US2995799A - Method of producing nested floor panels - Google Patents

Method of producing nested floor panels Download PDF

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US2995799A
US2995799A US613658A US61365856A US2995799A US 2995799 A US2995799 A US 2995799A US 613658 A US613658 A US 613658A US 61365856 A US61365856 A US 61365856A US 2995799 A US2995799 A US 2995799A
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panel
floor
panels
floor panels
oor
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Philip N Youtz
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/43—Floor structures of extraordinary design; Features relating to the elastic stability; Floor structures specially designed for resting on columns only, e.g. mushroom floors
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/57—Processes of forming layered products

Definitions

  • This invention relates to building construction and especially to the construction of buildings having a steel frame and concrete floors supported by the horizontal beams and girders of the frame.
  • One method of erecting a building having a plurality of stories and constructed with a steel frame and concrete floors is to rst erect the steel framework and then to cast the concrete floors for the individual iloor levels of each bay of the building at ground level and one on top of another to provide a stack of floor panels, each floor panel being of a size and shape to provide a complete upper lloor for any bay of the building.
  • each floor panel from the stack is raised to an upper level by means of a crane or other suitable device and is placed on the framework at said desired level thereby providing a complete concrete floor for a bay of the building at such level.
  • the invention described in the present application Ser. No. 613,658 relates to a novel method of casting the floor panels for a building such as referred to above, and it includes casting the yfloor panels in pairs, each pair of floor panels being cast in such a nested relation that the combined thickness of the two floor panels of a pair in their nested relation is the same as that of each individual panel of the pair.
  • each panel has a central body portion of uniform thickness and also has two opposite edge portions which are thicker than the body portion.
  • the novel method by which the floor panels are cast involves casting said floor panels in pairs with the two floor panels of each pair having such a nested relation that when the two floor panels are separated each floor panel constitutes a complete iloor for a bay of the building at any desired level.
  • Each pair of nested floor panels presents a unit which has a uniform thickness equal to the thickness of the thickened edge portions of the separate panels.
  • FIG. 1 is a plan view of 4a pair of nested floor panels after they have been poured in their nested relation;
  • FIG. 2 is a section on the line 2 2, FIG. 1;
  • FIG. 3 is a section on the line 3 3, FIG. 1;
  • FIGS. 4 and 5 are sectional perspective views showing a plurality of pairs of nested panels which have been poured to form a stack of panels, FIG. 4 showing the stack of panels in section corresponding to the section line 3 3, FIG. l and FIG. 5 showing the stack of nested panels in section corresponding to the section line 3 3, FIG. l;
  • FIG. 6 is a fragmentary perspective view showing one end of one of the floor panels of the pair in the position in which it will assume when laid in the lfloor of the building;
  • FIG. 7 is a fragmentary perspective -view showing one end of the other panel of each pair
  • LFIG. 8 is a plan view illustrating the portion of a floor of a building composed of the floor panels shown in FIG. 1 and illustrating their relative position; ⁇
  • FIG. 9 is an enlarged fragmentary view showing one of the columns of the building in section and illustrating the manner in which the various floor panels are attached thereto;
  • FIG. 10 is a perspective view illustrating the construction shown in FIG. 9.
  • FIGS. 1, 2, and 3 One way to cast the panels in pairs with the panels of each pair having a nesting relation is shown in FIGS. 1, 2, and 3 wherein the two panels of a pair are indicated at A and B.
  • the panel A is first poured, and any suitable llat surface such as the ground Hoor or lowest floor in one of the bays of the building being erected may be used for this purpose, it only being necessary to use edge forms in connection with such flat surface to provide a complete form for said panel.
  • the floor panel A has a at central or body portion 2 which is properly reinforced with reinforcing rods (not shown) in accordance with conventional practice, and it also has two opposite raised edge portions 3 which are thicker than the body portion. Each thickened edge portion 3 has a steel beam or iloor supporting element 4 embedded therein.
  • the floor panel A is cast with a notch 5 at each corner, and the ends 4a of the beams 4 project into the notches and provide means by which said beams can be secured to the columns 1 when the oor panel had been raised to its permanent position in the building, as will be hereinafter explained.
  • the extra thickness of the edge portions 3 extends such edge portions above the body 2 by a distance equal to the thickness of said body as shown in FIG. 2 and the outer face of each edge portion '3 is provided with an outwardly extending rib or ledge 6.
  • the floor panel may also be cast with a central opening 7, if desired, for a purpose presently to be described.
  • the cornpanion oor panel B is poured directly on the panel A, any suitable means being used to prevent the two panels from becoming bonded together.
  • One well known technique for this purpose would be to cover the top surface of panel A with so-called release material and then to pour the panel B on the release material.
  • the shoulders 8 which result from making the thick edge portions 3 of panel A constitute the edge forms for two opposite edges 9 of the panel B.
  • the other two opposite edge portions 10 of the panel lB overhang the edges 11 of the panel A and are thickened as shown in FIG. 3 so that the bottom face 12. of each thickened edge portion 10 is ilush with the bottom face 13 of the floor panel A.
  • Each thick edge 10 of the panel B has a steel beam 14 embedded therein and the ends 15 of such beams project into the notches 5.
  • the thickened edge portions 10 are provided with outwardly projecting ribs or ledges 17, as shown in FIG. 3 and each of the floor panels ⁇ B may also be cast with a central opening 7.
  • pairs of nested floor panels may be cast at ground level on any at surface.
  • the lowest floors in the several bays of the building being erected provide such flat surfaces, and when the requisite number of pairs of floor panels have been formed and have set suiciently, then the individual floor panels are raised to higher floor levels and attached to the columns 1 of the steel frame of the building.
  • the raising of the individual oor panels ,to their permanent position in the building may be done by a crane of the type commonly used in erecting the steel frame of the building.
  • a crane of the type commonly used in erecting the steel frame of the building.
  • the floor panel A of a nested pair it is necessary to invert it so that its smooth face 13 will be the oor top surface and the opposite surface will be the underside of the floor panel.
  • the ends of beams 4 and 14 carried b-y the floor panel are secured to the columns 1, and this may be done in any suitable way either by welding the ends of the beams to the columns or by means of angles 16 which are bolted or riveted to the projecting ends of the beams carried by the raised oor panel into the column, as shown in FIGS. 9 and 10.
  • the latter may be provided with properly placed shelf angles on which the projecting ends of the beams in the raised floor panel may rest while the attaching angles 16 are being secured to the columns and to the beam ends.
  • the construction of the floor panels A and B is such that when they are laid to provide a oor of a building having several bays said oor panels A and B are arranged alternately in each row of bays.
  • each of the two opposite edges 9 of any panel B rests on a ledge or rib 6 of the adjacent panel A, while each of the two opposite edges 11 of any panel A rests on a shelf or ledge 17 provided by an adjacent floor panel B.
  • each beam 4 embedded in a thickened edge portion of a oor panel A supports not only said edge of the panel A b-ut the adjacent edge of the adjacent floor panel B, and each supporting beam 14 which is embedded in an edge of the floor panel B serves to support not only said edge of floor panel B but the adjacent edge 11 of an adjacent floor panel A.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Description

Aug. 15, 1961 P. N. Youn 2,995,799
METHOD OF FRODUCING NESTED FLOOR PANELS Filed Oct. 3, 1956 4 Sheets-Shay:l 1
Aug. l5, 1961 v P. N. YoUTz 2,995,799
METHOD OF PRODUCING NESTED FLOOR PANELS Filed Oct. 3, 1956 4 Sheets-Sheet 2 Afro/ewfy Aug. 15, 1961 P. N. YouTz METHOD OF' PRODUCING NESTED FLOOR PANELS 4 Sheets-Sheet 3 Filed Oct. 5, 1956 Aug. 15, 1961 P. N. YOUTZ 2,995,799
METHOD OF PRODUCING NESTED FLOOR PANELS Filed Oct. 5, 1956 4 Sheets-Sheet 4 2,995,799 ll/mTHOD OF PRODUCING NESTED FLOOR PANELS Phiiip N. Youtz, Spring Road, Yorktown Heights, N.Y.
Filed Oct. 3, 1956, Ser. No. 613,658 2 Claims. (Cl. 2S154) This invention relates to building construction and especially to the construction of buildings having a steel frame and concrete floors supported by the horizontal beams and girders of the frame.
One method of erecting a building having a plurality of stories and constructed with a steel frame and concrete floors is to rst erect the steel framework and then to cast the concrete floors for the individual iloor levels of each bay of the building at ground level and one on top of another to provide a stack of floor panels, each floor panel being of a size and shape to provide a complete upper lloor for any bay of the building.
After the stack of separate floor panels has been cast then each floor panel from the stack is raised to an upper level by means of a crane or other suitable device and is placed on the framework at said desired level thereby providing a complete concrete floor for a bay of the building at such level. The method above set forth is disclosed in my U.S. Patent 2,721,533 dated February 3, 1959.
The invention described in the present application Ser. No. 613,658 relates to a novel method of casting the floor panels for a building such as referred to above, and it includes casting the yfloor panels in pairs, each pair of floor panels being cast in such a nested relation that the combined thickness of the two floor panels of a pair in their nested relation is the same as that of each individual panel of the pair.
The -floor panels herein shown are of that type in which each panel has a central body portion of uniform thickness and also has two opposite edge portions which are thicker than the body portion.
As stated above the novel method by which the floor panels are cast involves casting said floor panels in pairs with the two floor panels of each pair having such a nested relation that when the two floor panels are separated each floor panel constitutes a complete iloor for a bay of the building at any desired level. Each pair of nested floor panels presents a unit which has a uniform thickness equal to the thickness of the thickened edge portions of the separate panels.
Referring to the drawings:
FIG. 1 is a plan view of 4a pair of nested floor panels after they have been poured in their nested relation;
FIG. 2 is a section on the line 2 2, FIG. 1;
FIG. 3 is a section on the line 3 3, FIG. 1;
FIGS. 4 and 5 are sectional perspective views showing a plurality of pairs of nested panels which have been poured to form a stack of panels, FIG. 4 showing the stack of panels in section corresponding to the section line 3 3, FIG. l and FIG. 5 showing the stack of nested panels in section corresponding to the section line 3 3, FIG. l;
FIG. 6 is a fragmentary perspective view showing one end of one of the floor panels of the pair in the position in which it will assume when laid in the lfloor of the building;
FIG. 7 is a fragmentary perspective -view showing one end of the other panel of each pair;
LFIG. 8 is a plan view illustrating the portion of a floor of a building composed of the floor panels shown in FIG. 1 and illustrating their relative position;`
FIG. 9 is an enlarged fragmentary view showing one of the columns of the building in section and illustrating the manner in which the various floor panels are attached thereto;
FIG. 10 is a perspective view illustrating the construction shown in FIG. 9.
One way to cast the panels in pairs with the panels of each pair having a nesting relation is shown in FIGS. 1, 2, and 3 wherein the two panels of a pair are indicated at A and B. The panel A is first poured, and any suitable llat surface such as the ground Hoor or lowest floor in one of the bays of the building being erected may be used for this purpose, it only being necessary to use edge forms in connection with such flat surface to provide a complete form for said panel. The floor panel A has a at central or body portion 2 which is properly reinforced with reinforcing rods (not shown) in accordance with conventional practice, and it also has two opposite raised edge portions 3 which are thicker than the body portion. Each thickened edge portion 3 has a steel beam or iloor supporting element 4 embedded therein.
The floor panel A is cast with a notch 5 at each corner, and the ends 4a of the beams 4 project into the notches and provide means by which said beams can be secured to the columns 1 when the oor panel had been raised to its permanent position in the building, as will be hereinafter explained.
The extra thickness of the edge portions 3 extends such edge portions above the body 2 by a distance equal to the thickness of said body as shown in FIG. 2 and the outer face of each edge portion '3 is provided with an outwardly extending rib or ledge 6. The floor panel may also be cast with a central opening 7, if desired, for a purpose presently to be described.
When the floor panel A has set suiliciently, the cornpanion oor panel B is poured directly on the panel A, any suitable means being used to prevent the two panels from becoming bonded together. One well known technique for this purpose would be to cover the top surface of panel A with so-called release material and then to pour the panel B on the release material. The shoulders 8 which result from making the thick edge portions 3 of panel A constitute the edge forms for two opposite edges 9 of the panel B. The other two opposite edge portions 10 of the panel lB overhang the edges 11 of the panel A and are thickened as shown in FIG. 3 so that the bottom face 12. of each thickened edge portion 10 is ilush with the bottom face 13 of the floor panel A. Each thick edge 10 of the panel B has a steel beam 14 embedded therein and the ends 15 of such beams project into the notches 5. The thickened edge portions 10 are provided with outwardly projecting ribs or ledges 17, as shown in FIG. 3 and each of the floor panels `B may also be cast with a central opening 7.
It will be understood that suitable edge forms will be used to give proper shape to the outer face of the thick edges 10 of each panel B, these being the only forms in addition to that provided by the previously cast panel A that are necessary to cast said panel B.
The two floor panels A and B when in their nted relation, as shown in FIGS. 1, 2, and 3, present a fiat top surface on which another pair of similar nested floor panels can be cast, a shown in FIGS. 4 and 5.
These pairs of nested floor panels may be cast at ground level on any at surface. The lowest floors in the several bays of the building being erected provide such flat surfaces, and when the requisite number of pairs of floor panels have been formed and have set suiciently, then the individual floor panels are raised to higher floor levels and attached to the columns 1 of the steel frame of the building.
The raising of the individual oor panels ,to their permanent position in the building may be done by a crane of the type commonly used in erecting the steel frame of the building. In the case of the floor panel A of a nested pair it is necessary to invert it so that its smooth face 13 will be the oor top surface and the opposite surface will be the underside of the floor panel. When any baysize floor panel has been thus raised to an elevated position and placed in the bay which it is to occupy permanently, the four columns 1 defining the bay will occupy the four notches 5 of the elevated oor panel. When the floor panel is in its proper position and at the correct elevation, then the ends of beams 4 and 14 carried b-y the floor panel are secured to the columns 1, and this may be done in any suitable way either by welding the ends of the beams to the columns or by means of angles 16 which are bolted or riveted to the projecting ends of the beams carried by the raised oor panel into the column, as shown in FIGS. 9 and 10. To assist in holding any raised oor panel in its correct position while the beams embedded therein are being attached to the columns, the latter may be provided with properly placed shelf angles on which the projecting ends of the beams in the raised floor panel may rest while the attaching angles 16 are being secured to the columns and to the beam ends.
The construction of the floor panels A and B is such that when they are laid to provide a oor of a building having several bays said oor panels A and B are arranged alternately in each row of bays.
Upon referring to FIG. 8 it will be seen` that in the top horizontal row of complete bays the oor panels are arranged with a panel B at the right end of said top row adjacent the wall of the building and a panel A is the next panel to the left, while the third panel to the left is another panel B, and so on. 'I'he same alternate arrangement of floor panels A and floor panels B appears in each vertical row of bays.
When these floor panels A and B have been laid as shown in FIG. 8 it will be observed that each of the two opposite edges 9 of any panel B rests on a ledge or rib 6 of the adjacent panel A, while each of the two opposite edges 11 of any panel A rests on a shelf or ledge 17 provided by an adjacent floor panel B.
With this arrangement each beam 4 embedded in a thickened edge portion of a oor panel A supports not only said edge of the panel A b-ut the adjacent edge of the adjacent floor panel B, and each supporting beam 14 which is embedded in an edge of the floor panel B serves to support not only said edge of floor panel B but the adjacent edge 11 of an adjacent floor panel A.
I claim.:
1. The method of producing a pair of separate, individual rectangular concrete oor panels in a nested relation which consists in forming a first complete rectangular iioor panel which has a at bottom face and a uniform thickness except at two opposite edges where the two corresponding edge portions rise above the portion of uniform thickness by an amount equal to such thickness, applying release material to the top face of said first rectangular panel, forming a second complete and independent rectangular oor panel directly on said first panel in a nested relation therewith, which second panel is provided with a body portion of uniform thickness that lls the space between the raised edge portions of said first panel and has a flat top face which is ush with the top face of said raised edge portions, and which also has two oppositely disposed depending edge portions each of which is outside of and overlies the face edge of a nonthickened edge portion of the first iioor panel and has its bottom face iiush with the at bottom face of said rst oor panel, whereby the distance between the top and bottom faces of the two oor panels in their nested relation is the same as the distance between the top and bottom face of each individual floor panel.
2. The method of producing a pair of rectangular concrete oor panels as defined in claim 1 and which includes embedding a steel beam in each of the two raised edge portions of the iirst oor panel while it is being formed and also embedding a steel beam in each of the depending edge portions of the second oor panel as the latter is being formed.
References Cited in the file of this patent UNITED STATES PATENTS 461,890 Richardson Oct. 27, 1891 992,739 Meier May 16, 1911 1,066,436 Peltzer July 1, 1913 1,463,841 Richman Aug. 7, 1923 1,473,200 Sawyer Nov. 6, 1923 1,592,070 Blake July 13, 1926 2,115,949 Gurger May 3, 1938 2,499,532 Shearer Mar. 7, 1950 2,505,152 Shearer Apr. 25, 1950 2,531,990 Rappoli Nov. 28, 1950 2,720,017 Youtz Oct. 11, 1955 FOREIGN PATENTS' 43,274 Switzerland Dec. l, 1907
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3195277A (en) * 1957-06-27 1965-07-20 Ceco Corp Prestressed concrete slab construction
US3213572A (en) * 1960-12-14 1965-10-26 Hohla Johannes Multi-storied building construction
US3789557A (en) * 1970-06-08 1974-02-05 R Harvey Raised flooring
US4679374A (en) * 1984-12-03 1987-07-14 Robert Boehmig Building construction method
US20090188194A1 (en) * 2008-01-24 2009-07-30 Williams Martin R Panelization System and Method

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US461890A (en) * 1891-10-27 Concrete block and method
CH43274A (en) * 1907-12-01 1909-04-16 Hermann Huegli Process for the production of building structures
US992739A (en) * 1909-07-27 1911-05-16 Unit Construction Co System of constructing buildings.
US1066436A (en) * 1913-07-01 Albert Peltzer Method for constructing concrete buildings.
US1463841A (en) * 1919-02-24 1923-08-07 Richman Wallace Clinton Method of making concrete building boards or slabs
US1473200A (en) * 1920-01-12 1923-11-06 Sawyer Frank Mcmurray Method of making artificial building blocks
US1592070A (en) * 1924-11-26 1926-07-13 John T Blake Method for forming building slabs and mold therefor
US2115949A (en) * 1936-09-04 1938-05-03 Gurber Samuel Concrete building construction
US2499532A (en) * 1947-02-07 1950-03-07 Shearer David Mcd Mold for casting revetment mat sections
US2505152A (en) * 1949-02-11 1950-04-25 Shearer David Mcd Method of molding concrete revetment mat units
US2531990A (en) * 1947-11-18 1950-11-28 Edmund J Rappoli Method of molding concrete building units
US2720017A (en) * 1948-11-30 1955-10-11 Inst Of Inventive Res Method of erecting buildings

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US461890A (en) * 1891-10-27 Concrete block and method
US1066436A (en) * 1913-07-01 Albert Peltzer Method for constructing concrete buildings.
CH43274A (en) * 1907-12-01 1909-04-16 Hermann Huegli Process for the production of building structures
US992739A (en) * 1909-07-27 1911-05-16 Unit Construction Co System of constructing buildings.
US1463841A (en) * 1919-02-24 1923-08-07 Richman Wallace Clinton Method of making concrete building boards or slabs
US1473200A (en) * 1920-01-12 1923-11-06 Sawyer Frank Mcmurray Method of making artificial building blocks
US1592070A (en) * 1924-11-26 1926-07-13 John T Blake Method for forming building slabs and mold therefor
US2115949A (en) * 1936-09-04 1938-05-03 Gurber Samuel Concrete building construction
US2499532A (en) * 1947-02-07 1950-03-07 Shearer David Mcd Mold for casting revetment mat sections
US2531990A (en) * 1947-11-18 1950-11-28 Edmund J Rappoli Method of molding concrete building units
US2720017A (en) * 1948-11-30 1955-10-11 Inst Of Inventive Res Method of erecting buildings
US2505152A (en) * 1949-02-11 1950-04-25 Shearer David Mcd Method of molding concrete revetment mat units

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3195277A (en) * 1957-06-27 1965-07-20 Ceco Corp Prestressed concrete slab construction
US3213572A (en) * 1960-12-14 1965-10-26 Hohla Johannes Multi-storied building construction
US3789557A (en) * 1970-06-08 1974-02-05 R Harvey Raised flooring
US4679374A (en) * 1984-12-03 1987-07-14 Robert Boehmig Building construction method
US20090188194A1 (en) * 2008-01-24 2009-07-30 Williams Martin R Panelization System and Method
US8505599B2 (en) * 2008-01-24 2013-08-13 Consolidated Systems, Inc. Panelization system and method

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