WO2001042575A1 - Systeme de construction de panneaux en beton - Google Patents

Systeme de construction de panneaux en beton Download PDF

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Publication number
WO2001042575A1
WO2001042575A1 PCT/CA1999/001176 CA9901176W WO0142575A1 WO 2001042575 A1 WO2001042575 A1 WO 2001042575A1 CA 9901176 W CA9901176 W CA 9901176W WO 0142575 A1 WO0142575 A1 WO 0142575A1
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WO
WIPO (PCT)
Prior art keywords
panel
panels
ofthe
building
slab
Prior art date
Application number
PCT/CA1999/001176
Other languages
English (en)
Inventor
Nick Dilorenzo
Original Assignee
Brentmuir Developments (1993) Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Brentmuir Developments (1993) Limited filed Critical Brentmuir Developments (1993) Limited
Priority to PCT/CA1999/001176 priority Critical patent/WO2001042575A1/fr
Priority to AU15429/00A priority patent/AU1542900A/en
Priority to EP99957812A priority patent/EP1238172B1/fr
Priority to DE69939188T priority patent/DE69939188D1/de
Priority to AT99957812T priority patent/ATE402299T1/de
Publication of WO2001042575A1 publication Critical patent/WO2001042575A1/fr

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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
    • E04B1/38—Connections for building structures in general
    • E04B1/383—Connection of concrete parts using adhesive materials, e.g. mortar or glue
    • 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
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/382—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of concrete or other stone-like substance

Definitions

  • the present invention relates to the field of construction. More specifically, the invention relates to a concrete panel construction system.
  • Prefabricated concrete panels have been used in a variety of building applications to provide a relatively easily assembled and relatively inexpensive building.
  • Many ofthe prior construction systems have a disadvantage in that they require that at least basic horizontal and vertical structural components be constructed to act as a frame to which the prefabricated panels can be attached.
  • the building site is first excavated and footings are positioned in the excavation to define the outline of the building.
  • Prefabricated floor panels may be placed between the footings.
  • prefabricated, freestanding concrete corner sections are placed on the footings where it is intended that the building have a corner.
  • a plurality of concrete panels can then be joined end-to-end between the corner sections to complete the peripheral wall.
  • the present invention provides a concrete building panel comprising: a slab having an outside face and an inside face and top and bottom ends and first and second sides; the slab top and bottom ends each including a beam extending along the length thereof, both the beams extending from the inside face of the slab in the same direction perpendicular to the plane ofthe slab; the slab first and second sides comprising extensions extending from the inside face ofthe slab, along the length ofthe slab and extending perpendicular to the plane ofthe slab in the same direction as the beams; and a plurality of ribs extending between the top and bottom ends of the slab and from the inside face ofthe slab, the ribs being parallel to the extensions.
  • Figure 1 is a perspective view of a building panel in accordance with a first embodiment ofthe present invention.
  • Figure 2 is a back elevation ofthe panel of Figure 1.
  • Figure 3 is a plan section ofthe panel of Figure 2, along the line 3-3.
  • Figure 4 is an exploded cross-section of a panel-to-footing attachment in accordance with one embodiment ofthe present invention.
  • Figure 5 is an exploded cross-section of a panel-to-footing attachment in accordance with a second embodiment ofthe present invention.
  • Figure 6A and 6B are plan and side views of a footing member in accordance with one embodiment ofthe present invention.
  • Figure 7 is an exploded cross-section of a panel-to-footing attachment utilizing the footing of Figures 6A and 6B.
  • Figure 8a is a perspective view of an attachment means for the bottom portions of adjacent panels ofthe present invention according to one embodiment.
  • Figure 8b is a perspective view of an attachment means for the top portions of adjacent panels ofthe present invention according to one embodiment.
  • Figure 9 is a plan view of the attachment of Figure 8a according to another embodiment.
  • Figure 10 is a perspective view of one end of the attachment of Figure 9.
  • Figure 1 la is a front elevation of a series building panels ofthe invention connected together.
  • Figure 1 lb is a perspective view of a panel attachment means according to another embodiment.
  • Figure 12 is a cross-sectional plan view of an external corner building panel.
  • Figure 13 is a cross-sectional plan view of an internal corner formed from two building panels.
  • Figure 14 is a plan view of a drywall connector for use with the building panels of the present invention.
  • Figure 15 is a perspective view of a building panel in accordance with a second embodiment ofthe present invention.
  • Figure 16 is a plan section ofthe panel of Figure 15, along the line 16-16.
  • Figure 17 is a side elevation ofthe panel of Figure 15 along the line 17-17.
  • Figure 18 is a cross-section of a rib attachment.
  • Figure 19 is a cross-section through a wall formed by building panels in accordance with the present invention.
  • Figure 20 is a side elevation of a panel connector.
  • Figure 21 is a side elevation of a building panel in accordance with yet another embodiment ofthe present invention.
  • Figure 22 is a back elevation of a building panel in accordance with a third embodiment ofthe present invention.
  • Figure 23 is a sectional view of an eaves unit.
  • Figure 24 is a sectional view of an apex unit.
  • Figure 25 is a partial front elevation of a panel according to another embodiment ofthe invention illustrating a reinforced corner portion.
  • Figure 26a is a side cross sectional elevation of a building wall comprising two stacked panels.
  • Figure 26b is a rear elevation ofthe upper panel shown in Figure 26a.
  • Figure 26c is a side cross sectional view ofthe lower panel shown in Figure 26a.
  • Figures 27a and 27b are top cross sectional views of different embodiments of joining adjacent wall panels.
  • Figure 28 is a side cross sectional elevation of another embodiment of the invention wherein a wall panel is designed to support an exterior veneer of brick.
  • Figure 29 is a side elevation of a panel of the invention according to another embodiment wherein the panel is used for flooring.
  • Figures 30a to 30e are side cross sectional elevations of various embodiments of the invention illustrating different arrangements ofthe wall and floor panels.
  • Figures 31 and 32 is a side cross sectional view of wall panels ofthe invention according to another embodiment wherein apertures in the panels are used to support flooring.
  • Figure 33a is a front elevation of a wall panel ofthe invention for use in interior corners.
  • Figure 33b is an end cross sectional view through the line A-A of Figure 33a.
  • Figures 34(a) to 34(1) are side cross sectional views of further embodiments ofthe invention wherein concrete panels are used to construct a roof of a building.
  • Figure 35 is a side cross sectional view of another embodiment ofthe wall panel ofthe invention wherein the panel is used as a retaining wall.
  • Figure 36 is a partial side cross sectional view of another embodiment ofthe retaining wall of Figure 35.
  • Figure 37 is a perspective view of a wall panel according to another embodiment.
  • Figure 38 is a rear elevation of a wall of a building comprising a plurality of wall panels ofthe invention arranged according to one embodiment.
  • Figure 39 is a side cross sectional view of a wall of a building comprising a plurality of wall panels ofthe invention and illustrating various embodiments of flooring.
  • Figure 40 is a side cross sectional view of a wall panel according to another embodiment ofthe invention.
  • Figure 41a and 41b illustrate the application of wall panels of the invention in existing structures.
  • a prefabricated concrete building panel in accordance with one embodiment of the present invention is shown generally at 20 in Figures 1-3.
  • This type of building panel is particularly useful in the construction of basement walls.
  • the building panel comprises a slab 22 having an outside face 25 and an inside face 50.
  • the slab is integrally connected to generally parallel top and bottom beams 30 and 35, respectively, which extend from the inside face 50 ofthe slab.
  • Beams 30 and 35 lie in a plane perpendicular to that ofthe slab 22 and extend in the same direction.
  • the beams 30 and 35 are connected at their ends by a pair of generally vertical end ribs 40 and 45 to form a box-like structure. Between the end ribs 40 and 45 are provided a plurality of generally equally spaced, substantially vertical ribs 55 which extend between top panel 30 and bottom panel 35.
  • the size of the panel is limited only by the constraint imposed by having to physically handle the panel. It is envisioned that for house construction, the panels will be approximately 8' wide by 8' high. The width ofthe panel will likely depend on its utility. For example, in basement construction where the panels are subject to the weight of back-filled material, and serve as foundation walls for the upper levels of the building, it is envisioned that the panels may be approximately 10" wide. A 10" wide bottom beam will help in distributing load and help stabilize the vertical panel. Similarly, a 10" top beam will provide a stable base to support a panel forming a second storey to the building and allow for support of a sub-floor structure (see Figures 19 and 20 and the discussion below).
  • Reinforcement may be in the form of steel rebars or, for example, the concrete may be reinforced with fibreglass wool or nylon strings.
  • the slab and the ribs are provided with a wire metal grid or mesh.
  • Other reinforcement means is conventionally known in the art.
  • the precise dimension ofthe concrete panel will depend upon the particular building code in the jurisdiction in which the panel is used. However, for the remainder of this discussion the building panel will be assumed to have dimensions 8' x 8' x 10", with the slab 22, the top and bottom beams 30 and 35 and the ribs each having a thickness of approximately 2.5". As the exterior of the basement wall is subject to the pressure of backfilling, care should be taken to ensure that the slab 22 has sufficient strength to prevent cracking or collapse. Accordingly, it is desirable that the ribs 55, which provide rigidity and strength to the panel, are spaced apart by no more than 2'. This spacing also follows the basic building code standards of providing vertical studs at 2' separation.
  • a standard 8' x 8' panel will have three equally spaced ribs parallel to and between the two end ribs.
  • the spacing between ribs 55 may vary. See, for example, Figures 12 and 13 and the discussion on interior and exterior corner construction.
  • the opposed end ribs 40,45 and the vertical ribs 55 are preferably provided with apertures or knock-outs 60 which can be used to facilitate running of electrical wires and plumbing through the wall cavity. Further, as will be discussed in more detail below, these knockouts can be used to receive locking bolts or a tensioning rod or belt, to permit adjacent panels to be secured together.
  • a knock-out is a section of the beam or rib in which the thickness and strength ofthe concrete is less than that of the rest ofthe beam or rib. This weakened section may be removed on site by a builder by hitting the weakened section and "knocking-out" the concrete plug.
  • the formation of knock-outs in concrete panels is well known in the art. As illustrated, the preferred embodiment ofthe invention includes apertures created during the forming process instead of knock-outs.
  • apertures 60 are provided for each rib.
  • the apertures are spaced so that the top and bottom apertures are spaced 1 foot from the top and bottom beams, 30 and 35, respectively.
  • the remaining apertures are then spaced 2 feet from each other.
  • An example of this arrangement is illustrated in Figure 33a.
  • knock-outs 65 may also be provided in the top and bottom beams 30, 35 to facilitate fastening the building panel to the foundation and the second storey or roof of the building. As will be apparent, the size of the knock-outs will vary depending on the size of bolts used to fasten the panels.
  • FIGs 4-7 Various types of foundation footings are shown in Figures 4-7.
  • a building panel 20 is mounted on a foundation footing 70.
  • the foundation footing 70 may, if building conditions allow, be formed from compact earth or hardcore or, more likely, will be formed from concrete.
  • the concrete footing may be a continuously poured strip that runs the length ofthe wall or may be individual blocks placed under spaced locations along the length ofthe wall panel.
  • the footing is provided with a step 75 against which the back edge 80 of bottom beam 35 abuts. The step abutment helps prevent lateral movement ofthe wall in relation to the footing during backfilling against the outside face 25 ofthe building panel.
  • Building panel 20 is secured to footing 70 by means of a bolt 85, which projects from the footing through aperture 65.
  • the footing may be provided with pair of levelling bolts 90, which project from footing 70 and abut the underside of bottom beam 35.
  • the levelling bolts may be used to ensure that the panel lies in the desired plane when the ground under the foundation may not be sufficiently level.
  • FIG. 5 A footing arrangement in accordance with another embodiment is shown in Figure 5.
  • footing 70' is provided with an angle iron or channel section 100, which may be used to facilitate, correct alignment ofthe building panel.
  • Section 100 may be attached to footing 70' (with for example bolt 110) prior to having the building panel lowered into place.
  • FIG. 6 A, 6B and 7. The footing comprises an elongate body 115 and a securing head 120.
  • One end of body 115, distal to securing head 120, is provided with a recess 75" against which the bottom beam of a building panel abuts, as described above with respect to Figure 4.
  • Securing head 120 is provided with an aperture 130 adapted to receive a bottom- flared spike 140, which can be formed in the ground and which prevents movement of the footing.
  • the footing has an overall length of approximately 4', with the 2.5' long body having a width of 8" which is the same as the diameter ofthe aperture 130 in securing head 120.
  • the footing is preferably formed of reinforced concrete and may be precast and placed in the appropriate location in the foundation or, alternatively, the footing may be cast in- place by placing a suitable mold at the desired location.
  • the spike 140 is preferably also formed of reinforced concrete. Casting the spike in the ground provides a firm anchor for the footing; the shape of the spike helping to prevent it being lifted from the ground. Although not shown, this type of footing may also be provided with levelling bolts to facilitate alignment ofthe panel. In respect ofthe footing shown in Figures 6a, 6b and 7, it is apparent that the footing does not support the entire length ofthe panel but usually supports only one or two points along its length. In these circumstances, it is desirable to ensure that there is a solid foundation under the unsupported panel length. This may be achieved by simply hard packing the earth where ground conditions permit or may be achieved by forming a strip of "crush and run" packable aggregate between the footings.
  • the aggregate may be covered with a wire mesh or cloth to help distribute the load evenly across the strip, if desired.
  • the panels of the present invention may also be simply placed on top of a concrete slab. The exact configuration will depend upon local soil conditions.
  • adjacent concrete panels may be attached together in an end-to- end manner by using bolts, such as pipe bolts, which pass through aligned apertures 60 in the abutting end ribs.
  • bolts are described below in relation to Figure 13.
  • the building panels may be provided with a tensioning belt arrangement, shown schematically in Figures 8-11.
  • Figure 8a shows a pair of panels 20 and 20', each panel provided with a belt attachment ( 150 and 150') connected to one end of a rebar or tensioning belt (160 and 160').
  • the attachment means 150 and 150' may be located within the top or, as shown, the bottom beam of a building panel. Attachment means 150 and 150' are connected together by a bolt 170 which extends from attachment means 150', through aperture 175 and into attachment means 150 where it is secured with a nut (not shown).
  • the attachment means comprise shoes, which are positioned at the upper surface of the bottom beam of each panel and extend to the outer edge of the end ribs. Such an arrangement allows easy access to the shoes 150 and 150' after the panels are set in place so as to facilitate tightening of the bolts 170.
  • Figure 8b illustrates similar attachment means for the top beams 30 and 30' of adjacent panels 20 and 20'.
  • shoes 151 and 151 ' similar to those discussed above, are provided on the upper surfaces ofthe top beams and are exposed so as to allow easy access thereto.
  • the attachment means generally comprises a U-shaped shoe having a crimped end 180 and a sealed end 190. End 180 is crimped around tensioning belt 160 to prevent lateral movement thereof. Sealed end 190 is provided with an aperture to receive bolt 170.
  • the U-shaped shoe may be provided with nail holes 195, which will help maintain the shoe in place during casting ofthe panel.
  • the shoe need not necessarily be set in from the edge ofthe panel and in fact, sealed end 190 may be flush with the end wall. Under these circumstances, it is preferable if the shoe is slightly tapered, increasing in width away from the sealed end. This tapering will help prevent lateral movement of the shoe during tensioning ofthe belt.
  • the tensioning belt and attachment means are cast in the top and/or bottom beams ofthe building panel such that the builder is permitted access to the channel ofthe attachment means when the panels are in place.
  • the attachment means may be sealed within the panel with concrete.
  • FIG. 11a An example of the use of the tensioning belts is shown in Figure 11a.
  • three building panels (20, 20', 20") are connected to form a continuous wall that is stepped down an incline.
  • the panels are shown resting on a concrete footing 200. It is preferred that in such an arrangement, the panels are stepped so that the top of the lower panel is at the same height as apertures 60 in the adjacent higher panel. This facilitates connection ofthe panels, as the apertures in adjacent end panels will align.
  • the tensioning belt 160 which runs around the top beam of building panel 20" may be connected to the adjacent end rib of building panel 20' or, as shown, may be connected across building panel 20' and be secured to the closest end rib of building panel 20.
  • the tensioning belt 160' which runs around the bottom beam of building panel 20 may be connected to the adjacent end rib of building panel 20' or, as shown, may be connected across building panel 20' and be secured to the closest end rib of building panel 20". If the tensioning belts are connected as shown in Figure 11a, the belts tie the plurality of panels together in a continuous string. In a preferred embodiment, all the panels that form the perimeter of the building will be joined together with tensioning belts which will form a continuous loop around the entire building. In the stepped wall construction shown in Figure 1 1a, the wall may be built to a desired level by attaching smaller panels to the top of panels 20' and 20" or by using convention brick or block construction.
  • Figure 1 lb illustrates another embodiment for attaching adjacent panels using a belt system.
  • a belt 160 extends through apertures 60 in the ribs ofthe panels and forms a continuous loop.
  • a turnbuckle 161 is provided at given locations and is used to tighten the tensioning belt 160.
  • the belt 160 is capable of stretching.
  • tensioning belts 160 are an optional item and serve to provide an added securing means for the panels over the bolts (described below) connecting adjacent panels. Such belts may only be required where the panels are placed on irregular footings.
  • FIG 12 shows a schematic representation of an external corner formed from a single corner panel. Similar to the previously described panel, the corner panel has a front or external face 25' and an inside face 50'. Vertical ribs 55' extend inwardly from inside face 50'. As discussed above, it is preferable that the vertical ribs should be spaced no more than 2' apart.
  • Another embodiment of a panel designed for an exterior corner is shown and discussed below in relation to Figures 33a and b.
  • Drywall sheets 210 and 210a are preferably attached across the ends of ribs 55'. Drywall sheets are conventionally 4' wide and it is preferred that the sheets do not have to be cut prior to installation. Accordingly, "extra" ribs 55a may be included to act as support for the drywall. The "extra” ribs are provided 2' from the internal apex "P" of the external corner. The remaining ribs along the length ofthe wall can be spaced at 2' intervals from this "extra” rib.
  • FIG. 13 An internal corner formed from two building panels is shown in Figure 13.
  • Building panel 20' is a standard panel as described above, with the ribs 55' being equally spaced (2' apart) along its length.
  • Panel 20" has an "extra” rib 55a' spaced such that it is 2' from the external apex "Q" of the internal corner.
  • the ribs are provided no more than 2' apart and the "extra” rib permits drywall panels, 210, to be attached without cutting the 4' width.
  • an external corner may also be formed from a pair of building panels connected in a similar manner to that described for the internal corner.
  • a single-piece interior or exterior corner panel may also be formed. In such case, the corner panel would be a unitary structure that includes the corner section.
  • Figure 13 also illustrates a pipe bolt 57, which are used to connect adjacent panels.
  • the bolts 57 is passed through the apertures 60, described above, ofthe adjacent panels and tightened. By using a plurality of such bolts 57, the panels are connected together to form a continuous wall.
  • the pipe bolts 57 are preferably hollow thereby allowing the apertures to still be used as a conduit for passing electrical wire etc.
  • FIG 14 shows an enlarged cross-section of internal apex "P" ofthe external corner shown in Figure 12.
  • drywall panel 210 may be attached to the end of rib 55b using conventional methods.
  • rib 55b may be provided with a clip 220.
  • Clip 220 has a pair of depending legs 215 each of which have, at their distal ends, barbs which facilitate attachment of clip 220 to rib 55b.
  • Web 230 extends perpendicularly to the face of rib 55b and to drywall panel 210, to provide a body to which drywall panel 210a may be attached.
  • Clip 220 is preferably formed from high tensile steel.
  • conventional fastening means including adhesive may be employed.
  • wooden strips may be attached to the outer surface of the ribs, to form a surface suitable to attaching the drywall. These wooden strips can, if desired, be formed integral with the ribs when the concrete for the ribs is first poured.
  • FIG. 15-18 An alternative embodiment of the wall panel is shown in Figures 15-18, and 26b with like numerals referring to like parts with the suffix "d" added for clarity.
  • This particular panel construction is useful in above-ground wall construction.
  • the building codes specify that external, above-ground walls must provide an air gap between outer and inner skins of the wall.
  • the air gap acts as both an insulating layer and a barrier to help prevent water permeating between the exterior to the interior surface to the wall.
  • the panel (referred to henceforth as the "air-gap panel") shown in Figures 15-18 has a continuous air gap 300 between the inside face 50d of slab 22d and the top beam 30d, the bottom beam 35d, the end ribs 40d and 45d and the ribs 55d.
  • the actual continuous air gap is formed between the inside face 50d ofthe slab 22d and a plywood sheet 315 which extends between the ribs and is spaced from the inside face by the insulated connector.
  • the plywood sheeting is generally inserted into the panel during formation by supporting the sheeting on the insulating connector or fastening it to the rebars prior to casting the ribs and end panels. Alternatively, it is envisioned that the plywood sheeting may be inserted into position within the panel structure after casting ofthe entire panel.
  • the plywood sheeting may act a support for conventional insulation 320.
  • the top and bottom beams and the ribs are connected to the slab by means of a reinforcement such as rebar 307, which may be integral with reinforcing mesh 307 provided in the slab or may be a separate element embedded in the slab material.
  • the purpose ofthe reinforcement 305 is to establish a firm connection between the rib 55f and the slab 22d.
  • the concrete portion ofthe beams and ribs are spaced from the inside face 50d by insulating connectors 310.
  • the insulating connectors are generally spaced apart from one another to permit air flow within the air gap of individual panels and between air gaps in adjacent panels.
  • the insulating connectors may be provided in the form of continuous strips, which can later be drilled to provide air passages.
  • the insulating connector is preferably formed from a non-rusting, non-conductive structurally sound material such recycled plastic.
  • a non-rusting, non-conductive structurally sound material such recycled plastic.
  • An example of such a material is SAN- NOR CreteTM, manufactured by Advanced Solutions... Advanced Technologies, Ontario, Canada.
  • the insulating connector not only helps provide structural integrity between the slab and the top and bottom beams and the ribs, but also acts as a protective cover over the connecting rebars to help prevent them from rusting.
  • the insulating connectors are shown in the four corners ofthe panel as well as spaced along the length ofthe end panels and ribs. However, the exact positioning of the insulating connectors will depend primarily on the position ofthe interconnecting rebars 305.
  • the air-gap panel may be provided with knock-outs 60d to permit adjacent panels to be joined together with locking bolts or a tensioning belt, as described above with reference to the basement panel.
  • Figure 19 shows a cross-section through a wall formed by a basement panel 20 and an air-gap panel 20d in accordance with the present invention.
  • top beam 30 ofthe basement panel 20 is provided with an upstanding web of concrete 330 along its interior edge.
  • the web 330 has a dual function; to help prevent ingress of water from the exterior ofthe building along joint 335 between the basement and air-gap panels; and to provide additional lateral stability to the bottom ofthe air-gap panel 20d.
  • Web 330 need not be formed integral with top beam 30 and may in fact be added later.
  • the web may be formed of concrete or any other conventional building material such as brick or wood.
  • the web may provide part ofthe support for the floor structure 340.
  • the basement panel and the air-gap panel may be secured together by locking bolts (not shown) which pass through the knock-outs provided in the top beam ofthe basement panel and the bottom beam ofthe air-gap panel.
  • Top beam 30 of the basement panel may be provided with levelling bolts (not shown) to facilitate alignment of the air-gap panel.
  • the role of the levelling bolts is the same as described above with respect to the footings.
  • the levelling bolts may be incorporated into bottom panel 35d ofthe air-gap panel.
  • the levelling bolts also function as spacers between the two panels to help prevent mortar from being squeezed out of the joint due to the weight ofthe air-gap panel.
  • FIG. 20 An alternative technique for joining the basement and air-gap panels is shown in Figure 20.
  • a steel strap 350 is attached across the end ribs 45 and 45d of the basement and air-gap panels, respectively.
  • the steel strap has a pair of holes 355 in the basement panel attachment end to receive fastening bolts and a pair of slots 360 in the air- gap panel attachment end.
  • the pair of slots is adapted to receive fastening bolts in a manner which permits a small amount of adjustment so the builder can compensate for slight misalignment ofthe panels.
  • the steel connector may be recessed into the end ribs of the basement and air-gap panels so that the thickness ofthe connector does not prevent abutment between the end panels of adjacent building panels.
  • the steel connector is approximately 4' x 4" x 0.5", with the holes and slots aligning with the knockouts in the end panels ofthe building panels being joined.
  • a groove may be formed along the entire length of end ribs 45 and 45d. This groove can receive the steel connector and may also be filled with a concrete adhesive/sealant, which will facilitate the attachment and sealing of two adjacent panels.
  • a second embodiment of an air-gap panel is shown in cross-section in Figure 21.
  • the reinforced concrete slab is replaced with a brick fascia 365.
  • the air gap is formed between the inside surface 370 ofthe bricks and a plywood sheeting 315.
  • bottom beam 35d is extended outwardly to provide a support for the bricks.
  • the type of brick is not particularly limited and the choice of a suitable brick is within the purview of a person of skill in the art.
  • the brick fascia 365 provides both structural integrity to the wall and provides an aesthetic value. As will be apparent, the brick fascia 365 may not cover the entire height ofthe panel.
  • the bottom half of the slab may be formed from concrete, with only the top half being formed of brick.
  • a brick fascia may be incorporated into a basement panel when a portion of the panel is to be above ground.
  • the brick fascia may be supported on the top beam of a lower building panel as opposed to resting on bottom beam 35d. Further, the top of the brick fascia may engage with top beam 30d in a manner similar to that shown in Figure 21 with respect to the engagement of the brick fascia and bottom beam 35d.
  • Figure 22 shows a third embodiment of a building panel in accordance with the invention, with like numerals referring to like parts with an "e" added for clarity. This particular panel is provided with a plurality of apertures for forming windows 380 and a door 390. To maintain structural integrity in the panel, ribs 55e are supplemented with transverse ribs 395. The ribs 55e and 395 together define the frame for the windows 380 and the door 390.
  • All the panels described above may be connected directly together using the fastening systems discussed such that concrete-to-concrete joints are formed.
  • energy-absorbing, flexible material may be incorporated into some or all ofthe panel-to-panel joints. Suitable energy absorbing materials may include, for example, rubber and other resilient polymers.
  • the panels may be connected using spring bolts, which permit a slight degree of movement between the panels. The use of energy- absorbing spaces and/or spring bolts will help make the building resistant to earth tremors and the vibration associated with earthquakes and severe weather systems such as cyclones, hurricanes and tornadoes.
  • the building panels have been described with reference to their use as wall panels.
  • the panels can also be used as floor panels.
  • the panels can be supported on any conventional floor support structure.
  • the building panel may be laid horizontally with the slab 22 forming either the upper or lower surface, as required by the builder.
  • the panel ribs can be used as support for the internal wiring and plumbing which generally runs under a floor.
  • the building panels ofthe present invention may also be used in the construction of a roof for a building.
  • a method of joining a sloped roof panel to a vertical wall panel is shown in Figure 23.
  • a corner of sloped roof panel 400 to rest on top beam 30 of the wall panel 20.
  • the corner may be flattened to aid in weight distribution.
  • the eaves of the roof are formed by a stepped eaves unit 410 which is also preferably formed of reinforced concrete but may also be formed from wood, plastic or the like.
  • the eaves unit 410 is attached between the sloped roof panel 400 and the wall panel 20 by bolts 85.
  • sloped roof panel 400 is oriented such that slab 22 forms the lower (i.e., interior) surface ofthe roof.
  • the outer skin ofthe roof may be formed across the ribs ofthe panel in any conventional manner.
  • sloped roof panel 400 may be oriented such that slab 22 forms the upper (i.e., exterior) surface ofthe roof.
  • eaves unit 410 may be formed integral with sloped roof panel 400, i.e., a specialized, pre-cast roof panel may be formed having at one end thereof the shape ofthe stepped eaves unit. This would simplify construction of a building as there would be fewer pieces to be bolted together.
  • the apex ofthe roof may be formed by an apex unit 420 attached between ends of adjacent sloped roof panels 400.
  • the apex unit 420 is preferably formed from reinforced concrete and it is attached between the ends ofthe adjacent sloped roof panels by bolts 85.
  • the apex unit may also be formed from a steel channel.
  • the angle of the roof may be modified by changing the angle ⁇ of the apex unit. Further, if desired, the strength ofthe apex unit may be increased by reinforcing the interior ofthe unit with steel cross-member or poured concrete.
  • apex unit 420 need not necessarily be formed as a concrete tube, but rather, the lower concrete V-shaped walls 430 and 440 may act as a support for a plywood cap 450.
  • the plywood cap 450 may be treated in any conventional manner to form a secure, watertight seal between the sloped roof panels.
  • the front panel 22 may form either the interior surface or the exterior surface of the roof, depending on the builder's preference.
  • the end ribs 45 are provided with reinforced portions 500 near the juncture with the top beam 22.
  • This type or arrangement provides more reinforcement for joining adjacent panels.
  • rebar 502 may also be provided in the corners ofthe panels 20.
  • reinforced portions 500 adjacent panels may be joined together via bolts extending through their respective top beams without the need for the tensioning belt discussed above. Additional support may be derived by connecting the panels with bolts extending between adjacent end ribs.
  • Figure 26a shows a further embodiment ofthe invention illustrating one arrangement of panels for the basement and top floor.
  • the basement panel 504 is provided with a recess 506 on the top beam 30 thereof.
  • the top floor panel 508 includes an extension
  • top floor panel in the slab 22 thereof.
  • the extension 510 of the top floor panel is dimensioned to be inserted into the recess 506 of the basement panel 504 so as to provide a close fit.
  • a floor panel 511 which is described in more detail below. As illustrated in Figure 26b, the top floor panel is also provided with drainage holes
  • the drainage holes 512 are provided 2 feet from each side ofthe panel thereby resulting in the holes being separated by 4 feet.
  • the holes are also preferably V" in height and 1 '/_" deep.
  • top floor panel 508 shown in this embodiment is similar in construction to the "air-gap" panel described above with the exception ofthe extension 510 being provided.
  • a vapour barrier 514 may also be provided between the two panels.
  • Figure 26c more clearly illustrates the basement panel 504.
  • Figures 27a and 27b illustrate two means of connecting adjacent panels via adjacent end ribs.
  • a connection is shown that allows for expansion.
  • the adjacent end ribs, 40 and 45, respectively are connected by means of a pipe bolt and nut combination 516 that also includes springs 518 between the ribs and the bolt and nut.
  • the connection between two adjacent panels is more rigid by means of a pipe bolt and nut combination 516 without the use of springs.
  • the pipe bolts 516 are preferably hollow thereby allowing passage of electrical and plumbing etc., there-through.
  • Figure 28 shows a basement panel according to another embodiment wherein the panel 518 is provided with a ledge 520 for supporting an exterior brick veneer 522.
  • the panels of the present invention may also be used as floor panels 511.
  • a more detailed illustration of such panel is shown in Figure 29.
  • the panel 511 is essentially ofthe same construction as the wall panels described above.
  • the floor panel 511 may be provided with an extension 524 ofthe slab. The extension is then rested on the top beam ofthe basement wall panel to create a first floor for the building.
  • additional vertical support may be provided by means of pillars etc. as is conventionally known. The need for such additional support will, of course, depend upon the span ofthe floor.
  • Figures 30a to 30c depict various other embodiments of the invention wherein the panels are used for flooring.
  • the top floor panel, basement panel and floor panels are connected by means of bolts extending there- through.
  • the panels of the invention when used for flooring, may be oriented in either direction. That is, for a flat concrete floor, the panels may be placed with the slab 22 facing upwards. In the alternative, the panel may be reversed so that the ribs are positioned upwards. In the latter case, the ribs function as joists over which standard flooring may be attached.
  • the present invention includes the use of the above panels for use in top floor walls and for flooring.
  • any of these uses may be replaced with traditional methods of construction.
  • the panels for the top floor walls it is possible to use typical wood stud construction wherein the typical walls are connected to the basement wall panels by known methods.
  • the floor system may comprise traditional wood joists extending over the top beams ofthe basement panels.
  • metal joists may also be used. In the latter case, the metal joists may be used to support flooring panels made that comprise the concrete panels ofthe present invention.
  • Figures 30d and 30e illustrate a further embodiment ofthe invention wherein beams are provided to support the panels when used for flooring.
  • beam 513 one version of the beam is shown at 513.
  • beam 513 includes a pair of ledges 515, which are designed to support the extension 524 ofthe floor panel 511.
  • Figure 30e illustrates another embodiment wherein the letter "a” is used to identify elements that are similar in function.
  • the beam 513a comprises an inverted “U” shaped structure that provides a single ledge 515a for supporting flooring panels 511a.
  • the beams 513 and 513a extend over opposite vertical wall panels and provide a support surface for the floor panels. In this way, the floor panels can be installed without having to be directly resting on the wall panels.
  • FIGS 31 and 32 illustrate various embodiments wherein conventional flooring construction methods may be used with the panels ofthe present invention.
  • like elements are referred to with like reference numbers.
  • FIG 31 illustrates a further embodiment ofthe invention wherein the panels ofthe invention are used to construct a building.
  • top and bottom panels 526 and 528 are connected together to form top and bottom levels ofthe building.
  • the connection ofthe panels is achieved by conventional methods such as the use of bolts extending between the bottom beam 530 ofthe top panel 526 and the top beam 532 of the bottom panel 528.
  • the connection between the panels is preferably reinforced by a connecting plate 534, which is bolted to both panels at the end ribs thereof.
  • Such bolts extend through the apertures 536 provided in the ribs of each panel.
  • a groove is provided in the end ribs to accommodate the connecting plate so that the two panels are in contact.
  • the panels are provided with hangers 538.
  • the hangers are designed, at one end, to engage the apertures 536 of the ribs on the panels and, at the opposite end, are provided with a hook 540.
  • the hook 540 ofthe hanger 538 is adapted to receive 2 x 12 joist stringers 542 as are commonly known or 4 x 4 headers 544.
  • conventional wood joists 546 can be attached to the stringers 542 or headers 544 as is commonly know.
  • a typical plywood flooring 548 may be applied. In this manner, the level ofthe floors in a building can be adjusted to allow for a "sunken" effect where required.
  • FIG 32 another embodiment of an adjustable floor level is illustrated wherein a metal pipe 550 is inserted through the apertures 536 in the panels and a metal angle iron 552 is welded to the pipe.
  • the angle iron 552 thus creates a header onto which conventional joists 546 can be attached.
  • Figures 33a and 33b illustrate a preferred embodiment of the invention wherein a wall panel is specifically configured for use in interior corners.
  • the corner panel 554 is designed as discussed above for regular wall panels, but is provided with a return portion 556 on one ofthe end ribs 558.
  • the return portion comprises, preferably, a 12 Vi" slab that extends from the end rib 558 towards the neighbouring rib 560 on the panel.
  • the return portion 556 is generally parallel to the slab 562 of the comer panel 554.
  • the return portion 556 is provided with apertures 564 similar to those on the other ribs.
  • the end rib of a typical wall panel can be positioned adjacent and perpendicular to the comer panel 554 so as to form an interior comer.
  • the apertures in the end rib ofthe second panel would be at the same locations as apertures 564 ofthe return portion 556 thereby enabling the two panels to be connected together.
  • the return portion 556, the end rib 558 to which it is attached, the adjacent rib 560, and a portion 566, ofthe slab 568, between the end rib 558 and the adjacent rib 560 have a thickness of 3" whereas the rest ofthe panel has a thickness of 2 V_" as in the regular wall panels. The increased thickness provides added strength to the comer of the wall being formed.
  • the comer panel 554 preferably has a width of 8' 10" instead of the regular 8'. In this arrangement, once the second panel, having a 10" depth, is positioned, the remaining width ofthe panel would be the typical 8'.
  • the comer panel 554 is preferably first formed as a typical wall panel described previously. Subsequently, concrete is poured to form the return portion 556.
  • Figure 34 illustrates various embodiments ofthe panels ofthe invention for use in constructing a roof for a building.
  • Figure 35 illustrates an embodiment ofthe invention wherein the panels described above are used to construct a retaining wall.
  • the wall 570 is comprised of a number of stacked panels 572 each having apertures 574 as described above. Brackets 576 are provided which cooperate with the apertures to form ledges 578, which, in turn, support counter weights 580.
  • another embodiment of the invention comprises the wall panels 572 being formed with integral ledges 578' thereby removing the need for the brackets 576.
  • the wall panels of the invention may be provided with a unitary footing as illustrated in Figure 37.
  • the wall panel 582 according to this embodiment, includes an integral footing 584 under the bottom beam 586 ofthe panel. With this arrangement, the need for separate footing is overcome.
  • Figure 38 illustrates a further embodiment of the invention wherein a plurality of wall panels are stacked to form the walls of a multi-level building.
  • the wall panels are staggered so as to avoid a continuous seam.
  • the panels are bolted together as described above since although staggered, the apertures in the ribs would still be in line.
  • Figure 39 illustrates a wall of a multi-level building wherein a variety of flooring systems are used. The flooring systems shown are described above.
  • Figure 40 illustrates a further embodiment wherein a wall panel 588 serves to form a curtain wall.
  • the slab 590 ofthe panel 588 is extended past the top and bottom beams 589 and 591, respectively to result in top and bottom flanges 592 and 594, respectively.
  • the top and bottom beams 589 and 591 are then bolted to the floors of the building
  • the weight ofthe above panels may be reduced by using lightweight concrete in the forming process. It will be understood that the strength ofthe concrete will be determined by the required engineering specifications for the subject building. Further, where appropriate, the metal reinforcing material may be omitted in favour of other known reinforcing means such as fiberglass or vinyl strings etc. Preferably, such alternate reinforcing means will only be used for buildings less than four stories in height.
  • the panels ofthe invention can also be used in a "retrofit" manner in buildings constructed by conventional methods.
  • the preferred size of the panels, as described above, makes them compatible for this purpose since they are designed in accordance with existing North American building standards.
  • An example of this is illustrated in Figure 41a wherein a wall panel 598 is bolted to an existing concrete block wall 596.
  • the connection of a wall panel ofthe invention to an existing wood or metal stud wall 600 in accordance with conventional construction methods.
  • the wall panel can be attached to the existing structure using the bolts as described above. Such bolts are shown at 602.
  • Figure 41b illustrates the connection of a wall panel ofthe invention to an existing poured concrete wall 604.
  • the wall or roof panels described above may be insulated and finished by any variety of known methods.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Underground Structures, Protecting, Testing And Restoring Foundations (AREA)
  • Panels For Use In Building Construction (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)

Abstract

La présente invention concerne un panneau de construction en béton comprenant une dalle pourvue de rebords supérieur et inférieur qui définissent généralement une boîte, ainsi que plusieurs nervures s'étendant entre les rebords supérieur et inférieur, parallèlement aux rebords latéraux. Les panneaux de l'invention peuvent s'utiliser dans la construction des murs, du plancher ou du toit d'un bâtiment.
PCT/CA1999/001176 1999-12-08 1999-12-08 Systeme de construction de panneaux en beton WO2001042575A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
PCT/CA1999/001176 WO2001042575A1 (fr) 1999-12-08 1999-12-08 Systeme de construction de panneaux en beton
AU15429/00A AU1542900A (en) 1999-12-08 1999-12-08 Concrete panel construction system
EP99957812A EP1238172B1 (fr) 1999-12-08 1999-12-08 Systeme de construction de panneaux en beton
DE69939188T DE69939188D1 (de) 1999-12-08 1999-12-08 Konstruktionssystem mit betonplatten
AT99957812T ATE402299T1 (de) 1999-12-08 1999-12-08 Konstruktionssystem mit betonplatten

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CA1999/001176 WO2001042575A1 (fr) 1999-12-08 1999-12-08 Systeme de construction de panneaux en beton

Publications (1)

Publication Number Publication Date
WO2001042575A1 true WO2001042575A1 (fr) 2001-06-14

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Application Number Title Priority Date Filing Date
PCT/CA1999/001176 WO2001042575A1 (fr) 1999-12-08 1999-12-08 Systeme de construction de panneaux en beton

Country Status (5)

Country Link
EP (1) EP1238172B1 (fr)
AT (1) ATE402299T1 (fr)
AU (1) AU1542900A (fr)
DE (1) DE69939188D1 (fr)
WO (1) WO2001042575A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003097950A2 (fr) * 2002-05-20 2003-11-27 Iwood Singapore Pte Ltd Construction in situ d'un batiment en beton
FR2925541A1 (fr) * 2007-12-21 2009-06-26 David Damichey Element prefabrique pour unite d'habitation.
CN110056111A (zh) * 2019-04-18 2019-07-26 江苏广兴集团建筑装配科技有限公司 一种连接稳定的叠合板

Citations (9)

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Publication number Priority date Publication date Assignee Title
FR483834A (fr) * 1916-02-21 1917-08-14 Const Economiques Soc D Système de constructions démontables en ciment armé
FR863026A (fr) * 1940-01-23 1941-03-21 Construction démontables
FR898765A (fr) * 1943-06-11 1945-05-07 Sainrapt & Brice Ets Système de construction de locaux à l'aide de panneaux préfabriqués
FR1422473A (fr) * 1965-01-12 1965-12-24 élément polyvalent, en béton armé, pour construction industrialisée
FR2045625A1 (fr) * 1969-06-12 1971-03-05 Valigiani Marc
US3683578A (en) 1970-05-07 1972-08-15 Harold M Zimmerman Concrete building construction and component parts used therewith
US4751803A (en) 1985-08-05 1988-06-21 Superior Walls Of America, Ltd. Prefabricated concrete wall structure
US5493838A (en) 1994-05-06 1996-02-27 Ross; David Method of constructing a concrete basement from prefabricated concrete panels
US5656194A (en) 1995-06-14 1997-08-12 Superior Walls Of America, Ltd. Assembly jig for prefabricated concrete walls

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR483834A (fr) * 1916-02-21 1917-08-14 Const Economiques Soc D Système de constructions démontables en ciment armé
FR863026A (fr) * 1940-01-23 1941-03-21 Construction démontables
FR898765A (fr) * 1943-06-11 1945-05-07 Sainrapt & Brice Ets Système de construction de locaux à l'aide de panneaux préfabriqués
FR1422473A (fr) * 1965-01-12 1965-12-24 élément polyvalent, en béton armé, pour construction industrialisée
FR2045625A1 (fr) * 1969-06-12 1971-03-05 Valigiani Marc
US3683578A (en) 1970-05-07 1972-08-15 Harold M Zimmerman Concrete building construction and component parts used therewith
US4751803A (en) 1985-08-05 1988-06-21 Superior Walls Of America, Ltd. Prefabricated concrete wall structure
US5493838A (en) 1994-05-06 1996-02-27 Ross; David Method of constructing a concrete basement from prefabricated concrete panels
US5656194A (en) 1995-06-14 1997-08-12 Superior Walls Of America, Ltd. Assembly jig for prefabricated concrete walls

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003097950A2 (fr) * 2002-05-20 2003-11-27 Iwood Singapore Pte Ltd Construction in situ d'un batiment en beton
WO2003097950A3 (fr) * 2002-05-20 2004-03-18 Iwood Singapore Pte Ltd Construction in situ d'un batiment en beton
SG131743A1 (en) * 2002-05-20 2007-05-28 Iwood Singapore Pte Ltd In-situ construction of concrete building
FR2925541A1 (fr) * 2007-12-21 2009-06-26 David Damichey Element prefabrique pour unite d'habitation.
WO2009106735A2 (fr) * 2007-12-21 2009-09-03 David Damichey Element prefabrique pour une unite d'habitation
WO2009106735A3 (fr) * 2007-12-21 2010-01-21 David Damichey Element prefabrique pour une unite d'habitation
US20110088333A1 (en) * 2007-12-21 2011-04-21 David Damichey Prefabricated element for a dwelling unit
US8590215B2 (en) * 2007-12-21 2013-11-26 David Damichey Prefabricated element for a dwelling unit
CN110056111A (zh) * 2019-04-18 2019-07-26 江苏广兴集团建筑装配科技有限公司 一种连接稳定的叠合板

Also Published As

Publication number Publication date
EP1238172B1 (fr) 2008-07-23
AU1542900A (en) 2001-06-18
EP1238172A1 (fr) 2002-09-11
DE69939188D1 (de) 2008-09-04
ATE402299T1 (de) 2008-08-15

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