WO2012060863A2

WO2012060863A2 - Wall panel construction and method for in situ assembly

Info

Publication number: WO2012060863A2
Application number: PCT/US2011/001821
Authority: WO
Inventors: Allen R. Moses
Original assignee: Moses Allen R
Priority date: 2010-11-01
Filing date: 2011-10-27
Publication date: 2012-05-10
Also published as: IL226058A0; WO2012060863A3

Abstract

A wall panel construction for in situ assembly includes a plurality of parallel elongate insulating members uniformly spaced from each other to form elongate substantially parallel channels between each two adjacent insulation members. Elongate attachment members extend along the channels proximate to the inner end surfaces. Concrete ribs fill voids between adjacent insulating members to fill said channels to form load-supporting concrete columns extending along the length directions of the insulation members. A sheathing panel abutts outer end surfaces. Fasteners attach the elongate attachment members and sheathing panel to the ribs, the inner end surfaces defining a plane substantially parallel to the sheathing panel suitable for attachment to a sheet of plaster board to cover the insulating members when incorporated into a building structure. A building structure and method of assembling the wall panels are also described.

Description

WALL PANEL CONSTRUCTION AND METHOD

FOR IN SITU ASSEMBLY

CROSS REFERENCE TO RELATED APPLICATION

BACKGROUND OF THE INVENTION

. Field of the invention

The invention generally relates to the field of construction and, more specifically, to wall panel and method for in situ assembly at a construction site.

2. Description of the prior art

In architecture and the construction trades in situ refers to construction which is carried out at a building site generally using raw materials. Compare that with prefabricated construction, in which building components are made in a factory and then transported to the building site for assembly. For example, concrete slabs may be in situ or prefabricated. In situ techniques are often more labour-intensive, and take longer, but the materials are cheaper, and the work is more versatile and adaptable. Prefabricated techniques are usually quicker to use, saving labor costs, but factory- made parts can be expensive. They are also inflexible, and must often be designed on a grid, with all details fully calculated in advance. Prefabricated units may require special handling and incur increased shipping costs due to increased dimensions and greater bulk.

While in situ constructions date back to the Egyptian pyramids and before prefabricated techniques are associated more with the Industrial Revolution. Both forms of construction have proliferated as housing demands have increased in developed and developing countries. Factors typically considered in deciding which construction to use include the availability of raw materials at a building site, costs of building materials, proximity of the building site to industrial facilities, costs of transporting materials to the building site, the ability to produce construction modules such as wall panels and the like having desired properties, etc. Because in situ constructions tend to be more labor-intensive there has been a need to produce construction components, such as wall panels, that minimize requirements for manual labor and, therefore, the cost of such components. Also, known panel constructions, while provide desired structural properties, including bearing strength, such panels are not inherently insulated and insulation must be added to the panels at some point during the construction, requiring additional labor and material costs. While numerous panel constructions have been known and proposed, they continue to be impractical for many applications, especially in remote regions or constructions in developing countries where there is a significant demand for constructions that provide suitable housing and shelter that is both low cost but also provides desired properties such as insulation from the heat and cold and is less prone to damage due to natural disasters, such as earthquakes.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide a wall panel construction that does not have the disadvantages inherent in prior wall panel constructions.

It is another object of the invention to provide prefabricated wall panel constructions that can be produced in situ. It is yet another object of the invention to provide a wall panel construction that is simple and inexpensive to make at a construction site.

It is still another object of the invention to provide wall panel construction as in the previous objects that significantly reduces, or minimizes, manual labor required to produce the wall panels.

It is a further object of the invention to provide a wall panel that is versatile and can be adapted to be used in almost any climatic conditions.

It is still a further object of the invention to provide a wall panel construction that inherently incorporates insulation so that insulation does not have to be added to the construction after the panels are assembled into a structure.

It is yet a further object of the invention to provide a wall panel construction of the type under discussion that can easily be modified on a panel-by panel basis to accommodate specific structural requirements.

It is an additional object of the invention to provide an in situ wall panel that can be formed, in whole or in part, with prefabricated components or can be produced entirely at a construction site.

It is still an additional object of the invention to provide a wall panel construction as in the previous objects that incorporates accommodations for utilities such as plumbing, electricity and wiring for various electrical/electronic systems.

In order to achieve the above objects, and others that will become apparent hereafter, a wall panel in accordance with the present invention is formed of a plurality of parallel elongate insulating members uniformly spaced from each other to form elongate channels between each two adjacent insulation members. Elongate attachment members extend along the channels and extend along the edges of the assembly. Concrete fills the voids to fill the channels to form load-supporting concrete columns or ribs extending along the length directions of the insulation members. The insulation members of each panel are arranged in a common plane to which any sheathing panel may be attached to complete the wall panel. Preferably, the sheathing panel comprises an MgO board to improve the overall properties of the panel. By assembling the panels while essentially in a horizontal plane the sheathing panel of an assembled panel assembly forms a base or support surface for an other wall panel assembly that can be assembled above a previously assembled panel. A plurality of such panels can be formed in the field or at a construction site. By stacking the panels one above the other a large number of assembled panels can be made while minimizing the footprint of the production and storage areas and thus increasing productivity.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

Fig. 1 is a front cross-sectional elevational view of a number of panel assemblies in accordance with the invention, in which the lower panels are fully assembled and the upper panel is partially assembled; Fig. 2 is similar to Fig. 1 but shows plastic extrusions that are forms for concrete ribs and the use of rebar positioners between adjacent molded rigid insulation forms or sections;

Fig. 3 is an elevational view of an assembled wall panel, as viewed from the insulation side, and shows the extruded nailer and steel tubes used to interface and connect to other panel assemblies;

Fig. 4 is a perspective view of a steel panel fitting/joist hanger for use with the panel assemblies of the invention;

Fig. 5 is a bottom plan view of panel assemblies, as viewed from the sheathing side but prior to attachment of the sheathing panels;

Fig. 6 is an elevation view of a fully formed wall panel assembly as viewed from the sheating side after the sheathing panel has been attached;

Fig. 7 is an enlarged elevation showing details of four joined panel assemblies, as viewed from the insulation side prior to application of drywall;

Fig. 8 is an elevation, showing details of a foundation supporting a bearing wall;

Fig. 9 is an elevation showing details of a non-bearing exterior wall section;

Fig. 10 is an elevation showing details of an interior bearing wall section;

Fig. 11 is an elevation showing parapet and roof details for a wall section of an exterior wall that is a bearing wall;

Fig. 12 is plan view of an exterior corner formed by the wall panel assemblies; and

Fig. 13 is plan view of a party wall secured to an exterior wall construction. DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to Fig. 1 a wall panel assembly in accordance with the invention is generally designated by the reference numeral 10.

The wall panel assembly 10 is particularly suited for being assembled at a construction site where the panel assemblies will be used to build a housing structure. The panel assemblies 10 may be arranged and assembled on any suitable surface S, such as a table, the ground or any other substantially horizontal surface. As the panel assemblies are made they are vertically stacked one upon the other in parallel horizontal planes as shown. In Fig. 1 an upper panel assembly 10 is shown at an intermediate stage of assembly, while the two lower panel assemblies lO'and 10" are fully assembled.

Each panel assembly 10 is formed of rigid foam insulation forms 12. These may be extruded as elongate members having suitable or typical lengths used in construction, or provided in custom lengths needed for specifically dimensioned panel assemblies for use in a specific construction project. Also, because the rigid foam insulation forms 12 can be cut, longer lengths can be cut to size to

accommodate given requirements.

The foam insulation forms 12 are shown to have a U-shaped cross-section, although the specific dimensions and cross-sectional configurations are not critical. The insulation forms may be made of any suitable foam insulation material, such as polyurethane foam. The form has opposing substantially parallel inner leg end surfaces 12a, 12b; an interior cavity or space 12c and outer end surfaces 12d. Each wall panel assembly 10 is formed by arranging a plurality of the foam forms 12 spaced from each other along a common horizontal surface S or on top of a previously formed panel assembly. The spacing between the foam forms 12 is selected to correspond to the dimensions of plastic extrusion nailers 14, shown as elongate rectangular extrusions that have the same length as the lengths of the foam forms 12. In assembly, the nailers 14 are used as spacers and placed in abutment against a foam form 12 before the next foam form is positioned as shown in Fig. 1. However, it will be clear that the specific sequence for positioning the foam forms 12 and the nailers 14 is not critical. It is only important that between each two foam forms 12 there is a nailer 14, also having one surface arranged substantially coextensive on a common surface S. However, if the foam form 12 is made from a material that is dense and strong, then the surfaces 12a and 12b can be used to receive either a nail or a screw for attaching other materials, such as drywall, during the building construction process.

Preferably, screw anchors 16 are fixed to the nailers, each screw anchor projecting upwardly as shown into the space created between two adjacent foam forms 12. Steel reinforcing bars (rebars) are arranged within spaces into which the screw anchors 16 project. Each of the rebars extends longitudinaly within the spaces adjacent to the forms 12 and are generally parallel to the support surface S. The steel rebars 18 serve to reinforce concrete ribs 20 formed by pouring concrete to fill the spaces up to the height of the foam forms 12 as shown. Before the concrete has hardened a suitable sheathing panel 22 is deposited on top of all of the foam forms 12 and suitable screw anchors or other fasteners 24 are used to secure the sheathing panels as shown. After the concrete hardens, these screw anchors or other suitable fasteners securely connect the sheathing panel 22 to the concrete ribs 20.

While the nailers 14 are made of extruded rectangular plastic forms steel tubes 26 may be selectively used in place of the plastic nailers at the ends of the panel, at the right side as viewed in Fig. 1 , and other locations where greater strength is needed and steel is a better choice than plastic. The steel tubes have comparable dimensions to the nailers and are likewise provided with anchors 16.

At the right end of the panel, as viewed in Figs. 1 and 2, no further foam forms 12 are to be added beyond the steel tubes 26 a temporary sidewall or form 28 is placed or butted against the steel tubes to contain the poured concrete above the steel tubes until the concrete has hardened.

The materials from which the components of the panel assemblies are made will be a function of the desired properties of the finished panel assemblies. As indicated, the foam insulation forms 12 may be made of a polyurethane foam. The sheathing panels 22 may be selected from a wide variety of available panels. However, in accordance with the presently preferred embodiment, the sheathing panels 22 are preferably a specific type of panel commonly known as magnesium oxide board or MgO board. Such panels are a technologically advanced building material that has superior performance properties in almost every category when compared to traditional wood, gypsum and cement-based products. Such MgO boards are virtually impervious to fire, water, insects, do not feed mold or mildew, is non-toxic, non-flammable and non-combustible. They are durable and maintain dimensional stability, even when wet, and have exceptional bonding surfaces. In addition, such boards are mineral-based "green" builder products and can have a positive impact on the health and safety of occupants of structures made of such boards, while extending the life of the structure itself. Magnesium oxide or MgO boards are marketed by numerous manufacturers, including panels sold under the brand names Dragonboard™ and Magnum™ board. Additional information and specifications on Dragonboard™ can be obtained at www.drasonboard.com , and specifications and additional information about Magnum™ board is available at www. masnumbp. com .

Referring to Figs. 1 and 2 the panel assembly 10 is made of preformed "building blocks" consisting of rigid foam insulation members 12, as described, and channellike extrusions 29 that include T-shaped anchors 30 that are embedded into the foam insulation members. Also, rebar positioners 34 may optionally be provided that maintain the position of the rebars 32 in a desired or predetermined spacings from the nailers 14 and/or steel tubes 26. The rebar positioners 34 are inserted into the spaces into which concrete is to be poured to thereby reinforce the concrete.

As viewed in Fig.s 1 and 2, each panel assembly has an insulation side, as viewed from the bottom upwardly in these Figures, and a sheathing side, as viewed from the top downwardly. Screw anchors or other suitable fasteners 24 are used to attach the sheathing panels to the concrete ribs 20.

Referring to Fig. 3, a wall panel assembly 10 is shown in elevation, having a height of 9 feet and a length or width of 12 feet. The panel is shown as viewed from the insulation side, therefore showing the flat surfaces 12a, 12b and the cavities or elongate channels 12c of each of the insulation forms or members 12. Between each two foam insulation forms 12 the plastic extrusion nailers 14 extend upwardly substantially up to a ceiling line 40', above which steel tubes 26 are positioned to provide additional strength for the mounting of joists, as to be described. The steel tubes 26 are also arranged below the plastic extrusion nailers 14 proximate to the floor line 40".

Metal fittings 37 are shown supported on the first two steel tubes 26 on the left, as viewed in Fig. 3. Thus, unlike many conventional wall panel assemblies, the wall panel 10 not only has the protective features of a partition wall but inherently provides a significant amount temperature as well as sound insulation, since the wall panel assembly primarily consists of rigid foam insulation forms or members 12.

In Fig. 4, a metal fitting 37, made of steel, is shown of the type that can be used in connection with the wall panel assemblies of the present invention. The metal fitting 37 is, as noted, attached to the steel tubes 26 at the top of the wall panel assemblies and extend downwardly essentially to the ceiling line 40' as shown in Fig. 3. The metal fitting 37 consists of a joist hanger 38 arranged and dimensioned to support a horizontal structural member, such as a metal joist 42 (Fig. 7). The joist hanger 38 is attached in any suitable manner, such as by welding, to an H-shaped panel connector 44 that includes a shorter vertical plate 44a, a longer vertical plate 44b, as shown and a transverse plate 44c connecting the two vertical plates. The specific dimensions of the plates 44a-44c are not critical.

Extending horizontally, above the metal joist 42, is a horizontal rebar anchor 46 that is ultimately embedded within a concrete or cement floor. In use, the top of the wall panel 10, and in particular associated steel tubes 26 formed at the top of the panel, is received within the lower space formed by the plates 44a-44c. Suitable holes 44d are provided that are vertically spaced proximate to each vertical edge of the vertical plate 44b as shown to allow the metal fitting 37 to be secured to the steel tubes 26 by any suitable fasteners.

In Fig. 5 sections of the wall panel assemblies are shown in bottom plan view, illustrating that the construction of the panels differ slightly for intermediate and end constructions. An intermediate construction is represented by 10a while an end construction is represented by the reference numeral 10b. Clearly, the last or end construction 10b, as indicated on the right side of Fig. 5, needs to include plastic extrusion nailers 14 and steel tubes 26 the vertical length of which generally corresponds to the lengths of the rigid foam insulation forms 12. The first intermediate insulation forms only require nailers and steel tubes at one vertical side, to the left as viewed in Fig. 5. The horizontal connecting members 36 extending between each two steel tubes 26 are also elongate extrusions rectangular in section and may be formed of either steel or plastic blockings.

While Fig. 3 shows the plastic nailers 14 and steel tubes 26, as well as the metal or plastic blocking 36 prior to the attachment of the drywall panels 68, Fig. 6 shows the assembly of Fig. 3 with the sheathing panel 22 attached to the concrete ribs 20 by any suitable means, such as a screw anchors 24. The wall panel assembly of Fig. 6 is also shown in elevation when it is arranged in a vertical plane and ready to be incorporated into a unit being constructed. Two metal fittings 37 are shown supported on the upper horizontal edge of the panel so that the lowermost parts of the joist hangers are generally coextensive with or proximate to the ceiling line 40, as mentioned. Referring to Fig. 7 panel assemblies A-D are shown, with the panels A and B being upper panels while panels C and D are lower panels. In assembling these panels the metal fittings 37 are placed along the upper edges of the panels to position the lower floor panel connectors 44 for attachment to steel tubes 26. Where two separate wall panel assemblies abut against each other as shown a wider, double panel connector 44' is arranged to bridge both wall panel assemblies to be joined. As indicated, the panel connectors are secured to the panels by means of suitable fasteners that extend through the holes 44d. The panel connectors 44, 44'therefore not only serve to support the joist hangers 38 but also to secure and maintain two adjacent wall panel assemblies in line or aligned in a common plane.

Still referring to Fig. 7, after the metal fittings 37 have been properly secured to the panels metal joists 42 are placed on the joist hangers 38. Clearly, any joists may be used. However, the cross-sectional dimensions of the joists should substantially corresponded to the receiving space formed by the joist hangers 38 so that once the ends of the joists are placed into and supported by the joist hangers 38 there is little clearance for movement of the joists and they can be stably supported by the joist hangers.

After the joists, metal or otherwise, have been placed into the joist hangers 38 any suitable or conventional metal decking 48 may be placed on top of the joists 42 to be supported thereby. The metal decking 48 essentially forms a substantially horizontal surface, with the rebar anchors being arranged just above the metal decking 48. Now, concrete that can be poured on the metal decking 48 so as to cover the rebar anchors 46, which become embedded within the hardened concrete. The concrete slab is designated by the reference numeral 50 and any suitable floor 52 may be deposited on the concrete slab 50 to provide a finished floor. This procedure is repeated for each floor that is added to the structure. Similarly, the lower portions of the metal joists 42 extent downwardly proximate to the ceiling line 40', and a suitable a ceiling may be attached to the lower surfaces of the joists. Clearly, the construction of the floor demands adequate reinforcement to support significant loads that may be placed on the floor. The construction of the ceiling is less demanding, as the weight of a ceiling is typically considerably less than the weight of the floor and the loads of placed thereon.

Fig. 8 shows additional construction details of a bearing wall in accordance with the invention. In certain constructions, suitable insulation 54 may be placed below the metal decking 48 for providing additional thermal as well as noise insulation between floors. A bearing wall is shown formed of a foundation wall 57 supported on a concrete footing 56. Optionally, when warranted by the region of the construction site, leveling blocks 60 may be placed on the foundation wall 57 prior to mounting of the metal fittings 37 in to absorb seismic vibrations. After the absorbing layers 60 are placed on the foundation wall the joist fitting 37 is mounted on the foundation wall 57 as shown. Now, the steel joists 42 can be placed on the joist hangers 38 and decking 48 placed on the joists. A concrete floor, embedding the rebar anchors 46, can be formed as described. At this time, a panel assembly 10 can be deposited within the upper cavity of the panel connector 44. Once the concrete slab 50 has been laid on the metal decking 48, shown in profile and Fig. 8, in addition to a finished floor 52, drywall 68 may be attached to the interior or insulation side of the panel assembly. Where applicable or desired, base molding 74 may be secured to the wall panel assembly to provide a finished appearance. Preferably, suitable trim 62 may also be used to cover the vertical plate 44c that is exposed on the exterior side of the wall. Any suitable trim or cover material may be used, such as a vinyl trim. As indicated, the metal fitting 37 may be secured to the panel assembly 10 prior to the pouring of the concrete floor by means of any suitable fasteners, such as rivets 72 that engage the steel tube 26 and concrete rib 64. This maintains the metal fittings 37 in place while the steel joists 42 are deposited on the joist hangers 38. Of course, once the concrete slab hardens, with the rebar anchors 46 embedded therein, this fixes the metal fittings 37 in place.

While Fig. 8 shows the manner in which a panel assembly in accordance with the invention can be used on the exterior bearing wall, Fig. 9 shows a similar construction for a non-bearing wall. As will be noted, the constructions are very similar, drywall 68 being shown attached to form the ceiling 40 and drywall 68 attached to a plastic nailer 14. It will also be noted that the steel tube 26 is preferably juxtaposed along the height of the plate 44b, thus allowing the metal fitting 37 to be attached to the steel tube 26.

A bearing interior wall section or party wall is illustrated in Fig. 10, in which a double ended or back-to-back metal fitting 37' facing opposite directions on opposite sides of two vertically stacked panel assemblies. Joist hangers 38 are arranged on both sides of the lower panel assembly and steel joists 42 are supported therein.

In Fig. 1 1 parapet and roof details are shown for an exterior wall. The

construction is similar to the construction shown, for example, in Fig. 8 of a bearing wall. However, instead of stacking an additional wall panel 10 within the upper receiving space formed by plates 44a-44c the upper surface of the metal fitting 37 receives blocking or filler blocks 76 covered by suitable vinyl caps and trim 78, 80, respectively, and these covered by suitable roofing covering sheet material 82. Fig. 11, therefore, illustrates one manner of terminating and finishing the construction when no further panel assemblies are to be added to an existing construction.

Referring to Fig. 12, a plan view shows an exterior corner of a structure employing the wall panel assemblies of the invention. Thus, once to all assemblies are aligned as shown a steel angle or bracket 84 may be used to secure the two panel assemblies together by means of any suitable fasteners, such as rivets, that engage the steel tubes 26. An end portion 12' (Fig. 12) of one of the legs of the U-Shaped insulation form may need to be removed by cutting or the like to gain access to the steel tube 26, which is normally accessible only from the exposed side facing the direction away from the sheathing panel 22. Corner moldings 86, including exterior and interior moldings 86', 86", respectively, to protect the corners of the exterior sheeting panels 22. Caulking or sealing material may be used, as appropriate, in accordance with standard or typical construction practices.

Fig. 13, a similar construction to the one shown in Fig. 12, illustrates a party wall attached to an exterior wall. Here, the steel bracket or angle 84 is connected to a steel tube 26 of a party wall and to two steel tubes 26 of the two butted or adjacent exterior wall panels by means of rivets 72 or any other suitable fasteners. Once the wall panel assemblies have been secured to each other by means of the steel angles or brackets 84suitable finishing corner moldings 86" and caulking 88 may be applied. In this instance, the party wall will have an interior sheathing panel 22'on one side of the party wall and a drywall panel 68 on the other side of the same party wall. Both Fig.s 12 and 13 show the surface 12b of foam form 12 abutting drywall 68. If the material of foam form 12 is dense and strong, then drywall 68 can be directly attached to surface 12b using a nail or screw, or even laminated with a strong glue. In the case where drywall 68 is attached directly to surface 12a or 12b of foam form 12, then it may not be necessary to attach drywall 68 to any other members like plastic nailer 14 or steel tube 26.

As will be evident from the figures and the above description of the wall panel assemblies they are extremely simple and convenient to assemble, provide extremely good structural properties and are easy and quick to assemble and made to any required or desired configurations. Once these panel assemblies are assembled there is no further need to provide insulation as the panels themselves are partly made of an insulation material and, therefore, inherently provide a level of desired temperature and sound insulation.

Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

WHAT IS CLAIMED:

1. A wall panel construction for in situ assembly comprising a plurality of parallel elongate insulating members uniformly spaced from each other to form elongate substantially parallel channels between each two adjacent insulation members and defining opposing substantially parallel inner and outer end surfaces; elongate attachment members extending along said channels proximate to said inner end surfaces; concrete ribs filling voids between adjacent insulating members to fill said channels to form load-supporting concrete columns extending along the length directions of said insulation members, said insulation members of each panel being arranged in a common plane; a sheathing panel abutting said outer end surfaces; first fastening means for attaching said elongate attachment members to said ribs; and second fastening means for attaching said sheathing panel to said concrete ribs, said inner end surfaces defining a plane substantially parallel to said sheathing panel suitable for attachment to a further panel to cover said insulating members.

2. A wall panel construction as defined in claim 1, wherein said insulating members are formed of rigid foam material sufficiently hard to support a plurality of wall panels when such panels are stacked horizontally one on top of the other.

3. A wall panel construction as defined in claim 1, wherein said sheathing panel comprises an MgO board.

4. A wall panel construction as defined in claim 1, wherein said insulating members are U-shaped and open in the direction of said inner end surfaces and closed in the direction of said outer end surfaces.

5. A wall panel construction as defined in claim 1, wherein said attachment members are in the form of elongate extrusions having widths substantially equal to the widths of said channels in which they are placed.

6. A wall panel construction as defined in claim 1, wherein said attachment

members are in the form of substantially rectangular tubes.

7. A wall panel construction as defined in claim 6, wherein said tubes are formed of plastic.

8. A wall panel construction as defined in claim 6, wherein said attachment

members comprise intermediate plastic tubes in said channels and metal tubes at opposing ends of said channels.

9. A wall panel construction as defined in claim 1, wherein said channels are formed by elongate extrusions formed with anchors that project into and are embedded within at least one side of said insulating members.

10. A wall panel construction as defined in claim 1, further comprising reinforcing bars extending within said concrete ribs.

1 1. A wall panel construction as defined in claim 10, further comprising rebar

positioners within said channels for supporting and positioning said reinforcing bars within said concrete ribs.

12. A wall panel construction as defined in claim 1, further comprising a sheet of plaster board secured to said inner end surfaces.

13. A building structure formed of a plurality of wall panels each of which comprises a plurality of parallel elongate insulating members uniformly spaced from each other to form elongate substantially parallel channels between each two adjacent insulation members and defining opposing substantially parallel inner and outer end surfaces; elongate attachment members extending along said channels proximate to said inner end surfaces; concrete ribs filling voids between adjacent insulating members to fill said channels to form load-supporting concrete columns extending along the length directions of said insulation members, said insulation members of each panel being arranged in a common plane; a sheathing panel abutting said outer end surfaces; first fastening means for attaching said elongate attachment members to said ribs; and second fastening means for attaching said sheathing panel to said concrete ribs, said inner end surfaces defining a plane substantially parallel to said sheathing panel suitable for attachment to a further panel to cover said insulating members, and further comprising a plurality of steel panel fittings or joist hangers including means for supporting same on each elongate attachment member.

14. A building structure as defined in claim 12, further comprising panel connector means for connecting two panels side by side at lateral edges thereof.

15. A building structure as defined in claim 12, further comprising panel connector means for connecting two panels one on top of the other at upper or lower edges thereof.

16. A building structure as defined in claim 12, further comprising bracket means for securing two wall panel at right angles to each other by connecting elongate attachment members of two adjacent angularly displaced wall panels to each other.

17. Method of assembling wall panels for building structures comprising the steps of placing plurality of parallel elongate insulating members uniformly spaced from each other on a substantially horizontal support surface to form elongate substantially parallel channels between each two adjacent insulation members and defining opposing substantially parallel inner and outer end surfaces; positioning elongate attachment members extending along said channels proximate to said inner end surfaces; filling voids between adjacent insulating members to fill said channels to form load-supporting concrete columns or ribs extending along the length directions of said insulation members, said insulation members of each panel being arranged in a common plane; abutting a sheathing panel against said outer end surfaces; attaching said elongate attachment members to said ribs; and attaching said sheathing panel to said concrete ribs, said inner end surfaces defining a plane substantially parallel to said sheathing panel suitable for attachment to a further panel to cover said insulating members, said sheathing panel forming a new substantially horizontal surface on which another wall panel may be assembled.

18. Method of assembling wall panels for building structures as defined in claim 17, further comprising assembling in situ a plurality of wall panels and stacking them one above the other to minimize assembly footprint at a construction site.

19. Method of assembling wall panels for building structures as defined in claim 17, wherein said attaching steps comprises insertion of fasteners through said elongate attachment members and sheathing panels and embedding at least portions of said fasteners into poured wet concrete and allowing said concrete to harden prior to use of said wall panel.

20. Method of assembling wall panels for building structures as defined in claim 17, further comprising the step of inserting reinforcing bars within said channels prior to pouring said concrete to reinforce said concrete ribs.