WO2007102830A1 - Construction de batiment modulaire utilisant un ensemble moule pour beton - Google Patents

Construction de batiment modulaire utilisant un ensemble moule pour beton Download PDF

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Publication number
WO2007102830A1
WO2007102830A1 PCT/US2006/009306 US2006009306W WO2007102830A1 WO 2007102830 A1 WO2007102830 A1 WO 2007102830A1 US 2006009306 W US2006009306 W US 2006009306W WO 2007102830 A1 WO2007102830 A1 WO 2007102830A1
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WO
WIPO (PCT)
Prior art keywords
construction according
wall
concrete
channel
channels
Prior art date
Application number
PCT/US2006/009306
Other languages
English (en)
Inventor
Dennis William Leblang
Original Assignee
Dennis William Leblang
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 Dennis William Leblang filed Critical Dennis William Leblang
Priority to PCT/US2006/009306 priority Critical patent/WO2007102830A1/fr
Publication of WO2007102830A1 publication Critical patent/WO2007102830A1/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
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8605—Walls made by casting, pouring, or tamping in situ made in permanent forms without spacers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8635—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8647—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties going through the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8652—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties located in the joints of the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/8688—Scaffoldings or removable supports therefor

Definitions

  • the invention is directed to a modular building construction involving the assembly of panelized and modular building units manufactured off site and installed on site, said units employing on site molded concrete juncture means, said units consisting of walled one, or a combination of walls, floor and ceiling section modules assembled and unified on site. DESCRIPTION OF THE PRIOR ART
  • the building has been constructed by the assembly of off site manufactured floor, wall and ceiling components brought to a building site and individually installed and unified at a construction site as a unified structure.
  • the finished materials are exposed to the inside of the structure, for example, typically drywall is installed on the walls and ceiling.
  • the floor of the unit is usually finished in carpet, ceramic or vinyl tile with the under layer of the floor being either concrete or wood sub floor finished.
  • conventionally is brought to the construction site unfinished on the interior with an exterior sheathing, such as plywood or insulation, forming a structural system of wood joists or metal light gauge metal channels.
  • an exterior sheathing such as plywood or insulation
  • metal light gauge metal channels After the floor, walls and ceilings are installed, lightweight concrete is poured over the plywood subfloor as sometimes required by National Building Codes.
  • the walls, floor and ceiling components are brought to the construction site as a single unit.
  • the panelized technique has similar size restrictions, but constructing a modular component under the same limitations is more difficult.
  • the width of all modular construction components are the width of what can be transported via a truck plus not exceeding the height limitations under bridges.
  • Modular construction involves the shipment of an entire three-dimensional structure, the interior being finished with dry wall or other material that is specified for that specific project.
  • the structural system is exposed and no sheathing or interior finish is shipped with the panel since the visible shipped transported unit having the visible finish that is the exterior structure of wood studs or galvanized metal channels.
  • the construction industry ships bathroom modulars, portions or sections of housing units, kitchen modulars, hotel room modulars, and jail cell modulars just to name a few.
  • a building can contain many smaller modules, which will then become a part of a larger unit module.
  • modules When these various modules are installed at a building site, such modules can be placed adjacent to each other or can have a void between the modules.
  • This void functions as the mold into which concrete can be installed so as to create a greater structural system, stronger than any of its parts.
  • the concrete wall also has a mass and mass reduces sound transmission, for example, between one apartment and another apartment.
  • concrete is a fire rated material; the thicker the concrete, the greater the fire protection. For example, a 12-inch concrete wall is rated as a 4-hour wall and a six-inch wall will be rated only as a two-hour wall.
  • Concrete forms are installed on both sides of a concrete wall and tied together with a form tie. Reinforcing bars are added between the forms and the forms are sprayed with a release agent prior to pouring concrete between the forms. After the concrete is poured and the concrete has cured enough, the forms are removed. The exposed concrete is the remaining finish of the wall. After the forms are removed, the walls are furred out, that is additional wood or steel furring strips are added inside surface can be installed and dry wall can be added to create an interior finished wall surface.
  • ICF Insulated Concrete Form
  • This method involves rigid insulation being used to create the outside surface and ties are used to hold the insulation together creating the mold into which concrete can be poured. Reinforcing bars are added into the insulated concrete form and exterior temporary wall bracing is installed for lateral bracing. In this case, the insulation remains as the exterior finish of the wall. After the wall is poured, the insulation is hollowed out for the electrical wiring, the drywall is glued onto the wall or additional furring strips are added and then the drywall is added to create the interior finished wall surface.
  • the invention provides a self-contained mold formed by installation of two or more modules spaced apart to allow for concrete to form between the modules.
  • the wall can be formed of metal or wood construction, preferably having an interior finish, which is to be the interior finish of the resulting structure. Reinforcing bars are added into the mold and floors, ceilings and interior walls are installed for wall bracing. In this case the insulation or wallboard, siding or brick remains as the exterior finish of the wall. The electrical distribution is distributed through the interior forming structure of the individual wall.
  • FIGURE 1 is an isometric representation of modular building components stacked on top of each other and joined together to form a larger unit or building component.
  • FIGURE IA is an isometric enlargement of two adjacent modules
  • FIGURE 2 is a representation of a modular wall section showing two adjacent modules installed adjacent to each other, the modules being illustrated separated with an air space between them. One of the modules is shown separated from the wall mold prior to being installed on the job site.
  • FIGURE 2A is a diagrammatic representation showing the relationship of a single portion of one of the adjacent walls shown in FIGURE 2;
  • FIGURE 3 is a plan section taken along line B-B of FIGURE 2 showing the mold formed by placing two modules adjacent to one another, but yet separated apart to form the mold for concrete to be installed; wall-forming ties being illustrated as installed between the one module and another module;
  • FIGURE 4 illustrates a wall section of a panelized construction
  • FIGURE 4A is a diagrammatic representation showing the relationship of a single portion of one of the adjacent walls shown in FIGURE 4;
  • FIGURE 5 is an isometric representation of two modules placed adjacent to one another, one of the modules illustrating the various components that make-up the module being coupled to the adjacent module;
  • FIGURE 6 illustrates a wall section showing a pair of modules installed near each other but separated by an air space, one of the modules being a modular wood construction
  • FIGURE 6A is a diagrammatic representation of a module wall illustrated in FIGURE 6, showing the components of the module construction adjacent the wall section illustrated in FIGURE 6;
  • FIGURE 7 is a plan view of a concrete mold formed by placing two modules adjacent to one another, but yet separated apart to constitute a mold for concrete to be installed, said view showing the wood studs and the floor and ceiling joists overlapping the wood studs.
  • FIGURE 8 is a sectional view of a panelized wood construction illustrating two separate building module units that are installed near each other, but separated by an air space.
  • One of the building units is illustrated as separated from the from the wall mold prior to being installed at the job site as well as separated by the wall, floor and ceiling building components;
  • FIGURE 8 A is a diagrammatic illustration showing the relationship of elements of
  • FIGURE 9 illustrates a modification of the panelized wood construction shown in
  • FIGURE 9 A is a diagrammatic illustration showing the relationship of elements of
  • FIGURE 9 to the wall section illustrated in FIGURE 9 to the adjacent module is an isometric representation of a module having a thin wall of a module building using one of many types of poured-in-place wall construction where only a portion of the wall is filled with concrete and the remainder of the wall interior is left exposed for future electrical installations.
  • FIGURE 11 is a section of the wall construction of FIGURE 10 taken along line A-A of FIGURE lO;
  • FIGURE 12 is a plan view of the wall construction of FIGURE 10 taken along line B-B of
  • FIGURE 10
  • FIGURE 13 is an isometric view of the wall construction of FIGURES 10 - 12 in which the wall is constructed as a double-sided construction;
  • FIGURE 14 is a section of the wall construction of FIGURE 13 taken along line A-A of
  • FIGURE 13
  • FIGURE 15 is a plan view taken through line B-B of FIGURE 13;
  • FIGURE 16 is an isometric representation of a wall construction using only hat channels as a supporting system.
  • FIGURE 17 is a section of the wall of FIGURE 16 taken along line A-A of FIGURE 16;
  • FIGURE 18 is a plan section of the wall of FIGURE 16 taken along the line B-B of 5 FIGURE 16;
  • FIGURE 19 is an isometric representation of a similar wall construction shown in FIGURES 16 -18 except here is a double-sided, i.e. a thicker wall with an interior rigid insulation thermal break similar to a precast concrete wall with rigid insulation in the interior; 10
  • FIGURE 20 is a plan section taken along the line B-B of FIGURE 19.
  • the wall construction is built in the same manner, that is, where hat channels are placed on a table the length of the wall;.
  • FIGURES 21 - 24 show a construction similar to the construction shown in FIGURES 19
  • FIGURE 21 is an isometric representation of the construction using hat channels as a supporting system and an electrical distribution system;
  • FIGURE 22 is a wall section taken through line A-A of FIGURE 21;
  • FIGURE 23 is a plan section taken through line B-B of FIGURE 21 ;
  • FIGURE 24 is a vertical wall section taken through hat channel 78 of FIGURE 21;
  • FIGURES 25 - 31 illustrate a wall structure having smaller vertical C channels and horizontal hat channels to create a wall structure
  • FIGURE 25 is an isometric drawing of the wall construction showing the vertical C- 5 channels extending below the interior structure of the wall form into a concrete footing, which can be installed simultaneously with the concrete within the form:
  • FIGURE 25 A is an enlarged isometric showing the vertical electrical distribution with the wall
  • FIGURE 26 is a wall section taken along taken along line A-A of FIGURE 25;
  • FIGURE 27 is a plan section taken along lines B-B of FIGURE 25;
  • FIGURES 28 -31 illustrate a wall structure where the interior structure of the mold extends to the outside surface of the wall board or rigid insulation;
  • FIGURE 28 is an isometric representation of the wall construction of FIGURE 28;
  • FIGURE 29 is a wall section shown along lines A-A of FIGURE 28
  • FIGURE 30 is a plan section taken along lines B-B of FIGURE 28
  • FIGURE 31 is an enlarged detail of the end of the U Channel and, instead of an angle added to the flange, the flange is bent 180 degrees and extends beyond the web of the
  • FIGURE 32 is an enlarged detail of the end of the U Channel and shows an angle member attached to the web of the U Channel and being level to the flange of the U channel;
  • FIGURE 33 is an isometric representation of the wall construction where the concrete structure within the wall is a vertical ribbed structure.
  • FIGURE 34 is a wall section taken along lines A-A of FIGURE 33 shows the interior rigid insulation not placed the full height of the wall, but shorter at both the top and bottom of the wall so concrete can form a beam at the top and bottom of the wall;
  • FIGURE 35 is a plan section taken along section B-B of FIGURE 33 shows holes in the hat channel allowing the concrete to flow more easily around and through the hat channels; additional hat channels being at the bottom of the wall due to increased pressure of the concrete at the bottom of the wall forming structure;
  • FIGURES 36 and 39 shows a wall construction similar to FIGURES 33 through 35 but instead of concrete being installed when the wall is erected in a vertical position, the concrete is installed in a horizontal position; the construction of the wall system being capable of being used either as a wall system, as a floor system or as a roof system;
  • FIGURE 36 showing metal C channels spaced in an array and a flange of the C channels being attached to the rigid board and to metal C channels creating a rigid frame since they criss-cross each other;
  • FIGURE 37 is similar to FIGURE 36 and provides interior foam spacers tapered to be wider at the bottom of the beam;
  • FIGURE 38 is similar to FIGURE 37 but adds metal hat channels between two rigid boards below the metal C channels plus a larger C channel with wire mesh embedded in concrete floor;
  • FIGURE 39 is similar to FIGURE 38 except the depth of the concrete is deeper; a spacer being installed between the metal C channel and the rigid board below the beam for increased fireproofing;
  • FIGURE 40 shows the flooring system attached to a vertical poured wall system plus a transverse beam criss-crossing the concrete floor beams;
  • FIGURES 41-45 show various types of connectors used to make the construction easier to build eliminating exposed screw connectors connecting the rigid wallboard to the interior structure of the wall;
  • FIGURE 41 is similar to FIGURES 13 through 15, except an H channel is used in lieu of the hat channel;
  • FIGURE 42 is similar to FIGURES 10 through 12 except H channels are used in lieu of fasteners connecting the rigid insulation;
  • FIGURE 43 substitutes a center groove in the rigid insulation instead of H channels encasing the rigid insulation;
  • FIGURES 44 and 45 both show connectors embedded within a wallboard and protrude out to become a fastening method to secure said wallboard to the inner structure of the mold;
  • FIGURE 44 has a space between the wallboard and the hat channel.
  • the stem of the connector has a flange added to hold the connector in place.
  • Both connectors have a V carrot at the end of the stem thereof that passes through a hole of the hat channel 86.
  • FIGURE 45 is similar to the structure of FIGURE 44 and has a space between the wallboard and the hat channel;
  • FIGURE 46 is built using the same wall structure as shown in FIGURES 19 and 20. rigid insulation is in the middle of the wall provides a thermal break between the interior wall and exterior wall but provides separate chambers to install two different materials on either side of the wall gravel, stones and sand being among the materials employed;
  • FIGURE 47 is built using the same wall structure as FIGURES 19 and 20;
  • FIGURE 48 shows the same wall structure as FIGURES 19 and 47;
  • wire mesh is installed over the outer hat channel. The wall is erected vertically, concrete is introduced, and flows through the wire mesh and into the skeleton chamber, excesses being removed by a trowel (not shown);
  • FIGURES 49 and 50 are similar in the wall construction, show control and expansion joints as decorative elements of the wall design;
  • FIGURE 49 shows a control joint
  • FIGURE 50 shows an expansion joint attached to a C channel. Two full depth channels are shown back to back to each other with a space between their webs;
  • FIGURES 51 and 53 are similar to FIGURES 13 and 15 except the exterior rigid insulation is a siding;
  • FIGURE 51 is an enlarged detail showing the siding attached to the wall forming structure such as aluminum siding, vinyl siding, wood siding or an exterior finish surfacing material which can be applied to a building exterior;
  • FIGURE 52 is a wall section similar to FIGURE 19 showing siding attached to the wall forming structure;
  • FIGURE 53 is similar to the plan view such as earlier shown and earlier described with reference to the plan view of FIGURE 20, showing exterior siding with vertical angles at the corners and the vertical and horizontal hat channels in the wall;
  • FIGURES 54 through 56 show an exterior finish material of thin brick attached to the wall forming structure and used as part of the mold;
  • FIGURE 54 is an isometric view of the wall construction;
  • FIGURE 55 is a wall section taken through section A-A of FIGURE 54;
  • FIGURE 56 is a plan view taken through line B-B of FIGURE 54;
  • FIGURE 57 through 59 are similar to the structures shown in FIGURES 54 through
  • FIGURE 56 except full width face bricks are used as part of the mold structure in lieu of the thin face bricks;
  • FIGURE 57 is an isometric view of the wall construction
  • FIGURE 58 is a wall section taken along section line A-A of FIGURE 57;
  • FIGURE 59 is a plan view taken along line B-B of FIGURE 57;
  • FIGURE 60 shows how to make a corner using the wall structure shown in FIGURES 25 through 27;
  • FIGURE 6OA is a plan section of a corner wall panel
  • FIGURES 61 through FIGURE 62 show a vertical wall sections similar to FIGURE 26 with horizontal recessed grooves or horizontal projections for use as a structural support system or for architectural wall accents;
  • FIGURE 61 illustrates a recessed U channel, normally called a ledger, to support the C channel floor joists;
  • FIGURE 62 also has a horizontal U channel ledger, however this ledger is secured on the center C channel 88, and also FIGURE 62 shows a C channel protruding from the main body of the wall;
  • FIGURES 63 and FIGURES 64 show similar looking architectural recessed grooves both showing the FIGURES show the same wall structure as FIGURE 53 except here the metal angles have both angle legs exposed;
  • FIGURE 63 is a sectional detail of an architectural groove shown in the elevation of the finished wall at FIGURE 65;
  • FIGURE 64 is a sectional detail of the architectural recessed groove shown in the finished wall at FIGURE 65;
  • FIGURE 65 is an elevation of a finished wall showing some of the recesses shown in
  • FIGURES 63 and 64 the vertical recess on the left is shown in FIGURE 63, the vertical recess on the right in FIGURE 64; the recessed groove being shown in FIGURE 64;
  • FIGURE 66 is similar to FIGURE 62, however the wall section shows how a steel bar joist is secured to the projection previously described in FIGURE 62;
  • FIGURE 67 shows a wall similar to FIGURE 11, however the right side of the wall uses a conventional concrete form that is removed after the wall is poured;
  • FIGURE 68 shows hat channels 132 as they would be laid out on a table (not shown) material is connected to the metal hat channels; wood or metal siding being shown and edge corner boards are installed at the edge of the panel;
  • FIGURE 69 shows a building panel turned upside down with the exterior finish facing upside down.
  • Metal C channels where used, as wall studs and a metal base plate being installed at both ends of the C channel;
  • FIGURE 70 illustrating a wall section shown in the opposite direction as FIGURES 68 and 69 with the exterior finish facing down.
  • Metal C channels where used as wall studs and a metal base plate is installed at both ends of the Metal C channel;
  • FIGURE 71 is similar to FIGURE 70 except the concrete is poured to the full depth of the metal C channels. The thickness of the panel depending if the panel will be used as a structural element or just as a veneer to a greater structural system;
  • FIGURE 72 illustrates a combination of a forming structure, showing a vertical wall similar to FIGURE 34 and roof section detail similar to FIGURE 36 showing how to connect a poured-in-place wall section with a precast roof panel;
  • FIGURE 73 similar to FIGURE 72 wherein a wall and roof structure is similar to
  • FIGURE 34 and where both the wall and roof structure are poured in place at the top of the wall and the ridge of the roof.
  • FIGURE 74 is an isometric representation of an ICF wall with a metal reinforcing channel as an interior support
  • FIGURE 75 is a concrete reinforcing channel and a coupling attaching two channels.
  • FIGURE 76 is a concrete reinforcing hat channel.
  • FIGURE 77 is a footing bracket assembly showing the vertical C channels extending below the interior structure of the wall form into a concrete footing, supporting the wall assembly prior to installing a concrete footing as well as stabilizing the wall assembly prior to installing concrete within the wall assembly.
  • FIGURE 78 is a footing bracket assembly showing the vertical C channels extending below the interior structure of an ICF form into a concrete footing, supporting the ICF form prior to installing a concrete footing as well as stabilizing the ICF form prior to installing concrete within the ICF form..
  • FIGURE 79 is a footing bracket used to attach a wall assembly to the ground prior to installing a concrete footing
  • FIGURE 80 - 81 are two different brackets used to attach an ICF block wall to the ground prior to installing a concrete footing.
  • FIGURE 82 is a ribbed ICF block where the concrete ribs are the concrete structure and the connecting thin concrete wall is the bracing structure.
  • FIGURE 83 is a combination of a run joist, anchor bolt and joist hanger assembly all in one piece.
  • FIGURE 84 is a combination of a metal cap, anchor bolt and joist hanger assembly all in one piece.
  • FIGURE 85 is a scaffolding brace where the brace fits on top of the wall to support a scaffold.
  • the self-contained mold according to the invention is formed by installation of two or more wall panels or the wall of several modular components placed adjacent to one another, however spaced apart to allow for concrete to form between the panels or modules.
  • the wall sections can be composed of metal construction or wood construction with the interior finish, preferably, to be the interior finish of the structure.
  • the prevention of air around the wall studs decreases the, cause for a fire to start.
  • Increasing the size of wood studs increases the strength and decreases the gauge size.
  • the wall mold also encases the ceiling joist and the floor joists into the concrete.
  • the encasement of the wood joist or steel joist is where the maximum moment occurs, that is, the greatest shear occurs due to the live and dead load weight the joists can carry.
  • the extension of the ends of the joists beyond the width of the wall studs results in the joists being encased in concrete.
  • a void has to be created at the location of the joist pocket.
  • the joist pocket must be larger than the size of the joist or beam entering into the concrete pocket.
  • the wood studs below could shrink, but the joist may not move thus reducing the settlement within the building forming systems considered wall systems and are comprised of wall forming structures.
  • FIGURE 1 the isometric shows modular building components stacked on top of each other and jointed together;
  • FIGURE IA is an enlargement of two adjacent building modular units.
  • the isometric in FIGURE 1 shows various modular units 10 that are stacked on top of each other and adjacent to one another, but are separated by a concrete wall 32a or structural/shear wall 38. It should be noted that the taller the building, the greater the wind loads are experienced. All buildings are required to withstand horizontal wind forces. The building structure must be designed for bending, requiring shear walls 38 to be added to the structure.
  • Another way to reduce bending is to install diagonal bracing between the columns in conventional construction, however by leaving a gap between modular units 10, a concrete wall 32a can be formed, creating a stronger wall and better than using diagonal braced walls.
  • Wood framing 43 or light metal framing 45 have limited structural 5 capabilities as well as fire limitations enforced by building codes. Therefore, either concrete or steel structural integrity must be used as subordinate building material have limited structural capabilities as well as fire limitations enforced by building codes. For example, to build a wood structure more than three stories high or five stories for a metal framing structure would not be permitted by building codes. Therefore, either a concrete
  • FIGURE IA A cut away section of two adjacent modules 10' and 10" is shown in FIGURE IA.
  • the modules 10 are three-dimensional structures consisting of a wall 38, a floor 16 and a ceiling.
  • the modules are built in a manufacturing plant, and finished on the interior, thereby leaving the structural system exposed on the exterior of the module where
  • modules 10' an4 10" abut one another.
  • Other walls 38 of a modular are finished with an exterior finished material directly from the manufacturing plant. Modules are shipped by truck and hoisted by crane to its specified location within the building. As one module is installed, additional horizontal or vertical steel reinforcement 30 is added between one module 10' and the other module 10". The additional steel reinforcing increases the
  • modules 10 As module 10' is installed adjacent to module 10", molds 12 are created between modules, into which concrete 32 is poured to form a concrete wall 32a. Some modules might have walls 38 that face the exterior, which can be finished with a variety of building materials and built using various wall forming structures 109, which when poured with concrete 32 become part of the concrete wall
  • the forming structures 109 can extend above, below or adjacent to another mold 12 to become part of and adjacent module.
  • a concrete floor 32b and ceiling joist's 18d are also part of the components of this module 10 that is shipped together as one unit module and are used as wall braces to secure the wall prior to pouring concrete.
  • a building module can also be shipped as molds 12 or panels 36 where the concrete is installed after
  • a module consists of separate floor panels 36a, wall panels 36b, ceiling panels 36c, and even roof panels 36d (not shown), which when installed together will complete a mold 12 of the module and a building.
  • Many different types of molds 12 can be manufactured using wood construction or metal construction to build various types of walls 38.
  • the molds can be finished with many different types of materials including drywall, fiber meshed drywall, concrete board, rigid insulation, decorative wallboard, however all the molds required a rigid board or more commonly known as a composite board.
  • Module 10' left outside concrete wall 32a is shown in FIGURE 25 and Module 10" right outside concrete wall 32a is shown in FIGURE 33.
  • Module 10 shows a concrete floor 32b and ceiling joists 18d shown in FIGURE 2 or FIGURE 4.
  • Module 10' doesn't show a ceiling, but instead shows a concrete floor 32b shown in FIGURE 37.
  • the modular wall section shows two adjacent modules 10 installed.
  • the floor 16 is constructed using an array of metal floor joists 18b with a rim joist 18a extending the full length of the module and are secured to the end of the floor joists 18b.
  • Rigid insulation 20 or floor decking 22 then is attached to the floor joists 18b and are secured to the end of the floor joists 18b.
  • Metal wall studs 24 are attached to the rim joists 18a.
  • Drywall 26 and a ceiling rim joist 18c are attached to the wall studs 24, concrete then is poured over the floor decking 22 to the outer flange 34 of the metal stud 24a thereby encasing the metal stud 24a in concrete 32 to the level of the concrete floor 32b.
  • the interior walls (not shown) are installed over the floor 16 and electrical, plumbing and heating are installed but not t shown as a part of this
  • FIGURE 2 An array of ceiling joists 18d are installed with or without drywall 26 attached and secured to the ceiling joists 18d.
  • the interior of the mold 12 therefore is left with drywall 26, metal studs 24a, concrete 32 and ceiling rim joists 18c.
  • additional reinforcing steel 30 can be added depending on the structural requirements of the concrete wall 32a for additional story modules.
  • Half of mold 12 is complete when the module 10 has been installed. The two modules 10 are shown separated with an air space 14 there between which then completes mold 12 between modules.
  • FIGURE 3 is a plan section along line B-B taken along FIGURE 2 and illustrating a concrete mold 32a (wall forming mold) formed by placing two modules adjacent one to the other. After the modules 10 are secured to the modules 10 below, wall forming ties
  • the metal wall tie 40a is a channel that is shaped to conform to the flange 34 and tip of the metal wall stud 24 or can be a channel having a web 23 and a pair of two bent ends. The web of either shaped channel covers the distance required for the thickness of the concrete wall 32a.
  • the wall- forming tie 40 slides down between the outer flanges 34 of the metal wall stud 24 of one module 10 to the outer flanges of the adjacent module.
  • FIGURE 4 appears identical to FIGURE % however in this case, the individual floor, wall and ceiling panels are manufactured at a manufacturing plant, then are trucked to the building site and installed thereat.
  • the flooring panels 36a are manufactured using light-gauge metal joists 18b and steel reinforcing 30 is installed parallel to the rim joist 18a.
  • Concrete 32 then is poured over the floor decking 22 and into a temporary form 93 that becomes a concrete beam 32a in floor panel 36a.
  • the wall panel 36b is manufactured using metal wall studs connected to a bottom base plate 27.
  • a vapor barrier 25 in the form of an ultra thin layer of plastic is placed between the flange 34 of the metal wall stud and the drywall interior surface of the completed wall panel 36b.
  • the ceiling wall panel 36c has ceiling joists 18d attached to a rim joist 18c and drywall 26 can be attached to the ceiling joists. The panels 36 are then loaded onto a truck and delivered to the job site.
  • the floor 16, wall panels 36b and ceiling panels 36c then are hoisted into position to their designated location within the building structure forming half of mold 12.
  • the interior of the mold 12 is left with a vapor barrier 25, in the form of a ultra thin layer of plastic (not shown), and drywall 26 or rigid insulation 20 is attached to the metal wall studs 24, concrete 32 and the rim joists 18c from the ceiling panel 36c.
  • a vapor barrier 25 in the form of a ultra thin layer of plastic (not shown)
  • drywall 26 or rigid insulation 20 is attached to the metal wall studs 24, concrete 32 and the rim joists 18c from the ceiling panel 36c.
  • FIGURE 5 shows two modules 10 and 10' placed adjacent to one another.
  • the two modules 10 and 10' are built exactly the same, however one of the modules 10 is a clear depiction of two adjacent modular units.
  • the concrete wall 32a including the concrete floor 32b is broken, thereby exposing the view of the adjacent module 10'.
  • the exposed module 10 shows the array of metal joists 18a of the floor. Attached to the metal studs 24a is the ceiling joists 18d and the rim joist 18c as well as the backside of the drywall 26.
  • a vapor barrier 25 is installed between the metal wall studs 24a and the drywall 26.
  • the floor assembly is exposed to the inside of the molds 12, and drywall 26.
  • the exposed area in the concrete wall 32a is the concrete beam 40 that is part of the concrete floor 32b structure.
  • the top of the wall structure below is at the base of the molds 10 and 10' along with any exposed steel reinforcing bars 30 protruding from the wall below.
  • the modular wall section shown in FIGURE 6 also shows two modules 10" and 10'" installed near each other, but separated by an air space 14.
  • One of modules 10" is shown closely separated from the wall mold 12' prior to being installed at the job site and is shown in FIGURE 6A.
  • the floor 16 is constructed using an array of wood floor joists 18f, which span the full width of the module and are connected with solid bridging 58 between each joist.
  • the joist's 18f are set on top of a structural bridge frame 17 below the floor 16, which also includes a sill plate 60 that is attached to the structural steel bridge frame 17.
  • Wood plywood decking 62 is attached to the array of floor joists 56.
  • the wall construction consists of an array of wood studs 64 with blocking 66 near the bottom and top of the wood studs 64.
  • a concrete floor 32b is added for fire resistance over the plywood subfloor, but is optional depending on local building requirements.
  • Other interior walls (not shown) are installed over the floor 16 and the electrical plumbing and heating also are installed with or without the drywall attached and secured to the plywood 62, wall studs 64 and ceiling joists 70.
  • the interior walls add additional bracing support to the exterior walls of the module.
  • the exterior of the module wall therefore is left with drywall 26, wood studs 64, blocking 60, 66, 72, floor joists 18f and ceiling joists 70.
  • additional reinforcing steel can be added depending upon the structural requirements of the concrete wall 32a for additional story modules.
  • Half of the forming mold 12' is complete when the module 10" is installed.
  • FIGURE 7 is a plan view of a concrete mold formed by placing two modules adjacent to each other.
  • the overlapping of the joists allows concrete 32 to flow under the joists 56 and 70 and therefore have a solid concrete base which permanently to rest upon after the modules 10"and 10"'are secured to the wall below and wall forming ties 40 installed between one module 10" and another module 10'".
  • FIGURE 8 shows a panelized modular sections illustrating two separate buildings installed near each other, but are separated by an air space 14 between one of the building units 10" and 10'" as shown separated from the wall mold 12'.
  • the wall, floor and ceiling building components are shown in FIGURE 8A prior to being installed at the job site. Since panel construction does not require a structural beam for transport to the job site, the construction is different from the heretofore described building units.
  • the floor panel 36a is constructed using an array of wood floor joists 56, plywood decking 62, concrete 32 and blocking 72 between the floor joists 56 and floor panel 36a.
  • the wall panel 36b consists of an array of wood studs 64 with blocking 72 attached to the wood studs and drywall 26.
  • mold 12' is completed when the array of ceiling joists 70 are installed and secured to the wood studs 64 with blocking 72 between the ceiling joists 70 and connected to floor panels 36a.
  • additional reinforcing steel can be added depending upon the structural requirements needed for the concrete wall 32a to accommodate additional building stories above.
  • a concrete floor 32b need be added over the plywood subfloor 62.
  • An array of ceiling joists 18h are installed and secured to the wood studs 64 with blocking 72 between the ceiling joists 18h and floor joists 18a.
  • additional reinforcing steel 30 can be added depending upon the structural requirements of the wall 38 for additional story modules.
  • Half of a forming mold 12' is complete when the module has been installed. After the utilities have been installed, a concrete topping is added over the plywood sub floor, but is optional depending upon local building code requirements.
  • FIGURE 9 is a very similar construction as the construction shown in FIGURE 8.
  • joist hangers 18i are used to support the floor 56 and ceiling joists 70.
  • anchor bolt 56 extends into the concrete wall 32a.
  • the floor panel 36a is constructed using an array of wood floor joists 56, which span the full width of the building module.
  • a joist hanger 18i is attached to the rim joist 54 of the floor panel 36a.
  • Plywood decking 22 is attached to the array of floor joists 56.
  • the floor panel 36a is complete.
  • the wall panel 36b consists of an array of wood studs 64 with blocking 72 near the bottom and top of the wood studs 64 with drywall 26.
  • Ceiling panel 36c consists of an array of ceiling joists 70 are attached to a rim joist 54. Joist hangers 18i and bolt assemblies 82 are used to secure the joists 56 and 70.
  • the interior of the mold 12' therefore is left with drywall 26, wood studs 64, and the blocking 72 between the ceiling joists 70 and floor joists 56.
  • additional reinforcing steel can be added depending upon the structural requirements of the concrete wall 32a for additional story modules 10" and 10'".
  • Half of a forming mold 12' is complete when the module 10" has been installed.
  • a concrete floor 16b is added for fire resistance over the plywood decking 22, but is optional depending on local building requirements.
  • a building can be built using many different types of poured-in-place wall constructions. Not all walls of a module abut one another as earlier disclosed, some are exterior walls which can be built using many different types of construction methods as shown in FIGURES 10 through 35. These walls also remain as part of the module.
  • FIGURES 10 through 12 show a thin concrete wall 32a where only a portion of the concrete wall 32a is filled with concrete 32 and the remainder of the wall interior is left exposed for future electrical installations.
  • FIGURE 10 is an isometric representation of a wall construction while FIGURE 11 is a wall section taken along lines A-A of FIGURE 10 and FIGURE 12 is a plan section taken along lines B-B of FIGURE 10.
  • FIGURE 10 the metal C channels 88 are placed in an array on a table and then, a horizontal bracing channel 46 is installed through the holes 90 formed in the web of the C channels 88.
  • Rigid insulation 20 is placed between the web 35 of the C channels 88 and snug to the horizontal bracing channel 46.
  • a hat channel 86 then is attached to the flange 34 of the C channel 88 perpendicular to the C channels.
  • the drywall 26 then is attached to the hat channels 86.
  • the space 14 created by the rigid insulation 20 between the C channels 88 and the outer drywall 26 or rigid insulation 20 is the area where concrete 32 is installed.
  • the horizontal bracing channel 46 holds the middle rigid insulation 20 from bending when any concrete or other material is installed from the top of the mold 12 into the wall forming structure 109.
  • the exposed portion of the C channels 88 act as furring strips normally required when a masonry or concrete wall 32a is finished on the interior as well as allowing electric or other items are installed prior to installation of the final drywall 26.
  • FIGURES 13 throughl5 are similar in construction to FIGURES 10-12 except here the wall forming structure 109 is constructed as a double-sided construction. Again the C channels 88 are placed in an array on a table and then horizontal bracing channels 46 are installed through rear holes 47 in the web 35 the C channel 88, however another horizontal bracing channel 46 is installed through the front hole 49 of the C channel web 35. The two horizontal bracing channels 46 secure both sides of the rigid insulation 20 in the middle of the C channel 88. A hat channel 86 is installed on the flange 34 of the C channel 88 and rigid insulation 20 is attached to hat channel 86.
  • FIGURES 16 through 18 show a simple self-contained wall system using only, hat channels 86 as its supporting system.
  • Furring hat channels 89 typically have been used as a non-combustible spacer to fur out or make a masonry or concrete wall 32a level in order to install drywall 26 or other materials, but never as a supporting structure for a wall 38.
  • FIGURE 16 is an isometric representation of a wall construction while FIGURE 17 is a wall section taken along lines A-A of FIGURE 16 and FIGURE 18 is a plan section taken along lines B-B of FIGURE 16.
  • the wall 38 is manufactured by placing furring hat channels 89 on a table, the length of the wall (not shown). Rigid insulation 20 is then placed over the furring hat channel 89 and a hat channel 86 is placed over the insulation 20 going in the opposite direction. The insulation 20 is secured by connecting the two hat channels 86 and 89 therefore locking the insulation 20 between the hat channels 86 and 89. Another hat channel 86 going in the opposite direction is connected to the second hat 5 channel 86 creating a criss-crossing structure.
  • the self-contained mold 12 is then erected and moved to the jobsite where concrete 32 or other interior material can be added between the interior structures of the form.
  • the first hat channel 89 acts as a furring strip where electrical or other items can be installed prior to the drywall 26 (shown in phantom
  • FIGURES 19 and 20 are similar in construction to FIGURES 16 to 18 except here
  • FIGURE 19 is an isometric drawing of the wall construction while FIGURE 20 is a plan section taken along line B-B of FIGURE 19.
  • the wall construction is built in the same manner, that is, hat channels 86 are placed on a table (not 5 shown) the length of the wall 38. Rigid insulation 20 is then placed over the hat channels 86 and another hat channel 86 is placed over the insulation 20 going in the opposite direction. The insulation 20 is secured by connecting the two hat channels 86 on either side of the rigid insulation 20 therefore locking the insulation 20 between the hat channels 86. Another hat channel 86 going in the opposite direction is connected to the second hat
  • channel 86 creating a criss-crossing structure and the outer rigid board 81 is installed.
  • the wall 38 is turned over and a fourth hat channel 86 is installed in the opposite direction.
  • Rigid insulation 20 or drywall 26 is then installed over the fourth hat channel 86 creating two chambers to install concrete 32 for thicker stronger concrete wall 32a.
  • FIGURES 21 through 24, is similar to FIGURES 16-18;
  • FIGURE 21 is an isometric representation of the wall construction;
  • FIGURE 22 is wall section taken along lines A-A of FIGURE 21 and
  • FIGURE 23 is a plan section taken along lines B-B of FIGURE 21 and
  • FIGURE 24 is a vertical section taken through vertical hat channel 78.
  • the FIGURES 21 through 24 differs from FIGURES 16-18 except here insulation bracing channels 83 are spaced between rigid insulation 20 and the open side of the insulation bracing channels 83 faces the interior side of the wall 38.
  • the flanges 34 of the insulation bracing channels 83 overlap the rigid insulation 20 and secure the rigid insulation 20 against the vertical hat channel 78.
  • the insulation bracing channels are 83 placed horizontally and faced down so that the open interior side is facing the table.
  • the rigid insulation 20 is spaced between the insulation bracing channels 83 so that the flanges 34 of the insulation bracing channels 83 overlaps the rigid insulation 20.
  • a vertical hat channel 78 is placed criss-cross over the insulation bracing channels 83 so that the interior side is facing the insulation bracing channels 83.
  • the vertical hat channel 78 is attached to the insulation-bracing channel 83
  • a hat channel 86 is attached to the vertical hat channel 78 thereby securing rigid insulation 20.
  • Hat channel 86 is installed parallel to the insulation-bracing channel 83 and rigid board 81 is then attached to hat channel 86.
  • Concrete 32 is then poured into the crisscrossed structure between the rigid insulation 20 and rigid board 81 after the wall 38 is erected vertically.
  • the hat channel 86 and the outer rigid board 81 can be eliminated should the wall configuration be poured in a horizontal position and erected vertically after the concrete 32 has been cured like the precast wall to be shown in FIGURE 37.
  • a hole 90 is shown connecting the insulation bracing channel 83 and the vertical hat channel 78 allowing electrical wiring to pass through the wall 38 in both a horizontal and vertical direction.
  • FIGURE 24 shows the insulation-bracing channel 83 securing the rigid insulation 20 and the vertical hat channel 78.
  • the hole 90 functions as a passage between the insulation bracing channel 83 and the vertical hat channel 78.
  • FIGURE 25 through 27 uses smaller vertical C channels 88 and horizontal hat channels 86 to create a wall forming structure.
  • FIGURE 25 is an isometric representation of the wall construction while FIGURE 26 is a wall section taken along line A-A of FIGURE 25 and FIGURE 27 is a plan section taken along line B-B of FIGURE 25.
  • FIGURE 25A is an enlarged detail showing a vertical small C channel 88' for establishing electrical access.
  • Horizontal hat channels 86 are placed on a table (not shown) the length of the wall 38.
  • Channels 88, on the right wall of the isometric are placed perpendicular to the hat channels 86 and attached to the flange 34 of the C channel and a rigid board 81 is attached to the hat channel 86.
  • the wall 38 is then turned over and a horizontal hat channel 86 is installed on the other flange 34 of the C channel 88 and rigid board 81 is attached to the hat channel 86.
  • Channels 88, on the left wall of the isometric, are placed with the web 35 parallel to the hat channels 86.
  • the hat channel 86 are connected to the lip 34' of the flange 34 of the C channel 88 and the opposite hat channel 86 is connect to the web 35 of the C channel.
  • the left wall also shows rigid insulation 20 can be installed between the two hat channels 86.
  • the horizontal hat channels 86 increase the structural integrity of the wall 38 as well as allowing the concrete 32 to flow easily around the C channels 88.
  • FIGURE 25 shows the web 35 of the ceiling rim joist 18c is attached to the flange 34 of the vertical C channel 88 for supporting the ceiling joists 18d, which is further described in FIGURE 61.
  • FIGURE 25 and FIGURE 26 shows the vertical C channel 88 extending below the mold 12 so a concrete footing can be installed simultaneously with the concrete wall 32a. By pouring the concrete at the footing, the concrete in the footing secures the wall forming structure prior to additional concrete poured in the wall 38.
  • FIGURE 25 A is an enlargement of vertical C channel 88 and a smaller vertical C channel 88'. The smaller vertical C channel 88' is located at the flange 34 of the vertical C channel 88 creating a hollow chamber for electrical wiring to be installed and connected to the horizontal hat channel 86'.
  • FIGURES 28 through 32 show a wall structure where the interior structure of the mold extends to the outside surface of the rigid board 81 or rigid insulation 20.
  • FIGURE 28 is an isometric representation of the wall construction of the wall structure while FIGURE 29 is a wall section taken along line A-A of FIGURE 28 and FIGURE 30 is a plan section taken along line B-B of FIGURE 28.
  • FIGURE 31 and FIGURE 32 are enlarged details of the end of the U channel 84.
  • FIGURE 32 shows an angle 27 attached to the web 35 of the U channel 84.
  • FIGURE 31 is similar to FIGURE 32 in that instead of adding the angle 27, the flange 34 is longer and is bent 180 degrees to extend beyond the web 35 of the U-channel 84.
  • the flange 34 or angle 27 extends beyond the web in both directions creating an H channel 84'.
  • the wall structure 85 is built by placing the H channels 84'on a table (not shown) and installing rigid insulation 20 or drywall 26 between each H channel 84'. By adding the rigid insulation 20 between each H channel 84' the flanges 34 are exposed to the outside of the wall 38.
  • the modified H channels 84' have a hole 90 in the middle so that a horizontal bracing channel 46 can be installed there through.
  • the wall structure 85 is erected vertically, the concrete 32 is poured into the mold 12 interior and presses the rigid insulation 20 against the flanges 34 of the H channel 84'.
  • the horizontal bridging channel 46 locks the array of H channels 84' into place and therefore, securing a rigid wall structure 85.
  • FIGURES 33 through 35 show a concrete wall 38 having a vertical ribbed configur-ation.
  • FIGURE 33 is an isometric view of the wall construction while FIGURE 34 is a wall section taken along line A-A of FIGURE 33 while FIGURE 35 is a plan section along line B-B of FIGURE 33.
  • the wall 38 is built first by placing horizontal hat channels on a table of the length of the wall. C channels 88 are placed perpendicular to the hat channels 86 and attached at the flange 34. Next, a rigid interior foam spacer 96 is then placed between an array of C channels 88 approximately the depth of the web 35 of the C channel 88 and less than the distance between the C channels 88.
  • the interior rigid insulation 20 is then attached to the flange 34 of the C channel 88 and the rigid interior foam spacer 96, forming the vertical ribbed configuration of the wall 38.
  • the wall 38 is turned over and a rigid board 81 is installed on a hat channel 86.
  • the holes 90 in the hat channel allow the concrete to flow easier around and through the hat channels 86.
  • Additional hat channels 86 are located at the bottom of the wall 38 due to the increase in pressure of the concrete at the bottom of the wall forming the vertical ribbed configuration of the wall 38.
  • a rigid interior foam spacer 96 is not placed at the full height of the wall 38 and is shorter at both the top and bottom of the wall 38 so a concrete beam 32d is formed at the top and bottom of the wall 38.
  • FIGURES 36 through 39 show a similar wall construction as shown in the FIGURES 33 through 35, however, here, instead of concrete being installed when the wall 5 is erected in a vertical position, the concrete is installed in a horizontal position.
  • the construction of the wall system 37 can be used either as a wall system 37 or as a floor system 37a.
  • the strength of the concrete beam 32d and floor system 37a depends on the depth of the concrete beam 32d and the thickness of the concrete floor 16b plus the amount of steel reinforcing 30 that is added.
  • the C channel 88 intent is to support the
  • the C channels 88 are spaced in an array and the horizontal bracing channels 46 connect the webs 35 of the C channels 88 creating a rigid frame.
  • a rigid board 81 is the attached to the C channel.
  • Rigid interior foam spacers 96 are placed between the metal C channels 88 to the width of the desired beam and the thickness of
  • interior foam spacers 96 is the height of the desired beam.
  • the depth of the rigid interior foam spacers 96 and the space between the foam spacers 96 determines the structural capacity of the concrete beams 32d in the ribbed concrete structure. Additional steel reinforcing 30 can be added into the mold 12 for added strength. Concrete is then poured into the mold 12 that is around the C channel 88 creating beams and above the C channels
  • the self contained mold 12 can be poured in a factory and then shipped to the job site, or can be built in place ready to be poured at the job site. However, typically, the mold 12 would be delivered to a construction site, set in place and poured in place. When the concrete 32 is cured, the mold 12 can be used as a precast wall or precast floor. Mold 12 can also be used as a poured in place floor, however temporary
  • braces would be required. Due to weight of the concrete, temporary braces (not shown) would be installed until the concrete has cured.
  • the C channels 88 will vary in height and thickness depending on the structural integrity on the span and weight requirements of the floor 16 and the number of temporary braces used to erect the flooring system 37a.
  • FIGURE 37 is similar in construction to FIGURE 36, except here the interior foam spacers 96 are tapered to be wider at the bottom of the concrete beam 32d.
  • the concrete beams 32d are poured to the top of the interior foam spacers 96 and steel reinforcing 30' is installed into the concrete beam 32d and left to cure.
  • Horizontal hat channels 86 are installed over the C channels 88 (on the right side) and the interior foam spacers 96 for additional structural support.
  • the foam spacer 96 is tapered creating additional friction and strength to support the weight of the concrete floor 32b above.
  • the two-step concrete pour allows more flexibility in construction of the flooring system 37a.
  • the concrete beam 32d in the middle shows an H channel 84' instead of the C channel 88 shown on the right side.
  • a T channel 84" is shown in the left concrete beam 32d instead of the H channel 84' and the flanges 34 of the T channel 84" also support the rigid board 81.
  • the electrical distribution systems described in Figures 21 through 26 (not shown in Figure 37) for the poured-in-place wall can also be applied for a poured-in-place floor as shown in Figure 36
  • FIGURE 38 is similar to FIGURE 37, except hat channels 86 are added between
  • the metal hat channel 86 adds strength either to support a person and the concrete 32 until it cures, the C channels 88 are deeper than the foam spacers 96 and additional reinforcing steel 30 or welded wire mesh 99 is installed and attached to the top flange 34 of the metal C channel 88.
  • FIGURE 39 is similar to FIGURE 38, except that the depth of the concrete beams
  • FIGURE 40 shows the flooring system 37a attached to a vertical poured wall system 37.
  • the wall 38 shown in FIGURE 34
  • the floor 16 (combination of FIGURE 37 and FIGURE 38) are similar, however hat channels 86 are installed above the foam spacers 96 and between the drywall 26 below the metal C channels 88.
  • the concrete floor beam 32e is shown perpendicular to the direction of the other concrete beam 32d shown in FIGURE 37.
  • the concrete floor beam 32e can be poured simultaneous with the concrete beams 32d as shown here or poured after the concrete beams 32d (shown in FIGURE 37), the ones with the (channel installed) have cured. By pouring the wall beam 32e at the time of the concrete floor 32b, a more precise fit between the floor 16 and the wall system 37 can occur.
  • horizontal concrete floor beams 32e can be installed anywhere a foam spacer 96 void occurs creating additional horizontal beams 32e, is installed between the concrete floor 32b and another wall 38 to assure a continuous structural system.
  • FIGURES 41 and 45 illustrate all various types of connectors 104 used to make the construction easier to build more and aesthetically pleasing by eliminating any exposed connectors that connects the drywall 26 to the interior structure of the mold.
  • the connector 104 has a lip 108, which can penetrate a hole 90 in the hat channel 86. After the lip 108 penetrates the hole 90, the lip 108 springs over the hole 90 and there secures the connector 104 to the hat channel 86.
  • FIGURE 41 is similar to FIGURES 13 through 15 except an H channel 84' is used in lieu of the hat channel 86.
  • the wall 38 is built placing the insulation 20' on a table (not shown) with the H channels 84' between the ends of each rigid insulation 20' .
  • the flange 34 of the H channel 84' secures the rigid insulation 20' without using a fastener.
  • the C channels 88 are installed in the opposite direction of the H channels 84' and are secured with connectors 104 (not shown) through the flange 34 of the C channel 88.
  • the remainder of the wall 38 using insulation bracing channels 83, hat channels 86 and the rigid insulation 20 is built the same as FIGURES 13 through 15. Even though the rigid insulation 20 is set in loose between the C channels 88, when the wall 38 is placed vertically and concrete 32 is installed through the top of the concrete will press against the bracing channels 46 securing the rigid insulation 20.
  • FIGURE 42 is similar to FIGURES 10 through 12 except here, H channels 84' are used in lieu of connectors connecting the rigid insulation 20.
  • the use of H channels 84' encases the edges of the rigid insulation 20 therefore allowing the wall 38 to be constructed differently.
  • the H channels 84' are first laid on a table, then rigid insulation 20 is installed between the H channels 84' securing the rigid insulation 20 and connected to smaller C channel 88' or hat channel 86.
  • the hat channels 86 are then fastened to the C channels 88 at the flange 34 and rigid insulation 20 is installed between the C channels 88.
  • the horizontal bracing channels 46 are installed through the holes 90 at the web 35 of the C channel 88.
  • the bracing channels 46 hold the rigid insulation 20 in place.
  • FIGURE 43 is similar to FIGURES 10 through 12 and FIGURE 41. Instead of the
  • the rigid insulation has a groove 103 to accept the H channel 84'.
  • the rigid insulation 20 is secured because the groove 103 is holding the rigid insulation 20 from any movement.
  • the remainder of the wall 38 is constructed the same as shown in FIGURES 10 through 12.
  • FIGURE 44 details connectors 104 that are embedded within a drywall 26 and protrude outward to become a fastening method to secure the drywall 26 to the wall forming structure 109 of the mold 12.
  • the connector 104 has a lip 108 which can penetrate a hole 90 in the hat channel 86. After the lip 108 penetrates the hole 90, the lip 108 springs over the hole 90 in the hat channel 86 and there secures the connector 104 to the hat channel 86.
  • FIGURE 45 shows connectors 104 embedded within a drywall 26 and protrude out to become a fastening method to secure the drywall 26 to the wall forming structure 109 of the mold 12.
  • the connector 104 has a lip 108 so that has a lip 108 penetrates the hole 90.
  • the stem of the connector 104 has a flange 34 added to hold the connector 104 in place.
  • Both connectors have a V carrot at the end of the stem 47 thereof.
  • the stem of the connector 104 has a flange 34 added to hold the connector in place.
  • the connectors 104 at FIGURES 44 and 45 have a V carrot at the end of the stem thereof added to hold the connector in place.
  • FIGURE 46 is built using the same wall forming structure 109 as FIGURES 19 and 20.
  • the rigid insulation 20 in the middle of the wall 38 provides a thermal break between the interior wall 119 and the exterior wall 120 and provides two separate chambers 123 and 124 for installing two different materials on either side of the wall 38.
  • the left side is shown filled with sand and the right side is shown filled with gravel.
  • the gravel stones could be heated or cooled such as a hot water or cooling coil pipe 76 to create a radiant heating or cooling system within the wall 38 and also act as a storage system for any solar heating system.
  • the gravel stones could be heated or cooled to create a heating or cooling system within the wall 38 and also act a storage system for any solar heating system.
  • a concrete beam 32d also can be poured over the sand (or gravel) and steel reinforcing bars can be installed for additional strength.
  • FIGURE 47 is built using the same wall structure as FIGURE 19 and FIGURE 20.
  • wire mesh 99 is installed over the hat channel 86.
  • a sprayed concrete finish is applied over the wire mesh 99 and allowed to protrude through the wire mesh 99, thus securing the concrete 32 the wire mesh 99.
  • the concrete will not fill the entire area between the rigid insulation 20 and the reinforcing mesh 99 and therefore, an air space 14 will develop.
  • the concrete is next troweled level and then smoothed to a desired textured finish.
  • FIGURE 48 is built using the same wall structure as FIGURE 17. Again a wire mesh 99 is installed over the hat channel 86.
  • concrete 32 is placed between the wire mesh 99 and the middle interior rigid insulation 20. Concrete 32 then is poured from the top of the wall and is allowed to flow through the reinforcing mesh 99 which can be troweled smooth prior to the concrete hardening. The concrete is then troweled and textured to the desired finish.
  • FIGURES 49 and 50 are similar to FIGURES 25 through 27 in the wall construction; however, the control joints 110 and expansion joints 111 are decorative architectural elements of a concrete wall design.
  • a control joint 110 is shown attached to a C channel 88.
  • the control joint 110 is a joint where potentially a wall 38 would have a tendency to crack and the control joint 110 allows that joint to move.
  • the control joint 110 is also used to level the excess concrete evenly over the entire panel 36 surface.
  • the V shaped groove of the control joint 110 could also be an architectural accent strip for design purposes as discussed further in FIGURES 63 through 65.
  • hi FIGURE 50 two full depth C channels 88 are shown back to back to each other with a space between their webs 35.
  • FIGURE 52 through FIGURE 53 is similar to FIGURES 13 through 15 except the exterior rigid insulation is wood siding.
  • FIGURE 52 is a vertical wall section similar to FIGURE 14 and FIGURE 53 is similar to the plan view as shown in FIGURE 15.
  • FIGURE 51 is an enlarged detail showing the horizontal wood siding attached to the wall forming structure 109.
  • Other types or styles of siding materials like aluminum or vinyl siding or other exterior finish surfacing material can be applied to the self contained mold and then remain part of the finish wall construction.
  • a finish material like siding is installed after the wall is complete, not as part of the form construction.
  • the wall construction can be built using any of the previous wall forming structures 109, however the exterior component of the wall forming structure 109 must be a vertical component in order to attach the horizontal siding 112. After the siding 112 is installed while in a horizontal position on a table (not shown), the wall is placed vertically and the wall is then ready to install concrete 32 into the mold 12.
  • a vapor barrier 25 can be installed behind the siding 112 in order to prevent any concrete 32 from passing through the siding 112.
  • the wall forming structure 109 supporting the siding 112 can be configured in many ways as previously described. Other systems available today do not have a finish exterior wall surface as part of their construction system. Usually finish materials are applied over their construction in order to create a finish wall product.
  • the plan view FIGURE 53 shows vertical angle 27 connecting the hat channels 86 from a continuous wall shown at a 90-degree angle. By installing the angles 27 at the corners, the corners are reinforced so the concrete 32 does not escape where the insulation 20 or drywall 26 intersect each other.
  • FIGS show how face bricks are part of a poured in place concrete mold prior to the wall forming structure 109 being filled with concrete.
  • One method is first building the self- contained wall system, then attaching a mesh to the wall forming structure 109. By attaching an adhesive to the mesh or cement type product and then placing the thin bricks onto the mortar, the face bricks become an integral part of the form and remain in place as part of the wall forming structure 109.
  • Another method is to first construct a brick veneer wall and then attach the forming structure to the backside of the face brick wall, m other concrete forming systems brick is not use as a form.
  • FIGURE 54 through FIGURE 56 shows an exterior finish material of face brick attached to the exterior of the wall forming structure 109.
  • FIGURE 54 is an isometric view of the construction and
  • FIGURE 55 is a wall section of FIGURE 54 taken through line A-A of FIGURE 54 and
  • FIGURE 56 is a plan view taken through line B-B of FIGURE 54.
  • FIGURES 16 through FIGURES 18 have a similar structure, however, in lieu of insulation 20 as part of the forming system, wire mesh 99 is installed over the exterior side of the wall forming structure 109.
  • An adhesive (not shown) can be installed behind each individual thin brick 128 or cement (not shown) can be installed over the wire mesh 99. The individual thin bricks 128 then are placed into the cement and allowed to dry.
  • the cement is allowed to harden to the back of the thin bricks 128, the mortar 129 can be installed between the thin bricks 128.
  • the thin bricks can be installed after the wall forming structure 109 is installed at the project site (that is when the wall is in a vertical position).
  • Other exterior wall materials such as ceramic tile or stone can be used in lieu of the thin brick 128.
  • FIGURES 57 through FIGURE 59 are similar to FIGURE 54 through FIGURE 56, except here, full width face bricks 128' are used as part of the wall forming structure 109.
  • FIGURE 57 is an isometric view of the wall construction and
  • FIGURE 58 is a vertical section taken along line A-A of FIGURE 57 and
  • FIGURE 59 is a wall section taken along line B-B of FIGURE 57.
  • the wall structure is the same as shown in FIGURES 16 through FIGURE 18, except that here, foil width face bricks replace the drywall 26. Due to the weight of face brick, a horizontal steel angle 27' is located at the bottom of the brick wall to support the brick 128' when shipping the wall.
  • vertical steel reinforcing 30 is added in the holes of the bricks for additional reinforcement.
  • An additional vertical steel reinforcing is added in the holes 92 of the bricks for additional reinforcement.
  • An additional vertical steel angle 27" is placed at the rear of the face bricks 128' and short steel reinforcing bars 30" are placed between some of the mortar joints 129 for additional support.
  • the steel reinforcing 30, as well as the vertical steel angle 27" adds temporary support until the concrete 32 can be poured within the wall forming structure 109 of which the face brick 128' acts as a mold 12 to withhold the concrete 32.
  • Many different types of wall forming structures have previously described hereinabove, however, all walls are not continuous and require corners.
  • FIGURE 60 shows how to make a corner using the wall forming structures shown in FIGURES 25 through 27.
  • the rigid insulation 20 or drywall 26 (not shown) is required to make a corner 106
  • the rigid insulation must be secured to the wall forming structure 109.
  • a metal angle 27 is installed parallel to the C channels 88 in the wall forming structure 109 and is attached at the horizontal hat channels 86.
  • some of the horizontal hat channels 86 are required to extend beyond the individual wall panel 36, so that the adjacent wall panel 36 perpendicular to it can be connected to the vertical C channels 88. This procedure has to be completed when the wall panel 36b is erected vertically and then connected.
  • FIGURE 6OA The shorter wall section is shown in FIGURE 6OA separated from the corner construction to show how various wall components are connected.
  • Conventional poured-in-place concrete walls have accent strips molds on the inside of their standard wall forms to create accents on the concrete wall when these standard wall forms have been removed. Precast concrete also provide accent strips or projections on their walls in the same manner as conventional construction.
  • FIGURES 61 and 62 show horizontal recessed grooves or horizontal projections in a poured-in-place wall.
  • FIGURE 61 and FIGURE 62 show a vertical wall section similar to that shown in FIGURE 26.
  • FIGURE 61 illustrates a vertical wall section similar to that shown in FIGURE 26.
  • FIGURE 61 shows a U-channel 84 that typically fits over the ends of a floor joist 18b.
  • the U-channel 84 is secured to the horizontal hat channels 86 that are part of the wall forming structure 109.
  • a reverse C channel 88' is installed directly below the floor joist shown on the left side of the wall section in FIGURE 61. When concrete is installed within the wall forming structure 109, the reverse C channel 88' is filled with concrete 32 giving the floor joist 18b ample structural support.
  • the U channel 84 is shown on the right side of FIGURE 61, attached to the horizontal hat channels 86 at the interior of the wall forming structure 109. In this case, however, there is no additional support below. Instead, anchor bolts 50 are installed in the web 35 of the C channel 88 and joist hangers 181 support the floor joists 18b.
  • FIGURE 62 also has a horizontal U channel 84, however, this U channel 84 is secured to the flange 34 at the C channel 88. In this case, the U channel 84 is further back in the wall forming structure 109 and there is sufficient support to achieve a proper bearing for the floor joists 18b. Also, in FIGURE 62, a modified C channel 88' protrudes from the main body of the wall 38, that is the flanges 34 of the modified C channel 88' is secured to the interior C channel 88.
  • FIGURE 65 Two steel reinforcing bars 30 are shown passing through the holes 90 in the center C channel 88 and a steel reinforcing stirrup 31 encases the two steel reinforcing 30 as well as two additional steel reinforcing 30 located in the protruding C channel 88'.
  • the protruding U channel 88', as well as the U channel 84, are used as structural elements for additional building components. Both of these channels could also be used as decorative elements shown in FIGURE 65 following.
  • FIGURE 63 and FIGURE 64 are similar appearing architectural recessed grooves.
  • FIGURE 63 is similar to FIGURE 53 except the groove 103 recess is different.
  • FIGURE 63 is similar to FIGURE 53 except here the metal angles 27 are turned so that the legs 28 of the angle 27 are exposed.
  • the one leg 28 is flush with the drywall 26 and the other leg 28' is attached to the horizontal metal hat channels 86 of the wall forming structure 109.
  • Two U channels 84 are used in the middle of the wall with an air space 14 between the webs 35 of the U channels 84.
  • the spacing of the U channels 84 allows the wall to move and, therefore, create an expansion joint 111.
  • Caulking 89 is installed between the U channels 84.
  • FIGURE 64 a vertical recess is a U channel 84 connected to the web 35 of the hat channel 86 in the wall structure 109.
  • FIGURE 65 is an elevation of a finished wall showing some of the recess and projection details.
  • the vertical grove 103 is the expansion joint 111 shown in FIGURE 63 and the vertical grove 103 on the right is FIGURE 64.
  • the horizontal projection on the top is similar to FIGURE 62 while the lower grove 103 is similar to FIGURE 61.
  • FIGURE 66 is similar to FIGURE 62, however the wall section shows how a steel bar joist is secured to the projection of the modified C channel 88' as previously described in FIGURE 62.
  • the bar joist is secured onto the ledge, a heavy steel plate 52 is required to be installed on top of the modified C channel 88'and secured with steel reinforcing 30 welded to the steel plate 52 that the steel bar joist 51 rests on.
  • FIGURE 67 illustrates the wall forming structure used in FIGURE 11 except without the horizontal hat channel 86 and the rigid insulation 20 at the outside wall.
  • a conventional concrete wall form 53 is shown which can be removed after the concrete 32 is installed.
  • a standard concrete wall tie connector 104 could be used to connect the one-half of the wall forming structure 109 of mold 12 of FIGURE 11 and the conventional concrete form 53.
  • the incorporating of a removable conventional concrete form 53 on one side of the wall allows for a concrete wall to be exposed for what- ever the reason might be.
  • a conventional concrete wall form 53 is shown except without the horizontal hat channel and the rigid insulation at the outside wall.
  • a standard concrete wall tie connector 104 could be used to connect the half of the wall forming structure 109 with the conventional concrete form 53.
  • a standard wall tie connector is broken off from the concrete wall 32a after a conventional concrete form 53 is removed.
  • a concrete wall tie 104' is shown with its end bent around a horizontal bracing channel 46 thereby securing the wall forming structure 109 to the concrete wall tie 104' without having to snap or brake off the connector 104' at the exposed concrete side of the wall 38 where the conventional concrete form 53 was located.
  • FIGURES 68-71 show configurations of exterior molds where the molds are placed horizontally upside down and concrete is filled into the mold.
  • Various exterior molds are built using some of the techniques described earlier, however here the exterior faces of the molds are placed face down and concrete is poured into the molds.
  • metal hat channels 86 are laid out in an array where a final building material is connected to the metal hat channels 86.
  • Wood or metal siding 112 is shown and the edge corner boards 126 are installed at the edge of the panel.
  • a metal channel 84 is used at the corner. Wood furring channels could be used in lieu the metal hat channels 84.
  • FIGURE 69 the exterior face of the building panel has been turned upside down. After the panel 36 is turned over so the finished exterior building surface now is facing down, another outside corner board 126a is added to complete a corner. The additional corner board 126a increases the thickness concrete, exterior finish facing down; concrete 32 is now poured inside the mold 12". Many different structures or materials can be added to this mold 12" to create different configurations. However .the result is still the same, that is, a finished building panel 36 where an exterior building material is the mold of the wall 38.
  • FIGURE 70 is a wall section shown in the opposite direction as FIGURES 68 and 69 and the exterior finish is facing down.
  • metal C channels 88 where used as the wall forming structure 109 and metal base plate 42 has been installed at both ends of the C channel 88.
  • the wood siding 112 and thin face bricks 128 were added to the C channels 88.
  • concrete 32 is poured to flow between the holes 90 into the mold 12" partially filling the mold and allowing the concrete 32 to flow between the holes 90 in the web 35 of the metal C channels 88.
  • FIGURE 71 is similar to FIGURE 70 except the concrete 32 is poured to the full depth of the metal C channels 88.
  • FIGURE 72 is illustrated as one of many wall forming structures, which can be integrated together.
  • FIGURE 72 is a detail of a vertical wall and roof section, which shows how to connect a poured-in-place wall 38 shown in FIGURE 34 to a roof panel.
  • the roof panel 36d is represented as a precast floor panel 36b such as shown in FIGURE 36, however the panel shown as a sloped roof panel 36d, horizontal beam 39 is installed as a sloped roof panel.
  • the bottom of the beams of the roof section will be notched to conform to the desired angle of the wall 38.
  • the roof panel 36d When pouring the roof panel 36d the bottom of the beams of the roof section will be notched to conform to the desired angle of the roof, so the roof panel 36d will set flat onto the walls 38.
  • middle rigid insulation 96 between one beam and another beam (the rigid insulation 20 and concrete beams are shown in FIGURE 36)
  • a horizontal beam 39 can be installed parallel to the wall is poured, a reinforcing steel bar 30a can be installed in the concrete 32 after the roof section is erected into place, the concrete beam 32b can be poured securing the panel 36d.
  • the roof precast panel 36d is not just a roof panel. It is a roof panel 36d incorporates the roof, soffit, fascia and gutter all in one panel.
  • the gutter and fascia are formed at the time the roof panel is poured.
  • the soffit is shown as a smaller C channel 88' connected the metal C channel 88 in FIGURE 36. Attached to the smaller C channels 88' is a soffit board 72' at the time the roof panel was precast. The soffit could be solid concrete, however, the smaller C channel 88' reduces the weight of the roof panel.
  • Horizontal hat channels 86" set into the concrete 32 after the panel has been leveled and ready to begin to dry. A non- flexible roof shingle, like cedar shakes can be installed.
  • the hat channels 86" have holes 90 (not shown) so air can flow under the roof shingles allowing the concrete roof structure 36d to maintain a lower temperature.
  • FIGURE 73 is similar in appearance to FIGURE 72. However, even though the roof looks similar, the wall forming structure 109 is the same as FIGURE 34, except therein the roof is at an angle.
  • a rigid roofing shingle 82 is connected to the hat channel 86 and a vapor barrier 25 (not shown) is installed between the rigid roofing shingle 82 and the hat channel 86.
  • a horizontal beam 39 will be installed parallel to the wall 38 and secured by the reinforcing bar 30a at the top of the wall 38.
  • a soffit board 72' and fascia board 72" would have to be installed at the eave of the roof panel 36d prior to the mold 12 being filled with concrete 32.
  • the mold 12 can now be poured with concrete 32 from the top of the ridge of the roof filling both the beams shown in FIGURE 36 and the horizontal beam 39.
  • the vertical C channel 88 extending above the rigid insulation 20 in FIGURE 74 is similar to FIGURE 25, however the horizontal hat channels 86 are not shown here.
  • the rigid insulation 20 is shown instead as a Insulating Concrete Form (ICF) which is manufactured using rigid insulation 20 as the exterior and interior surface of the mold 12 and connected by plastic ties (not shown) forming a wall panel 36b. Since there are so many different types of ICF' s on the market today, only the metal C channel 88 is shown at the interior of the mold 12.
  • the metal C channel 88 is placed on the interior of the ICF similar to a reinforcing steel bar 30, however the C channel 88 also acts as a vertical support for an unsupported wall panel 36b like an ICF.
  • the rigid insulation 20 of an ICF block 20' is very unstable vertically prior to concrete installed; therefore the metal C channel 88 adds the vertical support to a mold 12.
  • the C shape of a metal channel 88 is structurally stronger and deflects less than an equivalent steel reinforcing bar of the same area.
  • a screw 75 with washer 77 is installed through the rigid insulation 20 of a wall panel 36b into the metal C channel 88.
  • the C channel 88 is set in loose within the ICF block 20' and a temporary spacer (not shown) is used maintain a uniform distance from the interior of the mold 12.
  • the vertical C channel 88 in FIGURE 74 is shown enlarged in FIGURE 75.
  • the web 35 of a vertical C channel 88 is shown here with punch tabs 73.
  • the C channel 88 could be perforated metal, expanded metal or metal mesh similar to metal safety flooring grating used on scaffolding walkways. Also raised metal 5 embossing of the web (not shown) can also be used to eliminate the smooth finish produced by expanded metal C channel 88.
  • These punched tabs 73 increases the resistance of the expanded metal channels within the concrete similar to the raised area of standard steel reinforcing bars 30. The raised portion of a standard steel reinforcing bar 30, bonds with the concrete and reduces bending and increases bonding of the steel
  • FIGURE 75 also shows a U channel 84 connecting the C channel 88 and 88'
  • the bent tab 73' is used as a support for a horizontal reinforcing bar 30. At other times the bent tab 73' can be used as a spacer at the interior pf an ICF block (not shown) or as a support for securing a horizontal hat channel 86 used in FIGURE 33.
  • the C channel 88 and hat channel 86 as shown in FIGURE 75 and 76 respectively, can be manufactured using high grade plastics. Reinforcing steel bars 30 as well as the C
  • 25 channel 88 and hat channel 86 can now be manufactured using plastic and still maintain the structural integrity of the material.
  • FIGURE 76 is an enlarged view of a horizontal hat channel 86. Again like the web 35 of a C channel 88 in FIGURE 35, the diagonal portion of the horizontal hat channel 86 is shown with a large hole 90 as well as smaller holes 90'. The smaller holes
  • FIGURES 77 through FIGURES 81 show varies brackets 79 that can be used to support the C channel 88 prior to installing the concrete footing 32f.
  • FIGURE 79 shows the bracket 79 used in the construction of a concrete wall 32a shown in FIGURE 77.
  • the C channel 88 extends below the wall panel 36b and is secured to the bracket 79.
  • screws 75 can be attached to the web 35 of the bracket 79.
  • Concrete 32 is then placed in the concrete footing 32f and let to cure.
  • the wall panel is now ready to prepare to add concrete 32 within the mold 12, as the wall panel 36b is now a rigid mold and no temporary bracing will be required to keep the wall panel from moving.
  • FIGURE 78 also shows a C channel 88 installed within a wall panel 36b, however here the wall panel 36b is built using ICF blocks 20'.
  • a bracket 79 is installed at the center of a concrete footing 32f under the wall panel 36b, the wall panel 36a can be constructed.
  • the ICF blocks 20' can be installed individually at the job site or fasten together as a wall panel 36b, in either case the C channel 88 is installed within the mold
  • each ICF block 20' is installed or within a wall panel 36b if it is a panelized construction.
  • a temporary spacer (not shown) can be installed between the mold 12 interior and the flange 34 of the C channel 88 and connected by screws 75.
  • Another option is to install a permanent sleeve 97 with the screw 75 through the ICF block 20', the sleeve 97 will stop at the flange 34 of the C channel 88 allowing the screw 75 to penetrate
  • angle 27 is installed at the bottom of the ICF blocks 20' and parallel with the mold 12 in order to align the wall as a straight wall panel 36b. Also angle 27' is installed where on leg 28 is connected to the web 35 of the bracket 79, and the other leg 28' is connect to angle 27, thereby securing the ICF wall panel 36b to the bracket 79.
  • the wall panel support brackets shown in FIGURES 79 — 81 are similar.
  • the bracket 79 shown in FIGURE 79 uses a C channel 88 that has bent tabs 73' at the top and bottom of both the flanges 34. These bent tabs 73' have holes 90' in both the top and bottom bent tabs 73', so a reinforcing steel bar 30 can be hammered into the ground to secure the bracket 79. Holes 90 are installed at the web 35 of the bracket 79 to allow concrete 32 to flow through.
  • the bracket 79 in FIGURE 80 is similar to FIGURE 79, however here the web 34 of the C channel 88 is bent 90 degrees to form a bent web 35' with a lip 91 at the edges.
  • the bent web 35' and the lip 91 are used to support a wall panel 36b or ICF blocks 20' (not shown).
  • the bent web 35' can be used in lieu of using angle 27' as described in FIGURE 78.
  • the horizontal angle 27 as described in FIGURE 78 can also be installed between two brackets 79 to help stabilize the wall panel 36b.
  • the bracket 79 shown in FIGURE 81 shows a C channel 88 where the flanges 34 are parallel to the ground rather than perpendicular as shown in FIGURES 79 & 80.
  • the flanges 34 have holes 90' at both the top and bottom so reinforcing steel bars 30 can pass through to secure the bracket 79 into the ground.
  • the top flange 34 has a Hp 91 to help secure a wall panel 36c or ICF blocks 20' (not shown) onto the bracket 79.
  • the lip 91 of the bracket 79 can also penetrate the middle of the rigid insulation 20 of a wall panel 36c or ICF blocks 20' or on the exterior of the ICF blocks 20' (not shown).
  • a separate horizontal angle 27 also shown in FIGURE 78, is used to help align a concrete wall.
  • FIGURE 82 is a wall panel 36b using an ICF block 20' having the same configuration as FIGURE 33, however here an ICF block 20' is used in lieu of individual sheets of rigid insulation 20 to make the ribbed mold 12".
  • plastic ties 40b are imbedded into both sides of the ribbed mold 12" holding both sides of the ICF block 20' together.
  • Screws 75 are attached through the ribbed mold 12" to secure the ICF block 20' to the vertical C channel 88.
  • all other ICF blocks 20' are full width walls 4", 6", 8", 10" & 12" thick.
  • An array of structural concrete ribs 32g are connected by a thin 2 1 A" thick concrete wall 32a' .
  • the thin concrete wall 32a' is a non load bearing wall and by present engineering standards is calculated as a concrete floor 32b even though the concrete wall 32a' is vertical.
  • the rim joist 54 shown in FIGURE 83 is similar to the same rim joist 18a and 18c shown hi FIGURE 25 and 4a.
  • the rim joist 54 combines the anchor bolt 50 assembly as well as the joist hanger 181 into the rim joist 54.
  • the web 35 of the rim joist 54 has several bent tabs 73' that extend into the concrete wall 32a which act as an anchor bolt 50. 06
  • Holes 90" are incorporated into the bent tabs 73' for greater bonding with the concrete 32.
  • Another bent tab 73'" extends into the concrete wall 32a, but is connected to a reinforcing C channel 88 located within the wall panel 36b. By connecting the C channel 88 to the rim joist 54, a metal floor joist 18b or ceiling joist 18d can be installed and therefore can be used as a scaffold to pour the concrete wall 32a.
  • the end of the bent tabs 73' are bent to add additional strength so the rim joist 54 does not pull away from a concrete wall 32a.
  • bent tab 73" extends at right angles in the opposite direction towards the metal floor joists 18b in order to attach the metal floor joists 18b or ceiling joist 18d to the rim joist 54.
  • the bent tab 73" acts as a joist hanger 18i as previously described.
  • Holes 90' are incorporated to allow for ease in screwing the two components together. Insulation 20 (not shown) is installed over the holes 90 in the web 35 left by the formation of both bent tabs 73' and 73" prior to pouring concrete into a concrete wall.
  • FIGURE 84 is similar to FIGURE 83 except here the U channel 84 is oriented horizontally to secure ceiling joists 18d and rafters 18e to a concrete wall (not shown).
  • the metal cap 61 has bent tabs 73' that extend into a concrete wall and the ends are bent an additional 90 degrees to add additional bonding strength. Holes 90" are added to create a better bond between the bent tabs 73 ' and the concrete within the wall.
  • the reinforcing C channel 88 can also be connected to the bent tabs 73' to add additional strength to the wall panel 36b (not shown) as well as allow the ceiling joist 18d act as a support for any scaffolding (not shown) to be installed over the ceiling joist 18d.
  • bent tab 73 is bent in the opposite direction that is above the concrete wall. Screws 75 connect the bent tab 73" to the ceiling joist 18d or rafter 18e. Holes 90' are provided along the flange 34 for screws (not shown) to secure the metal cap 61 to a wall panel 36b (not shown). The holes 90 left by bent tabs 73 and 73' are large enough to pour concrete through in order to complete a concrete wall.
  • the metal C channel 88 When the metal C channel 88 is installed within a wall panel 36b, the metal C channel 88 gives the wall vertical support prior to installing concrete 32 within the wall panel 36b.
  • the metal C channel 88 as shown in FIGURE 85 gives the mold 12 rigidity to support a scaffolding brace 80.
  • the scaffold brace 80 consists of U channels 84 and a bolt assemblies 82 connected through the flanges 34 of the U channels 84.
  • One leg of the brace 84a is parallel with the wall panel 36b and another leg of the brace 84b is perpendicular to the wall.
  • a metal tie 74' passes through the holes 90 in the flange 34 of the vertical U channel 84a, through the rigid insulation 20 of the wall panels 36b and curves around the flange 34 of a C channel 88, both at the top and bottom of the vertical U channel 88 of the scaffold brace 80. Lumber (shown in ghost) will bridge between each scaffold brace 80.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne une construction de bâtiment modulaire, chaque module (10) étant constitué de moules autonomes permettant à du béton (32) de se former à l'intérieur des parois (38) de chaque module ainsi qu'entre les modules (10) quand deux ou plusieurs modules sont placés ensemble. Les capacités d'effort structural des modules sont transmises directement dans le béton (32) à l'intérieur de la paroi sans venir s'appuyer directement sur le module situé en dessous.
PCT/US2006/009306 2006-03-09 2006-03-09 Construction de batiment modulaire utilisant un ensemble moule pour beton WO2007102830A1 (fr)

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PCT/US2006/009306 WO2007102830A1 (fr) 2006-03-09 2006-03-09 Construction de batiment modulaire utilisant un ensemble moule pour beton

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PCT/US2006/009306 WO2007102830A1 (fr) 2006-03-09 2006-03-09 Construction de batiment modulaire utilisant un ensemble moule pour beton

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9234349B1 (en) 2013-08-30 2016-01-12 Convergent Market Research, Inc. Concrete panel system and method for forming reinforced concrete building components
CN108643394A (zh) * 2018-07-06 2018-10-12 武汉理工大学 一种带肋装配式剪力墙结构及其施工方法
US10364185B2 (en) 2017-04-03 2019-07-30 Michael John Mabey Light-weight, fire-resistant composition and assembly
US11933046B1 (en) * 2022-07-14 2024-03-19 Anthony Attalla Stiff wall panel assembly for a building structure and associated method(s)

Citations (4)

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Publication number Priority date Publication date Assignee Title
US3898779A (en) * 1973-10-16 1975-08-12 Apollo Plastics Modular building panels and enclosures
US5524861A (en) * 1994-04-22 1996-06-11 Modal Systems, Inc. Reusable mold for constructing housing units and method of use thereof
US6167624B1 (en) * 1995-11-13 2001-01-02 Qb Technologies, L.C. Synthetic panel and method
US6223487B1 (en) * 1998-10-06 2001-05-01 Innovative Foundations, Llc Concrete construction modules for building foundations and walls

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3898779A (en) * 1973-10-16 1975-08-12 Apollo Plastics Modular building panels and enclosures
US5524861A (en) * 1994-04-22 1996-06-11 Modal Systems, Inc. Reusable mold for constructing housing units and method of use thereof
US6167624B1 (en) * 1995-11-13 2001-01-02 Qb Technologies, L.C. Synthetic panel and method
US6223487B1 (en) * 1998-10-06 2001-05-01 Innovative Foundations, Llc Concrete construction modules for building foundations and walls

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9234349B1 (en) 2013-08-30 2016-01-12 Convergent Market Research, Inc. Concrete panel system and method for forming reinforced concrete building components
US10364185B2 (en) 2017-04-03 2019-07-30 Michael John Mabey Light-weight, fire-resistant composition and assembly
CN108643394A (zh) * 2018-07-06 2018-10-12 武汉理工大学 一种带肋装配式剪力墙结构及其施工方法
CN108643394B (zh) * 2018-07-06 2024-01-12 武汉理工大学 一种带肋装配式剪力墙结构及其施工方法
US11933046B1 (en) * 2022-07-14 2024-03-19 Anthony Attalla Stiff wall panel assembly for a building structure and associated method(s)

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