Note: Descriptions are shown in the official language in which they were submitted.
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CONCRETE PANEL CONSTRUCTION SYSTEM
The present invention relates to the field of construction. More specifically,
the invention
relates to a concrete panel construction system.
BACKGROUND OF THE INVENTION
Prefabricated concrete panels have been used in a variety of building
applications to provide
a relatively easily assembled and relatively inexpensive building. Many of the
prior construction
systems have a disadvantage in that they require that at least basic
horizontal and vertical structural
components be constructed to act as a frame to which the prefabricated panels
can be attached.
United States patent number 3,683,578 to Zimmerman, issued August 15, 1972,
discloses
a concrete building arrangement which purportedly eliminates the requirement
to pre-form the
vertical support structure. In Zimmerman's arrangement, wall panels are
aligned by co-operating
guide means on the base of the panels and on the foundation with which the
panels co-operate.
While alignment of the base of the wall panels is provided by the co-operating
guide means,
alignment of the upper portion of the panel is achieved by a bolt means, which
co-operates with
reinforcing bars within the panels. The co-operation between the bolts and the
bars also acts to
secure adjacent panels together. One disadvantage of Zimmerman's arrangement
is the requirement
to preform a concrete foundation slab to support the panels.
Another disadvantage of many prior art construction methods is that they have
limited utility
in the construction of basements. When concrete panels are used the basement
wall tends to shift
laterally where the panels join during backfilling. This is a particular
problem where the panels meet
to form a corner. The result is that the concrete panels used in basement
construction must be
secured to pre-poured concrete foundation pads in a manner to prevent lateral
movement. The need
to pour a foundation pad reduces the advantage sought to be gained by using
prefabricated concrete
panels.
United States patent number 5,493,838 to Ross, issued February 27, 1996,
discloses a
method of constructing a basement from prefabricated concrete panels which
purportedly eliminates
the requirement of pre-pouring a concrete foundation pad. In Ross' method, the
building site is first
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excavated and footings are positioned in the excavation to define the outline
of the building.
Prefabricated floor panels may be placed between the footings. Once the
footings are in place,
prefabricated, freestanding concrete corner sections are placed on the
footings where it is intended
that the building have a corner. A plurality of concrete panels can then be
joined end-to-end between
the corner sections to complete the peripheral wall. This reference does not
teach a system that
facilitates the construction of a second floor of a building.
In US patents 4,751,803 and 5,656,194, there are described concrete wall panel
systems
wherein concrete beam and stud members are assembled to form a panel. Such
panels are then
arranged to form outer walls for a building. However, these references do not
teach a concrete wall
panel system wherein the complete panel is formed simultaneously as a unitary
structure.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a concrete building panel
comprising:
a slab having an outside face and an inside face and top and bottom ends and
first and second
sides;
the slab top and bottom ends each including a beam extending along the length
thereof, both
the beams extending from the inside face of the slab in the same direction
perpendicular to the plane
of the slab;
the slab first and second sides comprising extensions extending from the
inside face of the
slab, along the length of the slab and extending perpendicular to the plane of
the slab in the same
direction as the beams; and
a plurality of ribs extending between the top and bottom ends of the slab and
from the inside
face of the slab, the ribs being parallel to the extensions.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described, by way of example
only, with
reference to the accompanying drawings, in which:
Figure 1 is a perspective view of a building panel in accordance with a first
embodiment of
the present invention.
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Figure 2 is a back elevation of the panel of Figure 1.
Figure 3 is a plan section of the panel of Figure 2, along the line 3-3.
Figure 4 is an exploded cross-section of a panel-to-footing attachment in
accordance with
one embodiment of the present invention.
Figure 5 is an exploded cross-section of a panel-to-footing attachment in
accordance with
a second embodiment of the present invention.
Figure 6A and 6B are plan and side views of a footing member in accordance
with one
embodiment of the present invention.
Figure 7 is an exploded cross-section of a panel-to-footing attachment
utilizing the footing
of Figures 6A and 6B.
Figure Sa is a perspective view of an attachment means for the bottom portions
of adjacent
panels of the present invention according to one embodiment.
Figure 8b is a perspective view of an attachment means for the top portions of
adjacent
panels of the present invention according to one embodiment.
Figure 9 is a plan view of the attachment of Figure 8a according to another
embodiment.
Figure 10 is a perspective view of one end of the attachment of Figure 9.
Figure 11 a is a front elevation of a series building panels of the invention
connected together.
Figure llb is a perspective view of a panel attachment means according to
another
embodiment.
Figure 12 is a cross-sectional plan view of an external corner building panel.
Figure 13 is a cross-sectional plan view of an internal comer formed from two
building
panels.
Figure 14 is a plan view of a drywall connector for use with the building
panels of the present
invention.
Figure 15 is a perspective view of a building panel in accordance with a
second embodiment
of the present invention.
Figure 16 is a plan section of the panel of Figure 1 S, along the line 16-16.
Figure 17 is a side elevation of the panel of Figure 15 along the line 17-17.
Figure 18 is a cross-section of a rib attachment.
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Figure 19 is a cross-section through a wall formed by building panels in
accordance with the
present invention.
Figure 20 is a side elevation of a panel connector.
Figure 21 is a side elevation of a building panel in accordance with yet
another embodiment
of the present invention.
Figure 22 is a back elevation of a building panel in accordance with a third
embodiment
of the present invention.
Figure 23 is a sectional view of an eaves unit.
Figure 24 is a sectional view of an apex unit.
Figure 25 is a partial front elevation of a panel according to another
embodiment of the
invention illustrating a reinforced corner portion.
Figure 26a is a side cross sectional elevation of a building wall comprising
two stacked
panels.
Figure 26b is a rear elevation of the upper panel shown in Figure 26a.
Figure 26c is a side cross sectional view of the lower panel shown in Figure
26a.
Figures 27a and 27b are top cross sectional views of different embodiments of
joining
adjacent wall panels.
Figure 28 is a side cross sectional elevation of another embodiment of the
invention
wherein a wall panel is designed to support an exterior veneer of brick.
Figure 29 is a side elevation of a panel of the invention according to another
embodiment
wherein the panel is used for flooring.
Figures 30a to 30e are side cross sectional elevations of various embodiments
of the
invention illustrating different arrangements of the wall and floor panels.
Figures 31 and 32 is a side cross sectional view of wall panels of the
invention according
to another embodiment wherein apertures in the panels are used to support
flooring.
Figure 33a is a front elevation of a wall panel of the invention for use in
interior corners.
Figure 33b is an end cross sectional view through the line A-A of Figure 33a.
Figures 34(a) to 34(1) are side cross sectional views of further embodiments
of the
invention wherein concrete panels are used to construct a roof of a building.
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Figure 35 is a side cross sectional view of another embodiment of the wall
panel of the
invention wherein the panel is used as a retaining wall.
Figure 36 is a partial side cross sectional view of another embodiment of the
retaining
wall of Figure 35.
Figure 37 is a perspective view of a wall panel according to another
embodiment.
Figure 38 is a rear elevation of a wall of a building comprising a plurality
of wall panels
of the invention arranged according to one embodiment.
Figure 39 is a side cross sectional view of a wall of a building comprising a
plurality of
wall panels of the invention and illustrating various embodiments of flooring.
Figure 40 is a side cross sectional view of a wall panel according to another
embodiment
of the invention
Figure 41a and 41b illustrate the application of wall panels of the invention
in existing
structures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A prefabricated concrete building panel in accordance with one embodiment of
the present
invention is shown generally at 20 in Figures 1-3. This type of building panel
is particularly useful
in the construction of basement walls. The building panel comprises a slab 22
having an outside face
and an inside face 50. The slab is integrally connected to generally parallel
top and bottom beams
20 30 and 35, respectively, which extend from the inside face 50 of the slab.
Beams 30 and 35 lie in
a plane perpendicular to that of the slab 22 and extend in the same direction.
The beams 30 and 35
are connected at their ends by a pair of generally vertical end ribs 40 and 45
to form a box-like
structure. Between the end ribs 40 and 45 are provided a plurality of
generally equally spaced,
substantially vertical ribs 55 which extend between top panel 30 and bottom
panel 35.
25 As will be apparent, the size of the panel is limited only by the
constraint imposed by having
to physically handle the panel. It is envisioned that for house construction,
the panels will be
approximately 8' wide by 8' high. The width of the panel will likely depend on
its utility. For
example, in basement construction where the panels are subject to the weight
of back-filled material,
and serve as foundation walls for the upper levels of the building, it is
envisioned that the panels may
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be approximately 10" wide. A 10" wide bottom beam will help in distributing
load and help
stabilize the vertical panel. Similarly, a 10" top beam will provide a stable
base to support a panel
forming a second storey to the building and allow for support of a sub-floor
structure (see Figures
19 and 20 and the discussion below).
It is envisioned that the slab and top and bottom beams, as well as the ribs
will be reinforced,
as is commonly known in the art. The reinforcement is not shown in Figures 1-
3. Reinforcement
may be in the form of steel rebars or, for example, the concrete may be
reinforced with fibreglass
wool or nylon strings. In one embodiment, the slab and the ribs are provided
with a wire metal grid
or mesh. Other reinforcement means is conventionally known in the art.
The precise dimension of the concrete panel will depend upon the particular
building code
in the jurisdiction in which the panel is used. However, for the remainder of
this discussion the
building panel will be assumed to have dimensions 8' x 8' x 10", with the slab
22, the top and
bottom beams 30 and 35 and the ribs each having a thickness of approximately
2.5". As the exterior
of the basement wall is subject to the pressure of backfilling, care should be
taken to ensure that the
slab 22 has sufficient strength to prevent cracking or collapse. Accordingly,
it is desirable that the
ribs S5, which provide rigidity and strength to the panel, are spaced apart by
no more than 2'. This
spacing also follows the basic building code standards of providing vertical
studs at 2' separation.
On this basis, a standard 8' x 8' panel will have three equally spaced ribs
parallel to and between the
two end ribs. However, under certain circumstances the spacing between ribs 55
may vary. See, for
example, Figures 12 and 13 and the discussion on interior and exterior corner
construction.
As shown in Figures 1-3, the opposed end ribs 40,45 and the vertical ribs 55
are preferably
provided with apertures or knock-outs 60 which can be used to facilitate
running of electrical wires
and plumbing through the wall cavity. Further, as will be discussed in more
detail below, these
knockouts can be used to receive locking bolts or a tensioning rod or belt, to
permit adjacent panels
to be secured together. A knock-out is a section of the beam or rib in which
the thickness and
strength of the concrete is less than that of the rest of the beam or rib.
This weakened section may
be removed on site by a builder by hitting the weakened section and "knocking-
out" the concrete
plug. The formation of knock-outs in concrete panels is well known in the art.
As illustrated, the
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preferred embodiment of the invention includes apertures created during the
forming process instead
of knock-outs.
In the preferred embodiment, four apertures 60 are provided for each rib. The
apertures are
spaced so that the top and bottom apertures are spaced 1 foot from the top and
bottom beams, 30 and
35, respectively. The remaining apertures are then spaced 2 feet from each
other. An example of
this arrangement is illustrated in Figure 33a. By ensuring the same spacing of
the apertures in all
the panels results in all the apertures in one panel line up with those of an
adjacent panel. This
would greatly facilitate the connection of adjacent panels. Further, if all
the panels have apertures
at the same positions, it is possible to create a continuous channel
throughout the building thereby
facilitating the passage of electrical wire, plumbing etc.
Further apertures or knock-outs 65 may also be provided in the top and bottom
beams 30,
35 to facilitate fastening the building panel to the foundation and the second
storey or roof of the
building. As will be apparent, the size of the knock-outs will vary depending
on the size of bolts
used to fasten the panels.
Various types of foundation footings are shown in Figures 4-7. In Figure 4, a
building panel
is mounted on a foundation footing 70. The foundation footing 70 may, if
building conditions
allow, be formed from compact earth or hardcore or, more likely, will be
formed from concrete. The
concrete footing may be a continuously poured strip that runs the length of
the wall or may be
individual blocks placed under spaced locations along the length of the wall
panel. In one
20 embodiment, the footing is provided with a step 75 against which the back
edge 80 of bottom beam
35 abuts. The step abutment helps prevent lateral movement of the wall in
relation to the footing
during backfilling against the outside face 25 of the building panel. Building
panel 20 is secured to
footing 70 by means of a bolt 85, which projects from the footing through
aperture 65. Optionally,
the footing may be provided with pair of levelling bolts 90, which project
from footing 70 and abut
the underside of bottom beam 35. The levelling bolts may be used to ensure
that the panel lies in
the desired plane when the ground under the foundation may not be sufficiently
level.
A footing arrangement in accordance with another embodiment is shown in Figure
5. In this
arrangement, footing 70' is provided with an angle iron or channel section
100, which may be used
to facilitate, correct alignment of the building panel. Section 100 may be
attached to footing 70'
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(with for example bolt 110) prior to having the building panel lowered into
place. In this way, it is
possible to mark the perimeter of the entire building on the footings with the
easily manoeuvred
angle sections, rather than manipulating entire concrete building panels.
Yet another embodiment of the footing is shown in Figures 6A, 6B and 7. The
footing
comprises an elongate body 115 and a securing head 120. One end of body 115,
distal to securing
head 120, is provided with a recess 75" against which the bottom beam of a
building panel abuts,
as described above with respect to Figure 4. Securing head 120 is provided
with an aperture 130
adapted to receive a bottom-flared spike 140, which can be formed in the
ground and which prevents
movement of the footing. In a preferred embodiment, the footing has an overall
length of
approximately 4', with the 2.5' long body having a width of 8" which is the
same as the diameter
of the aperture 130 in securing head 120. The footing is preferably formed of
reinforced concrete
and may be precast and placed in the appropriate location in the foundation
or, alternatively, the
footing may be cast in-place by placing a suitable mold at the desired
location. The spike 140 is
preferably also formed of reinforced concrete. Casting the spike in the ground
provides a firm
anchor for the footing; the shape of the spike helping to prevent it being
lifted from the ground.
Although not shown, this type of footing may also be provided with levelling
bolts to facilitate
alignment of the panel.
In respect of the footing shown in Figures 6a, 6b and 7, it is apparent that
the footing does
not support the entire length of the panel but usually supports only one or
two points along its length.
In these circumstances, it is desirable to ensure that there is a solid
foundation under the unsupported
panel length. This may be achieved by simply hard packing the earth where
ground conditions
permit or may be achieved by forming a strip of "crush and run" packable
aggregate between the
footings. The aggregate may be covered with a wire mesh or cloth to help
distribute the load evenly
across the strip, if desired.
In addition to the above described footings, it will be understood that the
panels of the
present invention may also be simply placed on top of a concrete slab. The
exact configuration will
depend upon local soil conditions.
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As mentioned above, adjacent concrete panels may be attached together in an
end-to-end
manner by using bolts, such as pipe bolts, which pass through aligned
apertures 60 in the abutting
end ribs. Such bolts are described below in relation to Figure 13.
In addition to or as an alternative to such bolt connectors, the building
panels may be
provided with a tensioning belt arrangement, shown schematically in Figures 8-
11. Figure 8a shows
a pair of panels 20 and 20', each panel provided with a belt attachment (150
and 150') connected to
one end of a rebar or tensioning belt (160 and 160'). The attachment means 150
and 150' may be
located within the top or, as shown, the bottom beam of a building panel.
Attachment means 150
and 150' are connected together by a bolt 170 which extends from attachment
means 150', through
aperture 175 and into attachment means 150 where it is secured with a nut (not
shown). As shown,
in the preferred embodiment of the invention, the attachment means comprise
shoes, which are
positioned at the upper surface of the bottom beam of each panel and extend to
the outer edge of the
end ribs. Such an arrangement allows easy access to the shoes 150 and 150'
after the panels are set
in place so as to facilitate tightening of the bolts 170.
Figure 8b illustrates similar attachment means for the top beams 30 and 30' of
adjacent
panels 20 and 20'. As shown, shoes 151 and 151', similar to those discussed
above, are provided
on the upper surfaces of the top beams and are exposed so as to allow easy
access thereto.
Another typical attachment means is shown in Figures 9 and 10. The attachment
means
generally comprises a U-shaped shoe having a crimped end 180 and a sealed end
190. End 180 is
crimped around tensioning belt 160 to prevent lateral movement thereof. Sealed
end 190 is provided
with an aperture to receive bolt 170.
The U-shaped shoe may be provided with nail holes 195, which will help
maintain the shoe
in place during casting of the panel. The shoe need not necessarily be set in
from the edge of the
panel and in fact, sealed end 190 may be flush with the end wall. Under these
circumstances, it is
preferable if the shoe is slightly tapered, increasing in width away from the
sealed end. This tapering
will help prevent lateral movement of the shoe during tensioning of the belt.
Preferably, the tensioning belt and attachment means are cast in the top
and/or bottom beams
of the building panel such that the builder is permitted access to the channel
of the attachment means
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when the panels are in place. After connection of adjacent panels, the
attachment means may be
sealed within the panel with concrete.
An example of the use of the tensioning belts is shown in Figure 11 a. In this
example, three
building panels (20, 20', 20") are connected to form a continuous wall that is
stepped down an
incline. The panels are shown resting on a concrete footing 200. It is
preferred that in such an
arrangement, the panels are stepped so that the top of the lower panel is at
the same height as
apertures 60 in the adjacent higher panel. This facilitates connection of the
panels, as the apertures
in adjacent end panels will align. The tensioning belt 160 which runs around
the top beam of
building panel 20" may be connected to the adjacent end rib of building panel
20' or, as shown, may
be connected across building panel 20' and be secured to the closest end rib
of building panel 20.
Similarly, the tensioning belt 160' which runs around the bottom beam of
building panel 20 may be
connected to the adjacent end rib of building panel 20' or, as shown, may be
connected across
building panel 20' and be secured to the closest end rib of building panel
20". If the tensioning belts
are connected as shown in Figure 1 la, the belts tie the plurality of panels
together in a continuous
string. In a preferred embodiment, all the panels that form the perimeter of
the building will be
joined together with tensioning belts which will form a continuous loop around
the entire building.
In the stepped wall construction shown in Figure 11 a, the wall may be built
to a desired level by
attaching smaller panels to the top of panels 20' and 20" or by using
convention brick or block
construction.
Figure l 1b illustrates another embodiment for attaching adjacent panels using
a belt system.
In this embodiment, a belt 160 extends through apertures 60 in the ribs of the
panels and forms a
continuous loop. A turnbuckle 161 is provided at given locations and is used
to tighten the
tensioning belt 160. Preferably, the belt 160 is capable of stretching.
It will be understood that the need for tensioning belts 160 described above
are an optional
item and serve to provide an added securing means for the panels over the
bolts (described below)
connecting adjacent panels. Such belts may only be required where the panels
are placed on
irregular footings.
Thus far, the building panels of the present invention have been described
with reference to
constructing a linear wall. However, building panels in accordance with the
present invention may
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also form or be used to form both internal and external corners. Figure 12
shows a schematic
representation of an external corner formed from a single corner panel.
Similar to the previously
described panel, the corner panel has a front or external face 25' and an
inside face 50'. Vertical ribs
55' extend inwardly from inside face 50'. As discussed above, it is preferable
that the vertical ribs
should be spaced no more than 2' apart. Another embodiment of a panel designed
for an exterior
corner is shown and discussed below in relation to Figures 33a and b.
Another consideration is in respect to the attachment of drywall to the inside
of the corner
panel. Drywall sheets 210 and 210a are preferably attached across the ends of
ribs 55'. Drywall
sheets are conventionally 4' wide and it is preferred that the sheets do not
have to be cut prior to
installation. Accordingly, "extra" ribs 55a may be included to act as support
for the drywall. The
"extra" ribs are provided 2' from the internal apex "P" of the external
corner. The remaining ribs
along the length of the wall can be spaced at 2' intervals from this "extra"
rib.
An internal corner formed from two building panels is shown in Figure 13.
Building panel
20' is a standard panel as described above, with the ribs 55' being equally
spaced (2' apart) along
its length. Panel 20" has an "extra" rib 55a' spaced such that it is 2' from
the external apex "Q" of
the internal corner. Thus, once again the ribs are provided no more than 2'
apart and the "extra" rib
permits drywall panels, 210, to be attached without cutting the 4' width.
As will be apparent when comparing the configurations of the external and
internal corners
shown in Figures 12, 13, and 33a and b, an external corner may also be formed
from a pair of
building panels connected in a similar manner to that described for the
internal corner. Alternatively,
a single-piece interior or exterior comer panel may also be formed. In such
case, the corner panel
would be a unitary structure that includes the corner section.
Figure 13 also illustrates a pipe bolt 57, which are used to connect adjacent
panels. The bolts
57 is passed through the apertures 60, described above, of the adjacent panels
and tightened. By
using a plurality of such bolts 57, the panels are connected together to form
a continuous wall. The
pipe bolts 57 are preferably hollow thereby allowing the apertures to still be
used as a conduit for
passing electrical wire etc.
Figure 14 shows an enlarged cross-section of internal apex "P" of the external
corner shown
in Figure 12. As will be apparent, drywall panel 210 may be attached to the
end of rib 55b using
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conventional methods. However, in order to provide support for the attachment
of drywall panel
210a, rib 55b may be provided with a clip 220. Clip 220 has a pair of
depending legs 215 each of
which have, at their distal ends, barbs which facilitate attachment of clip
220 to rib 55b. Web 230
extends perpendicularly to the face of rib 55b and to drywall panel 210, to
provide a body to which
drywall panel 210a may be attached. Clip 220 is preferably formed from high
tensile steel.
With regard to the attachment of drywall to the concrete ribs, conventional
fastening means,
including adhesive may be employed. Alternatively, if desired, wooden strips
may be attached to
the outer surface of the ribs, to form a surface suitable to attaching the
drywall. These wooden strips
can, if desired, be formed integral with the ribs when the concrete for the
ribs is first poured.
An alternative embodiment of the wall panel is shown in Figures 15-18, and 26b
with like
numerals referring to like parts with the suffix "d" added for clarity. This
particular panel
construction is useful in above-ground wall construction. In many
jurisdictions the building codes
specify that external, above-ground walls must provide an air gap between
outer and inner skins of
the wall. The air gap acts as both an insulating layer and a barrier to help
prevent water permeating
between the exterior to the interior surface to the wall. The panel (referred
to henceforth as the "air-
gap panel") shown in Figures 15-18 has a continuous air gap 300 between the
inside face 50d of slab
22d and the top beam 30d, the bottom beam 35d, the end ribs 40d and 45d and
the ribs 55d.
The actual continuous air gap is formed between the inside face 50d of the
slab 22d and a
plywood sheet 315 which extends between the ribs and is spaced from the inside
face by the
insulated connector. The plywood sheeting is generally inserted into the panel
during formation by
supporting the sheeting on the insulating connector or fastening it to the
rebars prior to casting the
ribs and end panels. Alternatively, it is envisioned that the plywood sheeting
may be inserted into
position within the panel structure after casting of the entire panel.
As shown in Figure 18, the plywood sheeting may act a support for conventional
insulation
320.
As shown in Figure 18, the top and bottom beams and the ribs are connected to
the slab by
means of a reinforcement such as rebar 307, which may be integral with
reinforcing mesh 307
provided in the slab or may be a separate element embedded in the slab
material. The purpose of
the reinforcement 305 is to establish a firm connection between the rib 55f
and the slab 22d.
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However, the concrete portion of the beams and ribs are spaced from the inside
face SOd by
insulating connectors 310. The insulating connectors are generally spaced
apart from one another
to permit air flow within the air gap of individual panels and between air
gaps in adjacent panels.
One exception to this is when the entire perimeter of a panel is sealed as may
occur if the panel is
used in forming a basement wall or where two panels are joined at a corner.
In another embodiment, the insulating connectors may be provided in the form
of continuous
strips, which can later be drilled to provide air passages.
The insulating connector is preferably formed from a non-rusting, non-
conductive
structurally sound material such recycled plastic. An example of such a
material is SAN-NOR
CreteTM, manufactured by Advanced Solutions...Advanced Technologies, Ontario,
Canada.
The insulating connector not only helps provide structural integrity between
the slab and the
top and bottom beams and the ribs, but also acts as a protective cover over
the connecting rebars to
help prevent them from rusting. The insulating connectors are shown in the
four corners of the panel
as well as spaced along the length of the end panels and ribs. However, the
exact positioning of the
insulating connectors will depend primarily on the position of the
interconnecting rebars 305.
The air-gap panel may be provided with knock-outs 60d to permit adjacent
panels to be
joined together with locking bolts or a tensioning belt, as described above
with reference to the
basement panel.
Figure 19 shows a cross-section through a wall formed by a basement panel 20
and an air-
gap panel 20d in accordance with the present invention. In this particular
embodiment top beam 30
of the basement panel 20 is provided with an upstanding web of concrete 330
along its interior edge.
The web 330 has a dual function; to help prevent ingress of water from the
exterior of the building
along joint 335 between the basement and air-gap panels; and to provide
additional lateral stability
to the bottom of the air-gap panel 20d.
Web 330 need not be formed integral with top beam 30 and may in fact be added
later. The
web may be formed of concrete or any other conventional building material such
as brick or wood.
The web may provide part of the support for the floor structure 340. The
basement panel
and the air-gap panel may be secured together by locking bolts (not shown)
which pass through the
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knock-outs provided in the top beam of the basement panel and the bottom beam
of the air-gap
panel.
Top beam 30 of the basement panel may be provided with levelling bolts (not
shown) to
facilitate alignment of the air-gap panel. The role of the levelling bolts is
the same as described
above with respect to the footings. Alternatively, the levelling bolts may be
incorporated into
bottom panel 35d of the air-gap panel. The levelling bolts also function as
spacers between the two
panels to help prevent mortar from being squeezed out of the joint due to the
weight of the air-gap
panel.
An alternative technique for joining the basement and air-gap panels is shown
in Figure 20.
In this technique a steel strap 350 is attached across the end ribs 45 and 45d
of the basement and air-
gap panels, respectively. The steel strap has a pair of holes 355 in the
basement panel attachment
end to receive fastening bolts and a pair of slots 360 in the air-gap panel
attachment end. The pair
of slots is adapted to receive fastening bolts in a manner which permits a
small amount of adjustment
so the builder can compensate for slight misalignment of the panels. As will
be apparent to a skilled
worker, the relative positions of the holes and slots may be reversed. Further
description of the strap
350 is provided in the discussion relating to Figure 31 below.
It is envisioned that the steel connector may be recessed into the end ribs of
the basement and
air-gap panels so that the thickness of the connector does not prevent
abutment between the end
panels of adjacent building panels. In a preferred embodiment the steel
connector is approximately
4' x 4" x 0.5", with the holes and slots aligning with the knock-outs in the
end panels of the building
panels being joined.
As an alternative to having a recess for receiving the steel connectors, a
groove may be
formed along the entire length of end ribs 45 and 45d. This groove can receive
the steel connector
and may also be filled with a concrete adhesive/sealant, which will facilitate
the attachment and
sealing of two adjacent panels.
A second embodiment of an air-gap panel is shown in cross-section in Figure
21. In this
embodiment the reinforced concrete slab is replaced with a brick fascia 365.
The air gap is formed
between the inside surface 370 of the bricks and a plywood sheeting 31 S. In
this particular
embodiment, bottom beam 35d is extended outwardly to provide a support for the
bricks. The type
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of brick is not particularly limited and the choice of a suitable brick is
within the purview of a person
of skill in the art. The brick fascia 365 provides both structural integrity
to the wall and provides
an aesthetic value. As will be apparent, the brick fascia 365 may not cover
the entire height of the
panel. For example, the bottom half of the slab may be formed from concrete,
with only the top half
being formed of brick. Further, if desired, a brick fascia may be incorporated
into a basement panel
when a portion of the panel is to be above ground.
In an alternative embodiment, the brick fascia may be supported on the top
beam of a lower
building panel as opposed to resting on bottom beam 35d. Further, the top of
the brick fascia may
engage with top beam 30d in a manner similar to that shown in Figure 21 with
respect to the
engagement of the brick fascia and bottom beam 35d.
Figure 22 shows a third embodiment of a building panel in accordance with the
invention,
with like numerals referring to like parts with an "e" added for clarity. This
particular panel is
provided with a plurality of apertures for forming windows 380 and a door 390.
To maintain
structural integrity in the panel, ribs SSe are supplemented with transverse
ribs 395. The ribs SSe
and 395 together define the frame for the windows 380 and the door 390.
All the panels described above may be connected directly together using the
fastening
systems discussed such that concrete-to-concrete joints are formed. However,
it is envisioned that
energy-absorbing, flexible material may be incorporated into some or all of
the panel-to-panel joints.
Suitable energy absorbing materials may include, for example, rubber and other
resilient polymers.
Further, the panels may be connected using spring bolts, which permit a slight
degree of movement
between the panels. The use of energy-absorbing spaces and/or spring bolts
will help make the
building resistant to earth tremors and the vibration associated with
earthquakes and severe weather
systems such as cyclones, hurricanes and tornadoes.
Thus far, the building panels have been described with reference to their use
as wall panels.
However, the panels can also be used as floor panels. The panels can be
supported on any
conventional floor support structure. The building panel may be laid
horizontally with the slab 22
forming either the upper or lower surface, as required by the builder. The
panel ribs can be used as
support for the internal wiring and plumbing which generally runs under a
floor.
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The building panels of the present invention may also be used in the
construction of a roof
for a building. A method of joining a sloped roof panel to a vertical wall
panel is shown in Figure
23. For safety reasons it is preferred for a corner of sloped roof panel 400
to rest on top beam 30 of
the wall panel 20. The corner may be flattened to aid in weight distribution.
The eaves of the roof
are formed by a stepped eaves unit 410 which is also preferably formed of
reinforced concrete but
may also be formed from wood, plastic or the like. The eaves unit 410 is
attached between the
sloped roof panel 400 and the wall panel 20 by bolts 85.
In the embodiment shown in Figure 23, sloped roof panel 400 is oriented such
that slab 22
forms the lower (i.e., interior) surface of the roof. In this case, the outer
skin of the roof may be
formed across the ribs of the panel in any conventional manner. Alternatively,
sloped roof panel 400
may be oriented such that slab 22 forms the upper (i.e., exterior) surface of
the roof.
In yet another embodiment, eaves unit 410 may be formed integral with sloped
roof panel
400, i.e., a specialized, pre-cast roof panel may be formed having at one end
thereof the shape of the
stepped eaves unit. This would simplify construction of a building as there
would be fewer pieces
to be bolted together.
The apex of the roof may be formed by an apex unit 420 attached between ends
of adjacent
sloped roof panels 400. Once again, the apex unit 420 is preferably formed
from reinforced concrete
and it is attached between the ends of the adjacent sloped roof panels by
bolts 85. The apex unit may
also be formed from a steel channel.
The angle of the roof may be modified by changing the angle 8 of the apex
unit. Further, if
desired, the strength of the apex unit may be increased by reinforcing the
interior of the unit with
steel cross-member or poured concrete.
As indicated in Figure 24, apex unit 420 need not necessarily be formed as a
concrete tube,
but rather, the lower concrete V-shaped walls 430 and 440 may act as a support
for a plywood cap
450. The plywood cap 450 may be treated in any conventional manner to form a
secure, watertight
seal between the sloped roof panels.
As discussed above with respect to the eaves units, the front panel 22 may
form either the
interior surface or the exterior surface of the roof, depending on the
builder's preference.
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In another embodiment of the building panel of the invention, as illustrated
in Figure 25, the
end ribs 45, for example, are provided with reinforced portions 500 near the
juncture with the top
beam 22. This type or arrangement provides more reinforcement for joining
adjacent panels. For
further reinforcement, rebar 502 may also be provided in the corners of the
panels 20. With
reinforced portions 500, adjacent panels may be joined together via bolts
extending through their
respective top beams without the need for the tensioning belt discussed above.
Additional support
may be derived by connecting the panels with bolts extending between adjacent
end ribs.
Figure 26a shows a further embodiment of the invention illustrating one
arrangement of
panels for the basement and top floor. As shown, the basement panel 504 is
provided with a recess
506 on the top beam 30 thereof. The top floor panel 508 includes an extension
510 in the slab 22
thereof. The extension 510 of the top floor panel is dimensioned to be
inserted into the recess 506
of the basement panel 504 so as to provide a close fit. Also shown is a floor
panel 511, which is
described in more detail below.
As illustrated in Figure 26b, the top floor panel is also provided with
drainage holes 512 at
two locations over its length to allow moisture to pass through. Preferably,
the drainage holes 512
are provided 2 feet from each side of the panel thereby resulting in the holes
being separated by 4
feet. The holes are also preferably '/4" in height and 1 %z" deep. The top
floor panel 508 shown in
this embodiment is similar in construction to the "air-gap" panel described
above with the exception
of the extension 510 being provided. To provide additional water tightness, a
vapour barner 514
may also be provided between the two panels.
Figure 26c more clearly illustrates the basement panel 504.
Figures 27a and 27b illustrate two means of connecting adjacent panels via
adjacent end ribs.
In Figure 27a, a connection is shown that allows for expansion. In this case,
the adjacent end ribs,
40 and 45, respectively, are connected by means of a pipe bolt and nut
combination 516 that also
includes springs 518 between the ribs and the bolt and nut. In this manner,
any expansion or slight
movement of the adjacent panels can be accommodated without any structural
damage. In Figure
27b, the connection between two adjacent panels is more rigid by means of a
pipe bolt and nut
combination 516 without the use of springs.
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As mentioned above, the pipe bolts 516 are preferably hollow thereby allowing
passage of
electrical and plumbing etc., there-through.
Figure 28 shows a basement panel according to another embodiment wherein the
panel 518
is provided with a ledge 520 for supporting an exterior brick veneer 522.
As shown in Figure 26a, the panels of the present invention may also be used
as floor panels
511. A more detailed illustration of such panel is shown in Figure 29. The
panel 511 is essentially
of the same construction as the wall panels described above. The floor panel
511 may be provided
with an extension 524 of the slab. The extension is then rested on the top
beam of the basement wall
panel to create a first floor for the building. If necessary, additional
vertical support may be provided
by means of pillars etc. as is conventionally known. The need for such
additional support will, of
course, depend upon the span of the floor.
The following description of Figure 30 will use the same element numbering as
for Figure
26a to identify similar elements in the drawings.
Figures 30a to 30c depict various other embodiments of the invention wherein
the panels are
used for flooring. As shown in these figures, the top floor panel, basement
panel and floor panels
are connected by means of bolts extending there-through. As shown in the
figures, when used for
flooring, the panels of the invention may be oriented in either direction.
That is, for a flat concrete
floor, the panels may be placed with the slab 22 facing upwards. In the
alternative, the panel may
be reversed so that the ribs are positioned upwards. In the latter case, the
ribs function as joists over
which standard flooring may be attached.
As described above, the present invention includes the use of the above panels
for use in top
floor walls and for flooring. However, it will be appreciated that any of
these uses may be replaced
with traditional methods of construction. For example, instead of using the
panels for the top floor
walls, it is possible to use typical wood stud construction wherein the
typical walls are connected
to the basement wall panels by known methods. Similarly, the floor system may
comprise
traditional wood joists extending over the top beams of the basement panels.
Further, metal joists
may also be used. In the latter case, the metal joists may be used to support
flooring panels made
that comprise the concrete panels of the present invention.
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Figures 30d and 30e illustrate a further embodiment of the invention wherein
beams are
provided to support the panels when used for flooring. In Figure 30d, one
version of the beam is
shown at 513. As shown, beam 513 includes a pair of ledges 515, which are
designed to support the
extension 524 of the floor panel 511.
Figure 30e illustrates another embodiment wherein the letter "a" is used to
identify elements
that are similar in function. In this embodiment, the beam 513a comprises an
inverted "U" shaped
structure that provides a single ledge 515a for supporting flooring panels
511a.
In Figures 30d and 30e, the beams 513 and 513a extend over opposite vertical
wall panels
and provide a support surface for the floor panels. In this way, the floor
panels can be installed
without having to be directly resting on the wall panels.
Figures 31 and 32 illustrate various embodiments wherein conventional flooring
construction
methods may be used with the panels of the present invention. In these
figures, like elements are
referred to with like reference numbers.
Figure 31 illustrates a further embodiment of the invention wherein the panels
of the
invention are used to construct a building. In this embodiment, top and bottom
panels 526 and 528,
respectively, are connected together to form top and bottom levels of the
building. As discussed
before, the connection of the panels is achieved by conventional methods such
as the use of bolts
extending between the bottom beam 530 of the top panel 526 and the top beam
532 of the bottom
panel 528. Also as discussed above, the connection between the panels is
preferably reinforced by
a connecting plate 534, which is bolted to both panels at the end ribs
thereof. Such bolts extend
through the apertures 536 provided in the ribs of each panel. In the preferred
embodiment, a groove
is provided in the end ribs to accommodate the connecting plate so that the
two panels are in contact.
Referring again to Figure 31, it is shown that the panels are provided with
hangers 538. The
hangers are designed, at one end, to engage the apertures 536 of the ribs on
the panels and, at the
opposite end, are provided with a hook 540. The hook 540 of the hanger 538 is
adapted to receive
2 x 12 joist stringers 542 as are commonly known or 4 x 4 headers 544. In
either case, conventional
wood joists 546 can be attached to the stringers 542 or headers 544 as is
commonly know.
Following this, a typical plywood flooring 548 may be applied. In this manner,
the level of the
floors in a building can be adjusted to allow for a "sunken" effect where
required.
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In Figure 32 another embodiment of an adjustable floor level is illustrated
wherein a metal
pipe 550 is inserted through the apertures 536 in the panels and a metal angle
iron 552 is welded to
the pipe. The angle iron 552 thus creates a header onto which conventional
joists 546 can be
attached.
Figures 33a and 33b illustrate a preferred embodiment of the invention wherein
a wall panel
is specifically configured for use in interior corners. In this embodiment,
the corner panel 554 is
designed as discussed above for regular wall panels, but is provided with a
return portion 556 on one
of the end ribs 558. The return portion comprises, preferably, a 12 '/2" slab
that extends from the end
rib 558 towards the neighbouring rib 560 on the panel. In this manner, the
return portion 556 is
generally parallel to the slab 562 of the corner panel 554. The return portion
556 is provided with
apertures 564 similar to those on the other ribs. In this manner, the end rib
of a typical wall panel
can be positioned adjacent and perpendicular to the corner panel 554 so as to
form an interior corner.
In this arrangement, the apertures in the end rib of the second panel would be
at the same locations
as apertures 564 of the return portion 556 thereby enabling the two panels to
be connected together.
In the preferred embodiment, the return portion 556, the end rib 558 to which
it is attached, the
adjacent rib 560, and a portion 566, of the slab 568, between the end rib 558
and the adjacent rib 560
have a thickness of 3" whereas the rest of the panel has a thickness of 2 '/Z"
as in the regular wall
panels. The increased thickness provides added strength to the corner of the
wall being formed.
Further, in order to ensure that the ribs are properly positioned to
accommodate the application of
drywall, the corner panel 554 preferably has a width of 8' 10" instead of the
regular 8'. In this
arrangement, once the second panel, having a 10" depth, is positioned, the
remaining width of the
panel would be the typical 8'.
In manufacturing the corner panel 554 is preferably first formed as a typical
wall panel
described previously. Subsequently, concrete is poured to form the return
portion 556. This
alleviates any problems associated with stripping the forms from the complete
panel. However, it
is still possible to manufacture the corner panel in one step.
Figure 34 illustrates various embodiments of the panels of the invention for
use in
constructing a roof for a building.
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Figure 35 illustrates an embodiment of the invention wherein the panels
described above are
used to construct a retaining wall. As shown, the wall 570 is comprised of a
number of stacked
panels 572 each having apertures 574 as described above. Brackets 576 are
provided which
cooperate with the apertures to form ledges 578, which, in turn, support
counter weights 580. As
shown in Figure 36, another embodiment of the invention comprises the wall
panels 572 being
formed with integral ledges 578' thereby removing the need for the brackets
576.
In another embodiment, the wall panels of the invention may be provided with a
unitary
footing as illustrated in Figure 37. As shown, the wall panel 582, according
to this embodiment,
includes an integral footing 584 under the bottom beam 586 of the panel. With
this arrangement,
the need for separate footing is overcome.
Figure 38 illustrates a further embodiment of the invention wherein a
plurality of wall panels
are stacked to form the walls of a multi-level building. In this embodiment,
the wall panels are
staggered so as to avoid a continuous seam. The panels are bolted together as
described above since
although staggered, the apertures in the ribs would still be in line.
Figure 39 illustrates a wall of a multi-level building wherein a variety of
flooring systems
are used. The flooring systems shown are described above.
Figure 40 illustrates a fiuther embodiment wherein a wall panel 588 serves to
form a curtain
wall. In this case, the slab 590 of the panel 588 is extended past the top and
bottom beams 589 and
591, respectively to result in top and bottom flanges 592 and 594,
respectively. The top and bottom
beams 589 and 591 are then bolted to the floors of the building
The weight of the above panels may be reduced by using lightweight concrete in
the forming
process. It will be understood that the strength of the concrete will be
determined by the required
engineering specifications for the subject building. Further, where
appropriate, the metal reinforcing
material may be omitted in favour of other known reinforcing means such as
fiberglass or vinyl
strings etc. Preferably, such alternate reinforcing means will only be used
for buildings less than
four stories in height.
The above concrete panel system results in a building that can be specifically
engineered to
withstand earthquakes. Further, such buildings would also be suited for areas
having unstable soils
and areas that are subject to cyclones and flooding.
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In addition to being used for new construction, the panels of the invention
can also be used
in a "retrofit" manner in buildings constructed by conventional methods. The
preferred size of the
panels, as described above, makes them compatible for this purpose since they
are designed in
accordance with existing North American building standards. An example of this
is illustrated in
S Figure 41a wherein a wall panel 598 is bolted to an existing concrete block
wall 596. Also shown
is the connection of a wall panel of the invention to an existing wood or
metal stud wall 600 in
accordance with conventional construction methods. In both cases, the wall
panel can be attached
to the existing structure using the bolts as described above. Such bolts are
shown at 602. Figure 41b
illustrates the connection of a wall panel of the invention to an existing
poured concrete wall 604.
Once the wall or roof panels described above are erected, they may be
insulated and finished
by any variety of known methods.
Although the invention has been described with reference to certain specific
embodiments, various modifications thereof will be apparent to those skilled
in the art without
departing from the spirit and scope of the invention as outlined in the claims
appended hereto.
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