Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: PRE-CAST RAIN SCREEN WALL PANEL
FIELD
The invention relates to the control of moisture within walls using a
pre-cast construction. In a particularly preferred embodiment, the invention
relates to a modular pre-fabricated wall panel, which may be used in the
construction of a building wherein the building has an outer facing of stucco,
brick, wood or aluminum siding or the like.
INTRODUCTION
Structural walls for buildings, such as residential, commercial or
industrial buildings, are often constructed in layers. Typically, a wall sits
on a
foundation and includes a back-up wall having a floor plate and a ceiling
plate
and a set of vertical studs. Usually sheathing, which may be plywood, oriented
strand board or the like, is disposed on the outside face of the back-up wall
(i.e.,
the side that faces towards the outside of the building). The sheathing is
covered
by a moisture barrier membrane. Insulation is typically installed on the
outside
face of the moisture barrier membrane. An outer facing, such as stucco, brick
or
a siding material is then typically provided as the outer component of the
wall.
Pre-fabricated wall sections are known. For example, Carlson (US
3,828,502) discloses a pre-fabricated panel wherein insulation is surrounded
by a
thin skin, which may be aluminum. Huettemann (US 4,841,702) discloses a
three-layer insulated concrete panel. The middle layer comprises an insulating
slab having grooves, which provide a form for casting of concrete supporting
ribs
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integral with a layer of concrete cast over the grooved face. Rebar may also
be
positioned in the grooves.
SUMMARY
In accordance with this invention, a pre-fabricated rain screen wall
panel is provided. The pre-fabricated wall panel comprises a multi-layer
panel,
which includes channels to permit water to flow internally in the wall panel
downwardly and be evacuated from the pre-fabricated construct by any means
known in the art. Accordingly, the pre-cast wall panels may be installed on
any
standard foundation and installed such that any water that accumulates at the
bottom of the wall panel may drain to the outside of the building.
An advantage of the design is that it permits wall panels to be
constructed, such as in a factory and then conveyed to a building site where
the
panels may be assembled together on a foundation to produce a wall of a
building. It will be appreciated that wall panels may be constructed in a
variety of
sizes so as to accommodate any particular profile of the outer perimeter of a
building.
The pre-fabricated construction permits the wall panels to be
assembled under more appropriate conditions than occur at a building site. For
example, the concrete may cure under more ideal conditions thereby increasing
the strength of the concrete. In addition, as opposed to pouring concrete into
a
vertical mould, the concrete may be pre-fabricated in horizontal layers
thereby
assisting in ensuring the absence of voids or the reduction of voids in the
concrete, which may impair the strength of the concrete.
In accordance with a first aspect of this invention, there is provided
a prefabricated assembly comprising:
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(a) inner and outer concrete panels;
(b) an intermediate drainage panel positioned adjacent the outer
concrete panel and having an inner face and an outer face and a
plurality of drainage channels provided on a face thereof, the outer
face is adjacent an inner face of the outer panel;
(c) an intermediate insulation panel positioned adjacent the
intermediate drainage panel;
(d) a vapour barrier positioned between the intermediate insulation
panel and the inner concrete panel; and,
(e) a plurality of shear connectors, each having a first portion, a
second portion and an intermediate portion extending between the
first and second portions, the first portion provided in the inner
concrete panel and the second portion provided in the second
concrete panel.
In some embodiments, the drainage channels are provided on the
inner face of the intermediate drainage panel.
In some embodiments, the inner face of the intermediate drainage
panel is adjacent an outer face of the intermediate insulation panel.
In some embodiments, the vapour barrier is positioned between an
inner face of the intermediate insulation panel and an outer face of the inner
concrete panel.
In some embodiments, the first and second portions are configured
to be secured in the concrete panels.
In some embodiments, the intermediate portion extends at an angle
to each of the first and second portions.
In some embodiments, the intermediate drainage panel comprises
insulation material.
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In some embodiments, the prefabricated assembly further
comprises rebar provided in each of the inner and outer concrete panels and
the
first portions are secured to rebar in the inner concrete panel and the second
portions are secured to rebar in the outer concrete panel.
In some embodiments, the intermediate drainage panel has an
absence of internal channels.
In accordance with another aspect of this invention, there is also
provided a prefabricated assembly comprising:
(a) inner and outer concrete panels;
(b) first and second intermediate panels positioned between the
inner and outer concrete panels, one of the first and second
intermediate panels having a plurality of drainage channels
provided on a face thereof, each of the intermediate panels having
an inner face and an outer face;
(c) a vapour barrier positioned between the inner and outer
concrete panels; and,
(d) a plurality of shear connectors, each having a first portion, a
second portion and an intermediate portion extending between the
first and second portions, the first portion provided in the inner
concrete panel and the second portion provided in the second
concrete panel.
In some embodiments, the drainage channels are provided on the
inner face of the first intermediate panel.
In some embodiments, the inner face of the first intermediate panel
is adjacent an outer face of the second intermediate panel.
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In some embodiments, the vapour barrier is positioned between an
inner face of the second intermediate panel and an outer face of the inner
concrete panel.
In some embodiments, the first and second portions are configured
to be secured in the concrete panels.
In some embodiments, the intermediate portion extends at an angle
to each of the first and second portions.
In some embodiments, the prefabricated assembly further
comprises rebar provided in each of the inner and outer concrete panels and
the
first portions are secured to rebar in the inner concrete panel and the second
portions are secured to rebar in the outer concrete panel.
In some embodiments, the intermediate drainage panel has an
absence of internal channels.
In accordance with another aspect of this invention, there is also
provided a method of preparing a prefabricated panel comprising:
(a) providing a first concrete panel having first portions of shear
connectors provided therein, the shear connectors having
intermediate portions extending outwardly from the concrete panel;
(b) providing a vapour barrier in overlying relation to the first
concrete panel, the intermediate portions extending through the
vapour barrier;
(c) providing an insulation panel in overlying relation to the vapour
barrier, the intermediate portions extending through the insulation
panel;
(d) providing a drainage panel in overlying relation to the insulation
panel, the intermediate portions extending through extending
through the drainage panel; and,
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(e) providing a second concrete panel in overlying relation to the
drainage panel, the intermediate portions extending to the outer
panel, wherein second portions of shear connectors are provided in
the second concrete panel.
wherein steps (a) - (e) and conducted sequentially in the order of step (a) to
step (e) or step (e) to step (a).
In some embodiments, step (a) further comprises providing rebar in
the first concrete panel and step (e) further comprises providing rebar in the
second concrete panel.
In some embodiments, step (a) further comprises securing the first
portions to the rebar in the first concrete panel and step (e) further
comprises
securing the second portions to the rebar in the rebar in the second concrete
panel.
In some embodiments, the method further comprises shipping the
prefabricated panel to a construction site.
It has surprisingly been determined that a pre-fabricated panel
utilizing sheer connectors to secure together the elements of a panel wherein
the
panel has internal voids permits a wall panel to be pre-fabricated at one
location
and then transported and installed without damaging the vapour barrier or the
rain channel system incorporated into the pre-fabricated panel.
DRAWINGS
These and other advantages of the instant invention will be more
fully and completely understood in conjunction with the following description
of a
preferred embodiment of the invention in which:
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Figure 1 is a perspective view of a modular pre-fabricated panel in
accordance with an embodiment of this invention;
Figure 2 is a partially broken away perspective view of the modular
panel of Figure 1;
Figure 3 is a perspective view of the inner surface of the
intermediate drainage panel shown in Figure 2;
Figure 4 is a perspective view of a form that may be utilized to
prepare one or more modular panels of Figure 1 wherein rebar and shear
connectors have been placed in the bottom of the form;
Figure 5 is a cross-section along the line 5 - 5 shown in Figure 4;
Figure 6 is a cross-section along the line 5 - 5 shown in Figure 4
wherein concrete has been placed in the bottom of the form;
Figure 7 is a cross-sectional along the line 5 - 5 in Figure 4 wherein
a plurality of intermediate drainage panels have been positioned on top of the
concrete with the drainage channels on the upper surface;
Figure 8 is a cross-section along the line 5 - 5 in Figure 4 wherein
a plurality of insulation layers have been positioned in the form on top of
the
intermediate drainage panel;
Figure 9 is a cross-section along the line 5 - 5 in Figure 4 wherein
a vapour barrier has been placed on top of the insulation panel; and,
Figure 10 is cross-section along the line 5 - 5 in Figure 4 wherein
concrete has been poured on top of the vapour barrier.
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DESCRIPTION OF VARIOUS EMBODIMENTS
As exemplified in Figure 1, in accordance with a preferred
embodiment of this invention, pre-cast rain screen wall panel 10 comprises a
first
or outer concrete panel 12 and a second or inner concrete panel 18 wherein a
vapour barrier 24, an intermediate insulation panel 30 and an intermediate
drainage panel 36 are provided between the inner and outer concrete panels 12,
18. A plurality of shear connectors 44 extend between the inner and outer
concrete panels 12, 18 and secure the pre-cast rain screen wall panel together
as an integral unit.
Outer concrete panel 12 has an outer surface 14 and an inner
surface 16 (see Figures 2 and 6). Outer surface 14 comprises the outer surface
of the rain screen wall panel 10 and accordingly faces outwardly from the
building. Accordingly, a facing or other construct, if desired, may be
provided on
outer surface 14, or spaced from and facing outer surface 14. It will be
appreciated that, in an alternate embodiment, the facing may be integrally
formed
with panel 10.
Outer concrete panel 12 preferably has a thickness in the direction
extending between outer and inner surfaces 14, 16 of between 2 - 6 inches and
preferably 3-4 inches and more preferably about 3 inches. Outer concrete panel
12 may be constructed from any concrete typically used in building
construction.
It will be appreciated that outer concrete panel may be of any dimensions and
may be customized for any building. For example, outer concrete panel 12 may
have a length of 20 feet or more and a width of 20 feet or more. Alternately,
outer
concrete panel 12 may have a length of eight feet and a width of four feet. It
will
be appreciated that, if larger dimensions are utilized, that the thickness of
outer
concrete panel 12 is preferably increased.
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Positioned inwardly from outer concrete panel 12 is intermediate
drainage panel 36. Intermediate drainage panel 36 has outer surface 38 and
inner surface 40 (see Figures 2 and 7). Outer surface 38 is preferably
positioned
immediately adjacent and touching inner surface 16 of outer concrete panel 12.
Inner surface 40 of drainage panel 36 is provided with at least one and
preferably
a plurality of drainage channels 42 (see Figures 2 and 3). The drainage
channels
42 are configured such that water positioned between intermediate drainage
panel 36 and intermediate insulation panel 30 may drain to the bottom of panel
10. Accordingly, drainage channels 42 preferably run from the top of panel 10
to
the bottom of panel 10, preferably in a straight line. Accordingly, as
exemplified in
Figures 2 and 3, drainage channels preferably extend vertically when panel 10
is
installed in a building.
Intermediate drainage panel 36 preferably has the same
dimensions as outer panel 12. However, intermediate drainage panel 36 may be
smaller than outer panel 12 and a plurality may be utilized in the
construction of a
single panel 10.
Intermediate drainage panel 36 may be constructed from a variety
of materials and, preferably, is constructed from an insulating material.
Preferably, intermediate insulation panel 36 is a rigid member. Accordingly,
panel
36 may be constructed from an insulating foam such as rigid, extruded
polystyrene. However, other insulating materials may be used or other rigid
materials capable of having drainage channels therein may be used.
Intermediate drainage panel 36 may provide insulation value and may contribute
to the overall R-value of the panel 10. Accordingly, the material that is used
and/or the thickness of intermediate drainage panel 36 may be selected to
achieve a particular R-value for intermediate drainage panel 36. For example,
intermediate drainage panel 36 may be from 1 to 4 inches thick and preferably
is
about 1-1.5 inches thick and more preferably is about 1 inch thick.
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Drainage channels 42 may be integrally constructed with panel 36
(e.g., molded into a surface of panel 36). Alternately, drainage channels may
be
cut into panel 36 after it is formed. In a further alternate embodiment,
drainage
channels 42 may be an additional layer that is secured to panel 36 after it is
formed. In a particular preferred embodiment, drainage panel 36 may be a
KoraxTM panel.
As exemplified in Figure 3, drainage channels 42 are spaced apart
and recessed inwardly with respect to projecting columns 54. Accordingly, each
drainage channel 42 may comprise a generally U-shaped channel, which is
recessed inwardly from the outer surface 56 of projecting columns 54. Outer
surface 56 of projecting columns 54 may be a continuous outer surface.
Alternately, a plurality of grooves 58 extending transverse to projecting
column
54 may be provided. Accordingly, grooves 58 may provide air or water flow
channels from one drainage channel 42 to the next spaced apart drainage
channe142.
Positioned inwardly from intermediate insulation panel 36 is
intermediate drainage panel 30. Intermediate insulation panel 30 has an outer
surface 32 and an inner surface 34 (see Figures 2 and 8). Outer surface 32 is
positioned facing inner surface 40 of intermediate drainage panel 36 and,
preferably, is positioned adjacent inner surface 40. For example, outer
surface 32
may abut outer surface 56 of projecting columns 54.
Similar to intermediate drainage panel 36, intermediate insulation
panel 30 may be the same dimension as outer panel 12. Alternately,
intermediate
insulation panel 30 may be smaller and a plurality may be used to construct a
single panel 10.
Intermediate insulation panel 30 may be constructed from any
insulating material. Preferably, intermediate insulation panel 30 is a rigid
member. Accordingly, panel 30 may be constructed from an insulating foam such
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as rigid, extruded polystyrene. However, other insulating materials may be
used.
The material that is used and/or the thickness of intermediate insulation
panel 30
may be selected to achieve a particular R-value for intermediate insulation
panel
30. For example, intermediate insulation panel 30 may be from 1 to 5 inches
thick and is preferably about 2 inches thick.
It will be appreciated that, combined, intermediate drainage panel
36 and intermediate insulation panel 30 may provide the requisite insulation
for
panel 10. Accordingly, the thickness and/or the material used to construct
either
may be varied provided that the requisite overall R-value for panel 10, if
needed,
is obtained. Additional intermediate layers may be provided and their sequence
varied. Further, if intermediate drainage panel 36 provides sufficient
insulation
value, then intermediate panel 30 need not provide any insulation value and
may
be made of any material. In such a case, intermediate panel 30 provides a
surface to ensure that the drainage channels remain open once the panel 10 is
constructed.
Vapour barrier 24 is positioned inward of intermediate insulation
panel 30 (see Figures 2 and 9). Vapour barrier 24 has an outer surface 26 and
an inner surface 28. Vapour barrier 26 may be made from any moisture control
membrane known or used in the building arts. It may be a thermally fused
membrane, a peel and stick air vapour barrier or any other approved air vapour
barrier. Preferably, vapour barrier 24 is the same size as panel 12. However,
it
will be appreciate that a plurality of pieces of vapour barrier 24 may be
utilized
and connected together so as to form a vapour barrier that has an extent so as
to
cover all of outer surface 20 of inner concrete panel 18. It will further be
appreciated that a plurality of layers of vapour barrier 24 may be provided.
Outer
surface 26 of vapour barrier 24 preferably abuts inner surface 34 of
intermediate
insulation panel 30.
Inner concrete panel 18 is positioned inward of vapour barrier 24
(see Figures 2 and 10). Inner concrete panel 18 has an outer surface 20 and an
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inner surface 22. Outer surface 20 preferably abuts inner surface 28 of vapour
barrier 24. Inner surface 22 may be the inner surface of panel 10 to which a
decorative interior coating may be applied. Alternately, inner surface 22 may
be
painted or otherwise treated as is known in the art.
Inner panel 18 may be made from the same type of concrete as
outer concrete panel 12. Alternately, a different type of concrete may be
utilized.
Inner concrete panel 18 may have the same thickness as outer concrete panel
12 or, alternately, it may have a different thickness. Preferably, in and
outer
concrete panels 12 and 18 have the same thickness.
Panel 10 is secured together by a plurality of shear connectors 44.
Shear connectors may be of any configuration that extends between concrete
panels 12, 18 and secure them together. As exemplified in Figure 10, shear
connector is provided with a first portion 46 in outer concrete panel 12, a
second
portion 50 in inner concrete panel 18 and an intermediate portion 48 extending
between the first and second portions. In the exemplified embodiment, shear
connector 44 is Z shaped. Accordingly, first and second portions 46, 50 extend
at
an angle, preferably a right angle, to intermediate portion 48. In this
configuration, shear connectors 44 are secured in the concrete of panels 12,
18
so as to resist being pulled outwardly therefrom. It will be appreciated that
alternate configurations of shear connectors 44 may be used. For example,
shear connectors 44 may have first and second portions 46, 50 that extend
parallel or generally parallel to intermediate portion 48 but which have at
least
one and preferably a plurality of openings therethrough. Accordingly, the
concrete of panels 12, 18, when poured, may flow through the openings and
thereby secure shear connectors 44 in panels 12, 18. Other designs may also be
used.
Shear connectors 44 may also be in any particular orientation. As
exemplified in Figures 2 and 5, shear connectors 44 have a first portion 46
and a
second portion 50 that are embedded in the concrete layers 12, 18. As
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exemplified, these portions preferably extend in the same direction and
preferably in a direction perpendicular to the longitudinal axis of the panel
10.
Referring to Figure 4, first portion 46 and second portion 50 extend away from
intermediate portion 48 in a direction perpendicular to sides 62 of the form
60.
Shear connectors 44 may also be positioned at various locations in
panel 10. As exemplified in Figures 2 and 5, shear connectors 44 are
preferably
evenly spaced apart in rows in panel 10. Referring to Figure 4, rebar 52a has
three shear connectors 44 positioned in a row, namely 44a', 44a" and 44a"'.
Similarly, rebar 52b has three shear connectors 44 positioned in a row, namely
44b', 44b" and 44b"'. The middle shear connector 44a" on rebar 52a is
preferably
positioned at the centre of panel 10. To either side of middle shear connector
44a" are outer shear connectors 44a' and 44a"' that are positioned between the
middle shear connector 44a" and the sides of panel 10 (i.e., the sides of the
panel at sides 62 of form 60). As there are 3 shear connectors 44 dividing
rebar
52a into four sections, each of these outer shear connectors is preferably
positioned inwards about '/4 of the distance of the width of the panel 10
(i.e. '/4 of
the length of side 64 of form 60). Accordingly, the distance between the side
of
panel 10 adjacent side 62 of form 60 and the proximate outer shear connector
44a' is preferably the same as the distance between that outer shear connector
44a' and the middle shear connector 44a". Similarly, the distance between the
middle shear connector 44a" and the other outer shear connector 44a"' is
preferably the same as the distance between that outer shear connector 44a"'
and other side of the panel 62. Alternately, or in addition, shear connectors
44
are preferably evenly spaced apart in columns in panel 10. Accordingly, for
example, each row of shear connectors 44 may be spaced from an adjacent row
of shear connectors 44 by a uniform amount. Referring to Figure 4, one column
of shear connectors includes shear connectors 44a', 44b' and 44c'. That row,
as
exemplified, comprises 7 shear connectors dividing the rebar into eight
sections,
each of which is preferably spaced apart the same distance W. Thus, the row of
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shear connectors 44a may be spaced apart from the row of shear connectors
44b by a distance W that is the same as the distance between the row of shear
connectors 44b and the row of shear connectors 44c. Further, the row of shear
connectors 44c may be spaced from wall 64 of form 60 be the same distance W.
Accordingly, each shear connector will have about the same load placed
thereon.
Reference will now be made to Figures 4 - 10 which exemplify a
method of construction, which may be utilized to prepare panel 10.
Referring to Figure 4, a form 60 is provided. Form 60 is preferably
sized so as to permit the production of a single panel 10. However, it will be
appreciated that form 60 may be sized to permit the production of a plurality
of
panels 10 at the same time. The form may be of any construction known in the
art, which is suitable to have concrete poured therein and removed therefrom
when secured. Preferably form 60 is made from wood. For example, referring to
Figure 4, form 60 may comprise first and second opposed wood panels 62, which
have a length corresponding to the desired vertical height of panel 10 as
shown
in Figure 1 and first and second opposed second panels 64, which correspond to
the width of panel 10 as shown in Figure 1. The sides 62, 64 may be nailed
together or otherwise secured together as is known in the art.
Preferably, shear connectors 44 are secured in position prior to
concrete being poured into form 60. Accordingly, for example, rebar 52 may be
provided in the bottom of form 60. Rebar 52 may extend to sides 62, 64 such
that
rebar 52 is visible when panel 10 is removed from form 60 (see Figure 1 for
example). Alternately, rebar 52 may terminate inwards of sides 62, 64 such
that
the outer edges of outer panel 12 are continuous and rebar 52 is not visible
when
panel 10 is removed from form 60. Preferably rebar 52 is positioned above
bottom 66 of form 60 (see for example Figure 5). Accordingly, when concrete is
poured into form 60 to produce outer concrete panel 12, concrete will be
located
above and below rebar 52 as shown in Figure 6. Accordingly, outer surface 14
of
outer panel 12 will be continuous (i.e. rebar 52 is not visible). Rebar 52 is
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positioned such that first portion 46 of sheet connector 44 is located in the
concrete. Sheer connectors 44 may be secured to rebar 52 by any means known
in the art. For example, shear connectors 44 may be secured to rebar 52 by
welding, mechanical fasteners such as tie or other means 68 known in the
building arts.
Once rebar 52 and shear connectors 44 are positioned in the
bottom of form 60, concrete may then be poured into form 60 so as to produce
outer layer 12. The concrete may be tamped or otherwise compacted to reduce
and preferably prevent the formation of voids or pockets in the concrete and
to
ensure that the concrete completely fills the bottom of form 60.
It will be appreciated that, in an alternate embodiment, rebar 52
may not be utilized. For example, the concrete may first be poured into form
60
and the shear connectors 44, and preferably the shear connectors tied to rebar
52, then positioned in the concrete. Alternately, shear connectors 44 could
otherwise be secured in position in form 60, such as being secured to form 60
itself. It will be appreciated that shear connectors 44 and rebar 52 may each
be
utilized but that shear connectors 44 need not be secured to rebar 52.
Subsequently, preferably after the concrete of outer panel 12 has at
least partially cured (e.g. has a rigid outer surface), intermediate drainage
panel
36 may then be positioned on top of inner surface 16 of outer panel 12 (see
for
example Figure 7).
In accordance with a preferred embodiment of this invention, the
shear connectors 44 are preferably arranged so as to allow panels 30 and 36 to
be inserted between a series of spaced apart shear connectors 44 and a section
of a wall form or between two series of spaced apart shear connectors..
Accordingly, for example, panels 36 and 30 may have a width that is equivalent
to the distance between spaced apart shear connectors 44a' and 44a". Thus, one
panel may be positioned between the columns of shear connectors defined by
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shear connectors 44a' and 44a" and a second panel may be positioned between
the columns of shear connectors defined by shear connectors 44a" and 44a"'.
Accordingly, the intermediate portion 48 of shear connectors 44 may be
positioned at the adjoining facing edges of adjacent panels 30 and at the
adjoining facing edges of adjacent panels 36.
In accordance with such a preferred embodiment, intermediate
drainage panel 36 is sized so as to have width corresponding to the distance
between adjacent columns of re-bar. Accordingly, in the embodiment of Figure
4,
four intermediate drainage panels 36 may be positioned side by side along the
width 64 of form 60. For example, a first intermediate drainage panel 36 maybe
positioned between rebar 52c to which shear connector 44a' is attached and
rebar 52d to which shear connector 44a" is attached. Accordingly, a first end
of
intermediate drainage panel 36 that is parallel to side 62 of form 60 may be
slid
under second portion 50 of the shear connectors 44 attached to rebar 52d and
then lowered to be adjacent inner surface 16 of panel 12. The opposed side of
intermediate drainage panel 36 adjacent rebar 52b may then be lowered by
rotating it downwardly so as to seat flush on inner surface 16 of panel 12.
Similarly, the first end of another intermediate drainage panel 36 may then be
slid
under second portion 50 of the shear connectors 44 attached to rebar 52c and
then lowered to be adjacent inner surface 16 of panel 12. The opposed side of
intermediate drainage panel 36 adjacent side 62 may then be lowered by
rotating
it downwardly so as to seat flush on inner surface 16 of panel 12. . The
remaining
sections of form 60 may then be similarly provided with sections of
intermediate
drainage panel 36. In this way, shear connectors 44 need not extend through
each intermediate drainage panel 36. Instead, sections of intermediate
drainage
panel 36 may be installed on outer surface 16 of panel 12 such that the joint
between adjacent intermediate drainage panels 36 is positioned such that
intermediate portion 48 of shear connectors 44 extends therethrough. The joint
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between adjacent panels 36 may then be sealed, such as by tape, an adhesive,
caulking or the like.
It will be appreciated that, in an alternate embodiment, panel 36
may have an extent (e.g., a length extending in the direction of side 62) such
that
a hole or holes must be provided therein for sliding downwardly over shear
connectors 44. For example, if an intermediate drainage panel 36 is of the
same
size as form 60, openings could be provided in intermediate drainage panel 36
for allowing the panel to be placed vertically downwardly on top of panel 12
with
shear connectors 44 passing therethrough. Subsequently, the openings, which
are provided for shear connectors 44, may be sealed, such as by an insulating
filler material such as foam.
In accordance with an embodiment of this invention, it will be
appreciated that the drainage channels are provided on the upper surface of
drainage panel 36 when panel 36 is positioned in form 60.
Subsequently, as exemplified in Figure 8, one or more insulation
panels 30 may be positioned on top of drainage panels 36. Insulation panel 30
may be positioned in form 60 in any manner discussed with respect to
intermediate drainage panel 36.
Subsequently, as exemplified in Figure 9, vapour barrier 24 may be
provided on top of insulation panel 30. Vapour barrier 24 may have an extent
similar to the extent of form 60. Accordingly, a plurality of openings may be
provided in vapour barrier 24 to allow vapour barrier 24 to be installed on
top of
insulation panel 30. The openings in the vapour barrier through which shear
connectors 24 pass may then be sealed by any means known in the building arts
to join together the edges of vapour barrier membranes, such as tape,
caulking,
placing portions of the barrier material over the joints and securing them in
position by tape or an adhesive, or the like. Alternately, a plurality of
strips of
vapour barrier may be provided on top of panel 30 and then sealed together,
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such as by tape. Such strips may have a width equal to the spacing between
adjacent rebar pairs (e.g., rebar pair 52a and 52b and rebar pair 52b and 52c)
so
that the strips are positioned such that intermediate portions 48 of shear
connectors 44 are positioned between abutting edges of such strips.
As exemplified in Figure 10, concrete may then be poured on top of
vapour barrier 24 to complete the formation of the panel 10. The concrete may
be poured so as to completely fill form 60 or to provide a desired thickness
of
concrete for concrete panel 10. Preferably, the concrete has a thickness such
that second portion 50 of shear connector 44 is positioned internally in
concrete
panel 18.
In a preferred embodiment, rebar is also provided in concrete panel
18. Preferably, the rebar associated with shear connectors 44 so as to secure
shear connectors 44 in position while concrete is poured into form 60 to form
concrete layer 18. For example, after vapour barrier 24 has been positioned in
form 60, rebar may be secured to, e.g., second portions 50 of shear connectors
44. Any attachment means known in the art may be used. Accordingly, second
portions 50 of shear connectors 44 are secured in position and will remain in
position as the concrete is poured into position and, preferably, tamped or
otherwise compacted to reduce and preferably prevent the formation of voids in
concrete panel 18.
Once the concrete of concrete panel 18 has cured to a sufficient
degree, form 60 may be removed and the resultant panel 10 may then be stored
for later use, shipped for use at a building site or used at the building site
at
which panel 10 is fabricated.
It will be appreciated that panel 10 may be constructed by pouring
the inner concrete panel 18 in the bottom of the form 60. The subsequent
construction steps would be in the reverse order of those set out in the
description of Figures 5-10.
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Although the invention has been described in conjunction with
specific embodiment thereof, it is evident that many alternatives,
modifications
and variations will be apparent to those skilled in the art. Accordingly, it
is
intended to embrace all such alternatives, modifications and variations that
fall
within the spirit of the following claims.
The citation or identification of any reference in this application shall
not be construed as an admission that such reference is available as prior art
to
the present invention.
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