall ponions are then formed about the rigid structure to form the individual foundation members depicted in the drawings. If desired, (he concrete curing process may

5 be accelerated by passing the members thiough an oven or by the use ol steam. Desired β 0 Z 0 0 / 4 6 .'d/dV

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2.1 finishes and waterproofing can also be added at this time. Tne individual foundation members are then connected together using the elastically deformable connecting flanges on each member to form a foundation for the entire building structure as shown in Figure 2.

The connecting flanges also connect together the stee! tubing members of the foundation members, thus forming a space frame lying in a fiat plane, with the tubing members of each of the foundation members acting as the space frame members.

Floor panel Figure 4

Referring to Figure 4, the fabrication of a floor panel according to a second embodiment of the invention is begun by cutting to length first, second, third, fourth and fifth 2' X 4' hollow steel tubing frame members as shown at ISO, 152, 153, 154 and 155, although it will be appreciated that the steel tubing may be of any suitable size to meet any desired structural ( loading requirement. The stee! tubing members act as frame members for the panel. Frame members 152 and 154 form a pair of adjacent sides of the frame and frame members 130 and 155 form a pair of opposite sides of the frame, the pair of opposite sides extending between the pair of adjacent sides. Frame member 153 extends between frame members 150 and 155 at a central location between members 152 and 154.

Frame members 150 and 155 have respective opposite end portions 156, 153, 160 and 162, respectively. Only end portion 156 will be described, it being understood that end portions 153, 160 and 162 are similar.

( Figures 5. 6 and 7

5 Referring to Figures 5, 6 and 7, end portion 156 is shown in greater detail. Frame member

150 has a longitudinal axis 164, an outside face 165, an inside face 190 and an end face 166.

The outside face 1 65 extends the length of the frame member and forms an outer edge of the ultimate panel. The inside face 190 faces inwards toward an interior portion of the frame. Secured to the end face 166 is a plate 163 extending to cover the end portion of the steel

0 frame member 150. Plate 163 has first and second service openings 176 and 178 which provide access to a hollow portion ISO within the longitudinal frame member 150 and extending the length thereof. Tne plate also has openings 182 and 134 for receiving threaded fasteners to permit the plate and hence the longitudinal frame member 150 to be fastened to an adjacent member of an adjacent panel.

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AP/P.' 94/00709

Referring to Figure 5, a parallel member 170 extends in a direction parallel to the longitudinal axis 164. Tne parallel member 170 is welded to the longitudinal frame member 150 and is welded to the plate 16S. A flange 172 extending perpendicular to the plate 168 and perpendicular to the parallel extending member 170 is connected to the parallel member

170 and the plate 166. Tne flange 172 has an opening 174 of sufficient size to receive electrical conduits and/or water service conduits (not shown).

Figure 6

Referring to Figure 6, inside face 190 has pin receptacles 186 and 1SS. Beginning adjacent 10 die receptacle IS6 on the inside face 190, a first plurality of steel plates 192, to which are fastened respective pre-welded steel hooks 196, extends in a first hook plane 30S, longitudinally along the frame member 150. Referring to Figure 4, the hooks 196 are located at spaced apart intervals along the frame member 150.

(.

(

Referring back to Figure 6, a second plurality of steel plates 194 to which are fastened respective hooks 19S, also extends in a second hook plane 312. longitudinally along the frame member 150. The first and second hook planes 308 and 312 are parallel and spaced apart and extend symmetrically on opposite sides of a transversely extending longitudinal plane 197 intersecting the longitudinal axis 164 of Figure 5.

Referring to Figure 7, the longitudinal plane 197 divides the frame member into two portions comprising a side one portion 199 and a side two portion 201. Thus, the hooks 196 lying in the first hook plane 30S are on the side one portion and the hooks 198 lying in the second hook plane 312 are on the side two portion. In the present embodiment, the side one portion

5 199 will ultimately form the floor surface of the panel and the side two portion 201 will ultimately face the ground beneath the house.

?; 94/00709

Figures 6 and 7

Referring to Figures 6 and 7, there is further secured to the inside face 190 a first plurality 3 0 of pre-cut bent chair bolster hooks 204, each having first and second opposing portions 206 and 208, respectively, shown best in Figure 7. The first portions 206 of the hooks are disposed in spaced apart relation in a third hook plane 310 extending longitudinally along the side one portion 199 of the frame member. The third hook plane is parallel to and spaced apart from the first and second hook planes 308 and 312 35

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AP . Ο Ο 5 3 4

2.3

A second plurality of pre-cut feet chair bolster hooks 210 aiso having first and second opposing hook portions 212 and 214, respectively are disposed in spaced apart relation along the side two portion 201 of the frame member. The first hock portions 212 are disposed in a fourth hook plane parallel to and spaced apart from the first, second and third hook planes

30S, 310 and 312.

Referring to Figure 4, it will be appreciated that the members 150 and 155 are mirror images of each other and therefore frame member 155 has a similar arrangement of hooks 196 and chair bolster hooks 204 (and 210 not shown).

Still referring to Figure 4, the side members 152 and 154 have first and second end portions respectively, the end portions being designated 216 and 21S, respectively. The end portions are similar and therefore only end portion 216 will be described.

Figure 3

Referring to Figure 8, frame member 152 has an outer face 220, an inner face 222 and a longitudinal axis 225, the longitudinal axis 225 lying in the same longitudinal plane 197 as the longitudinal axis 164 of frame member 150. An end face 226 is formed at end portion 216 and lies in an end face plane 217. To the inner face 222 is secured a transversely

0 extending angle member 224 having a projecting portion 228 and a parallel portion 229. The projecting portion 228 extends in the end face plane 217 and the projecting portion 229 ls welded to the inner face 222.

Figure 9

5 Referring to Figure 9 the projecting portion 228 has a first transversely extending hook 230 extending perpendicularly to the end face plane 217. The hook has a first shank portion 232 extending past the end face plane 217 and has a first hook portion 234 extending opposite the first shank portion 232, parallel and adjacent to the parallel portion 229. The fust hook portion 234 lies in a fifth hook plane 340 extending parallel to and spaced apart from the longitudinal plane 197, adjacent a side one portion 221 of the frame member. The fifth hook plane is also parallel to and spaced apart from the first, second, third and fourth hook planes 308, 312, 310 and 314.

Still referring to Figure 9, the end portion 216 also has a second hook 236 on a portion of

5 the angle member opposite the first hook 230. the second hook has a second shank portion ζ

_____

4C25

C.

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2-423S and has a second hook portion 240. The second shank portion 238 extends pa.-ah'el to the first shank portion 232 and is spaced apart therefrom. The second hook portion 240 lies in a sixth hook plane 341 extending parallel to and spaced apart from the longitudinal plane 197, adjacent a side two portion 223 of the frame member. The sixth hook plane is also parallel to and spaced apart from the first, second, third, fourth and fifth hook planes 30S 312, 310, 314 and 340.

Figures 9 and 10

Referring to Figures 9 and 10, secured to the side one portion 221 of the inner face 222 is 10 a first plurality of chair bolster hooks 242. The chair bolster hocks 242 are secured in spaced apart relation longitudinally along the frame member 152 and are similar to the chair bolster hooks 204 described previously and shown in Figures 5, 6 and 7. Referring back to Figures

3nd 10 each of the hocks 242 has a first portion 244 which lies in the third hook plane 310.

Similarly, secured to the side two portion 223 of the inside face is a second plurality of chair bolster hooks 248. The chair bolster hooks 24S are also secured in spaced apart relation longitudinally along the frame member 152 and are similar to the chair bolster hooks 210 described previously and shown in Figures 5, 6 and 7. Referring back to Figures 9 and 10, each of the hooks 24S has a first portion 243 which lies in the fourth hook plane 314.

Referring back to Figure 4, frame member 153 is similar to frame members 152 and 154 with the exception that frame member 153 has two inside faces 245 and 247 each with a respective plurality of chair bolster hooks 260 disposed such that hook portions thereof lie in

5 the third and fourth hook planes 310 and 314, respectively. In addition, frame member 153 has first and second end portions 262 and 264, respectively, each with four hooks and extending shank portions similar to shank portions 232 and 238 in Figures 9 and 10, only two of such hooks being shown in Figure 4 at 266 and 268.

0 To assemble the frame members together, the shank portions 232 and 238 shown in Figures and 10 are received in receptacles 186 and 1S8 of the frame member 150 shown in Figure

6. A similar insertion is performed at each of the remaining corners of the frame. In addition, the four hook portions, only two of which are shown at 266 and 26S in Figure 4, are received within corresponding receptacles (not shown) in longitudinal frame member 150.

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AP.00534 b

Νΰ screws or rivers ire used to connect the trame members together. The shank portions at each joint are merely loosely held in their receptacles and thus the opposite members 150 and 155 are permitted to move in a direction parallel with the longitudinal ixes of adjacent frame members 152, 153 and 154. This is important as it permits the frame to absorb forces exerted on the ultimate panel which renders the panel effective in absorbing dynamic forces such as seismic forces due to earthquakes, hurricanes, heat stresses from fire, and forces due to flooding.

Figure 1 1

Referring to Figure II, the frame members are connected together in the loosely connected arrangement described above to form a frame lying in a frame plane. In the embodiment shown, the frame members define the perimeter of the panel, the perimeter bounding First and second interior portions of the pane! 270 and 272. On side one of the panel, within the First interior portion 270, is disposed a First preformed or pre-cast insulating slab 274 of styrofoam. The styrofoam slab has outer dimensions which permit the slab to Fit snugly within the interior portion, between the frame members 150, 152, 153 and 155.

The styrofoam slab is preformed or pre-cast to have a plurality of longitudinally extending recesses 276, 278, 2S0, 282, 2S4 and 2S6. The slab also has first and second laterally

0 extending recesses 2S8 and 290 which extend laterally of the slab between opposite sides thereof. The slab also has first and second diagonal recesses 292 and 294 which form an X shape in the slab. The recesses are formed in what will ultimately form an interior side 296 of the panel. An exterior side (not shown) opposite the interior side is formed in a similar manner.

Figure 12

Referring to Figure 12, recess 27S is representative of the remaining recesses and is generally truncated triangular in shape. Each recess has first and second sloping side portions 298 and 300 connected by a bottom portion 302.

Each of the four sides of the insulating slab, adjacent the frame members 150, 152, 153 and 155 is formed with a projecting portion 304 having a thickness defined as the distance between opposing bottom portions of immediately adjacent recesses on opposite sides of the slab. The thickness is designated 306 in Figure 12 and is proportional to the desired insulative or 'R' value of the panel.

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AP/P/ 9 4 / 0 0 7 0 9

- .2 bFigure 13

Referring to Figure 13, the thickness 306 of the projecting portion 304 is formed such chat the projecting portion is received between the first and second pluralities of hooks 196 and

198 on the upper and lower portions of the inside face of member 150. The projecting portions on the remaining sides of the slab are received between corresponding hook members on adjacent frame members. The first and second pluralities of hooks 196 and 198 thus serve to locate the slab relative io the frame. Consequently, it is important chat the hooks 196 and 19S and similar hooks cm the other frame members are located symmetrically about the longitudinal axis of respective frame members to ensure that the insulating slab is located centrally between sides one and two of the panel.

Figure 14

Referring to Figure 14, a turnbuckle 316 is connected to a hook 196 adjacent recess 284. A 15 unitary, resiliently extendable cable 318 is connected to me turnbuckle 316 and is routed in recess 2S4 past the hook 196 on frame member 155 opposite frame member 150. Tne cable is then routed in recess 290 to an adjacent hook 196 adjacent recess 2S2 and is then further routed in recess 282 back to a hook 196 on frame member 150. The cable is routed in similar fashion between the frame members 150 and 155 until a first corner 322 of the panel is reached. It will be appreciated that as all of the hooks 196 lie in the first hook plane 30S, shown best in Figure 13, the ponion of the tension cable 318 routed thus far also lies in the first hook plane 308.

Figure 15 . Referring to Figure 15, when the cable is routed to the corner 322, the cable is routed from hook 196 upwards to first shank portion 232. From here, referring back to Figure 14, the cable is routed through a diagonal path in diagonal recess 292 to a diagonally opposite second corner 324 of die panel. As the first shank portion 232 in the comer 322 and corresponding first shank portion 232 in corner 324 lie in the fifth hook plane 340, shown in Figure 15, the

0 cable in diagonal recess 292 of Figure 14 also lies in the fifth hook plane 340.

Referring back to Figure 14, the cable is then routed downwards in corner 324 to an adjacent hook 196 lying in the first hook plane 308 (not shown in Figure 14) and extends in recess 2S6 to hook 196 in an opposite third corner 326. The portion of the cable extending in recess 2S6

5 thus lies in the first plane 30S. At corner 326, the cable is routed upwards to the first shank β 0 I 0 0 / V 6 Zd/dV

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AP . Ο Ο 5 3 4 ίο portion 232 lying in the fifth hock plane 340 and then extends diagonally in diagonal recess 294 to a diagonally opposite fourth corner 32S whereupon the cable is fastened to first shank portion 232. This diagonal extending portion of the cable thus also lies in the fifth hook plane 340.

The tumbuckle 316, which acts as tightening and tensioning means for tensioning the cable, is then tightened to tighten and tension the cable 318 to approximately 600 lbs., although the tension may be higher or lower to suit the particular structural loading expected to be imposed on the panel.

Tightening and tensioning of the cable biases the opposite frame members 150 and 155 inwards towards the interior portion 270 of the panel. The cable and turnbuckle thus act as biasing means for biasing at least some of the frame members inwardly, generally in the frame plane, towards the interior portion of the panel.

It will be appreciated that the cable 318 has longitudinally and transversely extending portions which extend within the longitudinally and transversely extending recesses and has diagonally extending portions which extend within the diagonally extending recesses. Referring to Figure IS, it will be appreciated that the longitudinally and transversely extending portions

0 lie in a first plane (308) whereas the diagonally extending portions lie in a second plane (340), the second plane being spaced apart from the first plane. Generally, the spacing between the first and second planes should be increased with increased structural loading and decreased with decreased structural loading.

A similar procedure of installing styrofoam and a tension cable is followed for the second interior portion 272 of the panel.

Figure 16

Referring to Figure 16, a first layer of wire mesh 330 is cut to fit within the interior portion

0 270 and has first, second, third and fourth edges 332, 334, 336 and 338. The wire mesh 330 is tensioned, through the use of a conventional tensioning tool, to tighten it between at least two frame members. The edges 332, 334, 336 and 338 are connected to the chair bolster hook portions lying in the third plane 310 on each of the frame members 150, 152, 153 and 155.

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-.'δFigure 17

Referring to Figure 17, the First layer of wire mesh 330 thus lies in the third hook plane 310 and is spaced apart from One remaining planes. It will te arcreoiated that Fe diagonal cable portions lying in the fifth hook plane 340 which is immediately adjacent, act as supports for the mesh. Tie wires (not shown) may be used to connect the mesh to the diagonal cables to prevent the mesh from movement during subsequent steps.

Referring back to Figure 16, the second interior portion 272 also includes its own first laver of wire mesh material similar to that of the first interior portion.

Stiil referring to Figure 16, a concrete form edge retaining member 343 is connected to the frame members to further detlne an outer perimeter of the panel. The retaining member is connected by means of rivets, screws or point w-elding to the frame members ISO, 152. 154 and 155. Concrete is Lhen poured onto the mesh 330, to FI! the recesses in the styrofoam slab, and is bounded by the form edge retaining member 343.

The concrete used in construction of the pane! may be of virtually any mix. The ratio of gypsum to grave! in the mix can be selected to suit the particular conditions under which the panel is to be used. Preferably, the mix includes a waterproofing agent such as epoxy resin which imparts to the resulting concrete an ability to prevent moisture ingress and a resilient flexibility useful in absorbing energy imparted to the pane! by seismic activity or even shellfire. In one embodiment in which the pane! was used in the Pacific Northwest, the ratio of cement to sand to gravel to water to epoxy was approximately 1:2:4:1:0.05.

5 It will be appreciated that chips of marble, granite, crystallized sand mixed with water and any colour of cement may be used in the mixture to produce a good architectural base suitable for finishing.

-o «0/00

Figure 18

0 Referring to Figure 18 the concrete passes through the mesh and flows into the recesses such as 276 of the insulating slab such that the concrete extends about the tension cable 318 and about the first layer of mesh 330. The concrete thus has a planar portion shown generally at 342 and has a plurality of rib portions 344. The rib portions extend perpendicularly from the planar portion 342 to form transverse, longitudinal and diagonal ribs deFned by the recess portions of the insulating slab. As the recesses extend substantially between the opposite

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AP .00534 frame members, so do the concrete ribs. The width of the recesses may be widened to increase the overall strength of the panel and if the bottom portion is widened the slope of the first and second sloping side portions is preferably reduced. Effectively, the shapes of Lhe recesses are optimized in cross-sectional area and section shape to optimize strength of the panel and to optimize the position of Lhe neutral axis of Lhe section for a given loading. The concrete ribs have embedded therein, portions' of the tension cable which act as positive reinforcement when loads are applied to the panel and Lhe planar portion has embedded Lherein the first layer of mesh which also acts as positive reinforcement. The diagonal ribs with embedded portions of the cables and the mesh in Lhe planar portion also act to distribute dynamic and static stresses to the frame members when positive loading is applied centrally of Lhe panel. The embedded portion of the cables and mesh also can act as negative reinforcement and distribute dynamic and static stresses when negative loading is applied centrally of the p3.nel.

The concrete acts as a first solidified castable substance cast in the interior portion of Lhe frame, between the frame members and about the biasing means such Lhat loads imposed on Lhe solidified castable substance (concrete) are transferred by the biasing means to Lhe frame members.

0 Figjre 19

Referring to Figure 19, side two 201 of the panel is finished in a manner similar to side one 199 and includes recesses similar to those on side one, includes a second turnbuckle, a second resiliently extendable tension cable having a second perpendicular portion 348 and a second diagonal portion 350, the second perpendicular portion lying in the second plane 312 and the second diagonal portion lying in the sixth hook plane 341. The second cable is routed in a manner similar to the first cable, about hooks 198 and 234 of Figure 13.

Side two 201 further includes a second layer of wire mesh material 346 extending in the fourth hook plane 314. Side two also has a second concrete retaining edge 358 and concrete

0 360 is poured over the second layer of mesh material 346 about the perpendicular and diagonal portions of the second resiliently extendable cable 34S and 350, into the recesses 2S8 formed in the second side of the insulating material. The concrete on the second side thus has a second planar portion 362 and a plurality of ribs 364 extending perpendicularly to the planar portion, in a manner similar to the concrete on side one 199.

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The concrete on sides one and two may be finished to have any desired surface to suit the placement of the pane!. If side one 199 is used to form the ground floor of the house, it preferably will be finished with a smooth surface to which finishing such as tile, carpet terrazzo, chips of marble, etc., may be fastened. Side two 201, which will ultimately face the ground when installed, need not be finished smooth but is preferably coated and sealed with a conventional water proofing compound.

Figure 20

Referring to Figure 20, a completed floor panel manufactured according to the steps above is shown generally a: 370. She pane! has first and second opposite longitudinal edges 372 and 374, respectively and has first and second opposite transverse edges 376 and 373, respectively which form a perimeter of the panel. These edges also define frst, second, third and fourth corners of the panels designated 171, 173, 175 and 177, respectively. The parallel members 170 and flanges 172 on each of the end portions of the frame members 150 and 155 extend beyond the perimeter of the panel and are used for lifting and handling the pane! and for connecting the pane! to the foundation members and wall panels.

The parallel members 170 and flanges 172 act as co-operating connecting means for connecting the panel to a co-operating connecting means of an adjacent building panel. As the parallel members and flanges are formed from plate steel they are operable to deform elastically when subjected to dynamic forces imposed on the panel. Due to this elastic deformability, the parallel members and flanges are operable to absorb seismic forces and due to the rigid connection of the parallel members and flanges to the adjacent frame member residual seismic forces are transmitted throughout the frame and to adjacent frame members of an adjacent panel.

Connection of Floor Panel to Foundation

Figure 21

Referring to Figure 21, the floor panel 370 is in position for connection with the foundation members. The pane! is positioned such that the first transverse edge 376 is adjacent the side foundation member 40 and the second longitudinal edge 374 is adjacent the end foundation member 42.

Prior to connecting the floor panel to the foundation members, a first corner connecting flange 3S0 is secured to the parallel member 170 adjacent the first transverse edge 376 and

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AP. Ο Ο 5 3 4 the second longitudinal edge 374 and a second corner connecting flange 382 is secured to the parallel member 170 adjacent the second transverse edge 37S and the second longitudinal edge 374. These corner connecting flanges are fastened by welding. Only the second longitudinal edge 374 of the pane!, which faces outwardly of the house has corner flanges connected thereto. The firs: longitudinal edge which faces inwardly, has no such comer flanges.

The first and second corner connecting flanges have respective parallel flange portions 384 and 3S6 which extend parallel to the second transverse edge and right angled flange portions 38S and 390 which extend perpendicular to the second transverse edge.

The parallel flange portions 3S4 and 386 have respective utility conduit openings 392 and 394 and respective adjacent fastener openings 396 and 398. The utility conduit openings 392 and 394 permit utility service conduits (not shown) to pass therethrough. The fastener openings 396 and 398 are for use in receiving a threaded fastener for fastening die pane! to the foundation members.

Installation of the floor pane! 370 onto the foundation members is effected by positioning the floor panel, using a crane (not shown), such that flange 172 and parallel flange portion 384 are received directly on top of the foundation connecting flanges 70 and 72, respectively. In addition, the pane! is positioned such that the remaining Ganges extending from the panel are disposed directly on top of corresponding foundation connecting flanges on corresponding foundation members below.

In this position, the utility service conduit openings in flanges 172 and 384 are in axial

5 alignment with the openings 82 in foundation connecting flanges 70 and 72 and are thus in communication with the interior of the steel tubing in the foundation members. Similarly, the fastener openings 176 and 396 are in axial alignment with corresponding threaded openings 84 in the foundation connecting flanges 70 and 72. Other fastener openings in other flanges on the panel are also in axial alignment with respective threaded openings in corresponding foundation connecting flanges. Threaded fasteners are then used in the threaded openings to securely fasten the panel to the foundation members, particularly if the floor is to be a deck portion of the house, with no wall panels connected thereto. If wall panels are to be connected however, the threaded fasteners would not be installed at this time.

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32.

Other Ποογ panels constructed as explained above are similarly connected to the remaining duct Ganges extending from the remaining foundation members. A first floor 400 of the house is thus formed by a plurality of floor panel members so connected to the foundation members.

In the embodiment depicted in the figures thus far, the dimensions cf a single f.ocr pane! are S' X S’. It will be appreciated, however, that the floor panel may be virtually any size. Interior and exterior wall panels, portions of which are shown a: 402, 404 (interior) and 406, 40S, 410 and 412 (exterior), respectively are connected to respective phates 16S extending from respective corners of the floor panels 370.

As floor panel 370 measures S' X S’, the installation of the interior and exterior wall panels 402, 404, 406, 40S and 412 define a first room which has dimensions of at least S' X 16’ as no interior panel is installed adjacent the first longitudinal edge 372 of the first floor panel.

Alternatively, an interior panel may be installed at this location in which case a room having tine dimensions of 3’ X S' would be defined. Also alternatively, the room may be made larger in the longitudinal direction of the floor panels by cutting off the plates at the third corner 175 of the floor panel 370 and omitting the installation of the interior panel 402.

Omitting the installation of interior panel 402 would leave a gap 414 between adjacent transverse sides of adjacent panels, however, such gap may be filled with concrete or water impermeable sealant such as silicone to provide a smooth floor surface. Various finishes such as linoleum or carpeting etc., may then be placed upon this smooth surface.

Before describing the specific connection of the interior and exterior panels to the floor

5 panels, each of these panels will be described.

c

Fxterior Panel Figure 22.

Referring to Figure 22, the fabrication of an exterior pane! according to the invention is begun by cutting to length first, second, third, fourth, fifth, sixth and seventh 2 X 4 hollow steel tubing members as shown at 420, 422, 424, 426, 428, 430 and 432, respectively. The steel tubing members act as frame members for the panel and are arranged to provide a window opening 434 and first, second and third pane! portions 436, 43S and 440.

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AP .0 0 5 3 4

Frame members 420 and 432 have respective opposite end portions 442, 444, and 446, 448, respectively. Each of the end portions is similar and therefore only end portion 444 will be described bet will be considered representative of each end portion.

Figu re_23

Referring to Figure 23, end portion 444 of frame member 420 is shown in greater derail. The frame member 420 has a longitudinal axis 450 extending centrally of the member. Inside and outside faces of the member are shown generally at 452 and 454, respectively, the inside face being directed towards an interior of the First panel portion 436 and the outside face being directed outwards from the panel and forming a portion of an outer perimeter of the panel. The frame member 420 also has a side one face 456 and a side two face 458, best seen in Figure 24. Tie side one face ultimately faces the interior of the house and the side i ^J t

two face ultimately faces the exterior of the house.

r

Figures 23, 24 and 25

Referring to Figures 23, 24 and 25, the end portion 444 of Frame member 420 has secured thereto, a transversely extending plate 460. The plate has a cover portion 462 for covering the end portion of the frame member and has a lip portion 464 which extends inwards, towards the interior portion of the panel. The cover portion 462 has an opening 466 which permits access to a hollow interior portion 468 of the frame member. As with the Poor panel, described previously, the hollow interior portion of the frame member permits utility service conduits to be routed therein.

ζ Referring to Figures 23 and 24, the end portion 444 further includes a first transversely

5 extending opening 470 in the side one face 456, a second transversely extending opening 472 in the side two face and a third opening 475 in the inside face 452 and first and second threaded openings 474 and 476 provided by first and second nuts 478 and 4S0 which are welded behind the side one 456 and side two 458 faces, respectively.

0 The inside face 452 has secured thereto a right angled member 482 having a mounting portion

484 and an extending portion 486. The mounting portion is welded to the inside face while the extending portion 486 projects perpendicularly to the inside face, toward the interior of the first panel portion 436. The extending portion has secured thereto a hook 4S8 having a hook portion 490 which is disposed in a first hook plane 492 adjacent the side one face 456,

AP/P/ 94/00708 bad original

and 3 projecting pin portion 491 which projects parade! to the longitudinal axis 450, toward the plate 460.

The inside face also has secured thereto a plurality of chair bolster hooks 494 similar to the 5 chair bolster hooks depicted as items 204 and 210 in Figure 7. Referring to Figure 22, the chair bolster hooks 494 are disposed in spaced apart relation, longitudinally along the frame member 420 and extend between the opposite end portions 442 and 444. Referring back to

Figures 24 and 25, the chair bolster hooks h3ve respective hook portions 496 disposed in a second hook plane 498 between the side one face 456 and the first hook plane 492.

The plate 460 acts as a foot for supporting the frame member, the openings 466, 470, 472, and 475 provide access to utility service conduits inside the frame member. Tne threaded openings 474 and 476 are for securing the resulting pane! to an adjacent panel and the extending portion 486 is for cooperating with an adjacent frame member of the same panel.

The hook 4S8 is for cooperating with a tension cable for holding the pane! together and the chair bolster hooks 494 are for holding a wire mesh in ohe second hook plane.

Referring back to Figure 22, the frame member 432 is similar to the frame member 420 and therefore requires no further description. Frame members 422 and 426 are however, slightly different from frame members 420 and 432 and therefore will now be described. ϋ

Frame members 422 and 426 form upper and lower portions of Lhe outer perimeter of the panel. Frame member 422 is divided into a first portion 500, a second portion 502 and a ¢- third portion 504. Frame member 426 is similarly divided into a first portion 506, a second portion 508 and a third portion 510.

c

Tire first portions 500 and 506 form part of the first panel portion 436 while the second portions 502 and 508 form portions of the second panel portion 438. The third portion 504 of member 422 forms a portion of a window frame about window opening 434 and tlie third 3 0 portion 510 of member 426 acts as a frame portion of the third panel portion 440. With the exception of the third portion 504 of member 422 adjacent the window opening 434, each of the above described portions has a respective plurality of chair bolster hooks, each indicated at 512 and has a plurality of tension cable hooks, each indicated at 514.

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AP . 0 0 5 3 4

Figure 26

Referring to Figure 26, the chair bolster hooks 512 each have respective hook portions 513 which lie in the second plane 498. In addition, the tension coble hooks 514 have respective hook portions 515 which lie in a third hook plane 517. 'line third plane 517 is parallel to and Spaced apart from the first and second planes 492 and 49S, respectively.

Referring back to Figure 22, the exterior panel further includes the frame members 424, 423 and 430 which are disposed intermediate the frame members 422, 424, 426 and 432. Frame members 424 and 430 are similar, mirror images of each other and therefore only member 424 will be described.

Frame member 424 extends between frame members 422 and 426. Member 424 has a longitudinal axis 519, a first end portion and a second end portion 520 and 522. The first end portion 520 has a hook 524 which is similar to the hook 4SS shown in Figure 24. The hook 524 has a hook portion 526 which lies in the same, first hook plane 492 as the hook 438 shown in Figure 24. Referring back to Figure 22, the hook 524 also has a projecting pin portion 528 which extends parallel to the longitudinal asxis 519 and which projects past the end portion 520 of the member.

The second end portion 522 of frame member 424 has first and second hooks 530 and 532 similar to hook 524, disposed on opposite sides of the end portion. Each of these hooks also has respective hook portions 534 and 536 lying in the first hook plane 492 (not shown in Figure 22) and has respective projecting portions 538 and 540 projecting past the end portion 522.

A right angled member 542 is secured to a side of (he frame member 424. The right angled member has a projecting portion 546 which projects inwards towards the third panel portion 440. A further hook 548 having a projecting portion 550 and a hook portion 552 is secured to the projecting portion. The projecting portion 550 extends parallel to the longitudinal axis 519, toward (he window opening 434. The hook portion 552 extends toward the third panel portion 440 and lies in the first hook plane 492 (not showm in Figure 22).

The frame member 424 has 3 first intermediate portion 554 which is disposed between the first and second end portions 520 and 522 and has a second intermediate portion 556 which is disposed between the right angled member 542 and the second end portion 522. The first

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-3 b intermediate portion has a plurality of chair bolster hooks 553 secured thereto m spaced apart relation along the length thereof. Similarly, the second intermediate portion 556 has a second plurality of chair bolster hooks 560. Both the firs; and second pluralities of chair bolster hooks have hook poitions disposed in the second hook plane 498 (not shown in Figure 22).

Frame member 42S extends between frame members 424 and 430 and has a plurality of hooks 562 having hook portions (not shown) lying in the third hook plane 517 seen best in Figure 26. In addition, referring to Figures 22 and 26, frame member 428 has a plurality of chair bolster hooks 564 which have hook portions lying in the second hook plane 498. Frame member 428 also has openings indicated at 566 and 56S for receiving the projecting pin portions 550 of adjacent frame members 424 and 430. In addition, frame members 422 and 426 have respective openings 570 for receiving the projecting pin portions 491, 52S, 53S, 540, 532 and 530 of frame members 420, 424, 430 and 532, respectively.

Figure 27

Referring to Figure 27, before the frame members are connected together, a sheet of wire mesh 572 is cut into a U“ shape corresponding to the ultimate shape of the exterior panel. A vapour barrier 574 is similarly cut to shape and is placed on top of the mesh material 572. A styrofoam slab 576 having First 578, second 580 and third 582 panel portions is laid on top of the vapour barrier 574. The First, second and third panel portions 578, 5S0 and 582 are similar and therefore only panel portion 578 will be described.

Panel portion 578 includes a plurality of longitudinally extending recesses 583 and crossdiagonal recesses 584 and 586, respectively. The panel portion also has longitudinal edge

5 portions 588 and 590 which are recessed for receiving the frame members 420 and 424, respectively as will be described further below.

Panel portions 580 and 582 have a similar constiuction and include a plurality of longitudinally extending recesses 592 and cross diagonal recesses 594 and 596, respectively.

Figure 28

Referring to Figure 28. frame members 420, 422, 424, 426, 428, 430 and 432 are placed in corresponding recesses of the styrofoam slab 576. Respective projecting portions 491, 538

5 and 540 on each of the frame members are received in corresponding openings 570 in frame

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3“l member 426. Frame member 42S is then installed between frame members 424 and 430, die projecting portions 550 being received in openings 566 and 56S on opposite end portions of member 42S, respectively. Finally, member 422 is placed adjacent the frame members 420, 424, 430 and 432 such that the projecting portions 523 and projecting portions 491 of respective frame members are received in corresponding openings 570 in frame member 422. At this point therefore, the frame is loosely connected together and lies in a flat frame plane parallel to the plane of the drawing sheet.

At this time in the fabrication process, a recess 59S is cut longitudinally into a centre portion 10 of the second pane! ponton 5S0 for receiving an electrical conduit 600 therein. The electrical conduit is connected to the frame member 426 by an electrical box 610 and is terminated in .· a second electrical box 612 operable to receive a standard wall socket cover. The conduit

600 is in communication with the hollow interior portion of frame member 426 and therefore electrical service conductors disposed in frame member 426 can be routed via conduit 600 to electrical box 612 to provide electrical service to a conventional wall receptacle (not shown) thereon.

Figure 29

Referring to Figure 29, first, second and third tension cables 614, 616 and 618 are routed in

0 longitudinal and cross diagonal recesses of respective pane! portions. Separate turnbuckles

620, 622 and 624 are used to tension respective tension cables 614, 616 and 618. The tension cable 614 is routed between the hooks 530, 526, 438, 514 in the first panel portion 436 such that portions of the cable lie in the diagonal recesses and portions of the cable lie _ in the longitudinal and transversely extending recesses. The second and third cables 616 and

618 are routed in a similar manner.

<;

Referring back to Figure 26, the portions of the tension cables in the longitudinal extending recesses 583 and 592, respectively extend in the third hook plane 517 whereas the tension cables extending in the cross-diagonal recesses 586 and 596 lie in the first hook plane 492.

Referring back to Figure 29, the first, second and third tension cables 614, 616 and 618 act as biasing means for biasing the frame members inwardly, generally in the frame plane, towards the interior portion of the panel.

The edge portions of the mesh material, indicated at 572 and 574 (in Figure 27) are then bent

5 over the adjacent frame members such as shown generally at 626 in Figure 29. The edge β 0 L 0 0 / 7 6 ,'d/dV

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- S3 portions are hooked or,to me chair bolster hooks 494, 512 and 562 on adtace.nt frame members.

Figure 30

Referring to Figure 30, frst, second and third individual rectangular pieces of flexible mesh material 628, 630 and 632 are then cut to ft respective frst, second and Lhird portions 57S, 5S0 and 582 and are placed over such portions. Edge portions of respective portions of the pieces of flexible mesh material are hooked onto adjacent hook portions of chair bolster hooks on respective adjacent frame members. Referring back to Figure 26, these hcok portions such as indicated at 513 lie in the second hook plane 498 and thus the mesh material also lies in the second hook plane 498.

Referring back to Figure 30, a concrete retaining edge 634 is then welded to respective frame members bounding the frst, second and third panel portions, respectively. A concrete mix as described above is then poured over the mesh material 628, 630 and 632 such that the concrete flows through the mesh and into the longitudinal and cross-diagonal recesses of each panel portion. The concrete is poured and finished flush with the concrete retaining edge 634. The concrete thus has a finished planar surface (not shown) which is parallel to the plane of the drawing page of Figure 30. This smooth surface will ultimately face the interior

0 of the house.

Figure 31

Referring to Figure 31, the panel is then turned upside down relative to its orientation depicted in Figure 30, whereupon a layer of stucco 636 is applied to the wire mesh 572

5 covering the First, second and third panel portions 436, 438 and 440, respectively. The manufacture of the panel is thus completed.

A window 638 may then be installed in the window opening 434. Alternatively, the window 638 may be installed after the panels are assembled to form the house.

The Finished exterior panel includes a generally rectangular portion 640 with Frst, second, Lhird and fourth panel connecting portions 642, 646, 648 and 650, respectively. Referring to Figure 23, the connecting portions are portions of corresponding end portions of the longitudinal frame members 420 and 432.

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Figure 32

Referring to Figure 32, it may be seen that the portions of the tension cable 616 which extend in the longitudinally extending recesses 583 lie in the third plane 517, portions of the tension cable which lie in die diagonal recesses lie in the Erst plane 492 while the mesh 630 lies in the second plane 49S. Each of the planes 492, 49S and 517 are parallel and spaced apart from each other.

In addition, the concrete has a planar portion 660 in which the mesh 630 and the diagonal portions of the tension cable 616 are disposed. Rib portions such as shewn at 662 extend perpendicularly to the planar portion 660, in the longitudinally extending recesses and in the diagonally extending recesses of the styrofoam slab 576. This is similar to that described with respect to the floor panel and thus the exterior wall panel has the same advantages of the floor panel which includes the ability to withstand positive and negative loads.

Interior Panel Figure 33

Referring to Figure 33, the fabrication of an interior pane! according to the invention is begun by cutting to length first, second, third and fourth panel frame members 670, 672, 674 and 676 and first, second, third and fourth door frame members 678, 680, 682 and 684.

Panel frame members 670 and 672 are similar and form longitudinal edge portions of the panel. Panel frame members 674 and 676 are similar and form transverse edge portions of the panel.

Frame members 670 and 672 have respective Erst and second similar end portions 6S6 and 688, respectively. End portion 686 is representative of each of the end portions and therefore will be described, it being understood that remaining end portions are similar.

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Figure 34

0 Referring to Figure 34, end portion 686 has a longitudinal axis 690 extending centrally of the member. The end portion has inside and outside faces designated generally at 692 and 694, respectively. The inside face 692 is directed towards an interior of the panel portion and the outside face 694 is directed outwards from the panel and forms a portion of an outer perimeter of the panel.

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Figu re_35

Referring to Figure 35, the end portion also has a side one face 696 and a side two face 69S. The side one face ultimately faces the interior of a first room of the house and the side two face ultimately faces the interior of a second, adjacent room of the house.

The end portion 6S6 is similar to the end portion 444 illustrated in Figures 23, 24 ar.d 25. In this regard, referring to Figure 35, the end portion has openings 700, 702, and 703 which are similar to openings 470, 472 and 475, respectively. The end portion also has first and second threaded openings 704 and 706 which correspond to threaded openings 474 and 476 of Figure 24.

y The end portion 686, is also similar to the end portion described in Figures 23, 24 and 25 in that it has an end plate 708 which covers the end portion 6S6 and which has a projecting portion 709. Face 692 has a right-angled member 710 secured thereto. The right-angled member has a connecting portion 712 and a projecting portion 714. Referring to Figure 35, the connecting portion 712 and the projecting portion 714 extend the full width of the member between faces 696 and 69S. First and second hook members 716 and 718 are connected to the projecting portion 714 in parallel spaced apart relationship. First hook member 716 has a first hook portion 720 which lies in a first hook plane 722. Similarly, the second hook 718 has a hook portion 723 which lies in a second hook plane 724. Jn addition, hook 716 has a projecting pin portion 726, tire projecting pin portion projecting in a direction parallel to the First hook plane 722. Similarly, the second hook 718 has a projecting portion 72S which is parallel to the projecting portion pin 726 and parallel to the second hook plane 724.

(

The frame member further includes a plurality of chair bolster hooks 730 which are disposed Q transversely across the franre member. The chair bolster hooks each have first and second hook portions 732 and 734, respectively. The first hook portion lies in a third hook plane 736 while the second hook portion 734 lies in a fourth hook plane 738. The First, second, third and fourth hook planes 722, 724, 736 and 738 are parallel and spaced apart relative to

0 each other.

Referring back to Figure 33, frame members 676 and 674 have respective opposite end portions 740 and 742. The end portions 740 and 742 are similar and therefore only end portion 740 will be described, it being understood that end portion 742 is similar.

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Figure 36

Referring to Figure 36, end portion 740 has first and second openings 744 and 746 for receiving the pin portions 726 and 72S of the hooks 716 and 718 shown in Figure 35. Referring back to Figure 36, the end portion 740 further includes a plate 748 extending transversely of the frame member, the plate having firs: and second upstanding hooks portions 750 and 752 depending therefrom.

Figure 37

Referring to Figure 37, the first and second hooks 750 and 752 have respective hook portions

754 and 756 which lie in third and fourth parallel spaced apart planes 75S and 760, respectively.

Referring back to Figure 36, the frame member further includes a plurality of chair bolster ( hooks 762 having first and second hook portions 764 and 766. The hook portion 764 lies in a fifth hook plane 76S while the second hook portion lies in a sixth hook plane 770.

Figure 38

Referring to Figure 38, end portions 6S6 and 740 are connected together as shown generally at 772. Pin portions 726 and 728 (not shown) are received in openings 744 and 746 (not

0 shown), respectively, such that the end portion 740 rests on the projecting portion 714 of the right angled member 710. Hooks 720 and 752 are therefore disposed parallel to and adjacent to each other.

Figure 39

Referring to Figure 39, a styrofoam slab 774 is inserted within an area bounded by the frame members 670, 672, 674 and 676. The styrofoam slab has a plurality of longitudinally C extending recesses 776, 778, 780, 782, 784, 786 and 788, first and second cross-diagonal recesses 790 and 792 and transversely extending recesses 794 and 796. A turnbuckle 798 is connected to hook 752 on frame member 676. A resiliently extendable flexible tension cable 800 is secured to the turnbuckle and routed in recesses 786, 794, 784, 796, 782, 794, 780,

796, 778, 794 and 776. The cable is then routed to hook portion 720 on frame member 670 and is then routed in cross-diagonal recess 790 to the corresponding hook portion 720 on frame member 672, in a diagonally opposite corner of the panel. The cable is then routed to hook 752 on frame member 674 and is routed longitudinally of the panel in recess 7S8 to a corresponding hook 752 on frame member 676. The cable is then routed to hook portion

5 720 on member 672 immediately adjacent hook 752, and is routed in cross diagonal recess

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792 to hook portion 720 on member 670, in the diagonally opposite corner of the panel. Tumbuckle 79S is tightened to place the cable under tension such that the frame members 670, 672, 674 and 676 are drawn inwardly towards the interior portion of the panel. Frame members 678, 680, 682 and 6S4 are welded together to form a door opening 802, with member 678 being welded longitudinally to frame member 672 A second insulating slab 804 is inserted between members 678, 6S0, 6S2 and 6S4.

Figure 40

Referring to Figure 40, a first layer of wire mesh 806 is placed between the frame members

670, 672, 674 and 676. lodge portions of the mesh material S06 are fastened to the first hook portions 732 of the chair bolster hooks 730 on frame members 670 and 672 and are connected to the second hook portions 766 of the chair bolster hooks 762 of members 674 and 676. The wire mesh is thus secured to the frame members. A second layer of wire mesh SOS is connected to frame members 678, 6S0, 682 and 684, respectively. A concrete reiaining edge

810 is then connected to the frame members 670, 672, 674 and 676 to form an outer perimeter of the panel. Similarly, a second concrete retaining edge 810 is connected to frame members 678, 680, 682 and 684 to form a second retaining edge above the door opening 802.

Figure 41

0 Referring to Figure 41, a concrete mix as described above is then poured over the fiist and second layers of mesh material 806 and SOS and finished to form smooth surfaces indicated generally at 814 and 816, respectively. After pouring the concrete, the panel has first, second, third and fourth connecting members 818, 820, 822 and 824 corresponding to respective end portions of frame members 670 and 672 (not shown), for connecting the panel

5 to adjacent panels and to floor and ceiling panels as will be described below. In addition, these members 8IS - 824 may be used for handling and lifting the pane! on the job site.

The panel is then turned upside-down relative to its orientation shown in Figure 41 whereupon the side two portion of the panel is completed in a manner similar to the side one

0 portion. Effectively therefore, the steps discussed above in forming the side one portion are repeated in forming the side two portion.

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Figure 42

Referring to Figure 42, a cross-section of a completed interior panel according to the 35 invention is shown generally at S26. The finished panel thus includes wire mesh 806 on a

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AP.00534 . 4 3 side one portion S2S of the panel and includes a further wire mesh 830 adjacent a side two portion 832 of the panel. The mesh 806 lies in the sixth plane 770 while the mesh portion 830 lies in the fifth plane 768. As stated earlier, the fifth and sixth planes 768 and 770 are parade! and spaced apart from each other and therefore the wire mesh portions S06 and 830 are also parallel and spaced apart.

The concrete poured on each side of the pane! includes respective planar portions S34 and 835 and respective rib portions 836 and 837, the rib portions being formed by concrete flowing into the recessed portions such as shown at 778, of the styrofoam slab 774. The planar portions 834 and 835 extend about the mesh material S06 and 830, respectively. In addition, the phnar portions extend about diagonally extending portions S3S and S40 of the flexible cable associated with the side one portion 82S and the planar portion of the concrete on the side two portion 832 extends about the diagonal portion 840 of the flexible cable on the side two portion S32. Similarly, the rib portions 836 extend about longitudinally extending portions of the flexible cable indicated at 842 for the side one portion 828 and S46 for the side two portion 832. It should be apparent that the diagonal portions of the cable 838 lie in the second plane 724 while the longitudinally extending portions and transversely extending portions of the cable 842 lie in the fourth plane 760. The second plane and the fourth plane 724 and 760 are parallel to and spaced apart from each other.

By routing the flexible cable in the manner described i.e. using diagonal portions and longitudinally and transverse portions in spaced apart planes, the panel is rendered with the ability to withstand positive and negative dynamic loading.

5 Roof Panel

Figure 43

Referring to Figure 43, the fabrication of a roof panel according to the invention is begun by cutting to length First, second, third, fourth and fifth panel frame members 850, 852, S53, 854 and 8S6. Frame members 850 and 852 are similar and frame members 854 and 856 are

0 similar. All frame members are formed from steel tubing but may be formed from generally any alloy operable to withstand any desired loading.

Frame member 850 has a first end portion 860 and a second end portion 862. The frame member also has a main roof portion illustrated generally at 864 3nd an overhang portion

5 illustrated generally at 866. The main roof portion 864 and overhang portion 866 are β β L 0 0 / V 6 i'Wd

BAD ORIGINAL sqrarated by a connecting portion S6S. The main roof portion bas a plurality of books S70 for securing a tensioned resiliently flexible cable to the frame member and has a plurality of chair bolster hooks S72 for securing w ire mesh as will be described below. The overhang portion also has a plurality of tension cable hooks 874 and chair bolster hooks S76 for similar purposes. As frame member S52 is similar to frame member S50, frame member S52 also includes similar chair bolster hooks and main roof portions, connecting portions and overhang portions and therefore these components are labelled with the same numbers as corresponding components on member S50.

Frame member 854 also has first and second opposite end portions S7S and 8S0 and has an intermediate ponion shown generally at SS2 having a plurality of chair bolster hooks 884. Frame member 856 is similar to frame member 854 and has similar components. Similar components are labelled with the same numerical reference numbers as those indicated on frame member 854. Frame member S5S also has first and second opposite end portions 886 and SS8 and has 2n intermediate portion S90 with a roof side 892 and an overhang side 894. The roof side 892 has a plurality of chair bolster hooks 896 mounted thereon and the overhang side has a plurality of chair bolster hooks 898 mounted thereon.

Figures 44 and 45

0 Referring to Figures 44 and 45, end portion S60 of frame member 850 is shown. Referring to Figure 44, frame member 850 has an outside face 900 and an inside face 902. Referring to Figure 45, the frame member has a roof side 904 and a ceiling side 906. The end portion 860 is cut at an angle 908 which determines the slope of the roof relative to the vertical. The end portion S60 includes an end plate 912 which is fastened by welding to a cut face 910 of the longitudinal member 850. The end plate 912 extends flush with the roof side 904 and has a connecting portion 914 which extends past the ceiling side 906. The connecting portion 914 has an opening 916 for receiving a connector such as a bolt therethrough.

The end portion further includes a flat horizontal plate 918 having an extending portion 920

0 and a flat connecting portion 922. The flat connecting portion 922 is secured to the outside face 900 of the end portion 860. The flat plate has an axis 924 which extends at right angles to the plate 912. A connecting plate 926 is further connected to the extending portion 920 and the plate 912 such that it is disposed at right angles to both the extending portion 920 and the plate 912. The connecting plate has 3n opening 928 extending therethrough for receiving

5 a connector such as a bolt therethrough.

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Tne end portion further includes a hook plate 930 secured to die inside face 902. A hook 932 having a hook portion 934 disposed in a first hook plane 936 is secured to the plate 930. Tne plate 930 is disposed immediately adjacent a chair bolster hook 872. The hook 932 corresponds to hook S70 illustrated in Figure 43,

The end portion further includes a pair of laterally spaced apart openings in the face 902, the openings being designated 93S and 940, respectively. Opening 93S is disposed adjacent ceiling side 906 while opening 940 is disposed adjacent roof side 904.

Figures 46 and 47

Referring to Figures 46 and 47, the connecting portion S6S is shown in greater detail. The connecting portion S6S includes an open space 942 disposed between the pluralities of chair bolster hooks on the roof portion S64 and the overhang portion 86S. Tne open space includes transversely and longitudinally spaced apart openings 944, 946, 948 and 950 for receiving pins on the end portion 886 of frame member 85S shown in Figure 43. Referring back to Figure 47, immediately adjacent the openings 944 and 950, adjacent the ceiling side 906, a plate 952 is secured to the ceiling side 906. An angularly extending portion 954 is connected to the plate 952. The angularly extending portion 954 includes a portion of 4 X 4 steel tubing. The extending portion 954 extends at an angle 956 which is the same as angle 908

0 of Figure 45. The extending portion 954 has an end plate 958 secured thereto for covering the end portion of the extending portion 954. The extending portion 954 further includes first and second threaded openings 960 and 962 for receiving fasteners therethrough.

Figure 48 and 49

5 Referring to Figures 48 and 49, end portion 878 of Frame member 854 is shown in greater derail. The end portion includes a roof surface designated 964, an inner surface 966, an outer surface 968 and a ceiling surface 970. Referring to Figure 49, the end portion 878 has a transversely extending angle member 972 having a connecting portion 974 and a projecting portion 976, the projecting portion 976 projecting at right angles to the inner surface 966.

A pin 978 is secured to the projecting portion 976 adjacent the roof surface 964, A hook 980 having a pin portion 982 and a hook portion 984 is also connected to the projecting portion 976 in parallel spaced apart relation to the pin 978. Both the pin 97S and the pin portion 982 extend parallel to a longitudinal axis 986 of the member 854. In connecting the panel together, pin 978 and pin portion 9S2 are received in openings 940 and 938, respectively,

5 shown in Figure 45.

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Referring to Figure 50, a sheet of wire mesh material 988 is laid flat and cut to the approximate size of a finished roof panel. A membrane such as tar paper 990 is also cut to size and laid upon the wire mesh 9SS. A First styrofoam slab 992 having a roof portion 994 and an overhang portion 996 is laid upon the tar paper 990. The styrofoam slab has longitudinal recesses 99S and 1000 extending along edges thereof and has a plurality of transversely extending recesses 1002, 1004, 1006, 1008, 1010, 1012 and 1014. In addition, the styrofoam slab has first and second cross diagonally extending recesses 1016 and 101S and has third and fourth cross diagonal recesses 1020 and 1022. The cross diagonal recesses

1018 and 1016 extend between diagonally opposite corners of the roof portion 994. The cross diagonal recesses 1020 and 1022 extend between diagonally opposite comers of the overhang portion 996.

C

The styrofoam slab 992 Further has frame holding recesses (not shown) in which frame C 15 members 850, 852, 854, S56 and S5S are received. When the frame members are placed into the recesses, the pin 978 and pin portion 982 depicted in Figure 49 ate received in openings

940 and 938 depicted in Figure 45. Similarly, projecting pins on frame member SSS in Figure 50 are received in openings 944, 946, 948 and 950, respectively in Figure 47 and projecting pins on frame member 856 are received in corresponding openings (not shown) in end portion 862.

Figure 51

Referring to Figure 51, a turnbuckle 1024 is connected to one of the hooks 870. A resiliently . extendible flexible tension cable 1026 is secured to the turnbuckle 1024 and is routed between

5 hooks 870 on frame member 850 and 852 such that the cable has a plurality of portions lying in the first and second longitudinally extending recesses and in each of the transversely extending recesses. In addition, the cable has portions 1030 and 1032 extending in the cross diagonal recesses 1016 and 1018.

0 Similarly, the overhang portion has a turnbuckle 1034 connected to a hook 872 and a resiliently extendible flexible cable 1036 is fastened to the turnbuckle 1034. The cable 1036 is routed between hooks 872 and 874 on trame members 852 and 850, respectively such that the cable has portions 1038 which lie in the transversely extending and longitudinally extending recesses and has portions 1040 and 1042 which lie in the cross diagonally extending

5 recesses 1020 and 1022, respectively.

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Upon fastening the cables, edge portions of the tar paper 990 and wire mesh materia! 9S8 are bent over respective adjacent frame members S54, S56, S50 and 852.

Figure 52 .Referring to Figure 52, the panel further includes first and second portions of mesh material portions 1044 and 1046, respectively. Tne first portion 1044 is cut to fit between respective chair bolster hooks 872 on frame members 850 and 852 and between chair bolster hooks 884 and 896 on frame members 854 and 858. The second layer of mesh material 1046 is cut to extend between chair bolster hooks 876 on the overhang ponion S66 of frame member 850 and 852. In addition, the second wire mesh extends between chair bolster hooks 898 and 884 on frame members S5S 2nd S56, respectively. A concrete retaining edge 104S extending the entire perimeter of the panel comprising both the roof portion and the overhang ponion is then secured to respective perimeter frame members S54, S56, 850 and 852.

A concrete mix as described above is then poured over the mesh materia! ponions 1044 and 1046 such that the concrete flows through the mesh material portion 1044 into the transversely, longitudinally, and cross diagonally extending recesses in the roof and overhang ponions of the styrofoam slab. The ceiling side of the roof panel is thus completed.

Tie pane! is then, turned upside-down relative to its orientation depicted in Figure 52 and concrete is poured over the wire mesh (999 not shown) to form a roof surface (not shown).

Figure 53

Referring to Figure 53, a ponion of the roof panel is shown in cross-section and includes a ceiling side 1050 and a roof side 1052. The ceiling side includes the concrete which has a planar ponion 1056 which extends the entire width and length of the panel and has a rib ponion 1054 which extends perpendicularly to the planar ponion in recess 1002. The remaining recesses in the styrofoam slab also have similar rib ponions. The mesh material ponion 1044 is disposed within a first plane 1058 while the cross diagonally extending ponions of the flexible cable are disposed in a second plane 1060. The longitudinally and transversely extending ponions of the cable 1026 lie in a third plane 1062. The first, second and third planes are parallel and spaced apart from each other. The cable 1026 lying in the third plane 1062 is thus spaced apart from the cable ponion 1032 lying in the second plane

1060. This provides positive and negative reinforcement of the panel. The exterior mesh 999 >

<O <35

CD <35 <O

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-tQlies in a fourm plane 10o4. Concrete, such as shewn at 1066, forms a roof surface of the panel and is embedded within minor exterior recesses 1068 formed in the styrofoam slab 992.

Figure 54

Referring to Figure 54, a finished panel according to the invention is shown generally at 1070. TChe Finished panel includes a ceiling surface 1072, first and second peak connecting portions 1074 and 1076, frst and second wall connecting portions 1078 and 10S0 and frst and second gutter connecting portions 1082 and 1084. The frst and second peak connecting portions 1074 and 1076 connect the panel to an adjacent panel to form a peak of the roof of the house. The second peak connecting portions 1074 and 1076 correspond to the end portion 860 of frame members 850 and 852. Similarly, the wall connecting portions 1078 and 10S0 correspond to the connecting portions depicted in Figures 46 and 47 and shown a; S6S in Figure 43.

Connecting Panels Togefber

Referring back to Figure 21, two exterior panels such as shown in Figure 31 are shown generally at 406 and 408. The third and fourth projecting portions 646 and 648 of pane! 406 •rj project downwardly for engagement with flanges 382 and 380, respectively. The third and _ ^r j fourth projecting portion of panel 408 project downwardly for engagement with flanges 172.

To facilitate connection of the exterior panels to the flanges, W-shaped and T-shaped connectors shown at 1090 and 1092, respectively are used. The W-shaped connectors 1090 are used in comers formed by abutting exterior panels while the T-shaped connectors 1092 are used to conned aligned, adjacent exterior panels.

The W-shaped connectors include frst and second flat portions 1094 and 1096 and a Wshaped wall portion shown generally at 1098. The fat portions 1094 and 1096 have respective conduit openings 1100 and 1102 and have respective threaded openings 1 104 3nd 1106. The wall portions have openings 1108 and 1110, respectively.

Similarly, the T-shaped connector has frst and second fat portions 1112 and 1114 and an upstanding wall portion 1116 with the characteristic T-shape. Each of the fat portions has respective conduit openings 1118 and 1120 and has respective connecting openings 1122 and 1124. In addition, the wall portion 1116 has first and second openings 1126 and 1128

5 adjacent the frst and second fat portions 1112 3nd 1114. respectively.

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The exterior panels are connected to the floor panel 370 by first connecting the W-shaped connector and T-shaped connectors to corners and side portions, respectively. The panels 406 and 40S are placed in posit ion whereupon the connecting portions 646 and 64S of panel 406 are placed upon the fiat porions 1114 and 1094, respectively. Similarly, the connecting porions 646 and 64S of panel 40S are placed upon the fiat porions 1096 and 1112, respectively.

Referring specifically to panel 408, the openings 474 in the connecting porions 646 align with openings 1110 and 1126, respectively. As the openings 474 are threaded, a bolt may simply be inserted through opening II10 and a second bolt can be inserted through opening 1126 and threadedly engaged with openings 474 on opposite end porions of the panel respectively. The pane! is thus secured to the W-shaped and T-shaped connectors.

In the case of the corner, the upstanding plate 16S of the floor panel 370 has an opening 1S2 which engages with a corresponding opening (476 not shown in Figure 21) on an opposite side of the connecting portion 646 of the pane! 408. A bolt is received through the opening 182 and is threadedly engaged with the opening (476) on the opposite side of the connecting porion 646. The opposite end porion of panel 408 is secured to corner 171 in a similar manner. Panel 406 is secured to the corners 177 and 173 in a similar manner. The exterior

0 panels are thus connected to the floor panels and foundation.

Connection of Interior Panels

The interior panels are connected to the floor panels in a manner similar to the way in which the exterior panels are connected. The interior panels, shown best in Figure 41, have

5 respective downwardly projecting connecting portions 820 and 824. Each of the downwardly projecting connecting portions 820 and 824 has a respective threaded opening 704. A corresponding opening 706 (not shown) is available on an opposite side of the projecting portions as shown in Figure 35.

Referring back to Figure 21, to install the interior panels, the projecting portions 820 and 824 are placed in receptacles 1130 and 1132 formed between respective plates 168 of adjacent floor panels. Each of the plates has a respective opening 182 which is aligned with the opening 704 (and 706) when the interior panel is properly in place. A threaded fastener such as a bolt may be inserted through the openings 182 and threadedly engaged with openings 704

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BAD ORIGINAL and 706, respectively to secure the interior pane.' to the Boor panels. A similar procedure is performed to secure other interior panels to the floor panels.

It will be appreciated that the downward projecting connecting portions S20 and 824 have 5 openings shown best in Figure 34 at 700, 702 and 703 for routing conduits from the foundation members to the individual interior panels.

Referring back to Figure I, with the interior and exterior panels fastened to the floor and foundation members, a first storey 1139 of the house is completed. Additional exterior and interior panels may be secured to the panels forming the first storey in order to form a second storey 1141 of the house.

Referring to Figures 31 and 41, both the exterior panel shown in Figure 31 and the interior panel shown in Figure 41 have upwardly projecting pane! connecting portions. With regard to the exterior panel in Figure 31, the connecting portions are shown at 642 and 650, respectively. With regard to the interior panel shown in Figure 41, the connecting portions are shown at SIS and 822, respectively.

The connecting portions 642, 650, SIS and 822 of Figures 31 and 41, respectively, are 20 similar to the vertically extending duct portions 66 and 76 shown in Figure 3. Thus, a floor panel member will act as a ceiling to a room on the first floor of die house and will act as a floor of a second floor of the house. Such a floor pane! member is installed on the connecting members similar to the manner in which the floor panel 370 was installed on the foundation members as depicted in Figure 21. Referring to Figure I, a second plurality of pre-fabricated exterior wall panels 28 are thus installed upon the panels of the first storey 1139.

AP/F/ 94/ 00709

Figure 55

Referring to Figure 55, the second plurality of pre-fabricated exterior and interior panels 2S 3 0 and 30 forms an arrangement of connecting portions 642, 650, 818, the arrangement being similar to the upstanding flanges 70, 72, 124 shown in Figure 3. Additional panels similar to the first and second pluralities of interior and exterior panels may be secured to these upstanding connecting portions 642, 650, SIS and 822 to create a house or structure having any number of storeys. In a preferred embodiment however, the house includes first and

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571 second storeys only and therefore the plurality of roof panels is installed above the second storey panels 28,

With the second plurality of second storey exterior panels 28 in place, the third floor pane! 5 32 is secured to the upstanding connecting portions 642, 650, 818 and S22, respectively. Tine third floor panel 32 acts as a ceiling for a room enclosed by the exterior panels 28 and he interior panels 30. The third floor 32 however, has an upper surface 1140 which acts as a floor surface of an attic portion of the house.

An attic panel 1142, similar in construction to the interior panel described in figures 33 through 41 has connecting portions 1144, 1146, 1 14S and 1150. These connecting portions ar e similar to connecting portions SIS, 820, 822 and 824 shown in Figure 41. The attic pane! 1142 has the same longitudinal dimension as the interior panel of Figure 41, however, the attic panel 1142 has approximately one-half the vertical dimension of the interior panel shown in Figure 41. The roof pane! 1070 shown in Figure 54 is then installed with second peak connecting portions 1074 and 1076 (not shown) connected to connecting portions 1144 and 1148 and with connecting portions 1078 and 1080 (not shown) being connected to the connecting portions 650 and 642 of the second storey exterior panel 28,

Figure 56

Referring to Figure 56, the connecting portion 1144 has first, second and third threaded openings 1152, 1154 and 1156, respectively. To install roof panels 1070 and 1158, the plate connecting portions 914 are abutted against opposite sides 1160 and 1162. In this position, the connecting plates 926 of respective roof panels 1070 and 1158 are received on top of the

5 connecting portion 1144, such that openings 928 in the respective flange portions are aligned.

This enables a bolt 1164 to be inserted through the openings 928 and secured in the threaded opening 1156. In addition, openings 916 in plate connecting portions 914 are aligned with the first and second threaded openings 1152 and 1154, respectively which enables first and second bolts 1166 and 1168 to be threadedly engaged with the threaded openings 1152 and

0 1154 to secure the roof panels in place.

Figure 57

Referring to Figure 57, to install the connecting portion 1078 of roof panel 38, a T-shaped connector 1170 having a horizontal portion 1172 and first and second vertical portions 1174 and 1176 is placed on top of the flange 172 of the third floor panel 32. The horizontal

BAD ORIGINAL portion 1172 rests on the flange portion 172 and plate 958 of the extending portion 954 rests upon the horizontal poition 1172. With the T-shaped connector 1170 and the extending portion 954 and the floor panel 32 disposed as shown in Figure 7, opening 962 is aligned with opening 182 in the plate 168 of the floor panel 32 and therefore a bolt 1178 may be inserted through the opening 182 to threadedly engage with the threaded opening 962. Similarly, first and second openings 1180 and 1182 are disposed in the first and second vertical portions 1174 and 1176 of the T-shaped member 1170. Opening 1180 is in alignment with threaded opening 960 in the extending portion 954 and therefore is operable to receive a bolt 11S4 therethrough to threadedly engage the bolt with the threaded opening 960 to secure the extending portion 954 to the T-shaped connector 1170. Similarly, opening 1182 is in axial alignment with threaded opening 1186 in the connecting portion 642 of panel 28.

In addition, opening 182 in the plate 168 is axially aligned with a threaded opening 11SS on 15 an inside portion of the connecting portion 642 and thus a bolt 1190 may be inserted through the opening 182 to threadedly engage with the threaded opening 11SS to secure the third floor panel to the connecting portion 642. The roof panel 32 is thus secured to the third floor panel 32 and the connecting portion 642. Other roof panels are secured in a similar manner.

Referring back to Figure 1, the house 10 is formed by assembly of a plurality of panels. It will be appreciated that small gaps 1196 exist between adjacent panels and thus continuous wall portions extending an entire side or end of the house are eliminated. Rather, the sides and ends of the house are formed from a plurality of discrete panel portions connected together. This permits the panels to move slightly relative to each other which, in effect,

5 permits portions of the wall formed by the discrete panels to move relative to each other. As there is no one continuous wall, such movement is less likely to permit the formation of cracks in the surfaces of the wall and thus the structural integrity of the wall and appearance of the wall is maintained. There are, however, small gaps 1196 which, at the time of assembly, are filled with a Fire-proof elastic sealant such as silicone with ceramic thread or

0 with expandable elastic fo3m which permits the panels to move relative to each other while maintaining an air tight seal in the gaps.

Co-operation ofthe assemhled panels

A structure according to the invention disclosed herein is particularly well adapted to withstand moments creaied by seismic forces or shell-blast forces. Referring back to Figure

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2, it will be appreciated that the foundation of the house is formed from a plurality of foundation members connected together. This renders the foundation ductile which serves to absorb moments, imposed at one location on the foundation, in a plurality of locations on die foundation. The joints between adjacent foundation members serve to absorb such moments. This is an advantage over conventional one-piece rigid, continuous foundation designs wherein a moment applied to, say, one corner of such a foundation m3y cause the foundation to crack due to its inability to absorb such moments.

Referring back to Figure 1, it will be appreciated that as each p2ne! member has a solid frame 10 member forming an outer perimeter of each panel, when the panels are connected together as explained above, the connected frame members form a three-dimensional, ductile, space frame. As the space frame is comprised of essentially the frame members bolted together, phe members of the space frame are not rigidly connected together, but rather, provide some ductility and thus provide for some absorption of moments and forces transmitted to the space frame, such as from seismic forces or shell-blast forces travelling in the ground, through the foundation to the space frame or from shell-fire adjacent the building.

Thus, the panels are able to move slightly, relative to each other to absorb such forces. Thus the panels act elastically relative to each other. It will be appreciated that the horizontal

0 portions of each of the wall panels are essentially connected to the vertical portions of the wall panels by pins which permit vertical movement of the horizontal frame members relative to the vertical members. In addition, as the tension cables in each panel are used to bias the frame members inwards towards an interior portion of each panel, the tension cables are Operable to extend or contract slightly in the event of positive or negative loading on the

5 panels and thus forces exerted on the panels and the frame members can be further absorbed in the resiliency of the tension cable. This is particularly provided by the use of diagonally extending tension cables in a plane parallel to and spaced apart from the transversely and longitudinally extending portions of the tension cables.

0 Seismic forces exerted on the foundation are absorbed by the joints in the foundation.

Residual moments and forces are transmitted to the panels connected to the foundation and hence to the space frame structure formed by the connected panels. Further residual forces are transmitted to the structure in each panel, specifically, the mesh, the cables and concrete thereof. The mesh and cables are resilient and act to absorb most of the residual forces and moments. Thus, the magnitude of forces and moments finally reaching the concrete forming

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S4 the panel is mimmiaed, which reduces the risk of creating cracks in the concrete panel portions. Tne Boor, wall and ceiling surfaces of the house thus remain virtually crack free, even after seismic activity or nearby shell-fire.

In addition, the invention presents a structure w-nich is dynamically stable in various wind conditions. As the structure is comprised of a plurality of panels, the surface area over which the wind effects can act is reduced, relative to a unitary wall of a conventional house structure. Each panel itself can withstand both tension and compression and hence can absorb inwardly directed forces (positive loading) and outwardly directed forces (negative loading).

For example, an inward force in direction of arrow 1192 exerts positive loading on an exterior wall panel. A central portion of the panel, indicated generally at 1194, is permitted to move slightly inwards thereby stretching the tension cables on both the side one and side two portions of the pane!, the tension cables resil ient!y resisting such stretching and absorbing the force accordingly. A force applied in a direction opposite to arrow 1192 represents negative loading and is absorbed in a similar manner, with the central portion of the panel moving slightly outwards to absorb the force, and then returning to its original position.

The above panels, foundation members and connectors permit a three-dimensional building

0 structure such as the house shown in Figure 1 to be quickly and efficiently erected. As the panels are pre-fabricated, the entire manufacturing process of the panels can be complexed in the factory. In particular, the aggregates used in forming the concrete can be selected and controlled to ensure uniformity, the concrete can be cured under controlled conditions, and can be ground, painted, baked or any other architectural finish can be applied.

5

In addition structural steel components can be precisely cut and formed using computer control techniques. Furthermore, the job-site on which the stiucture is being erected need only be provided with the necessary bolts and wrenches to fasten the panels together, a crane for lifting the panels into pbee, and a cutting torch for selectively cutting any undesired

0 protruding connecting portions of panels. Furthermore, the panels are sufficiently robust that they may be shipped easily in a specially designed shipping container having conventional shipping container dimensions. Thus, the prefabricated panels are easily transported from the factory to the job-site.

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AP.00534

Other uses for the panels Hi-rise Structure Figure 58

Referring to Figure 58, a further use of the panels according to the invention is realized in 5 co-operation with the conventional hi-rise office or aparment building structure. A conventional hi-rise structure typically includes a plurality of vertical columns 1200 arranged in a rectangular array when viewed from above and a plurality of horizontal cross members

1202 arranged in a plurality of horizontally spaced apart planes 1204, 1206, 120S, 1210, 1212, 1214 along the vertical columns.

The vertical columns 1200 and horizontal cress members 1202 form the main structural components of the hi-rise and are conventional in design. By dimensioning the cross members for structural integrity and by suitable spacing of the planes, exterior 1216, interior 1218, and floor 1220 parrels according to the invention can be connected together to form a module 1222, say, three storeys high, three units wide and four units long where each unit is an individual apartment cr office.

The hi-rise can thus be built in a modular form, eliminating the pouring of each concrete floor of the hi-rise as is conventionally done.

Individual outer, or boundary panels, which lie adjacent the vertical columns or cross members are connected, using the connecting means associated with each panel, to respective adjacent vertical and horizontal members 1200 and 1202 such that a space frame is formed by the frame members of each panel and by the vertical and horizontal members of the hi25 rise. A relatively large, unitary space frame is thus formed, the space frame defining an array of tenantable units between the spaced apart vertical planes. The projecting portions extending from the panels in a direction parallel to the edge portion of the panel act as the connecting means and are operable to deform elastically under seismic forces, the space frame having all of the benefits described earlier, including the ability to absorb moments and forces created by seismic activity or shell- fire. In addition, all of the benefits of the panels including the ability to absorb residual moments without cracking the concrete surface and the ability to withstand and distribute wind loading forces are obtained in the hi-rise.

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Figure 59

Referring to Figure 59, transportation of the panels forming a house can be easily accomplished by connecting floor panels of the house together to form a 16’X S’X 9' shipping container as shown a; 1230, with panels and other components of th.e house shewn in broken outline, inside the container. Tne floor panels are connected together to form eicht container corners, only seven of which are shown at 1232, 1234, 1236, 123S, 1240, 1242 and 1244, and four mid-portion connectors, only three of which are shown at 1248, 1250 and 1252.

Figures 60a-h

Referring to Figures 60a and 60b, mid-portion connector 1248 is illustrated. First and second floor panels 1256 and 1258 are shown butted together end to end, in a horizontal plane. Similarly, third and fourth floor panels 1260 and 1262 are butted together end to end in a vertical plane. Plate portions 1264 and 1266 of the first and second floor panels 1256 and 1258 are bent at respective right angles to lie flat against respective undersides of the first and second floor panels. This allows respective edges 1268 and 1270 of the third and fourth panels to lie immediately adjacent the undersides of the first and second floor panels, reispectively. In this configuration, respective flanges 1272 and 1274 and parallel members

1276 and 1278 abut with a relatively large top gap 12S0 being formed between end edges

1282 and 1284 of Phe first and second floor panels, respectively. Opposite portions 1286 and 1288 of the plate portions are left to project vertically upward.

Similarly, parallel members 1290 and 1292 and flanges 1294 and 1296 on the third and fourth panels 1260 and 1262 abut, leaving a side gap 1298 and plate portions 1300 and 1302 projecting horizontally outward from the panels.

Referring to Figure 60c, a top, middle wooden member 1304 is pre-notched to rest on the flanges (1272 and 1274 of Figure 60a and Figure 60b) such that a top surface 1306 thereof

0 is approximately flush with the adjacent outer surfaces 130S and 1310 of the first and second floor panels 1256 and 125S and such that an end surface 1312 thereof is approximately flush with the parallel members 1276 and 1278. The plate portions 1286 3nd 12SS are then bent at right angles to overlap and secure the wooden member 1304 in the top gap.

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Λ similar procedure is followed with a side middle wooden member 1314 such uhat an outer surface 1316 thereof is approximately flush with adjacent outer surfaces 13 IS and 1320 of the third and fourth panels 1260 and 1262. The plate portions 1300 ar.d 1302 are then bent ar right angles to overlap and secure the side middle wooden member inside the side gap.

Referring to Figure 60d, first 3nd second plate portions 1322 and 1324 are secured across the top and side gaps, to the first and second floor panels 1256 and 125S and to the third and fourth floor panels 1260 and 1262 respectively. Preferably, pre-threaded openings (not shown) are provided in the respective portions of the first and second floor pane's, respectively, to receive bolts 1326 for securing plate portion 1322 to floor panels 1256 and 125S and for securing plate portion 1324 to floor panels 1260 and 1262. The plates rigidly secure the floor panels together.

Referring to Figures 60e and 60f, the first container corner is shown generally at 1232. Th.e comer is formed by the first and third panels 1256 and 1262 which are 8' X 16’ floor panels. These panels are connected to a fifth floor pane! 1328 having a square shape and measuring 8’ X 8’. The fifth floor panel acts as an end portion of the container. A first plate portion 1330 of the first panel is bent parallel to the underside of the floor panel to permit an edge 1332 of the third panel 1262 to lie closely adjacent to the underside of the first floor pane!

0 1256. A second plate portion 1334 is left upstanding.

Similarly, a first plate portion of the third panel 1262 is bent as shown generally at 1336, in broken outline. The first plate portion is bent to extend parallel to an inside surface of the third panel 1262, while a second plate portion 1338 of the third panel 1262 is permitted to

5 extend outwardly. In this configuration, respective parallel members 1340 and 1342 and respective flange members 1344 and 1346 are spaced apart and do not interfere with each other.

The fifth floor panel 1328 has first and second plate portions, the first plate portion being shown in broken outline at 1348 in Figure 60e and the second plate portion being shown in solid outline at 1350 in Figures 60e and 60f. The first plate portion 1348 extends under the first panel 1256 while the second plate portion 1350 extends outwardly. The panel also has a parallel member 1352 and a flange member 1354 which project vertically upwardly relative to an edge 1356 of the panel 1328. Thus, a top edge gap 135S and a side edge gap 1360 are

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SF formed at respective inter me.; cf the first and fifth panels 1256 and 1328 and the third and fifth panels 1262 and 132S.

Referring to Figure 60g, the top edge gap is filed by a wooden top edge member 1362 5 suitably notched to accomm;date the parallel and flange members (1340, 1344 and 1352,

1354 of Figures 60e and 60f) cf the first and fifth panels, respectively, This permits first and second sides 1364 and 1366 of the top wooden member 1362 to lie flush with respective surfaces 1308 and 1368 of the first and fifth panels and permits an end face 1370 thereof to lie flush with the edge surface 1372 of the first panel 1256. The second plate portions 1334 and 1350 are then bent over the wooden member 1362 to secure it in place.

Similarly, a wooden side edge member 1374 is suitably notched (not shown) to accommodate the parallel and flange members 1342 and 1346 shown in Figure 60f, such that frst and second side surfaces 1376 and 1378 thereof lie generally flush with adjacent surfaces 13S0 and 1382 respectively when placed in the edge gap 1360 shown in Figure 60e. Referring back to Figure 60g, the second plate portion 133S is bent over the wooden side edge member 1374 to secure it in position.

Referring to Figure 60h, a corner connector is shown generally at 1384. The comer 2 0 connector is installed over the comer portion of the container after preparing the comer portion as shown in Figure 60g. The corner connector includes a first right angled member

1386 and a top plate member 13S8 to which is welded a crane adapter 1390. The first right angled member 1386 has frst and second portions designated at 1392 and 1394 respectively. The first and second portions 1392 and 1394 are oriented at right angles to each other such

5. that the first portion 1392 is operable to extend parallel to surface 1366 while the second portion is operable to extend parallel to surface 1372. Tie first and second members are secured to their respective adjacent surfaces by lag bolts 1400 extending into the nearby wooden member and by carriage bolts 1402 threaded into preformed threaded openings (not shown) in the edge surface 1372 and into preformed threaded openings in the fifth panel 1328

0 and in the third panel 1262.

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The top plate member 1388 has frst and second portions 1404 and 1406 which rest on the wooden surface 1364 and on panel surface 1310, respectively. The first portion 1404 is secured to the wooden surface 1364 by lag bolts 1408 while the second portion is secured to

5 the first panel by carriage bolts 1410 cooperating with threaded openings (not shown) in a

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“I frame members (such as 1412 shown in broken outline) of the pane! 1256. Die right angled ciane adapter 1390 has portions extending parallel to the surfaces 1366, 1310 and edge surface 1372 and allows a conventional container lifting crane found in most shipping ports to engage the corner.

Referring back to Figure 59 it will be appreciated that the remaining container comers 1234, 1236, 1238, 1240, 1242 and 1244 (and the one not shown) are formed in the same manner as described above with respect to comer 1Σ32. Similarly, the remaining mid-portion connectors 1250, 1252 (and the one not shown) are formed as described above with respect to mid-portion connector 1245. Thus, the floor panels of the house are effectively connected together to form a shipping container capable of holding all of the components necessary to build the house. The floor panels which are used to form the container are also used in ( building the house, after straightening or cutting off the bent plate portions 1264, 1266, 1286,

12S8, 1300 and 1302 in Figure 60c and 1334, 1336, 1338 and 1350 in Figure 60e.

Referring back to Figure 59, The container thus forms an open box' into which the various other panels and components necessary to form the house are placed as indicated by the following list of components:

Floors

2001. floor, underside of container

2002. floor c/w plumbing connections, underside of container

2003. floor, topside of container

2004. floor, topside of container 1256. floor, side of container 1258. patio, side of container 1260. patio, side of container 1262. front porch, side of container 1328. deck, end of container

2010. deck, end of container

Exterior Walls

2011. back left corner cJw window

2012. back left c/w glass doors

2013. back centre

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2014. back right c/w window

2015. back right corner c/w window

2016. front left corner c/w window

2017. front left c/w window

201S. front centre c/w frosted window and door

2019. front right c/w window

2020. front right corner c/w window

2021. left back c/w window

2022. left centre c/w window

2023. left front c/w window

2024. right back c/w glass doors

2025. right centre c/w window

2026. right front c/w window

Roof

2027. gable end left back

2028. middle left

2029. gable end left front

2030. gable end right back

2031. middle right

2032. gable and right front

Interior Walls and Partitions

2033. full height wall

2034. 8’ high wall c/w door

2035. wall above 2034. & 2101.

2036. full height wall

2037. full height wall c/w door

2038. full height wall

2039. 8' high partition c/w door

2040. (a & b) partition above 2101.

2041. full height wall

2042. full height wall

2043. (a & b) partition above 2101.

2044. 8' high partition c/w closet doors

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AP.00534

2044.	t. top of closet	Cu. 1
2045.	S' high partition c	:/w closet doors
2045.	t. top of closet

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2100. Kitchen Unit

2101. Bathroom Unit

2102. Refrigerator/Freezer

2103. Washer Dryer

2104. Hot Water Heater

The container thus contains all of the components required to build the house. The crane adapters 1390 on each corner permit the container to be handled using conventional container handling equipment as commonly found on the docks of major shipping ports and therefore act as means for cooperating with a handling crane for lifting the container. As the containers themselves are formed from panels comprising a steel frame and concrere interior portions, a plurality of containers may be stacked, one upon the other, on the deck or in the shipping hold of an ocean going vessel without fear of damaging the containers due to listing of the vessel during a voyage. Typically, the foundation members for the house are shipped

0 separately or manufactured near the job site on which the house is to be installed.

Figures 61 and 62

When a container as shown in Figure 59 is received on a job site, the components inside the container and the panels forming the container are assembled to form a house according to the invention. In the embodiment disclosed herein, the house provides more than 800 square feet of living space using 6 inch Boor panels, 4.75 inch exterior wall panels, 7 inch roof panels, 3 inch interior wall panels and 2 inch interior partitions.

Assuming the foundation members have already been shipped and installed on site, the house

0 is assembled as described above. As best seen in the plan view of Figure 61, the floor, sides, ends and top (2001-2010) of the shipping container form the Boor (2001-2005), patio (2006 and 2007), front porch (2008) and deck (2009) of the house while the components which were inside the container form the house itself. The invention thus provides a shipping container capable of holding all components necessary to build a house with the components of the

5 container itself also forming components of the house in the final assembly thereof. Thus, ₆ o L 0 0 / V 6 /d/dV

BAD ORIGINAL efficient use of materials and space is provided while at the same time providing a convenient, strong shipping container for die house components.

The projecting portions on each panel act as connecting means for connecting each of the 5 panels to a co-operating connecting means of an adjacent pane!. As described above, these projecting portions are operable to deform elastically under severe forces imposed on the panel.

Alternatives

Figure 63

Referring to Figure 63, an alternative finish to the smooth finish imparted to the concrete, described above, is formed using a plurality of pre-formed conventional rectangular marble tiles, one of which is shown at 3000. The tiles are pre-fitted with a plurality of hooks shown generally at 3002 which are secured to the adhesive side of the conventional marble tile.

Each hook has a flat backing surface portion 3004 which is glued to the adhesive or backing side of the tile. A projecting portion 3006 extends normal to the flat surface portion, away from the tile. The projecting portion is terminated in a hook portion 3008 which is arranged to project downward, toward the floor when the tile is used on a wall panel. The hook 3002 is preformed such that Ore distance between the adhesive side of the tile and the hook portion

3008 is equal to the approximate thickness of the concrete, designated in Figure 63 as 3010.

To use the marble tiles, the tiles are pre-fitted with hooks 3002. Then, after the concrete 3010 has been poured over the mesh 3012 of the panel, but before the concrete cures, the tiles are placed on the concrete such that the hook portions 3008 project into the uncured concrete until the backing surface rests on the surface of the uncured concrete. In this position the hooks engage with the mesh 3012, while the adhesive side of the tile contacts the uncured concrete. The panel is then left undisturbed while the concrete cures. The cured concrete firmly sets about the hooks and secures the hooks 3002 to die mesh 3012 and the tiles are securely fixed to the panel. It will be appreciated that the tiles need not necessarily

0 be marble but may be of any suitable architectural finish such as rock, granite, slate, wood siding etc.

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Figure 64

In the embodiment described above the panels were stated to measure 8’x 8'. Similar benefits to those available using an S'x 8’ panel, as described above are available in panels of various other dimensions. Examples of panels with other dimensions are shewn in Figure 64.

All of the panels shown in Figure 64 measure 8' in height. The smallest practical panel (a) able to achieve die stated benefits is 6 wide and includes only vertical tension cables. The 12 and 18’ panels (b) and (c) are similar. The 2’ through 3'6 panels (d,e,f,g,) each include diagonal portions of tension cable although each forms a reverse K form rather than an X form as described in the embodiment described above. The remaining panels each include at least one X form of diagonal cables with some panels including a combination of an X form and a K form (rn,n,q,s,u,w). The indicated forms 3re preferable for the panel dimensions indicated in order to achieve the structural, seismic and wind benefits described above.

Curved Foundation and Panels Figure 65

Referring to Figure 65, a curved foundation portion is shown generally at 4000. To use the curved foundation portion, an end foundation adapter portion 4002 and a side foundation

0 adapter portion 4004 are used. The end foundation adapter portion 4002 includes a length >

*χ» of end foundation similar to the foundation portion designated 42 in Figure 3, but with first —— and second upstanding connecting portions 4008 and 4010 extending vertically upward, adjacent the curved foundation portion 4000. The first and second upstanding connecting portions 4008 and 4010 are similar to the vertically extending duct portions 74 and 76 on the

5 side member 40 of Figure 3 and thus have respective plates 4012 and 4014 having respective conduit and threaded openings 4016, 4018 and 4020, 4022, respectively.

The side foundation adapter 4004 is similar to the side foundation member 40 of Figure 3 with the exception that it does not have the right angled end portion 48 shown in Figure 3.

0 Rather, the side foundation adapter 4004 has a straight end portion 4024 which has first and second upstanding channel portions 4026 and 4028, respectively. The first and second upstanding channel portions extend vertically upwards relative to the end portion 4024, the channel portions being similar to channel portions 4008 3nd 4010 just described.

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44The first and second channel ponions 4026 and 4028 are ter minuted in respective plates 4030 and 4032. Each plate has a respective conduit and threaded opening 4034, 4036 and 4038, 4040.

The curved foundation member 4000 extends through 90 degrees, following an arc of a circle of radius 5 feet. The member has first and second end portions 4042 and 4044 which mate flush with respective end portions of the end foundation adapter ponion 4002 and the side foundation adapter ponion 4004. Adjacent end ponions are connected together using respective mating connectors 4046 and 404S similar to connecting flanges 86 shown in Figure

3.

Referring to Figure 65, the end foundation adapter portion 4002, curved foundation member 4000 and side foundation adapter 4004 each has a respective conduit 4001, 4003 and 4005 which is in communication with the conduits (as shown at 56 in Figure 3) of adjacent foundation members. Thus, electrical service cables can be routed in the conduits of the various foundation members and can be accessed through openings 4016, 4020, 4034, 4038. Electrical service can, therefore, be provided to panels connected to plates 4012, 4014, 4030 and 4032.

0 Floor Panel With Curyed Corner Figure 66

Referring to Figure 66, a plurality of frame members of a floor pane! with a curved corner portion are shown generally at 5000. The plurality of frame members includes first, second, third, fourth, fifth and sixth frame members 5002, 5004, 5006, 5008, 5010 and 5012,

5 respectively. Frame members 5002, 5004 and 5006 are similar to frame members 150, 152 and 153 of Figure 4 and therefore are not described further. Frame members 5008 and 5010 are straight frame members while frame member 5012 is curved longitudinally to extend through 90° of an arc of a circle having a radius 5014 of 5 feet to match the radius of curvature of the curved foundation member 4000 shown in Figuie 65.

Referring back to Figure 66, frame memher 5012 has first and second end faces 5016 and 5018 disposed at right angles to ench other. Each end portion has a respective radially extending opening 5020 and 5022, respectively for receiving co-opetating pins 5024 and 5026 on adjacent frame members 500S and 5010. The adjacent frame members also have

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CT respective flat end faces 5023 and 5030 which abut the first and second end faces 5016 and 5018, respectively when the frame members are assembled together.

Adjacent fame member 5008 has first, second, third and fourth connecting flanges 5032, 5 5034, 5036 and 503S which are used to connect the finished panel to the foundation shown in Figure 65. The first connecting flange 5032 is similar to the connecting flange 172 of

Figures 5, 6 and 7 and piojects outwardly of the panel, along the longitudinal axis 5040 of frame member 5008. The second, third and fourth connecting flanges 3034, 3036 and 3038 have structure similar to the first connecting flange but extend transversely to the longitudinal axis 5040. The second connecting flange is disposed adjacent the first connecting flange while the third and fourth connecting flanges are disposed adjacent each other and adjacent the third frame member 5006.

The fifth frame member 5010 also has connecting flanges 5044 and 5046 extending transversely thereto and has an inside face with a plurality of spaced apart chair bolster hooks 5048, similar to those indicated at 204 in Figure 4.

Frame members 5002, 5008 and 5012 also have a plurality of spaced part tension cable hooks 5050 similar to those indicated at 196 in Figure 4.

Figure 67

Referring now to Figure 67, the frame members 5002 - 5012 are assembled together to form first and second interior portions 5052 and 5054, respectively. The interior portions include respective slabs of preformed styrofoam 5056 and 5058 similar to the slabs on the interior

5 portion of the panel shown at 270 and 272 in Figure 11. Slab 5056 is virtually identical to the slab shown on interior portion 270 and therefore will not be described further. Slab 5058 is similar to the slab on interior portion 272 with the exception of a rounded corner portion 5060. Slab 5058 has longitudinal, transverse and curved recess portions, the longitudinal portions being indicated at 5062, the transverse portions being indicated at 5064 and the curved recess portion being indicated at 5066. The slab also has first and second intersecting diagonal recess portions 5068 and 5070, respectively. Tie first diagonal recess portion extends between the curved recess portion and an opposite corner, the second diagonal recess portion extends between opposite corners, transversely to the first diagonal recessed portion.

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BAD ORIGINAL bFjgure 68

Referring to Figure 62, a first resiliency extendable flexible tension cable 5072 is routed in the recessed portions of the first slab 5056 in a manner similar to that shown in Figure 11 and serves to bias the frame portions inwardly. A second resilier.tly extendable flexible tension cable 5074 is routed in recessed portions 5062, 5064, 5066, 506S and 5070 and serves to hold frame members 5002, 5008, 5010 and 5012 together. As with the floor panel described in Figure 14, Ore portions of the tension cable which are routed in a longitudinal and transverse recesses lie in a first plane whereas the portions 'which are routed in the diagonal recesses lie in a second plane, spaced apart from the lust plane, similar to die routing of cables described with respect to Figure 11.

Figure. 6 9

Referring to Figure 69, first and second layers of mesh material 5076 and 507S are tensioned and connected to the bolster hooks 504S facing respective first and second inner portions of the panel. The first layer of mesh material is similar to wire mesh 330 shown in Figure 16. The second layer is 3lso similar to wire mesh 330 of Figure 16 with the exception that it has a rounded corner portion 5080 to match the curvature of frame member 5012. The first and second layers of mesh material lie in a third plane, above the second plane in which the diagonally extending portions of tension cable are routed. Concrete (not shown) is then poured over the mesh material such that the transverse, longitudinal and diagonal recesses are filled and the concrete is finished to have a smooth planar surface. The reverse side of the panel is finished in a similar manner and includes third and fourth tension cables, third and fourth layers of mesh and a second finished side of concrete.

Figure 70

Referring to Figure 70, a finished panel according to the invention is shown generally at 5082 and has a finished interior surface 5084 and protruding connecting flanges 5032, 5034, 5036, 5038, 5042, 5044, 5046 and 5086 which mate with contesponding connecting Ranges 124, 124, 4012, 4014, SO, 4032, 4030. 80 and 134, respectively, shown in Figure 65, the connecting flanges protruding from the pane! and the flanges protruding from the foundation act as co-oper3ting connecting means which are operable to deform elastically under seismic forces imposed on the foundation or panel.

AP/P/ 9 4/0070$

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Curved Extz_rior_W 3!I Panel Figure 71

Referring to Figure 71 a plurality of frame members for forming a curved exterior wall panel is shown generally at 5088. The plurality of frame members includes first and second curved frame members 5090 and 5092, first and second end members 5094 and 5096 and first, second, third and fourth intermediate frame members 5098, 5100, 5102 and 5104.

The end members 5094 and 5096 are similar to members 420 and 432 of Figure 22 while the intermediate frame members 5098, 5100, 5102 and 5104 are similar to member 5006 shown in Figure 66. These members therefore require no further description. The first and second curved frame members 5090 and 5092 are mirror images of each other and therefore only the first curved frame member 5090 will be described.

Figure 72

Referring to Figure 72, the first curved frame member 5090 has an interior facing face 5106 having first, second, third, fourth and fifth panel portions 5108, 5110, 5112, 5114 and 5116, respectively which are spaced apart by first, second, third and fourth intermediate portions 5118, 5120, 5122 and 5124, respectively. The frame member 5090 also has frst and second opposite end portions 5126 and 5128, respectively.

Each end portion 5126 and 5128 has an opening 5130 and 5132, respectively for receiving respective pins 5134 and 5136 on mating end portions of corresponding end members 5094 and 5096, respectively (of Figure 71). Similarly, each intermediate portion 5118, 5120, 5122 and 5124 has a respective pair of openings 5138, 5140, 5142 and 5144 for mating with respective pairs of pins 5146, 5148, 5150 and 5152 on the end portions of the corresponding intermediate members 5098, 5100, 5102 and 5104, respectively (of Figure 71). The pins are permitted to move axially in the openings thereby permitting the curved end member to move in a direction parallel to the intermediate members and end members.

The panel portions 5108, 5110, 5112, 5114 and 5116 are similar and therefore only panel portion 5108 will be described. Panel portion 5108 includes frst and second spaced apart tension cable hooks 5154 and 5156, respectively, the hooks being similar to those shown at 5050 in Figure 66. Between the tension cable hooks 5154 and 5156 are located three spaced apart chair bolster hooks 5158, 5160 and 5162, arranged in a line.

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Figure 73

Referring to Figure 73, a curved slab of styrofoam 5164 is formed with the same curvature as the curved frame members 5090 and 5092 of Figure 71 and has a web portion 5166, a plurality of longitudinally extending recessed portions 5170 and a plurality of rib portions

5163.

Figure 74

Referring to Figure 74, the manufacture of the curved panel is begun with a sheet of mesh material 5172 w-hich is laid flat on the manufacturing floor. A water impermeable membrane such as tar paper 5174 is laid flat on the mesh material 5 172 and tne cursed styrofoam slab 5164 is laid on the tar paper 5174.

( ' Figure 7S

Referring to Figure 75, the end and intermediate frame members 5094, 5096, 5093, 5100, C’ 15 5102 and 5104 are laid in the recessed portions 5170 and the curved frame members 5090 and 5092 are. placed against them such that the pins of respective members (such as 5134 and

5136) are received in cot responding openings (such as 5130 and'5132) in the curved end frame members. The tar paper 5174 and mesh material 5172 are then bent upwards to follow the shape of the curved styrofoam and the edges of the membrane and mesh 3re bent over the

0 end members to embrace the end members 5094 and 5096 and the curved frame members

5090 and 5092.

Figures 76 and 77

Referring to Figures 71, 72 and 76, a single resiIiently extendable flexible tension cable 5176 25 is routed between the tension cable hooks 5154 and 5156 of each panel portion and is tensioned using a turnbuckle 5157 such that the curved frame members 5090 and 5092 are held snugly against the end members 5094 and 5096 and the intermediate members 5098 5104.

AP/P/ 94/00709

A further layer of mesh material 5178 is then connected between the end members 5094 and 5096 and the curved frame members 5090 and 5092 such that a curved inner plane 5180 is defined by the mesh material, as best seen in Figure 77f A concrete retaining edge 5182, shown best in Figure 76, is preformed to conform to the curved inner plane 5180 and is riveted, welded or screwed to adjacent frame members to !orm an edge defining a perimeter of an inner surface of the panel.

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Figure 78

Concrete is then pcuied over the mesh material 5178 such that it flows into the recessed portions 5170 of the styrofoam slab to form concrete ribs 5184 therein with concrete web portions 5IS6 extending between the ribs 5184. The concrete of the ribs thus extends about the intermediate members 5093, 5100, 5102 and 5104 and the tension cable 5176 while tlie web portions 5186 extend about the mesh material 5178. The concrete is left undisturbed to cure, whereupon a smoothly curved inner surface 5188 is formed. A smoothly cur/ed outer surface 5190 is formed by the first mesh material 5172 and may be smoothly finished using any conventional finish such as stucco or the like.

Figure_79

Refer ring to Figure 79, a finished curved pane! according to the invention is shown generally at 5192. The pane! has projecting connecting portions 5194, 5196, 5198, 5200 which extend Outwards from respective corners thereof. The connecting portions are similar to connecting portions 642 , 646 , 643 and 650 shown in Figure 31, and thus each has a respective opening for routing of utility service conduits and each has a threaded opening 5201 for securing the pane! to an adjacent panel or foundation member.

Figure 80

Referring to Figure 80, a floor pane! is shown immediately prior to assembly on the curved foundation member 4000, end foundation adapter portion 4002 and side foundation adapter 4004.

The floor pane! is lowered onto the foundation members such that flanges 5032, 5034, 5036,

5 5038, 5046, 5044, 5042 and 50S6 mate with corresponding connecting flanges 124, 4012,

4014, 4030, 4032, 80 and 134, respectively. The curved corner portion 4052 is located adjacent the curved foundation member 4000.

Next, first, second, third and fourth adapter connecting Ganges 5202, 5204, 5206 and 5208 are laid upon connecting Ganges 5034, 5036/5038 5046/5044 and 5042, respectively. The curved wall panel 5000 is then placed upon the foundation such that connecting portions 5200 and 5198 mate with connecting Ganges 5204 and 5206, respectively. First and second adjacent wall panels 5203 and 5205, each having a length of 3 feet are then installed on the connecting Ganges 5202, 5204. 5206 and 5208 in a similar manner to complete the corner

5 portion of the structure.

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The wall panel connecting ponions 5198 and 5200, flanges 5202, 5204, 5206, 5208, floor panel connecting flanges 5034, 5036, 5038, 5042, 5044, 5046, 5086 and corresponding foundation connecting flanges 124, 124, 4012, 4014, 80, 4032, 4030, 80 and 134, icspectively, are then connected together using bolts to rigidly secure the panels to the foundation. The connection of the panels and foundation in this manner creates a three dimensional space frame wherein the individual frame members of each panel act as structural members in the space frame. The connectors projecting from the foundation and panel members respectively act as elastically deformable connections which are capable of absorbing and distributing dynamic forces.

Finally, it will be appreciated that the wall, floor or roof panels may be made in virtually any geometric shape 3nd are not limited to flat planar or cum-ed planar forms.

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While specific embodiments of the invention have been described and illustrated such ' 15 embodiments are not considered to limit the invention as construed in accordance with the accompanying claims.

Claims

A building panel comprising:

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a) a plurality of frame members;

b) frame member connecting means for connecting together said frame members to form a frame lying in a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior portion of the panel;

c) biasing means for biasing at least one of said frame members inwardly, generally in said frame plane, towards said interior portion of the panel;

d) a first solidified castable substance cast in said interior portion of tire frame, between said frame members and about said biasing means such tliat loads imposed on said solidified castable substance are transferred by said biasing means to said frame members.
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ii>) iv) biasing means for biasing at least one of said frame members inwardly, generally in said frame plane, towards said interior portion of the panel;

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(O a first solidified castable substance cast in said interior portion of the frame, between said frame members and about said biasing means such that loads imposed on said solidified castable substance are transferred by said biasing means to said frame members;

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v) connecting means for connecting each of said panels to a co-operating connecting means of an adjacent said panel, the connecting means being Operable to deform elastically under forces imposed on said panel, and vi) a plurality of connectors co-operating with said panel connecting means for connecting at least some of said panels together to form a transportation container capable of holding a sufficient number of panels and connectors to form a dwelling from said sufficient number of panels and said panels used to form said transportation container.

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71. A three dimensional structure as claimed in Claim 70 wherein the plurality of connectors co-operating with said panel connecting means includes cooperating means for co-operating with a handling crane for lifting said transportation container.

2 5 b) a plurality of connectors for co-operating with respective connecting means on each member to secure adjacent members together.

58. A foundation for a building structure as claimed in Claim 57 wherein the hollov/ conduits in each of said foundation members are in communication with each other.

AP/P.' 94/0070»

59. A foundation for a building structure as claimed in Claim 57 wherein the connecting means on each of the foundation members is rigidly connected to a respective hollow conduit in its respective member and wherein the connecting together of the

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A foundation members forms a space frame with the hollow conduits of each of the foundation members acting as the space frame members.

60. A foundation for a building structure as claimed in Claim 59 wherein the space frame 5 lies in a flat plane.

61. A method of securing an architectural finish element to a surface ultimately formed by a castable material cast about a mesh material, the method including the steps of:

10 a) securing at least one projection to 2 backing surface of said architectural finish element such that said projection extends generally away from said backing surface;

b) insetting said at least one projection into said castable material before said 15 castable material has set, until said backing surface rests on a surface of said castable material, said at least one projection co-operating with said mesh material to engage therewith; and

c) permitting said castable material to set about said at least one ptojection, 2 0 thereby firmly securing said projection in said castable material and securing said architectural finish element thereto.

62. A method of securing an architectural finish element as claimed in Claim 61 wherein the step of inserting is preceded by the step of securing.

63. A method of securing an architectural f nish as claimed in Claim 61 wherein the step of securing is preceded by the step of forming said at least one projection with a portion for engaging and hooking on to die mesh during the step of inserting.

2 5 material over the frame.

46. A method as claimed in claim 45 wherein the step of laying includes die step of connecting the second layer of mesh material to frame members on opposite sides of the panel.

47. A method as claimed in claim 46 wherein the step of connecting is preceded by the step of securing mesh-fastening hooks to the frame portions.

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48. A method as claimed in claim 45 wherein the step of laying comprises the step of 35 tensioning the second layer of mesh material.

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49. A method as claimed in claim 45 further including the step of casting a second curable substance about said second layer of mesh material.

50. A building structure foundation member, the member comprising:

a) a solidified castable material formed to include a footing portion for resting on the ground and a support portion for supporting a building structure;

b) a hollow conduit extending lengthwise in at least one of said footing portion

10 and said support portion for holding utility service provisions;

c) openings in said support portion for permitting access to said hollow conduit and said utility service provisions; and

15 d) connecting means for connecting said member to an adjacent similar member, the connecting means being operable to deform elastically when seismic forces are imposed on said member.

51. A building structure foundation member as claimed in Claim 50 wherein the member 2 0 has engaging faces for mating with similar engaging faces of respective adjacent members.

52. A building structure foundation member as claimed in Claim 51 wherein the hollow conduit includes a unitary length of structural tubing having first and second end

25 openings accessible at said engaging faces respectively.

53. A building structure foundation member as claimed in Claim 52 wherein said connecting means includes at least one elastically deformable flange rigidly connected to said structural tubing and protruding from said solidified castable material, for

2 5 step of securing mesh-fastening hooks to the frame members.

37. A method as claimed in claim 34 wherein the step of laying comprises the step of tensioning the first layer of mesh material between frame members on opposite sides of the panel.

38. A method as claimed in claim 33 further including the step of placing insulating material in said interior portion.

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39. A melhc-d as claimed in claim 38 further including the step of preforming the insulating material with recesses, the iccesses being in a first planar side of said insulating material.

5 40. A method as claimed in claim 39 wherein the step of preforming the insulating material compr ises the step of preforming vertical, horizontal and diagonal recesses in a side of said panel, the recesses extending between the frame members.

41. A method as claimed in claim 33 wherein the step of biasing includes the step of 10 connecting a fust resilient,y extendable tension link between two fiame members on opposite sides of the panel and tensioning the first link prior to the step of casting.

42. A method as claimed in claim 41 wherein the step of casting includes casting the first curable substance about said first tension link.

43. A method as claimed in claim 42 wherein the step of biasing includes the step of connecting a second resiIiently extendable tension link between frame members on opposite sides of the frame.

20 44. A method as claimed in chim 43 further including the step of securing to the frame concrete form edge retaining members in corners of the frame prior to the step of casting.

45. A method as claimed in claim 34 including the step of laying a second layer of mesh

2. A building panel as claimed in claim 1 wherein the biasing means includes a resiliently extendible tension link extending between at least (wo of said frame members.
3 0 spaced apart vertical planes, the connecting means on panels adjacent the vertical and horizontal members connecting the space frame to the vertical members and horizontal members.

68. A hi-rise building as claimed in Claim 67 wherein the connecting means for 3 5 connecting adjacent panels together and the connecting means for connecting the

BAD ORIGINAL \Zspace frame to the vertical members and horizontal members include respective projecting portions extending from panels adjacent the vertical columns and horizontal beams.

5 69. A hi-rise building as claimed in Claim 68 wherein said projecting portions extend in a direction parallel to an edge portion of a frame member of the panel and wherein tlie projecting portions are integral w'ith respective frame members of said panel.

70. A plurality of building panels for forming a three dimensional structure, the panels 10 including;

i) a plurality of frame members;

ii) frame member connecting means for connecting together said frame members to form a frame lying in a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior portion of the panel;

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3 0 64. A three dimensional building structure comprising:

a) a plurality of building panels, each panel including:

i) a plurality of frame members;

AP/P’ 94/00709

BAD ORIGINAL ii) frame member connecting means for connecting together said frame members to form a frame lying m a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior jxrrtion of the panel;

iii) biasing means for biasing at leers: one of said frame members inwardly, generally in said frame plane, towards said interior portion of the panel;

iv) a first solidified castable substance cast in said interior portion of the frame, between said frame members;

b) pane! connecting means for connecting said building panels together, the pane! connecting means being operable to deform elastically under forces imposed on said panel.

c) a plurality of connectors for co-operating with respective connecting means on each panel to secure adjacent panels together.

20 65. A three dimensional building structure as claimed in Claim 64 wherein the cooperating connecting means on each panel includes a projecting portion extending from each panel, the projecting portion extending in a direction parallel to an edge portion of the fiame of the pane! and being integral with at least one frame member of the panel.

66. A three dimensional building structure as claimed in Claim 64 wherein the frame members of adjacent panels form a rigid space frame defining the shape of said three dimensional structure.

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30 67. A hi-rise building comprising:

a) a plurality of spaced apart vertical members aligned to lie in spaced apart vertical planes;

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b) a plurality of horizontal members connected to and extending between said vertical members to define a plurality of spaced apart horizontal planes intersecting said venical members;

5 c) a plurality of building panels disposed between said spaced apart horizontal planes, each of said panels including:

i) a plurality of frame members;

ii) frame member connecting means for connecting together said frame members to form a frame lying in a frame plane, the frame defining a perimeter of the panel, the perimeter bounding an interior portion of the panel;

iii) biasing means for biasing at least one of said frame members inwardly, generally in said frame plane, towards said interior portion of the panel;

iv) a first solidified castable substance cast in said interior portion of the 20 frame, between said frame members and about said biasing means such that loads imposed on said solidified castable substance are transferred by said biasing means to said frame members; and

v) connecting means for connecting said each panel to an adjacent panel, 25 the connecting means being operable to deform elastically under force;

AP/PZ 94/00708 the panels being connected together to form a space frame defining an array of units between said spaced apart horizontal planes and said

3 0 engaging with a co-operating flange on an adjacent member.

54. A building structure foundation member as claimed in Claim 53 wherein said flange is bolted to said flange on said adjacent member.

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55. A building structuie foundation member as claimed in Claim 50 wherein said openings are formed in upstanding lengths of structural tubing secured generally at right angles to and in communication with said hollow conduit, said upstanding lengths projecting from said support portion of said member and being operable to

5 be secured to a building member mounted thereon.

a) a plural

i)

56. A building structure foundation member as claimed in Claim 50 wherein said footing portion includes a hollow conduit containing insulating material to provide insulating properties to the foundation member.

57. A foundation for a building structure, the foundation including: ity of foundation members each comprising:

a hollow conduit extending lengthwise in at least one of said footing portion and said support portion for holding utility service provisions;

ii) openings in said support portion for permitting access to said hollow conduit and said utility service provisions;

iii) connecting means for connecting said member to an adjacent similar member, the connecting means being operable to deform elastically when forces are imposed on said member; and

3 5 at an angle to said two opposing frame members.

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31. A building panel as claimed in Claim 1 wherein 3t least one of the frame members is curved and the building panel generally lies in a Bat plane.

32. A building panel as claimed in Claim 1 wherein at least two parallel frame members

5 are similarly curved to form a curved panel lying in a curved plane.

33. A method of making a building panel, the method comprising the steps of:

a) connecting together frame members to form a frame lying in a frame plane;

b) biasing at least some of said frame members inwardly genei ally in said frame plane towards an interior portion bounded by the frame members;

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c) casting a first curable substance in said interior portion of the frame, between

15 said frame members such that loads imposed on said first curable substance, when cured, are transferred to said frame members.

34. A method as claimed in claim 33 further including the step of laying a first wire mesh over the frame prior to the step of casting.

35. A method as claimed in claim 34 wherein the step of laying includes the step of connecting the first mesh material to members on opposite sides of tire panel frame.

I

36. A method as claimed in claim 35 wherein the step of connecting is preceded by the

3 0 in a fifth plane, the filth plane being spaced apart from said fourth plane, the fourth plane being spaced apart from the first and second planes.

30. A building panel as claimed in claim 29 wherein said fourth portion extends generally perpendicular to two opposing frame members and wherein said fifth portion extends

3 5 of said panel.

AP/P/ 9 4 / 0 0 7 0 #

BAD ORIGINAL /422. A building panel as claimed in claim 20 wherein the frame portions have hollow portions disposed longitudinally therein and wherein the projecting portion has an opening for permitting utility service conduits to be routed in said hollow portions.

5 23. A building panel as claimed in claim 20 wherein the projecting portion has an end portion and a plate secured to the end portion for securing the panel to an adjacent panel, the plate having an opening therein for passage of utility service conduits therethrough.

10 24. A building panel as claimed in claim S further including a second resiliently extendable wire mesh materia! extending between the frame portions, said second wire mesh being spaced apart from said first wire mesh.

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25. A building panel as claimed in claim 24 further including a second solidified castable

15 substance cast about said second layer of mesh material.

26. A building panel as claimed in claim 2 wherein the biasing means includes a second resiliently extendable tension link extending between at least two of S3id frame members.

27. A building panel as claimed in claim 26 wherein the biasing means includes second tensioning means for tensioning said second tension link.

28. A building pane! as claimed in claim 27 wherein the second tensioning means

25 includes a second turnbuckle.

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29. A building panel as claimed in claim 8 wherein the biasing means includes a second resiliently extendable tension link extending between the frame members, said second tension link having a third portion lying in a fourth plane and a fourth portion lying

3 0 20. A building panel as claimed in claim 19 wherein the cooperating connecting means includes a projecting portion extending from said panel.

21. A building panel as claimed in claim 20 wherein the projecting portion extends in a direction parallel to an edge portion of the frame and is integral with a frame member

3 5 in said ribs.

AP/P/ 9 4/ 00709 bad original 8

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14. A building panel as claimed in claim 8 wherein the castable substance is formed to include a generally planar portion parallel to said frame plane and a plurality of ribs projecting perpendicularly to said planar portion, the ribs extending substantially between said frame members, said first and second planes intersecting said ribs and

5 said third plane intersecting said planar portions such that said first and second portions of said resiliently extendable tension link are disposed within said ribs and said tensioned mesh is disposed within said planar portion.

15. A building pane! as claimed in claim 12 wherein the panel further includes an

10 insulating material in said interior portion, said insulating material having recessed portions therein for forming said ribs when said castable substance is cast.

16. A building panel as claimed in claim 13 wherein the panel further includes an insulating material in said interior portion, said insulating material having recessed

15 portions therein for forming said ribs when said castable substance is cast.

17. A building panel as claimed in claim 14 wherein the panel further includes an insulating material in said interior portion, said insulating material having recessed portions therein for forming said ribs when said castable substance is cast.

18. A building panel as claimed in claim 2 wherein said frame members have hooks thereon and wherein said resiliently extendable tension link is looped around said hooks.

25 19. A building panel as claimed in claim I further including cooperating connecting means for connecting the panel to a cooperating connecting means of an adjacent building panel, the connecting means being operable to deform elastically under forces imposed on said panel.

3. A building panel as claimed in claim 2 wherein the biasing means includes tensioning means for tensioning said flexible tension link.
4. A building panel as claimed in claim 3 wherein the tensioning means includes a turnbuckle.

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6.

A building panel as claimed in claim I wherein the biasing means includes a first tensioned wire mesh extending between at least two frame members.

A building panel as claimed in claim 1 wherein the biasing means includes a resiliently extendable tension link extending between the frame members, said flexible tension link having a first portion lying in a first plane and a second portion lying in a second plane, the second plane being spaced apart from said first plane.

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7. A building panel as claimed in claim 6 wherein said firs' portion extends generally perpendicular to two opposing frame members aid therein said second portion extends at an angle to said two opposing frame members.

5 8. A building panel as claimed in claim 7 wherein so.id biasing means further includes a first tensioned flexible mesh member extending between at least two frame members, said mesh member lying in a third plane spaced apart from said first and second planes.

10 9. A building panel as claimed in claim 1 wherein at least two of said frame members form a first pair of opposite sides of said frame and wherein at least two of said frame members form a pair of adjacent sides of said frame, said first pair of opposite sides extending between said pair of adjacent sides.

15 10. A building panel as claimed in claim 9 wherein said frame member connecting means permits movement of said frame members forming said pair of opposite sides relative to and in a direction parallel to the longitudinal axis of said frame members forming said pair of adjacent sides.

20 11. A building panel as claimed in claim 9 wherein said each frame member of said pair of adjacent sides has a respective pin projecting in a direction parallel with the longitudinal axis of the member and wherein each frame member of said pair of opposite sides has a respective pin receptacle for receiving a respective said pin therein.

12. A building pane! as claimed in claim 1 wherein the castable substance is formed to include a generally planar portion parallel to said frame plane and a plurality of ribs projecting perpendicularly to said planar portion, the ribs extending substantially between said frame members.

13. A building pane! as claimed in claim 2 wherein the castable substance is formed to include a generally planar portion parallel to said fame plane and a plurality of ribs projecting perpendicularly to said planar portion, the ribs extending substantially between said frame members, said resiliently extendable tension link being disposed
5 72. A three dimensional structure as claimed in claim 71 wherein said cooperating means includes a crane adapter operable to be engaged by said handling crane.