WO2009031139A2

WO2009031139A2 - Reinforced, load-bearing precast concrete wall panels

Info

Publication number: WO2009031139A2
Application number: PCT/IL2008/001186
Authority: WO
Inventors: Uzi Etgar
Original assignee: Uzi Etgar
Priority date: 2007-09-05
Filing date: 2008-09-03
Publication date: 2009-03-12
Also published as: IL185738A0; WO2009031139A3

Abstract

Presented herein is a wall assembly comprising at least two precast concrete wall panels, each precast concrete wall panel comprising a main body member that is shorter than the full height of the wall panel; at least one upper paired reinforcement member extending out from the top side of the main body member; a lower projection member that projects down from the bottom side of the main body member and that is thinner than the main body member; and at least one lower paired reinforcement member extending down from the bottom side of the main body member; wherein, a recessed area, created by the differences in thickness and in length between the main body member and the lower projection member, provides full access to the precast concrete wall panel after a floor system has been installed.

Description

REINFORCED, LOAD-BEARING PRECAST CONCRETE

WALL PANELS

FIELD OF INVENTION

[0001] This invention relates generally to modular wall assemblies, and more specifically to precast concrete wall panels.

BACKGROUND OF THE INVENTION

[0002] There are many advantages to using precast concrete components for construction, rather than pouring concrete on the site or using concrete blocks. For example, factory controlled settings enable a uniformity in the pouring and curing processes that is not available at the construction site, and components cured in a factory arrive at the construction site ready for use, a factor that substantially reduces or eliminates concrete pouring delays due to weather conditions and other uncontrollable events.

[0003] Precast concrete wall panels have been in use for decades in the modular construction of wall structures. In addition to the above, precast concrete wall panels offer further advantages. A precast panel is reasonably simple to set in place, attaching side-by-side precast panels is a straightforward procedure, and walls constructed from precast panels tend to be thinner and lighter weight than walls constructed from concrete block or poured concrete walls. Examples of precast concrete wall panels that can be used to form wall structures are shown in U.S. Pat. Nos. 4934121 and 5524405, both of which are incorporated by reference in their entirety herein. [0004] However, when precast concrete wall panels are used to construct the load- bearing walls of a multi-story building with poured concrete floors, there are other factors to consider.

[0005] A load-bearing wall of precast panels must be able to resist both lateral and vertical loads. These loads are typically transmitted to the supporting structure of the building via the interconnected joints between precast panels. Thus, in addition to providing stability, the joints between stacked precast panels must also enable transferring lateral and vertical loads to the supporting structure. Therefore, significant attention and resources must be allocated to the task of connecting, or tying together, the precast panels comprising an upper level to the precast panels comprising the level beneath.

[0006] The concrete floor between two levels of precast panels is usually cast in two sections, to ensure access to the joints between the stacked precast panels. The central region of the floor is cast first, leaving a gap around the perimeter of the floor, between the floor and the wall panels. The concrete must cure sufficiently before the panels may be secured together. Securing the precast panels together is a difficult, time-consuming, labor-intensive, exacting task involving, for example, installing a plurality of vertical anchors that are then bolted to the panels. Once the precast panels are properly joined, a second course of concrete must be cast to fill the gap between the floor and the wall. Finally, after all of the concrete has sufficiently cured, a next level of precast panels is assembled. If, during either the casting of either floor section, the weather is unfavorable, the process may be further delayed.

[0007] As an alternative to the casting a floor in two sections, International Pat. No. WO02099208, which is incorporated by reference in its entirety herein, discloses a precast concrete wall panel that may enable a floor to be cast as a single section. However, this precast panel does not provide an integrated means for transferring lateral and vertical loads to the supporting structure of the building.

[0008] Furthermore, currently available precast wall panels do not generally have sufficient strength for use in structures such as elevator shafts, stairwells, protected rooms, and bomb shelters that require additional or specialized reinforcement. This problem is often resolved by using two types of wall panels wherein a first group of panels is used for constructing the majority of the building, and a second group of panels, with increased or specialized reinforcement, is brought in or cast on site for the areas that require the additional reinforcement. This practice interrupts the workflow, as the different panels often require different installation and joining procedures.

SUMMAHY OF THE INVENTION

[0009] Hence, there is a need for a wall assembly, comprising a plurality of precast concrete wall panels, that enables the full floor to be cast as a single section, that does not restrict access to the joints between precast panels, and that also provides an uncomplicated method for securely joining stacked precast concrete wall panels. Furthermore, the precast concrete wall panels comprising such a wall assembly should have interconnecting joints that enable transferring lateral and vertical loads to the supporting structure. Moreover, there is a need for a wall assembly that comprises precast concrete wall panels that are suitable both for standard constructions and for structures that require additional or specialized reinforcement.

[0010] Accordingly, a wall assembly comprising at least two precast concrete wall panels is provided, each precast concrete wall panel comprising a main body member that is shorter than the full height of the wall panel; at least one upper paired reinforcement member extending out from the top side of the main body member; a lower projection member that projects down from the bottom side of the main body member and that is thinner than the main body member; and at least one lower paired reinforcement member extending down from the bottom side of the main body member; wherein, a recessed area, created by the differences in thickness and in length between the main body member and the lower projection member, provides full access to the precast concrete wall panel after a floor system has been installed. [0011] An important feature of the present invention are the paired reinforcement members that project out from the top and bottom of each main body member of the precast concrete wall panels. The meshing of the corresponding paired reinforcement members that occurs when precast concrete wall panels according to the present invention are stacked enables a simple and secure joining means between the stacked precast concrete wall panels without restricting access to the joints between the precast concrete wall panels.

[0012] Additionally, the main body member may be substantially rectangular in shape.

[0013] Additionally, at least one precast concrete wall panel may further comprise an upper projection member that projects up from the top side of the main body member and is thinner than the main body member.

[0014] Additionally, the height of the at least one upper paired reinforcement member may be greater than the height of the upper projection member.

[0015] Additionally, at least one lower paired reinforcement member may be shorter than the length of the lower projection member.

[0016] Additionally, the upper and lower paired reinforcement members may be disposed on the precast concrete wall panels such that, when a first precast concrete wall panel is stacked on a second precast concrete wall panel, the lower paired reinforcement members of the first precast concrete wall panel mesh with the upper paired reinforcement members of the second precast concrete wall panel.

[0017] Additionally, the distance from the top of the upper projection member to the bottom of the lower projection member may define the full length of the precast concrete wall panel.

[0018] Additionally, at least one precast concrete wall panel may further comprise at least one support column disposed on the bottom side of the main body member, wherein a first end of the at least one support column is integral to the main body member and a second end of the support column extends down to the end of the lower projection.

[0019] Additionally, at least one precast concrete wall panel may further comprise reinforcing material embedded in at least one of the main body member and the upper and lower projection members.

[0020] Additionally, at least one precast concrete wall panel may further comprise a floor support ledge at the top of the main body member for receiving an outer edge of a floor system, wherein the difference in thicknesses of the main body member and the upper projection member creates the floor support ledge.

[0021] Additionally, at least one precast concrete wall panel may further comprise a panel support ledge on the upper projection member, within which may be seated the lower projection member of a second precast concrete wall panel that has been disposed on a first precast concrete wall panel.

[0022] Additionally, at least one precast concrete wall panel may further comprise a template, with a funneled upper portion, that may be placed over the recessed area in order to supply fill material into the recessed area.

[0023] Additionally, the floor system may comprise a poured concrete or a precast concrete floor.

[0024] Additionally, at least one face of at least one precast concrete wall panel may be finished with exterior facing material.

[0025] Additionally, both faces of at least one precast concrete wall panel may be configured for interior walls.

[0026] Additionally, the upper and lower paired reinforcement members may be vertically disposed lengths of reinforcing steel bar.

[0027] Additionally, the upper paired reinforcement members may be joined to form a looped reinforcement member and the lower paired reinforcement members may be joined to form a looped reinforcement member. [0028] Additionally, at least one precast concrete wall panel may further comprise at least one lifting loop, shear recess on at least one edge of the main body member, sealing detail, exposed loop in at least one side of the main body member, and insert for attaching at least one diagonal support.

[0029] Additionally, a floor may be adapted to receive at least one precast concrete wall panel according to the present invention.

[0030] Additionally, a method for connecting at least two precast concrete wall panels is provided, wherein a first precast concrete wall panel as described above is placed over a second such precast concrete wall panel, and the lower paired reinforcement members of the first precast concrete wall panel mesh with the upper paired reinforcement members of the second precast concrete wall panel.

BRIEF DESCRIPTION OF THE FIGURES

[0031] The subject matter regarded as the invention will become more clearly understood in light of the ensuing description of embodiments herein, given by way of example and for purposes of illustrative discussion of the present invention only, with reference to the accompanying figures, wherein

Figure 1 is a perspective view of a precast concrete wall panel, according to an embodiment of the present invention, with a recessed lower area and exposed upper and lower reinforcement members, and configured for use in a wall that has at least one exterior face;

Figure 2 is an elevated view of the embodiment of Figure 1;

Figure 3 is a bottom view of the embodiment of Figure 1 ;

Figure 4 is a cross-sectional view of the embodiment of Figure 1; Figure 5A is a cross-sectional view of a first precast concrete wall pane] according to the embodiment of Figure 1, stacked on a second such precast concrete wall panel;

Figure 5B is a cross-sectional view of the precast concrete wall panels of Figure 5A, showing the assembled concrete components and various reinforcement materials; and

Figure 5C is a cross-sectional view of the arrangement of an exposed upper reinforcement member of a first panel in relation to an exposed lower reinforcement member of a second panel, according to the embodiment of Fi *CgΛure 5 A.

Figure 6 is a perspective view of a precast concrete wall panel according to another embodiment of the present invention, with a recessed lower area and exposed upper and lower looped reinforcement members, and configured for use in a wall that has at least one exterior face;

Figure 7 is an elevated view of the embodiment of Figure 6;

Figure 8 is a bottom view of the embodiment of Figure 6;

Figure 9 is a cross-sectional view of the embodiment of Figure 6;

Figure 1OA is a cross-sectional view of a first precast concrete wall panel according to the embodiment of Figure 6, stacked on a second such precast concrete wall panel;

Figure 1 OB is a cross-sectional view of the precast concrete wall panels of Figure 10A₃ showing the assembled and reinforcement the concrete components and various reinforcement materials; and

Figure 1OC is a cross-sectional view of the arrangement of an exposed upper looped reinforcement member of a first panel in relation to an exposed lower looped reinforcement member of a second panel, according to the embodiment of Figure 1OA.

Figure 11 is a perspective view of a precast concrete wall panel, according to yet another embodiment of the present invention, with a recessed lower area and exposed upper and lower reinforcement members, and configured for use in a wall that has two interior faces;

Figure 12 is an elevated view of the embodiment of Figure 11;

Figure 13 is a bottom view of the embodiment of Figure 11;

Figure 14 is a cross-sectional view of the embodiment of Figure 11;

Figure 15 is a cross-sectional view of a first precast concrete wall panel according to the embodiment of Figure 11. stacked on a second such precast concrete wall panel;

Figure 15A is a cross-sectional view of the precast concrete wall panels of Figure 15, showing the assembled and reinforcement the concrete components and various reinforcement materials; and

Figure 15B is a cross-sectional view of the arrangement of an exposed upper reinforcement member of a first panel in relation to an exposed lower reinforcement member of a second panel, according to the embodiment of Figure 15.

Figure 16 is a perspective view of a precast concrete wall panel according to a further embodiment of the present invention, with a recessed lower area and exposed upper and lower looped reinforcement members, and configured for use in a wall that has two interior faces;

Figure 17 is an elevated view of the embodiment of Figure 16;

Figure 18 is a bottom view of the embodiment of Figure 16; Figure 19 is a cross-sectional view of the embodiment of Figure 16;

Figure 20 is a cross-sectional view of a first precast concrete wall panel according to the embodiment of Figure 16, stacked on a second such precast concrete wall panel;

Figure 2OA is a cross-sectional view of the precast concrete wall panels of

Figure 20, showing the assembled and reinforcement the concrete components and various reinforcement materials;

Figure 2OB is a cross-sectional view of the arrangement of an exposed upper looped reinforcement member of a first panel in relation to an exposed lower looped reinforcement member of a second panel, according to the embodiment of Figure 20;

Figure 21A is an isometric view of a wall panel with funnel-cavities, according to some embodiments of the invention;

Fig. 2 IB is a cross-sectional view of the precast concrete wall panels of Figure 2 IA, showing the assembled concrete components and various reinforcement materials, according to some embodiments of the invention; and

Figure 21C is a cross-sectional view of a first precast concrete wall panel with a funnel-cavity according to the embodiment of Figure 2 IA, stacked on a second such precast concrete wall panel.

[0032] The figures together with the description make apparent to those skilled in the art how the invention may be embodied in practice.

[0033] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.

DESCRIPTION OF SOME EMBODIMENTS OF THE INVENTION

[0034] Disclosed herein is a wall assembly comprising at least two precast concrete wall panels 100 that is suitable for constructing continuous interior and exterior load bearing walls that enables the single casting of a concrete floor and that enables transferring lateral and vertical loads to the building structure via interconnecting joints between adjoined precast concrete wall panels 100. Further disclosed herein is a method of connecting a plurality of precast concrete wall panels 100 that comprise such a wall assembly.

[0035] Referring in detail to the accompanying figures 1-4, a precast concrete wall panel 100 according to embodiments of a wall assembly of the present invention may comprise a main body member 102, an upper projection member 110 attached to and extending beyond the top of main body member 102, at least one upper paired reinforcement member 108 protruding vertically out from the top side of main body member 102, a lower projection member 118 attached to and extending below the bottom of main body member 102, at least one lower paired reinforcement member 116 protruding vertically out from the bottom side of main body member 102, and at least two support columns 106 vertically disposed against lower projection member 118.

[0036] It is to be understood that an embodiment is an example or implementation of the invention. The various appearances of "one embodiment," "an embodiment" or "some embodiments" do not necessarily all refer to the same embodiments.

[0037] Although various features of the invention may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, the invention may also be implemented in a single embodiment. [0038] Reference in the specification to "one embodiment", "an embodiment", "some embodiments" or "other embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one embodiment, but not necessarily all embodiments, of the inventions.

[0039] It is understood that the phraseology and terminology employed herein is not to be construed as limiting and is for descriptive purpose only.

[0040] The principles and uses of the teachings of the present invention may be better understood with reference to the accompanying description, figures, and examples.

[0041] It is to be understood that the details set forth herein should not be construed as limiting any applications of the invention.

[0042] Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description below.

[0043] It is to be understood that the terms "including", "comprising", "consisting" and grammatical variants thereof do not preclude the addition of one or more components, features, steps, integers or groups thereof and that the terms are not to be construed as specifying components, features, steps or integers.

[0044] The phrase "consisting essentially of, and grammatical variants thereof, when used herein, is not to be construed as excluding additional components, steps, features, integers or groups thereof but rather that the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed composition, device or method.

[0045] If the specification or claims refer to "an additional" element, that does not preclude there being more than one of the additional element. [0046] It is to be understood that where the claims or specification refer to "a" or "an" element, such reference is not to be construed as there being only one of that element.

[0047] It is to be understood that where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.

[0048] Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.

[0049] The term "method" refers to manners, means, techniques and procedures for accomplishing a given task including, but is not limited to those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belon ¹Sgs¹³.

[0050] The descriptions, examples, methods, and materials presented in the claims and the specification are not to be construed as limiting but rather as illustrative only.

[0051] Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined.

[0052] The present invention can be implemented in the testing or practice with methods and materials equivalent or similar to those described herein.

[0053] The terms "bottom", "below", "top" and "above" as used herein do not necessarily indicate that a "bottom" component is below a "top" component, or that a component that is "below" is indeed "below" another component or that a component that is "above" is indeed "above" another component. As such, directions, components or both may be flipped, rotated, moved in space, placed in a diagonal orientation or position, placed horizontally or vertically, or similarly modified. Accordingly, it will be appreciated that the terms "bottom", "below", "top" and "above" may be used herein for exemplary purposes only, to illustrate the relative positioning or placement of certain components, to indicate a first and a second component or to do both.

[0054] Additionally, it is understood that use of the phrases "panel", "precast panel", "wall panel", "concrete panel", "concrete wall panel", and the like all refer to "precast concrete wall panels" as discussed herein.

[0055] Any publications, including patents, patent applications and articles, referenced or mentioned in this specification are herein incorporated Ln their entirety into the specification, to the same extent as if each individual publication was specifically and individually indicated to be incorporated herein. In addition, citation or identification of any reference in the description of some embodiments of the invention shall not be construed as an admission that such reference is available as prior art to the present invention.

[0056] According to embodiments of a wall assembly of the present invention, reinforced concrete wall panels 100 may be precast according to known in the art techniques, and using any appropriate materials and reinforcement materials, without departing from the scope of the invention. Additionally, the dimensions, materials, and other such parameters may vary according to the specific architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable, without departing from the scope of the invention.

[0057] Some embodiments of the present invention may comprise at least one exterior type precast concrete wall panel 100 or 150, wherein at least one face is finished with facing material suitable for exterior use and the second face may be finished with interior or exterior facing material. Examples of such embodiments are illustrated in Figures 1, 2, 3, 4, 5, 5A, 5B, 6, 7, 8, 9, 10, 1OA, 1OB. 21A, 21B and 21C. Some other embodiments of the present invention may comprise at least one interior type precast concrete wall panel 160 or 170, wherein both faces may be configured for interior walls. Examples of such embodiments are illustrated in Figures 11, 12, 13, 14, 15, 15A, 15B, 16, 17, 18, 19, 20, 2OA and 2OB.

[0058] For the sake of brevity and clarity, reference herein is made primarily to a precast concrete wall panel 100. However, it is understood that all references to and descriptions of precast concrete wall panel 100 may apply equally to all embodiments of the present invention, including the above disclosed exterior type precast concrete wall panel 150, interior type precast concrete wall panel 160, and interior type precast concrete wall panel 170, unless otherwise and specifically stated.

[0059] A precast concrete wall panel 100 according to embodiments of a wall assembly of the present invention may further comprise reinforcing material 126, such as, inter alia, a net constructed from reinforcing steel bars (rebar) that is, for example, embedded in at least one of main body member 102, upper projection member 110, and lower projection member 118. It is understood, that other materials and constructions may be used for reinforcing the components of precast concrete wall panel 100 in order to provide a long-lasting, robust, sturdy, and versatile precast concrete wall panel 100.

[0060] The overall configuration of precast concrete wall panel 100 is determined according to the relevant architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable.

[0061] According to some embodiments, main body member 102 of precast concrete wall panel 100 may be substantially rectangular in shape and comprises the majority of precast concrete wall panel 100. Additionally, main body member 102 is shorter than the full height of precast concrete wall panel 100.

[0062] The size and configuration of main body member 102, as well as the materials used to manufacture main body member 102, are intended to withstand, inter alia, the vertical and lateral loads, wind shear, impacts, and other stresses that commonly effect wall structures. According to embodiments of a wall assembly, main body member 102 may be further constructed and reinforced to withstand the greater stresses created by, for example, powerful blasts from exploded ammunition, earthquakes, and hurricanes.

[0063] Main body member 102 of precast concrete wall panel 100 may further comprise additional, optional components including, inter alia, lifting loops 104, shear recesses on the sides, top and bottom of main body member 102, sealing details, exposed loops in the sides of main body member 102, inserts to attach, for example, diagonal supports, and other such components as are known in the practice of manufacturing and using precast concrete walls panels.

[0064] Precast concrete wall panel 100 may further comprise an upper projection member 110 that projects up beyond the top of main body member 102.

Upper projection member 110 is a substantially planar member that is thinner than main body member 102. Upper projection member 110 may be cast together with main body member 102 of precast concrete wall panel 100 so that upper projection member 110 is integral to precast concrete wall panel 100. The thickness and reinforcement of upper projection member 110 may be determined according to the architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable.

[0065] Precast concrete wall panel 100 may be configured so that a vertical face of upper projection member 110 and a vertical face of main body member 102 form a single surface, as seen in Figures 4 and 9.

[0066] According to some embodiments of a wall assembly of the present invention, precast concrete wall panel 100 may further comprise a panel support ledge 114 disposed on the topmost edge of upper projection member 110. Panel support ledge 114 provides a seat which may accommodate a lower projection member 118 (described below) of a first precast concrete wall panel 100 that has been disposed on a second precast concrete wall panel 100. The shape and configuration of panel support ledge 114 enables panel support ledge 114 to provide a stable and sturdy area on which to seat a second precast concrete wall panel 100. It is understood that other configurations consistent with industry practice may also be used in order to provide a stable and sturdy area on which to rest a second precast concrete wall panel 100, without departing from the scope of the invention.

[0067] Precast concrete wall panel 100 may further comprise a floor support ledge 112 that enables embodiments of the present invention to receive, for example, an outer edge of a floor system 500. According to some embodiments, floor support ledge 112 is the surface area created by the difference between the thicknesses of main body member 102 and upper projection member 110 enabling engaging with the side surface of floor system 500. According to some other embodiments, floor support ledge 112 may be the top edge of main body member 102. It is understood that other configurations consistent with industry practice may also be used in order to provide a stable and sturdy area on which to receive and support a floor system 500 without departing from the scope of the invention.

[0068] According to some embodiments of the invention, as illustrated in

Figures 5A and 5B₃ floor system 500 may be substantially perpendicular to main body member 102 of each wall panel 100 interlocking floor system 500 there between.

[0069] According to some embodiments of a wall assembly of the present invention, a floor system 500 received by floor support ledge 112 may comprise, for example, a poured concrete floor or a precast floor slab. According to other embodiments, floor system 500 may. in fact, be a ceiling or a floor and ceiling component. It is further understood that other materials, constructions, and configurations could be used for a floor system 500 without departing from the scope of the invention.

[0070] Disposed across the length of floor support ledge 112 is a plurality of upper paired reinforcement members 108 that extend up from main body member 102.

[0071] A first end of upper paired reinforcement member 108 is disposed within main body member 102 of precast concrete wall panel 100 far enough to cooperatively engage reinforcement material 126 or to provide an adequate anchoring length for main body member 102 or both. [0072] A second end of upper paired reinforcement member 108 is of sufficient length to extend up beyond the top of precast concrete wall panel 100, and into a recessed area 120 of another precast concrete wall panel 100 stacked thereon.

[0073] According to some embodiments of a wall assembly of the present invention, upper paired reinforcement members 108 may be arranged in at least two rows on floor support ledge 112.

[0074] According to some embodiments, upper paired reinforcement members

108 may comprise, for example, vertically disposed lengths of rebar that are anchored within main body member 102 of precast concrete wall panel 100. According to some other embodiments, the individual components comprising upper paired reinforcement members 108 may extend up from vertical members of reinforcement material 126 embedded within main body member 102. For example, where reinforcement material 126 is a reinforcement net of rebar, the rebar and the members comprising upper paired reinforcement members 108 may be welded together, or the rebar comprising reinforcement material 126 may extend up from of main body member 102 to further function as upper paired reinforcement members 108.

[0075] The material comprising upper paired reinforcement members 108 and dimensions such as the length of the exposed portion of each upper paired reinforcement member 108 and the depth to which the embedded portions of upper paired reinforcement members 108 are anchored within main body member 102, are determined according to the architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable.

[0076] Precast concrete wall panel 100 may further comprise a lower projection member 118 that projects down beyond the bottom of main body member 102. Lower projection member 118 is a substantially planar member that is thinner than main body member 102. Lower projection member 118 may be cast together with main body member 102 of precast concrete wall panel 100 such that lower projection member 118 is an integral part of precast concrete wall panel 100. The thickness and reinforcement of lower projection member 118 comply with the overall construction and design requirements of precast concrete wall panel 100.

[0077] According to some embodiments, precast concrete wall panel 100 is configured so that a vertical face of lower projection member 118 and a vertical face of main body member 102 form a single surface, as seen in Figures 4 and 9. According to some other embodiments of the present invention, lower projection member 118 may be disposed along a center portion of the bottom side of main body member 102. Such an embodiment is shown in Figures 11, 12, 13, 14, 15, 15A, and 15B, which describe an interior type precast concrete wall panel 160.

[0078] The distance from the top of upper projection member 110 to bottom of lower projection member 118 defines the full length of precast concrete wall panel 100.

[0079] According to embodiments of a wall assembly of the present invention, the concrete on the inner face of lower projection member 118 may be, for example, roughened with horizontal slots 122 in order to increase the strength of the bond between precast concrete wall panel 100 and any fill material 305 that may be used, for example, to fill recessed area 120. Horizontal slots 122 may be created according to known in the art methods, for example, by combing the inner face of lower projection member 118 after casting precast concrete wall panel 100 or by adding texture to the template used to cast precast concrete wall panel 100. It should be understood that horizontal slots 122 are not necessary to use embodiments of the present invention, and are merely an optional feature.

[0080] According to some embodiments of a wall assembly of the present invention, lower projection member 118 may further comprise a toe 124 disposed on the bottom edge of lower projection member 118. According to such embodiments, toe 124 further ensures the secure seating of a first precast concrete wall panel 100 that is stacked over a second precast concrete wall panel 100. For example, toe 124 of a first precast concrete wall panel 100 may be configured to match the shape of a panel support ledge 114 of a second precast concrete wall panel 100 on which said first precast concrete wall panel 100 is to be stacked.

[0081] The differences in thickness and in length between main body member

102 and lower projection member 118 create a recessed area 120.

[0082] Recessed area 120 ensures full access to precast concrete wall panel

100, a feature that enables precast concrete wall panel 100 to be fully secured in place after a floor system 500 has been installed, while also eliminating the need to leave a gap around the perimeter of floor system 500. As a result, there is no need to pour a second course of concrete to finish construction of floor system 500.

[0083] The dimensions of recessed area 120 are determined by architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable, as well as the requirements and design of the other components comprising precast concrete wall panel 100.

[0084] Precast concrete wall panel 100 may further comprise at least two support columns 106. According to embodiments, support columns 106 are vertically disposed in bottom recess 120, against lower projection member 118, wherein a first end of support column 106 is integral to main body member 102 and a second end of support column 106 extends down to the end of lower projection member 118.

[0085] Support columns 106 serve several purposes. Support columns 106 stabilize precast concrete wall panels 100 during assembly of, for example, a wall, and they also help distribute the weight of precast concrete wall panel 100, which improves the capacity for precast concrete wall panel 100 to bear its own weight.

[0086] The combined thickness of lower projection member 118 and support column 106 is less that the total thickness of precast concrete wall panel 100.

[0087] Support columns 106 may be reinforcement according to architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable. [0088] Other support members, both permanent and temporary, may also be provided to help hold precast concrete wall panels 100 steady during assembling, according to known in the art techniques including, for example, diagonal supports that brace the upper part of precast concrete wall panel 100.

[0089] According to some embodiments, precast concrete wall panel 100 may further comprise, for example, metal plates 107 disposed, for example, at the bottoms of support columns 106. Such embodiments may be useful for further strengthening the connection of a precast concrete wall panel 100 to the building structure or the connection between two stacked precast concrete wall panels 100. Metal plates 107 may, for example, be used according to known in the art techniques to attach a precast concrete wall panel 100 to, for inter alia, a foundation or a precast concrete wall panel 100 of a lower level.

[0090] Along the bottom side of main body 102, which side also comprises the top of recessed area 120, are disposed a plurality of lower paired reinforcement members 116, that extend down from the top of recessed area 120 to the bottom of precast concrete wall panel 100.

[0091] A first end of lower paired reinforcement member 116 is disposed within main body member 102 of precast concrete wall panel 100 far enough to cooperatively engage reinforcement material 126 or to provide an adequate anchoring length for main body member 102 or both.

[0092] According to some embodiments, lower paired reinforcement members

116 may comprise, for example, vertical lengths of rebar that are anchored within main body member 102 of precast concrete wall panel 100. According to some other embodiments, the individual components comprising lower paired reinforcement members 116 may extend down from vertically disposed members of reinforcement material 126 embedded within main body member 102. For example, where reinforcement material 126 is a reinforcement net of rebar, the rebar and the members comprising lower paired reinforcement members 116 may be welded together, or the rebar comprising reinforcement material 126 may extend down from of main body member 102 to further function as lower paired reinforcement members 116.

[0093] A second end of lower paired reinforcement members 116 comprises an exposed portion of lower paired reinforcement member 116. The length of the exposed portion of each lower paired reinforcement member 116 is shorter than the height of recessed area 120. Therefore, lower paired reinforcement members 116 project down from the top of recessed area 120 towards the bottom, but not to the bottom, of precast concrete wall panel 100. For example, lower paired reinforcement members 116 of some embodiments may stop a few centimeters above the bottom of precast concrete wall panel 100.

[0094] According to some embodiments, the individual components that comprise lower paired reinforcement members 116 may be arranged along the bottom side of main body member 102 into at least two rows that are parallel to lower projection member 118, creating an exterior row of lower paired reinforcement members 116 and in interior row of lower paired reinforcement members 116.

[0095] According to embodiments of a wall assembly of the present invention configured for interior use, such as an interior type precast concrete wall panel 160 or an interior type precast wall panel 170, at least one of the rows formed by lower paired reinforcement members 116 may function together with at least one reinforcement material 126 of precast concrete wall panel 100 in place of lower proj ection member 118.

[0096] Additionally, according to embodiments of a wall assembly of the present invention configured for interior use, such as an interior type precast concrete wall panel 160 or an interior type precast wall panel 170, lower paired reinforcement members 116 may be arranged into two rows, wherein one row is disposed on each recessed area 120, as can be seen in Figures 13, 14, and 15.

[0097] The materials comprising lower paired reinforcement members 116 and dimensions such as the length of the exposed portion of each lower paired reinforcement member 116 and the depth to which the embedded portions of lower paired reinforcement members 116 are anchored within main body member 102 are determined according to the architectural, structural, engineering, and manufacturing requirements and local building code specifications and regulations, as applicable.

[0098] According to embodiments of a wall assembly of the present invention, upper paired reinforcement members 108 and lower paired reinforcement members 116 are disposed on a plurality of precast concrete wall panels 100 such that when a first precast concrete wall panel 100 is stacked on a second precast concrete wall panel 100, lower paired reinforcement members 116 of first precast concrete wall panel 100 mesh with and cooperatively engage upper paired reinforcement members 108 of second precast concrete wall panel 100. Once the meshed upper paired reinforcement members 108 and lower paired reinforcement members 116 are connected, they provide substantially continuous reinforcement as well as means for transferring lateral and vertical loads from precast concrete wall panels 100 to the supporting structure.

[0099] According to some embodiments of a wall assembly of the present invention, upper paired reinforcement members 108 may be bent, for example, into loops, creating looped reinforcement members 202 and lower paired reinforcement members 116 may be bent, for example, into loops, creating looped reinforcement members 204. Examples of such embodiments are shown in Figures 6, 7, 8, 9, 10, 1OA, and 1OB, which describe an exterior type precast concrete wall panel 150, and Figures 16, 17, 18, 19, 20, 2OA, and 2OB, which describe an interior type precast concrete wall panel 170.

[00100] According to such embodiments, looped reinforcement members 202 may be comprised of, for example, a single length of rebar, and looped reinforcement members 204 may be comprised of, for example, a single length of rebar.

[0100] Where either exterior type precast concrete wall panels 150 or interior type precast concrete wall panels 170, - with upper looped reinforcement members 202 and lower looped reinforcement members 204 - are used to construct a structure, a first precast concrete wall panel 150 or 170 may be stacked on a second precast concrete wall panel 150 or 170, and lower looped reinforcement members 204 of a first precast concrete wall panel 150 or 170 mesh with the upper looped reinforcement members 202 of a second precast concrete wall panel 150 or 170. Horizontally disposed locking rebar 138 may be inserted through the joint created by the meshed loops of looped reinforcement members 202 and 204 and used to secure together looped reinforcement members 202 and 204 and reinforce the joint.

[0101] According to some embodiments of a wall assembly of the present invention, an interior type precast concrete wall panel 160 or an interior type precast concrete wall panel 170 or both may be provided, wherein both faces of interior type precast concrete wall panels 160 and 170 may be finished or treated for use in the construction of interior walls. Interior type precast concrete wall panels 160 and 170 may also be used together with exterior type precast concrete wall panels 100 and 150.

[0102] As can be seen in Figures 11, 12, 13, 14. 15, 15A, and 15B, an interior type precast concrete wall panel 160 according to some embodiments of the present invention may be equipped with two recessed areas 120 but has no upper projection member 110.

[0103] As can be seen in Figures 16, 17, 18, 19, 20_; 2OA, and 20B, an interior type precast concrete wall panel 170 according to some embodiments of the present invention may be have neither a recessed area 120 nor an upper projection member 110.

[0104] According to either such embodiment, upper projection member 110 may be replaced by the upper paired reinforcement members 108 that may be configured to cooperate with reinforcement net 126.

[0105] According to some embodiments of a wall assembly of the present invention, precast concrete wall panel 100 may further comprise a filling template 300 with a funneled upper portion 302. Template 300 may be placed over recessed area 120 in order to supply fill material 305 into recessed area 120. According to some embodiments, filling template 300 comprises a single funneled upper portion 302 along the full length of precast concrete wall panel 100. According to some other embodiments, filling template 300 may comprise a plurality of shorter fiinneled upper portions 302 disposed along precast concrete wall panel 100 at predetermined intervals.

[0106] The placement of fiinneled upper portions 302 along filling template

300 and the determination of whether to use one or more funneled upper portions 302 is determined according to engineering, architectural, structural, and manufacturing requirements and local building code specifications and regulations, as applicable.

[0107] It is understood that a filling template 300 is not necessary to use precast concrete wall panel 100. It should be further understood that other methods may be used to supply fill material 305 into recessed area 120 without departing from the scope of the invention. Additionally, fill material 305 may be any type of material suitable for filling gaps, recesses, and other open areas, according to known in the art techniques.

[0108] In order to more fully describe the present invention, the following describes an exemplary mode of use.

[0109] According to embodiments, precast concrete wall panels 100 may be cast at a remote location, according to known in the art manufacturing methods. Strengthening and reinforcing elements, including inter alia, wire mesh and rebar may be cast within each precast concrete wall panel 100 according to the architectural, structural, engineer, and manufacturing requirements and local building code specifications and regulations, as applicable. Additionally, horizontal slots 122 may be applied to recessed area 120 according to the specifications. Precast concrete wall panels 100 may be transported to the construction site after properly curing.

[0110] On the construction site, a first level of precast concrete wall panels

100 may be erected according to standard construction processes, and adjacent precast concrete wall panels 100 may be tied together according to standard construction processes. If required, locking rebar 138 may be disposed horizontally along recessed area 120 and tied or otherwise attached to lower paired reinforcement members 116, consistent with industry standards.

[0111] According to embodiments of a wall assembly comprising at least one precast concrete wall panel 150 or 170 that are equipped with upper looped reinforcement members 202 and lower looped reinforcement members 204, locking rebar 138 may be inserted into each corner of the substantially rectangular area created by the overlapped loops of reinforcement members 202 and lower looped reinforcement members 204 and locking rebar 138 may be attached as described above.

[0112] Once a first level of precast concrete wall panel 100 is assembled and set in place, recessed areas 120 may be filed. Filling template 300 may be positioned over a recessed area 120 of at least one precast concrete wall panel 100. Filling template 300 is positioned such that funneled upper portion 302 is accessible.

[0113] According to embodiments comprising an exterior type precast concrete wall panel 100 or 150, a single filling template 300 may be used. According to embodiments comprising an interior type precast concrete interior wall panel 160 or 170, there may be two filling templates 300, one for each recessed area 120.

[0114] Fill material 305 may be poured into recessed area 120 of precast concrete wall panel 100 through funneled upper portion 302 of filling template 300. Fill material 305 may be poured until it is substantially level to the top of funneled upper portion 302 of filling template 300 in order to ensure that recessed area 120 is sufficiently filled. It is preferable that fill material 305 be non-shrinking type concrete or grout.

[0115] According to some embodiments, filling template 300 comprises a single funneled upper portion 302 along the full length of precast concrete wall panel 100. According to other embodiments, filling template 300 may comprise a plurality of short funneled upper portions 302 disposed along precast concrete wall panel 100, wherein the placement of funneled upper portions 302 is determined according to the engineering design. [0116] Filling template 300 may be removed after fill material 305 has set.

[0117] A next floor system 500 may now be set in place. Floor system 500 is seated on floor support ledge 112 of a wall comprising precast concrete wall panels 100, with the outer edge of floor system 500 abutting against precast concrete wall panels 100. Upper paired reinforcement members 108 extend up beyond the top surface of floor system 500. Floor system 500 may be cast or otherwise installed according to known in the art techniques.

[0118] Once floor system 500 is in place, a next level of wall panels 100 may be assembled.

[0119] Precast concrete wall panels 100 of the second level are lifted into place, using known in the art techniques. When a first precast concrete wall panel 100 of an upper level is set in place on a second precast concrete wall panel 100 below, lower paired reinforcement members 116 of first precast concrete wall panel 100 cooperatively engage with upper paired reinforcement members 108 of second precast concrete wall panel 100. This cooperative engagement enables the interconnected joints to transfer lateral and vertical loads to the supporting structure.

[0120] With floor system 500 in place, upper paired reinforcement members

108 and lower paired reinforcement members 116 also cooperatively engage floor system 500. Figures 5, 10, 15, and 20 clearly describe this connection.

[0121] Recessed area 120, which is located at the lowermost region of a precast concrete wall panel 100, enables access Tr ^"upper paired reinforcement members 108. lower reinforcement members 116. and any additional anchoring components; therefore, there is no need to cast floor system 500 in two sections, thus saving time and, consequently money.

[0122] The second level of precast concrete wall panel 100 may be attached to the first level of precast concrete wall panel 100 as described above, and the process continues as needed. [0123] According to some embodiments of t of a wall assembly of the present invention, as illustrated in Figures 21A, 21B and 21C, precast concrete wall panel 100 may further comprise one or more funnel-cavities 20. Template 300 may be placed over recessed area 120 in order to supply fill material 305 into recessed area 120. Funnel-cavities 20 may be concaved niches curved in the lower part of main body member 102, curved above lower paired reinforcement members 116 or anywhere else above recessed area 120, to allow filling recessed areas 120 with fill materials.

[0124] While the invention has been described with respect to a limited number of embodiments, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of some of the embodiments. Those skilled in the art will envision other possible variations, modifications, and applications that are also within the scope of the invention. Accordingly, the scope of the invention should not be limited by what has thus far been described, but by the appended claims and their legal equivalents. Therefore, it is to be understood that alternatives, modifications, and variations of the present invention are to be construed as being within the scope and spirit of the appended claims.

Claims

What is claimed is:

1. A wall assembly comprising at least two precast concrete wall panels, each precast concrete wall panel comprising:

- a main body member that is shorter than the full height of the wall panel;

- at least one upper paired reinforcement member extending out from the top side of the main body member;

- a lower projection member that projects down from the bottom side of the main body member and that is thinner than the main body member; and

- at least one lower paired reinforcement member extending down from the bottom side of the main body member;

wherein,

a recessed area, created by the differences in thickness and in length between the main body member and the lower projection member, provides full access to the precast concrete wall panel after a floor system has been installed, wherein said recessed area enables engaging with the side surface of said floor system.

2. The wall assembly of claim 1. wherein the main body member is substantially rectangular in shape.

3. The wall assembly of claim 1, wherein at least one precast concrete wall panel further comprises an upper projection member that projects up from the top side of the main body member and is thinner than the main body member.

4. The wall assembly of claim 3, wherein the height of the at least one upper paired reinforcement member is greater than the height of the upper projection member.

5. The wall assembly of claim 1, wherein the at least one lower paired reinforcement member is shorter than the length of the lower projection member.

6. The wall assembly of claim 1, wherein the upper paired reinforcement members and the lower paired reinforcement members are disposed on the precast concrete wall panels such that, when a first precast concrete wall panel is stacked on a second precast concrete wall panel, the lower paired reinforcement members of the first precast concrete wall panel mesh with the upper paired reinforcement members of the second precast concrete wall panel.

7. The wall assembly of claim 1, wherein the distance from the top of the upper projection member to the bottom of the lower projection member defines the full length of the precast concrete wall panel.

8. The wall assembly of claim I₅ wherein at least one precast concrete wall panel further comprises at least one support column disposed on the bottom side of the main body member, wherein a first end of the at least one support column is integral to the main body member and a second end of the at least one support column extends down to the end of the lower projection.

9. The wall assembly of claim I₅ wherein at least one precast concrete wall panel further comprises reinforcing material embedded in at least one of the main body member, the upper projection member and the lower projection member.

10. The wall assembly of claim I₃ wherein at least one precast concrete wall panel further comprises a floor support ledge at the top of the main body member for receiving an outer edge of a floor system, wherein the difference in thicknesses of the main body member and the upper projection member creates the floor support ledge.

11. The wall assembly of claim I₅ wherein at least one precast concrete wall panel further comprises a panel support ledge on the upper projection member, within which sits the lower projection member of a second precast concrete wall panel that has been disposed on the precast concrete wall panel of claim 1.

12. The wall assembly of claim 1, wherein at least one precast concrete wall panel further comprises a template, with a funneled upper portion, that is placed over the recessed area in order to supply fill material into the recessed area.

13. The wall assembly of claim 1, wherein the floor system comprises a poured concrete floor.

14. The wall assembly of claim 1, wherein the floor system comprises a precast concrete floor.

15. The wall assembly of claim 1, wherein at least one face of at least one precast concrete wall panel is finished with exterior facing material.

16. The wall assembly of claim 1, wherein both faces of at least one precast concrete wall panel are configured for interior walls.

17. The wall assembly of claim 1, wherein the upper paired reinforcement members and the lower paired reinforcement members are vertically disposed lengths of reinforcing steel bar.

18. The wall assembly of claim 1, wherein the upper paired reinforcement members are joined to form a looped reinforcement member and the lower paired reinforcement members are joined to form a looped reinforcement member.

19. The wall assembly of claim 1, wherein at least one precast concrete wall panel further comprises at least one of a lifting loop, a shear recess on at least one edge of the main body member, a sealing detail, an exposed loop in at least one side of the main body member, and an insert for attaching at least one diagonal support.

20. The wall assembly of claim 1, wherein a floor is adapted to receive at least one precast concrete wall panel of claim 1.

21. The wall assembly of claim 1 , wherein at least one precast concrete wall panel further comprises a template and at least one funnel-cavity to enable supplying fill material into said recessed area,

wherein said at least one funnel-cavity is a concaved niche curved in the main body member, wherein said niche is disposed curved above the said recessed area.

22. A method for connecting at least two precast concrete wall panels, wherein a first precast concrete wall panel comprising

- a main body member that is shorter than the full height of the wall panel;

at least one upper paired reinforcement member extending out from the top side of the main body member;

is placed over a second precast concrete wall panel comprising

- a substantially rectangular main body member that is shorter than the full height of the wall panel;

- a lower projection member that projects down from the bottom side of the main body member and that is thinner than the main body member; and at least one lower paired reinforcement member extending down from the bottom side of the main body member;

wherein the lower paired reinforcement members of the first precast concrete wall panel mesh with the upper paired reinforcement members of the second precast concrete wall panel.

23. The method of claim 22 for connecting at least two precast concrete wall panels, wherein the main body member is substantially rectangular in shape.

24. The method of claim 22 for connecting at least two precast concrete wall panels, wherein a floor system is adapted to receive at least one precast concrete wall panel.