US1501986A - Building construction - Google Patents

Description

W. L. EVANS, JR

BUILDING CONSTRUCTION Filed July 27, 1921 4 Sheets-Sheet 1 WITNESSES ATTOR N EY w L. EVANS. JR

I BUILDING CONSTRUCTION Filed July 27, 1921 4 Sheets-Sheet 2 IN VENTOR Jul 22 1924,

W. L. EVANS, JR

BUILDING CONSTRUCTION Filed July 27. 1921 4 Sheeis-Sheet 5 E575. 17..

LEI/ails J INVEN he: H. ..w Tn. H. E

ATTORNEY -.Fuly 22 192%.

W. L. EVANS. JR

BUILDING CONSTRUCTION WITNESSES ATTORNEY Patented July 225, I24.

BUILDING CONSTRUCTION.

Application filed July 27, 1921. Serial No. 487:919.

To all whom it may concern:

Be it known that 1, WILLIAM L. EvANs, Jr., acitizen of the United States, residing at Washington, in the county of 'Daviess and State of Indiana, have invented new and useful Improvements in Building Constructions, of which the following is a specification. i

This invention has reference to building construction, and its object is to provide a construction utilizing concrete or some similar cementitious material as the filling-in material, with metal facings or skins serving as forms and which become a permanent part of the wall, floor, ceiling or column entering into the building construction, which is of a nature permitting rapid assembly without those delays incident to the drying out or hardening of the filling-in material, and permitting, particularly in alls, of the completion of the forms to the full height contemplated before the filling-in material is poured.

The invention has the advantage of extremely economical construction, since the outer walls, which also constitute the forms may be made of cheap sheet metal of suitable gage, sheet iron answering the purpose, as sheet iron is susceptible (3f protection against rust or deterioration by various treatments, of which sherardizing may be taken as an example. This is a process of treating the iron in a receptacle with powdered zinc and heating the materials to a temperature a little less than the melting point of the zinc, whereby the zinc is caused to enter the pores of the iron and combines with it into an alloy to produce the protecting coating.

In preparing the metallic skin to produce the outer or mold surfaces, which may be both inner and outer surfaces in the case of a wall or the receptacle for the filling-in material, in the case of a floor or a ceiling, or the sides in the case of a column, troughlike elements are provided, consisting of suitably eicngated sheets of metal of appropriate gage, with the long edges bent at an to constitute flanges, the troughs being assembled into any desirable area with adjacent flanges in contact and riveted or otherwise secured together, while the opposite faces, in the case of an upright wall are joined at appropriate intervals by spacer strips or tie rods determining the thickness of the completed wall, which is ultimately filled with concrete or the like poured between the joined walls and althrough in a manner to provide matching passages with raw edges, the punching resulting in the extension of these raw edges then returned or upset against that face of the flanges from which they project, after which the projecting edges are upset in a manner to anchor the adjacent flanges together. The perforations thus produced are made to match throughout the length of the construction to provide forthe passage of reinforcing rods, but the perforations are alsq made of relatively large size with respect to the rods so that the latter may lie close. to one side of the perforations, providing ample room about the rod for the spontaneous flow of the concrete through the holes'made in the flanges to produce anchoring junctions through the flanges from one troughlike member to the next in order.

In this manner the-concrete fillingis to an extent monolithic. Instead of securing the flanges of the adjacent troughs or skinelements together, by punching holes therethrough with ragged edges and upsetting and rlveting them together after the manner of tubular rivets, the holes may be smooth holes, but matching to pass reinforcing rods and bolts, may be employed to fasten the troughs together. Furthermore, the plane faces of the troughs between the flanges may be strengthened and stifiened by lateral corrugations which, in conjunction with the reinforcing rods and tie or spacer bar's, im "art particular rigidity and resistance to co lapse of the metallic skins containing the concrete fillin The invention will be best understood from a consideration of the following debeyond one face of the joined flanges, and

tailed description taken in connection with the accompanying drawings forming part of this specification, with the understand ing, however, that the invention is not confined to any strict conformity with the may he as such no Ina-- features the apshowing of the drawings, but changed and modified so long changes and modifications mark terial departure from the salient or the invention as expressed in pended claims.

In the drawings: v

1 igure 1 is a perspective vi w, partly completely and partly broken away and in section, of an upright wall embodying the invention.

Figure 2 is a plan view of the structure shown in Figure 1.

Figure 3 is a partly complete and partly incomplete perspective view of a floor structure embodying the invention.

Figure i is a similar view of a floor structure somewhat modified from the arrangement ofFigure 8. 7

Figure 5 is an upright section in the line of the reinforcing rods, and showing a small portion of a completed part or a floor section, formed after the plan of Figure 3.

Figure 6 is a similar view but following the construction of Figure igure 7 is an upright section showing two sides or a corner in an upright wall, similar to the arrangement o'f'lligure 1.

Figure 8 is a vertical section or" an upright wall and a cross section of a ceiling einloodying feature of the invention.

Figure 9 is a detail cross section of a portion of ceiling shown in Figure 8,

Figure 10 is a view similar to Figure 9 hut showing a modified :iorrn oi": the ceiling structure.

Figure ii is a perspective view of a portion or the structure shown in. Figure 8 and 9 but with the *olaster omitted,

Referring to the drawings, there is shown in Figures l, 2 and '3', an upright wall construction in which there are inner and outer shins A and Each skin or surface A and B is resale up of numerous trough-like box-like sections 1, simulating wall blocks, eech composed of an elongated strip of metal or suitable width and also oi appropriate gage, terminating at the long edges in. inturneol flanges 2 which may he perpendicular, to the plane or the trough-like structure 1, so that the flanges may he brough into face-to-face contact, with the two meeting flanges constituting a reinforcement lodged within space hetween the two outer skins of the wall. in order to determine the thickness of the completed wall, the flanges 2 on o csite laces thereof, are secured together ..,i spaced relation hy angropriaite bars 3, each bar being riveted,

pinned, or bolted to flanges with which itis connected. The are pro l with. openings and the bars or tie rods have loolts or rivets which engage said openings and connect and hold the skins or sections together, 5o Each pair or flanges 2 has matching perforations or passages 4, and these of perforations also aline throughout the extent of the wall to pass reinforcing rods 5 located between the trough-like joins of the wall and initially upheld by flanges at the bottoms of the perforations by which the rods are supported,

lihe perforations 4c are -produced at quent intervals so t iat an appropriate 1 her or reinforcing rods 5 may he utlr. but the spacing bars 3 may be less numerous and are utilized to receive and sustain reinforcing bars 6 located intermedia of the space between the shins A m The reinforcing" r ois 5 extend in posed order so ciently close to the or facings A and B to pass through to perforations while the intervening between the nor and outer walls or A and B contain the reinforcing 3 6 in superposed order about inter ate the thickness this particular ohligat,

or elem nts oi. gether, 1n the showing o" short bolts are made to elements tog After the metallic facings or s assembled, and this operation may tinned through the extent or the s a suitable concrete rniXtme is not the sloace between the we.

s l3 facings A, B, embedding the rods 5 joined reinforcing e 9 l flowing through the A sides of the 2 so that wh Crete has set, the variou lay the concrete are one cally monolithic mass of manner the metallic pal comes eilectively joined at vals whereby the skin is so tribute to the whole struc' U the clue to contraction and er nsion metal, confining such strains to small I while the metal and concrete he-c curely bound together.

In order to stiffen the e ings or skins to withsl sure caused by the we hefore it has set, the i parts trouglrlike members A and hetw fian ee 2 provided with sc -ru extending lengthwise of alily spaced one aoove he other. rugations may rolled or other recipes of which the one member of the completed wall, While in the other completed wall joining the first wall at an angle, the flanges 2 are in alignment therewith so as to provide aligned extensions 2* secured to the respective flanges 2 by bolts or rivets or other suitable fastening devices 7 I The construction already described is susceptible to employment not only for upright walls, but for the production of floors or ceilings. In Figures 4. and 6, the troughlike elements are horizontal, or approximately so, and in Figure 4, trough-like elements A have upstanding flanges 2 with I smooth matching perforations 4' through lustrated.

which reinforcing rods 5 project, and the flanges are secured together by bolts 7. The rods 5 naturallygravitate to the botatoms of the holes or perforations 4, and when concrete is filled into the trough-like members 1, the rods 5 become embedded and, on the hardening of the concrete, the floor material confined in the'troughs assumes a monolithic character with integral anchors of concrete through the passages .4.

In the structure shown in Figures 3 and 5, a somewhat different construction is il- The meeting flanges 2 have the edges remote from the plate-like bases of the trough-like elements each formed with a return bead 8*? with one return bead housing the other one, .whercb to interlock' the otherwise free. long ec ges of the flanges, besides greatly stiffening the reinforcing quality imparted to these flanges. Furthermore, matching perforations 4 are punched through the contacting flanges so that there is a raw edge or burr 9 formed about the raw edge of the perforation 4 and the burr is turned back against the face of the flange through which it projects, after the manner of the tubular rivet, thereby securing the two flanges solidly together, this being shown particularly in Figure 5 and indicated in Figure 3. The reinforcing quality of the flanges 2 in the st ructure shown in Figures 3 and 4 is greatly increased and the metal skin or facing of the completed structure is greatly strengthened.

This invention is an improvement upon the building construction. illustrated and described in my application No.466,843, filed May 4th, 1921, in which one face of the wall is made up of a single-thick'layer of brick, with a removable molding form ten'lporarily secured thereto in spaced relation thereto so that the concrete is poured between the permanent brick wall and the forcement, while the holes temporary mold face to complete the wall.

For certain classesof Work, this construction is very desirable, althoughit has some disadvantages. The cost of the brick and the cost of laying them represents a high initial cost. Moreover, it is difficult ,to get brick masons sufliciently skilled to lay up the brick with water-tight joints, or even to get brick masons in sufficient numbers and at prices whichwill justify the laying of the brick. Furthermore, the brick, after being laid, must stand long enough for the mortar tovset before the forms can be put into place and the concrete poured.

' In accordance with the present invention, the skin employed not only acts asa form for the concrete wall, but also as a permanent skin or facing for the building, and is cheap in first cost and easy of construction. It will also permit the work to go forward as soon as the skin is put in place, and without having to Wait for the drying of mortar. Furthermore, such a skin is impervious to moisture and can constitute both the outside and inside of the wall so that the latter may be completed as soon as the concrete is poured.

Since there are several known processes of rendering sheet iron rust-proof, the skin construction may be set up Very cheaply and may constitute a permanent part of the Wall, thus. necessitating-no false work to be subsequently torn down.

In producing an upright wall or partition, which it is desired to subsequently plaster, the inner skin or form may be made removable and expanded metal lathing may replace .it. In the case. of a floor but one skin or facing, the bottom member, is needed to receive and hold the concrete. and a finishing coating of cement or other material may be added.

In floor construction it is evident'that, the metal employed should be of somewhat heavier gage than that for walls, with the flanges and holes larger and the reinforcing rods proportionately heavier.

By the, arrangemeiit herein disclosed, the

reinforcing rodsextending through the holes in the flanges causes the rods to be brought close to the bottom of the concrete slab,

where it is most desirable to place the reinermit the concrete to flow together and join on both sides of the flanges with the result that the slab is not weakened by the ribs or flanges extending partly through it. The flan es form reinforcing ribs extending in one i.- rection with the reinforcing rods extending in the opposite direction.

In using this invention for floor construction, it will be found most valuable for the construction of floors for buildings, bridges, piers, platforms, the rust-proofing of the metal facing peculiarly adapting it for the upright wall formed of inner and outer the ceiling as shown in purposes mentioned. The holes or perforations in the flanges .may bemade of any shape.

, In Figures 8 and 9 there is shown a form ofwall construction similar in some respects to Figures 3 and 7, Figure 8 illustrating an skins D and E, respectively, which are similar to the skins A and B shown in Figure 7 and other figures of the drawings. The skins D and E may be made up of troughs having flanges 2 with matching perforations a formed with burrs 9, by means of which the facing flanges are anchored together, as in the structure shown in Figure 3. The perforations 45* receive reinforcing rods 5. as in other forms of the invention.

lln Figure 8 and associated figures, provision is made for the application of plaster or stucco, or both, respectively. on opposite walls. To prepare the wa D and E and gure 8, for the application of plaster, 1 metal skin is punched t rough on in =1BlOUS elongated lines prod .cing perforations 10 with closely adjacent but separate flanges 11 or 12, the latter being indicated in Figure 10. In Figures 8, 9. and 11 the flanges 11 are oppositely curved with respect to each other to form hooks 13 by the return of the flanges upon themselves, thus providing anchors to receive and retain a surface coating 14 of plaster or the like, permitting use of-an interior wall filling 15, which in cheap con- 'structions may be composed of clay but in the case of floors may consist of concrete or the like. I

The slots 10 and struck-out flanges 11 or 12 are each of considerable length and are arranged more or less parallel with each other and in relatively close relation, and serve to very sensibly stiffen the metal skin, thus materially aiding in strengthening the walls. The slots and flanges bordering them act after the manner of metallic lathing and firmly retain plaster applied to the inner surface of the walls while the metallic lathing on the exterior of the walls serves to receive and hold stucco thereby greatly enhancing the appearance of the exterior finish of the building without material addition to the cost, wherefore the arrangement is particularly advantageous where it is desirable to produce buildings of small initial cost but with an appearance equaling that of more expensive constructions.

The plaster can be put directly upon the perforated shin either before or after the filling-in process, but preferably after. Furthermore, when the metallic skin is embedded in the wall with concrete on one face and plasteron the other, little or no rustpro ofing of the metal is needed, for the construction excludes the. access of air to the metal and rusting does not occur,

recipes The construction made up of metal shins, steel reinforcements, concrete and plaster is a most desirable construction for buildings up to any size or height and such construction is also available for the production of cheaper buildings now in demand.

A cottage can be built permanently at a low price by using a metal skin for the walls plastered on the inside and stuccoed on the outside and filled withclay of a thickness which will be cool in summer and warm in the winter, while the ceilings of such buildings can be made permanent and fire-proof by using a metal form such as hereinbefore described, that is, by using a metal form plastered on the underside and filled with c on the upper side. Moreover, the floors be made with a metal form having steel rein- .forcements and filled with concrete.

For purposes of brevity, the word is employed in the claims to include a c ing, floor, partition or inside or outside wan of any building structure.

l v'hat is claimed is:-

1. in building construction, the combi e tion of elongated sheet-metal trcugii-lil elements having longitudinal angle flan at the edges meeting face to face, fasten moans securing the flanges of the elements together, where meeting, to form a cor nous wall-facing, with said flanges ha matching perforations in alignment, a'

inforcing rods smaller in diameter than the perforations and traversing said perforalions,v said elements being adapted to ieceive a iilling-in-material, embedding rods andiflanges and passing through perforations and filling the spaces betneul said flanges.

tion of-a facing coi weed of elon metal sheets with the lbng edges projec from the sheets an angle to pro flanges, and the flanges being associated held in face-to-face engagement, sc flanges having matching perforations, re forcing rods of materially smaller 1 than the perforations and traversir aligned perforations, means for securing metal sheets together, and a flowahle a subsequently hardening lling for the embedding the said flanges and the rent. forcing rods and also extending throu 'h said matching perforations to provide l'etive continuity of the wall filling.

ln building construction, the combination of sheet-metal sections with angle flanges at the long edges, said flanges being provided with matching perforations and secured together, reinforcing rods extending 1,501.,ese

flanges and initially flowable and subsequently hardening and setting, to spontaneously pass through the perforations to thereby join the sheet metal and filling material together and connect the rods to said material.

4. In building construction,'the combination of sheetmetal sections, with angle flanges at the long edges, said flanges being provided with matching perforations and secured together, reinforcing rods extending through the flanges, with the perforations of materially greater diameter than the rods, and a filling of material embedding the rods and flanges and initially flowable and subsequently hardening and setting to spontaneously pass through the per forations to join the metal and filling material together and connecting the rods to said material, said wall also comprising joined metallic units on both faces with the junction means in the form of metallic bars, and reinforcing bars located between the facing means and embedded in the filling means.

5. In building construction, a sheet metal trough-like unit with edge flanges projecting at an angle to the plane of the main portion of the unit, said flanges being in face-to-face contact, and means for connecting the trough-like units together, consisting of matching perforations in said flanges having burrs formed about the edges of the perforations of one flange and pro jecting through the perforations of the otherflange and returned upon and upset against said other flange to connect the two flanges firmly together in the manner of a tubular rivet. said connecting means not obstructing the assage of filling-in-material through said perforations, and said perforations being adapted to receive reinforcing rods.

6. In building construction, a sheet metal trough-like unit with edge flanges projecting at an angle to the plane of the main portion of the unit, said flanges having perforations which are alined when the units are assembled with theflangcs in face-to-face contact, said perforations being adapted to receive reinforcing rods, and tubular rivets uniting adjacent units together at the perforations, said rivets being formed integral with one flange and engaging the other flange.

7. In building construction, the combination of a sheet metal casing composed of joined trough-shaped units defining the outer skin of a wall, with joined flanges-connecting the units, the interior of the'wall being filled with an initially flowable mixture of a character to harden while in the wall, said metallic skin having slots punched therethrough and forming outstanding flanges on op osite sides of the slots to receive and hol a coating of iniof joined-trough-shaped units defining the outer skin ofthe wall, having joining flanges connecting the units, with one face of each unit provided with punched through elongated slots having curved 'free edges bent away from each other and returned toward the facing to form outstanding hook-shaped locking edges, a coating of wall-finishing material applied to the outstanding edges of the slots and the corresponding face of the metallic skin, a filling of initially flowable and subse uently hardening materialwithin the 'wa 1, said inner and outer coatings embedding the sheet-- metal to protect it against rust.

9. In building construction, an exterior metallic casing composed of opposite skins formed of trough-like sections having inturned flanges 'rovided with perforations, said sections belng fitted together with the flanges in face-to-face contact and the perforations alining, rods passed through the per't'orations in the flanges and being of a length to connect two or. more sections, and a plastic filling poured between the sections of the opposite skins. I

10. In building construction, the combination of elongated sheet metal troughlike sectionshaving longitudinal angle flanges at the edges, said sections being fitted together with the flanges in face-to-face contact, said flanges having matching perforations in alinement, and transverse rods passed through the perforations and spaced from the body of the sections, said sections being adapted to receive a filling-in material which embeds the rods and flanges and fills in the spaces betweensaid flanges.

11. In building construction, an exterior metallic casing composed of oppositeskins formed of trough-like sections having inturned flanges provided with perforations, said sections being fitted together with the flanges in faoe-to-face contact and the per-D. fora tions alining, rods of materially less diameter than and passing through the perforations in the flanges so that the rods occupy the bottom walls of the perforations, and a plastic filling poured between the sections of the opposite skins.

12. In building construction, a metallic casing composed of opposite skins formed of trough-like sections or units having inturned flanges provided with perforations, said sections or units being fitted together with the flanges in face-to-face contact, reinforcing rods passed through the perfora= tions and connecting the sections or units at one side, spacing means for joining'fthe units at opposite sides and holding them apart, other reinforcing bars supported by said spacing means, and a plastic filling ploured between the sections of the opposite sons.

13. In building construction, e metallic casing composed of opposite skins formed of trough-like sectionsor units having in turned flanges, reinforcing bars connecting the sections or units at one side and supported by said flanges, spacing means for joining-the sections or units at opposite sides and holding them apart, and other reinforcing bars supported by said spacing -II162H1S between the opposite skins, and a plastic filling poured between the sections otthe opposite skins and embeddin'g'q neoneee i6 flanges, the two sets'of reinforcing bars and the spacing means.

14. fiL concrete structure, including an ex:

terior metallic casing composed of oppositeskins comprising box-like sections having upturned flanges provided with openings, said sections being fitted together and simuleting Wail blocks, interconnecting tie rods engaging the openings in the flanges and holding the sections together, and a plastic filling poured between the sections of the opposite skins.

In testimony that I cleinithe foregoing as my own, it have hereto efixed my nature.

Lewis EVANS, JR.

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