WO2014017931A1 - Waffle box building technology - Google Patents

Waffle box building technology Download PDF

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Publication number
WO2014017931A1
WO2014017931A1 PCT/PH2013/000002 PH2013000002W WO2014017931A1 WO 2014017931 A1 WO2014017931 A1 WO 2014017931A1 PH 2013000002 W PH2013000002 W PH 2013000002W WO 2014017931 A1 WO2014017931 A1 WO 2014017931A1
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WO
WIPO (PCT)
Prior art keywords
waffle
boxes
box
type
building
Prior art date
Application number
PCT/PH2013/000002
Other languages
French (fr)
Inventor
Jerry A. CHIN
Original Assignee
Chin Jerry A
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 Chin Jerry A filed Critical Chin Jerry A
Priority to BR112015001824A priority Critical patent/BR112015001824A2/en
Priority to AU2013293648A priority patent/AU2013293648A1/en
Priority to CN201380043055.4A priority patent/CN104641048B/en
Publication of WO2014017931A1 publication Critical patent/WO2014017931A1/en
Priority to IN2320MUN2014 priority patent/IN2014MN02320A/en
Priority to ZA2015/00503A priority patent/ZA201500503B/en
Priority to HK15106651.0A priority patent/HK1206085A1/en

Links

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
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815—Elements not integrated in a skeleton
    • E04B1/34823—Elements not integrated in a skeleton the supporting structure consisting of concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14—Conveying or assembling building elements
    • E04G21/142—Means in or on the elements for connecting same to handling apparatus
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/41—Connecting devices specially adapted for embedding in concrete or masonry
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/48—Dowels, i.e. members adapted to penetrate the surfaces of two parts and to take the shear stresses
    • E04B1/483—Shear dowels to be embedded in concrete
    • 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
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B2001/34876—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form with a sloping or barrel roof
    • 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
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B2001/34876—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form with a sloping or barrel roof
    • E04B2001/34884—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form with a sloping or barrel roof creating a living space between several units

Definitions

  • Waffle Box Building Technology is an alternative prefabricated or cast-in-place building system that is lighter but equally stronger, highly resistant to earthquake, typhoon and hurricane, subsequently cheaper and fast that aims to address the backlog in the affordable housing, public and private schools and other small, medium rise or large high rise shelter, or building projects of any country.
  • Box (noun) as defined by Encarta dictionary is "something that is square or rectangular in shape", “a container for objects or dry goods", “an enclosed area", “a small building that is used as a shelter”, and “a compartment".
  • Waffle also as defined by Encarta dictionary is "a pattern of indentations on both sides ", or "as in waffle iron for pancakes”.
  • the Diaphragms and Shear Walls are also as defined by Encarta dictionary.
  • a diaphragm is a flat structural unit acting like a deep, thin beam.
  • a shear wall is a vertical cantilevered diaphragm.
  • a diaphragm structure results when a series of such vertical and horizontal diaphragms are properly tied together to form a structural unit.
  • the structural system is termed as "box system”.
  • This invention is about prefabricated or cast-in-place structural "waffle box” 27 made of concrete or other materials; a square or rectangular in shape, an enclosed area used as a shelter or room, with or without wings 10, 10a, 10b, with punched openings for windows 12b, 12c, doors 12, 12a and stairs or elevator shafts, etc. 12d that will form part of a shelter or building or any other similar structure for a specific use.
  • this invention is a prefabricated or cast-in-place structural "waffle" 1 , 2 (a diaphragm of thin wall 3 or slab 4 with a pattern of indentations on both directions called ribs) 5, 5a, 5b, 5c, 5d "box” 27 (a series of horizontal and vertical diaphragms and shear walls tied together to resist vertical, horizontal, torsion and other building loads) building technology that is resistant to earthquakes, typhoons, or hurricanes at a lower cost compared to a planar walls or slabs.
  • structural "waffle" 1 , 2 a diaphragm of thin wall 3 or slab 4 with a pattern of indentations on both directions called ribs
  • 5a, 5b, 5c, 5d "box” 27 a series of horizontal and vertical diaphragms and shear walls tied together to resist vertical, horizontal, torsion and other building loads
  • the waffle wall 1 (vertical side) which is a composition of thin walls 3 and ribs 5 ( 5a (walls and columns in traditional design) ( Figures 2a, 4, 5, 6, 25, 29, 29b) and waffle slab 2 (horizontal side) which is a composition of thin slabs 4, ribs 5b, 5c, (slabs, beams and/or girders in traditional design) ( Figures 1 , 3, 4, 5, 6, 7, 28, 27, 31 , 32) are integrated with one another that will form a waffle box 27.
  • This waffle box 27 invention defines a very specific thin wall 3 or slab 4 (sometimes called skin) with a series of indentations (called ribs 5) ( Figures
  • the waffle box 27 will either have five (5) sides (Type 1 ) ( Figures 1 , 2,
  • All the sides of the waffle box 27 are designed to carry structural (vertical, horizontal, torsion, etc) loads of a building.
  • the waffle box 27 can either be square or rectangular in shape.
  • the ribs 5, 5a, 5b, 5c (sometimes called flange or chord) are rectangular or trapezoidal in shape for easy removal of forms ( Figures 2, 2a, 29, 29b).
  • the pattern of the ribs 5 to 5d can be vertical, horizontal, diagonal, longitudinal or transverse.
  • the sizes and spacing of the ribs 5, 5a, 5b, 5c, and its reinforcement are dictated by the number of floors, use of the structure, sizes of rooms, zoning and other design factors of the shelter or building and is the product of the structural design.
  • a strictly rib (no crisscrossing member) design is strong for loads in one direction while the waffle 1 , 2 (vertical, horizontal, diagonal, longitudinal or transverse members) ( Figures 7, 7a, 34) design is strong for loads in both directions.
  • a diaphragm acts in a manner analogous to a deep beam or girder, where the panels act as a "web,” resisting shear, while the diaphragm edge members perform the function of "flanges,” resisting bending stresses.”
  • the ribs 5, 5a, 5b, 5c are sometimes redesigned to serve a unique or special purpose.
  • a corbel 7, 7a, 7b, 7c, ( Figures 3, 4, 5, 7, 9, 10, 1 1 , 12, 13, 16, 38, 39, 40) for example is an improved rib that will hold and carry the upper waffle boxes 27, slabs 2 or walls 1 as the case maybe.
  • the rib or corbel 7 to 7d has holes 15, 15a, 15b, 15c, 15d for fixing, lifting, and joining. It also has sockets 14, 14a, 14b, 14c ( Figures 9, 10, 12, 13) also for fitting or fixing the dowels or pins 17, 17a ( Figures 9, 10, 12, 13, 16, 38, 39, 42) , for hauling 14b, and for fork lifting 14c.
  • Some ribs or corbel 7 has welding plates 16 (Figures 10, 12, 40, 43, 44) and welding angles 16a ( Figures 40, 43, 44) to attach one with the other in order to attain structural integrity of the shelter or building.
  • ribs or corbels 7, 7a, 7b, 7c are also provided with lifting cylinders/bolfs 13a (Figure 18), or lifting bolts 13b (Figure 46) for lifting purposes. They also have vertical and horizontal target 22 and match groove 23 for alignment, better quality control and speed in the
  • the ribs are developed as notches 8, 9 ( Figures 3, 4, 5, 6, 17, 31 , 32, 45) that will fit these corbels 7, 7a, 7b, 7c.
  • the notch 8, 9 has holes 15, 15a, 15b, 15c, 15d, ( Figures 5, 7, 9, 1 1 , 16, 17, 38, 39) welding plates 16 ( Figures 10, 12) to best prepare these waffle boxes 27 for an integrated structural box system of the shelter or building.
  • the weight of the structural box that was designed as waffle 1 , 2 is lighter than those designed using the traditional flat walls and columns or slabs and beams or girders, because of the hollow sections between ribs 5, 5a, 5b, 5c ( Figures 2, 29).
  • the walls 3 or slabs 4 (sometimes called skin) that connect the ribs are generally thinner.
  • waffle 1 , 2 Figures 2, 28
  • a reduced mass or volume or weight requires thinner structural members, including foundation 26, and lesser or smaller steel
  • planar box which has a flat surface with end posts is different from the waffle box 27; that has thin wall 3 and slab 4 with a pattern of indentations called ribs 5 to 5d.
  • the planar box has posts while the waffle box 27 has none.
  • the planar box has flat walls while the waffle box 27 has a thin wall 3 with a pattern of vertical, horizontal or diagonal ribs 5.
  • the planar box is closed on the top and bottom slab, while the waffle box 27 can be both closed and open provided that the perimeter corbel 7, 7a, 7b, 7c, 7d or notch 8, 9 or other ribs are retained for structural integrity of the waffle box 27.
  • Waffle boxes 27 with open slabs 12d are used for stair well, air well, elevator shaft, pipes chase, atrium or the like, while the closed planar box is silent on this feature.
  • the planar box is not the same as the waffle box 27 in form and in appearance. Additional research was made in
  • the waffle box 27 building technology is consistent in its goal to provide a lighter but equally stronger, highly resistant to typhoons, hurricanes and earthquake, cheaper, and fast construction method that will address the backlog in the affordable housing, public and private school, and other shelter or building projects of any country.
  • the waffle box 27 will have punched openings for windows 12b, 12c and doors 12, 12a on its vertical walls ( Figures 5, 6, 30, 31 , 32).
  • One door opening 12a (closed during casting but can be opened later) ( Figures 2, 25) more or less situated at the mid span of the longer vertical side wall is earmarked for sideward room expansion ( Figures 22, 23, 24).
  • This expansion which is equivalent to a minimum one half (1 /2) size of the waffle box 27 ( Figure 24), one waffle box 27 ( Figure 23) or to as many as two waffle boxes 27, ( Figures 22) allows the occupant, user, or buyer for more options to expand.
  • Some waffle boxes 27 (Figure 27f) have punched opening for slabs
  • waffle box 27 which are intended for the stairwell, air well, elevator shafts, pipe chases, atrium or the like.
  • the opening can be resized accordingly provided that the perimeter corbel or notch or other ribs are retained to maintain the structural integrity of the waffle box 27.
  • Still some waffle boxes 27 are fabricated with limited or even without walls in front and rear sides (Figure 27e) to give designers options for bigger windows and doors. In addition to this design option, this kind of waffle boxes 27 are best suited for mass production as the feature of free ends paves the way for fast and easy removal of interior forms. This will also make the waffle box 27 lighter.
  • positioning of the waffle boxes 27 may be done in perpendicular with the other waffle boxes 27 in order to maintain structural integrity in both lateral directions of the shelter or building. This kind of mixed positions will require some features of the waffle box 27 to be adaptable.
  • Type I five (5) sides waffle box 27 and Type II six (6) side waffle box 27 have different installation procedures. Both processes are claimed by this invention.
  • Type I Waffle Box 27 (5 sides, bottom slab open, installation is vertical on top of one another)
  • Type I waffle box 27 has five (5) sides. The bottom slab is left open. This opening is designed to fit to the upper slab of that same Type I waffle box 27. They are installed vertically on top of the other ( Figure 20).
  • Type I waffle boxes 27 ( Figures 1 , 2, 3, 4, 5, 6 7) vary in width and length but not in height when positioned in any part of the shelter or building ( Figure 26). Type I waffle boxes 27 are installed in linear
  • each column of boxes must have uniform width, length and height.
  • the user of this invention might opt for Type I waffle boxes 27 with another width and length but not height in some other section of the shelter or building, but must follow the general rule of installing a uniform waffle box 27 from foundation 26 or base until it reaches the topmost deck ( Figures 20, 21 ).
  • Type I waffle boxes 27 in a shelter or building gives the user flexibility in the design. It is however, suggested to use a uniform waffle box 27 in any section of the building in order to save for the cost of formworks and to benefit from operating on the economies of scale.
  • Standard connection details like the dowels or pins 17 to 17b, bolts 18 to 18b, welding plate 16 and welding angle 1 ⁇ are available for users to choose from.
  • Type II Waffle Box 27 (6 sides, installation is horizontal with extra space 24 in between waffle boxes 27)
  • Type II waffle box 27 has six (6) sides. They have uniform width, length and height in all parts of the shelter or building ( Figures 36, 37).
  • Type II waffle boxes 27 are laid horizontally with uniform space apart ( Figure 27a), thereby creating one extra space 24 or room or unit between them.
  • the horizontal distance of the center of the thin walls 3 of the waffle box 27 and that of the extra space 24 are equal ( Figure 36, 37).
  • Figure 45 the center line of the thin walls 3 from the foundation 26 ( Figure 45) or base up to the topmost deck is aligned.
  • Type II waffle boxes 27 have the same length, width and height (Figure 27b).
  • the installation of the Type II waffle boxes 27 must start directly above the leftmost or rightmost extra space 24 and progressively towards the other end (Figure 27a).
  • a waffle wall 1 and waffle wall and slab 29 are introduced at exterior end (Figure 27c) as the case maybe to complete the floor or level of the shelter or building.
  • the horizontal installation of the Type II waffle boxes 27 is repeated to the next upper level until the structural box system of the shelter or building is completed ( Figure 27a, 36, 37).
  • the construction period of a shelter or building is very much shorter as compared with a building done using the traditional way (post, beam, slab, wall system).
  • This invention having included in the installation or stacking process the punched opening 12d for the stair, elevator, chases and the like which are vital elements of a shelter or building laid a predicate that the prior art and this invention are two different special technical features. Cast-in-place operations will affect the concept of mass production if those openings are done on site.
  • the double loaded design as featured by this invention utilizes a common corridor or hallway for the livable units in the case of housing project or classrooms in the case of school projects, thereby maximizing the use of the lot.
  • This invention considers both single loaded and double loaded designed buildings. Beyond the installation or stacking process of the first row of waffle boxes 27, there exists in this invention another unique product and process of installing the second row of waffle boxes 27 (Figure 27a), specifically designed for a double loaded shelter or buildings.
  • the waffle boxes 27 have corridors 6 which are extensions (or wings) of both the top and bottom slabs 4, ( Figure 27b, 36, 37). The protruding length of the corridor 6 is half the width of the hallway.
  • the new waffle boxes 27 will be fitted alternately in front of the extra spaces 24 ( Figures 27a, 27b, 36) aligning the edges of both the corridors 6 of the first row and the second row of the waffle boxes 27 ( Figure 27a).
  • the resulting structure will have the top corridor 6 of the first row of waffle boxes 27 meet with the bottom corridor 6 of the second row of waffle boxes
  • waffle wall 3 and combined waffle wall and slab 29 are introduced at exterior end to complete the structural box system of the shelter or building.
  • Type I waffle box 27 (5 sides) which is installed vertically on top of one another ( Figures 20, 21 ). This installation process of Type I waffle box 27 is significantly different from the said stacking process of the said prior art. All the waffle boxes 27 are precast and mass produced in
  • construction system comprising of a set of lower frames anchored to the ground foundation such that the upper horizontal ribs of said lower frames are horizontally aligned with each other, ... and a set of upper frames rigidly secured on top of said set of lower frames and consisting of spaced-apart frames such that the vertical ribs of the upper frames are vertically aligned with their corresponding vertical ribs of the lower frames...
  • the Type I waffle boxes 27 with five (5) sides (no bottom slab) are installed on top of one another ( Figures 20, 21 ), while the Type II waffle boxes 27 with six (6) sides are installed alternately on top of the two other waffle boxes 27 ( Figures 36, 37).
  • a waffle wall 1 , combined waffle wall and slab 29 and a waffle slab 2 are special waffle individual units (not fabricated as box) that will be integrated at exterior ends and deck ( Figures 27c, 36), as the case maybe, until the installation of the waffle box 27 shelter or building is completed ( Figure 37).
  • the corridor of the Type I five (5) side is a precast slab 2 ( Figure 26) or a cas ⁇ -in-place slab whichever is economical and feasible.
  • cast-in-place foundation 26 ( Figures 17, 45) is dictated by the nature of soil, heighf and size of the building, earthquake zoning and other design parameters.
  • the Type II six (6) sides waffle boxes 27 are laid one space apart, some aligned in front while others are moved forward or backward ( Figures 47, 48, 49, 50, 51 , 52, 53, 54, 55, 56) as the case maybe, in order for the designers to be creative in aesthetic designs and specific purpose like balcony, stair, attic, toilet and bath, etc. Roof is an option while users of the invention can utilize the concrete slab 2 as deck. Walls are specially fabricated. It is the goal of this invention to simplify, reduce, or eliminate the redundancy, repetitive work, wastages, etc.
  • the waffle boxes 27 therefore, including its electrical, plumbing, cable, telephone, internet, alarm, background music pipes, etc., wiring and architectural and other finishes are done or can be done af the ground floor level or off-site fabrication sites, thereby transforming these waffle boxes 27 as a pre-assembled, pre-finished or plug-in, and ready to use units of a shelter or building.
  • Fabrication of the structural waffle boxes 27; in sections or whole, is dictated by the hauling, lifting, stocking, and actual situations on site or off-sites.
  • the mass production of the waffle boxes 27 is done in controlled fabrication sites.
  • Cast-in-place waffle boxes 27, in extreme or special circumstances are done or can be done at job sites.
  • Lifting mechanisms are made of metal rods 13, cylinder 13a, bolts 13b with matching hooks (Figures 18, 19), that are all embedded in the concrete ( Figures 18, 19), or socket 14b at the base in the case of a fork lifting equipment
  • Their frequency, sizes and anchorages are all subject to the results of the structural design.
  • this invention minimizes the repetitive hauling, lifting, transporting of materials, tools, manpower from the ground up to the building (especially for high rise building), thereby cutting construction costs, improving work efficiencies, and maintaining product quality under a controlled work place at the ground floor or fabrication sites.
  • the space between the ribs 5 where the waffles are created can be used to hold heat and sound insulation materials thereby upgrading this invention as an insulated concrete building technology.
  • Materials to be used for the present design and for the further development of the technology in order ⁇ o maximize the benefits therein, can be any kind of concrete, steel, formed sheets, plastic, wood, laminates, or their combinations and other adaptable, cheaper and available building materials of the future.
  • the technology can shift to a cas ⁇ -in- place method of construction but still using the same process of building the waffle boxes 27 either directly above one another or alternately above the others.
  • Type I describes about the five (5) side waffle box 27 ( Figures 1 to 26), while Type II describes about the six 6) side waffle boxes 27( Figures 27 to 56).
  • the Type I five (5) side waffle box 27 is ideal for houses, shelter or building with different sizes of rooms.
  • the Type I waffle box 27 with one bottom side open are installed on top of the other from foundation or base level to the topmost deck.
  • the shelter or building can use different sizes of Type I waffle boxes 27.
  • the general rule however, in using Type I waffle box 27, is to use same size waffle boxes and install them vertically in linear progression from foundation or base level to the topmost deck of the shelter or building. Then a different size of Type I waffle box 27 (but height must be the same) may be used in other parts of the same building, but the installation must be similar which is vertically in linear progression from foundation or base level to the topmost deck of the same shelter or building.
  • the adjacent waffle slabs 2 are designed and fabricated to fit to the peripheral spaces around the Type I waffle boxes 27.
  • the Type II six (6) side waffle box 27 use the same waffle boxes (uniform in width, length and height) from foundation or base level to topmost deck, regardless of its position in the shelter or building.
  • the waffle boxes 27 are placed horizontally with an extra space 24 in between them. These extra spaces 24 or units are created using the walls 1 of these two adjacent waffle boxes 27.
  • the distance between the center lines of the thin walls 3 of the waffle box 27 and that of the extra space 24 are equal, so that when another waffle box 27 is laid on top of them (above the extra space 24), the corbel 7 will be able to receive and fit the succeeding waffle box 27.
  • the process is repeated until the shelter or building is completed.
  • the general guideline is that all centerline of the thin walls 3 of all the waffle boxes 27 at any level of the shelter or building are vertically aligned from the base level or foundation up to the topmost deck
  • End waffle wall 30, combined waffle wall and slab 29 and waffle slab 2 are placed at exterior end or deck to complete the box system.
  • Figure 36 illustrates these components.
  • Type II six (6) side waffle box 27 have walls 1 in front and rear with punch opening for doors 12 and windows 12b, 12c or stairs, elevator shaft, etc. 12d.
  • Type II six (6) side waffle box 27 is ideal for mass production especially for large projects or buildings. With front and rear walls 1 open, of the Type II waffle box 27, the removal of forms is faster. The reduction of walls 1 as a result of the front and rear opening 12, 12b will be addressed by rearranging the waffle boxes' 27 position (architect's' design) or in extreme cases introducing cast-in-place walls or other structural elements (structural engineer's design) at strategic areas in the shelter of building to maintain the structural integrity of the building. Punch opening or block out on walls 1 or slabs 2 intended for these cast-in-place structural elements can be integrated during casting of waffle boxes 27. Once poured on site, they become an integral part of the structure.
  • waffle boxes 27 have punched openings 12, 12a, 12b, 12c, 12d to meet a desired need (window, door, stair, shaft, view area like atrium, or scenic elevator etc.) on almost all sides of the waffle boxes 27. These conditions are allowed provided that the general rule is that those critical horizontal and vertical ribs including the corbel 7 8, 9 and notch are left intact and must seek clearance from a structural engineer.
  • FIG. 1 is a plan of the five (5) sides waffle slab 2 with some basic features.
  • Figure 2 and 2a is a plan showing the bottom open side and the waffle wall 1 and its components like the wall 3 > ribs 5, door and window opening 12.
  • the ribs 5 are trapezoidal in shape for easy removal of forms.
  • Figure 3 is a sectional elevation showing ribs 5, window opening 5b, corbel 7 and inverted notch 8. Also shown near the corbel 7 is a vertical and horizontal target 22 that will help plumb or align the building during the installation process. Below also shows the match groove 23 that will help align the lower and upper waffle boxes 27 during the installation process.
  • Figure 4 is cross section showing waffle wall 1 and slab 2, ribs 5, window opening 12b, corbel 7 and inverted notch 8. Also shown on the corbel 7 are sockets for dowels 14. Shown on the inverted notch 8 below are holes 15e also for dowels.
  • Figure 5 is cross section showing waffle wall 1 and slab 2, window and door opening 12, corbel 7 and inverted notch 8. Sockets for corbel 14 and holes for the inverted notch 15e and lifting 15d are also shown.
  • Figure 6 is a sectional elevation showing ribs 5, window and door opening 12, corbel 7, inverted notch 8 and vertical/horizontal target 22.
  • Figure 7 is sectional elevation showing ribs 5, waffle wall 1 , door opening 12, inverted notch 8 and holes for lifting 15d. Also shown are dotted lines showing holes for dowels or pins 15, vertical and horizontal target 22 and match groove 23.
  • Figure 7a is similar to Figure 7 but features the diagonal ribs 5.
  • Figure 8 is a longitudinal section showing waffle wall 1 and slab 2, corbel 7, door and window opening 12 holes for lifting and dowels or pins 15. Also shown on the upper left is the wall and slab connection and also on right is the corbel 7 and waffle slab 2 connections.
  • Figure 9 is a waffle box 27 to waffle box 27 and waffle slab 2 connections.
  • the Type I five (5) side box is placed on top of each other. After alignment of the waffle boxes 27, the dowels or pins 17 are fixed and grouted. The waffle slab 2 is placed next. In the Type I five (5) side waffle box 27, these waffle slabs 2 around the waffle boxes 27 differ in length and width but not in height. These waffle slabs 2 are fabricated and installed individually.
  • Figure 10 is a waffle box 27 and deck slab 2 connections. Also shown are the sealant 21 , hole 15 > dowel or pin 17 and socket 14.
  • Figure 1 1 is a bolt connection 18a which is an alternative waffle box 27 to waffle box 27 connection. This type of connection can be also used as a temporary connection because the bolts 18 can be loosened and removed.
  • Figure 12 is a welding plate 16 and/or dowel or pin 17 connections.
  • the plates 16 are welded to fix the slab 2 to the corbel 7.
  • the socket 1 , hole 15, dowel or pin 17 is a separate type of connection that can be used as an alternative to fix the waffle slab 2 to the corbel 7.
  • Figure 13 is a waffle box 27 to corridor 6 waffle slab 2 connections. Shown also are the socket 14, hole 15 and dowel or pin 17 connections. Sealant 21 is also shown.
  • Figure 14 is waffle slab 2 ⁇ o waffle slab 2 connections. This connection is used when two (2) waffle slabs 2 meet.
  • Figure 15 is waffle box 27 front wall connection. Shown are welding plate and angle connection. Socket, hole, dowel or pin connection can be used also.
  • Figure 16 is end waffle wall 30 connection. This connection applies when no adjacent slab is needed.
  • Figure 1 7 is cast-in-place slab-on-fill and/or foundation 26 to waffle box 27 connection
  • Figure 18 is an alternative lifting mechanism using a threaded cylinder with matching bolt with hook 13a.
  • Figure 19 is another lifting mechanism using rod with matching hook and eye 13.
  • Figure 20 shows how the Type I five (5) side waffle boxes 27 are placed or installed on top of another. Also shown is the adjacent waffle slab 2.
  • the waffle boxes 27 are uniform while the waffle slab' 2 width and length may vary.
  • the uniform waffle boxes 27 with their corbel 7 and connections support these waffle slabs 2 around fhem.
  • This type of waffle box 27 is ideal for residential or multi storey buildings with different room sizes.
  • the general rule here is to make one or a couple of boxes uniform from foundation or base level to the topmost deck of the building so they can be installed or placed on top of one another.
  • the waffle slabs 2 around the Type I waffle boxes 27 will follow.
  • Figure 21 is a cross section of a completed horizontal and vertical installation of the Type I five (5) side waffle boxes 27 and waffle slabs 2
  • Figure 22 is a floor plan showing the side door opening 12a that allows the user ⁇ o expand sideward equivalent to two rooms or waffle boxes 27.
  • Figure 23 is a floor plan showing the side door opening 12a that allows the user to expand sideward equivalent to one room or waffle box 27.
  • Figure 24 is a floor plan showing the side door opening that allows the user to expand sideward equivalent to one half room or waffle box 27.
  • Figure 25 is an isometric of Type I 5 sides waffle box 27 with window and door opening 12.
  • Figure 25a is an isometric of Type I waffle box with window and door opening 12. This kind of waffle box 27 normally is installed on the deck.
  • the bottom slab 2 is open for stair well, pipe chase, elevator shaft or the like.
  • Figure 26 shows the progressive placement or installation of Type I 5 side prefabricated waffle boxes 27 and waffle slabs 2 around it.
  • Figure 27 is an isometric of Type II 6 side waffle box 27 with wings 10 (front, rear walls, and corridors),
  • Figure 27a is an isometric of a Type II 6 side waffle box 27 with wings (front and rear walls, and corridor) 10 showing progressive installation.
  • Figure 27b is an isometric of the installation process of Type II 6 side waffle box 27 with wings (front and rear walls, and corridor) 10.
  • the installation of the waffle boxes 27 at any same level is one extra space 24 apart.
  • the installation of the second row of waffle boxes 27 for a double loaded designed building is also shown.
  • the new waffle box 27 will rest above the extra space 24 created by the 2 lower waffle boxes 27.
  • Figure 27c is an isometric of the installation process of Type II 6 side waffle box 27 with wings (front and rear walls, and corridor) 10. Also shown is the combined waffle wall with slab 30, waffle slab 2, and waffle wall 1. These four (4) structural elements comprise the structural box system of the shelter or building. The waffle slabs 2 are punched or left open if you need it as stair, air well, elevator shaft or the like.
  • Figure 27d is an isometric of the waffle slabs 2, waffle walls 1.
  • Figure 27e is an isometric of the Type II 6 side waffle box 27 with corridor wings 10.
  • Figure 27f is an isometric of the Type II 6 side waffle box 27 with corridor wings 10, with punch opening for stair well 12d.
  • Punch opening 12d for waffle slab 2 can be wider or 100 percent open depending on the use, provided the perimeter frames, ribs 5, corbel 7, notch 8, 9 are left intact.
  • Figure 28 is a plan of the Type II six (6) sides waffle box 27 showing top waffle slab 2 including corridor 10a and some basic features.
  • Figure 29 is a plan showing the bottom waffle slab 2 and the waffle wall 1 and its components like the wall 1 , ribs 5, door and window opening 12.
  • Figure 29a is a plan showing the Type II 6 side waffle box 27' bottom waffle slab 2 and the waffle wall 1 and its components like the wall 1 , ribs 5, door and window opening 12 and corridor wing 10a.
  • Figure 29B is a plan showing Type II 6 side waffle box 27 opening for stairwell 12d. Openings for slabs 2 are variable as needed, provided the horizontal and vertical ribs 5 including corbel 7 and notch 8, 9 around are left intact.
  • Figure 30 is a sectional elevation showing the wings 10, ribs 5, window opening 12, and corbel 7. Also is a vertical and horizontal target 22 that will help plumb or align the building during the placement or installation process. Below also shows the match groove 23 that will help align the lower and upper waffle boxes 27 during the placement or installation process.
  • Figure 31 is cross section showing waffle wall 1 , wings 10 and slab 2, ribs 5, window opening 12, corbel 7 and "z” notch 9. Also shown are sockets 14 and holes 15 for dowels or pins 17 and holes for lifting rod 15d.
  • Figure 32 is cross section showing waffle wall 1 , wings 10 and slab 2, window and door opening 12, corbel 7 and "z” notch 9. Sockets for corbel 15 and holes for the "z" notch 15b and lifting 15d are also shown.
  • Figure 33 is a sectional elevation showing wings 10, ribs 5, windows and door opening 12, corbel 7 and "z" notch 9. Vertical and horizontal target 22 and match groove 23 are also shown.
  • Figure 34 is sectional elevation showing corridor 10a, ribs 5, waffle wall 1 , door opening 12a, "z" notch 9 and holes for lifting 15d. Also shown are dotted lines showing holes for dowels or pins 15, vertical and horizontal target 22 and match groove 23.
  • Figure 35 is a longitudinal section showing corridor 10a, waffle wall 1 and slab 2, corbel 7, door and windows opening 12, holes for lifting 15d and dowels or pins 17. Also shown is the corridor rib 5.
  • Figure 36 shows the placement or installation process of the Type II six (6) side waffle boxes 27.
  • the waffle boxes 27 have one size only. First, they are laid horizontally with extra space 24 between waffle boxes 27. The waffle walls 1 of the waffle boxes become the wall of the extra space 24. The distance between the center line of the thin wall 3 of the waffle box 27 and the extra space 24 are equal.
  • the Type II six (6) side boxes 27 are placed on top of the extra spaces 24.
  • the "z" notch 9 of the waffle box 27 being installed on the upper level will rest on the corbel 7 of the two waffle boxes 27 which are already installed below.
  • the waffle slab 2 becomes the ceiling of the extra space 24.
  • the installation process is repeated until the shelter or building is completed.
  • the general rule is that the thin walls 3 from the foundation or base level up to the topmost deck are aligned.
  • the number of waffle boxes 27 installed will create rooms or usable spaces equivalent to twice as much as their number.
  • end waffle wall 30 Shown in the figure are end waffle wall 30, combined waffle wall and slab 29 and waffle slab 2 that are placed on exterior end or deck to complete the waffle box 27 system.
  • the foundation 26 or slab is also designed to fit to the "z" notch 9 of the waffle boxes 27.
  • Figure 37 is a cross section of a completed horizontal and vertical placement or installation of the Type II six (6) side waffle boxes 27 including end waffle wall 30, combined waffle wall and slab 29 and waffle slab 2.
  • the figure shows that the number of usable spaces or units created by this technology is twice the number of waffle boxes' 27 fabricated and installed.
  • the technology cuts the labor cost and construction time by a substantial figure by almost half,
  • Figure 38 is a waffle box 27 to waffle box 27 connection.
  • the six (6) side waffle box 27 is placed on top of the extra space 24, thereby having the "z" notch 9 rests on the corbel 7 of the waffle boxes 27 previously installed below.
  • the figure shows the socket 14, hole 15 and dowel or pin 17 connections.
  • Figure 39 is a bolt connection 18a which is an alternative waffle box 27 to waffle box 27 connection. This type of connection can be also used as a temporary connection because the bolts can be loosened and
  • Figure 40 shows welding plate and welding angle 16 connection.
  • Figure 41 shows the front wall 3 connection using welding
  • Figure 42 is waffle slab 2 to waffle slab 2 connections. This connection is used when two (2) waffle slabs 2 meet, in this case, at the corridor.
  • Figure 43 shows welding plates and welding angle 16 connection, Shown are waffle deck slab 31 and corbel 7 connections.
  • Figure 44 shows welding plates and welding angle 16 connection, Shown is end waffle wall 30 and corbel 7 connections.
  • Figure 45 shows cas ⁇ -in-place slab and foundation 26 and prefabricated waffle box 27
  • Figure 46 is an alternative lifting mechanism using a bolt 13b.
  • Figure 47 is a ground floor plan for single detached house showing aligned waffle boxes 27wi ⁇ h an extra space 24 created at ground level and forwarded waffle box 27 at the second level.
  • the garage, porch, living, dining, kitchen, stair well, or toilet and bath were created at the ground level.
  • Figure 48 is a second floor plan for single detached house showing aligned waffle boxes 27 with extra space 24 at ground level and forwarded waffle box 27 at the second level. The bedrooms, stair well, family area, balconies, toilet and bath were created at the second level.
  • Figure 49 is an attic plan for single detached house showing aligned waffle boxes 27 with extra space 24 at ground level and forwarded waffle box 27 at the second level and an attic with roof at the third level. The attic was created by utilizing the upper slab 2 of the waffle box 27. Roof was used to cover the extra spaces 24 at the second level and attic at third level.
  • Figure 50 is a cross section showing the 3 waffle boxes 27 and the 3 extra spaces 24 plus the attic that were created. All the needed spaces like living, dining, kitchen, garage, stair, toilet and bath, balconies, family room, etc. of a typical house were provided for.
  • Figure 51 is a ground floor plan for single detached house showing 2 aligned waffle boxes 27 with 3 extra spaces 24 (1 at ground and 2 at second level). The garage, living, dining, kitchen, stair well, or toilet and bath were created at the ground level.
  • Figure 52 is second floor plan for single detached house showing 2 aligned waffle boxes 27 with 2 extra spaces 24 or bedrooms at the second floor level. A roof was made to cover this second floor level. The arrangement of the waffle boxes 27 are versatile and will depend on the ideas of the architect or user of the technology.
  • Figure 53 is a cross section showing the 2 waffle boxes 27 and the 3 extra spaces 24 that were created. A roof covering is shown.
  • Figure 54 is a ground floor plan for single detached house showing a single waffle box 27 with 2 extra spaces 24 created at ground level and one extra space 24 at the second level. The garage, living, dining, kitchen, stair well, or toilet and bath were created at the ground level.
  • Figure 55 is a second floor plan for single detached house showing a single waffle box 27 with one extra space 24 at the second level. A bedroom and a stair well were created at the second level.
  • Figure 56 is a cross section showing a single waffle box 27 and the 3 extra spaces 24 (2 at ground and 1 at second level). All the basic elements of a house were provided for.
  • Figure 57 is a waffle box building technology code.

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Abstract

The invention is about a five (5) and six (6) side prefabricated, prefinished, plug in, insulated or cast-in-place rectangular structural waffle box 27 designed specifically for shelters, buildings or any box-like structures. The invention utilizes a waffle made of thin walls 3 or slabs 4 with a pattern of indentations on all sides called ribs 5. The Type I five (5) side waffle box 27 is installed vertically on top of another while the Type II (6) side waffle box 27 is installed horizontally (with a bonus space created between waffle boxes 27) to form a shelter or building. This invention aims to address the backlog in affordable housing, public or private schools and other building or shelter in any country thru an alternative building system that is lighter but equally stronger, highly resistant to earthquake and hurricane, subsequently cheaper and fast.

Description

WAFFLE BOX BUILDING TECHNOLOGY
DESCRIPTION
The Waffle Box Building Technology is an alternative prefabricated or cast-in-place building system that is lighter but equally stronger, highly resistant to earthquake, typhoon and hurricane, subsequently cheaper and fast that aims to address the backlog in the affordable housing, public and private schools and other small, medium rise or large high rise shelter, or building projects of any country.
The name of the invention "waffle box" 27 came about from these succeeding meaning and terms.
Box (noun) as defined by Encarta dictionary is "something that is square or rectangular in shape", "a container for objects or dry goods...", "an enclosed area...", "a small building that is used as a shelter", and "a compartment...".
Waffle (noun) also as defined by Encarta dictionary is "a pattern of indentations on both sides ", or "as in waffle iron for pancakes". In its technical terms, the Diaphragms and Shear Walls,
Design/Construction Guide, by APA (The Engineered Wood Association, www.apawood.org), quoted herein, "A diaphragm is a flat structural unit acting like a deep, thin beam.", " A shear wall, however, is a vertical cantilevered diaphragm. A diaphragm structure results when a series of such vertical and horizontal diaphragms are properly tied together to form a structural unit. When diaphragms and shear walls are used.in the lateral design of a building, the structural system is termed as "box system".
This invention is about prefabricated or cast-in-place structural "waffle box" 27 made of concrete or other materials; a square or rectangular in shape, an enclosed area used as a shelter or room, with or without wings 10, 10a, 10b, with punched openings for windows 12b, 12c, doors 12, 12a and stairs or elevator shafts, etc. 12d that will form part of a shelter or building or any other similar structure for a specific use.
In addition, this invention is a prefabricated or cast-in-place structural "waffle" 1 , 2 (a diaphragm of thin wall 3 or slab 4 with a pattern of indentations on both directions called ribs) 5, 5a, 5b, 5c, 5d "box" 27 (a series of horizontal and vertical diaphragms and shear walls tied together to resist vertical, horizontal, torsion and other building loads) building technology that is resistant to earthquakes, typhoons, or hurricanes at a lower cost compared to a planar walls or slabs.
The waffle wall 1 (vertical side) which is a composition of thin walls 3 and ribs 5( 5a (walls and columns in traditional design) (Figures 2a, 4, 5, 6, 25, 29, 29b) and waffle slab 2 (horizontal side) which is a composition of thin slabs 4, ribs 5b, 5c, (slabs, beams and/or girders in traditional design) (Figures 1 , 3, 4, 5, 6, 7, 28, 27, 31 , 32) are integrated with one another that will form a waffle box 27.
In reference to the prior art or Philippine Utility Model Registration No. 2-2001 -000254 issued on May 19, 2005, with the Title : A Modular Wall Panel for Fence, Housing, or Building Units and Maker : Claude Edwin Andrews of Mandaluyong City, Philippines, the precast modular panels as claimed, are laid horizontally with poured concrete between joints. The same modular panels are laid piece by piece with some panels having tongue and grove to complete a certain height or length. It is noted in this prior art that the panel indentations are strictly around the perimeter edges.
The Philippine Utility Model Registration No. 2-2001-000254 is a useful model and a good contribution in the construction industry as a whole. This waffle box 27 invention defines a very specific thin wall 3 or slab 4 (sometimes called skin) with a series of indentations (called ribs 5) (Figures
2, 29) that runs in many directions (not in edges only).
The waffle box 27 will either have five (5) sides (Type 1 ) (Figures 1 , 2,
3, 4, 25, 26) or six (6) sides (Type II) (Figures 27, 27a, 28, 29, 29a, 29b) as the case maybe. All the sides of the waffle box 27 are designed to carry structural (vertical, horizontal, torsion, etc) loads of a building. The waffle box 27 can either be square or rectangular in shape.
The ribs 5, 5a, 5b, 5c (sometimes called flange or chord) are rectangular or trapezoidal in shape for easy removal of forms (Figures 2, 2a, 29, 29b). The pattern of the ribs 5 to 5d can be vertical, horizontal, diagonal, longitudinal or transverse.
The sizes and spacing of the ribs 5, 5a, 5b, 5c, and its reinforcement are dictated by the number of floors, use of the structure, sizes of rooms, zoning and other design factors of the shelter or building and is the product of the structural design. A strictly rib (no crisscrossing member) design is strong for loads in one direction while the waffle 1 , 2 (vertical, horizontal, diagonal, longitudinal or transverse members) (Figures 7, 7a, 34) design is strong for loads in both directions. In the same mentioned APA design guide, it stated further that, "A diaphragm acts in a manner analogous to a deep beam or girder, where the panels act as a "web," resisting shear, while the diaphragm edge members perform the function of "flanges," resisting bending stresses." The ribs 5, 5a, 5b, 5c are sometimes redesigned to serve a unique or special purpose. A corbel 7, 7a, 7b, 7c, (Figures 3, 4, 5, 7, 9, 10, 1 1 , 12, 13, 16, 38, 39, 40) for example is an improved rib that will hold and carry the upper waffle boxes 27, slabs 2 or walls 1 as the case maybe. The rib or corbel 7 to 7d has holes 15, 15a, 15b, 15c, 15d for fixing, lifting, and joining. It also has sockets 14, 14a, 14b, 14c (Figures 9, 10, 12, 13) also for fitting or fixing the dowels or pins 17, 17a (Figures 9, 10, 12, 13, 16, 38, 39, 42) , for hauling 14b, and for fork lifting 14c.
Some ribs or corbel 7 has welding plates 16 (Figures 10, 12, 40, 43, 44) and welding angles 16a (Figures 40, 43, 44) to attach one with the other in order to attain structural integrity of the shelter or building.
Still, some ribs or corbels 7, 7a, 7b, 7c are also provided with lifting cylinders/bolfs 13a (Figure 18), or lifting bolts 13b (Figure 46) for lifting purposes. They also have vertical and horizontal target 22 and match groove 23 for alignment, better quality control and speed in the
installation process.
On the lower part of the waffle box 27, the ribs are developed as notches 8, 9 (Figures 3, 4, 5, 6, 17, 31 , 32, 45) that will fit these corbels 7, 7a, 7b, 7c. As a matching element of the corbel , 7a, 7b, 7c, (Figures 4, 5, 7, 8, 9, 1 1 , 16, 17), the notch 8, 9 has holes 15, 15a, 15b, 15c, 15d, (Figures 5, 7, 9, 1 1 , 16, 17, 38, 39) welding plates 16 (Figures 10, 12) to best prepare these waffle boxes 27 for an integrated structural box system of the shelter or building.
These matching connections like the socket 14, 14a, 14b, 14c , dowel or pin 17, 17a, welding plate 16, welding angle 16a, bolt 18, 18a, 18b and hole 15b, 15c , are then fixed (Figures 9, 1 1 , 16, 37), grouted
(Figures 9, 38), welded (Figure 40), tightened (Figures 1 1 , 39) , painted or sealed 21 (Figures 9, 1 1 , 38, 39, 40) , etc. to avert misalignment and corrosion and†o ensure the structural integrity of the shelter or building (Figures 21 , 37).
Optional features that are called wings 10, 10a, 10b (Figures 27, 28, 29) or corridors 8 or slabs 4 with specific purpose are monolithically added on corners of the box. Once installed in accordance with the procedures as stated in the later part herein, the extra space 24 (Figures 21 , 27a, 36, 37) or other spaces around the waffle box 27 receives the needed wall covering, slab, corridor or balcony or even additional living spaces without the need of extra activities on site. Punch openings for windows 12b, 12c, doors 12, 12a and stairs or elevator shafts 12, 12a, 12b, 12c, 12d, etc. are integrated in the
production process that will form part of the waffle box 27 for a specific use.
The weight of the structural box that was designed as waffle 1 , 2 is lighter than those designed using the traditional flat walls and columns or slabs and beams or girders, because of the hollow sections between ribs 5, 5a, 5b, 5c (Figures 2, 29). The walls 3 or slabs 4 (sometimes called skin) that connect the ribs are generally thinner. Furthermore, the term waffle 1 , 2 (Figures 2, 28) completely describes this reduced mass. A reduced mass or volume or weight requires thinner structural members, including foundation 26, and lesser or smaller steel
reinforcements or the like, hence, cheaper shelter or building.
Another prior art is worth mentioning as it is useful in understanding this invention.
Philippine Patent Number 24939, issued on December 26, 1990 with the Title: Shelter Components and Stocking Process for Multi-Storey Building; Inventor: Cesar V. Canchela of Quezon City, Metro Manila, Philippines, claimed in Item # 1 , "for a unitary prefabricated reinforced concrete rectangular-like shape body with opened longitudinal ends", "body having a planar bottom wall", "a pair of opposed planar sidewalls", "a pair of spaced apart outwardly extending post members , "a pair oppositely disposed support members" and "a planar top wall". Figures 1 and 2 of the said prior art also describes the claim.
The special technical features of a planar box which has a flat surface with end posts is different from the waffle box 27; that has thin wall 3 and slab 4 with a pattern of indentations called ribs 5 to 5d. The planar box has posts while the waffle box 27 has none. The planar box has flat walls while the waffle box 27 has a thin wall 3 with a pattern of vertical, horizontal or diagonal ribs 5. The planar box is closed on the top and bottom slab, while the waffle box 27 can be both closed and open provided that the perimeter corbel 7, 7a, 7b, 7c, 7d or notch 8, 9 or other ribs are retained for structural integrity of the waffle box 27. Waffle boxes 27 with open slabs 12d are used for stair well, air well, elevator shaft, pipes chase, atrium or the like, while the closed planar box is silent on this feature. The planar box is not the same as the waffle box 27 in form and in appearance. Additional research was made in
http://patentscope.wipo.int/search/en/search.isf, of which none appeared to have the slightest similarity with this invention.
A waffle slab tank for example as stated below dealt with tanks.
httDJ/patentscope.wipo.int/search/en/detail.isf?docld=WO2005056936& recNum=l &maxRec=l &office=&prevFil†er=&sor†Option=&auervStrina=FP %3A%28waffle+box+concrete%29&tab=PCTDescrip†ion
International application number PCT/AU 2004/001728, inventor Stephen Cordell, title Slab Tank. The waffle box 27 building technology is consistent in its goal to provide a lighter but equally stronger, highly resistant to typhoons, hurricanes and earthquake, cheaper, and fast construction method that will address the backlog in the affordable housing, public and private school, and other shelter or building projects of any country.
The waffle box 27 will have punched openings for windows 12b, 12c and doors 12, 12a on its vertical walls (Figures 5, 6, 30, 31 , 32). One door opening 12a (closed during casting but can be opened later) (Figures 2, 25) more or less situated at the mid span of the longer vertical side wall is earmarked for sideward room expansion (Figures 22, 23, 24). This expansion which is equivalent to a minimum one half (1 /2) size of the waffle box 27 (Figure 24), one waffle box 27 (Figure 23) or to as many as two waffle boxes 27, (Figures 22) allows the occupant, user, or buyer for more options to expand. Some waffle boxes 27 (Figure 27f), have punched opening for slabs
12d which are intended for the stairwell, air well, elevator shafts, pipe chases, atrium or the like. The opening can be resized accordingly provided that the perimeter corbel or notch or other ribs are retained to maintain the structural integrity of the waffle box 27. Still some waffle boxes 27 are fabricated with limited or even without walls in front and rear sides (Figure 27e) to give designers options for bigger windows and doors. In addition to this design option, this kind of waffle boxes 27 are best suited for mass production as the feature of free ends paves the way for fast and easy removal of interior forms. This will also make the waffle box 27 lighter.
In some instances, positioning of the waffle boxes 27 may be done in perpendicular with the other waffle boxes 27 in order to maintain structural integrity in both lateral directions of the shelter or building. This kind of mixed positions will require some features of the waffle box 27 to be adaptable.
Still, in remote cases whereby these waffle boxes 27 (without front and rear wall) (Figures 27e, 27f) lacks the needed lateral frame as a result of the removal of its front and rear wall, the structural engineer may integrate cas†-in-si†u structural elements like walls, beams, etc. in the system to come up with a structurally viable shelter or building.
Described in the preceding paragraphs are typical features of the waffle boxes 27 with five (5) Type I or six (6) sides Type II.
Type I five (5) sides waffle box 27 and Type II six (6) side waffle box 27 have different installation procedures. Both processes are claimed by this invention.
A. Type I Waffle Box 27 (5 sides, bottom slab open, installation is vertical on top of one another)
Type I waffle box 27 has five (5) sides. The bottom slab is left open. This opening is designed to fit to the upper slab of that same Type I waffle box 27. They are installed vertically on top of the other (Figure 20).
Type I waffle boxes 27 (Figures 1 , 2, 3, 4, 5, 6 7) vary in width and length but not in height when positioned in any part of the shelter or building (Figure 26). Type I waffle boxes 27 are installed in linear
progression from foundation 26 or base until the boxes reach the topmost deck (Figures 20, 21 ); hence, each column of boxes must have uniform width, length and height. The user of this invention might opt for Type I waffle boxes 27 with another width and length but not height in some other section of the shelter or building, but must follow the general rule of installing a uniform waffle box 27 from foundation 26 or base until it reaches the topmost deck (Figures 20, 21 ).
The practice of using different Type I waffle boxes 27 in a shelter or building gives the user flexibility in the design. It is however, suggested to use a uniform waffle box 27 in any section of the building in order to save for the cost of formworks and to benefit from operating on the economies of scale.
A series of pre-designed waffle slabs 2 or waffle walls 1 (Figure 27d) must be installed around these Type I waffle boxes 27 in order to
complete the structural box system of the shelter or building. Standard connection details like the dowels or pins 17 to 17b, bolts 18 to 18b, welding plate 16 and welding angle 1 όα are available for users to choose from.
B. Type II Waffle Box 27 (6 sides, installation is horizontal with extra space 24 in between waffle boxes 27)
Type II waffle box 27 has six (6) sides. They have uniform width, length and height in all parts of the shelter or building (Figures 36, 37).
The Type II waffle boxes 27 are laid horizontally with uniform space apart (Figure 27a), thereby creating one extra space 24 or room or unit between them. The horizontal distance of the center of the thin walls 3 of the waffle box 27 and that of the extra space 24 are equal (Figure 36, 37). As a general rule, the center line of the thin walls 3 from the foundation 26 (Figure 45) or base up to the topmost deck is aligned. Type II waffle boxes 27 have the same length, width and height (Figure 27b).
On the next upper level, the installation of the Type II waffle boxes 27 must start directly above the leftmost or rightmost extra space 24 and progressively towards the other end (Figure 27a). A waffle wall 1 and waffle wall and slab 29 are introduced at exterior end (Figure 27c) as the case maybe to complete the floor or level of the shelter or building. The horizontal installation of the Type II waffle boxes 27 is repeated to the next upper level until the structural box system of the shelter or building is completed (Figure 27a, 36, 37).
Using this horizontal installation process for Type II waffle boxes 27 means that when you install "x" number of waffle boxes 27, the result is "2x" number of usable boxes or spaces (Figure 36, 37) with end waffle wall 1 and combined waffle wall and slab 29, (Figure 36) being
introduced at some exterior end to complete the structural box system of the shelter or building. As a prefabricated construction system, plus this special method of horizontal installation, the construction period of a shelter or building is very much shorter as compared with a building done using the traditional way (post, beam, slab, wall system).
Should the users of the invention opt to design a double loaded shelter or building (Figure 27a) (two waffle boxes facing each other with common corridor), the horizontal installation of the line of waffle boxes 27 fronting the first row shall be alternate; the waffle box 27 facing the extra space 24 or the extra space 24 facing the waffle box 27 (Figure 27a). The Type II waffle box 27, (Figures 27, 27b) with extending corridor 6 is best suited for this design.
Users of the Type II waffle boxes 27 save on cost of formworks and enjoy the benefits from operating on the economies of scale. Again, a prior art mentioned earlier uses a similar process of installation for a single loaded shelter or building, one (1 ) row as shown in Figures 1 , 2, 5, 6 and 9 of the said invention. The same prior art was useful in the understanding of this invention that gave way for a better or improved horizontal installation process that is in accord with the invention's goal to address the backlog in the affordable housing, public schools, and other shelters or buildings in any country today thru an alternative building system that is lighter but equally stronger, high resistant to earthquake, typhoon or hurricane and subsequently cheaper and fast.
Philippine Patent Number 24939, issued on December 26, 1990, with the Title: Shelter Components and Stocking Process for Multi-Storey Building; Inventor: Cesar V. Canchela of Quezon City, Metro Manila, Philippines, claims as follows:
Claim 5. "A stacking process for shelter components as recited in claim 4 wherein mounting one shelter component on top of the shoulder portions of the two shelter components includes a plurality of spaced apart downwardly projecting anchoring bolts oppositely disposed at the bottom portion of said one shelter component adapted to be snugly fitted to a corresponding plurality of spaced apart embedded metal tubes disposed on top of the planar sidewall of said two shelter
components."
Claim 6. "A stacking process for the shelter components as recited in claim 4 wherein mounting one shelter component on top of the shoulder portions of the two shelter components further includes an upstanding angularly bent embedded steel bars having a fixedly secured metal plates disposed on opposite planar sidewalls of said one shelter component adapted to be weldably secured to the corresponding angular metal plates fixedly secured to an interconnected generally V- shaped steel bars embedded on the shoulder portions of said shelter components". Both claims 5 and 6 are supported with Figures 3, 4, 5, 6 and 7 of the said invention.
While there appears to be a similarity in the process of installation in both the planar box (prior art) and the waffle box 27(†his invention), both having space in between boxes and the next box above rests on both boxes below, and so on, there exists a seemingly obvious differences between the two arts which are summarized as follows:
1. While the installation process is seemingly similar, the prior art is silent to address or describe in the specifications and also by way of figures how the stairs, elevator shafts, pipe chases, air wells, garbage chutes, or the like which are vital elements of a shelter or building, are incorporated during the upward installation of boxes. There is a need for an opening 12d in the slab or even wall to accommodate these basic features of a building or shelter. This invention attempts to provide a unique solution to that need.
This invention of Type II six (6) side waffle boxes 27 with punch opening for stair, elevator shaft, etc. (Figure 27f) that are laid similarly as the prior art, but will not need any introduction of cas†-in-place walls or structure to accommodate those vital openings of the shelter or building. Stairs can be prefabricated and installed in the open stair wells without cast-in-place operations. Same with the others like elevators, etc. as the predesigned punched opening 12 are provided for.
This invention having included in the installation or stacking process the punched opening 12d for the stair, elevator, chases and the like which are vital elements of a shelter or building laid a predicate that the prior art and this invention are two different special technical features. Cast-in-place operations will affect the concept of mass production if those openings are done on site.
While both prior art and this invention aim to address the backlog in the affordable or mass housing and other building project of any country by means of the stacking or
installation process of the boxes (Figures 27a, 36, 37 of this invention), the prior art cited on the single loaded shelter or building (single row building) as explained in the
specifications and shown in Figures 3, 4, 5, 6 and 7 of the said prior art. The double loaded design as featured by this invention utilizes a common corridor or hallway for the livable units in the case of housing project or classrooms in the case of school projects, thereby maximizing the use of the lot.
This invention considers both single loaded and double loaded designed buildings. Beyond the installation or stacking process of the first row of waffle boxes 27, there exists in this invention another unique product and process of installing the second row of waffle boxes 27 (Figure 27a), specifically designed for a double loaded shelter or buildings. The waffle boxes 27 have corridors 6 which are extensions (or wings) of both the top and bottom slabs 4, (Figure 27b, 36, 37). The protruding length of the corridor 6 is half the width of the hallway. Using the first row of installed waffle boxes 27 (also with corridors 6), the new waffle boxes 27 will be fitted alternately in front of the extra spaces 24 (Figures 27a, 27b, 36) aligning the edges of both the corridors 6 of the first row and the second row of the waffle boxes 27 (Figure 27a). On the next upper level, the resulting structure will have the top corridor 6 of the first row of waffle boxes 27 meet with the bottom corridor 6 of the second row of waffle boxes
27(Figure 27a). The installation process is repeated
alternately for the waffle box 27 in front of the extra space 24 and the extra space 24 in front of the waffle box 27, (Figures 27a, 36). As the top and bottom corridors 6 of the waffle boxes 27 meet alternately, the hallway is completed (Figure 27a). The width of the hallway is the total length of the two meeting corridors 6 (Figure 27a, 35, 42). Like in the previous specifications of the Type II waffle boxes
27, waffle wall 3 and combined waffle wall and slab 29 (Figure 27c) are introduced at exterior end to complete the structural box system of the shelter or building.
In the above difference #2, the lot is maximized by designing a double loaded high density shelter or building using the invention, which is an improvement of the prior art. The cost is cheaper as the cost of common facilities like the hallways, stairs, or elevators is distributed between the fronting units. Another unique feature of this invention is Type I waffle box 27 (5 sides) which is installed vertically on top of one another (Figures 20, 21 ). This installation process of Type I waffle box 27 is significantly different from the said stacking process of the said prior art. All the waffle boxes 27 are precast and mass produced in
fabrication sites without or in extreme cases a very minimal cas†-in-place operation on site. All the waffle boxes 27 are uniform (except for the punched slab opening 12) thereby the user of the invention enjoys the benefit of producing by economies of scale.
Another prior art, Philippine Patent Number 12302, issued on
January 16, 1979, with the Title: Pre-cast Reinforced Concrete Frame for a Multi-story Building Construction System, whose inventor Gregorio C.
Concepcion of Quezon City, Metro Manila, Philippines, claims as follows: "A concrete wall structure for use in multi-storey building
construction system, comprising of a set of lower frames anchored to the ground foundation such that the upper horizontal ribs of said lower frames are horizontally aligned with each other, ... and a set of upper frames rigidly secured on top of said set of lower frames and consisting of spaced-apart frames such that the vertical ribs of the upper frames are vertically aligned with their corresponding vertical ribs of the lower frames... "
While the above prior art describes a similar stacking process of a frame that also runs in parallel with the previous Philippine Patent Number # 24939 that uses a planar box, there exist in this invention a unique product (waffle box 27) and installation process (beyond the single- loaded building) that will differentiate this invention from what was earlier contributed by the mentioned prior arts.
Basing on the above installation process of a double loaded designed shelter or building, there is a totally different concept of installation by this invention. First, the double loading concept and the second is the alternate installation of the second row of waffle boxes 27 which was not touched by the prior art and third, the vertical installation process of Type I waffle boxes 27.
Further to the Type II waffle box 27 with six (6) sides, the waffle slab 2 will meet with the waffle wall 1 which will form a "z" notch 9 (Figure 38, 39, 44, 45) at the bottom (Figures 38, 39, 40). These matching connections like the socket 14, 14a, 14b, 14c, dowels or pins 17, 17a, welding plates 16, welding angles 16a, and holes 15b, 15c, as earlier described are then fixed (Figure 37, 39, 40), grouted (Figure 38, 39 ), welded (Figure 40), tightened (Figure 39), painted or sealed 21 (Figure 37), etc. to avert misalignment and corrosion and to ensure the structural integrity of fhe shelter or building (Figure 37).
Buildings or shelters that are designed to have uniform room layout per floor (Figures 36, 37) (as in high rise buildings, dormitories, inns, mass housing, schools, etc) are easier, faster, and cheaper to construct using this invention.
The Type I waffle boxes 27 with five (5) sides (no bottom slab) are installed on top of one another (Figures 20, 21 ), while the Type II waffle boxes 27 with six (6) sides are installed alternately on top of the two other waffle boxes 27 (Figures 36, 37). A waffle wall 1 , combined waffle wall and slab 29 and a waffle slab 2 are special waffle individual units (not fabricated as box) that will be integrated at exterior ends and deck (Figures 27c, 36), as the case maybe, until the installation of the waffle box 27 shelter or building is completed (Figure 37).
The corridor of the Type I five (5) side is a precast slab 2 (Figure 26) or a cas†-in-place slab whichever is economical and feasible.
The uppermost deck (Figure 20, 21 ) of the building using the waffle boxes 27 will be given special attention to control leak in the future. A slope and a sealant 21 , (Figure 42) is a must for the roof deck to be leak- free (Figure 37).
The design of cast-in-place foundation 26 (Figures 17, 45) is dictated by the nature of soil, heighf and size of the building, earthquake zoning and other design parameters.
In either type of waffle boxes 27, the stair well, air well, elevator shaft, pipe chase, and the like (opening 12d is dictated by need) are left open (Figure 27f) with attachments or provisions for their specific use. Stairs can be prefabricated concrete or steel. In either case, these waffle boxes 27 create additional spaces around, between, below and above them without spending more for the vertical support (Figures 20, 21 , 36, 37). This invention, especially the Type II six (6) sides waffle box 27, creates almost double the number of usable spaces (Figures 36, 37) without the need for more extra activity and cost except in some end spaces (where a box can't fit) wherein a combined waffle wall and slab 29 ("L" shape slab) and waffle wall 1 is to be installed or constructed (Figure 36).
In the case of single detach residential houses, the Type II six (6) sides waffle boxes 27 are laid one space apart, some aligned in front while others are moved forward or backward (Figures 47, 48, 49, 50, 51 , 52, 53, 54, 55, 56) as the case maybe, in order for the designers to be creative in aesthetic designs and specific purpose like balcony, stair, attic, toilet and bath, etc. Roof is an option while users of the invention can utilize the concrete slab 2 as deck. Walls are specially fabricated. It is the goal of this invention to simplify, reduce, or eliminate the redundancy, repetitive work, wastages, etc. brought about by the numerous construction activities done above ground including hauling up of materials, tools, equipment and movement of workers up and down (especially for high rise buildings), resulting to speed, efficiency, economy, and quality of the building. The waffle boxes 27 therefore, including its electrical, plumbing, cable, telephone, internet, alarm, background music pipes, etc., wiring and architectural and other finishes are done or can be done af the ground floor level or off-site fabrication sites, thereby transforming these waffle boxes 27 as a pre-assembled, pre-finished or plug-in, and ready to use units of a shelter or building.
Fabrication of the structural waffle boxes 27; in sections or whole, is dictated by the hauling, lifting, stocking, and actual situations on site or off-sites. The mass production of the waffle boxes 27 is done in controlled fabrication sites.
Cast-in-place waffle boxes 27, in extreme or special circumstances are done or can be done at job sites.
Lifting mechanisms are made of metal rods 13, cylinder 13a, bolts 13b with matching hooks (Figures 18, 19), that are all embedded in the concrete (Figures 18, 19), or socket 14b at the base in the case of a fork lifting equipment Their frequency, sizes and anchorages are all subject to the results of the structural design.
Simple but strong connection notches 8, 9, holes 15, dowels/pins 17, bolts 18, steel angles 16a or plates 16, lifting hooks 13, or cylinders 13a, etc. (Figures 1 1 , 12, 14) of different materials, sizes and shapes that encompasses the invention's goal of ease, practicability, efficiency, economy, stability and strength as shown or as presented in the drawings including the design, formworks, fabrication, lifting, hauling, placing, and fixing of the boxes to form a complete "waffle box 27" building sysfem are covered by this invention.
Most specifically, as a prefabricated, prefinished, plug-in or insulated structural waffle box 27, this invention minimizes the repetitive hauling, lifting, transporting of materials, tools, manpower from the ground up to the building (especially for high rise building), thereby cutting construction costs, improving work efficiencies, and maintaining product quality under a controlled work place at the ground floor or fabrication sites.
The space between the ribs 5 where the waffles are created can be used to hold heat and sound insulation materials thereby upgrading this invention as an insulated concrete building technology.
Other than the purpose of creating a unique product and
installation process claim for the invention, it is further aimed to develop a simple, durable, workable, economical, efficient, functional, light, fast and easy construction system that will solve the backlog in affordable housing, public and private schools, offices, hotels, dormitories, inns, apartments, etc, and in other small, medium or high rise building or shelter projects in any country. In the design and the actual implementation of this invention, some or several parts of the waffle boxes 27 and the technology as a whole will be modified to suit its adaptability to the present and future times.
Materials to be used for the present design and for the further development of the technology in order†o maximize the benefits therein, can be any kind of concrete, steel, formed sheets, plastic, wood, laminates, or their combinations and other adaptable, cheaper and available building materials of the future.
These stated improvements above become parts and partial of the invention.
For practical reasons in future site conditions, magnitude of projects, budget limitations, etc. the technology can shift to a cas†-in- place method of construction but still using the same process of building the waffle boxes 27 either directly above one another or alternately above the others.
Covered by this invention are the following:
1. For residential use whether one or two-storey, single detached, multi-dwelling, duplex, quadrant, row house, walk-up or multistorey apartment, townhouse, dormitory, condominium, affordable or mass housing, or all kinds of shelters.
2. For commercial use like office building, hotel, motel, inn, call center, mall, parking space, or all kinds of shelters of similar use.
3. For institutional use like school building, learning center, day care center, hospital, clinic, government center, or all kinds of shelters of similar use.
4. For any kind of box-like structures laid vertically, horizontally or diagonally like bridge, canal, caisson, well, tunnel, shaft, or the like that will fall within the basic principle of mass production, economics, speed, strength, etc.
BRIEF DESCRIPTION OF THE FIGURES
The figures below will describe and illustrate the waffle box 27 technology. The figures although numbered in progression are grouped in two types. Type I describes about the five (5) side waffle box 27 (Figures 1 to 26), while Type II describes about the six 6) side waffle boxes 27(Figures 27 to 56).
The Type I five (5) side waffle box 27 is ideal for houses, shelter or building with different sizes of rooms. The Type I waffle box 27 with one bottom side open are installed on top of the other from foundation or base level to the topmost deck. The shelter or building can use different sizes of Type I waffle boxes 27. The general rule however, in using Type I waffle box 27, is to use same size waffle boxes and install them vertically in linear progression from foundation or base level to the topmost deck of the shelter or building. Then a different size of Type I waffle box 27 (but height must be the same) may be used in other parts of the same building, but the installation must be similar which is vertically in linear progression from foundation or base level to the topmost deck of the same shelter or building. The adjacent waffle slabs 2 are designed and fabricated to fit to the peripheral spaces around the Type I waffle boxes 27.
The Type II six (6) side waffle box 27 use the same waffle boxes (uniform in width, length and height) from foundation or base level to topmost deck, regardless of its position in the shelter or building. The waffle boxes 27 are placed horizontally with an extra space 24 in between them. These extra spaces 24 or units are created using the walls 1 of these two adjacent waffle boxes 27. The distance between the center lines of the thin walls 3 of the waffle box 27 and that of the extra space 24 are equal, so that when another waffle box 27 is laid on top of them (above the extra space 24), the corbel 7 will be able to receive and fit the succeeding waffle box 27. The process is repeated until the shelter or building is completed. The general guideline is that all centerline of the thin walls 3 of all the waffle boxes 27 at any level of the shelter or building are vertically aligned from the base level or foundation up to the topmost deck
End waffle wall 30, combined waffle wall and slab 29 and waffle slab 2 are placed at exterior end or deck to complete the box system. Figure 36 illustrates these components.
Type II six (6) side waffle box 27 have walls 1 in front and rear with punch opening for doors 12 and windows 12b, 12c or stairs, elevator shaft, etc. 12d. Type II six (6) side waffle box 27 is ideal for mass production especially for large projects or buildings. With front and rear walls 1 open, of the Type II waffle box 27, the removal of forms is faster. The reduction of walls 1 as a result of the front and rear opening 12, 12b will be addressed by rearranging the waffle boxes' 27 position (architect's' design) or in extreme cases introducing cast-in-place walls or other structural elements (structural engineer's design) at strategic areas in the shelter of building to maintain the structural integrity of the building. Punch opening or block out on walls 1 or slabs 2 intended for these cast-in-place structural elements can be integrated during casting of waffle boxes 27. Once poured on site, they become an integral part of the structure.
There are instances where waffle boxes 27 have punched openings 12, 12a, 12b, 12c, 12d to meet a desired need (window, door, stair, shaft, view area like atrium, or scenic elevator etc.) on almost all sides of the waffle boxes 27. These conditions are allowed provided that the general rule is that those critical horizontal and vertical ribs including the corbel 7 8, 9 and notch are left intact and must seek clearance from a structural engineer.
A. Type I Five (5) Sides Waffle Box 27; Figures 1 to 26 Figure 1 is a plan of the five (5) sides waffle slab 2 with some basic features.
Figure 2 and 2a is a plan showing the bottom open side and the waffle wall 1 and its components like the wall 3> ribs 5, door and window opening 12. The ribs 5 are trapezoidal in shape for easy removal of forms. Figure 3 is a sectional elevation showing ribs 5, window opening 5b, corbel 7 and inverted notch 8. Also shown near the corbel 7 is a vertical and horizontal target 22 that will help plumb or align the building during the installation process. Below also shows the match groove 23 that will help align the lower and upper waffle boxes 27 during the installation process.
Figure 4 is cross section showing waffle wall 1 and slab 2, ribs 5, window opening 12b, corbel 7 and inverted notch 8. Also shown on the corbel 7 are sockets for dowels 14. Shown on the inverted notch 8 below are holes 15e also for dowels. Figure 5 is cross section showing waffle wall 1 and slab 2, window and door opening 12, corbel 7 and inverted notch 8. Sockets for corbel 14 and holes for the inverted notch 15e and lifting 15d are also shown.
Figure 6 is a sectional elevation showing ribs 5, window and door opening 12, corbel 7, inverted notch 8 and vertical/horizontal target 22. Figure 7 is sectional elevation showing ribs 5, waffle wall 1 , door opening 12, inverted notch 8 and holes for lifting 15d. Also shown are dotted lines showing holes for dowels or pins 15, vertical and horizontal target 22 and match groove 23.
Figure 7a is similar to Figure 7 but features the diagonal ribs 5.
Figure 8 is a longitudinal section showing waffle wall 1 and slab 2, corbel 7, door and window opening 12 holes for lifting and dowels or pins 15. Also shown on the upper left is the wall and slab connection and also on right is the corbel 7 and waffle slab 2 connections.
Figure 9 is a waffle box 27 to waffle box 27 and waffle slab 2 connections. The Type I five (5) side box is placed on top of each other. After alignment of the waffle boxes 27, the dowels or pins 17 are fixed and grouted. The waffle slab 2 is placed next. In the Type I five (5) side waffle box 27, these waffle slabs 2 around the waffle boxes 27 differ in length and width but not in height. These waffle slabs 2 are fabricated and installed individually. Figure 10 is a waffle box 27 and deck slab 2 connections. Also shown are the sealant 21 , hole 15> dowel or pin 17 and socket 14.
Figure 1 1 is a bolt connection 18a which is an alternative waffle box 27 to waffle box 27 connection. This type of connection can be also used as a temporary connection because the bolts 18 can be loosened and removed.
Figure 12 is a welding plate 16 and/or dowel or pin 17 connections. The plates 16 are welded to fix the slab 2 to the corbel 7. The socket 1 , hole 15, dowel or pin 17 is a separate type of connection that can be used as an alternative to fix the waffle slab 2 to the corbel 7. Figure 13 is a waffle box 27 to corridor 6 waffle slab 2 connections. Shown also are the socket 14, hole 15 and dowel or pin 17 connections. Sealant 21 is also shown. Figure 14 is waffle slab 2†o waffle slab 2 connections. This connection is used when two (2) waffle slabs 2 meet.
Figure 15 is waffle box 27 front wall connection. Shown are welding plate and angle connection. Socket, hole, dowel or pin connection can be used also.
Figure 16 is end waffle wall 30 connection. This connection applies when no adjacent slab is needed.
Figure 1 7 is cast-in-place slab-on-fill and/or foundation 26 to waffle box 27 connection Figure 18 is an alternative lifting mechanism using a threaded cylinder with matching bolt with hook 13a.
Figure 19 is another lifting mechanism using rod with matching hook and eye 13.
Figure 20 shows how the Type I five (5) side waffle boxes 27 are placed or installed on top of another. Also shown is the adjacent waffle slab 2. The waffle boxes 27 are uniform while the waffle slab' 2 width and length may vary. The uniform waffle boxes 27 with their corbel 7 and connections support these waffle slabs 2 around fhem. This type of waffle box 27 is ideal for residential or multi storey buildings with different room sizes. The general rule here is to make one or a couple of boxes uniform from foundation or base level to the topmost deck of the building so they can be installed or placed on top of one another. The waffle slabs 2 around the Type I waffle boxes 27 will follow.
Figure 21 is a cross section of a completed horizontal and vertical installation of the Type I five (5) side waffle boxes 27 and waffle slabs 2, Figure 22 is a floor plan showing the side door opening 12a that allows the user†o expand sideward equivalent to two rooms or waffle boxes 27.
Figure 23 is a floor plan showing the side door opening 12a that allows the user to expand sideward equivalent to one room or waffle box 27. Figure 24 is a floor plan showing the side door opening that allows the user to expand sideward equivalent to one half room or waffle box 27.
Figure 25 is an isometric of Type I 5 sides waffle box 27 with window and door opening 12.
Figure 25a is an isometric of Type I waffle box with window and door opening 12. This kind of waffle box 27 normally is installed on the deck. The bottom slab 2 is open for stair well, pipe chase, elevator shaft or the like.
Figure 26 shows the progressive placement or installation of Type I 5 side prefabricated waffle boxes 27 and waffle slabs 2 around it.
B. Type II Six (6) Sides Waffle Box, Figures 27 to 56
Figure 27 is an isometric of Type II 6 side waffle box 27 with wings 10 (front, rear walls, and corridors),
Figure 27a is an isometric of a Type II 6 side waffle box 27 with wings (front and rear walls, and corridor) 10 showing progressive installation.
Figure 27b is an isometric of the installation process of Type II 6 side waffle box 27 with wings (front and rear walls, and corridor) 10. The installation of the waffle boxes 27 at any same level is one extra space 24 apart. The installation of the second row of waffle boxes 27 for a double loaded designed building is also shown. The new waffle box 27 will rest above the extra space 24 created by the 2 lower waffle boxes 27.
Figure 27c is an isometric of the installation process of Type II 6 side waffle box 27 with wings (front and rear walls, and corridor) 10. Also shown is the combined waffle wall with slab 30, waffle slab 2, and waffle wall 1. These four (4) structural elements comprise the structural box system of the shelter or building. The waffle slabs 2 are punched or left open if you need it as stair, air well, elevator shaft or the like.
Figure 27d is an isometric of the waffle slabs 2, waffle walls 1. Figure 27e is an isometric of the Type II 6 side waffle box 27 with corridor wings 10.
Figure 27f is an isometric of the Type II 6 side waffle box 27 with corridor wings 10, with punch opening for stair well 12d. Punch opening 12d for waffle slab 2 can be wider or 100 percent open depending on the use, provided the perimeter frames, ribs 5, corbel 7, notch 8, 9 are left intact.
Figure 28 is a plan of the Type II six (6) sides waffle box 27 showing top waffle slab 2 including corridor 10a and some basic features.
Figure 29 is a plan showing the bottom waffle slab 2 and the waffle wall 1 and its components like the wall 1 , ribs 5, door and window opening 12. Figure 29a is a plan showing the Type II 6 side waffle box 27' bottom waffle slab 2 and the waffle wall 1 and its components like the wall 1 , ribs 5, door and window opening 12 and corridor wing 10a.
Figure 29B is a plan showing Type II 6 side waffle box 27 opening for stairwell 12d. Openings for slabs 2 are variable as needed, provided the horizontal and vertical ribs 5 including corbel 7 and notch 8, 9 around are left intact. Figure 30 is a sectional elevation showing the wings 10, ribs 5, window opening 12, and corbel 7. Also is a vertical and horizontal target 22 that will help plumb or align the building during the placement or installation process. Below also shows the match groove 23 that will help align the lower and upper waffle boxes 27 during the placement or installation process.
Figure 31 is cross section showing waffle wall 1 , wings 10 and slab 2, ribs 5, window opening 12, corbel 7 and "z" notch 9. Also shown are sockets 14 and holes 15 for dowels or pins 17 and holes for lifting rod 15d. Figure 32 is cross section showing waffle wall 1 , wings 10 and slab 2, window and door opening 12, corbel 7 and "z" notch 9. Sockets for corbel 15 and holes for the "z" notch 15b and lifting 15d are also shown.
Figure 33 is a sectional elevation showing wings 10, ribs 5, windows and door opening 12, corbel 7 and "z" notch 9. Vertical and horizontal target 22 and match groove 23 are also shown.
Figure 34 is sectional elevation showing corridor 10a, ribs 5, waffle wall 1 , door opening 12a, "z" notch 9 and holes for lifting 15d. Also shown are dotted lines showing holes for dowels or pins 15, vertical and horizontal target 22 and match groove 23. Figure 35 is a longitudinal section showing corridor 10a, waffle wall 1 and slab 2, corbel 7, door and windows opening 12, holes for lifting 15d and dowels or pins 17. Also shown is the corridor rib 5.
Figure 36 shows the placement or installation process of the Type II six (6) side waffle boxes 27. The waffle boxes 27 have one size only. First, they are laid horizontally with extra space 24 between waffle boxes 27. The waffle walls 1 of the waffle boxes become the wall of the extra space 24. The distance between the center line of the thin wall 3 of the waffle box 27 and the extra space 24 are equal. On the next upper level, the Type II six (6) side boxes 27 are placed on top of the extra spaces 24. The "z" notch 9 of the waffle box 27 being installed on the upper level will rest on the corbel 7 of the two waffle boxes 27 which are already installed below. Once installed, the waffle slab 2 becomes the ceiling of the extra space 24. The installation process is repeated until the shelter or building is completed. The general rule is that the thin walls 3 from the foundation or base level up to the topmost deck are aligned. The number of waffle boxes 27 installed will create rooms or usable spaces equivalent to twice as much as their number.
Shown in the figure are end waffle wall 30, combined waffle wall and slab 29 and waffle slab 2 that are placed on exterior end or deck to complete the waffle box 27 system.
The foundation 26 or slab is also designed to fit to the "z" notch 9 of the waffle boxes 27.
Figure 37 is a cross section of a completed horizontal and vertical placement or installation of the Type II six (6) side waffle boxes 27 including end waffle wall 30, combined waffle wall and slab 29 and waffle slab 2. The figure shows that the number of usable spaces or units created by this technology is twice the number of waffle boxes' 27 fabricated and installed. The technology cuts the labor cost and construction time by a substantial figure by almost half,
Figure 38 is a waffle box 27 to waffle box 27 connection. The six (6) side waffle box 27 is placed on top of the extra space 24, thereby having the "z" notch 9 rests on the corbel 7 of the waffle boxes 27 previously installed below. The figure shows the socket 14, hole 15 and dowel or pin 17 connections. Figure 39 is a bolt connection 18a which is an alternative waffle box 27 to waffle box 27 connection. This type of connection can be also used as a temporary connection because the bolts can be loosened and
removed. Figure 40 shows welding plate and welding angle 16 connection.
Figure 41 shows the front wall 3 connection using welding
plate/anchorage and welding angle/anchorage 16.
Figure 42 is waffle slab 2 to waffle slab 2 connections. This connection is used when two (2) waffle slabs 2 meet, in this case, at the corridor. Figure 43 shows welding plates and welding angle 16 connection, Shown are waffle deck slab 31 and corbel 7 connections.
Figure 44 shows welding plates and welding angle 16 connection, Shown is end waffle wall 30 and corbel 7 connections.
Figure 45 shows cas†-in-place slab and foundation 26 and prefabricated waffle box 27
Figure 46 is an alternative lifting mechanism using a bolt 13b.
Figure 47 is a ground floor plan for single detached house showing aligned waffle boxes 27wi†h an extra space 24 created at ground level and forwarded waffle box 27 at the second level. The garage, porch, living, dining, kitchen, stair well, or toilet and bath were created at the ground level.
Figure 48 is a second floor plan for single detached house showing aligned waffle boxes 27 with extra space 24 at ground level and forwarded waffle box 27 at the second level. The bedrooms, stair well, family area, balconies, toilet and bath were created at the second level. Figure 49 is an attic plan for single detached house showing aligned waffle boxes 27 with extra space 24 at ground level and forwarded waffle box 27 at the second level and an attic with roof at the third level. The attic was created by utilizing the upper slab 2 of the waffle box 27. Roof was used to cover the extra spaces 24 at the second level and attic at third level.
Figure 50 is a cross section showing the 3 waffle boxes 27 and the 3 extra spaces 24 plus the attic that were created. All the needed spaces like living, dining, kitchen, garage, stair, toilet and bath, balconies, family room, etc. of a typical house were provided for.
Figure 51 is a ground floor plan for single detached house showing 2 aligned waffle boxes 27 with 3 extra spaces 24 (1 at ground and 2 at second level). The garage, living, dining, kitchen, stair well, or toilet and bath were created at the ground level. Figure 52 is second floor plan for single detached house showing 2 aligned waffle boxes 27 with 2 extra spaces 24 or bedrooms at the second floor level. A roof was made to cover this second floor level. The arrangement of the waffle boxes 27 are versatile and will depend on the ideas of the architect or user of the technology. Figure 53 is a cross section showing the 2 waffle boxes 27 and the 3 extra spaces 24 that were created. A roof covering is shown.
Figure 54 is a ground floor plan for single detached house showing a single waffle box 27 with 2 extra spaces 24 created at ground level and one extra space 24 at the second level. The garage, living, dining, kitchen, stair well, or toilet and bath were created at the ground level. Figure 55 is a second floor plan for single detached house showing a single waffle box 27 with one extra space 24 at the second level. A bedroom and a stair well were created at the second level.
Figure 56 is a cross section showing a single waffle box 27 and the 3 extra spaces 24 (2 at ground and 1 at second level). All the basic elements of a house were provided for.
Figure 57 is a waffle box building technology code.

Claims

CLAIMS The claims consist of the following:
1 . A series of thin walls 3 or slabs 4 (prefabricated and/or cast or
mould- in-place) with a pattern of rib 5 indentations (Figures 2, 29) on all sides that form square, rectangular or triangular waffles (Figures 7, 7a)so that when joined (welded, bolted, pinned, cast monolithically and/or other improved method) will constitute the structural box system of a shelter or building (Figure 21 , 37). The pattern of the indentations can be vertical, horizontal, diagonal, longitudinal or transverse.
2. A five (5) or six (6) side rectangular prefabricated, prefinished, plug- in or insulated waffle boxes 27 grouped as Type I and Type II.
Type I, having five (5) side waffle box 27 of which the bottom slab is open, with or without wings (window, door, corridor, or slab) 10, with punched openings for windows, doors or stair, elevator shaft, etc. 12, with adjacent waffle slab 2 or wall 1 so that when joined together following the vertical installation process (Figures 20, 21 ) as explained above will form the structural box system of a shelter or building.
Type II, having six (6) side waffle box 27 with or without wings , (window, door, corridor, or slab) 10, with punched openings for windows, doors, stair, elevator shaft, etc. 12, so that when joined together following the horizontal installation process (Figures 27a, 36, 37) as explained above will form the structural box system of a shelter or building.
3. A vertical process of installation of the Type I five (5) side)
prefabricated waffle boxes 27 done in vertical linear progression (one on top of the other) from the foundation or base level to topmost deck (Figures 20, 21 ). This Type I prefabricated waffle boxes 27 become the vertical support of the waffle box 27 above them and the waffle slabs 2 or waffle walls 1 around them. The lower floor or level composed of waffle boxes 27, waffle slabs 2 or waffle walls 1 must be integrated or completed first before proceeding to the next upper level. Once interconnected (waffle box 27, waffle wall 1 , and waffle slabs 2), using the enumerated connections like the bolt 18, weld plate or angle 16, dowels or pins 17, etc., they become the structural box system of a shelter or building.
4. A horizontal process of installation of the Type II six (6) side)
prefabricated waffle boxes 27. These Type II waffle boxes 27 are laid one extra space 24 apart horizontally, thereby creating one extra space 24 or room or unit between them (Figures 27a, 36, 37). This horizontal distance of the center line of the thin walls 3 of the waffle box 27 and the extra space 24 are equal. As a general rule, the centerline of the thin walls 3 of Type li waffle boxes 27 from the foundation 26 or base level to the topmost deck are aligned. Type II waffle boxes 27 have the same length, width and height.
On the next upper level, the installation of the Type II waffle boxes 27 must start directly above the leftmost or rightmost extra space 24 and progressively towards the opposite end (Figure 36). A waffle wall 1 and combined waffle wall and slab 29 are introduced at exterior end as the case maybe to complete and stabilize the floor or level. The horizontal installation is repeated to the next upper level until the structural box system of the shelter or building is completed.
Should the user of the invention opts to design a double loaded shelter or building (two waffle boxes 27 facing each other), the horizontal installation of the line of waffle boxes 27 fronting the first row shall be alternate; the waffle box 27 facing the extra space 24 or the extra space 24 facing the waffle box 27. The Type II waffle box 27 with extending corridor (wing) 10a is best suited for double loaded design.
5. A trapezoidal corbel 7 and inverted notch 8 for Type I waffle boxes 27 and also a trapezoidal corbel 7 and "z" notch 9 for Type II waffle boxes 27 complete with sockets 14, holes 15, welding plate or welding angle 16, embedded mechanisms, vertical/horizontal target 22 and groove 23 , all created with specific purpose, for connection: dowel 17, bolt 18, or weld 16, for lifting: cylinder with bolt, rod with eye, bolt with fork 13, socket for fork lift), for hauling: socket with lock 14, for quality control and fast installation:
vertical/horizontal target 22 and match groove, 23 all shown in the figures.
6. A lightweight or standard weight waffle boxes 27 made of all kinds of concrete (standard or blended), plastic, wood or its derivative like laminated wood, metal including steel sheet or its improved products like the pre-formed, bended, punched sections, aluminum, fiber glass, glass or any applicable materials of today and of the future that will encompass or fulfill its true objective to be lighter but equally stronger, highly resistant to earthquake and hurricanes, cheaper and fast alternative shelter or building technology.
7. All sorts of false or formworks to cast, fabricate, mould, create and turn these waffle boxes 27 and its components as described above into usable parts of the shelter, building, or any type box-like structure.
PCT/PH2013/000002 2012-07-27 2013-01-23 Waffle box building technology WO2014017931A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
BR112015001824A BR112015001824A2 (en) 2012-07-27 2013-01-23 horizontal and vertical installation process, and prefabricated, prefinished product.
AU2013293648A AU2013293648A1 (en) 2012-07-27 2013-01-23 Waffle box building technology
CN201380043055.4A CN104641048B (en) 2012-07-27 2013-01-23 Waffle grid casing Building technology
IN2320MUN2014 IN2014MN02320A (en) 2012-07-27 2014-11-14
ZA2015/00503A ZA201500503B (en) 2012-07-27 2015-01-23 Waffle box building technology
HK15106651.0A HK1206085A1 (en) 2012-07-27 2015-07-13 Waffle box building technology

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PH12012000216 2012-07-27
PH12012000216 2012-07-27

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IN (1) IN2014MN02320A (en)
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CN108532766A (en) * 2018-05-20 2018-09-14 王燏斌 A kind of assembled box building and its constructing device and construction method

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WO2018029073A1 (en) * 2016-08-08 2018-02-15 Fundación Tecnalia Research & Innovation Construction module
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CN112853916A (en) * 2021-03-09 2021-05-28 甘肃畅陇公路养护技术研究院有限公司 Assembled waffle bridge panel combined box girder structure and construction method thereof

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CN104641048B (en) 2017-11-07
HK1206085A1 (en) 2015-12-31
IN2014MN02320A (en) 2015-08-07
AU2013293648A1 (en) 2014-12-04
CN104641048A (en) 2015-05-20
BR112015001824A2 (en) 2017-07-04

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