Note: Descriptions are shown in the official language in which they were submitted.
CA 02671646 2009-07-10
MODULAR PANEL WALL ASSEMBLIES
Field of the Invention
[00011 The invention relates generally to modular building construction, and
more
particularly to modular wall panels used in the construction of foundation
walls and upper
floor exterior walls.
Background of the Invention
[00021 Building structures are often built upon perimeter wall foundations.
Typical
perimeter wall foundations have been formed from poured or modular concrete or
built up by
grouted blocks placed atop a concrete footing. The perimeter foundation walls,
and any cross
beams bridging across the walls, support the first floor and higher load
bearing walls of the
structure.
[00031 Structures such as manufactured and modular homes may be installed on
interior
piers as the primary foundation support rather than using the perimeter wall
as the primary
support. Even when using interior pier support, however, it often required by
building code
to provide some type of perimeter wall to reduce shear loads, seismic
vibration effects and
wind uplift, and to prevent flooding and pest invasion under the foundation.
While a
perimeter foundation in conjunction with these interior pier supports could be
constructed as
traditionally done with concrete or block before the building structure is
lowered into
position, the difficulties and expense of precise wall placement and leveling
for this type of
perimeter wall has led to the use of steel panels that can be hung from the
perimeter floor
boards of a manufactured or modular home, and then anchored at the bottom edge
in a
concrete-filled trench that serves as a footer for the foundation wall.
[00041 Panel assemblies for this type of steel panel perimeter foundation are
known, such
as the AnchorPanel assemblies by Fast Track Foundation Systems. These are
corrugated
steel panels that can be cut to length and installed with lag screws hanging
under the
perimeter floor boards of a pier-supported structure. The corrugated shape
provides
stiffening against bending under vertical and side loads. The panels have the
bottom 5 or 6
inches cut along the outfacing corrugation channel and bent inward at 90
degrees to form an
anchorage flange that will be encapsulated in the concrete footer. While such
steel panel
foundations are easier to install than concrete or grouted block, the
corrugated shape requires
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some external facing if it is to appear flat in areas exposed above ground or
to be used to
attach decorative surface finishing materials to make an attractive facade.
[0005] There is a need for more efficient and versatile wall panel assemblies
for
foundation walls, including panels with flat exterior wall surfaces, bottom
anchorage for
encapsulation in concrete slab floors, robust support for full foundation
walls and cross wall
beams, provisions for attached steel frame stairways, more variations of
corners and curved
panels, ease of thermal insulation, ease of drywall support, and reinforcing
shear walls where
much of the wall face is taken up by widow and door cutouts.
[0006] Many of these objectives can be attained by using wall panel structures
similar to
those used in the construction of in-ground swimming pools, made from steel
which can be
galvanized or otherwise weather coated, with adaptations as necessary to serve
as weight
bearing foundation walls and shear walls for exposed foundations and upper
floor exterior
walls. The attainment of these and other objectives will become apparent in
the description
that follows.
Summary of the Invention
[0007] According to one aspect of the invention, a perimeter foundation wall
is
constructed from modular wall panels with flat exterior wall surfaces. The
panels are
preferably made of steel. In one embodiment, the individual panels have a
generally planar
shape defining a wall face and a flange formed on each vertically extending
side by bending
the side edges of the panel at a right angle in the same direction. These side
flanges have
matching bolt holes to allow another panel to be joined to the panel on either
side to form a
section of vertical wall. The panels are also bent at the top and base into
the same direction
to the panel as the side flanges to form a top cap and base pan, as described
more fully in the
detailed description.
[0008] In an alternative embodiment, the individual panels have a generally
planar shape
defining a wall face, two vertical-side framing studs, a top cap and a bottom
pan, that are all
integrally constructed, preferably from a steel sheet. Each side framing stud
of the panel
extends at a right angle away from the wall face to a side depth distance to
form a panel side
wall. The side walls have matching bolt holes to allow similar panels to be
joined to the
panel on either side, as in the previous embodiment. Different from the
previous
embodiment, however, each side-framing stud then is bent and extends parallel
to the wall
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face from the side depth distance toward the opposite side stud of the panel
for a distance of
about three quarter inch to two inches to form a surface for attaching a
finishing strip. At the
opposite end of the finishing strip surface the stud may be bent again to
reflect back parallel
to the panel side for a short distance toward the wall face.
[00091 In this embodiment, the top cap again extends at a right angle from the
wall face
in the same direction as the side panels, but may now extend to a distance
from the wall face
that is longer than the side depth by substantially the depth of the finishing
strip. The top cap
is then bent downward to form a top flange that will lie over the finishing
strips. Similarly,
the base pan extends at a right angle from the wall face in the same direction
as the side
panels to a distance from the wall face that is longer than the side depth
distance by
substantially the depth of the finishing strip, and then is bent upward to
form a bottom flange
to overlie the finishing strips.
[00101 As small variations on the above embodiment, the top cap may only
extend to the
side depth before bending downward to form a flange over the side studs, so
that the finishing
strips provide a thermal barrier between the metal panel and any drywall or
other wall
covering. The bottom flange may also be longer than the top flange to provide
a screed
support for leveling a poured concrete floor pad.
[00111 The finishing strips are made from non-metallic material having good
insulating
properties to form a thermal barrier between the wall panel and any interior
wall surface such
as drywall or paneling. The strips also have sufficient strength to hold
staples, screws,
drywall nails or similar fasteners used to support interior wall surface
materials or wall
hangings on hangers passing through the drywall. While natural wood could be
used,
engineered wood or plastic composite provides sufficient strength and thermal
barrier in
narrow strips and are preferred for that reason. The finishing strips are
attached to each side
wall framing support and extend from the bottom pan to the top cap.
[0012] In the first embodiment where the side walls are just flat side flanges
extending
from the wall face, the panel side walls may be reinforced as needed by
vertical "C"-shaped
support brackets bolted to one or both panel side walls along the seams where
adjacent panels
are bolted together. In the embodiment where the side walls are also integral
framing
supports with a finishing strip surface, no additional vertical support
bracket is needed at the
side wall seams. In both embodiments, the side walls and the vertical framing
studs have
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aligned cutout chase-ways to accommodate the passage of electrical conduit
and/or fluid
piping along the wall.
[0013] The wall panels may also be reinforced by vertical reinforcement studs
as interior
framing studs spaced at regular intervals (e.g. at 16 inch centers on a 48
inch wide panel).
The interior studs are generally "Z-shaped. In a preferred embodiment, the
vertical
reinforcement studs have a top and bottom plate for contact against the top
cap and bottom
pan of the panel and, similar to the side framing studs, extend parallel to
the wall face for a
distance of about three quarter inch to two inches to form a surface for
attaching a finishing
strip, and at the opposite end of the finishing strip surface reflect back a
short distance toward
the wall panel's face. In this embodiment a finishing strip is attached to
each vertical framing
stud and extends from the bottom pan to the top cap.
[0014] The top caps of the panels, supported by the framing studs, provide a
base for a
sill plate. The base pans of the panels provide an anchor that can be fastened
to a concrete
footer or be encapsulated in a concrete slab floor. The corners of the
foundation wall may be
formed by corner panels. The corner panels can form a right angle corner, or
be curved
corners of various radii. The right angle corners can be either inside corners
(90 degree) or
outside corners (270 degree). The corner panels have side walls that match
with the flat wall
panels, and bolt holes and conduit cutouts aligned with those in the wall
panels. The corner
pieces also have a top cap and base pan like the wall panels, and may have
surfaces for
attaching finishing strips.
[0015] A beam support post may be installed between adjacent wall panels to
form a
beam pocket in which to seat a beam extending across the foundation to a
similar beam
pocket located on an opposite side of the perimeter wall. Alternatively, a
beam support post
may be installed within a wall panel, with the panel's top cap having a gap to
accommodate
the beam.
[0016] A modular stair well may be placed between adjacent wall panels to form
a
basement walkout or egress. Windows, doors and egress windows may be formed in
above
grade sections of the wall. Where the windows or doors are in a shear wall,
beam pockets
may support a hollow beam over door or window openings for greater shear
resistance.
[0017] The panels may have insulation material sprayed onto the inside of wall
face. The
panels may also be coated with a decorative protective finish, such as Rhino
Lining TM finish.
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[00181 Wall panels of the embodiment having two vertical-side framing supports
and
finishing strips are preferred when constructing the foundation walls of a
full height
basement. According to one exemplary method of using the panels to construct
the
foundation walls for a full height basement, a foundation outline box is laid
out and the
basement pit is excavated to below the frost line with an over-dig of at least
about two feet
wider than the outline box. A layer of crushed stone may be needed depending
upon soil
condition. Drainage piping and other filter or vapor membranes may be used
under the area
where the concrete slap floor will be poured. A perimeter footer wider than
the width of the
wall panels is poured and leveled in the outline of the foundation.
[00191 Wall panels pre-manufactured to the particular foundation wall
specifications are
then assembled together with bolts at the side wall seams. The assembly
preferably starts at a
comer section and works both directions from the corner. The corner panel is
set in place and
aligned on the footer. There are pre-punched anchor holes in the base pan of
the corner panel
through which anchor holes can be drilled into the footer. Concrete anchor
screws (e.g.
TAPCON TM screws) and washers are used to immobilize the panel on the footer
as the other
panels are assembled to it. At each side seam, a bead of urethane sealant is
drawn about one
quarter inch thick running along the top cap then down to the bottom pan in
the surface
between the wall face and the bolt holes. After checking alignment and level,
more concrete
anchor screws can be used to immobilize the wall section as the next adjacent
panels are
bolted on.
[00201 When all of the wall panels are joined and leveled, a continuous bead
of urethane
sealant is also placed at the seam between the concrete footer and the base
pan at both the
interior and exterior sides of the wall area. A concrete slap floor may be
poured in the
interior basement space between the walls. If the wall panels are intended to
be encapsulates
in the slab, the panels are made with a short flange on the bottom pan such
that the poured
concrete flows into the entire base pan. Alternatively, if the intention is to
contain the slab
along the inside perimeter formed by the base pan, the flange of the base pan
is increased in
height and serves as a screed support for leveling the poured concrete. Any
cross beams or
other support beams are placed into the beam pockets. A sill plate is then
installed over the
top cap to fix the top alignment of the panels and ready the foundation for
support of upper
levels.
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[0021] Upper levels of the building structure may also use the wall panels of
the present
invention, particularly where the exterior walls may be subject to high shear
forces or need
increased weight bearing capacity.
Brief Description of the Drawings
[0022] Figure 1 is a top front perspective view of a basement wall constructed
from wall
panels having a generally flat exterior face in which the basement perimeter
wall provides the
main support for the building foundation, coupled with a cross beam pocket.
[0023] Figure 2 is a top rear prospective view of the basement wall of Figure
1.
[0024] Figure 3 is a section view of a vertical reinforcing stud taken along
the line 3-3' in
Figure 2.
[0025] Figure 4 is a section view of a vertical edge reinforcing bracket taken
along the
line 4-4' in Figure 2.
[0026] Figure 5 is a perspective view of an alternative wall panel with
integral side wall
framing support.
[0027] Figure 6 is a perspective view of the wall panel of Figure 5 with
interior framing
studs.
[0028] Figure 7 is a section view of an interior reinforcing stud taken along
the line 7-7'
in Figure 6.
[0029] Figure 8 is a section view of an integral sidewall reinforcing stud
taken along the
line 8-8' in Figure 6.
[0030] Figure 9 is a view of a portion of a wall having a cross beam installed
in a beam
pocket between adjacent wall panels.
[0031] Figure 10 is a view of a wall panel having an interior beam support
within the
panel.
[0032] Figure 11 is a view of a section of wall having inside and outside
corners, cross
beams, a window frame and a door frame.
[0033] Figure 12 is a view of an outside corner wall panel.
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[0034] Figure 13 is a view of an inside corner wall panel.
[0035] Figure 14 is a hollow beam structure for support over lager window and
door
openings.
Description of the Invention through Embodiments
[0036] Referring to the drawings, where like numerals identify like elements,
Figures 1
and 2 illustrate an in-ground basement foundation where the basement perimeter
wall is the
primary foundation for a building. A foundation of this type may include one
or more cross
beams supported in two opposite beam pockets of the wall. Attached to the wall
is a steel
staircase forming a basement walkout. This figure will be used to identify
elements of a
foundation constructed from modular wall panels having a generally flat
exterior face.
[0037] As shown in Figures 1 and 2, the foundation wall 10 is formed from
preformed
structural wall panels 12. A preferred panel is made from a steel sheet, for
example a 14-
gauge galvanized G-235 steel sheet that is stamped and bent into the desired
shape and then
weather coated with a spray-on polyurea or similar protective coating. Each of
the panels 12
includes an upstanding wall portion 14 that is substantially smooth on its
outside surface (the
outside surface may have minor irregularities such as the stubs of mechanical
fasteners such
as toggle locks or rivets used to attach vertical reinforcing studs and beam
supports on the
interior side, as described below).
[0038] Attached to the wall 10 is a steel stair well 16 with steps to provide
a walkout exit.
The wall 10 also includes two opposite beam pockets 18 to accommodate a cross
wall
support beam. A longer wall could have more than one cross beam. Cross beams
can also
be used with walls of different shapes and dimensions. The structural wall
panels 12 have a
generally flat or planner outside surface 20, although the panels can be
curved for customized
buildings where the foundation is not rectangular and yet retain a smooth
outside surface.
Standard panels are 4-foot wide and up to 10 foot in height, but custom panels
can be made in
various dimensions.
[0039] The panel can be constructed from a steel sheet by cutting or punching
the
dimensions and bolt holes and keyways, and then bending the edges to form the
panel. As
shown in Figure 2, the inside surface of a panel may have a generally flat
portion 22 in its
interior, but it is bent at the edges. In one embodiment of the panels, the
individual panel 12
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has a side flange 24 formed on each vertically extending side by bending the
two side edges
of the panel at a right angle in the same direction. The wall panel 12 also is
bent at its top
edge to from a top cap 26, and at its bottom edge to form a base pan 28,
extending in the
same direction as the side flanges 24. The side flanges have bolt holes 30 at
set intervals to
allow two panels to be joined together by bolts and nuts.
[0040] Depending upon how much load the perimeter wall be subjected to, the
wall
panels may require additional structure to resist bending. When the perimeter
wall 10 is the
main support structure of the foundation, as in the basement wall embodiment
of Figures 1
and 2, the wall panels may require additional structure to resist bending
under the vertical and
side loads. In this embodiment of wall panel, vertical reinforcement members
or framing
studs 36 are spaced at regular intervals (i.e., at 16 inch centers on a 48
inch wide panel) and
vertical support brackets 38 are placed along the seams where adjacent panels
are bolted
together provide such resistance. The vertical reinforcement members (or
framing studs) 36
are preferably 14 gauge coated steel channels having a roughly Z-shaped cross
section as
shown in Fig 3. One flange 42 is fastened against the flat surface 22 on the
inside of the wall
panel. The web 44 of the stud 36 extends inwardly perpendicular to the plane
of the wall
then is bent at a right angle to form a second flange 46 in the direction
opposite the first
flange 42. One or both flanges may terminate with a short reflected edge 45,
47 that extends
parallel to the web 44. The spacing of the vertical reinforcement studs can be
matched to the
expected load. For example, in the basement wall shown in shown in Figures 1
and 2, the
studs can be placed at 8 inch, 12 inch or 16 inch centers depending upon the
expected vertical
and side loading. The studs 36 may have cutouts to allow passage of electrical
conduit or
plumbing.
[0041] Vertical support brackets 38 are used to stiffen the wall panel
connection between
adjacent panels and to increase vertical support. A support bracket is
preferably C-shaped in
cross section as shown in Fig 4. One flange 48 extends against the flat
surface 22 on the
inside of the wall panel. The web 50 of the bracket 36 extends inwardly
perpendicular to the
plane of the wall then is bent at a right angle to form a second flange 52 in
the direction
opposite the first flange 48. One or both flanges may terminate with a short
reflected edge
49, 53 that extends parallel to the web 44. The web 50 has bolt holes arranged
to align with
the bolt holes in the side flanges of the wall panels. A bracket 38 can be
attached to the wall
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flanges on one or both sides of a panel connection. The brackets 38 may have
cutouts to
allow passage of electrical conduit or plumbing.
[0042] In an alternative embodiment as shown in Figures 5 and 6, the panels
have
integral side framing studs. An individual panel 112 has a generally planar
shape defining a
wall face 114, two vertical-side framing studs 116, a top cap 118 and a bottom
pan 120, all
integrally constructed, preferably from a steel sheet. Each side framing stud
116 of the panel
extends at a right angle away from the wall face 114 to a side depth distance
D to form a
panel side wall 122. The side walls have matching bolt holes 124 to allow
similar panels to
be joined to it on either side, as in the previous embodiment. As shown in
Figure 7, however,
the side framing stud 116 then is bent and extends parallel to the wall face
from the side
depth toward the opposite side support of the panel for a distance of about
three quarter inch
to two inches to form a surface 127 for attaching a finishing strip 128. At
the opposite end of
the finishing strip surface 127 the stud is bent again to reflect back
parallel to the panel side
for a short distance toward the wall face as a support post 129. In this
embodiment, the top
cap 118 again extends at a right angle from the wall face in the same
direction as the side
panels, but here extends to a distance from the wall face that is longer than
the side depth D
by substantially the depth of the finishing strips. The top cap 118 is bent
downward to form a
top flange 130 over the finishing strips. Similarly, the base pan 120 extends
at a right angle
from the wall face in the same direction as the side panels to a distance from
the wall face
that is longer than the side depth distance by substantially the depth of the
finishing strips,
and then is bent upward to form a bottom flange 132 over the finishing strips.
[0043] In a variant of this embodiment, the top cap 118 extends only to the
side depth D
before being bent downward to form a top flange 130. In this variation, the
finishing strips.
Similarly, the base pan 120 extends at a right angle from the wall face in the
same direction
as the side panels to a distance from the wall face that is longer than the
side depth distance
by substantially the depth of the finishing strips, and then is bent upward to
form a bottom
flange 132 over the finishing strips. In this variation, the finishing strips
overlie the top cap
flange to provide a thermal barrier between the metal pane and the dry way or
other wall
covering.
[0044] In another variation, the bottom flange may be longer than the top
flange, for
example a 3-inch high bottom flange as opposed to a 1-inch top flange. The
longer bottom
flange may be used when the concrete basement floor is to be contained within
the inside
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perimeter of the base pan. A shorter flange is used when the concrete is
intended to flow
over the flange and into the base pan.
[00451 In this embodiment of panel having integral side-framing studs, the
interior
framing studs 134, similar to the previously described side framing studs 116,
are preferably
14 gauge coated steel channels having a roughly Z-shaped cross section, as
shown in Fig 8.
One flange 142 is fastened against the flat surface of the inside of the wall
panel. The web
144 of the stud extends inwardly perpendicular to the plane of the wall then
is bent at a right
angle in the direction opposite the first flange 142 and extends parallel to
the wall face for a
distance of about three quarter inch to two inches to form a surface 146 for
attaching a
finishing strip. One or both flanges may terminate with a short reflected edge
147 that
extends parallel to the web 144. In addition, the top and bottom ends of the
studs have an
integral generally rectangular plate extending in opposite directions. The
plate 148 in Figure
8 is at the bottom end of the stud and extends to the left in the drawing. A
similar plate (not
shown) at the top of the stud extends to the right. Thus, the stud can be
attached to the wall
face by fasteners at the rear flange 142, to the base pan by fasteners into
the bottom plate 148
and to the top cap by fasteners through the top plate. The spacing of the
vertical
reinforcement studs can be matched to the expected load, such as 12 inch or 16
inch centers,
and cutouts matching those in the side framing to allow passage of electrical
conduit or
plumbing. A finishing strip 128 is attached the front flange surface 146 and
extends from the
bottom pan to the top cap.
[0046] The finishing strips 128 are made of non-metallic material having good
insulating
properties to form a thermal barrier between the wall panel and any interior
wall surface such
as dry wall or paneling. The strips also have sufficient strength to hold
staples, screws, dry
wall nails or similar fasteners used to support interior wall material or wall
hangings. While
natural wood could be used, engineered wood or plastic composite provides
sufficient
strength and thermal barrier in narrow strips and are preferred for that
reason. The finishing
strips 128 are attached to each side wall framing support and extend from the
bottom pan to
the top cap.
[00471 As shown in Figures 2 and 9, a beam pocket 18 may be formed in the
perimeter
wall by placing a beam post 84 between two wall panels 12. The beam post 84 is
essentially
the same configuration as a wall panel, except that it is shorter than the
height of the wall
panel by about the height of a standard steel I-beam 90, and is about the
width of the beam's
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flanges, so that the I-beam sits conformingly in the beam pocket 18 formed
between the two
higher panels on each side. The sides of the beam post may be reinforced by
bolting a "C"
support bracket 38 (not shown, but essentially as in Figure 4) 38 onto each
side wall of the
adjacent wall panels. The top of the beam post is covered by a plate and the
beam may be
fixed in the pocket by bolts extending through the plate and though holes
drilled through base
flange of the beam.
[00481 Alternatively, as shown in Figure 10, a beam support post 184 may be
attached to
the interior wall of a wall panel 112, instead of being located between
adjacent panels. The
beam support post 184 is preferably formed of 11 gauge steel. A pocket opening
for the
beam 190 is stamped out of the sheet before it is bent to form the top cap.
The beam post is
shorter than the height of the wall panel by about the height of a standard
steel I-beam, and is
about the width of the beam's flanges, so that the cross-beam 190 sits
conformingly in the
beam pocket. The top face of the support post has holes to accept fastening
bolts though the
bottom flange of a floor support cross beam. The column is attached to the
wall panel by
fasteners, such as Tog-L-LocTM weldless fasteners.
[00491 A section of wall 200 as shown in Figure 11 has inside corners 212 and
outside
corners 210, cross beams 190, 214, a window frame 216 and a door frame 218.
The corners
of the wall may be formed of corner panels 210 that form outside corners such
as shown in
Figure 12, or panels 212 that form inside corners such as shown in Figure 13.
The wall 10 in
Figure 2 also has outside corner panels 94. An inside corner panel 212 may be
made shorter
than the wall panels 220 on either side to form a beam pocket 222 for an
interior cross beam
224. The outside corner panels 212, 94 can form right angle corners, or be
curved corners of
various radii. The corner panels have side support studs 226 like the wall
panels and have
bolt holes 228 aligned with those in the wall panels. The corner panels also
have a top cap
230 and base pan (not shown) extending over finishing strips 234 as with the
wall panels.
[00501 Windows and doors windows may be formed in above grade sections of the
wall.
Where large windows such as egress windows or doors form openings in a shear
wall, a
hollow support beam 230 (also shown in Figure 14) may be used over the window
or door
218 frames. The beam 232 is attached at each end over beam support posts 184
attached to
the wall panels sides of the opening. A short wall panel skirt 234 may be
attached to the
bottom edge of the support beam.
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[00511 A conventional sill plate (not shown) may be placed around the top caps
of the
wall panels and corner panels and over the cross beams. Floor joists are then
placed across
the walls transverse to the beam. To assist in locating and installing the
floor joists, a joist
anchor can be mounted on the sill plate. The joist anchor is an elongated 90
degree angle
bracket formed from sheet steel of suitable thickness, such as 14 gauge. The
sheet is cut to
dimension and bent to a right angle at the bottom to form a short bottom
flange having a
width that is less than the width of the sill plate that will be laid on the
foundation wall, and
an upright flange having a height to make it approximately flush with the top
of a floor joist
placed in the anchor resting on the bottom flange. Holes may be drilled or
stamped in the
bottom flange to pass through anchor bolts extending from the foundation wall
panels and
cross beam though the sill plate. Holes may also be provided in the upright
flange for screws
attaching the end of the floor joist to the anchor, or the screws can self-
drill these holes.
Since the short bottom flange of the sill plate has a width that is less than
the width of the sill
plate, there is room behind the joist anchor to fit a trim board to cover the
heads of the
screws.
[00521 Although not shown in the drawings, insulation be sprayed or otherwise
adhered
to the inside surface of the wall panels and beam posts, preferably to an
efficiency rating of
R- 14 or greater.
Example 1: Basement Foundation
[0053] According to one exemplary method of using the panels to construct the
foundation walls for a full height basement, a foundation outline box is laid
out and the
basement pit is excavated to below the frost line with an over-dig of at least
about two feet
wider than the outline box. The pit is excavated to sufficient dimensions to
accommodate
the planned basement and allow working space around the exterior of the
basement walls. A
layer of crushed stone may be needed depending upon soil condition. Drainage
piping and
other filter or vapor membranes may be used under the area where the concrete
slap floor will
be poured. A concrete perimeter footer wider than the width of the wall panels
is poured and
leveled in the outline of the foundation, and includes the footer for a
walkout stairwell if one
will be installed. The footer should provide a smooth surface of about 8-12
inches
(increased to three times the wall width under any cross beam posts) on which
to erect and
anchor the wall panels and stairwell.
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[0054] If a steel stairwell is used, it is set in place and anchored first on
the respective
portion of the footer. If no stairwell is used, the assembly preferably starts
at a corner section
and works both directions from the corner. The wall panels made to the
particular foundation
wall specifications are then assembled together with bolts at the side wall
seams. The vertical
support studs preferably have been are fastened onto the wall panels at the
proper spacing
before the panels are connected together, the finishing strips have been
installed on the side
wall studs and vertical studs, and thermal insulation has been sprayed onto
the inner wall
surface prior to delivery of the wall panels to the site.
[0055] If starting a corner panel, it is set in place and aligned on the
footer. There are
pre-punched anchor holes in the base pan of the corner panel through which
anchor holes can
be drilled into the footer. Concrete anchor screws (e.g. TAPCON TM screws) and
washers are
used to immobilize the panel on the footer as the other panels are assembled
to it. At each
side seam, a bead of urethane sealant is drawn about one quarter inch thick
running along the
top cap then down to the bottom pan in the surface between the wall face and
the bolt holes.
After checking alignment and level, more concrete anchor screws can be used to
immobilize
the wall section as the next adjacent panels are bolted on. A wall panel
having the beam post
support column is used at the foundation location where a cross beam will span
across
opposite walls. Corner panels are used to make the inside and outside corners.
Panels having
window or door frames are placed in the intended locations. Preferably all of
these pieces
can be marked to indicate the order of installation and location prior to site
delivery to reduce
any likelihood of placing the wrong panel in a sequence.
[0056] When all of the wall panels are joined and leveled, a continuous bead
of urethane
sealant is also placed at the seam between the concrete footer and the base
pan at both the
interior and exterior sides of the wall area. A concrete slab floor may be
poured in the
interior basement space between the walls. In a preferred embodiment, the
flange on the
bottom pan is about three inches high and the depth of the slab is preferably
poured up to the
height of the flange, using the top of the flange as a screed support for
leveling the concrete
surface. Alternatively, the concrete could be allowed to flow into the base
pan area and
encapsulate the base of the panels. Any cross beams or other support beams are
placed into
the beam pockets. A sill plate is then installed over the top cap to fix the
top alignment of
the panels.
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CA 02671646 2009-07-10
[0057] The outside surface of the wall structure may be sealed by caulking the
seams and
spraying a urethane sealing layer on the entire exterior wall before the pit
is backfilled. The
exterior surface may also be prepared for supporting a decorative facade.
Support stakes
may be attached to the wall to support a ledge or shelf mounted on the stakes
at a height that
will be below grade when the pit is back filled. The ledge can be used to
support decorative
facing, such as a brick stone facade. Other exterior surfaces visible above
ground can be
painted or covered with mesh and stucco or other decorative finish before or
after backfilling
the pit.
[0058] The wiring and any in-wall plumbing or conduit work can be installed
through the
keyway cutouts in the side walls and vertical supports. The dry wall or other
surface cover
can be hung on the finishing strips.
[0059] Although the use of the panels has been described above in relation to
a
foundation wall, it should be clear that the same panels could be used in
upper floor exterior
walls. The panels provide increased shear resistance and weight bearing
capacity, and are
easy to install by bolting side-by-side panels. The finishing strips provide
ease of attachment
for wallboard, and the keyways allow for wiring and other conduit. Thicker
insulation may
be required in upper floor wall panels. The outside surfaces of upper floor
walls can be
covered by siding or other facade material, or painted if an appearance other
than the
polyurethane coating is wanted.
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