Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
2(~1~600
WALL UNITS FOR CONSTRUCTING BUILDINGS
Background of the Invention
Field of the Invention
This invention relates generally to methods and
apparatus for constructing buildings, and more
particularly to wall units for assembly into building
constructions.
Description of the Prior Art
The erection of buildings is a time consuming and
expensive process. Attempts to simplify the process
have often resulted in a reduction in the quality of
the finished product. A properly constructed building ~-
should be strong, durable, and have good insulating ;~
characteristics. Attempts to speed the process, or to
reduce its cost, usually result in a reduction in the
quality of at least one of these characteristics.
Pre-formed wall units have been constructed but ~q~
typically are heavy and difficult to transport, and ;;
also are difficult to position and to secure. ; -~
Buildings constructed according to these systems are
often limited in style and design. `~
It would be desirable to provide a building -
construction system by which buildings could be quickly -
assembled by a relatively few workers. Buildings
constructed with the system should preferably be
relatively inexpensive. It would further be desirable,
however, that gains in speed and cost of construction
be made not at the sacrifice of strength, durability,
insulating characteristics, or design flexibility. -- -
"" ~,
....
, .. '. .
":, . .", . ." ........
20126~)0
--2--
Summary of the Invention
It is an object of the invention to provide a
building construction system by which buildings can be
constructed in shorter periods of time, or with
comparatively fewer man-hours of labor, than is
possible with conventional building construction
techniques.
It is another object of the invention to provide a
building construction system which has good insulating
properties.
It is still another object of the invention to
provide a building construction system with good
strength and durability characteristics.
It is yet another object of the invention to
provide a building construction system which can be
utilized to produce buildings of several different
styles and designs.
These and other objects are accomplished by a
building construction system comprising a plurality of ;
wall units. The wall units are prepared by placing ~ ,
pieces of insulation, preferably polystyrene blocks, ~ ;~
into a mold. Furring members can be placed between the -
insulation blocks, as well as reinforcement members.
The reinforcement members can be attached directly to
the furring members to secure their position within the
mold. A cementitious material is then poured into the
mold to form an individual wall unit.
The insulation and furring members can be
positioned in a mold having at least one facing surface
and a plurality of perimeter side edges, and preferably
rest on the facing surface of the mold. The -`
cementitious material is poured into the mold and -
hardens. The furring members and insulation are
provided substantially at the face of the completed
wall unit which becomes the interior surface of the
wall.
Wall units prepared according to the invention
have good construction properties. The insulation ~ -
~ :,
~ =', ~c.i~ "
2012600
-3-
provides light weight with good insulating
characteristics, while the cementitious matrix and ~ ~
reinforcement members provide good strength and ; ~-
durability characteristics. The furring members, being
provided at the interior face of the wall unit, speed -
the attachment of wall panels and other items to the
wall units at the construction site. ;
A layer of the cementitious material covers the
insulation and furring members to provide an exterior
wall surface. A stamp or other suitable molding device -
can be applied to the exterior surface while the
cementitious material is still wet to provide a wall
unit with a particular exterior appearance, for
example, simulating brick. The exterior finish can be
altered simply by changing the die used to stamp the i~
exterior surface. ~- `
Fastening structure for securing the wall units to
one another and to the foundation of the building can
also be provided. The fastening structure for
interconnection of the wall units can be metal plates
which are cast into perimeter side portions of the wall
units, and which align when the wall units are
positioned at the building site. The metal plates are
secured together by suitable means, such as welds.
Alternatively, strapping plates can be attached across
adjacent wall units to secure the wall units together.
Suitable fastening structure for the strapping plates
can be anchored into the wall units during
construction. The fastening structure can also be `~
utilized for the temporary attachment of lifting cables ~`
or the like for placement at the construction site. ~.~
- :~.. . - ...
The wall units are secured to a foundation - i ;
preferably by structure adapted to receive one or more
projections extending upwardly from the foundation or
other surface. Clamping structure on the projections i
is adapted to press against portions of the wall units
to secure the wall units to the projections and to the
foundation. The projections are preferably bolts, and
',~ ,~`''`' ' :'.'.:
: 2012~n~
-4-
the clamping structure is preferably a plate slidably
mounted over the bolt. A threaded nut cooperates with
threaded structure on the bolt to force the plate
against a portion of the wall unit to secure the wall
unit in place.
A furring member according to the invention has
structure for engaging one or more reinforcement
members so as to space the reinforcement members from
the face of the mold as the cementitious material is
poured. The reinforcement members will thereby be
thoroughly embedded within the cementitious material to
provide a durable wall construction. Additional
reinforcement structure, such as wire mesh, can be laid
into the mold prior to pouring and will rest on the -~
blocks of insulation.
Door frame members and window frame members can be -
positioned in the mold prior to pouring so as to
integrate window frames and door frames into the
individual wall units. The door frame members and
window frame members also serve as portions of the mold
during pouring of the cementitious material to provide
door openings and window openings in the completed wall
units. Anchor structure adapted to extend into the
cementitious material, when poured, i~ preferably
provided on the door frame members and window frame
members so that these members will become firmly
secured to the cementitious material when it hardens.
The invention can be used to make a plurality of
wall units in different shapes and sizes by changing -~
the dimensions and design of the mold. The wall units
are relatively light weight and can be fashioned in a
location remote from the building site, and thereafter
transported to the site when needed. The wall units ~-
are set in place, connected to the foundation, and
interconnected with one another to quickly create a
strong and durable building construction having good
strength and insulating characteristics.
20~260~
-5- ~-
Brief Description of the Drawings
There are shown in the drawings embodiments which -~
are presently preferred it being understood, however, -~
that the invention is not limited to the precise
arrangements and instrumentalities shown, wherein:
Fig. 1 is a perspective view, partially broken
away, of a wall unit according to the invention at a
first stage of construction. ~ ~
Fig. 2 is a plan view, partially broken away. ~-
Fig. 3 is a cross-section taken along line 3-3 in
Fig. 1.
Fig. 4 is a perspective view of a wall unit ~;-
according to the invention at a second stage of
construction.
Fig. 5 is a cross-section taken along line 5-5 in
Fig. 4.
..
Fig. 6 is a perspective view of a completed wall ~ i
unit according to the invention, broken away to show -
internal features. ;~
Fig. 7 is a perspective view of a furring member
according to the invention, broken away to indicate
indefinite length.
Fig. 8 is a front elevation of a completed wall
unit, partially broken away.
Fig. 9 is a cross-section taken along line 9-9 in
Fig. 8.
Fig. 10 is a front elevation of an interconnected
"~ ~, . -~. .
wall system.
~,, ,'~ ,.', '
.",.;,,;.
, . ~ 'd '
;''.~;`',..''` ~',' '
~'"'. '. , `''' '.''.''
. '::: ' , ' -, , ~
"'' '"' ' '':''~
', :. ' :`
~''`.,'': ' '.' '"'''',',"''''' ',,'''"'.'
` ~:
~o~z~oo
--6--
Detailed Description of the Preferred Embodiments
The wall units of the invention are preferably
constructed in molds as shown in Figs. 1-5. The mold
20 has at least one large area facing surface 22 with
upstanding side edges 24-27 which are joined to one
another at ends thereof and to the perimeter of the
facing surface 22 to form the mold 20. The mold 20 can
be made from several suitable materials, including
wood.
Pieces of insulation such as the blocks 30-33 are ;
placed into the mold 10 during an initial stage of ;~
construction. Polystyrene is a preferred insulating
material because of its good insulation properties, ~ i
light weight and durability. Other insulating
materials could alternatively be utilized. The
insulation can be cut to fit the mold 20 as well as to -
accomodate other items within the mold such as the
window frame 38. The blocks 32-33 are accordingly of a
reduced length relative to the blocks 30-31 to allow
for the provision of the window frame 38.
The blocks 30-33 rest on the facing surface 22 of ~ - -
the mold 20. A plurality of furring members 42 are
positioned on the facing surface 22 between the
insulating blocks 30-33 and about the perimeter. The - -~
furring members 42 include a strip of furring material
43 fashioned from wood or any other suitable material.
The furring members 42 preferably include anchor
structure adapted to extend into the mold 20 so as to
become embedded in the cementitious material when it
hardens. The furring members 42 will thereby be ;
securely fixed at the interior face of the completed
wall unit, and can be used for the attachment of wall
panels or other fixtures ~;
Reinforcement members are preferably positioned in
the mold so as to become embedded within the completed
wall unit. The reinforcement members 46 should be
supported in the mold a distance from the facing - -
surface 22 so that the reinforcement members 46 will
Z0~2600 ~ ~:
-7-
become embedded within the cementitious material. The
reinforcement members are preferably elongated bars of
a rigid material such as iron or steel. Other
reinforcement materials are possible.
The reinforcement members 46 can be supported by ~
engagement structure extending outward from the furring ~;
strips 43. This engagement structure can also serve to
anchor the furring members 42 in the cementitious
material. The engagement structure can be a plurality
of posts 48 which extend substantially perpendicularly
to the furring strip 43 and can be provided in two or
more locations along the length of the strip 43 (Fig.
7). Each post 48 has structure for engaging and
supporting the reinforcement members, such as the
support arms 50. The support arms 50 engage the
reinforcement members 46 to support the reinforcement ~-
members 46 a distance from the furring strips 43. The - -
reinforcement members 46 become thoroughly embedded in
the cementitious material when it is poured. One or
more support arms 50 can be provided on each post 48 so
that more than one reinforcement member can be
supported at different heights above each furring strip
43, as depicted in Fig. 7.
~he furring members 42 are preferably distributed ,-;~
in many locations about the facing surface 22 of the '
mold 20. It is preferable that the furring members 42
be present in several locations around the interior ;
face of a completed wall unit so that there will be
sufficient points of attachment for wall panels, ;;`
plaster board and the like, or other interior fixtures.
The furring members 42 are preferably provided between
the blocks 30-33 and about the perimeter of the mold
20. Additional furring members 42 can be provided
about the interior moldings such as the window frame
38. ~:~
Additional reinforcement can be provided in the
form of heavy gauge wire ribbing 54, which can be
positioned in the mold 20 atop the elongated
.. : :,
.
20~Z60Q
--8--
reinforcement bars 46. A mesh or sheet 58 of wire or ~ --
another high tensile strength material can be laid atop ~ -
the reinforcement bars 46 and insulating blocks 30-33
to provide still further strength and durability in the
completed wall unit.
Structure for fastening the wall units to a
foundation and structure for fastening the wall units
to one another is also positioned in the mold 20. The
structure for attaching the wall units to a foundation
can be provided by suitable channel forming means such
as extensions 60 of the blocks 30-33 are used to form a
groove in the cementitious material when it hardens.
The extensions 60 can be positioned adjacent the facing
surface 22 and bottom side edge 24 of the mold 20 in
one or more locations as shown in Fig. 3. The
frangible insulation material forming the extensions 60
is removable by a knife or other suitable means to form
a projection receiving channel 61 (Fig. 8) which can be
used to secure the wall unit to the foundation. -
The structure for attaching the wall units to one
another can be provided as plates 64 which are
positioned adjacent to the facing surface 22 of the ~;
mold and the perimeter side edges 24-27, and preferably
in the corners of the perimeter side edges 24-27 as -
shown in Fig. 2. Each of the metal plates 64 has an
anchor post 65 extending upwardly therefrom which
becomes embedded in the cementitious material so as to -;,
anchor the attachment plates 64 in the completed wall
units. The anchor plates 64 of adjacent wall units can ;
be aligned and secured together by suitable means such
as welds to attach the adjacent wall units to one
another. ~-~
The wall units of the invention are relatively
light in weight, however, it is preferable to provide ~
structure within the wall units themselves to permit ,
the attachment of lifting cables or machines. A
preferable attachment structure is the threaded channel
member 66. The channel member 66 has an anchor portion
Z~12600
g
68 which ls adapted to engage the cementitious material
when it hardens. A threaded engagement portion 70 is
adapted to receive a bolt 74 or the like. The channel
member 66 can be conveniently positioned in the mold 20
by the provision of suitable holes 76 throuyh one of
the side edge 24-27 of the mold 20. The bolt 74 can be
passed through the hole 76 in the side 26 of the mold
20 and engaged to the channel member 66 positioned on
the interior side of the mold 20, as shown in Fig. 2.
The bolt 74 is tightened to secure the channel member
66 in place. The channel member 66 will become firmly
embedded within the cementitious material when it is
poured into the mold 20, and after the cementitious
material has hardened the channel bolt 74 can be ,, i
removed from the channel member 66 and the mold 20 to
permit removal of the wall unit from the mold.
Door frame members and window frame members such ---~
as the window frame 38 can be positioned in the mold 20 ~
so that door frames and window frames will be , ,- -
incorporated into the completed wall units. The window ~
frame 38 is comprised of individual window frame ~ :
members 79-82. The window frame members 79-82
preferably have anchor means which can be posts or -
screws 83 extending outwardly into the mold 20 where
they become embedded in the cementitious material to
anchor the frame members 79-82 into the wall unit. i~
The window frame members 79-82 and any door frame
members also serve as mold members when the
cementitious material is poured, to form window
openings and door openings in the wall units.
The cementitious material can be selected from a
variety of flowable construction materials which will
harden to a structural strength. The cementitious
material is mixed and poured into the mold 20 by means ;~
known in the art and flows over and around the ~ ;~
insulation blocks 30-33 and furring members 42. The -,~ ~-
posts 48 of the furring members 42, the reinforcement
members 46, wire mesh 58, attachment plates 64 and ~ ~
'.~, .
20~2600
--1 o--
their posts 65, channel members 66, and reinforcement
grid 54 become thoroughly embedded in the cementitious
material. The cementitious material is poured around,
but not within the window frame members 79-82 so that
the completed wall unit will have a suitable window
opening. The cementitious material is poured into the
mold until a layer 90 of the cementitious material
covers all of the components within the mold except the
window frame members 79-82 (Figs. 4-5). This layer 90
will form the exterior surface of the wall, while the
furring members 42 will be provided at an opposite side
of the wall unit which will form the interior surface
of the wall. A suitable stamp can be applied to the
exterior surface prior to curing to form a decorative
finish such as the simulated brick facing 91 (Fig. 4).
The cementitious material will harden, and the
above-described components will become securely
embedded within the hardened cementitious material.
The bolts 74 are removed from the channel members 66 to
free the wall unit from the mold 20. The wall unit 94
is then removed by suitable methods, which might
include inversion of the mold 20 or dismantling the
mold 20. The above-described method can be utilized to
form wall units of several designs and sizes. A
complete set of suitable wall units can be pre-formed -~-~
to erect the walls of a building.
Installation of the pre-formed wall units at the
: . , .
building site follows the initial preparation of the '~
site, usually including the construction of the
foundation. The foundation 98 is preferably formed -
with a number of upstanding projections 102 embedded
therein. The projections 102 can be substantially
L-shaped such that the base 103 of the L-shaped -
projection 102 will become firmly embedded within the
foundation 98 when hardened. Other projection designs
are possible. The projections are provided
substantially about the perimeter of the foundation 98
or other floor structure and define the resting
. .
,
~" 201ZfiOO
positions of the walls of the building. The wall units
94 can be formed at the construction site, but
preferably are formed in a central facility and ;
transported to the construction site as complete units.
The completed wall unit 94 can be positioned on
the foundation 98 by suitable methods and with the use ~ -
of suitable equipment. It is preferred, however, to ,,
install eye-bolts 106 in order to provide for the
attachment of lifting cables 108 or other suitable ~ ;
lifting structure. The eye-bolts 106 can be threadably ~;
engaged to the channel members 66 to provide a secure ~
attachment site for hooks 110 associated with the - -
lifting cables 108. Other means could alternatively be ;
provided to lift the wall units 94. ~ -
The wall units 94 are positioned on the foundation ,~
98 (or other suitable support surface) with the -
receiving channels 61 positioned over the projections
102 (Fig. 8). The receiving channels 61 are opened ~,
toward a face of the wall units 94 so that they may be -~
sideways positioned over the upstanding projections
102. The receiving channels 61 can be in the form of ~
hollow shafts, but preferably are formed as upwardly ;s
directed grooves. The ability to laterally align and - -
position the projections 102 in the receiving channels -
61 prevents the difficult and sometimes dangerous task
of having to lower the wall units 94 vertically onto
the projections 102.
The receiving channels 61 can include widened ~;`
portions 111 which allow for the placement of clamping,--
structure such as the clamping plate 113 and the nut
112. The nut 112 is adapted to threadably engage -~
cooperating thread structure on the upstanding
projections 102 and to press the clamping plate 113
against structure in the wall unit 94. Lips 114 formed -
from a portion of the widened opening 111 can engage ~
the clamping plate 113. The wall unit 94 will thereby ~ ~-
be firmly fixed to the foundation 98. Alternative -;
..
',.:' '''
`~
2012600
-12-
clamping structure for engaging the projections 102 is
possible.
The wall units 94 are set in place about the
foundation 98 to construct the walls of the building
(Fig. 10)~ Adjacent wall units are then secured to one
another. The attachment plates 64 of adjacent wall
units 94 abut one another when the wall units 94 are
set in place on the Eoundation 98. The attachment
plates 64 provide a means for attaching the wall units
94 to one another. The attachment plates 64 can, for
example, be made of metal and welded together by
suitable welds 118. It is possible to alternatively
secure adjacent wall units 94 together by the provision ~
of a strapping member 122 (phantom lines in Fig. 10) -
which can span between the adjacent wall units 94 along
a top edge thereof. Bolts 126 can be provided through ;~
suitable apertures in the strapping member 122 and -~
engage the channel members 66 to secure the strapping
member 122 in place and the adjacent wall units 94
together. Caulking or other suitable sealing materials
can be placed along the joint between the adjacent wall ~
units 94 to seal the joint completely. --
The wall units 94 are set in place about the
foundation 98 and attached as described to form the
exterior walls of the building. Corners can be formed -~
by beveling side edges of adjacent wall units forming
the corner to permit the adjacent wall units to mate ~;
evenly with one another. The invention has been
described particularly in the setting of a single story
exterior wall construction. It is apparent, however, ;~
that the principles disclosed herein could be equally
applicable to multi-story constructions and to interior ~;
walls, if desired.
This invention can be embodied in other forms
without departing from the spirit or essential
attributes thereof, and accordingly, reference should
be had to the following claims, rather than to the ~;
' '. "-~,'
-13- Z 0~2 6 00 '~
foregoing specification, indicating the scope of the
invention. ~ ~
, . ., ' ' ,-,.
: '': '' ,.-~"
~, . . ...
, . :,, .
.
.,: ,, . . -:
~ .; ,: . .
'''' ~''"''
',:-, :"'.,
; ~ ; - .
.~ . .: ~ ,- .,
`.'''.''.~ ~' ;"''',
.':~"~,. :.
':'':"''' :''`~
~,"-'-';'' ;'-,
,"` `. .. ',
