US2114048A - Precast slab with insulating insert - Google Patents

Description

12, 1938.` l Q F DAVlS y y 2,114,048

" RRECAST SLAB WITH INSULATI'NGINSERT n .Filed May 1o, 19:53

ATTORNEY.

l* (Patented 1938 mesne assignments, to'Ameriean Cyanamid i Chemical Corporatioma corpmfaticmA of Dcla-` c f ware'Y sound,` and a deck in which VsuchslabsareA used.

In applyinginsulation' of the `above time lto perienced in that suchlmaterialis usually ot a 1 broken. or mutilated. Hencefits `application to highbreakage'loss. f g y f1 insulating Amat'erial ini-the form of `porous ompositions such as gypsum or concrete are apuplied as aplaster to walls or ceilings{.diiilculties kewise arise in that the materialmust be ycareully` controlled inmixing or processing,` and sevdling, which 'means 'highly skilled` workmen,` and tionswili not stayA ony the wx'tilsorv ceilings evenly u and. this' involves theuse of expensive scaolding Vgmaterial; forms and the like.-y

" 'Itisone of the principal objects of thisinveni' factory made, towhich insulationboth 4trol-r1 heat "and/or soundj may Vbe *applied either during the i u making/of rthe slab r *at sometime subsequent v f thereto but prior Kto installation.` vSuch-a pro- Fcedure hasl distinct *advantagesA in` that no'L scatio'lding or forms are necessary onthe job inasuch as the insulationis put in placealongwith ""the slab in the erection 'of the building. The lfact l that the entire Objectis factory made facilitates Y its `manufacture withy theleast amount of handling and hence `initial costs are kept atla 'mini- `Itis another obiectrof the invention to provide da s'lab of the precast variety to which a relatively `fragile insulating insert will-be applied; the insert being completely within the-contines of the slab 40itself so vasfto be entirely protected lduring han- 'dling andshipping. f L

Anotherimpcrtant'object ofthe invention is f the provision `of a Vslab of the precast type containing a section of insulating material of `a na- 4 ture which maybecast' therein in the factory and Lwliikzhvill be of such al composition as will yform an? eilective bond i* to the slab'without'iurther treatment. m

\ Another important object oi the invention =is' mrragile soundy ms'umting insert-thereinyfhesab l of the slab. may form an effective ceiling for the l 55 roomor space below, the metal edges of the slab '6 wbuildings 'alreadyherecte some diiiiculty is exi .more'orless"delicate or *i'riablenatura` readiiy eralf coats must be applied because such composif tion to provide a slab of the precast type; ythat is -To` this'end the inventioncontemplatesaslab of set cernentltious material oi' which gypsum is typical, either `with or without fillers or admix ,l

50 the `provision of va precast-slab having a relatively #itself having metallic edgeswso that when such F slabs are used as aro'o'i orfioorythe under side Application Mario, 193s, serial No. 670,235l

v c c g' `s write-ear The present inventic'nrelates 'to a precast slab j oisetfcementitious material with which isincor- "1 "lporatedvaninsulatingcfinsert `either for heat or llmpported directly from the roof purlinsor 'filoor beams. -As arresult, neither the material of which the slab is m'ade'northe relatively fragile .y insulating insert jmakes direct contact withfthe l supporting element,L but `on the vcontrary the 5 jweightfof the vslab isborne-principally by the metaledg'ep n y c' 4 Stiilanotherobject oi the invention is ther prof vvision'of a slab ofthe above type in which the' insulating insert has a'suriace areav lessthan 10 the surface vareaoi' the slab to which it is attachedg that is, the rslab proper will have a \mar' ginal edge Ofcementitious materialsurroundingl the insert.` Thisl construction permits the entire "insulating insert Ato' beexposed free from interl5 tering purlins or beams wheresuch slabs are incorporated into a oor, ceiling or roof.y As a rereplacement or decoration.

to provide a slabof the above type rwhich may 'be used as iioor, roof, ceiling or wall' slabs with of, as a single slab oras two slabs facing each other or baciato back.

tures ysuch as wood chips, fibers or the like,y hav` "ing achannelled face.V x'I'his channel may' eirtend i substantially the entire length and widthof lthe slab or it may be interrupted by cross ribsso that therewill be several channels or depressions inra single slab.` f

'It is proposed in one form that aporous vcom 35 positionrthat is, a composition of set material having bubbles orporesjtherein, either communieating or non-communicating, be used asa iill-v lng for this cavity, either w completely" fm the "channei'or depression 'or cast separately; cut to 4o proper dimensions and inserted into the cavity so that the 'surface oi the insert isj substantially flush with the surfaceof the slab face within which it is contained,` leaving an airspace between the bottom ,of the cavity of `the slab andthe back l5 'l Vof the insulating insert. Where such jporousc'om- I `positionis of material involving Athe use `of'gry'psum,` it maybe readily bonded` tothe precast slabl of gypsum without any additional attentionbeing paid tosecuring means, that isfthe gypsumfslabto itself may iirst be ca'stzand then "either beforeor after drying' the same the yporous composition poured therein', thel two being permitted to" set In still another modiilcation` the insulating in- 55 `It is another important objectof(` the invention; so f' sert may take the form of a more or less rigid sheet of material of which'Celotex is typical.

Where sheet material is used. such as either Celotex or the cast slabs of a porous composition as above described, it is contemplated that the sides of the slab constituting the cavity will be stepped or provided with a shoulder so that such inserts may be readily positioned within the cavslab, which edging shall extend over three faces so that when the slabs are supported on,V the purlins, beams or the like. the metal covering will come in contact with the slab support rather than i the gypsum itself. This, therefore, prevents any undue cracking or spalling of the gypsum material. It is likewise desirable that opposite metal members be provided with complementary parts such as a tongue and groove so thatwhen two slabs are erected adjacent' each other, their metal parts may interlock, not only to prevent undue'separation of the parts under vibration but to cause a strengthening and supporting action between the various slabs, andparticularly the ends thereof which occur between beam spacings. (This mating interlock may be provided on all four edges or only on opposite edges, as circumstances will dictate. The invention further consists in the novel arrangement and construction of parts4 more fully hereinafter described and shown in the drawing.

In the drawing- Fig. 1 is a plan view lof a slab of this invention with the insert partially broken away.

Fig. 2 is a sectional view of a building construction involving the invention of Fig. 1.

Fig. 3 is a fragmentary sectional elevation showing a modified form of slab.

Fig. 4 is a sectional view of another form of insert.

Referring now with particularity to the embodiments illustrated, a precast slab is shown at i of gypsum or the like with or without fillers and admixtures such as chips, fibers or the like, having a series of cavities 2 in one face thereof. Obviously this cavity may extend as a single depression over substantially the entire area of the slab face or it may be separated into a plurality of cavities such as shown in Fig. l, in which six cavities occur separated by ribs l.

In Fig. 2 the walls of this cavity are formed with a shoulder as at l, which permits the insertion of a heat and/or sound insulating section l thereinto, the bottom edge of the insert contacting with the shoulder I. By choosing an insert of the proper thickness and suitably positioning the shoulder s during the manufacture of theslab l, the parts may be standardized and put together with a minimum amount of effort. Where desired the insert 5 may be secured to the' slab as by means of nails 8 or the like.

In this form shown in Fig. 2, the cavities in the face of the slab are divided laterally thereof by,

means of the rib I so that two cavities occur across the slab. In such case the rib 3 preferably terminates short of the slab face so as to form an additional base or support for the center portion of the insert I.

Obviously by suitably proportioning the slab thickness, a space may exist between the bottom of the cavity 2 and the back of the insert 5. 'I'his air space has been found to be of considerable advantage from the `standpoint of insulation both for heat and sound. It will also be apparent that in some instances this air space may be cut down or adjusted yto the desired extent by suitably proportioning the thickness of the top wail 1 of the slab I or the thickness of the insert B, or both, as desired.

the patent to Sanford 230.151 of 1880 and those,

in the patent to Sabine and Guastivino 1.119.543 of 1914 are typical. Itis preferred, of course.

that if the precast slab is made of gypsum orV the llike or lpredominantly of gypsum, that such porous composition shall likewise include sufiicient gypsum or other material of a nature that when the porous composition is pouredvinto the precast slab there will be a natural and effective bonding between the two bodies, making unnecessary any further fastening devices. Experience hasl found that for the best sound insulating effects the porous composition should be such that the poresr therein are intercommunicating, said ,n pores having substantial openings at the surface.

This seems to produce an effect in which when sound impinges upon the surface thereof, it passes into the cavities or pores and due to their circuitous and tortuous nature. is trapped and lost or absorbed therein. y

It will be apparent, of course, that the pouring of this composition presents no great difficulties as a factory product. It is true, of course, that porous compositions are of a relatively fragile nature and hence are easily broken or mutilated. The fact that the composition as shown in Fig. 4

has its surface flush with the surface of theslab, is a desirable circumstance for the outer edges' of the more dense and rigid gypsum effectively protect .the more delicate material therein from damage. When such slabs are shipped from the factory to the job or handled on the Job, they may be laid one on the other and there is no real danger of destruction or mutilation of lthe insulating material.

The sheet insulating insert oflig. 2 may be of any desired nature such as the commercial Celotex now on the market, or it may even be f made of a porous composition as described in connection with the insert s of Fig. 4. cast into "'Ihis protecting rnetaledgey may take the form of anV element 9 covering oneuedge ofthe slab @and extendingas a flangeflll over oneface, the end Il'being turned down and embedded into yor the like IZjengageable with acorresponding groove I3 on the lcomplementary metal member attached to the opposite edge ofthe slab. 0bviously all of the edges of the slab may be thus provided. or only some.

` tofmetalcontact,lthat'is,flange |01of7the `metal of the beam o lng of the comparatively fragile inserti which would be the case `ii.' that sheet'4 extended completely over the entire face of -the slab I.

the'slab toprevent4 separation therefrom. 'Ihe element 91 may also be provided with a tongue `Inv erection, `referenceis made to Fig. 2 in "which,` slabs Aand B as Vabovedescribed are i. i inte'rlockecl together` by means `of the `mating action ofthe metal'members '9 and aresupported from the beam or purlin IL As shown. the slab propercontacts with the support I4 'by a metal is in direct contact with-the flange elements 9 Il. This prevents any undue crush- Due to this interlocking effect of the metal elements on adjacent slabs, an effective I beam resultsl so that a single slab may extend well beyond two given beams or supports and the free end entirely supported and held by the interlocking engagement therewith `of the surround-v ing slabs. 'This makes for a very effective construction, rendering unnecessaryv the `special designing of the steel work for `particular lengths of slabs or vice versa. The Apresent slabs may,

therefore, be erected at random ywithout regard to beam spacing. .n These inserts may be decorated orpainted with 'any' desired 'material -which will not destroy the i `porosity thereof to such anv extentk as would de-s -l `tract .from the efficient `absorption of sound or prevention ofheat transmission. Such paint or `decoration may take the form of cold water mixtures Aorin fact vany material which will not o close the pores.

5 as being p1aced with` their insert suis` down, as v `for instance in the roof` of a large auditorium,

While in Fig. V2' .the slabs lhave*y been shown where the under face or the slab forms the ceiling thereof; yet-obviously `it may be desirable in some instances to place the slabs of Fig. 2

in an up-side-down mannerjon the beams I4,

.as for instance in the oor of a building. In v such event a wood or other floor may be ap- 1 .plied directly l o out in any waydisturbing the insert Bfand still "maintaining the effectiveness thereof. v

"In like mannerjthese slabs may be yused in` over the topof such slab withpartitions` erected vertically, with the insulation f 5 or 8 at one sidefonly, ora slab of double thick-A ness havingy cavities on each side thereof may be utilized effectively, or two slabs erected withy their inserts facing each other.

By suitably v, spacing such slabs, or even slabs without inserts,

from each other, partitions or walls `of any ydesired thickness may be had with the use of slabs of 4a standardized thickness. Obviously more insulating ymaterial may be inserted between such slabs ii.' foundnecessary or desirable. It Vwill be obvious, of course, that if during the vening walls of eachof said` cavities.

course of time `these inserts become damaged or inefficient by reason of the 'clogging' of the pores, they maybe readily replaced byV simply taking. them out and putting. new inserts inthe cavities.

' This may be done with the minimum amountrofv l effort and without in any manner destroying or disturbing the slabs within which they occur. Inasmuch as the` insulation inserts are of comparatively small4 extent, a large area neednot be replaced in case ofY damage to a- 1. A precast slab of set cementitiouslmaterial small part;

having'a cavity in'one face thereof and an in`r` `sulatinginsert located in said cavity in which" an air spacezexists between the slab body andok j.

the insert.

l 2. A precast slab of setcementitious material having a plurality of; cavities in one face thereof,` a web located between two adjacent cavities and insulation in each cavity and inl contact with the face of saidL web. i

3. A precast slab of set cementitious vmaterial having a pluralityrof cavities in one face thereof, a web located between twoadjacent cavities and sheet insulation bridging a plurality of cavities.

4. A precast slab of set cementitious material having a plurality of cavities in one face thereof, aweb` locatedbetween two adjacent cavities` f and sheet insulation bridging a plurality of cavities and supported by, said web.

5. A precast slab of set cementitious material having edge portions of greater thickness thana point intermediate said edges,v a cavity between said edges, a shoulder between an edge and -a.

cavity and insulation materialv seated on said shoulder andvcovering said cavity.

6. A precast slab of set cementitious material having edge portions of greater thickness than a point intermediate saidedges, a cavitylbetween saidv edges, av shoulder between an edgeand all cavityv and insulation material seated on said` y shoulder and covering said cavity, said slab have.y

ing a web ofless thickness than theslab edge, said insulation being also supported by said web.

1. A building constructionincluding supporting elements, adeck` supported thereon, fsaid deck comprising a series of precast `slabs of set cementitious material each slabr having a cavity in one face,l insulation in said cavity, the surfaceof the sound insulation being flush` with the slab face, those portions of thesiab in ,con-.o tact with the supporting element being covered 1 with metal.

8. An accoustical construction comprising a backing member having` its front area formed to providev a multiplicity of cavities and an inf tervening cavity wall, and a facing of thin sheet," material covering said cavities and ,being `secured to the front surface areas of the `inter- CLARKE Davis.;

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