CA1214658A - Precast reinforced concrete panel - Google Patents
Precast reinforced concrete panelInfo
- Publication number
- CA1214658A CA1214658A CA000454254A CA454254A CA1214658A CA 1214658 A CA1214658 A CA 1214658A CA 000454254 A CA000454254 A CA 000454254A CA 454254 A CA454254 A CA 454254A CA 1214658 A CA1214658 A CA 1214658A
- Authority
- CA
- Canada
- Prior art keywords
- panel
- panels
- trusses
- pair
- concrete
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
- E04B1/06—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material the elements being prestressed
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A precast panel for a building comprises a pair of molded concrete inner and outer panel elements with a steel wire mesh embedded throughout each panel element. A series of laterally spaced continuous steel rod trusses are interposed between and extend at right angles to the panel elements with end portions of the trusses embedded into the panel elements. An insulating layer overlies and is bonded to the interior side of the outer panel element occupying part of the space between the panel elements, the remainder of the space providing an air barrier zone. Pairs of aligned panels and right angularly related corner panels are interconnected by a concrete column poured in situ between the adjacent panels. The method of making the building panel includes the steps of assembling and interconnecting a series of wire trusses between a pair of wire mesh reinforcements forming a reinforcement member, supporting the reinforcement member upon a first mold, pouring concrete into the mold to enclose one steel wire mesh reinforcement and the one edge portions of the trusses, and curing to form a reinforced inner panel element with one of the wire mesh and portions of the trusses embedded therein. Further steps include applying and bonding series of strips of insulating material between the trusses in a plane spaced from the inner panel element and mounting the inner panel element, reinforcement and insulating strips horizontally with the insulating strips forming the bottom of a second mold and successively pouring concrete into the second mold enclosing the other wire mesh reinforcement and other edge portions of the trusses and curing to provide a unit building panel.
A precast panel for a building comprises a pair of molded concrete inner and outer panel elements with a steel wire mesh embedded throughout each panel element. A series of laterally spaced continuous steel rod trusses are interposed between and extend at right angles to the panel elements with end portions of the trusses embedded into the panel elements. An insulating layer overlies and is bonded to the interior side of the outer panel element occupying part of the space between the panel elements, the remainder of the space providing an air barrier zone. Pairs of aligned panels and right angularly related corner panels are interconnected by a concrete column poured in situ between the adjacent panels. The method of making the building panel includes the steps of assembling and interconnecting a series of wire trusses between a pair of wire mesh reinforcements forming a reinforcement member, supporting the reinforcement member upon a first mold, pouring concrete into the mold to enclose one steel wire mesh reinforcement and the one edge portions of the trusses, and curing to form a reinforced inner panel element with one of the wire mesh and portions of the trusses embedded therein. Further steps include applying and bonding series of strips of insulating material between the trusses in a plane spaced from the inner panel element and mounting the inner panel element, reinforcement and insulating strips horizontally with the insulating strips forming the bottom of a second mold and successively pouring concrete into the second mold enclosing the other wire mesh reinforcement and other edge portions of the trusses and curing to provide a unit building panel.
Description
1~146~3 PRECAST REINFORCED CONCRETE WALL PAN~LS
AND METHOD OF ERECTING SAME
Thi3 invention relates to prec~st reinforced ~oncrete construction o~
bearing, retaining and ~urtain walls and including wall panel3 erected side by ~ide together with ~e method of making and erecting said panels for a building construction.
BACKGROUND OF THE INVENTION
Precsst concrete w~l p~nel~ are commonly used as architectural non-bearirg curtain walls in residential, commercial, and industrial buildings for ~eir appearance and insul~tion qualities. However, some ~rchitectural precsst wall panels are designed to functior. as bearin~ or retaining walls as well.
Existing precast concrete wall p~nels have either solid or sandwich sections. However, the latter are more commonly used due to their light weight flnd insulation characteristics.
Sandwich pAnels are produced in many different forms and confir~rations aiming at the optimization of strength, weight and cost ~actors to achieve a structurally and economically sound panel. The sandwich wall panel derives its bearing capacity for compressi~n and/or bending from the individual capacities of ~e different ~ection elements and the composite ~ction of these elements provided th~t there are enough shear connectors between ~em c~pable of transferir~ the shear forces without exhibiting ~ppreciable slip~ge ~etween the separatP layers. This can usually be ~chieved by using U~e lnsulating core material as a sned~um transmitting l~e ~ear nOw or by providing the section with metallic shear connectors of different shapes and configurations.
v~
65~il I~IE PRIOl~ ART
Examples of concret~ reinforced strllctural panels are sh~wn in one or more of the following United Ss~tes Qnd ~oreigrl Patents 1,818,443 8/11/31 W.~. WDaon
AND METHOD OF ERECTING SAME
Thi3 invention relates to prec~st reinforced ~oncrete construction o~
bearing, retaining and ~urtain walls and including wall panel3 erected side by ~ide together with ~e method of making and erecting said panels for a building construction.
BACKGROUND OF THE INVENTION
Precsst concrete w~l p~nel~ are commonly used as architectural non-bearirg curtain walls in residential, commercial, and industrial buildings for ~eir appearance and insul~tion qualities. However, some ~rchitectural precsst wall panels are designed to functior. as bearin~ or retaining walls as well.
Existing precast concrete wall p~nels have either solid or sandwich sections. However, the latter are more commonly used due to their light weight flnd insulation characteristics.
Sandwich pAnels are produced in many different forms and confir~rations aiming at the optimization of strength, weight and cost ~actors to achieve a structurally and economically sound panel. The sandwich wall panel derives its bearing capacity for compressi~n and/or bending from the individual capacities of ~e different ~ection elements and the composite ~ction of these elements provided th~t there are enough shear connectors between ~em c~pable of transferir~ the shear forces without exhibiting ~ppreciable slip~ge ~etween the separatP layers. This can usually be ~chieved by using U~e lnsulating core material as a sned~um transmitting l~e ~ear nOw or by providing the section with metallic shear connectors of different shapes and configurations.
v~
65~il I~IE PRIOl~ ART
Examples of concret~ reinforced strllctural panels are sh~wn in one or more of the following United Ss~tes Qnd ~oreigrl Patents 1,818,443 8/11/31 W.~. WDaon
2,0~,1û9 7/1~36 ~.~. Nag~l 2~213,~55 913/~ .D. Woodworth 4,3~9,848 11/a3/8a Ernst Haeu~aler German2,0a~,l92 4130/70 W.A. Shuckmsnn PCTY~O 81102910 10/lS/81 Denzer ee al ~U~ O~ vr~n~
An ~nportant feature of ~e present irmtention ~s to psovlde ~ wall panel in ~e ~orm v~ ~ ~tructural ~andwich p~nel consistin~ of.two hy~8 0~ ~eel reiDrorced ooncrete connected by gslY~nized steel trusses m~d~ of spq~ial reinforoir~ steel rods. The ~;ap between ths two ~oncrete layer~ rthlly ~Ued with ~ layer ot rtgid insulation in direct contact with ffle outer ~n~rete layer l~a~ring ~e rest of the gap for air circulation tnside the lall seQtion. The ~rner eollcrste lay~ ~Ickened at ~e top o~ ~e panel to provide ~ sufficlent bearing surf~ce ~or ~e different noor or rODf element~ ~o be ~upported by ~e paneL Tl~ paneLs COMect to eaeh o~her vertic~lly by csst in s~tu concrete pill~rs located at the ~uncffon be~ween ad~acent p~nela As a ~urther ~eature the two concrete laye re retntoraed hy v~elded wire meahes o~ approprlQte ~ize ~nd spacing to Q~hieve the strength ~nd code requ~re ments for mlnimum rein~orce ment.
- Another fe~ure ~ ~o provk1e a vsn~ated w ~ p~nel which ~ modullr, prec~st and ar~hitectuu~ly fin~hed Uhat effectivedy ~ombines aesthetl~s, s~rength, energy conservatlon ~nd e~onomy.
465~
As another feature t}!e exterior of the panels is adapted to receive dif~erent architectural finishes such as c~ncrete textured surfaces, ~ine stone finish, stucco finish, thin brick vanier and thirl stone vanier. The paneLs have a smooth interior surface that need not be finished. However, the panel surfaces can be plastered, directly painted or wall papered.
Another feature is to provide panels haYing Qdequate strength for supporting a floor and roof construction as well as reta;ning earth. These panels do not require additional structural supports ~s in the case of architectural curtain walls, thus offering significant SQVing in material and labor.
A further fe~ture is to provide a space between the exterior ~nd interior concrete layers of ~e p~els large enough to accommodate variable thicknesses of rigid insulation to offer the desired R valbe according to the design of the buildin~ and its locality.
A fslrther feature ineludes providing an air space between ffle concrete l~yers which improves ~e insul~ting characteristics of the wall panel, and can be used for plumbing pipes and electrical wiring.
As another feature ~ir circulation will be maintained throughout the length and height of ~e wall panels by connecting the ~ir spaces in adjacent psnels and throughcut the different stories of the building. Thus the panels will be thoroughly ventilated elirllinating any moisture penetrating the interior surface of the wall.
A further feature includes an insul~tion which envelopes the entire exterior of the building and connects to the roof insul~t;on ~us minimizing heat losses through cold bridges.
- A further feature includes poured ,n situ concrete at the vertical joints between ~dj¢ p~nels and including corner panels, and horizontal joints between consecutive flo~rs which c~>nne~t the prec~st panels by me~ns of steel dowels t~ a monolithicslly poured concrete grid.
l`:J
12146SI~
An important feDtur~ is to provide for a unit precast panel molded concrete inner and outer p~nel elements of rectanguLqr sh~pe with a steel wire mesh reinforcing member embedded into and throughout each panel element, and a series of parallel laterally spaced continuous steel wire ~usse or shear connectors which are interpo~ed between, embedded into, and extend at right angles to ~e panel elementst and with ~e wire mesh reinforcing members and the trusses interconnected to form a unit reinforcement.
Another feature is to provide a fiberglass insulating layer, or other known equivalent insulator which overlies and is bonded to the interior surface of the outer panel element so as to OCcllpy part of the space between the panel elements and with the remainir~ space providin~ an air barrier or zone between panel elements ~nd adapted to accornmodate wiring and plumbing conduits.
These and other features and objects will be seen from the foUowing specification and claims in cGnjunction with the &ppended drawings.
TilE DRAWINGS
Figure 1 is a fragmentary vertical æction of a portion of a building construction illustrating assembly of a pair of vertically aligned wall panels~
fiooring and ceiling.
Figure 2 is a schemRtic plan view of ~ building havin~ a series of walls utilizing the present panels Figure 3 is a partly broken away front elevational view of a building panel. --~ igiJre 4 is a verti~LI section taken in the direction of arr~ws 4-4 o l~igure 3.
~ igure 5 is a transverse section taken in the direction of arrows 5-5 o Figure 3.
lZ146SI~
Figure 6 is a fragmentary perspective view of a portion of building panel illustrating the steel wire mesh reinforcement and interconnecting trusses.
Figure 7 is a fragmentary plan view based upon the circular inset applied to Pigure 2, on an increased scale.
Figure 8 îs a fragmen~ary plan view of a pair of corner panels based upon the circular inset applied to Pigure 2.
Figure 9 is a front elevational view of a panel on Q reduced scale to which there has been applied a brick Iacing.
It will be understooitl that the above drawings illustrAte merely a preferred embodiment of the invention ~nd ~e steps of the present method and that other embodiments and steps are contemplated in the scope of the claims hereafter set forth.
DETAlLED DESCRIPTION OF AN EMBODIMENT OF THE INVENllON
Referring to the drawings the present precast building panel 11 is shown as a part of a building wall 13 for a building in Figure 1, and includes a cast concrete inner panel element 15 of rectangular shape, 50mm thick, for illustration. Embedded within panel element 15 is a welded steel wire mesh reinforcement 17, generally rectangular in shape corresponding to the shape of inside panel element.
Precast panel 11 includes ~n assembled outside or outer cast concrete panel element 19, Figures 3 and 4, of similHr rectangular sh~pe. ~terposed between ~nd embedded into the respective inside and outside panels sre a series of parallel laterally spaced steel rod trusses 21, fr~gmentarily shown in perspective in Pigure 6, sometimes referred to ~s shear connectors. The outside concrete panel element 19 in ~e il~trative embodiment is 60mm in thickness.
The respective lstcrally spaced ~usses 21 each include ~ pair of p~ra~lel spaced rods 23 of galvanized steel, 10mm in diameter, for illustration, which are connected to the corresponding wire mesh reinforcement 17 as by the welds 24, Figure 4.
_5_ ~2~S~
For each of the steel trusses 21 in between the spaced rods 23 there is provided a continuous zig-zag steel truss element defined by a series of angul~rly related bars "5, sometimes referred to as shear transfer bnrs. These bars are part of a single ben~ zig-zag truss element or are individually positioned and welded at 27, Figure 6, to the corresponding rods 23. Each of the respective trusses have top and b~ttom eonnectors ~6, Figure 4, suitably welded to ~e adjacent rods 23~
The z~-zag truss elements 25 may be forrned of contirluous wire properly bent as shown in Figure 6 as a unit and welded at the corresponding apexes 27 to adjacent rods 23.
The eorresponding apexes forming a part of ~e zig-zag truss element 25 are respectively embedded into and anchored within tlle corresponding inner and outer panel elements lS and 19, Figures 1, 3, 4, 5 and 6. Each of the corresponding welds 27 are embedded within the precast concrete panels.
~ he outer concrete panel element 19 has embedded therein a second welded wire mesh reinforcemerlt 17, Figure 6, which extends over the length and width of the panel element. The corresponding wire mesh reinforcements 17 lie in parallel planes and are arranged outwardly of the laterally spaced trusses 21 and are secured thereto as by welding at 24 to provide ~ unit reinfir~ement.
IJpon the interior of t!,e outer panel element l9 there Is applied insulation layer 29, generally rectangular in shape, suitably bonded or otherwise secured to the outer psnel element 1~. ~n the illustrative ernbodirnent, in Figure
An ~nportant feature of ~e present irmtention ~s to psovlde ~ wall panel in ~e ~orm v~ ~ ~tructural ~andwich p~nel consistin~ of.two hy~8 0~ ~eel reiDrorced ooncrete connected by gslY~nized steel trusses m~d~ of spq~ial reinforoir~ steel rods. The ~;ap between ths two ~oncrete layer~ rthlly ~Ued with ~ layer ot rtgid insulation in direct contact with ffle outer ~n~rete layer l~a~ring ~e rest of the gap for air circulation tnside the lall seQtion. The ~rner eollcrste lay~ ~Ickened at ~e top o~ ~e panel to provide ~ sufficlent bearing surf~ce ~or ~e different noor or rODf element~ ~o be ~upported by ~e paneL Tl~ paneLs COMect to eaeh o~her vertic~lly by csst in s~tu concrete pill~rs located at the ~uncffon be~ween ad~acent p~nela As a ~urther ~eature the two concrete laye re retntoraed hy v~elded wire meahes o~ approprlQte ~ize ~nd spacing to Q~hieve the strength ~nd code requ~re ments for mlnimum rein~orce ment.
- Another fe~ure ~ ~o provk1e a vsn~ated w ~ p~nel which ~ modullr, prec~st and ar~hitectuu~ly fin~hed Uhat effectivedy ~ombines aesthetl~s, s~rength, energy conservatlon ~nd e~onomy.
465~
As another feature t}!e exterior of the panels is adapted to receive dif~erent architectural finishes such as c~ncrete textured surfaces, ~ine stone finish, stucco finish, thin brick vanier and thirl stone vanier. The paneLs have a smooth interior surface that need not be finished. However, the panel surfaces can be plastered, directly painted or wall papered.
Another feature is to provide panels haYing Qdequate strength for supporting a floor and roof construction as well as reta;ning earth. These panels do not require additional structural supports ~s in the case of architectural curtain walls, thus offering significant SQVing in material and labor.
A further fe~ture is to provide a space between the exterior ~nd interior concrete layers of ~e p~els large enough to accommodate variable thicknesses of rigid insulation to offer the desired R valbe according to the design of the buildin~ and its locality.
A fslrther feature ineludes providing an air space between ffle concrete l~yers which improves ~e insul~ting characteristics of the wall panel, and can be used for plumbing pipes and electrical wiring.
As another feature ~ir circulation will be maintained throughout the length and height of ~e wall panels by connecting the ~ir spaces in adjacent psnels and throughcut the different stories of the building. Thus the panels will be thoroughly ventilated elirllinating any moisture penetrating the interior surface of the wall.
A further feature includes an insul~tion which envelopes the entire exterior of the building and connects to the roof insul~t;on ~us minimizing heat losses through cold bridges.
- A further feature includes poured ,n situ concrete at the vertical joints between ~dj¢ p~nels and including corner panels, and horizontal joints between consecutive flo~rs which c~>nne~t the prec~st panels by me~ns of steel dowels t~ a monolithicslly poured concrete grid.
l`:J
12146SI~
An important feDtur~ is to provide for a unit precast panel molded concrete inner and outer p~nel elements of rectanguLqr sh~pe with a steel wire mesh reinforcing member embedded into and throughout each panel element, and a series of parallel laterally spaced continuous steel wire ~usse or shear connectors which are interpo~ed between, embedded into, and extend at right angles to ~e panel elementst and with ~e wire mesh reinforcing members and the trusses interconnected to form a unit reinforcement.
Another feature is to provide a fiberglass insulating layer, or other known equivalent insulator which overlies and is bonded to the interior surface of the outer panel element so as to OCcllpy part of the space between the panel elements and with the remainir~ space providin~ an air barrier or zone between panel elements ~nd adapted to accornmodate wiring and plumbing conduits.
These and other features and objects will be seen from the foUowing specification and claims in cGnjunction with the &ppended drawings.
TilE DRAWINGS
Figure 1 is a fragmentary vertical æction of a portion of a building construction illustrating assembly of a pair of vertically aligned wall panels~
fiooring and ceiling.
Figure 2 is a schemRtic plan view of ~ building havin~ a series of walls utilizing the present panels Figure 3 is a partly broken away front elevational view of a building panel. --~ igiJre 4 is a verti~LI section taken in the direction of arr~ws 4-4 o l~igure 3.
~ igure 5 is a transverse section taken in the direction of arrows 5-5 o Figure 3.
lZ146SI~
Figure 6 is a fragmentary perspective view of a portion of building panel illustrating the steel wire mesh reinforcement and interconnecting trusses.
Figure 7 is a fragmentary plan view based upon the circular inset applied to Pigure 2, on an increased scale.
Figure 8 îs a fragmen~ary plan view of a pair of corner panels based upon the circular inset applied to Pigure 2.
Figure 9 is a front elevational view of a panel on Q reduced scale to which there has been applied a brick Iacing.
It will be understooitl that the above drawings illustrAte merely a preferred embodiment of the invention ~nd ~e steps of the present method and that other embodiments and steps are contemplated in the scope of the claims hereafter set forth.
DETAlLED DESCRIPTION OF AN EMBODIMENT OF THE INVENllON
Referring to the drawings the present precast building panel 11 is shown as a part of a building wall 13 for a building in Figure 1, and includes a cast concrete inner panel element 15 of rectangular shape, 50mm thick, for illustration. Embedded within panel element 15 is a welded steel wire mesh reinforcement 17, generally rectangular in shape corresponding to the shape of inside panel element.
Precast panel 11 includes ~n assembled outside or outer cast concrete panel element 19, Figures 3 and 4, of similHr rectangular sh~pe. ~terposed between ~nd embedded into the respective inside and outside panels sre a series of parallel laterally spaced steel rod trusses 21, fr~gmentarily shown in perspective in Pigure 6, sometimes referred to ~s shear connectors. The outside concrete panel element 19 in ~e il~trative embodiment is 60mm in thickness.
The respective lstcrally spaced ~usses 21 each include ~ pair of p~ra~lel spaced rods 23 of galvanized steel, 10mm in diameter, for illustration, which are connected to the corresponding wire mesh reinforcement 17 as by the welds 24, Figure 4.
_5_ ~2~S~
For each of the steel trusses 21 in between the spaced rods 23 there is provided a continuous zig-zag steel truss element defined by a series of angul~rly related bars "5, sometimes referred to as shear transfer bnrs. These bars are part of a single ben~ zig-zag truss element or are individually positioned and welded at 27, Figure 6, to the corresponding rods 23. Each of the respective trusses have top and b~ttom eonnectors ~6, Figure 4, suitably welded to ~e adjacent rods 23~
The z~-zag truss elements 25 may be forrned of contirluous wire properly bent as shown in Figure 6 as a unit and welded at the corresponding apexes 27 to adjacent rods 23.
The eorresponding apexes forming a part of ~e zig-zag truss element 25 are respectively embedded into and anchored within tlle corresponding inner and outer panel elements lS and 19, Figures 1, 3, 4, 5 and 6. Each of the corresponding welds 27 are embedded within the precast concrete panels.
~ he outer concrete panel element 19 has embedded therein a second welded wire mesh reinforcemerlt 17, Figure 6, which extends over the length and width of the panel element. The corresponding wire mesh reinforcements 17 lie in parallel planes and are arranged outwardly of the laterally spaced trusses 21 and are secured thereto as by welding at 24 to provide ~ unit reinfir~ement.
IJpon the interior of t!,e outer panel element l9 there Is applied insulation layer 29, generally rectangular in shape, suitably bonded or otherwise secured to the outer psnel element 1~. ~n the illustrative ernbodirnent, in Figure
3, applied to the inner surt~ce of ff7e outer panel element 1~, sre R series of IQter~lly spaced elongated p~el insul~tion strips 29 arranged side by side and interposed between adjacent pairs of trusses 21. The thickness of the insul~tion layer is lODmm ~4n~.
The respective strips of insulating material are of fiberglass, for illustration, and have applied ts~ their outer edges a suitable resin or adhesive material which bears against adiacent portions vf the corresponding trusses 21 for securing thereto. The spacirg between adjacent insulation str ps 29 is filled by a suitable grout 32 or other insulation material Figure 3. The respective insulation fiberglass panel strips 29 are initially, in the me~od hereafter set forth, mounted between the respective pairs of trusses 21 and Ibonded thereto by a suitable resin. The fiberglass insulation panel strips or layer 29 are generally rectangular in shape and overlie substantially the entire interior srea of outer panel element 19.
The insulation layer 29 fills a part of the air g~ or air space between the iMer and outer panels. The remainin~ space provides an air barrier zone 33 which is approximately lOmm wide, for illustration. The air barrier zone serves as a further insulator between the panel elements 17 and 19 and is also used to accommodate wiring and plumbing conduits.
The inner panel element 15 is formed in a steel mold and has an inner facing 35 which is smooth for use as is or to which paint or wa~lpaper or plaster may be applied. The outside facing 3~ of the outer panel element 19 can have different architectural finishes applied thereto such as a concrete textured surface, a fine stone finish, a stucco finish, a thin brick veneer such as shown at 39, Figure 9, or a thin stone veneer. In the illustrative embodiment the thin brick veneer facing 39 is 1/2" thick.
The upper end of the inner panel element 15, Figures 1, 3 and 4J has an inwardly directed end support flange 41 which extends laterally outward into engagement with insulation ~yer 29 of the outer panel element. The corresponding end portion of the outer panel element extends outwardly beyond support nange 41 for a distance sufficient to accommodate the right angularly related floor panel or slab 81, Figure 1.
1;214~;S~3 )2 In the concrete casti ~ of the inner panel element including the end support flange 41, a .series of l~terally spaced steel dowels 7S are cast into and anchored through end support fl~lnge 41 and project outwardly, Figures 1 and 3.
The series of walls 1~ for a building or the like eonsist of a series of laterally aligned unit preca~t p~nel eiements 11 arranged side by side and mounted snd supported and anchored to the underlying continuous concrete cast ~ootin~ 43, Figure l. The footing 43 is norms~ly below the gro~lnd surface a predetermined amount~ depending upon whether there is to be a full basement or a limited crawl space beneQth the building.
Footing 43, gener~lly rect;angular in cross-section, has a continuous elongated top slot 4g. Cast into the outside lower corner of the respective outer panel element 19 is a steel protectiYe &ngle 45 which extends throughout its width and is embedded within the outer panel element 19, Pigure 1. A series of upright laterally spacecl dowels ~7 similar to the dowel arrangement in Figure 3, are welded to angle 45 along its length and &re embedded within the cast concrete formlng a part of the outer panel element.
Dowel mount plate 49 is cast into footing 43 and includes welded thereto a depending series of l&teraUy sp~ced reinforcing steel dowels 51~
Adjacent to the botto!n of air space or zone 33 within the upright panel 11 as shown in Figure l, there i~ a b~se plate concrete horizontal connector 53 which consists of concrete which h~s been poured in situ into the lower space 33 between the iMer and outer panel elements 15, 19 and extends down into footing slot 44. Also formed within footing ~13, as c~st, are a æries of laterally spaced upright dowels 55 which project up into zone 33 so as to be embedded and anchored into the poured horizontal concrete connector 53 and cured. Suitable - lathing 57 overlies connector 53. The lath may be constructed of styrofoam, plywood, or metal, and overlie~ the horizontal connector or joint between panel 11 and the underlying footir~ 4~.
In the illustrative emtmdimentt this construction provides a means by which the respective laterally aligned wall panels or other parlels ll are arranged side by side upon footing 43 around its peri-~eter, with a horizontal joint provided which extends between the lower ends of the corresponding pane's and footing 43 and interlocked therewith.
A suitable vertical connector or p~nel column 59 is interposed between adjacent pairs of closely spaced panels 11~ Figure 7. Upon assembly of an adjacent pair of closely spaced wall panels 11 upon the footing 43, the vertical joint between adjacent panels is cornpleted by applying to the respective panels 11 sdjacent and along their inner edges and throughout their height a pair of laterally spaced laths 57. They extend down to the footing and define a chamber into which is poured in situ a concrete column throughout the height thereof.
When cured there is provided a reinforcing vertical column 59 for the buildlng construction and particularly ~OI~ inferconnecting and supporting the adjacent panels 11, Figure 7.
The outer trusses 21 of the corresponding steel reinforced adjacent panel~ extend into the chamber between the laterally spaced laths 57 and are embedded into the panel connector column 59 when ~ully cured. The concrete for columns 59 is poured in situ as a pair of adjacent panels are erected upon footing 43~ Figures 1 and 7.
As shown in Figures ~, 5 and 7, the outer most of the insulated panel strips 29 have column clearance flanges 60 adjacent their outer edges so that the concrete column 59 when poured nests into the notch defined within the adjacent 5nsulated panel and interlocks tllerewith on curing.
s~
While a pair of pam ls forming wall 13, ~igure 2, are in lateral alignment, they are closely sp~ced defining a limited spacing 6~ between their corresponding upright edges. Vpright elongated shim str j? 63, preferably of steel, is interposed between adjacent portions of the panels outw~rdly of columrl 59. A suitable sealant or exterior caulking 65 furShermore fills the spacing 61 between the adjacent upright edges of the p~nels throughout their height. The concrete used in completing the column 59, is referred to as ~a high slump concrete mix" to avoid segregation of the mix components until the concrete has cured over a period of time and sufFiciently hardened.
The buildir~ scl ematically shown in Figure 2 includes right angularly related walls 13. ~n Figure 8 on an increased scale, there is shown a pair of right angularly related corner panels 11 which are mitered at 67 throughout their height and are closely spaced apart defining upright spacing 61, ht the adjacent mitered corners 67. A elongated steel shim 63 is interposed between adj~cent mitered portions 67 of ~e corner panels throughout ~eir height. The vertical column 68 interconnects the corner p~nels 11 and is poured in situ.
Before pouring there are provided within the adjacent corner panel elements Figure 8, a pair of upright right angularly reLqted laths 57? which may be of styrofoam, plywood or metal. These are arranged inwardly of the mitered corners 67 of the Qdjacent panels and extend at right angles to the corresponding inner and outer panel elements of the respective panels.
The laths extend down into the footings and define with the interior surfaces of ~le panel element~ lS and 19 ~ chamber into which the column of concrete 68 is poured in situ throughout the height thereof. The outermost trusses 21 or shear connectors of the adjacent right angularly related panels are embedded within ~e concrete pour~d colllmn 68 to reinforce ~e column when cured. Thi~ provides a vertic~LI connector ~int for the adjacent corner panels~
fragmentarily shown in ~igure 8.
~146S8 As a part of the erection of a building, such as shown in Pigure 2, including a series of aligned ~ncl right angularly related upright wall panels 11, ~ere is provided a suitable door opening 71 and a plurality of window openings 73.
A suitable tlooring s~!çh as a precast concrete ~loor ~lab 77 is arranged horizontally so as to be supported at one end upon footing 43. The slab 77 may have upon and along its undersurface a suitable insulation sheet 79. lt is considered as equivalent that instead of the cast steel reinforced floor slab 77, there could be employed in a horizontal position wall panels 11.
In the erection of a building, fragmentarily in Figure 1, there is provided a floor panel or concrete slab 81 having an air space 83 which at one end extends over Rnd is mounted upon wall panel 11 overlying the end support flsnge 41 of the inner wall panel element 15 and suitably secured thereto.
It is contempL~ted as equivalent that ~he flooring 81 m~y be one of the wall panels 11, otherwise supported and at the end, where shown, overlies and is mounted upon the upright erected wall panel 11 and is of the same lateral width~
In the illustrative embodiment, the building construction contemplates the use of a æcond wall panel 11 vertically aligned with and supported upon the initial wall panel 11, Figure lr and suitably anchored thereon. The air zone 33 of the upper panel 11 is in communicqtion with the air zone 33 of the lower panel to improve the ventilation within the assembled wall defined by the series of pairs of vertically sligned and interconnected panels 11. As desired a lsveling metallic shim fi3 may be interposed ~etween the vertic~lly aligned pMels 11. The connection may otherwise be closed by a suitable seal~nt or other material to seal ~e wall construction.
1;~14658 There is provided bet\~een the vertically aligned panels 11 a vertical poured concrete joint 53 simiklr to ~e joint 53 described for anchoring the lower-most panel upon footing 43. On erection of l:he second verti~ally aligned wall panel 11 over the first wall panel, the respective reinforcement steel dowels 75 which are embedded within the lower wall panel and particularly through ~he support flange 41 project up into the air zone 33 between the inner and outer p~nel elements 15 and 19 of the ~per-most panel shown in Figure 1.
Concrete is p~ured in situ into the zone 33 at the lower end of the upper most wall panel Rt 53 SO as to enclose end portions of dowels 75 with portions of the concrete p8SSillg downwardly as at 82 ~djacent one end of flooring 81 further embedding the corresponding laterally spaced dowels 75. This defines when cured, an effective vertical joint between the respective upper and lower panel elements and adjacent flooring 81.
The inner concrete panel elements 15 are thickened at the top as at 41 to provide sufficient bearing surface for the floor or roof elements shown in F~gure 1. The respective panels 11 are connected to each other vertically by cast in situ concrete columns S9 located at the junction between adjacent panels 11 and including the corner columns 68 between the junction of a pair of adjacent right angul~rly related wa~l panels, Figure 8.
The respective inner and outer panel elements 15 and 19 are reinforced by Ule welded wire mesh 17. Sandwiched between the wire meshes 17 for the respective panel elements are the corresponding series of laterally spaced parallel trusses or shear connectors 21. These are suitably intergr~ted and secured to the wire mesh 17 of the respective panel elements as by a series of connectors or welds at 24, Figure 4. Thus, the concrete ilmer and outer panel elements are suitably reinforced by the welded ~ire meshes 17. There is provided between the respective inner and outer panel elements the series of laterelly rel~ted pflr~llel steel t~usses 21, These interconnect the corresponding inner and outer panels and are em~ed~ed and ~nchored ~ereinto at their apexes 27, Figure 6.
, ~-1~465~
The vcntiIated wall panels ll are modular, precast, architecturally finished structural wall panels that ef~ectively combine aesthetics, strength, energy conservation and economy.
The ~looring 81 could be a unit concrete reinforced slab or one of the panels 11 designated 81 ha~ing an insulating air space 83. In the ~ssembly in Figure 1 of the panel Bl or floor slab there is embedded a laterally extending dowel molmt plate 49 underIying the corresponding angle 45 c&st upon the upper p~nel element.
A series of Lqterally spaced steel dowels 51, of L shape in the illustrative embodiement, depend from dowel mount plate 49 and are embedded within the ~a~ slab 81. Thls completes l:he flnchoring and reinforcement of the upper panel 11 aligned with and located upon the lower panel In ~igure 1.
Fra~mentar~y shown in Figure 1 there is provided a roof panel 85 which may be of the snme constructi~n as the p~inel 11. Roof panel 85 has depending therefrom fln insulator 87 which may correspond to and be similar to insulation l~yer 29 made of fiberglass or equivalent insulating material.
C~le end of the roof panel 85 overlies the top wall panel 11 and particularly is supported upon t~e end support n~nge 41 which extends laterally across an upper end portion of the inner panel element 15 and is suitably secured thereto. The outer panel element 19 extends above roof panel 85 and has connected thereto a suitable protective galvanized steel cap 93. Such cap normally extends peripherally around the entire top surface of the adjacent and interconnected wall panels 11 defining the building WflllS, Figure 2.
In the illustrHtive embodiment, there is shown schematically ~ drop ceiling 89 supported upon the ~ngle or br~cket. 45 which extends irom the ~djacent dowel mount plate 49 as a means o~ supporting the perimeter outer edge portions of the ceiling assembly 89. Suitable wire supports 91 suspend portions o~
the ceiling 89 ~rom the overlying rooI asse~nbly 85.
--~3--s~
THE METllOD OF MAKING A I3ANEL
The present invention further includes the method of making a bui~ding panel which includes the following steps:
As~sembling and interconnecting by welding a series of parallel laterally spaced steel rod trusses 21 between and flt r ight angles to a pair of p~rallel steel wire mesh reinforcing rmembers t7 to provide a unit panel reinforcement.
Successively mounting and supporting the reinforcement horizontally upon and above an elongated rectanguL~r mold of such shape and depth as to provide for the molding of the inner panel element 15.
Successi~rely p~uring eoncrete into the mold to a depth sufficient to enclose one of the steel wire meshes 17 and the corresponding adjacent edge portions of the assembled trusses 21. This would include the adjacent steel rods 23 and the adjacent welded apexes of the corresponding trusses 21.
This is followed by the steps of curing or hardening the concrete to f~rm a steel reinforced inner panel element 15 having ~e trusses upon one side thereof along their length and one of the wire mesh reinforcing members 17 embedded and anchored therein.
As a further step, a layer OI insulating material is applied to the truss assembly. This is accomplished by applying a series of strips 29 of suitable insul~ting material, as for exhniple fiberglas~s, between each pair of the trus es 21 side by side as shown in Figure 3. 1`he strips whe:n assembled are arranged in a plane which is spaced from the inner panel element. Before in~rtion of the strips of insulating material at 29, there corresponding edges have applied thereto a suitable adhesive ~ bonding agent or se~n so ~hat upon assernbly within and between Ule respeetive trusses 21 the panels will adhere to adjacent portions of the trusses and be tn~nde~ thereto~
The respective strips of insulating material are of fiberglass, for illustration, and have applied ts~ their outer edges a suitable resin or adhesive material which bears against adiacent portions vf the corresponding trusses 21 for securing thereto. The spacirg between adjacent insulation str ps 29 is filled by a suitable grout 32 or other insulation material Figure 3. The respective insulation fiberglass panel strips 29 are initially, in the me~od hereafter set forth, mounted between the respective pairs of trusses 21 and Ibonded thereto by a suitable resin. The fiberglass insulation panel strips or layer 29 are generally rectangular in shape and overlie substantially the entire interior srea of outer panel element 19.
The insulation layer 29 fills a part of the air g~ or air space between the iMer and outer panels. The remainin~ space provides an air barrier zone 33 which is approximately lOmm wide, for illustration. The air barrier zone serves as a further insulator between the panel elements 17 and 19 and is also used to accommodate wiring and plumbing conduits.
The inner panel element 15 is formed in a steel mold and has an inner facing 35 which is smooth for use as is or to which paint or wa~lpaper or plaster may be applied. The outside facing 3~ of the outer panel element 19 can have different architectural finishes applied thereto such as a concrete textured surface, a fine stone finish, a stucco finish, a thin brick veneer such as shown at 39, Figure 9, or a thin stone veneer. In the illustrative embodiment the thin brick veneer facing 39 is 1/2" thick.
The upper end of the inner panel element 15, Figures 1, 3 and 4J has an inwardly directed end support flange 41 which extends laterally outward into engagement with insulation ~yer 29 of the outer panel element. The corresponding end portion of the outer panel element extends outwardly beyond support nange 41 for a distance sufficient to accommodate the right angularly related floor panel or slab 81, Figure 1.
1;214~;S~3 )2 In the concrete casti ~ of the inner panel element including the end support flange 41, a .series of l~terally spaced steel dowels 7S are cast into and anchored through end support fl~lnge 41 and project outwardly, Figures 1 and 3.
The series of walls 1~ for a building or the like eonsist of a series of laterally aligned unit preca~t p~nel eiements 11 arranged side by side and mounted snd supported and anchored to the underlying continuous concrete cast ~ootin~ 43, Figure l. The footing 43 is norms~ly below the gro~lnd surface a predetermined amount~ depending upon whether there is to be a full basement or a limited crawl space beneQth the building.
Footing 43, gener~lly rect;angular in cross-section, has a continuous elongated top slot 4g. Cast into the outside lower corner of the respective outer panel element 19 is a steel protectiYe &ngle 45 which extends throughout its width and is embedded within the outer panel element 19, Pigure 1. A series of upright laterally spacecl dowels ~7 similar to the dowel arrangement in Figure 3, are welded to angle 45 along its length and &re embedded within the cast concrete formlng a part of the outer panel element.
Dowel mount plate 49 is cast into footing 43 and includes welded thereto a depending series of l&teraUy sp~ced reinforcing steel dowels 51~
Adjacent to the botto!n of air space or zone 33 within the upright panel 11 as shown in Figure l, there i~ a b~se plate concrete horizontal connector 53 which consists of concrete which h~s been poured in situ into the lower space 33 between the iMer and outer panel elements 15, 19 and extends down into footing slot 44. Also formed within footing ~13, as c~st, are a æries of laterally spaced upright dowels 55 which project up into zone 33 so as to be embedded and anchored into the poured horizontal concrete connector 53 and cured. Suitable - lathing 57 overlies connector 53. The lath may be constructed of styrofoam, plywood, or metal, and overlie~ the horizontal connector or joint between panel 11 and the underlying footir~ 4~.
In the illustrative emtmdimentt this construction provides a means by which the respective laterally aligned wall panels or other parlels ll are arranged side by side upon footing 43 around its peri-~eter, with a horizontal joint provided which extends between the lower ends of the corresponding pane's and footing 43 and interlocked therewith.
A suitable vertical connector or p~nel column 59 is interposed between adjacent pairs of closely spaced panels 11~ Figure 7. Upon assembly of an adjacent pair of closely spaced wall panels 11 upon the footing 43, the vertical joint between adjacent panels is cornpleted by applying to the respective panels 11 sdjacent and along their inner edges and throughout their height a pair of laterally spaced laths 57. They extend down to the footing and define a chamber into which is poured in situ a concrete column throughout the height thereof.
When cured there is provided a reinforcing vertical column 59 for the buildlng construction and particularly ~OI~ inferconnecting and supporting the adjacent panels 11, Figure 7.
The outer trusses 21 of the corresponding steel reinforced adjacent panel~ extend into the chamber between the laterally spaced laths 57 and are embedded into the panel connector column 59 when ~ully cured. The concrete for columns 59 is poured in situ as a pair of adjacent panels are erected upon footing 43~ Figures 1 and 7.
As shown in Figures ~, 5 and 7, the outer most of the insulated panel strips 29 have column clearance flanges 60 adjacent their outer edges so that the concrete column 59 when poured nests into the notch defined within the adjacent 5nsulated panel and interlocks tllerewith on curing.
s~
While a pair of pam ls forming wall 13, ~igure 2, are in lateral alignment, they are closely sp~ced defining a limited spacing 6~ between their corresponding upright edges. Vpright elongated shim str j? 63, preferably of steel, is interposed between adjacent portions of the panels outw~rdly of columrl 59. A suitable sealant or exterior caulking 65 furShermore fills the spacing 61 between the adjacent upright edges of the p~nels throughout their height. The concrete used in completing the column 59, is referred to as ~a high slump concrete mix" to avoid segregation of the mix components until the concrete has cured over a period of time and sufFiciently hardened.
The buildir~ scl ematically shown in Figure 2 includes right angularly related walls 13. ~n Figure 8 on an increased scale, there is shown a pair of right angularly related corner panels 11 which are mitered at 67 throughout their height and are closely spaced apart defining upright spacing 61, ht the adjacent mitered corners 67. A elongated steel shim 63 is interposed between adj~cent mitered portions 67 of ~e corner panels throughout ~eir height. The vertical column 68 interconnects the corner p~nels 11 and is poured in situ.
Before pouring there are provided within the adjacent corner panel elements Figure 8, a pair of upright right angularly reLqted laths 57? which may be of styrofoam, plywood or metal. These are arranged inwardly of the mitered corners 67 of the Qdjacent panels and extend at right angles to the corresponding inner and outer panel elements of the respective panels.
The laths extend down into the footings and define with the interior surfaces of ~le panel element~ lS and 19 ~ chamber into which the column of concrete 68 is poured in situ throughout the height thereof. The outermost trusses 21 or shear connectors of the adjacent right angularly related panels are embedded within ~e concrete pour~d colllmn 68 to reinforce ~e column when cured. Thi~ provides a vertic~LI connector ~int for the adjacent corner panels~
fragmentarily shown in ~igure 8.
~146S8 As a part of the erection of a building, such as shown in Pigure 2, including a series of aligned ~ncl right angularly related upright wall panels 11, ~ere is provided a suitable door opening 71 and a plurality of window openings 73.
A suitable tlooring s~!çh as a precast concrete ~loor ~lab 77 is arranged horizontally so as to be supported at one end upon footing 43. The slab 77 may have upon and along its undersurface a suitable insulation sheet 79. lt is considered as equivalent that instead of the cast steel reinforced floor slab 77, there could be employed in a horizontal position wall panels 11.
In the erection of a building, fragmentarily in Figure 1, there is provided a floor panel or concrete slab 81 having an air space 83 which at one end extends over Rnd is mounted upon wall panel 11 overlying the end support flsnge 41 of the inner wall panel element 15 and suitably secured thereto.
It is contempL~ted as equivalent that ~he flooring 81 m~y be one of the wall panels 11, otherwise supported and at the end, where shown, overlies and is mounted upon the upright erected wall panel 11 and is of the same lateral width~
In the illustrative embodiment, the building construction contemplates the use of a æcond wall panel 11 vertically aligned with and supported upon the initial wall panel 11, Figure lr and suitably anchored thereon. The air zone 33 of the upper panel 11 is in communicqtion with the air zone 33 of the lower panel to improve the ventilation within the assembled wall defined by the series of pairs of vertically sligned and interconnected panels 11. As desired a lsveling metallic shim fi3 may be interposed ~etween the vertic~lly aligned pMels 11. The connection may otherwise be closed by a suitable seal~nt or other material to seal ~e wall construction.
1;~14658 There is provided bet\~een the vertically aligned panels 11 a vertical poured concrete joint 53 simiklr to ~e joint 53 described for anchoring the lower-most panel upon footing 43. On erection of l:he second verti~ally aligned wall panel 11 over the first wall panel, the respective reinforcement steel dowels 75 which are embedded within the lower wall panel and particularly through ~he support flange 41 project up into the air zone 33 between the inner and outer p~nel elements 15 and 19 of the ~per-most panel shown in Figure 1.
Concrete is p~ured in situ into the zone 33 at the lower end of the upper most wall panel Rt 53 SO as to enclose end portions of dowels 75 with portions of the concrete p8SSillg downwardly as at 82 ~djacent one end of flooring 81 further embedding the corresponding laterally spaced dowels 75. This defines when cured, an effective vertical joint between the respective upper and lower panel elements and adjacent flooring 81.
The inner concrete panel elements 15 are thickened at the top as at 41 to provide sufficient bearing surface for the floor or roof elements shown in F~gure 1. The respective panels 11 are connected to each other vertically by cast in situ concrete columns S9 located at the junction between adjacent panels 11 and including the corner columns 68 between the junction of a pair of adjacent right angul~rly related wa~l panels, Figure 8.
The respective inner and outer panel elements 15 and 19 are reinforced by Ule welded wire mesh 17. Sandwiched between the wire meshes 17 for the respective panel elements are the corresponding series of laterally spaced parallel trusses or shear connectors 21. These are suitably intergr~ted and secured to the wire mesh 17 of the respective panel elements as by a series of connectors or welds at 24, Figure 4. Thus, the concrete ilmer and outer panel elements are suitably reinforced by the welded ~ire meshes 17. There is provided between the respective inner and outer panel elements the series of laterelly rel~ted pflr~llel steel t~usses 21, These interconnect the corresponding inner and outer panels and are em~ed~ed and ~nchored ~ereinto at their apexes 27, Figure 6.
, ~-1~465~
The vcntiIated wall panels ll are modular, precast, architecturally finished structural wall panels that ef~ectively combine aesthetics, strength, energy conservation and economy.
The ~looring 81 could be a unit concrete reinforced slab or one of the panels 11 designated 81 ha~ing an insulating air space 83. In the ~ssembly in Figure 1 of the panel Bl or floor slab there is embedded a laterally extending dowel molmt plate 49 underIying the corresponding angle 45 c&st upon the upper p~nel element.
A series of Lqterally spaced steel dowels 51, of L shape in the illustrative embodiement, depend from dowel mount plate 49 and are embedded within the ~a~ slab 81. Thls completes l:he flnchoring and reinforcement of the upper panel 11 aligned with and located upon the lower panel In ~igure 1.
Fra~mentar~y shown in Figure 1 there is provided a roof panel 85 which may be of the snme constructi~n as the p~inel 11. Roof panel 85 has depending therefrom fln insulator 87 which may correspond to and be similar to insulation l~yer 29 made of fiberglass or equivalent insulating material.
C~le end of the roof panel 85 overlies the top wall panel 11 and particularly is supported upon t~e end support n~nge 41 which extends laterally across an upper end portion of the inner panel element 15 and is suitably secured thereto. The outer panel element 19 extends above roof panel 85 and has connected thereto a suitable protective galvanized steel cap 93. Such cap normally extends peripherally around the entire top surface of the adjacent and interconnected wall panels 11 defining the building WflllS, Figure 2.
In the illustrHtive embodiment, there is shown schematically ~ drop ceiling 89 supported upon the ~ngle or br~cket. 45 which extends irom the ~djacent dowel mount plate 49 as a means o~ supporting the perimeter outer edge portions of the ceiling assembly 89. Suitable wire supports 91 suspend portions o~
the ceiling 89 ~rom the overlying rooI asse~nbly 85.
--~3--s~
THE METllOD OF MAKING A I3ANEL
The present invention further includes the method of making a bui~ding panel which includes the following steps:
As~sembling and interconnecting by welding a series of parallel laterally spaced steel rod trusses 21 between and flt r ight angles to a pair of p~rallel steel wire mesh reinforcing rmembers t7 to provide a unit panel reinforcement.
Successively mounting and supporting the reinforcement horizontally upon and above an elongated rectanguL~r mold of such shape and depth as to provide for the molding of the inner panel element 15.
Successi~rely p~uring eoncrete into the mold to a depth sufficient to enclose one of the steel wire meshes 17 and the corresponding adjacent edge portions of the assembled trusses 21. This would include the adjacent steel rods 23 and the adjacent welded apexes of the corresponding trusses 21.
This is followed by the steps of curing or hardening the concrete to f~rm a steel reinforced inner panel element 15 having ~e trusses upon one side thereof along their length and one of the wire mesh reinforcing members 17 embedded and anchored therein.
As a further step, a layer OI insulating material is applied to the truss assembly. This is accomplished by applying a series of strips 29 of suitable insul~ting material, as for exhniple fiberglas~s, between each pair of the trus es 21 side by side as shown in Figure 3. 1`he strips whe:n assembled are arranged in a plane which is spaced from the inner panel element. Before in~rtion of the strips of insulating material at 29, there corresponding edges have applied thereto a suitable adhesive ~ bonding agent or se~n so ~hat upon assernbly within and between Ule respeetive trusses 21 the panels will adhere to adjacent portions of the trusses and be tn~nde~ thereto~
4~X~
The assembled and cast imler panel element 15, the reinforcement and the insulating strips 29 which ~-~e temporarily ~upported by a series of wood blocks, for illustratiQn, are then arranged in a horizontal position with the , Pinforcement extending upward'y. In such a position the insulating strips define the bottom wall of ~ suitable rectarlgular mold into which the outer panel element 19 is to be poured.
A further step in~ des the pouring of a concrete rnix into ~he second mold to such depth as to arer~ie the insulating strips 29 and to enclose apex portions of the adjacent trusses where they are welded as at 27 and to further enclose the adjacent steel rods 23 and of sufficient depth as to form when cured the outer panel element 1~, fragmentarily shown in Figure 6.
After pouring, the concrete is cured to permit~ hardening of the concrete to form the steel reinforced insulated outer panel element 19 which has embedded therein outer edge portions of the corresponding trusses along their lengths, and the other steel wire mesh 17.
Upon curing, the finished wall panel is æparated from the second mold as a unit modular panel 11 such as would be used in the construction of the building fragmentar~y shown in Figures 1 and a.
As a further step in connection with the assembly and secslring of the insulating strips within the reinforcement and between the respective pairs of trusses 21, sp~cing between the adjacent strips 29 required because of the thi~kne.ss of the respective husses is filled with a suitable flller, epoxy or other insul~tir~ material. When sealed ~e laterally aligned planer insulating strips define the bottom surface for the casting mcld for the outer panel elemer~t 19.
During pouring and curing of the concrete upon the layer of tempor~rily supported insulator strips 29, interior portions of the outer panel element 19 adhere to or are otherwise bonded to the insul~ting layer 2g or series of strips of insulating materi~l.
~L4651~
METHOI) O~ EREC'rl~dG A BUILDING
Once the unit wall panels 11 have been cast, they are mounted upon a suitably previously cured concrete footing 43, Figure 1~ A ~urther s~ep in erecting of ~e building includes assembli7l~ laterally spaced laths 57, of styrofoam, plywood or metal, between and at right ar~les to the panel elements 15 and 19 of the adjacent panels, Figure 7, inwardly of the outer edges of each panel to define a chamber between the laths including the air zone 33 within the panels.
A further step includes pourhlg in situ into ~e chamber down to the footing 43 a column 59 of concrete to the height of the respective panels.
Portions of the outermost trusses ~1 extend into and are embedded within concrete column 59. Concrete for the column extends into the footing channel 44.
The final step includes curing the column of concrete for a time sufficient for hardening with a column of cement reinforced by the truss portions 21 and intercQnneCti7lg the panels 11 and the corresponding panel elements throughout their height~ The column 59 interlocks with the footing 43.
The ~spective columns 59 form the vertical joints between adjacent aligned pRnels 11 forming a part of the building structure, Figure 2.
Part of the present method includes forMir4~ of vertical concrete columns 68 between corner panel elements as fragmentarily shown in Figure 8.
This includes the assembling of a pair of rigllt angularly related panels having adjacent mitered edges 67 along their length which are closely spaced apart and form a corner for a pair of right ~ngularIy related building walls.
~;~14658 A further step includes aæembling later~lly spaced right angularly related laths 57 between and at r ight angles to ~e respective panel elements of each pair of panels inwardly of the outer edges of each panel to define a chamber alon~ with ~e interior walls of the inner and outer panel elements, Figure 8.
A further stsp includes pouring in ~itu into the chamber down to the footing 43 concrete to the height of the corner panels. Portions of the trusses 21 are embedded within column 68. The column 68 interloek~ with footing 43.
A further step includes curing of the column of concrete. The column 88 is reinforced by the trusses 21 and interconnects the corner panels and the panel elements throughout their height.
A study was conducted on the insulation propertie~ of the panels 11 at the University of Western Ontario, London, Canada which shows the insulation qualities of the panels to be satisfactory for all normal function buildin~fs whether residential, commercial, instituional or industri~l. The following is a summary of the expected inside wall surface temperatures (~) for ~e paneLs.
Toutside Twall insiderwall inside with no insulation with insulation (~) (~) (F) .
42.6 68.5 37.2 68.2 0 31.fi 67.8 -~0 26.2 67.6 The calculations assumed in the following:
i) The "R" value of "SM Blue" insulation is 5/inch.
ii) The inside film coefficient has an "Rl' value of 0.68.
iii) All other coefficients are taken from ASHRA~/81.
iv) The inside room temperature is 70F and ff~ere is 4 inches of SM Blue insulation in ~e cavity for a total "R" equsl to 22.63 (Imperial Units).
The estimates are not ~s accurate as an overall "R" value estimate.
This is because of the difficulty of accurately estimating the inside film coefficient. Less than 2% of the heat will be transferred through ~e steel rods.
This is evident in that our 4 inches of insulation the "R-' value of 22.67 reduces to 22.63 as a result of the steel bars. These values are n~t dependent on temperature and ~erefore have no difference with respect to the temperatures noted.
Condensation as a result of large outside humidity conditions is not a problem since a continuous vapour barrier is expected by the "SM E~lue"
insulation.
SE~U~ E OF CONSTRUCTION
In constructing n building, ~e following is a summary cf the recommended sequence of construction:
a) Foundations are poured with dowels 10M at 400 placed in footings 43. The top surface of the footings 43 are provided with keys 44 as shown in Figure 1. Sleeves are provided to pour the concrete.
b) The walt panels 11 are aligned on top of the footing 43J one panel at a time. Tempor~ry bracing is provided to keep the panels in place.
c) Concrete is poured at the joints between the panels to fill the joint and at the sleeves in the footing 43 to fill the footing beam.
Pouring of the concrete is terminated only when the concrete starts to over~low the top of the pint. The use of a high slump concrete or a concrete pump is recommended.
d) The temporary bracing is removed after at least 3 days of pouring the concrete.
e~ The first ~loor slab is coslstructed.
s~
f) Baclcfill is then provided around the first noor.
g) Align 1he ~econd floor wall panels 11 and ~ereafter steps c and d are repeated. Execute all necessary welding of inserts, bolts, etc.
before pouring the concrete at ~e pints.
The assembled and cast imler panel element 15, the reinforcement and the insulating strips 29 which ~-~e temporarily ~upported by a series of wood blocks, for illustratiQn, are then arranged in a horizontal position with the , Pinforcement extending upward'y. In such a position the insulating strips define the bottom wall of ~ suitable rectarlgular mold into which the outer panel element 19 is to be poured.
A further step in~ des the pouring of a concrete rnix into ~he second mold to such depth as to arer~ie the insulating strips 29 and to enclose apex portions of the adjacent trusses where they are welded as at 27 and to further enclose the adjacent steel rods 23 and of sufficient depth as to form when cured the outer panel element 1~, fragmentarily shown in Figure 6.
After pouring, the concrete is cured to permit~ hardening of the concrete to form the steel reinforced insulated outer panel element 19 which has embedded therein outer edge portions of the corresponding trusses along their lengths, and the other steel wire mesh 17.
Upon curing, the finished wall panel is æparated from the second mold as a unit modular panel 11 such as would be used in the construction of the building fragmentar~y shown in Figures 1 and a.
As a further step in connection with the assembly and secslring of the insulating strips within the reinforcement and between the respective pairs of trusses 21, sp~cing between the adjacent strips 29 required because of the thi~kne.ss of the respective husses is filled with a suitable flller, epoxy or other insul~tir~ material. When sealed ~e laterally aligned planer insulating strips define the bottom surface for the casting mcld for the outer panel elemer~t 19.
During pouring and curing of the concrete upon the layer of tempor~rily supported insulator strips 29, interior portions of the outer panel element 19 adhere to or are otherwise bonded to the insul~ting layer 2g or series of strips of insulating materi~l.
~L4651~
METHOI) O~ EREC'rl~dG A BUILDING
Once the unit wall panels 11 have been cast, they are mounted upon a suitably previously cured concrete footing 43, Figure 1~ A ~urther s~ep in erecting of ~e building includes assembli7l~ laterally spaced laths 57, of styrofoam, plywood or metal, between and at right ar~les to the panel elements 15 and 19 of the adjacent panels, Figure 7, inwardly of the outer edges of each panel to define a chamber between the laths including the air zone 33 within the panels.
A further step includes pourhlg in situ into ~e chamber down to the footing 43 a column 59 of concrete to the height of the respective panels.
Portions of the outermost trusses ~1 extend into and are embedded within concrete column 59. Concrete for the column extends into the footing channel 44.
The final step includes curing the column of concrete for a time sufficient for hardening with a column of cement reinforced by the truss portions 21 and intercQnneCti7lg the panels 11 and the corresponding panel elements throughout their height~ The column 59 interlocks with the footing 43.
The ~spective columns 59 form the vertical joints between adjacent aligned pRnels 11 forming a part of the building structure, Figure 2.
Part of the present method includes forMir4~ of vertical concrete columns 68 between corner panel elements as fragmentarily shown in Figure 8.
This includes the assembling of a pair of rigllt angularly related panels having adjacent mitered edges 67 along their length which are closely spaced apart and form a corner for a pair of right ~ngularIy related building walls.
~;~14658 A further step includes aæembling later~lly spaced right angularly related laths 57 between and at r ight angles to ~e respective panel elements of each pair of panels inwardly of the outer edges of each panel to define a chamber alon~ with ~e interior walls of the inner and outer panel elements, Figure 8.
A further stsp includes pouring in ~itu into the chamber down to the footing 43 concrete to the height of the corner panels. Portions of the trusses 21 are embedded within column 68. The column 68 interloek~ with footing 43.
A further step includes curing of the column of concrete. The column 88 is reinforced by the trusses 21 and interconnects the corner panels and the panel elements throughout their height.
A study was conducted on the insulation propertie~ of the panels 11 at the University of Western Ontario, London, Canada which shows the insulation qualities of the panels to be satisfactory for all normal function buildin~fs whether residential, commercial, instituional or industri~l. The following is a summary of the expected inside wall surface temperatures (~) for ~e paneLs.
Toutside Twall insiderwall inside with no insulation with insulation (~) (~) (F) .
42.6 68.5 37.2 68.2 0 31.fi 67.8 -~0 26.2 67.6 The calculations assumed in the following:
i) The "R" value of "SM Blue" insulation is 5/inch.
ii) The inside film coefficient has an "Rl' value of 0.68.
iii) All other coefficients are taken from ASHRA~/81.
iv) The inside room temperature is 70F and ff~ere is 4 inches of SM Blue insulation in ~e cavity for a total "R" equsl to 22.63 (Imperial Units).
The estimates are not ~s accurate as an overall "R" value estimate.
This is because of the difficulty of accurately estimating the inside film coefficient. Less than 2% of the heat will be transferred through ~e steel rods.
This is evident in that our 4 inches of insulation the "R-' value of 22.67 reduces to 22.63 as a result of the steel bars. These values are n~t dependent on temperature and ~erefore have no difference with respect to the temperatures noted.
Condensation as a result of large outside humidity conditions is not a problem since a continuous vapour barrier is expected by the "SM E~lue"
insulation.
SE~U~ E OF CONSTRUCTION
In constructing n building, ~e following is a summary cf the recommended sequence of construction:
a) Foundations are poured with dowels 10M at 400 placed in footings 43. The top surface of the footings 43 are provided with keys 44 as shown in Figure 1. Sleeves are provided to pour the concrete.
b) The walt panels 11 are aligned on top of the footing 43J one panel at a time. Tempor~ry bracing is provided to keep the panels in place.
c) Concrete is poured at the joints between the panels to fill the joint and at the sleeves in the footing 43 to fill the footing beam.
Pouring of the concrete is terminated only when the concrete starts to over~low the top of the pint. The use of a high slump concrete or a concrete pump is recommended.
d) The temporary bracing is removed after at least 3 days of pouring the concrete.
e~ The first ~loor slab is coslstructed.
s~
f) Baclcfill is then provided around the first noor.
g) Align 1he ~econd floor wall panels 11 and ~ereafter steps c and d are repeated. Execute all necessary welding of inserts, bolts, etc.
before pouring the concrete at ~e pints.
Claims (23)
- Having described my invention, reference should now be had to the following claims.
I Claim:
A panel for a building comprising a pair of spaced opposed elongated molded concrete inner and outer panel elements of rectangular shape;
a steel wire mesh reinforcing member embedded into and throughout each panel element;
a series of parallel laterally spaced continuous steel rod trusses interposed between and extending at right angles to said panel elements;
each truss including a pair of parallel spaced elongated steel rods embedded into said panel elements respectively along their length;
and a continuous zig-zag steel truss element at its apexes welded to the adjacent rod and embedded into the respective panel elements as a unit construction;
a fiberglass insulating layer overlying and bonded to the interior surface of said outer panel element, and occupying part of the space between said panel elements, the remaining space providing an air barrier zone between said panel elements and adapted to accomodate wiring and plumbing conduits;
and an end support flange across one end of the inner panel element extending to said fiberglass layer. - 2. In the panel of claim 1, there being a pair of said panels closely spaced and laterally aligned, forming part of the building wall;
upright laterally spaced laths snugly interposed between and at right angles to said panel elements, inwardly of the outer edges of each panel defining a chamber between said laths;
and a panel connector column of concrete material poured in situ between said laths when curved interconnecting said panels and panel elements throughout their height. - 3. In the panel of claim 1, and means interconnecting said wire mesh reinforcing members with said truss rods providing a unit reinforcement.
- 4. In the panel of claim 2, the outer most parallel trusses of said panels being embedded and anchored within said panel connector column.
- 5. In the panel of claim 2, there being opposed marginal flanges defining longitudinal notches in the insulating layers adjacent said laths cooperatively receiving corners of said column and interlocked therewith.
- 6. In the panel of claim 1, said insulating layer including a series of insulator strips extending the height of the panel and interposed between an adjacent pair of trusses and bonded thereto.
- 7. In the panel of claim 6, said bond including a resin applied to the edges of said insulator strip for registry with corresponding portions of said trusses.
- 8. In the panel of claim 1, there being a pair of right angularly related panels having adjacent mitered edges along their length, closely spaced apart and adapted to form the corner of a pair of building walls;
upright spaced right angularly related laths snugly interposed between and at right angles to the panel elements inwardly of the outer edges of each panel; and a corner panel connector column of concrete material poured in situ between said laths, when cured interlocking said corner panels and panel elements throughout their height. - 9. In the panel of claim 8, the outer most pair of trusses of said corner panels being embedded and anchored within said corner panel connector column.
- 10. In the panel of claim 2, an elongated shim nested in a portion of the space between said panels throughout their height outwardly of said connector column; and a sealant filler within the remaining spaces between said panels throughout their height flush with the inner and outer surfaces of said panels.
- 11. In the panel of claim 8, an elongated shim nested in a portion of the space between said corner panels throughout their height outwardly of said corner column; and a sealant filler within the remaining spaces between the panels throughout their height flush with the inner and outer surfaces of said corner panels.
- 12. In the panel of claim 1, and top and bottom end connector rods on each truss extending at right angles to and interconnecting the respective ends of said pair of steel rods.
- 13. In the panel of claim 1, said outer panel element extending above said end support flange; and a unit cast flooring having a width corresponding to said panel, at one end overlying said end support flange and spaced from the outer panel element of said panel.
- 14. In the panel of claim 13, a series of laterally spaced upright dowells extending through and above said end support flange and anchored therein;
said dowels being interposed between said flooring and said outer panel element; and a connector column of concrete material poured in situ between said flooring and the end of said outer panel element enclosing said dowels and when cured interconnecting said flooring with said panel. - 15. In the panel of claim 14, there being a second panel of the same construction as said first mentioned panel and endwise overlying and supported upon said first mentioned panel and upon an end portion of said flooring;
said laterally spaced dowels extending up into the lower end of said second panel between its panel elements;
said concrete connector extending up into and interposed between the panel elements of said second panel and enclosing adjacent portions of said dowels, and when cured interconnecting said panels and panel elements. - 16. In the panel of claim 1, a footing of rectangular cross section anchored within the ground surface and having an upwardly opening elongated slot therein;
a plurality of upright laterally spaced anchor dowels embedded in said footing and projecting upwardly thereof;
said panel being upright and at one end mounted upon said footing and receiving said dowels; and a base connector spacer of concrete material poured in situ between said panel elements for a portion of their height enclosing said dowels and extending down into said footing slot, said base connector when cured anchoring said panel upon said footing. - 17. In a building construction having a plurality of right angularly related enclosing walls mounted upon a footing, each of said walls including a series of laterally aligned closely spaced upright panels,;
each panel comprising a pair of spaced opposed elongated molded concrete inner and outer panel elements of rectangular shape;
a steel wire mesh reinforcing member embedded into and throughout each panel element;
a series of parallel laterally spaced continuous steel rod trusses interposed between and extending at right angles to said panel elements;
each truss including a pair of parallel spaced elongated steel rods embedded into said panel elements respectively along their length;
and a continuous zig-zag steel truss element at its apexes welded to the adjacent rod and embedded into the respective panel elements as a unit construction;
a fiberglass insulating layer overlying and bonded to the interior surface of said outer panel element, and occupying part of the space between said panel elements, the remaining space providing an air barrier zone between said panel elements and adapted to accomodate wiring and plumbing conduits;
and an end support flange across one end of the inner panel element extending to said fiberglass layer. - 18. In the building construction of claim 17, and a longitudinal connector between adjacent edges of adjacent aligned panels including upright laterally spaced laths snugly interposed between and at right angles to said panel elements, inwardly of the outer edges of each panel defining a chamber between said laths;
and a panel connector column of concrete material poured in situ between said laths, and when cured interconnecting said panels and panel elements throughout their height. - 19. In the building construction of claim 17, and a longitudinal connector between adjacent edges of a pair of right angularly related panels for each corner of a building;
each pair of right angularly related panels having adjacent mitered edges along their length, closely spaced apart and adapted to form a corner for a pair of building walls;
upright spaced right angularly related laths snugly interposed between and at right angles to the panel elements, inwardly of the outer edges of each panel; and a corner panel connector column of concrete material poured in situ between said laths, and when cured interlocking said corner panels and panel elements throughout their height. - 20. In the building construction of claim 18, and a longitudinal connector between adjacent edges of a pair of right angularly related panels for each corner of a building;
each pair of right angularly related panels having adjacent mitered edges along their length, closely spaced apart and adapted to form a corner for a pair of building walls;
upright spaced right angularly related laths snugly interposed between and at right angles to the panel elements, inwardly of the outer edges of each panel; and a corner panel connector column of concrete material poured in situ between said laths, and when cured interlocking said corner panels and panel elements throughout their height. - 21. The method of making a building panel comprising the following steps:
assembling and interconnecting a series of laterally spaced steel rod trusses between and at right angles to a pair of parallel steel wire mesh reinforcing members, providing a unit panel reinforcement;
mounting and supporting the reinforcement horizontally upon and above an elongated rectangular mold;
pouring a concrete mix into the mold to a depth to enclose one of the steel wire meshes and corresponding adjacent one edge portions of the assembled trusses;
curing for a time sufficient for hardening of the concrete to form a steel reinforced inner panel element with the trusses upon one side along their length and one if the wire mesh reinforcing members embedded and anchored therein;
applying a series of strips of insulating material between each pair of trusses side by side in a plane spaced from the inner panel element;
bonding the longitudinal edges of said strips to adjacent portions of said trusses respectively;
mounting the inner panel element, reinforcement and insulating strips horizontally with the insulating strips temporarily supported to define with a series of connected side walls a second elongated rectangular mold with the planer insulating strips defining the mold bottom;
pouring a concrete mix into the second mold to enclose the adjacent other edge portions of the assembled trusses and of H depth to enclose the other steel wire mesh reinforcing member; and curing for a time sufficient for hardening of the concrete to form a steel reinforced insulated outer panel element, the other side of the trusses along their length and the second steel wire mesh reinforcement being embedded and anchored therein and providing a unit building panel. - 22. The method of assembling a building including a plurality of right angularly related walls mounted upon a footing, with each wall including a series of upright closely spaced unit precast building panels, each panel including a pair of spaced opposed elongated precast inner and outer steel reinforced panel elements of rectangular shape and trusses interconnecting and embedded into the panel elements, comprising the following steps:
assembling laterally spaced laths between and at right angles to the panel elements of a pair of adjacent panels inwardly of the outer edge of each panel defining a chamber;
pouring in situ into said chamber down to said footing a column of concrete material to the height of said panels, portions of said trusses extending into and embedded within said column;
and curing said column of concrete for a time sufficient for hardening, with the column of cement reinforced by said truss portions and interconnecting said panels and panel elements throughout their height. - 23. The nethod of assembling a building including a plurality of right angularly related walls mounted upon a footing with each wall including a series of upright closely spaced unit precast building panels, each panel including a pair of spaced opposed elongated precast inner and outer steel reinforced panel elements of rectangular shape and trusses interconnecting and embedded into the panel elements, comprising the following steps:
assembling a pair of right angularly related panels having adjacent mitered edges along their length, closely spaced apart and adapted to form corner for a pair of building walls;
assembling laterally spaced right angularly related laths between and at right angles to the panel elements of each pair of panels inwardly of the outer edges of each panel defining a chamber;
and pouring in situ into said chamber down to said footing u column of concrete material to the height of said corner panels, portions of said trusses extending into and embedded within said column;
and curing said column of concrete for a suffficient time for hardening, with said column of cement reinforced by said trusses and interconnecting said corner panels, panel elements throughout their height.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA000454254A CA1214658A (en) | 1984-05-14 | 1984-05-14 | Precast reinforced concrete panel |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA000454254A CA1214658A (en) | 1984-05-14 | 1984-05-14 | Precast reinforced concrete panel |
Publications (1)
Publication Number | Publication Date |
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CA1214658A true CA1214658A (en) | 1986-12-02 |
Family
ID=4127861
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA000454254A Expired CA1214658A (en) | 1984-05-14 | 1984-05-14 | Precast reinforced concrete panel |
Country Status (1)
Country | Link |
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CA (1) | CA1214658A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9267283B1 (en) | 2014-12-11 | 2016-02-23 | Thomas Kentz | Kit for precast panels and method of assembling panels |
-
1984
- 1984-05-14 CA CA000454254A patent/CA1214658A/en not_active Expired
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9267283B1 (en) | 2014-12-11 | 2016-02-23 | Thomas Kentz | Kit for precast panels and method of assembling panels |
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