US20050229516A1 - Precast wall section and method of making walls from same - Google Patents
Precast wall section and method of making walls from same Download PDFInfo
- Publication number
- US20050229516A1 US20050229516A1 US10/865,858 US86585804A US2005229516A1 US 20050229516 A1 US20050229516 A1 US 20050229516A1 US 86585804 A US86585804 A US 86585804A US 2005229516 A1 US2005229516 A1 US 2005229516A1
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- United States
- Prior art keywords
- pillar
- vertical
- face
- flange
- wall
- 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.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title description 2
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 15
- 239000011150 reinforced concrete Substances 0.000 claims abstract description 5
- 239000004567 concrete Substances 0.000 claims description 25
- 239000000758 substrate Substances 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 10
- 230000000284 resting effect Effects 0.000 claims description 4
- 230000000717 retained effect Effects 0.000 claims description 3
- 238000010276 construction Methods 0.000 description 4
- 235000013305 food Nutrition 0.000 description 3
- 239000002984 plastic foam Substances 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- -1 gravel Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000009428 plumbing Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000011012 sanitization Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
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
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
- E04B2002/7498—Partitions for clean rooms
Definitions
- the invention relates generally to prefabricated wall constructions.
- clean rooms These rooms are generally furnished with corrosion resistant furniture and equipment where the food products are actually prepared. As the name implies, these clean rooms, and the equipment contained therein, are maintained at a high level of cleanliness in order to minimize the possibility of food contamination.
- workers clean down the equipment, walls and floor of the clean room using high pressure washers. While washing with high pressure washers is generally effective, even the most effective high pressure washer is not always capable of removing all traces of debris from tight comers of the room, particularly where the floor meets the walls. Therefore, there is always the possibility that the room will not be totally sanitized even after the room has been thoroughly washed with high pressure washers.
- a wall section for forming a wall, said wall section comprising a precast reinforced concrete pillar having a vertical portion and a flange portion.
- the vertical portion has a top end, a bottom end, and a vertical face, the flange portion projecting perpendicularly away from the vertical face immediately adjacent the bottom end.
- the flange portion also has a horizontal face.
- a curved concave face is formed on the pillar where the horizontal face of the flange portion joins the vertical face of the vertical portion.
- the vertical section is reinforced by reinforcing bars which extend through the bottom end and projecting horizontally below and beyond the flange.
- an improved method of constructing a wall including the steps of providing a plurality of precast reinforced concrete pillars each pillar having a vertical portion and a flange portion, the vertical portion having a top end, a bottom end, and a vertical face, the flange portion projecting perpendicularly away from the vertical face immediately adjacent the bottom end.
- the flange has a substantially flat bottom and a horizontal face and the pillar has a curved concave face where the horizontal face of the flange portion joins the vertical face of the vertical portion.
- a substrate is provided upon which the concrete pillars are placed with the bottom of the flanges resting on the substrate.
- the floor is formed by pouring concrete over the substrate to a level flush with the horizontal flat face of the flange portions, and finally, the poured concrete is left to cure.
- FIG. 1 is a perspective view of a wall section made in accordance with the present invention.
- FIG. 2 is a cross sectional view of a wall and floor made in accordance with the method of the present invention.
- FIG. 3 is a top view of a wall section made in accordance with the present invention.
- FIG. 4 is a side view of a wall section made in accordance with the present invention.
- FIG. 5 is a cross sectional view taken along line A-A of FIG. 3 .
- FIG. 6 is a cross sectional view taken along line B-B of FIG. 3 .
- FIG. 7 is a cross sectional view of an alternate embodiment of the present invention.
- FIG. 8 is a perspective view of an alternate embodiment of the present invention.
- the present invention is a precast wall section, shown generally as item 10 which consists of an elongated pillar 12 having opposite ends 14 and 16 , vertical portion 15 and flange portions 22 and 23 .
- Vertical portion 15 has top portion 18 , bottom portion 20 , and opposite vertical faces 24 and 25 .
- Flange portions 22 and 23 have horizontal faces 26 and 27 , respectively.
- Curved faces 28 and 29 are formed on pillar 12 at the junction of flat faces 24 and 26 and at the junction of flat faces 25 and 27 , respectively.
- Pillar 12 is precast from concrete and is reinforced by a plurality of vertical reinforcing bars 30 .
- Reinforcing bars 30 each have a vertical portion 32 which is substantially contained in pillar 12 and a horizontal portion 36 which extends perpendicularly away from the pillar below the flange portions. A portion 34 of reinforcing bars 30 extend below pillar 12 .
- epoxy coated reinforcing bars 30 are oriented such that horizontal portions 36 of approximately half of the bars project to one side of the pillar while the other half project to the other side of the pillar.
- Horizontal reinforcing bar 38 is provided in pillar 12 and extends between ends 14 and 16 .
- Horizontal bars 30 and 38 provide structural strength to the pillar.
- Mounting elements 40 are provided at the corners of flanges 22 and 23 towards ends 14 and 16 . Each mounting element 40 consists of a threaded nut 44 and a threaded tap 46 .
- Threaded nut 44 is countersunk into the bottom of the flange portion and threaded tap 46 is mounted within the flange such that the treaded tap is coaxially aligned with the nut. Threaded tap 46 and threaded nut 44 form a single mounting unit 40 permitting a threaded bolt (see FIG. 2 ) to be inserted and retained in mounting unit.
- Top portion 15 of pillar 12 has a mounting unit 42 consisting of a threaded tap 46 which is securely retained in the pillar. Mounting unit 42 permits an anchor bolt (not shown) to be mounted to the mounting unit, permitting an attachment means to lift the entire pillar with a crane (not shown).
- End 14 may be provided with female connector element 33 which is dimensioned and configured to bind to male connector element 35 of an adjacent pillar 12 .
- Male connector element 35 is preferably a length of reinforcing bar cast into the pillar.
- Male/female connector elements 33 and 35 make it easier to mount a series of pillars in a row to form a wall.
- Male/female connector elements 33 and 35 also help to strengthen the finished wall.
- a substrate 56 is first provided.
- Substrate 56 may be crushed stone, gravel, sand or some other suitable substrate for supporting a concrete floor. Pillar 12 is then set on top of substrate 56 . If the height of pillar 12 must be adjusted, anchor bolts 50 may be mounted to mounting units 40 .
- Anchor bolts 50 consist of a threaded rod 52 rigidly mounted on top of feet 54 . By threading rod 52 into mounting units 40 the height at which the pillar sits above substrate 56 can be adjusted. This makes plumbing the pillar so that the pillar sits vertically on the substrate a simple procedure.
- a layer of concrete 58 is poured over the substrate.
- the amount of concrete poured is adjusted such that the top surface 60 of the concrete is flush with the horizontal surface 26 of flange 22 .
- Horizontal portions 36 of the reinforcing bars anchor pillar 12 to the poured concrete forming the floor.
- the concrete is left to cure.
- a wall/floor junction is thereby formed with a smooth continuous curved face 28 joining floor surface 60 to vertical face 24 .
- the height of the wall can be increased by attaching upper wall segment 62 to the top 18 of pillar 12 .
- the present invention has numerous advantages. Firstly, since the pillars are precast, the curves on the pillar may be made hard and durable, thereby lengthening the life of the finished wall. Furthermore, since the pillars are preformed, assembling the wall is accomplished relatively quickly. Finally, since the pillar is anchored to the concrete floor by reinforcing bars, the overall wall structure is very strong and durable.
- the wall segments may be formed as corner units or as side units where the curved concave surface is present on only one side. Therefore, nearly any type of room can be constructed simply by using a variety of different precast units. Each of these units will have reinforcing steel bars 100 , curved concave surface 102 , flange portion 106 , vertical portion 108 , and mounting units 104 as discussed in the previous example.
- a wall segment made in accordance with the present invention shown generally as item 200 may also take the form of a precast pillar 202 .
- Precast pillar 202 is made of plastic foam panels 204 and 206 which are held together by a plurality of ties 208 .
- the pillar is given additional strength by a layer of concrete 210 which is poured in between foam panels 204 and 206 .
- Pillar 202 has reinforcing bars 212 have vertical faces 214 and 216 , curved concave faces 218 and 220 and horizontal flat faces 222 and 224 as in the previous embodiment.
- Pillar 212 is identical to the embodiment shown in FIG. 1 .
Abstract
The present invention is a wall section for use in constructing the walls of clean rooms. The wall section consists of a precast reinforced concrete pillar having a vertical portion and a flange portion. The vertical portion has a top end, a bottom end, and a vertical face. The flange portion projects perpendicularly away from the vertical face immediately adjacent the bottom end. The flange also has a horizontal face. The pillar has a curved concave face where the horizontal face of the flange portion joins the vertical face of the vertical portion. The vertical section of the pillar is reinforced by reinforcing bars which extend through the bottom end and project horizontally below and beyond the flange.
Description
- The invention relates generally to prefabricated wall constructions.
- The manufacture of various food products usually occurs in what are referred to as clean rooms. These rooms are generally furnished with corrosion resistant furniture and equipment where the food products are actually prepared. As the name implies, these clean rooms, and the equipment contained therein, are maintained at a high level of cleanliness in order to minimize the possibility of food contamination. At the end of each work day, workers clean down the equipment, walls and floor of the clean room using high pressure washers. While washing with high pressure washers is generally effective, even the most effective high pressure washer is not always capable of removing all traces of debris from tight comers of the room, particularly where the floor meets the walls. Therefore, there is always the possibility that the room will not be totally sanitized even after the room has been thoroughly washed with high pressure washers.
- In order to maximize the ease of sanitation, clean rooms are now being constructed without tight comers where the walls and floor meet. The walls and floor of these rooms are generally made from concrete and have a smooth curved junction between the walls and floor. These smooth curved junctions permit water to flow easily through the comers in order to wash away any accumulated debris. However, these improved clean rooms have one major drawback, they tend to be expensive to construct. Generally speaking, these rooms are formed from a concrete floors with walls made of insulating pre-finished panels. This construction leaves a sharp angle where the wall meets the floor. A gentle curve is formed at the junction of the wall and floor by applying a layer of concrete at the wall/floor junction and molding the concrete to form the curved junction. As can be imagined, the curved junction formed is not always uniform. Furthermore, the concrete curved junctions have a tendency to deteriorate over time, leaving a fractured junction, which is ideal for retaining debris. Finally, the step of forming the junction is both time consuming and expensive. An improved wall construction technique is therefore required.
- In accordance with the present invention, there is provided a wall section for forming a wall, said wall section comprising a precast reinforced concrete pillar having a vertical portion and a flange portion. The vertical portion has a top end, a bottom end, and a vertical face, the flange portion projecting perpendicularly away from the vertical face immediately adjacent the bottom end. The flange portion also has a horizontal face. A curved concave face is formed on the pillar where the horizontal face of the flange portion joins the vertical face of the vertical portion. The vertical section is reinforced by reinforcing bars which extend through the bottom end and projecting horizontally below and beyond the flange.
- There is also provided an improved method of constructing a wall including the steps of providing a plurality of precast reinforced concrete pillars each pillar having a vertical portion and a flange portion, the vertical portion having a top end, a bottom end, and a vertical face, the flange portion projecting perpendicularly away from the vertical face immediately adjacent the bottom end. The flange has a substantially flat bottom and a horizontal face and the pillar has a curved concave face where the horizontal face of the flange portion joins the vertical face of the vertical portion. A substrate is provided upon which the concrete pillars are placed with the bottom of the flanges resting on the substrate. The floor is formed by pouring concrete over the substrate to a level flush with the horizontal flat face of the flange portions, and finally, the poured concrete is left to cure.
- With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the preferred typical embodiment of the principles of the present invention.
-
FIG. 1 . is a perspective view of a wall section made in accordance with the present invention. -
FIG. 2 . is a cross sectional view of a wall and floor made in accordance with the method of the present invention. -
FIG. 3 . is a top view of a wall section made in accordance with the present invention. -
FIG. 4 . is a side view of a wall section made in accordance with the present invention. -
FIG. 5 . is a cross sectional view taken along line A-A ofFIG. 3 . -
FIG. 6 . is a cross sectional view taken along line B-B ofFIG. 3 . -
FIG. 7 . is a cross sectional view of an alternate embodiment of the present invention. -
FIG. 8 . is a perspective view of an alternate embodiment of the present invention. - In the drawings like characters of reference indicate corresponding parts in the different figures.
- Referring firstly to
FIG. 1 , the present invention is a precast wall section, shown generally asitem 10 which consists of anelongated pillar 12 havingopposite ends flange portions top portion 18,bottom portion 20, and oppositevertical faces Flange portions horizontal faces Curved faces pillar 12 at the junction offlat faces flat faces Pillar 12 is precast from concrete and is reinforced by a plurality ofvertical reinforcing bars 30. Reinforcingbars 30 each have avertical portion 32 which is substantially contained inpillar 12 and ahorizontal portion 36 which extends perpendicularly away from the pillar below the flange portions. Aportion 34 of reinforcingbars 30 extend belowpillar 12. - Referring now to
FIGS. 3, 4 , 5 and 6, epoxy coatedreinforcing bars 30 are oriented such thathorizontal portions 36 of approximately half of the bars project to one side of the pillar while the other half project to the other side of the pillar.Horizontal reinforcing bar 38 is provided inpillar 12 and extends betweenends Horizontal bars Mounting elements 40 are provided at the corners offlanges ends mounting element 40 consists of a threadednut 44 and a threadedtap 46. Threadednut 44 is countersunk into the bottom of the flange portion and threadedtap 46 is mounted within the flange such that the treaded tap is coaxially aligned with the nut. Threadedtap 46 and threadednut 44 form asingle mounting unit 40 permitting a threaded bolt (seeFIG. 2 ) to be inserted and retained in mounting unit. Top portion 15 ofpillar 12 has amounting unit 42 consisting of a threadedtap 46 which is securely retained in the pillar. Mountingunit 42 permits an anchor bolt (not shown) to be mounted to the mounting unit, permitting an attachment means to lift the entire pillar with a crane (not shown).End 14 may be provided withfemale connector element 33 which is dimensioned and configured to bind tomale connector element 35 of anadjacent pillar 12.Male connector element 35 is preferably a length of reinforcing bar cast into the pillar. Male/female connector elements female connector elements - Referring now to
FIG. 2 , the method of the present invention shall now be discussed. To form a wall, asubstrate 56 is first provided.Substrate 56 may be crushed stone, gravel, sand or some other suitable substrate for supporting a concrete floor.Pillar 12 is then set on top ofsubstrate 56. If the height ofpillar 12 must be adjusted,anchor bolts 50 may be mounted to mountingunits 40.Anchor bolts 50 consist of a threadedrod 52 rigidly mounted on top offeet 54. By threadingrod 52 into mountingunits 40 the height at which the pillar sits abovesubstrate 56 can be adjusted. This makes plumbing the pillar so that the pillar sits vertically on the substrate a simple procedure. When the pillar is properly set on the substrate, a layer of concrete 58 is poured over the substrate. The amount of concrete poured is adjusted such that thetop surface 60 of the concrete is flush with thehorizontal surface 26 offlange 22.Horizontal portions 36 of the reinforcing bars anchorpillar 12 to the poured concrete forming the floor. The concrete is left to cure. When the concrete has hardened and cured, a wall/floor junction is thereby formed with a smooth continuouscurved face 28 joiningfloor surface 60 tovertical face 24. The height of the wall can be increased by attachingupper wall segment 62 to the top 18 ofpillar 12. - The present invention has numerous advantages. Firstly, since the pillars are precast, the curves on the pillar may be made hard and durable, thereby lengthening the life of the finished wall. Furthermore, since the pillars are preformed, assembling the wall is accomplished relatively quickly. Finally, since the pillar is anchored to the concrete floor by reinforcing bars, the overall wall structure is very strong and durable.
- Referring now to
FIG. 7 , the wall segments may be formed as corner units or as side units where the curved concave surface is present on only one side. Therefore, nearly any type of room can be constructed simply by using a variety of different precast units. Each of these units will have reinforcingsteel bars 100, curvedconcave surface 102,flange portion 106,vertical portion 108, and mountingunits 104 as discussed in the previous example. - Referring now to
FIG. 8 , a wall segment made in accordance with the present invention shown generally asitem 200 may also take the form of aprecast pillar 202.Precast pillar 202 is made ofplastic foam panels concrete 210 which is poured in betweenfoam panels Pillar 202 has reinforcingbars 212 havevertical faces 214 and 216, curved concave faces 218 and 220 and horizontal flat faces 222 and 224 as in the previous embodiment. Other than the construction ofpillar 212 from a combination of plastic foam and concrete,pillar 212 is identical to the embodiment shown inFIG. 1 . - A specific embodiment of the present invention has been disclosed; however, several variations of the disclosed embodiment could be envisioned as within the scope of this invention. It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
Claims (11)
1. A wall section for forming a wall, said wall section comprising:
a) a precast reinforced concrete pillar having a vertical portion and a bottom portion, the vertical portion having a top end, a bottom end, and a vertical face, the flange portion projecting perpendicularly away from the vertical face immediately adjacent the bottom end, the flange having a horizontal face;
b) the pillar having a curved concave face where the horizontal face of the flange portion joins the vertical face of the vertical portion,
c) the vertical section being reinforced by reinforcing bars,
d) the reinforcing bars extending through the bottom end and projecting horizontally below and beyond the flange.
2. The precast wall section defined in claim 1 wherein the flange has a substantially flat bottom and wherein the pillar has a plurality of nuts, each nut being countersunk into the fat bottom.
3. The precast wall section defined in claim 1 wherein the vertical portion of the pillar has opposite sides, each side having a flat vertical face and wherein two projecting flanges extend from the bottom of the vertical portion, one flange extending perpendicularly from each of the opposite sides, each flange having a flat horizontal surface, the pillar having a curved concave face on each side of the vertical portion, each curved concave face joining the flat horizontal face of the flange portion with the corresponding flat vertical face.
4. The precast wall section defined in claim 1 further comprising a plurality of mounting elements mounted to the bottom of the pillar.
5. The precast wall section defined in claim 4 wherein the mounting elements each comprise a tap retained in the pillar.
6. The precast wall section defined in claim 5 wherein the pillar further comprises a mounting element mounted to the top of the pillar.
7. A method of constructing a wall comprising the steps of:
a) providing a plurality of precast reinforced concrete pillars each having a vertical portion and a bottom portion, the vertical portion having a top end, a bottom end, and a vertical face, the flange portion projecting perpendicularly away from the vertical face immediately adjacent the bottom end, the flange having a substantially flat bottom and a horizontal face, the pillar having a curved concave face where the horizontal face of the flange portion joins the vertical face of the vertical portion, the vertical section being reinforced by reinforcing bars;
b) providing a substrate upon which the concrete pillars are placed with the bottom of the flanges resting on the substrate,
c) pouring concrete over the substrate to a level flush with the horizontal flat face of the flange portion,
d) letting the poured concrete cure.
8. The method of constructing a wall as defined in claim 7 further comprising the step of mounting a top wall segment to the top end of the vertical portions of the pillars after the concrete has cured.
9. The method of constructing a wall as defined in claim 7 wherein the reinforcing bars have a horizontal section extending perpendicularly away from the vertical portion of the pillar below the flange.
10. The method of constructing a wall as defined in claim 7 wherein the pillar rests on a plurality of adjustable anchor bolts mounted to the bottom of the pillar, said mounting bolts each having a foot, said feet resting on top of the substrate, and further including the step of adjusting the height of the pillar above the substrate by adjusting the anchor bolts before pouring the concrete.
11. The method of constructing a wall as defined in claim 9 wherein pillar rests on a plurality of adjustable anchor bolts mounted to the bottom of the pillar, said mounting bolts each having a foot, said feet resting on top of the substrate, and further including the step of adjusting the height of the pillar above the substrate by adjusting the anchor bolts before pouring the concrete.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002464208A CA2464208A1 (en) | 2004-04-15 | 2004-04-15 | Precast wall section and method of making walls from same |
CA2,464,208 | 2004-04-15 |
Publications (1)
Publication Number | Publication Date |
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US20050229516A1 true US20050229516A1 (en) | 2005-10-20 |
Family
ID=35094807
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/865,858 Abandoned US20050229516A1 (en) | 2004-04-15 | 2004-06-14 | Precast wall section and method of making walls from same |
Country Status (2)
Country | Link |
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US (1) | US20050229516A1 (en) |
CA (1) | CA2464208A1 (en) |
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