WO2013020228A1 - Module de paroi préfabriquée et procédé de fabrication - Google Patents

Module de paroi préfabriquée et procédé de fabrication Download PDF

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Publication number
WO2013020228A1
WO2013020228A1 PCT/CA2012/050523 CA2012050523W WO2013020228A1 WO 2013020228 A1 WO2013020228 A1 WO 2013020228A1 CA 2012050523 W CA2012050523 W CA 2012050523W WO 2013020228 A1 WO2013020228 A1 WO 2013020228A1
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WO
WIPO (PCT)
Prior art keywords
core
assembly
wythe
wythes
studs
Prior art date
Application number
PCT/CA2012/050523
Other languages
English (en)
Inventor
Jeffrey Rae BRADFIELD
Original Assignee
Bradfield Jeffrey Rae
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bradfield Jeffrey Rae filed Critical Bradfield Jeffrey Rae
Publication of WO2013020228A1 publication Critical patent/WO2013020228A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
    • E04B1/043—Connections specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0068—Embedding lost cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • B28B7/0073—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating assembled bricks or blocks with mortar joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • B28B7/186—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article for plates, panels or similar sheet- or disc-shaped objects, also flat oblong moulded articles with lateral openings, e.g. panels with openings for doors or windows, grated girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
    • E04C2002/045—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete with two parallel leaves connected by tie anchors

Definitions

  • the present invention relates to systems and methods for the construction of buildings and other permanent structures, and more particularly to a prefabricated insulated wall panel comprising a module for a structure and a method for fabricating said panel.
  • the invention further relates to individual components of said panel.
  • Prefabricated wall components including pre-assembled building wall panels (both exterior and interior), as well as wall components that may be assembled on site into complete wall structures.
  • Prefabricated wall panels may comprise a sandwich construction consisting of exterior concrete (or other suitable material) wythes that sandwich an internal insulation layer. The wythes can be connected by wythe connectors which tie the wythes together and pass through the central insulation layer. Examples of prefabricated wall panels and wall panel components including the following :
  • prefabricated wall panels that are efficiently insulated with rigid foam insulation and that incorporate structural elements formed from concrete or other formable substance that form at least part of the load-bearing framework. It is also desirable to provide a fabrication method for a wall panel assembly that permits design flexibility in certain key areas such as structural design for loading, locations for doors and windows, insulation requirements, and exterior and interior decorative fascias.
  • the assembly may also provide efficient means to accommodate mechanical, electrical and other required systems that incorporate the structure's needs and reduce construction costs both in dollars and from an environmental standpoint, as well as time reduction.
  • the present invention relates to an improved wall panel assembly and a method for fabricating the assembly.
  • the present invention relates to a prefabricated wall panel assembly and a method for fabricating complete wall panel assemblies remotely from the building site.
  • the assembly can comprise a modular wall panel which is incorporated into a structure such as a building, dwelling, or other permanent structure.
  • Wall assemblies according the invention are particularly suited to be maintained in an upright position during steps of fabrication and transport, thereby reducing costs and space requirements over certain prior art assemblies that are fabricated and/or transported in a prone position.
  • the invention relates to a prefabricated wall panel assembly for a structure, comprising :
  • wythes comprising a sheet of rigid insulation having opposed first and second lateral surfaces facing respective ones of the first and second wythes, said core comprising an array of generally vertical stud channels open to the first surface of the core;
  • first wythe and the studs that are integral therewith form a monolithic structural member that can perform the load-bearing function of the assembly.
  • the first wythe may be configured to generally face the interior of the structure and the second wythe for facing the exterior, or vice-versa.
  • the second wythe may comprise a substantially non-structural cladding panel.
  • At least one of the wythes, and optionally both wythes are embossed with a decorative pattern on an exterior face thereof.
  • the assembly includes a
  • the reinforcement structure embedded within the first wythe and optionally also a second such structure embedded in the second wythe.
  • the reinforcement structure may comprise a wire mesh panel or grill fastened to and spaced apart from the core, wherein the structure is embedded therein during the moulding stage when fabricating the assembly.
  • Reinforcement members may also be embedded within the studs, such as rebars or the like.
  • the reinforcement members and optionally the studs may be anchored to the first wythe by means of an array of wythe connectors that engage the
  • the wythe connectors may be configured to anchor both of the first and second wythes to the core by extending from the first wythe and/or stud, passing through the core between the respective lateral surfaces thereof and into the second wythe.
  • the resulting assemblage provides a rigid, monolithic structural support for the assembly.
  • the assembly may further comprise upper and/or lower generally horizontal recesses within the core open to the first wythe and the stud channels. These recesses are filled with the same settable material that forms the wythes and studs during the moulding stage to form at least one horizontal beam, plate or sill integral and continuous with the studs and the first wythe panel.
  • the upper and lower sills can comprise interlocking structures to permit vertical stacking of multiple assemblies, for example for use with a multi-story non load-bearing wall.
  • the first wythe and structural components integrated with this wythe serve as anchors to fasten brackets and the like for fastening the wall assembly to a slab or to an adjacent assembly to form a corner.
  • a corner bracket is fastened to adjacent assemblies to form an interior wherein the edges of respective assemblies are directly adjacent.
  • the corner bracket comprises a cap plate that is fastened to the exposed edge of an assembly, and an angled connector plate extending at an angle to the cap plate.
  • the cap plate can be bolted or otherwise fastened to the internal wythe or a vertical stud integral therewith.
  • the connector plates of respective adjacent assemblies are fastened together to form the corner.
  • a corner bracket is fastened to adjacent assemblies to form an exterior corner wherein the adjacent assemblies are spaced apart at the corner.
  • the corner bracket comprises an additional spacer plate to between the cap plate and connector plate, to space apart the respective assemblies when connector plates of adjacent assemblies at a corner are fastened together.
  • the invention relates to a method of fabricating a wall assembly for a structure, comprising the steps of:
  • a suitable material for this purpose is concrete, although other materials that provide sufficient strength when solid may be used.
  • one or more reinforcement structures as described above are fastened to the first and/or second surfaces of the core prior for positioning within the mould.
  • the core with one or more reinforcement structures as described above are fastened to the first and/or second surfaces of the core prior for positioning within the mould.
  • reinforcement structure engaged thereto is positioned within the mould whereby the reinforcement structure(s) are located in the gap between the core and corresponding inside surface(s) of the jacket panel(s).
  • the reinforcement structure(s) Upon filling of the mould with settable liquid, the reinforcement structure(s) become embedded within the liquid, which then hardens about the reinforcement structure to permanently embed the reinforcement structure within the wythe.
  • additional reinforcement members are positioned within the stud channels and connected with wythes ties or connectors to the first wythe. Filling of the stud channels with the hardenable liquid during the moulding process embeds these members within the studs.
  • the mould is maintained in a substantially upright, vertical position throughout the assembly and moulding steps, as well as post-moulding stages such as removal of the mould, storage, transport and assembly of the wall in a structure.
  • At least some of the jacket panels, end walls and floor plate of the mould are provided as discrete mould components which are assembled around the core prior to pouring of the liquid substance.
  • At least one of the sidewalls and floor of the mould are adjustable, the method comprising the further steps of adjusting the vertical position of the floor and/or the horizontal position of at least one of the sidewalls to define the height and width of the wall assembly.
  • wall assembly refers to a prefabricated wall according to the invention that can be installed in a building, dwelling or the like to form an exterior or interior wall or portion thereof, wherein an "exterior” wall has one surface which faces the exterior of the structure and one surface facing the interior, and an “interior” wall comprises both surfaces facing the interior of the structure.
  • a wall need not be strictly vertical, but may comprise a sloping or even horizontal wall when installed. Similarly, a wall can be flat or curved.
  • building and “structure” are used broadly herein to include any permanent or temporary structure that can include an insulated wall, such as a dwelling, commercial building, storage facility or other such structure.
  • stud refers to a generally vertical (when the wall is vertical) elongate structural member embedded within a wall between the respective ends thereof.
  • a stud does not fully span the cavity between exterior sheathing panels, or wythes, but extends only partway across this cavity to permit a continuous layer to exist adjacent one of the wythes within the internal cavity.
  • the term "wythe” refers to a rigid panel or sheet which forms an exterior layer of a sandwich-type wall panel assembly.
  • Figure 1 is a perspective view of a composite building wall structure, according to an embodiment of the present invention.
  • Figure 2 is a side elevational view of the wall structure.
  • Figure 3 is a sectional view, along line A-A of Figure 2.
  • Figure 4 is a sectional view, along line B-B of Figures 2 and 3.
  • Figure 5 is a sectional view, along line C-C of Figure 2.
  • Figure 6 is a sectional view along line A-A of Figure 1, showing a portion of the wall, for detail.
  • Figure 7 is an enlarged view of the encircled portion of Figure 6.
  • Figure 8 is a perspective view of the foam core portion of the wall assembly.
  • Figure 9 is a cross-sectional view of the foam core, along line D- D of Figure 8.
  • Figure 10 is a further perspective view of foam core, showing the reinforcing structure installed therein.
  • Figure 10a shows a detail of the core shown in Figure 10.
  • Figure 11 is a further perspective view of the foam core with reinforcement structure, in expanded (exploded) view.
  • Figure 12 is a perspective view of a mesh rebar chair for the reinforcing assembly.
  • Figure 13 is a perspective view of rebar wheel for the reinforcing assembly.
  • Figure 14 is a top of the core.
  • Figure 15 shows a detail of the core shown in Figure 14.
  • Figure 16 is a sectional view of a wall assembly according to a second embodiment.
  • Figures 17a, b and c are a side, top and front views respectively of a wythe connector and associated reinforcement bars according to the second embodiment.
  • Figure 18 is a cross-sectional view of the assembly of Figure 14.
  • Figure 19 is a cross-sectional view showing a corner assembly with two abutting wall assemblies.
  • Figure 20 is a perspective view of a connector for the wall assembly.
  • Figure 21 is a cross sectional view showing multiple wall assemblies installed in a multi-story construction.
  • Figure 22 shows a portion of a wall comprising assemblies of the present invention, showing two such assembles joined end to end.
  • Figure 23 is a perspective view of a portion of the mould for fabricating an assembly according to the invention.
  • Figure 24 is an exploded view of a mould, in perspective, including a core portion of a wall assembly according to the invention.
  • Figures 25a and 25b are transverse sectional views showing two assemblies in external and internal corner configurations, respectively.
  • Figures 26a and 26b are side sectional views showing two assemblies in multi-story arrangements, wherein Figure 26a shows a slab/transverse wall assemblies wherein the wall assemblies are in direct vertical stacked contact and Figure 26b shows a slab/load-bearing wall configurations wherein a slab is interposed between the assemblies and the upper assembly bears on the slab.
  • FIGS 1 and 2 illustrate a wall assembly 10 according to the present invention intended for installation in a permanent structure (not shown).
  • Assembly 10 comprises a module or panel which can form a complete wall for the structure or a segment of a wall wherein multiple assemblies 10 of the same or different configuration are assembled to form the complete wall.
  • Assembly 10 can be fabricated at a fabrication facility remote from the building construction site and transported to the construction site for assembly into the structure.
  • Assembly 10 may include various openings for windows, doors, or other openings, as well as various projections and other decorative or functional elements and features. As discussed below, provision may also be made for various ventilation openings, chases for electrical or plumbing lines, and the like.
  • Assembly 10 comprises opposing interior and exterior lateral sides 3 and 5.
  • the terms “interior” and “exterior” are used for convenience with reference to the assembly 10 when this is used to form an external wall of a structure, wherein the exterior surface of the assembly faces the exterior of the structure and the interior of assembly 10 faces the interior of the structure. It will be evident that assembly 10 may also form an interior wall, and may comprise a load-bearing or non load-bearing wall, with appropriate modifications to configuration. As well, although assembly 10 is described herein by reference to exterior and interior faces, these may be reversed such that the elements described herein facing the exterior instead face the interior and vice-versa.
  • the perimeter of assembly 10 comprises opposed vertical end faces 7 and 9, and horizontal upper and lower faces 11 and 13.
  • assembly 10 includes a door opening 14, a window opening 16, raised corner elements 18, and a cornice 20.
  • the exterior of the wall surface, visible in Figure 1, is embossed with a decorative pattern 22, which may resemble bricks (as in Figure 1), or any other desired pattern such as stone, woodwork, etc. , or a non-representational pattern, or a functional pattern such as numbering, lettering, graphics or the like.
  • Wall assembly 10 may be dimensioned such that one assembly is employed for each side of the structure and for each floor of the structure. Since assembly 10 is typically fabricated off-site and transported to the building site by truck, certain practical limitations can dictate the dimensions of the assembly. However, apart from such practical limitations, assembly 10 may take on a wide range of dimensions.
  • assembly 10 consists of a composite sandwich structure comprising a rigid foam core 30 sandwiched between interior and exterior solid concrete sheathing panels or wythes, 32 and 34, respectively.
  • Pattern 22 may be embossed into either or both of the exposed surfaces of wythes 32 or 34, as desired.
  • Wythes 32 and 34 are formed from concrete or other settable substance which can be poured in place while in a liquid phase and which hardens to form a suitable rigid structure, as described below, along with other integrally-formed components as described below.
  • wythes 32 and 34 form the exposed interior and exterior wall surfaces of assembly 10, and no further surface layer or treatment (apart from paint or other surface treatment) is required to provide the finished wall.
  • Core 30 of assembly 10 is shown in detail in Figures 8 and 9.
  • Core 30 comprises opposed first and second lateral surfaces 51 and 53 facing sides 3 and 5 respectively of assembly 10.
  • Core 30 comprises one or more sheets 50 of dense high R-value rigid foam material. Suitable materials include Class II, III or IV expanded polystyrene or extruded polystyrene. The material should be selected such that it has a high R value, is relatively rigid and can sustain the head pressure of 8 to 12 feet of liquid concrete and not appreciably deform or compress under such loads.
  • insulation sheets 50 may be at least 100 mm thick, with suitable dimensions being 1220 mm x 2700 mm x 150 mm, which constitutes a stock size for rigid insulation sheets.
  • Sheets 50 comprise tongue and groove end surfaces 48 which can be brought into end to end engagement with similar sheets 50 on either side to form the full length of core 30.
  • Core 30 includes an array of vertical stud channels 52 to receive poured in place concrete studs 36.
  • Channels 52 are oriented generally vertically to form a regularly-spaced array of generally vertical studs within the interior of core 30.
  • Channels 52 each comprise an outer slot-shaped throat 82 open to an external surface of core 30, which in the present example consists of surface 51.
  • Throat 82 is relatively narrow in width and is defined by opposed parallel sidewalls.
  • Throat 82 terminates within the interior of core 30 in a relatively broad head 84.
  • Head 84 may take on any selected cross-sectional configuration such as circular, multi-sided etc., wherein head 84 has a broader cross-sectional configuration than throat 82.
  • the cross-sectional configuration of head 84 is multi-sided to retain wheel-shaped anchors 128, described below and seen in Figure 13, and preventing movement thereof when engaged within head portion 84 of channel 52.
  • Head 84 is located within the interior of core 30 such that a layer of foam material exists between head 84 and the exterior surface 53 of core 30.
  • studs 36 are continuous and integral with interior wythe 32. Studs 36 and wythe 32, as will be discussed below, are formed concurrently with concrete during the moulding process. Studs 36, seen in detail in Figure 7, have a configuration which corresponds with channels 52, namely a generally rail-like shape comprising a relatively narrow neck 38 and broad head 40, when viewed in cross-section.
  • Head 40 is located within the interior of core 30 between the respective surfaces while neck 38 faces the first surface of core 30 and is continuous with first wythe 32.
  • the broader width of head 40 relative to neck 38 locks the stud within the interior of core 30 once the concrete has cured, thereby preventing separation of wythe 32 from core 30.
  • all channels 52 open to a single one of the exterior lateral surfaces of core 30, with the result that all of studs 36 are continuous with wythe 32.
  • studs 36 are continuous with wythe 34.
  • some of the channels 52 are open to the opposing face of core 30, for example to provide a staggered configuration of the studs alternately continuous with opposing wythes 32 and 34.
  • Core 30 further includes hollow chases 54 for locating wiring, plumbing, fibre optic cables and the like.
  • chases 54 are oriented vertically, but it will be evident that chases 54 may be oriented in any desired direction.
  • some or all of chases 54 may be temporarily plugged with removable plugs 55 prior to assembly into the wall structure in order to prevent entry of concrete into chase 54 during the fabrication process. As discussed below, plugs 55 can be removed
  • the upper and lower edges of core 30 further comprise upper and lower horizontal cutaway regions 60a and 60b, respectively, open to the inner face 3 and upper and lower faces 11 and 13 respectively and extending the full or partial length of core 30.
  • Stud channels 52 are open at their upper and lower ends to horizontal upper and lower cutaway regions 60a and b.
  • cutaway regions 60a and b define horizontal upper and lower beams or plates 86 and 88 extending lengthwise along assembly 10. Plates 86 and 88 are integral with studs 36 and interior wythe 32.
  • Plates 86 and 88 do not fully traverse the width of core 30, thereby providing for a continuous or substantially continuous layer of foam between the outside surface 5 of core 30 and plates 86 and 88 in order to minimize thermal bridging by components formed from concrete or other highly thermally-conductive materials.
  • interior wythe 32 is also continuous with cast-in-place concrete end plates 89 located on opposing end faces of assembly 10. End plates 89 extend inwardly into a cutaway portion of core 30 along the end walls of assembly 10. Plates 89 are aligned with studs 36 to provide for a portion of foam core 30 to overlie plates 89 to reduce thermal bridging.
  • Openings 14 and 16 are framed with concrete framings 44 (as seen particularly in Figure 2) which are integral with, and integrally formed with, wythes 32 and 34.
  • Frames 44 provide an attachment surface for conventional windows, doors and the like.
  • Assembly 10 further comprises at least one reinforcement structure 122, which in the present example comprises a wire mesh panel, embedded within one or both of exterior and interior wythes 32 and 34.
  • Mesh panel 122 is fastened to and spaced from core 30 by an array of plastic spacers or chairs 124.
  • Chairs 124 seen in more detail in Figure 12, comprise a plastic body having a flat base for contacting the respective face of core 30.
  • Chairs 124 are fastened to core 30 by any suitable fastening means, such as double-stick tape or other adhesive or a suitable mechanical fastening means, not shown.
  • Chair 124 comprises a tubular wall having a flat upper rim with grooves therein for engaging the rods of mesh panel 122.
  • Mesh panels 122 are anchored to core 30 by an array of wythe connectors 70, 132 or 134, described below, that extend into assembly 10. As will be discussed below, these wythe connectors also serve to anchor wythes 32 and 34 to core 30.
  • Mesh panel 122 may be ferrous or non-ferrous; while the use of a non-ferrous material generally permits use of a thinner wythe, the use of a ferrous material may be less costly and provide easier compliance with local regulatory requirements or construction standards.
  • mesh panel 122 is formed from steel wire and is embedded within interior wythe 32 which is about 60 mm thick to fully embed the mesh therein and provide a minimum thickness of concrete cover over mesh panel 122.
  • Assembly 10 further comprises multiple interior to exterior wythe connectors 70 to anchor the exterior and interior wythes 32 and 34, core 30 and studs 36, as seen in Figure 11.
  • wythe connectors 70 comprise fibreglass rebar shafts sharpened at one end to penetrate core 30. The sharp point of connector 70 also minimizes any possible exposure of connector 70 to the environment if it protrudes through the surface of exterior wythe 34.
  • a washer may be joined to one end of connector 70 to prevent pull back through core 30.
  • Connectors 70 may include hooks at opposing ends thereof for added retention.
  • the length of connector 70 can be equal to the overall wall assembly thickness minus about 5 mm. in order that it may be fully embedded within wythe 34.
  • Connector 70 can extend to the outside surface of wythe 32 to support core 30 within the mould during the concrete pouring steps, as described below. At least some of connectors 70 can traverse stud channels 52, which when filled with concrete serve to securely anchor connectors 70.
  • vertical reinforcement bars 126 which may comprise
  • Anchors 128, seen in detail in Figure 13, comprise a tubular central hub which engages bar 126 and radiating spokes configured for retention within concrete when embedded therein.
  • An array of anchors 128 are pre-installed along each bar 126, which can then be installed within a corresponding channel 52 and held in a central position within head region 82 by anchors 128 that contact the wall of head region 84.
  • Anchors 128 are configured to fit snugly within head region 84 of stud channel 52. When channel 52 is filled with concrete to form stud 36, anchor 128 is embedded within stud 36 to fixedly anchor bar 126 within the interior of stud 36 to extend the full length thereof.
  • wythe connectors 130 and 132 comprise an assemblage of L-and T-shaped steel rods that are engaged within the assembly in various orientations to provide improved anchoring of the wythe panels and reinforcement structures.
  • Connectors 130 and 132 comprise a foot portion 134 and leg portion 136 at right angles thereto.
  • a first wythe connector is positioned whereby the foot portion 134 is embedded within wythe 34 in a horizontal orientation.
  • the leg portion 136 thereof protrudes horizontally through the interior of core 30, extending between the respective wythes 34 and 32.
  • an array of openings may be formed in advance within core 30 to permit insertion of a plurality of connectors 130, prior to forming the wythes, in an array that fastens the entirety of mesh panel 122 to core 30.
  • Leg portion 136 extends fully across the width of core 30 and extends into the opposed sheathing wythe 32 to the exterior surface thereof, to thereby anchor the respective wythes 32 and 34 to core 30.
  • leg 136 extends through stud channel 52, whereby connector 130 engages stud 36 when formed.
  • Leg 136 has sufficient length to traverse the full width of wythe 32, to thereby contact an interior surface of the mould during the fabrication process, as will be described below.
  • a second connectorl32 is provided, similar in configuration to first connector 130 but having an angled leg as described below.
  • Second connector 132 is installed whereby the leg portion 136 thereof extends in a sloping orientation through assembly 10. For this purpose, an abtuse angle is formed between foot 134 and leg 136.
  • the foot portion 134 of connector 132 is embedded within wythe 34 in a vertical orientation.
  • Connector 132 protrudes through core 30 whereby the respective ends thereof are both embedded within wythes 32 and 34 and the intermediate portion thereof extends through stud channel 52.
  • the foot portions 136 of the wythe connectors 130 and 132 are 250mm long, which permits them to straddle two wires of the 200mm x 200mm spacing of mesh 122.
  • foot portions 134 are embedded within wythe 34 and do not engage mesh 122.
  • FIG. 17a Seen in side, top and front views in Figures 17a-c, respective foot portions 134 of connectors 130 and 132 are disposed transversely to each other, wherein one foot portion is disposed in a horizontal orientation and the other of which is disposed vertically, thereby securely anchoring the connectors to mesh panel 122.
  • a side view of connectors 130 and 132 is shown in Figure 17a.
  • foot 134 of connector is embedded vertically within wythe 34.
  • Leg 136 of first connector 130 extends at right angles thereto and traverses core 30 horizontally.
  • Leg 136 contacts and bar 126 and reinforcement panel 122.
  • the foot 134 of second wythe connector 132 is embedded within wythe 34 horizontally, as seen in the top view of Figure 17b.
  • Connector 143 comprises a leg that angles upwardly as it traverses core 30, thereby preventing pull-out. The free ends of legs 136 terminate within wythe 32.
  • assemblies 10 may be assembled into a structure in various configurations. In one example, shown in Figures 19 and 20, two assemblies 10 may meet at a corner of a structure. An angled connector 150 is anchored with bolts 152 to respective end plates 89 of assemblies 10.
  • Connector 150 is an angle iron fabricated from metal or other suitable material. Connector 150 may extend the full height of assembly 10, or alternatively multiple shorter connectors 150 may be employed. The resulting gap at the corner between adjacent assemblies 10 may be filled with foam layers 154 and 156, for example one or more of a rigid foam sheet configured to fit into the corner and/or expandable foam. The corner may also be capped with a protruding architectural foam corner element 158 which provides both insulation and decoration. The foam corner components are continuous with core 30 to provide an uninterrupted foam insulation layer.
  • FIGs 25a and 25b illustrate an alternative configuration of two assemblies 10.
  • assemblies 10 comprise an exterior corner of the structure ( Figure 25a) or an interior corner of the structure ( Figure 25b).
  • the exterior corner is configured for spacing the respective corners apart.
  • an exterior corner member 200 is connected to the exposed end surface 201 of each wall assembly 10 facing the corner. Corner member 200 is connected to the respective assembly by anchors 202 comprising U-bolts embedded within wythe 32 in the respective assemblies.
  • Corner member 200 comprises an end cap plate 204 covering the end surface 201, an angled connector plate 206 sloping at a 45 degree angle for contacting the connector plate 206 of an opposing corner member, and a spacer plate 208 between connector plate 206 and cap plate 204 respectively, to space these components apart.
  • Connector plates 206 of adjacent assemblies 10 are bolted together, as seen in Figure 25a, to form a corner wherein the respective assemblies 10 are spaced apart and corner member 200 is exposed on both the inside and outside of the corner.
  • Brace 210 provides additional bracing between connector plate 206 and cap plate 204.
  • Figure 25b illustrates an interior corner comprising a corner member 220.
  • Corner member 220 comprises a flat end cap plate 222, similar to plate 204, mounted to assembly 10 by anchors 202.
  • An angled connector plate 224 extends from end cap plate 222, configured to contact the connector plate 224 from an adjacent assembly 10.
  • Brace 226 provides additional bracing between cap plate 222 and connector plate 224. When two assemblies are connected to form an internal corner, the respective assemblies are in near- contact along their respective corner edges.
  • Figure 18 illustrates a wall modulelO comprising a core 30, internal wythe 32 and reinforcement panel 122.
  • Module 10 comprises a slab tie 140 for anchoring the module to floor or ceiling slab.
  • Slab tie 180 comprises an angled metal tie member, such as a length of angle-iron, mounted to module 10 by anchor bolts 182 extending through wythe 132 on either side of stud 36.
  • Figure 21 illustrates two assemblies 10 in stacked relation, installed in a multi-storey structure.
  • the lowermost assembly 10 rests on a conventional concrete footing and may be fastened thereto by one or more angled connectors 150.
  • An intermediate floor plate 160 is supported by lowermost assembly 10, and in turn supports an upper assembly 10.
  • Floor plate 160 is covered at its exposed edge with a foam cap 162 which is continuous with foam core 30 for an uninterrupted insulating layer.
  • An architectural strip 164 may be installed to cover the exposed edge of floor plate 160 and adjacent portions of assemblies 10.
  • Figure 26a shows non load bearing assemblies in stacked relation wherein abutting lower and upper sill plates of respective upper and lower assemblies 10 interlock, and the upper assembly bears on the lower assembly.
  • FIG. 26b shows load bearing assemblies in stacked relationship, in which the upper assembly 10 bears on a slab interposed between the respective assemblies.
  • the respective assemblies are fastened to the slab by brackets bolted to the respective wythes 32 where there are integral with the respective lower and upper sill plates.
  • Figure 22 illustrates two assembles 10 in side by side abutting relation, for example in a large structure where multiple assemblies 10 are required to form the wall of a structure.
  • the abutting assemblies 10 are connected by flat connector plates 163, which are bolted into adjacent end plates 89 of assemblies 10 to securely and rigidly retain assemblies 10 together.
  • assembly 10 Fabrication of assembly 10 will now be described by reference to Figures 23 and 24. Based on the size, shape and other requirements of the building structure, the configuration of assembly 10 is determined, including its dimensions, framed openings and other aspects. A typical building construction requires multiple assemblies 10, either comprising multiple configurations or identical configurations. The overall size and weight of assembly 10 may in some cases be limited by transport or handling
  • assembly 10 as a full- length wall module for the building.
  • Shop drawings for each wall assembly 10 are produced showing all required details of the assembly including overall dimensions, door, window and other penetration locations, style of wythes, electrical, communication and other wall duct or chase locations.
  • Foam sheets 50 of the desired thickness are assembled to form core 30 by fitting the tongue and groove edges 48 together to form a continuous sheet. Openings for windows, doors and other elements, such as openings 14 and 16, are cut into core 30 using a precisely controllable cutting means such as a computer-controlled hot wire cutter.
  • the mould for fabricating assembly 10 consists of a mould or jacket 100, seen in detail in Figures 23 and 24.
  • Jacket 100 comprises members that can be assembled together in various configurations to adjust the various dimensions of wall assembly 10.
  • Jacket 100 includes interior and exterior jacket plates 102 and 104 which correspond with the interior and exterior faces of assembly 10. It is contemplated that plates 102 and 104, and thus jacket 100, may have height and length of about 13 x 60 feet in order to permit fabrication of a wide range of wall assemblies 10 within the scope of this overall size.
  • a pallet 106 forms a floor or bottom plate of jacket 100 between plates 102 and 104 and extends the full length of jacket 100. Pallet 106 is adjustable in vertical position in order to vary the overall height of wall 10.
  • Pallet 106 may be bolted to jacket plate 104 in a selected position, wherein plate 104 includes an array of bolt holes at selected positions. Pallet 106 includes an array of upstanding nails (not shown) or other restraining members configured to secure the bottom of core 30 to the pallet, to fix the position of the core on the pallet during the pouring steps.
  • Jacket 100 further comprises end walls 110. End walls 110 serve to space plates 102 and 104 apart and define the overall length and width of the resulting wall assembly 10. Walls 110 are bolted to jacket plate 104 in a similar fashion as pallet 106 to define a selected wall length.
  • one or both of the inside surfaces of the jacket panels 102 or 104 are partially or fully lined with textured form liner panels 167 which are configured to form a selected pattern in the exposed concrete surfaces.
  • the form liner comprises a rubber sheet which is textured with a pattern which when embossed into liquid concrete provides a desired surface structure or texture. The effect may be enhanced by colouring the concrete in a suitable fashion to resemble brick, stone, etc.
  • the textured form liner panels 167 may be engaged to one or both jackets 102 or 104 to emboss the exterior and/or interior wythe panels 32 or 34.
  • Form liner panels 167 may come in a variety of lengths, widths and thicknesses and may be made from a variety types of materials such as rubber, plastic, foam, polyurethane, wood etc.
  • Form liner panels 167 include magnets (not shown) mounted in the back face to allow them to be arranged and held in place on the flat panel steel moulds.
  • Form liner panels 167 comprise a material that resists being caused to deform or compress by more than the allowable tolerances for the dimensions of the wall assemblies under the loads applied by the liquid concrete during the pouring process.
  • jacket 100 is partially assembled by attaching end walls 110 and pallet 106 to jacket plate 102 at predetermined locations to establish the length and height of the assembly 30. At this point, one side of jacket 100 remains open to permit the various components of the assembly to be positioned within the interior of jacket 100.
  • the door, window and other penetration locations are marked on the inside surface of exterior jacket plate 104, to assist in the placing of form liners, doors windows, other penetrations and insulation sheets.
  • core 30 comprises multiple foam sheets 50
  • these are assembled together on the pallet 106 to form core 30.
  • the sheets are assembled against the exterior jacket plate 104 (with space allowed for the exterior sheathing wythe 34 on assembly 10) and in between the end walls 110, by fitting the tongue and groove edges of sheets 50 together, creating a continuous insulation layer, save and except where it may be cut to allow for door, window and other penetrations.
  • further structural elements including studs, sills and header grooves or slots may be cut within core 30, which will allow concrete to fill these to create any additionally required structure as may be required around the various openings.
  • core 30 is fitted with wythe connectors 70 or alternatively a combination of connectors 130 and 132, along with vertical stud reinforcement bars 126 within stud channels 52.
  • wythe connectors 70 or alternatively a combination of connectors 130 and 132 are installed such that a first end thereof is spaced from exterior jacket plate 104, to fully embed this end of the connector within exterior wythe 34, and the opposed ends of the connectors can be positioned to contact the interior jacket panel 102, when the mould is assembled.
  • connectors 70 or 130 are preferably fabricated from fibreglass or other non-corroding material to avoid corrosion of the exposed ends of the connectors.
  • Rubber gaskets (not shown) with adhesive on one side are fastened to the exterior and interior wythe sides at the door, window and other frames, to allow the frames to "seal" against the main steel panels of jackets 100 to prevent concrete from entering into these openings while the concrete is liquid.
  • Adhesive backed chairs 124 are then fastened onto the interior and exterior sides of core 30 at regular (approximately 600 mm x 600 mm) intervals, both horizontally and vertically to hold mesh reinforcement panels 122 in place, spaced apart from core 30.
  • Two opposed mesh panels 122 are installed, on opposing sides of core 30.
  • Mesh panels 122 are then snapped into place into the chairs 124.
  • mesh panels 122 are fully embedded within wythes 32 and 34 to provide reinforcement thereto and to serve as an anchor for the wythe connectors.
  • Legs 136 are tied in place using tie wires which prevents slippage or rotation.
  • additional chairs 124 or similar spacers are attached to mesh panels 122 to keep these properly spaced from jacket 100 at a constant spacing therefrom.
  • a pre-pour inspection is performed on the prepared wall assembly to ensure conformity to the drawings and specifications.
  • Interior jacket plate 102 is then positioned against pallet 106 and end walls 110 and locked in place to create a sealed 5-sided box with an open top. At least some of the chairs 124 contact plate 102 to support core 30 in an upright position within mould 100 with the precise spacing with jacket plates 102 and 104 to provide the predetermined thickness of wythes 32 and 34. [0087] Assembly lifting devices are then inserted into jacket 100 at predetermined locations.
  • the concrete used for the concrete components of assembly 10 preferably comprises the following characteristics, which persons skilled in the art can prepare from a range of options of known formulations:
  • fresh concrete will be highly fluid, allowing assemblies 10 to be poured from the top and all studs, cavities, sills, lintels, top plates, bottom plates and other recesses to be completely filled with concrete either with or without vibration;
  • Liquid concrete is poured into the open top of jacket 100, initially filling the exterior side fully between core 30 and exterior jacket plate 104, to form exterior wythe 34.
  • concrete forces are transferred in a sequence, initially to core 30 directly then to the back of chairs 124, through chairs 124 to mesh panel 122, from mesh panel 122 to opposed chairs 124, and then to interior jacket 102 which is in contact with chairs 124.
  • This allows the cavity which defines exterior wythe 34 to be completely filled without displacing core 30, while the cavity which defines interior wythe 32 remains unfilled.
  • the final step involves finishing the top surface of the concrete. Following the pouring of the liquid concrete, the concrete is allowed to harden and cure in a controlled environment to reach the required level of hardness, following which the jacked is disassembled using cranes and other lifting devices and the finished assembly 10 is removed. Assembly 10 may then be transported on site and assembled into the building or other structure.
  • jackets 100 are cleaned for re-use. The fabrication process may then be repeated for another assembly 10, if required.
  • Jacket 100 is maintained in a vertical position throughout the pouring and post-pouring steps such that assembly 10 may be retained in a vertical position throughout the fabrication process, as well as the subsequent steps of storage, transport and final assembly. It will be seen that the ability to retain assembly 10 in a vertical position throughout substantially all of these stages provides significant benefits, including more efficient and space- effective fabrication, transportation and storage. Assemblies 10 will usually be handled and shipped vertically as opposed to traditional flat or horizontally poured precast concrete assemblies which take up more plant space to manufacture and which may require extra structural considerations to tilt the assemblies from flat to vertical.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Load-Bearing And Curtain Walls (AREA)

Abstract

L'invention porte sur un ensemble paroi préfabriquée pour une structure, lequel ensemble comprend des première et seconde parois mutuellement espacées comprenant des côtés latéraux opposés dudit ensemble, une partie centrale entre lesdites parois comprenant une feuille d'isolation rigide ayant des première et seconde surfaces latérales opposées faisant face à des parois respectives parmi les première et seconde parois, ladite partie centrale comprenant de plus un groupement de canaux de goujon globalement verticaux ouverts vers la première surface latérale de la partie centrale, et des goujons disposés à l'intérieur desdits canaux s'étendant partiellement à travers ladite partie centrale. Les goujons et les parois comprennent du béton ou un autre matériau pouvant être coulé. Les goujons sont intégrés et continus avec ladite première paroi, de façon à former une structure monolithique. Une structure de renfort peut être intégrée à l'intérieur de la première et, facultativement, la seconde paroi, avec des raccords de paroi pour verrouiller ensemble les parois respectives, les structures de renfort et la partie centrale.
PCT/CA2012/050523 2011-08-05 2012-08-02 Module de paroi préfabriquée et procédé de fabrication WO2013020228A1 (fr)

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US201161515630P 2011-08-05 2011-08-05
US61/515,630 2011-08-05

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108571096A (zh) * 2018-05-15 2018-09-25 中国十七冶集团有限公司 一种湿式连接的装配式剪力墙t形节点及其施工方法
EP3848525A1 (fr) * 2020-01-10 2021-07-14 Rc Panels Holding B.V. Panneau de construction comprenant une couche de base et deux couches supérieures

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US2709291A (en) * 1945-03-22 1955-05-31 Harkness John Maxwell Molds for use in building walls
US5095674A (en) * 1988-02-22 1992-03-17 Huettemann Erik W Concrete building panel with intermeshed interior insulating slab and method of preparing the same
WO1994023143A1 (fr) * 1991-10-18 1994-10-13 Ab Dala Cementvarufabrik Elements en beton et procede de fabrication
US5440846A (en) * 1992-11-13 1995-08-15 Record; Grant C. Construction for building panels and other building components
US7100336B2 (en) * 2002-03-06 2006-09-05 Oldcastle Precast, Inc. Concrete building panel with a low density core and carbon fiber and steel reinforcement
EP1884352A2 (fr) * 2006-08-04 2008-02-06 Roxbury Limited Panneau de construction
CN201236412Y (zh) * 2008-07-16 2009-05-13 中国建筑第六工程局有限公司 一种现浇混凝土模板内置用外墙外保温结构
US20100024355A1 (en) * 2006-06-14 2010-02-04 Sarl Comeps France Prefabricated panel for building construction and process for manufacturing such a panel

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2709291A (en) * 1945-03-22 1955-05-31 Harkness John Maxwell Molds for use in building walls
US5095674A (en) * 1988-02-22 1992-03-17 Huettemann Erik W Concrete building panel with intermeshed interior insulating slab and method of preparing the same
WO1994023143A1 (fr) * 1991-10-18 1994-10-13 Ab Dala Cementvarufabrik Elements en beton et procede de fabrication
US5440846A (en) * 1992-11-13 1995-08-15 Record; Grant C. Construction for building panels and other building components
US7100336B2 (en) * 2002-03-06 2006-09-05 Oldcastle Precast, Inc. Concrete building panel with a low density core and carbon fiber and steel reinforcement
US20100024355A1 (en) * 2006-06-14 2010-02-04 Sarl Comeps France Prefabricated panel for building construction and process for manufacturing such a panel
EP1884352A2 (fr) * 2006-08-04 2008-02-06 Roxbury Limited Panneau de construction
CN201236412Y (zh) * 2008-07-16 2009-05-13 中国建筑第六工程局有限公司 一种现浇混凝土模板内置用外墙外保温结构

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108571096A (zh) * 2018-05-15 2018-09-25 中国十七冶集团有限公司 一种湿式连接的装配式剪力墙t形节点及其施工方法
EP3848525A1 (fr) * 2020-01-10 2021-07-14 Rc Panels Holding B.V. Panneau de construction comprenant une couche de base et deux couches supérieures

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