US2116946A - Pre-cast building unit or slab and method of assembling same - Google Patents

Description

May 10, 1938. c. M. HUNTIN GTON 2,115,946

PRE-CAST BUILDING UNIT 0R SLAB AND METHOD OF ASSEMBLING SAME. Filed July 9, 1937 2 Sheets-Sheet 1 May 10, 1938. HUNTINGTQN 2,116,946

PRE-CAST BUILDINQUNIT OR SLAB AND METHOD OF ASSEMBLINGSAMH Filed July 9. 1957 2 Sheets- Sheet 2 ,7 7L c a. q 8 7.9

9 m wa y/ e Mia/ 117a m 'ml in mm Patented May 10, 1938 FEE-CAST BUILDING UNIT 01!. SLAB AND- METHOD OF ASSEMBLING SAME Charles M. Huntington, Ladoga, Ind; Application July 9,1937, Serial No. 152.847

17 Claims.

This invention relates to pre-cast buildingunits orslabs and method of assembling same,

and pertains more particularly to the use of av plurality of such units or slabs in double wall constructions for buildings, enclosures etc.

The primary important object of the invention is to provide an improved pre-cast slab and method of assembling a pluralityof such slabs, whereby any structure iormedthereof, embodies strength, insulating and moisture proof qualities.

Another important object of the invention is to provide pre-cast slabs of the above character and method of, assembly thereof, whereby a double wall structure may be rapidly and economically erected at a minimum cost of labor and materials and with a considerable saving in time. i

A further important object of this invention is to provide a method and means of assembling pre-cast slabs of theabove character which eliminates mathematical precision in the casting of the latterwhen same are composed of comparatively coarse aggregate. A still further important object of this invention is to provide pre-cast slabs of the above character, whereby they may be readily assembled into a double wall structure having passages therein for the reception of piping, wirin insulation, etc., or which may be utilized for ventilating or air conditioning purposes.

These and other important objects and advane tages of the present invention wfll be readily obvious throughout the course of the following 35 specification and accompanying drawings, in

which v Figure 1 is a fragmentary perspective view of a portion of a double wall constructed in accordance with the present invention; 40 Figure 2 is a-perspective view of one of'th units or slabs with parts broken away to disclose one form of reinforcement therefor;

Figure 3 is a sectional view taken on line 3-3 of Figure 1, showing the detachable guide 45 member and the bracing therefor;

Figure 4 is a fragmentary horizontal sectional view taken through one of the detachable guide members and a portion of the surrounding wall,

the dotted lines indicating the position to which 50 the guide member is rotated preparatory to removal from the wall; c

Figure 5 is a fragmentary horizontal sectional view similar to Figure 4 with the guide member removed and the space formerly occupied by the 55 -latter filled with a plastic material; and

Figure 6 is a'fragmentary perspective view of the footing, guide pin and guide member for aligning the slabs during the construction of a Referring more speciflcallyto the drawings. 5 'wherein like reference characters refer to similar and like parts throughout the several views,

i indicates a unit or slab, of preferred form which, together with similar or other slabs or units, are assembled to provide an improved 10 double walled structure. a e

As shown in-Figure 2, the slab or unit I is precast of concrete or other. suitable plasticmaterial in a horizontally disposed open top mold ,(not shown), and during such casting is provided with 15 an embedded metallic reinforcing element 2 of open mesh fabric or the like. While such slabs are preferably cast in a substantially flat rectangular configuration, some may be formed in any other desired shape to meet various prob- 20 lems encountered in buildingconstructions.

The molds (not shown), in which slabs I are cast, are formed so as to provide one face of the slabs, intermediate the ends of the latter, ,with a pair of integrally cast and vertically extending 25 spaced ribs 3, which results in the formation of a substantially U-shaped channel 4 substantially centrally located with respect to the ends of said slabs. Also on the same side or face of the slab, and equally spaced inwardly from each 30 of its ends and from the ribs 3, is an integrally cast vertically extending rib 5 substantially semi- U-shaped providing a groove lywhich, with a corresponding groove in an adjacent slab, forms a channel corresponding tochannel 4. All of the ribs 3 and 5 are of greaterwidth at their point of connection with the slab body, and it is preferred that the distance from the center of the rib i to the end of the slab or unit shall equal the distance from the center of the channel 4 to the center of either rib 3, but, any arrangement of ribs which provides the construction and results hereinafter described and claimed may be employed. 1 I n The slabs are further proVided adJacent the outer sides of the ribs 3 and, inner sides of the ribs 5, with vertically aligned and spaced openings 6 extending transversely therethrough. 'Ihe openings I, of each slabandits opposed slab in a double walled construction, are adapted to receive temporary tie-rods I, the latter having one of its ends headed as at ,8, and their opposite ends I screw threaded to receive winged nuts ll. Through the bottom wall of the channels 4 and l", the slab is also provided with a seto cause the adjacent end ribs I of one row of slabs to engage or contact with the intermediate ribs 2 of the opposite rows of slabs, thus resulting in an overlapping of opposed slabs so that the channels 4'' of two adjacent .slabs cooperate with the channel 4 of an opposing slab to provide vertically extending tubular passageways il therebetween, while the spaces between the ribs 3 and 5 provide vertically extending elongated passagesways it. The passages II may be used as conduits for ventilation or air conditioning, for the disposition of pipes and wiring or for insulation if, while passages ii .are for the reception of a cementitious material to provide load supporting, strengthening and bonding columns for the wall. I

The first course of the oppositely facing rows of slabs are laid on edge and in end to end abutting relation upon the usual footing or foundation II. The footing Ii has embedded therein, at predetermined spaced intervals, a series of vertically extending guide pins IO, said pins being so spaced as to project within the tubular column spaces ll of the completed courses.

In proceeding with a double walled construction, the tubular passageways or column spaces II are adapted to receive tubular guide members l'l, .each of the latter having a plugged lower end socketed as at II for the reception of a guide pin it when said tubular guide member is moved vertically downwardly thereover. The guide members ll are provided or formed intermediate their ends with a plurality of equidistantly spaced longitudinally extending cam faced ribs H which are four in number and preferably arcuate in cross-section.

The upper ends of the guide members ll, above the ends of the cam faced ribs it, are provided with diametrically extending bars or handles 20. The guide members II are secured together at their upper ends by spaced bracing members 2i which may be-detachably connected thereto by bolts 22.

Reinforcing rods 22- are adapted to be placed in tubular column spaces l4, in alternate relation to guide members ll and when the latter are removed, the same may be replaced with other of said reinforcing rods 23 and reinforcing pins i2.

In proceeding with the assembly of the precast slabs, to construct a double-walled building or enclosure, the'footing i5 is first formed in the usual manner, having vertically extending gu'ide pins i6 embedded therein at predetermined spaced intervals.

Then, the tubular guide members ll are vertically positioned, as shown in Fig. 1, and have their lower ends centered on the guide pins Ii, which are, respectively, received in the socketed ends I. of said guide members. Guide members I! are placed in alternate column spaces and the reinforcing elements or rods 23, when used, may be disposed in the other alternate column spaces, as shown in Figure 1.

The guide members are further positioned to have two opposite cam faces extended in the direction of the center line of the wall and the other two at right angles to said center line as indicated in Figures 4 and 6. In so positioning the cam faces l0, each is to contact with at least one, but preferably opposite side walls of its column space ll. Upon the completion of this operation, the upper ends of the guide members H and the reinforcing rods '23 are clamped between bracing members 2| detachably held in position by bolts 22, which bracing members are in turn rigidly braced from outside the wall strucstructure, by means not shown.

Then, the first row or course of :slabs l are placed on edge and in end-abutting relation with their ribs 2 and 5, extending inwardly of the wall structure, with the channels 4 and 4 thereof partially embracing the guide member i1 and the reinforcing rods 23. Each slab is thus definitely and accurately positioned horizontally by reason of the surfacesof the channels 4 and 4' contacting with the cam ribs It. An opposite row of similar slabs are then placed on edge in overlapping relation to the first row of slabs so drawing same together by winged nuts II. This insures the accurate positioning of the first courses both horizontally and vertically. At this point in the construction, the reinforcing rods 22 may be positioned inplace whenever it is desirable to employ such rod 22.

The succeeding courses of slabs are placed on the preceding courses in staggered relation thereto, so that column spaces I are continuous in a vertical direction throughout the height of the wall. V

As the building of the wall progresses, reinforcing pins i2 are inserted through openings Ii into the column spaces ll containing the reinforcing elements 23 which are then filled to the top of each course by pouring concrete therein. This procedure causes the alternate column spaces ll to be formed into binding columns as the construction of the wall progresses, and the portions of the columns thus formed, harden and tie the lower courses of .slabs together in a monolithic structure to support the increasing weight of the wall as additional courses are laid. Since each slab contacts or registers with three successive column spaces, they will be held securely either at their mid-sections or ends when every alternate column ll has been filled with concrete- When the last course of slabs has been laid, the

guide members ll are withdrawn. from the tubular column spaces H, by first detaching bracing members 2i and then rotating the guide members, by means of bars or handles 20, through an arc of 45 degrees so as to release the cam faced ribs ll from their points of previous contact with the walls of the column spaces and to place them opposite the non-contactible free spaces a: provided by widened areas or corner portions of the U-shaped channels 4, and l, as shown in dotted lines in Figure 4. Upon removal of the guide members, reinforcing rods 23 and pins i2 are then inserted'in the column spaces I4, and the latter filled by pouring concrete therein, so as to tie or bond the slabs together.

The spaces l3 formed between opposite rows of slabs may be filled with insulating material l3, or the same may be used as conduits for piping.

wiring, or for air circulating ducts in ventilating and air conditioning systems Horizontal joints between courses may be filled with mortar as the building of the wall progresses, while the vertical joints between slabs are formed by filling the tubularcolumn spaces It with concrete, as heretofore stated.

After the'concrete in column spaces It has hardened, the temporary tie-rods I are removed, the openings previously receiving said tie-rods being used to assist in bonding plastic coatings to the walls, or plugged with mortar as desired.

The foregoing description has been limited 'to wall structures in the vertical plane. It can be readily seen however that the method of construction is also adapted to structure wherein the center plane of the wall structure is at a substantial angle to the true vertical, andthe wall may be constructed at any angle that will allow the concrete or like plastic to flow into the column spaces for forming the permanent columns. Therefore, by the disclosure in the drawings, the description and claims hereof, it is contemplated to include a wall structure in an inclined position.

Having thus described my invention, it will be seenthat I have provided an extremely practical pre-cast,slab and the method of assembling same, either of which may be varied for practical uses. Thus, it is to be understood that while certain details of construction and the manner in which the invention is to be performed, having been described and shown for purposes of an example, the invention is not to be limited to the exact details of the description and disclosure in the drawings herewith, because the same may be modified and varied in numerous ways within the scope of the present invention, and it is intended that the invention is to include everything within the scope of the appended claims.

That which is claimed is:

l. A pre-cast wall unit comprising a slab having on one face thereof a plurality of spaced parallel transverse ribs, two ofsaid ribs being positioned near the center of said slab and forming together with the rib supporting face of said slab, between said centrally positioned ribs, a substantially U-shaped groove, and single similar ribs positioned adjacent each end of said slab and spaced inwardly therefrom, each of said single end ribs forming together with the adjacent end portion of the rear face of said slab a groove of substantially one-half U-shaped configuration, the center plane of each of said ribs being nor ml to said face of the slab, and each of said ribs being of greater width at its base portion which is integral with the face of the slab than at its free outer end.

2. A pre-cast wall unit comprising a slab having a front and a rear face and having on the rear face thereof a plurality of transverse parallel spaced ribs extending outwardly therefrom,

each of said ribs being of greater width at itspoint of connection with the rear face of said slab than at its free outer end, the center plane of each of said ribs being normal to the rear face of the slab, the reduction in rib thickness being continuous on each side of the center plane thereof from its greater width at the rear, face of said slab to the free outerend of said rib, all of said ribs being positioned to form a plurality of transversely extending grooves, one of said grooves being pomtioned substantially centrally of said slab and others of said grooves being positioned adjacent the ends of said slab.

3. A wall structure comprising an outer portion and an inner portion, each of said outer portions and inner portions being composed of aplurality of similar pre-cast slabs, each of said slabs having a plurality of inwardly projecting spaced fins extending from the rear face thereof, the fins of opposite slabs being in contact with each other in the center vertical plane of the wall structure and cooperating to form vertical column spaces, said column spaces being filled with concrete, corrugated metal reinforcing pins extending through said slabs into the said concrete in the column spaces, the ends of the wall slabs being staggered in opposite rows of the same course and staggered vertically in adjacent courses on each side of the wallstructure, and each of said slabs being secured to three successive concrete columns by a plurality of reinforcing pins in each column.

4. A wall structure comprising inner and outer walls composed of a plurality of pre-cast slabs,

' said inner. and outer walls being spaced from each other by spaced ribs formed on and extending umn spaces engage, the remaining column spaces being filled with concrete, said wall structure con taining substantially wide spaces between successive column spaces and at least one of said wide spaces having communicating openings to exterior ducts adapted to the circulation of air.

5. A wall construction comprising vertical substantially cylindrical guide members braced at top and bottom, an inner wall and an'outer wall composed of precast slabs, said slabs having ribs extending inwardly and cooperating to form vertical column spaces within the said wall structure, means for temporarily maintaining said slabsin position, one of said guide members being encased in each alternate column space, said guide members each having a plurality of outwardly projecting surfaces thereon arranged at degree intervals on the circumference thereof, said surfaces providing guides for the positioning of said slabs, said column spaces being of such shape that rotation of the said guide member through 45 degrees will increase the clearance between the said proiecting surfaces and the walls defining said column spaces to permit the vertical withdrawal of said guide members.

6. A wall construction of the character described wherein a plurality of vertical guide and bracing members are rigidly secured in line at predetermined intervals and preformed building slabs are clamped together on opposite sides of and encasing said guide members, said slabs having a plurality of ribs on the inner faces thereof and a plurality of grooves formed by said ribs, said ribs and grooves on adjacent slabs cooperating to form column spaces between said slabs, said guide members being encased in alternate column spaces, said column spaces not occupied by guide members being filled with concrete, and said concrete containing reinforcing pins extending inwardly through the outer surfaces of said slabs, thereby forming a monolithic wall structure and permitting the removal of the said guide members when the said concrete hardens.

'1. A double-walled building structure, comprised of opposed rows of pre-cast slabs, each having a body of substantially fiat rectangular form, a pair of inwardly projecting vertically extending spaced ribs formed on the rear face of each of said slabs intermediate the ends of the latter to provide a groove of substantially U- shaped cross-section, and an inwardly projecting-vertically extending rib formed on the rear 5 face of each of said slabs adjacent each of the ends of the latter, whereby all of said ribs of one row of slabs together with similar ribs of opposed rows of slabs form columns and spaces therebetween. 1

8. A guide member for use with a building structure of the character set forth in claim 6,

wherein the guide members are tubular and each has a socketed end andJongitudinally extending cam-faced ribs formed thereon equi-distantly spaced about the circumference of the exterior surface of the guide member.

9. A method of forming a wall construction which wall comprises pre-formed block units having channels therein and adapted to be arranged in courses with said channels in alignment to form column spaces, said method including placing certain of said channels of each unit in each course in contact with a temporary guide, filling other of said column spaces with a cementitious material to form columns within said units, and inserting through the channel portion of each unit transverse reinforcing pins which extend into the column spaces and become anchored or 30 embedded in the cementitious material when the latter hardens.

10. A method of forming a double-walled construction which wall comprises preformed wall units having channels therein and adapted to be arranged in courses with said channels in align-, ment to form column spaces, said method including the steps of placing pre-cast units on opposite sides of a temporary vertical guide with certain of said channels of each unit in contact therewith, filling the other channels with cementitious material to form columns within the wall structure, then removing the temporary guides and filling those aligned channels with cementitious material.

11 A method of forming a concrete wall construction as set forth in claim 10, further characterized by temporarily clamping said units of each course in position by passing clamping bolts through opposing units of each course, removing 5 said temporary clamping bolts when the cementitious material between the respective units is hardened.

12. A method of forming a wall construction comprising preformed wall units adapted to be 5 arranged in courses and having channels therein adapted to align to form column spaces whose side walls are at different distances from the longitudinal center of said column spaces, said method including placing certain of said chanoo nels of each unit in each course in contact with a temporary guide so that the shortest dimension of each column space will contact with the guide, filling other of said channels with cementitious material to form columns within the units, paras tially rotating said temporary guide within the column spacesto remove the same out of contact with the surfaces of the column spaces and removing the temporary guide.

13. The method of forming double-walled structuresfor buildings or the like, which includes casting in situ a foundation therefor, supporting spaced guiding elements on the foundation, arranging and temporarily securing precast units in staggered and vertically successive courses on the foundation and around the guiding elements so as to provide confined column spaces thereabout, removing the guiding elements in a vertical direction from said column spaces, inserting reinforcing members transversely from the exterior of said units into the confined spaces from which the guiding elements have been re.- moved, and then filling said confined spaces with a self-hardening plastic.

14. A precast wall slab of plastic material having a front face and a rear face and having on the rear face thereof a plurality of transverse grooves, two of said grooves being positioned adjacent to the ends of said slab and each adaptedto surround one fourth of the circumference of a cylindrical guide member and to make contact with the said guide member only at the edges of the groove, another groove being positioned centrally of saidrear face and adapted to surround one half the circumference of a cylindrical guide member and to make contact with the said guide member only at the edges and center of said groove, provision being made by a plurality of regularly spaced holes through the slab for the insertion of tie rods for the purpose of clamping such slabs on opposite sides of and enclosing the said guide members in the spaces formed by cooperating grooves.

15. A wall structure comprising an outer portion and an inner portion, each of said outer portions and inner portions being composed of a plurality of similar pre-cast slabs, each of said slabs having a plurality of inwardly projecting spaced fins extending from the rear face thereof, the fins of opposite slabs being in contact with each other in the center vertical plane of the wall structure and cooperating to'form vertical column spaces, said column spaces being filled with spaces being filled with a self-hardening plastic 1 material and reinforcing pins extending from the outer surface of the slabs into said plastic material in said column spaces.

CHARLES M. HUNTINGTON.

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