WO2023229640A1 - Systèmes de construction non combustibles à bilan énergétique nul - Google Patents
Systèmes de construction non combustibles à bilan énergétique nul Download PDFInfo
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- WO2023229640A1 WO2023229640A1 PCT/US2022/052301 US2022052301W WO2023229640A1 WO 2023229640 A1 WO2023229640 A1 WO 2023229640A1 US 2022052301 W US2022052301 W US 2022052301W WO 2023229640 A1 WO2023229640 A1 WO 2023229640A1
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- WIPO (PCT)
- Prior art keywords
- concrete
- insulation layer
- wall panel
- layer
- fiber
- Prior art date
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- 238000009413 insulation Methods 0.000 claims abstract description 96
- 239000011210 fiber-reinforced concrete Substances 0.000 claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 39
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
- E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/001—Mechanical features of panels
- E04C2002/002—Panels with integrated lifting means, e.g. with hoisting lugs
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
- E04C2002/045—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete with two parallel leaves connected by tie anchors
- E04C2002/047—Pin or rod shaped anchors
Definitions
- the present disclosure generally relates to non-combustible building systems in the residential and commercial construction industry.
- the present disclosure describes an insulated concrete wall panel for residential and commercial structures.
- the systems described herein may be used for preventing structural fire and combustion damage and, additionally, for providing energy-efficient and net-zero energy results to residential and commercial buildings.
- Embodiments of the present disclosure present a sandwich wall panel with an insulation layer between two layers of concrete. Unlike prior sandwich wall configurations that use steel- reinforced concrete for the outer layers, the present disclosure describes the use of fiber- reinforced concrete, which is lighter, stronger, and more fire resistant. It is known throughout the construction industry that concrete has high strength under compression but relatively low strength under tension.
- a wall panel that includes: at least two fiber-reinforced concrete layers including concrete with interwoven fibrous materials; an insulation layer; and a connector.
- the insulation layer is sandwiched between the at least two fiber-reinforced concrete layers, and the connector extends through the insulation layer and concrete layers to create composite action between the insulation layer and the concrete layers.
- Other implementations of this aspect include corresponding systems, apparatus, and methods.
- innovative aspects of the subject matter described in this specification can be embodied in methods that include actions of: providing a preset mold having a length in a first lateral dimension and a width in a second lateral dimension; forming a first concrete layer by pouring a wet concrete mix containing fibrous material into the preset mold; while the concrete mix is still wet, installing an insulation layer and one or more connectors such that the insulation layer and connectors embed into the first concrete layer in the preset mold; forming a second concrete layer by pouring the concrete mix containing fibrous material over the insulation layer and the connectors in the preset mold; and allowing the first and second concrete layers to dry such to form a sandwich wall panel with composite action between the first and second concrete layers, the insulation layer, and the connectors.
- a length of the insulation layer is less than the width of the preset mold, a width of the insulation layer is less than the width of the present mold, or both.
- a building system that includes: multiple wall panels, each wall panel including a first concrete layer and a second concrete layer, each including fiber- reinforced concrete including concrete embedded with interwoven fibrous materials; an insulation layer disposed between the first concrete layer and the second concrete layer; multiple connectors spaced throughout the wall panel, each connector extending from the first concrete panel through the insulation layer and into the second concrete panel; a lifting anchor embedded in a first region at an upper end of the wall panel at which the insulation layer is recessed, thereby forming a first area of solid fiber-reinforced concrete extending between the first and second concrete layers; and a second region at a lower end of the wall panel at which the insulation layer is recessed, thereby forming a second area of solid fiber-reinforced concrete extending between the first and second concrete layers, the second region sized to accept at least two tapcon anchors.
- a perimeter edge of the insulation layer is inset from respective perimeter edges of the first and second concrete layers and
- first and second sandwich wall panels include: two fiber-reinforced concrete layers; an insulation layer between the two fiber- reinforced concrete layers; at least one connector extending through the insulation layer and concrete layers; and a solid fiber-reinforced concrete section.
- the fiber-reinforced concrete layers are no greater than approximately two inches thick. [0014] In some implementations, the insulation layer is at least approximately four inches thick.
- the fiber-reinforced concrete layers include polypropylene fibers, polyethylene fibers, or both.
- the wall panel includes a solid concrete section covering the insulation layer.
- the solid concrete section includes fiber-reinforced concrete material.
- the solid concrete section includes at least one large diameter tapcon anchor.
- the fibrous materials in the concrete layers are configured to form air pockets when exposed to heat.
- the wall panel does not include reinforcing steel materials.
- the wall panel includes a solid fiber-reinforced concrete section having no insulation layer.
- the solid concrete section includes at least one large diameter tapcon anchor.
- the preset mold includes an opening.
- the actions include forming a window or a door in the sandwich wall panel from the opening in the preset mold.
- the actions include lifting the sandwich wall panel from the preset mold.
- the sandwich wall panel includes a solid fiber-reinforced concrete section.
- the actions include adding a fiber-reinforced concrete section over the insulation layer such that the solid concrete section fully covers the insulation layer.
- the length of the insulation layer is two inches less than the length of the preset mold, the width of the insulation layer is two inches less than the width of the preset mold, or both.
- the preset mold has a length in a first lateral dimension and a width in a second lateral dimension, and where a length of the insulation layer is less than the width of the preset mold, a width of the insulation layer is less than the width of the present mold, or both.
- the first concrete layer does not include steel reinforcements that extend completely within a plane defined by the first concrete layer.
- the second concrete layer does not include steel reinforcements that extend completely within a plane of the second concrete layer.
- at least one of the wall panels includes a conduit box embedded within the first concrete layer and conduit connected to the conduit box embedded within the first concrete layer.
- the actions include: positioning a first set of wall panels at a first elevation; after positioning the first set of wall panels, installing a floor over the first set of wall panels; after installing the floor, lifting and positioning a second set of wall panels over the first set of wall panels at a second elevation higher than the first elevation; and after lifting and positioning the second set of wall panels, installing a roof over the second set of wall panels.
- the first set of wall panels includes the first sandwich wall panel and the second sandwich wall panel.
- High-strength concrete is non-flammable and non-combustible, providing superior fire resistance over conventional wood materials. Further, high-mass concrete with an insulation core stores and releases thermal energy allowing for lower use of HVAC systems to maintain desired temperature, thus providing a more affordable net-zero energy result.
- FIG. 1 is a perspective cutaway view of an exemplary embodiment of a wall panel configuration according to the present disclosure.
- the embodiment shown includes an insulation layer sandwiched between two concrete layers with multiple connectors joining the wall layers.
- FIG. 2 is sectional end view of one embodiment of a wall panel configuration according to the present disclosure.
- FIG. 3 is sectional front view of one embodiment of a wall panel according to the present disclosure.
- FIGS. 4-6 show onsite molding and lifting processes for manufacturing wall panels according to the present disclosure.
- a preset mold e.g., “jig”
- jig is shown that can be reused without the need for set-up before each use, which reduces the need for highly skilled onsite labor.
- FIG. 7 shows a bolted connection for use with wall panels according to the present disclosure.
- FIGS. 8-9 show wall panels according to the present disclosure after being erected and bolted.
- FIGS. 10A-C depict consecutive layers of the building being constructed.
- FIG. 11 is a flow diagram of a process for constructing a wall panel.
- FIG. 12 is a flow diagram of a process 1200 for constructing a building.
- Embodiments of the present disclosure include unique building systems with fiber- reinforced, insulated concrete wall panels for fire and combustion protection and energy efficiency.
- FIG. 1 is a perspective cutaway view of one embodiment of a wall panel configuration 100 according to the present disclosure.
- the embodiment shown includes an insulation layer 102 sandwiched between two concrete layers 104 with multiple connectors 106 spaced throughout the wall panel configuration 100.
- the connectors 106 join the wall layers by extending from the first concrete layer to the second concrete layer.
- FIG. 2 is sectional end view of one embodiment of a wall panel configuration 200 according to the present disclosure.
- Some embodiments may include a structural composite wall panel configuration with multiple layers functioning as a single wall.
- Some sections of the wall panel configuration 100 include an insulation layer 102 sandwiched between two concrete layers 104 on either side, as shown in FIG. 1. In other sections, the wall panel may be solid concrete without an insulation layer.
- the insulation layer 102 may have a certain thickness (e.g., at least approximately four inches) and each concrete layer 104 may have a certain thickness (e.g., approximately two inches or less), forming, for example, a 2"-4"-2" wall panel configuration 200, as shown in FIG. 2.
- the sandwich wall panels may include connectors 106 through the layers that create composite action between the layers (e.g., binding the layers together so strongly that they act together structurally as a single unit).
- the combination of composite materials creates a composite mold effect, meaning that the combination of the composite connectors 106 with the interwoven composite reinforcing fibers work together structurally once a bonding agent (e.g., solid concrete 206) is applied.
- a bonding agent e.g., solid concrete 206
- the majority of the wall panel material is composite material (e.g., approximately 70% composite material and approximately 30% concrete). Note that while two layers of concrete are illustrated in FIGS. 1-2, the insulation layer 102 may be sandwiched between more than two layers of concrete and more than one insulation layer may be present.
- the solid concrete 206 can allow for sturdy sections of the wall panel for providing the structural inserts for lifting and attaching the panels during the assembly of a building.
- the “top”, e.g., area of a wall panel that will be highest after assembly, can include structural attachment points, e.g., a lifting anchor, recessed in the solid concrete 206 regions of the wall panel 200 that do not include the insulating layer 102.
- the lifting anchor can be metal tabs with a loop at the edge of the wall panel with a hook cabling, facilitate the lifting of the wall panel.
- the “bottom”, e.g., the area of the wall panel that will be lowest after assembly, can have attachment anchors in the solid concrete 206.
- the attachment anchors ring clutches than can allow for a range in orientations of wall panels as they are lifted and assembled.
- the presence of solid concrete 206 around the perimeter of the wall panel can also prevent fire or water penetration to the insulation layer 102 or interior of the assembled building.
- This solid concrete perimeter can improve the safety and stability of a home, for example, compared to homes with exposed insulation.
- Standard concrete used in home construction generally has an ideal temperature range, given that concrete is prone to cracking at extreme temperatures, e.g., greater than 120 °F and less than 10 °F, given its differing coefficients of expansion and contraction.
- the disclosed combination of composite material, e.g., the fiber-reinforced concrete is less likely to crack under extreme conditions, such as fluctuating temperatures in extreme climates, large temperature differentials between the inside and outside of the building, and tensile or compressive stress and strain.
- the presence of the composite connectors 106 can have beneficial effects for the structural stability of a building, such as transferring load in deflection and shear stress from one layer concrete to another layer concrete. For example, during an earthquake, the force on the building from the ground shaking can be transferred from one layer concrete to another, preventing one particular layer from surpassing a threshold force that causes damage.
- the composite connectors 106 are fiber-reinforced rebar.
- FIG. 1 also shows an optional solid concrete section 110 on the top of the wall panel.
- the solid concrete section 110 can have a certain thickness (e.g., approximately two inches thick or less) and can run along the entire length of all panel edges where the insulation layer 102 would be exposed.
- the solid concrete section 110 may protect the insulation layer 102 from combustion or direct fire exposure and seal the walls from water damage and moisture so that no water or moisture reach and damage the insulation layer 102.
- the solid concrete section 110 can be made from similar concrete mix discussed above containing fibrous material, which provides additional strength and prevention of thermal cracking.
- the concrete layers 104 are made from a fiber-reinforced concrete composite material, which avoids the need to use heavier steel reinforcements.
- the fibers are interwoven into the concrete and can include, but are not limited to, polypropylene, polyethylene macro fibers, or a combination thereof.
- the insulation layer 102 can be, but is not limited to, a foam material such as extruded polystyrene.
- Reinforcing the concrete allows the concrete layers 104 to be thinner (e.g., approximately two inches) without losing shape and form, and reinforcing the concrete with fibrous material allows the concrete layers 104 to be lighter- weight than steel -reinforced concrete layers.
- fiber-reinforced concrete is also stronger than steel-reinforced concrete.
- a lighter-weight wall panel provides numerous benefits during construction such as the ability to use smaller equipment, ship more product per square foot, provide safer working conditions, and lessen the reinforcement needs for the footing system (e.g., less material needed to reinforce a house against slippage in soft ground conditions).
- the concrete layers 104 do not have steel reinforcements (e.g., rebar) that extend within the plane defined by the concrete layer 104 and which are completely embedded in the layer.
- steel reinforcements e.g., rebar
- some embodiments may include composite connectors 106 made of fiber-reinforced rebar that extend between panels 104 in a direction along the thickness of the panels in order to join two panels 104.
- Fiber-reinforced concrete is stronger under tension than steel-reinforced concrete. Improved tensile strength provides benefits particularly during shipping and installation, for example, when lifting the panels and preventing the wall panels from bowing under pressure. Further, the reinforcing fibers in the composite concrete material create air pockets when exposed to heat and fire, which slows the thermal transfer through the wall panel and provides additional fire and combustion resistance. The fibers also help strengthen the adhesion between the concrete layers 104, insulation layers 102, and adjoining connectors 106, strengthening the composite action in the wall panel.
- Lifting anchors 202 can lift wall panel configuration 200.
- lifting anchors 202 can connect to a portion of the concrete layers 104 through a hairpin rebar 204.
- the lifting anchors 202 can lift weights as great as several tons, e.g., four tons.
- each panel may include one or more (e.g., two to four) lifting anchors 202 depending on the weight off the panel, and the lifting anchors can be evenly spaced to keep the panel level.
- the lifting anchors can be approximately three feet across.
- fiber-reinforced concrete provides additional fire-resistance to the wall panel, where the reinforcing fibers create air pockets when exposed to heat and fire, which slows the thermal transfer through the wall.
- FIGS. 4-6 show onsite molding and lifting processes for manufacturing wall panels according to the present disclosure.
- a preset mold e.g., “jig”
- jig is shown that can be reused without the need for set-up before each use, which reduces the need for highly skilled onsite labor.
- wall panels are generally custom-made, e.g., not made with preset molds.
- the disclosed preset molds can be repeatedly used in a modular fashion. For example, a particular preset mold could be used for any story of the house or for different floor layouts.
- the molds can be made from steel, concrete, composite, or a combination thereof.
- wall panels are formed by pouring fiber concrete mix, bolting steel together, or a combination of both.
- the preset molds can be formed by welding steel down.
- embodiments of the present disclosure also include onsite molding and lifting methods and processes for manufacturing the wall panels disclosed herein. These processes greatly reduce the need for skilled labor by using a preset mold (e.g., a “jig”). These methods standardize the construction process and therefore standardize the wall panels for each respective building.
- a preset mold e.g., a “jig”.
- FIG. 11 is a flow diagram of a process 1100 for constructing a wall panel.
- a building system 400 FIG. 4 can perform the process 1100.
- the building system 400 can provide a preset mold (1110).
- the preset mold includes an opening.
- the preset mold rests on a substantially level plane.
- the building system 400 can form a first concrete layer.
- a concrete layer can be formed by pouring a concrete mix, e.g., concrete mix 406, containing fibrous material into the preset mold, e.g., preset mold 402, as can be seen in FIG. 4 (1120).
- the concrete mix being a fluid, flows to fill the total area within the preset mold. Consequently, it can have the same lateral dimensions as the preset mold, e.g., the same height and width in a rectangular preset mold.
- the final wall panel will include electrical wiring or sleeves for plumbing.
- a standard conduit box with one or two outlets can be embedded in the first layer concrete, and conduits, e.g., wires 0.5-0.75 inches in width, can vertically run through the wall panel, such that the conduits of a first and a second wall panel would align in an assembled building.
- electrical wiring in the wall panel is realized by placing a spacer in the preset mold before pouring the concrete mix. The spacer provides a cavity for standard conduit box. The junction boxes can be added flesh to the surface of the wall panel.
- a sleeve can be placed within the preset mold before pouring the concrete mix.
- the concrete layer When the concrete mix dries, the concrete layer includes a cavity through which a plumbing pipe can run. A similar approach can also be used for outdoor hoses.
- the building system 400 can install an insulation layer and one or more connectors, e.g., connector 410, such that the insulation layer and connectors embed into the wet concrete in the preset mold 402 (1130).
- the insulation layer is shorter in one or more dimensions than the first layer concrete, e.g., 97% of the length of the first concrete layer.
- the length of the insulation layer can be two inches less than the length of the first concrete layer, which can be determined by the length of the preset mold.
- the insulation layer can have a similar shape to the preset mold, but have its lateral dimensions scaled down in size.
- a perimeter edge 112 of the insulation layer can be inset from respective perimeter edges 114 of the first and second concrete layers 104.
- Leaving a gap from an insulation layer at this stage in process 1100 can lead to forming a gap in height between the top of the insulation layer and the first layer of concrete at the edges of the preset mold.
- this gap is filled by concrete in the process 1100.
- the concrete that fills in this gap can form a perimeter around the wall panel.
- the thickness of the insulation layer can depend on the environment and heating or cooling needs of the building for which the wall panel being constructed.
- the wall panel can provide as much or more insulating effects than a conventional wall panel with continuous barrier insulation, because more of a standard eight inch thick wall can be used for insulation, e.g., thick (approximately four inches) insulation sandwiched by thin (approximately two inches) concrete walls.
- the building system 400 can form a second concrete layer by pouring the concrete mix containing fibrous material over the insulation layer and the connectors in the preset mold (1140).
- the second concrete layer can have substantially the same dimensions as the first concrete layer and be larger than the insulation layer in one or more dimensions.
- the insulation layer is shorter than the first layer concrete in one or more dimensions, there will be a gap in height between the first concrete layer and insulation layer that is filled with step 1140.
- the filling in of this gap can create a solid concrete section when the wall panel drives.
- the solid concrete section formed in this way is less likely to crack compared to how a typical, non-fiber-reinforced concrete would behave in process 1100. Consequently, it is not an industry standard to include a solid concrete perimeter.
- the building system 400 can allow the first and second concrete layers to dry in order to form a sandwich wall panel 502 from building system 500 with composite action between the first and second concrete layers, the insulation layer, and the connectors (1150), as can be seen in FIG. 5.
- the edges of the wall panel can include a solid concrete perimeter.
- openings 504 may be formed in the preset molds 402 to create windows, doors, or other building features.
- the process 1100 can include additional steps, fewer steps, or some of the steps can be divided into multiple steps.
- the building system 400 can form a window in the sandwich wall panel from the opening in the preset mold, a door in the sandwich wall panel from the opening in the preset mold, place electrical wiring within one or more of the layers of concrete, provide sleeves for plumbing through the wall panel, or a combination of two or more of these.
- the process 1100 includes lifting the sandwich wall panel from the preset mold.
- the process 1100 includes forming a fiber- reinforced concrete solid section, e.g., a “cap”, where insulation does not connect the layers of concrete, such that the cap 116 fully covers the entirety of the perimeter edge 112 of the insulation layer from the exterior of the wall panel.
- FIG. 3 is sectional front view of one embodiment of a wall panel 300 according to the present disclosure.
- the wall panel 300 can include portions corresponding to slab connections 302, lifting anchors 304, which can be surrounded by solid concrete areas 306 with no foam.
- the solid concrete areas 306 can be formed in regions where a recess 312 is formed in the insulation layer 106.
- Solid concrete areas 306 at the bottom of the wall panel 300 can be sized to accept two or more tapcon anchor bolts for slab connections 302.
- the outer perimeter edge 112 of the insulating panel 106 can be inset from the outer perimeter edges of the concrete layers 114.
- openings 308 can be surrounded by areas with hold back foam 310, the perimeter being marked by a dashed line.
- the wall panel 300 can be approximately ten feet by ten feet.
- the openings 308 can be windows, e.g., a four feet by six feet window.
- the sandwich wall panel 502 may be lifted and erected from the mold to form a section 602 of a building wall.
- the processes disclosed herein of casting wall panels with a preset mold allows repeated use of the same mold many times without the need for skilled labor to tear down and set the mold back up, as opposed to traditional construction processes where each panel is different, requiring additional set up, and tear down for molds each time a panel is poured.
- the processes disclosed herein are more efficient and faster to complete, in part, by the use of fibrous concrete mix as opposed to traditional reinforcing steel because reinforcing steel requires manual installation on lifting chairs and tying the steel together with wire tires.
- the fiber-reinforced wall panels also provide sufficient strength for a wide variety of roofing and flooring options and systems.
- the wall panels disclosed herein can be used with steel bar joist and decking roofing and flooring systems.
- the wall panels can be used with wood-based systems, steel stud systems, concrete floor and roof planking, and cast in place concrete roof and floor systems.
- the roofing and flooring systems may also include preset molds such that the walls, roofs, and floors can be assembled without skilled labor or the need for on-site measurements as all attachments (wall to wall, wall to floor, and wall to root) are predetermined and anchor-bolted in place in a preformatted, interlocking system.
- FIG. 7 shows a bolted connection 700 for use with wall panels 702 and 708 according to the present disclosure.
- This bolted connection 700 avoids the need for a traditionally installed weld plate and reduces the need for highly skilled onsite labor.
- the insulation layer is reduced or eliminated to create a solid concrete section that can be drilled into and secured with large diameter tapcon (LDT) anchors 706.
- LDT large diameter tapcon
- the LDTs may be sized to meet necessary seismic shear strength requirements (e.g., approximately 5/8" x 6" or 5/8" x 8").
- FIGS. 8-9 show the wall panels 702 and 708 after being erected and bolted with LDT anchors 706.
- the preset mold system and wall panels disclosed herein allow for construction of buildings story by story, such that a first set of wall panels can be positioned to form a perimeter at a first elevation (e.g., ground level) and a second set of wall panels can be lifted and positioned to form a perimeter over the first set of wall panels at a higher second elevation (e.g., a second, third, or fourth story).
- the flooring for each story may be laid down after each set of wall panels is positioned; for example, the flooring for the second story can be laid down on top of the first set of wall panels before the second set of wall panels are positioned.
- the roofing can then be applied upon completion of positioning the last set of wall panels on the top story of the building.
- FIG. 12 is a flow diagram of a process 1200 for constructing a building.
- building system 600 can carry out the process 1200.
- FIGS. 10A-C depict consecutive layers of the building being constructed.
- the building system 600 can form a first sandwich wall panel from a first preset mold and a second sandwich wall panel from a second preset mold (1210).
- Each of the first and second sandwich wall panels, e.g., wall panels 702 and 708, can include two fiber-reinforced concrete layers, e.g., concrete layers 104, an insulation layer between the two fiber-reinforced concrete layers, e.g., insulation layer 102, at least one connector extending through the insulation layer and concrete layers, e.g., connector 106, and a solid fiber-reinforced concrete section.
- the building system 600 can bolt the first sandwich wall panel to the second sandwich wall panel by drilling at least one large diameter tapcon anchor through the solid fiber- reinforced concrete sections of the first and second sandwich wall panels (1220).
- Step 1220 can result in the building system 600 forming a comer, such as comer walls 800 of FIG. 8, of a building, e.g., where two walls 702 and 708 meet at an angle above floor 604.
- FIG. 9 provides another perspective of comer walls 800.
- the building system 600 bolts more than two sandwich wall panels together in order to form a complete wall around the building.
- FIG. 10A includes many wall panels lOlOa-e that together form the ground-floor exterior of a building 1000.
- the process continues with the building system 600 positioning a first set of wall panels at a first elevation (1230).
- the first set of wall panels can include the first sandwich wall panel and the second sandwich wall panel.
- FIG. 10A shows a ground-floor level of the building 1000, which can include a first set of panels 101 Oa-e at a first elevation 1020, marked by the dashed lines. Although only five panels of the first set of panels lOlOa-e are referenced, there can be any number, e.g., ten or fifty, wall panels.
- the panels can include openings 1030 for windows 1030a, garage doors 1030b, entrance doors 1030c, internal windows 1030d and internal doors 1030e in the building, and the like.
- FIG. 10B shows a building 1040, which has a first-floor level added to the building of FIG. 10A.
- the building 1040 has a floor 1052 over the first set of wall panels 1010.
- the building system 600 can lift and position a second set of wall panels over the first set of wall panels at a second elevation higher than the first elevation (1250).
- the building 1040 includes a second set of wall panels 1050a-e at a second elevation 1060, marked by the dashed lines. Although only five panels of the second set of panels 1050a- e are referenced, there can be any number, e.g., ten or fifty, wall panels. Measured from the ground, the second elevation 1060 is greater than the first elevation 1020.
- FIGS. 10B and 10C both display roofs.
- FIG. 10B shows a roof 1070 over a portion of the first set of wall panels 1010.
- FIG. 10C shows a building 1080, which has a roof 1090 over a portion of the building 1040 from FIG. 10B.
- the roof 1090 goes over the second set of wall panels 1050.
- the process 1200 can include additional steps, fewer steps, or some of the steps can be divided into multiple steps.
- step 1220 can be repeated multiple times for more than two sandwich wall panels depending on how many wall panels form a story of a building.
- Steps 1250 and 1260 can be repeated multiple times for different portions of the building, in order to create a building that has roofs at multiple heights over different portions of the building, such as roofs 1070 and 1090 on building 1080 from FIG. 10C.
- Manufacturing processes according to the present disclosure eliminate the need for casting in structural steel to weld the panels together as described above, the elimination of which can help prevent fire hazards. Due to the preset mold processes described herein, all wall panel coordinates can be predetermined by engineering and cast accordingly. This allows the wall panels to be produced without the need for skilled labor and further allows the wall panels and the structural steel floors and roofs to be erected and bolted together without the use of measuring tools (e.g., tape measure) or using a “stringer layout.” This again reduces or eliminates the need for skilled labor on construction sites and standardizes and simplifies the construction building process.
- measuring tools e.g., tape measure
- inventions of the present disclosure may be used for a wide variety of residential building structures, including without limitation, single-family homes, multi-family homes, condominiums, apartments. Further, embodiments may be used for commercial and other structures, for example, car washes, storage garages, cladding panels for high-rise buildings, low-rise cold storage, low-rise office buildings, medical and dental offices, strip malls, schools, hotels, manufacturing centers, data centers, gun ranges, retail centers, municipal buildings, low-rise warehousing, grocery stores, beverage packing and production buildings, restaurants, and basements. Some or all windows, doors, and mechanicals (e.g., electrical and plumbing) for these residential and/or commercial structures may be cast into the wall during the manufacture and construction process.
- windows, doors, and mechanicals e.g., electrical and plumbing
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Abstract
L'invention concerne des procédés, des systèmes et un appareil de construction d'un panneau mural et d'un bâtiment. Le panneau mural peut comprendre : des couches de béton renforcées par des fibres (104) comprenant du béton ayant des matériaux fibreux entrelacés ; une couche d'isolation (102) ; et un raccord (106). La couche d'isolation est prise en sandwich entre les couches de béton renforcées par des fibres, et le raccord s'étend à travers la couche d'isolation et les couches de béton pour créer une action composite entre la couche d'isolation et les couches de béton.
Applications Claiming Priority (4)
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US202263344757P | 2022-05-23 | 2022-05-23 | |
US63/344,757 | 2022-05-23 | ||
US17/982,428 | 2022-11-07 | ||
US17/982,428 US11885132B2 (en) | 2022-05-23 | 2022-11-07 | Non-combustible, net-zero energy building systems |
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WO2023229640A1 true WO2023229640A1 (fr) | 2023-11-30 |
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PCT/US2022/052301 WO2023229640A1 (fr) | 2022-05-23 | 2022-12-08 | Systèmes de construction non combustibles à bilan énergétique nul |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4974381A (en) * | 1989-07-27 | 1990-12-04 | Marks Karl R | Tie anchor and method for manufacturing insulated concrete sandwich panels |
US8877329B2 (en) * | 2012-09-25 | 2014-11-04 | Romeo Ilarian Ciuperca | High performance, highly energy efficient precast composite insulated concrete panels |
US20170350122A1 (en) * | 2016-05-11 | 2017-12-07 | Joel Foderberg | System for insulated concrete composite wall panels |
US20180058081A1 (en) * | 2016-08-25 | 2018-03-01 | Midwest Concrete & Masonry Supply, Inc. | Erection anchor for precast insulated concrete wall panels |
US20190383045A1 (en) * | 2018-06-19 | 2019-12-19 | David L. Kelly | Composite tilt-up panel |
-
2022
- 2022-12-08 WO PCT/US2022/052301 patent/WO2023229640A1/fr unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4974381A (en) * | 1989-07-27 | 1990-12-04 | Marks Karl R | Tie anchor and method for manufacturing insulated concrete sandwich panels |
US8877329B2 (en) * | 2012-09-25 | 2014-11-04 | Romeo Ilarian Ciuperca | High performance, highly energy efficient precast composite insulated concrete panels |
US20170350122A1 (en) * | 2016-05-11 | 2017-12-07 | Joel Foderberg | System for insulated concrete composite wall panels |
US20180058081A1 (en) * | 2016-08-25 | 2018-03-01 | Midwest Concrete & Masonry Supply, Inc. | Erection anchor for precast insulated concrete wall panels |
US20190383045A1 (en) * | 2018-06-19 | 2019-12-19 | David L. Kelly | Composite tilt-up panel |
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