U.S. patent application number 09/846526 was filed with the patent office on 2002-04-25 for pre-cast building system.
Invention is credited to Steinacker, Delano SR..
Application Number | 20020046521 09/846526 |
Document ID | / |
Family ID | 26896539 |
Filed Date | 2002-04-25 |
United States Patent
Application |
20020046521 |
Kind Code |
A1 |
Steinacker, Delano SR. |
April 25, 2002 |
Pre-cast building system
Abstract
A pre-cast building system includes a plurality of modular,
pre-cast components. There is an elongate footing component having
an upwardly facing longitudinal channel and a longitudinal first
keyway section formed therein. One end of the footing component
carries a pocket and the opposite end carries an insertion member
for interengaging the pocket of an adjacent, aligned footing
component. An elongate foundation component is received in the
channel. A lower edge of the foundation component includes a
second, complementary keyway section that faces the first keyway
section to form an elongate keyway that receives a bonding
adhesive. An exterior wall component is interengaged with the
opposite upper edge of the foundation wall component. A pair of
opposing receptacles are formed respectively in the upper edge of
the foundation component and the lower edge of the exterior wall
component. These receptacles face one another and receive a
connector component that interlocks the foundation component and
the exterior wall component. The inside surface of the foundation
component carries a longitudinal ledge on which a peripheral
portion of a pre-cast floor slab is supported. The upper edge of
the exterior wall panel includes an inverted receptacle that
accommodates a roof tie down component such that the positioning of
the component may be adjusted.
Inventors: |
Steinacker, Delano SR.;
(Ocala, FL) |
Correspondence
Address: |
William E. Noonan
Post Office Box 07338
Fort Myers
FL
33919
US
|
Family ID: |
26896539 |
Appl. No.: |
09/846526 |
Filed: |
May 1, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60201235 |
May 1, 2000 |
|
|
|
Current U.S.
Class: |
52/274 ; 52/284;
52/293.1; 52/589.1; 52/596 |
Current CPC
Class: |
E04C 2/044 20130101;
E04B 1/04 20130101; E04B 1/383 20130101; E02D 27/02 20130101 |
Class at
Publication: |
52/274 ; 52/284;
52/293.1; 52/589.1; 52/596 |
International
Class: |
E04B 001/00; E02D
027/00; E04C 002/04 |
Claims
1. A precast building system comprising: an elongate footing
component including an upwardly facing longitudinal channel that
has a longitudinal first keyway section formed therein; a
foundation wall component received by said channel and having an
elongate second keyway section facing and generally aligned with
said first keyway section, said generally aligned keyway sections
defining an elongate keyway for receiving an adhesive material to
secure together said footing and foundation wall components; said
foundation wall component further including a first receptacle
formed in an upper edge thereof; and an upper wall component that
interengages said foundation wall component and having a lower edge
that includes a second receptacle opposing said first receptacle,
said first and second receptacles receiving a connector element,
said receptacles and said connector element being configured to
hold together said upper wall component and said foundation wall
component.
2. The system of claim 1 in which said first and second keyway
sections have opposing dovetail shapes.
3. The system of claim 1 in which said first and second receptacles
include opposing "T" shapes.
4. The system of claim 1 in which each of said receptacles extends
longitudinally for substantially the entire length of said
foundation wall component and said upper wall component
respectively.
5. The system of claim 3 in which said connector element includes a
generally "Z" shaped configuration that fits within the opposing
"T" shaped receptacles to hold together said foundation wall
component and said upper wall component.
6. The system of claim 1 further including a second foundation wall
component, one of the longitudinal ends of one of said foundation
wall components including a tongue and one of the ends of the other
foundation wall component including a complementarily shaped groove
for receiving said tongue of the other said foundation wall
component to interlock said foundation wall components in an
adjoining, end-to-end arrangement.
7. The system of claim 1 further including a second upper wall
component, one of said upper wall components including a side edge
that carries a longitudinal tongue, the other said upper wall
component including a side edge that carries an elongate groove for
receiving said tongue to interlock said upper wall components
together in an adjoining arrangement.
8. The system of claim 1 further including a second footing
component, one of said footing components carrying a pocket
proximate one end thereof and the other said footing component
carrying an insertion member that is inserted into said pocket to
interlock said footing component together in an adjoining,
end-to-end arrangement.
9. The system of claim 6 in which adhesive is contained between
said tongue and said groove of said adjoining upper wall
components.
10. The system of claim 7 in which adhesive is contained between
said tongue and said groove of said adjoining foundation wall
component.
11. The system of claim 8 in which an adhesive interconnects said
pocket and said insertion member of said adjoining footer
components.
12. The system of claim 1 further including a corner footing
component that includes a pair of elongate footing sections
unitarily interconnected at an angle less than 180.degree. to one
another, each said footing section including a longitudinal channel
and a longitudinal keyway section within said channel, said system
further including a pair of elongate footing components, each
having a pocket proximate one end thereof and an insertion member
proximate the opposite end thereof, each said footing sections
carrying one of a pocket and an insertion member for respectively
interengaging said insertion member and said pocket of an adjoining
foundation component.
13. The system of claim 1 wherein said foundation wall component
further includes a longitudinal lip for supporting an edge of a
floor slab.
14. The system of claim 13 further including a corner foundation
wall component comprising an elongate member with a longitudinal
receptacle formed therein and a keyway section formed in said
receptacle of said corner foundation wall component, said corner
foundation component further including a lip that extends
longitudinally along said elongate member and terminates at a
distance from one end of said member to form a notch proximate said
end, a transverse tongue being formed on said corner foundation
component within said notch, said foundation wall component
including a complementarily shaped end that has a groove for
receiving said transverse tongue of said corner foundation
component.
15. The system of claim 1 further including a corner upper wall
component that includes a pair of panels permanently interconnected
at an angle less than 180.degree., one of said panels having a
distal side edge that includes an elongate wall groove and the
other said panel including a distal side edge that has an elongate
wall tongue formed therein, each panel further including a
longitudinal receptacle formed in a bottom edge thereof, said
receptacle having elongate keyway formed therein, said receptacles
in said panels intersecting proximate a vertex of said corner of
the wall component, said system further including an upper wall
component, each upper wall component including a longitudinal
tongue formed in one side edge thereof and a longitudinal groove
formed in the other side edge thereof, said tongue carried by one
of said corner panels fitting into said groove of one of said wall
components and said groove carried by the other said panel
receiving said tongue of the other said wall component.
16. The system of claim 1 in which said upper wall component
includes an upper edge that has a longitudinal receptacle for
receiving a roof truss tie down component, said longitudinal
receptacle in said upper edge of said upper wall component and said
tie down component having complementary shapes that restrict
removal of said tie down component from said receptacle.
17. The system of claim 1 in which at least one of said receptacles
includes an insert component that is precast into said associated
one of said foundation wall and said upper wall components.
18. The system of claim 17 in which said receptacle in said upper
edge of said upper wall component includes an insert that is
precast into said upper wall component.
19. The system of claim 18 in which said receptacle in said upper
edge of said upper wall component includes a generally inverted
T-shaped configuration and said truss tie down component is
interlocked with and longitudinally slidable within said upper edge
receptacle.
20. The system of claim 13 in which said lip includes a
longitudinal groove that receives a seal for restricting intrusion
of insects between the floor slab and said foundation wall
component.
21. A pre-cast building system comprising: an elongate footing
component having a longitudinal first keyway section formed
therein; a foundation wall component interengaging said footing
component and having an elongate second keyway section facing and
generally aligned with said first keyway section, said generally
aligned keyway sections defining an elongate keyway for receiving
an adhesive material to secure together said footing and foundation
wall components; said foundation wall component further including a
first receptacle formed in an upper edge thereof; and an upper wall
component that interengages said foundation wall component and
having a lower edge that includes a second receptacle opposing said
first receptacle, said first and second receptacles receiving a
connector element, said receptacles and said connector element
being configured to hold together said upper wall component and
said foundation wall component.
Description
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/201,235 filed May 1, 2000.
FIELD OF THE INVENTION
[0002] This invention relates to a pre-cast building system and,
more particularly, to a system that employs a plurality of modular
pre-cast concrete components that are assembled more quickly and
efficiently, and far less expensively than the components of
conventional building systems.
BACKGROUND OF THE INVENTION
[0003] Construction of a conventional cement block building is
typically a very involved process, featuring various tasks that
must be carefully coordinated. For example, initially a footing
trench is excavated and reinforcing steel is arranged in the
trench. The job is then halted while the work is inspected. After
inspection, concrete footings are poured and cement blocks are
installed to create a foundation wall. The dirt within the
foundation is then graded and compacted. Construction is stopped
again to allow the plumber, air conditioning contractor and
electrical contractor to install appropriate pipes and conduits.
Each of these installations must undergo multiple inspections.
Eventually, a concrete floor is poured and finished. After the
floor is allowed to sufficiently harden, concrete blocks are
assembled to form the exterior walls of the building. A further
inspection of the reinforcing steel used in the blocks is then
required. After the cement blocks are installed, the concrete
finishing work must be performed. Skilled concrete artisans
complete a number of finishing tasks before the roof of the
building is installed. Immediately before the roof is constructed,
the workers insert steel anchors into the concrete at the top of
the wall to fasten the roof framing members to the wall. These
anchors must be installed at precise locations and depths. The
foregoing construction process is complicated even further when a
wood floor system employing a tie beam is involved. Standard poured
or pre-cast concrete buildings employ an analogous procedure.
Instead of using blocks, concrete forms are utilized to build the
foundation and exterior walls.
[0004] The known concrete construction techniques described above
are fairly complex, time consuming and expensive. Multiple crews of
highly paid skilled tradesmen are required to perform the
respective tasks. Work schedules must be precisely coordinated.
Delays in the delivery of materials, adverse weather conditions,
inspection delays and other problems can be extremely costly and
detrimental to the project, particularly when time is of the
essence. One or more errors or miscalculations during construction
can delay the project and drive up costs even further. Human error
frequently accompanies the assembly and installation of the
concrete building components. Mistakes are particularly common
because each of the primary components (e.g. footing, foundation
and exterior wall) is built "in the field", i.e. at the job
site.
[0005] A need currently exists for a simpler, more efficient
concrete building system, which utilizes modular parts and which
can be installed quickly and precisely, with little risk of error,
even when inexpensive, unskilled workers are used to perform the
work.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of this invention to provide a
highly efficient pre-cast building system that permits a concrete
building to be constructed much more quickly and more accurately,
but far less expensively than previously accomplished using
conventional concrete and cement block building systems.
[0007] It is a further object of this invention to provide a
building system employing modular concrete components pre-cast in a
factory rather than in the field so that expense is reduced and
quality control is significantly improved.
[0008] It is a further object of this invention to provide a
building system that may be installed rapidly and relatively
inexpensively, even by a fairly small team of unskilled or
semi-skilled workers.
[0009] It is a further object of this invention to provide a
building system that significantly reduces the need for multiple
inspections at various points of the construction process and which
thereby significantly reduces construction delays and costs.
[0010] It is a further object of this invention to provide a
building system that may be reliably assembled in a virtually
fail-safe manner thereby reducing construction delays and cost
overruns.
[0011] It is a further object of this invention to provide a
building system that permits roof tie downs to be positioned
quickly, conveniently and accurately even by unskilled
laborers.
[0012] It is a further object of this invention to provide a
pre-cast concrete building system employing modular components that
interlock simply and securely and which provide the finished
building with exceptionally strong structural integrity and
durability.
[0013] It is a further object of this invention to provide a
pre-cast concrete building system that exhibits extremely high
quality but at far less cost than that of conventional construction
systems.
[0014] It is a further object of this invention to provide a
pre-cast concrete building system that achieves an aesthetically
attractive building.
[0015] It is a further object of this invention to provide a
building system that is extremely resistant to severe weather, fire
and insect intrusion.
[0016] It is a further object of this invention to provide a
pre-cast concrete building system that is extremely energy
efficient.
[0017] This invention features a pre-cast building system including
a plurality of pre-cast modular components composed of concrete or
other suitable building material. Specifically, this system
includes an elongate footing component that is installed within a
trench in the ground. The footing component includes an upwardly
facing longitudinal channel that receives a lower edge of an
elongate foundation component. A longitudinal first keyway section
is formed in the channel of the footing component. That keyway
section faces and is generally aligned with a complementary second
longitudinal keyway section formed in the lower edge of the
foundation wall component. The aligned keyway sections define an
elongate keyway. An adhesive material is introduced into the keyway
to secure together the footing component and the foundation wall
component. The foundation wall component also includes an interior
lip or ledge that supports a floor slab of the building. An upper
or exterior wall component includes a lower edge that interengages
an upper edge of the foundation wall component. A pair of opposing
receptacles are formed respectively in the upper edge of the
foundation wall component and in the lower edge of the exterior
wall component. The receptacles include complementary
configurations that enable the opposing receptacles to receive a
connector element that secures together the exterior wall component
and the foundation wall component.
[0018] In a preferred embodiment, the abutting keyway sections in
the footing component and the foundation wall component have
opposing dovetail shapes. The opposing receptacles in the
foundation wall component and the exterior wall component may
include complementary "T" shapes and each of the opposing
receptacles may extend longitudinally for the length of the
foundation wall component and the exterior wall component,
respectively. The connector element may have a generally "Z" shaped
configuration that fits within the aligned "T" shaped receptacles
to hold together the foundation wall component and the exterior
wall component.
[0019] One of the longitudinal ends of the foundation wall
component may include a tongue and the other end of the foundation
wall component may include a complementarily shaped groove. When a
pair of foundation wall components are aligned and abutted, the
tongue of one of the components is receivable in the groove of the
other component to interlock the adjoining components. Similarly,
each exterior wall component may include a vertical edge that
carries a longitudinal tongue. The other vertical edge of the
exterior wall component may carry an elongate groove that receives
the tongue of an adjacent exterior wall component to interlock a
pair of adjoining exterior wall components. One end of each footing
component may carry an upwardly facing pocket and the opposite end
of the footing component may carry a downwardly facing peg or
insertion member. When a pair of footing components are aligned and
interengaged, the peg of one of the components is inserted into the
pocket of the adjacent component to interlock the adjoining
components. The orientation of the pocket and the insertion member
may be reversed. An adhesive may be introduced between the tongue
and groove interconnections of the exterior wall and foundation
wall components as well as between the pocket and peg of the
adjoining footer components.
[0020] The building system of this invention may also include
assorted comer components. For example, a corner footing component
may include a pair of elongate footing sections that are unitarily
interconnected at an angle of 90.degree. or otherwise. Each of the
elongate footing sections may include a longitudinal channel and a
longitudinal keyway section within the channel, analogous to the
elements previously described for the elongate footing components.
The channel and keyway sections of the respective footing sections
interconnect at the same angle at which the footing sections
interconnect. Each elongate footing section of the corner footing
component may carry at its distal end either a pocket or insertion
member as previously described. These parts interengage with
complementary connecting parts (i.e. a pocket interengages an
insertion member and vice versa) carried by adjoining elongate
footing components.
[0021] A corner foundation wall component may include simply an
elongate member having a receptacle and an interior ledge as
previously described. In this piece, the ledge does not extend for
the entire length of the component. Rather, it stops short of one
end of the component and thereby forms a notch proximate that end
of the corner component. A transverse tongue is formed on the comer
component within the notch. The notch receives a complementary end
of an adjacent standard foundation wall component such that the
groove formed in one end of the latter component receives the
transverse tongue of the corner component. As a result, a completed
foundation corner part is formed.
[0022] A corner exterior wall component may include a pair of
panels permanently interconnected at an angle of less than
180.degree. and preferably about 90.degree.. An elongate wall
groove is formed in the distal vertical edge of one of the panels
and an elongate tongue is formed along the distal vertical edge of
the other panel. Each panel includes a receptacle analogous to that
previously described and formed in the bottom edge of the panel.
The receptacles in the respective panels intersect proximate the
vertex of the component. The corner exterior wall component
interengages and interlocks with a pair of previously described
exterior wall components. The tongue carried by the vertical edge
of one of the corner panels fits into the groove of an adjoining
exterior wall component. The groove carried along the vertical edge
of the other corner panel receives the tongue of a second exterior
wall component.
[0023] The upper edges of the exterior wall component and the
corner exterior wall component may include a longitudinal
receptacle. That receptacle may have a general T-shaped
cross-sectional configuration for receiving a roof truss tie down
component in a slidable fashion.
[0024] Each receptacle described herein may comprise an insert that
is pre-cast into its respective component. The insert has an
opening with the configuration described above (e.g. the "T" shaped
configuration) for receiving an associated connector element (e.g.
the "Z" shaped connector interengaging the foundation wall and
exterior wall components, and the typically "L" shaped roof truss
tie down component attached at the upper edge of the exterior wall
component).
[0025] An upper surface of the ledge carried by the foundation wall
component may include a longitudinal groove. The groove receives a
seal that restricts passage of insects between the floor slab and
foundation wall component.
[0026] Transverse holes may be formed through the footing
components and the corner footing components to reduce the weight
of those components.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Other objects, features and advantages will occur from the
following description of a preferred embodiment and the
accompanying drawings, in which:
[0028] FIG. 1 is a perspective, partially exploded view of a
section of a building constructed utilizing the pre-cast building
system of this invention; FIG. 2 is a cross sectional view
illustrating the interengagement between the footing component,
foundation component and upper or exterior wall component of the
system;
[0029] FIG. 3 is an elevational view of a representative footing
component;
[0030] FIG. 4 is an elevational end view of the footing component
facing the end of the component that carries the insertion
member;
[0031] FIG. 5 is an elevational end view of the footing component
facing the end of the component that carries the pocket;
[0032] FIG. 6 is a top plan view of a corner footing component in
accordance with this invention;
[0033] FIG. 7 is an elevational side view of a representative
foundation component according to this invention;
[0034] FIG. 8 is an elevational end view of the foundation
component taken along line D-D of FIG. 7;
[0035] FIG. 9 is a cross sectional top view of a pair of adjoining
foundation components, which particularly illustrates the tongue
and groove interconnection between those components;
[0036] FIG. 10 is a top plan view of a preferred corner foundation
component according to this invention;
[0037] FIG. 11 is an elevational side view of a representative
exterior wall component according to this invention;
[0038] FIG. 12 is a cross sectional view of the exterior wall
component taken along line F-F of FIG. 11; and
[0039] FIG. 13 is a top plan view of a preferred corner exterior
wall component according to this invention.
[0040] There is shown in FIG. 1 a pre-cast building system 10 that
comprises a plurality of modular pre-cast components designed to be
assembled in a quick, efficient and very inexpensive manner, yet
which provide superior structural integrity. It should be
understood that each of the components of this system is typically
composed of a conventional building material such as concrete.
Various alternative substances that exhibit a high strength and
that are suitable for use in building applications may also be
employed. When cement or concrete components are employed,
conventional rebar may be cast within the components to enhance the
strength of the components. The specifics of the casting and
reinforcing steps are well known to persons skilled in the art and
do not comprise a feature of this invention.
[0041] Building system 10 includes, as its principal parts, footing
components 12, foundation components 14 and upper or exterior wall
components 16. Each component is pre-cast. Components 12, 14 and 16
are interengaged in the manner best shown in FIG. 2. System 10 also
includes pre-cast corner components. More particularly, as shown in
FIG. 1, there is a corner footing component 18, a corner foundation
component 20 and a corner upper or exterior wall component 22. The
precise manner of interconnecting these corner components to one
another and to the footing, foundation and exterior wall components
is described more fully below.
[0042] It should be understood that a typical building comprises a
number of sections that include components 12, 14 and 16
interengaged as shown in FIGS. 1 and 2. A typical building will
also include a number of interengaged corner components. The
structure of a representative one of each of the components is
described herein. It should be understood that a similar
construction applies for each other modular component of a
particular type.
[0043] Footing component 12 is installed in a conventional footing
trench formed in the building site. Component 12, which is depicted
by itself in FIGS. 3-5, includes an elongate body portion 24 that
supports a tapered, upwardly facing surface 26. At the upper end of
surface 26 there is formed a raised longitudinal section 27 that
contains a longitudinal, upwardly facing channel 28. A dovetail
shaped first keyway section 30 is formed in the base of channel 28.
Keyway section 30 extends for the entire length of the channel.
[0044] As best shown in FIGS. 1 and 3-5, each footing component 12
carries a pair of extension sections 34 and 36 that are connected
unitarily to respective ends of body section 24. Extension section
34 extends from one end of the footing component proximate the top
of the component and second extension section 36 projects from the
opposite end of the footing component proximate the bottom of the
component. As best shown in FIGS. 1 and 4, extension section 34
supports an extension of the previously described tapered surface
26 as well as extensions of raised section 27, channel 28 and
keyway section 30. The bottom surface of section 34 carries a
downwardly facing insertion member or peg 38. This peg is unitarily
connected to the remainder of extension portion 34 and has a
generally rectangular or square configuration.
[0045] As shown in FIGS. 1 and 5, each extension section 36 is
unitarily connected to body section 24 of footing component 12.
Extension portion 36 includes a generally square or otherwise
rectangular shaped pocket 40 that faces upwardly. Extension
sections 34 and 36 are constructed such that peg 38 and pocket 40
have complementary shapes and sizes and are positioned to
interlockably interengage when the upper extension section 34 of
one footing component overlaps the lower extension section 36 of an
adjacent footing component 12. In this manner, a pair of adjoining
footing components are secured together. An appropriate bonding
agent may be introduced into the pocket to strengthen this
interengagement. Any selected number of adjoining footing
components may be interconnected in this manner to form a generally
linear footing arrangement. When the footing components are so
arranged, the channels 28 and keyway sections 30 of the respective
footing components are similarly aligned to define a continuous
channel and keyway section along the entire length of the assembled
footing. As shown in FIGS. 1 and 3, each footing component 12 may
include a plurality of transverse arches or openings 42. These
permit the footing components to employ less material so that
weight and cost are reduced. At the same time, strength and
durability are not sacrificed.
[0046] At each corner of the building, there is formed a corner
footing component 18, FIG. 1. This component is similarly disposed
in a standard footing trench and is typically interconnected
between the ends of two transverse footing components 12. Each such
component typically traces a respective side of the building.
Corner component 18 is depicted by itself in FIG. 6. The corner
footing component includes a pair of elongate footing sections 50
and 52, which are unitarily interconnected at an angle of
90.degree. or otherwise. Typically, the corner footing section is
pre-cast or molded in a single piece. Alternatively, multiple
pieces may be used. Each footing section of the corner component
includes an elongate body 24a, best shown in FIG. 1. A tapered
upper section 26a extends upwardly from body section 24a. A raised
section 27a extends upwardly from tapered section 26a. A channel
28a extends longitudinally through each of the footing sections 50
and 52. A generally dovetail shaped keyway section 30a having a
size and configuration identical to previously described keyway
section 30 is formed through each of the footing sections 50 and
52. As best shown in FIG. 6, the channels 28 and keyway sections
30a of the respective footing sections 50 and 52 join in a mitered
fashion at the junction of sections 50 and 52. As a result,
channels 28a and keyway sections 30a form a perpendicular
angle.
[0047] Each corner component 18 also includes a pair of corner
extensions 54 and 56, FIGS. 1 and 6. Each extension projects from
the distal end of one of the sections 50 and 52 and, more
particularly, from the body section 24a of that particular footing
section. A rectangular pocket 40a having a size and shape that are
analogous to previously described pocket 40, is formed in each of
the upwardly facing surfaces of extension sections 54 and 56. Each
of the pockets lockably receives a respective peg 38 that projects
downwardly from and adjacent footing component 12. Once again, a
suitable adhesive may be placed in pockets 40a. In this manner,
each linear section of interconnected footing components 12 is
secured to a respective section 50, 52 of corner footing component
18. In alternative versions, the insertion members and pockets may
be reversed such that the corner component carries pegs and the
elongate footing components have pockets that engage those pegs. As
with the linear footing components 12, corner component 18 includes
a plurality of transverse arches or holes 42a, which reduce
material, weight and expense, while maintaining strength of the
component.
[0048] A representative one of the linear foundation components 14
is depicted in FIGS. 7 and 8. Component 14 includes a panel 60 that
features a flat outer surface 62. The inner surface 64 of component
14 carries a unitary lip or ledge 66. As best shown in FIG. 2,
ledge 66 supports the peripheral edge of a standard concrete floor
slab 68. The ledge is positioned along inside wall 64 of component
14 such that when slab 68 is laid within the foundation, the upper
surface 70 of the slab is generally level with the upper edge 72 of
component 14. The upwardly facing surface of ledge 66 preferably
includes a longitudinal groove 74. That groove receives a seal 76
that interengages ledge 66 and the bottom surface of slab 68. Seal
74 prevents insects from intruding into the finished building
between foundation component 14 and slab 68.
[0049] Foundation component 14 includes lower and upper edges 72
and 74 respectively. As best shown in FIG. 2, lower edge 74 is
received within longitudinal channel 28 of footing component 12. A
second dovetail shaped keyway section 78 is formed longitudinally
in lower edge 74 of component 14. Keyway section 78 faces the first
keyway section 30 formed in footing component 12. As a result, the
opposing keyway sections 30 and 78 define an elongate locking
keyway. Foundation component 14 is inserted into footing component
12 in the manner shown in FIG. 2. An adhesive grout or similar
bonding substance is pumped through the aligned keyway sections 30
and 78. This material is allowed to harden, which permanently
secures foundation component 14 within channel 68 of footing
component 12. Channel 68 is approximately 2" deep so that the
foundation component may be adjusted relative to the footing
component. This enables the foundation component to be quickly and
conveniently leveled when necessary.
[0050] A receptacle 80 is formed in upper edge 72 of wall component
14. Receptacle 80 preferably extends for the entire length of
component 14 and includes a generally inverted T-shaped cross
sectional configuration. The receptacle may simply comprise a void
formed or cast into the upper edge of the foundation component,
although preferably, the receptacle is defined by a metal or
plastic insert having the cross sectional shape depicted.
[0051] As best shown in FIGS. 7 and 9, one vertical side edge of
component 14 carries an elongate tongue element 82. The opposite
vertical side edge of the foundation component includes an elongate
groove 84 formed therein. Tongue 82 and groove 84 include
complementary tapered shapes, best shown in FIG. 9. Each component
14 includes a tongue along one vertical edge and a groove in the
other vertical edge. Accordingly, adjoining components 14,
illustrated in FIG. 9, are interengaged by introducing the tongue
82 from one of the components into the groove 84 of the adjoining
component. This interlocks adjacent foundation components. An
adhesive may be introduced between the tongue and groove
interconnection to enhance the interconnection.
[0052] As shown in FIG. 1, corner foundation component 20
interconnects two lengths of adjoining foundation components 14 at
a 90.degree. angle. Other non perpendicular angles may be utilized.
Component 20 is shown alone in FIG. 10. That component actually
comprises a pair of individually pre-cast components 90 and 14a
that are joined in the manner described below. It should be noted
that component 14a features a construction that is analogous to the
previously described linear foundation components 14. FIG. 10 shows
component 14a looking down on upper edge 72. The ledge 74 that
projects from the inside surface of component 14a is also clearly
visible. A groove 84 is formed in one vertical end and a tongue 82
is formed on the opposite vertical end of component 14a.
[0053] Corner component 20 also includes an elongate piece 90. This
piece is modified somewhat from the previously described foundation
pieces. In particular, piece 90 includes a vertical groove 84a
formed in one side edge thereof. However, piece 90 does not include
a tongue at its opposite edge. A receptacle 80a having a generally
inverted T-shaped configuration extends form the base of groove 84a
to the opposite end of component 90. A ledge 74a is formed on the
inside surface of component 90a. Ledge 74a does not extend for the
entire length of component 90. Rather, it terminates a distance
from the vertical edge of piece 90 opposite the edge in which
groove 84a is formed. As a result a recess 93 is formed proximate
one end of component 90. The distance that the ledge terminates is
approximately equal to the thickness of piece 20. A transverse,
tapered tongue 94 extends from piece 90 into recess 93. As best
shown in FIG. 10, components 14a and 90 are interengaged to form an
angle of 90.degree.. In particular, one end of piece 14a fits into
recess 93 at the end of piece 90. Tongue 94 of piece 90 fits into
groove 84 of piece 14a in a generally mating fashion. As a result,
pieces 14a and 90 form an angle of 90.degree.. Once again, an
appropriate adhesive may be introduced between groove 84 and tongue
94. The distal end of piece 14a carries a vertical tongue 82 that
fits into a complementary groove formed in an adjoining foundation
component 14. Similarly, groove 84a formed in piece 90 receives the
tongue of an adjoining foundation component. In this manner, two
lengths of interconnected foundation components may be joined at
the corner of the building by corner component 20.
[0054] As shown in FIGS. 1 and 2, exterior wall component 16 is
mounted upon foundation component 14 such that lower edge 100 of
component 16 directly inter-engages upper edge 72 of component 14.
As shown in FIG. 1, at least some of the exterior wall components
16 may include windows W or other standard features formed
therein.
[0055] A representative component 16 is shown by itself in FIGS. 11
and 12. In particular, this component includes a panel 102 that has
a generally rectangular configuration. The panel includes opposing
lower and upper edges 100 and 104, respectively. As illustrated in
FIGS. 1 and 2, a relatively thick portion 106 may protrude from the
outer face of each exterior wall component proximate upper edge
104. Such a protrusion is not depicted in FIGS. 11 and 12.
[0056] Each wall component 16 includes a lower receptacle 108 that
is formed longitudinally in lower edge 100. As best shown in FIGS.
2 and 12, receptacle 108 has a generally "T" shaped cross sectional
configuration that is identical or closely analogous to the shape
of receptacle 80 in upper edge 72 of foundation component 14. Once
again, receptacle 108 may comprise a void or opening or, more
typically, may include a steel or synthetic insert. Receptacles 108
and 80 abut in the manner best shown in FIG. 2 such that they are
generally opposed to and aligned with one another. In this
condition, the aligned receptacles 80 and 108 slidably receive a
connector element that comprises a "Z" shaped bar 110. This
Z-shaped bar fits in the aligned receptacles such that foundation
component 14 and wall component 16 are interlocked with one another
and prevent it from separating. As a result, the wall components
are securely connected to the underlying foundation components.
Receptacles and connector pieces having differing configurations
may also be used within the scope of this invention.
[0057] An additional receptacle 112, FIGS. 2 and 12, is formed in
upper edge 104 of wall component 16. Receptacle 112 is typically
constructed in a manner identical or similar to the previously
described receptacles. In this case, receptacle 112 comprises an
inverted "T" shaped cross sectional configuration. The receptacle
extends longitudinally through the upper edge of the wall
component. A standard roof truss tie 114 features an L-shaped
configuration including a foot 116 that fits within the base 118 of
receptacle 112. The vertical portion 120 of tie 114 likewise fits
slidably within the vertical portion 122 of receptacle 112. The
receptacle at the top of wall component 16 allows standard truss
ties 114 to be slid into position as shown in FIG. 1. In this
manner, the roof of the structure may be mounted to the assembled
exterior wall components. The truss ties may be located quickly and
conveniently even by unskilled workers. If the positioning is
initially incorrect, the truss ties may be quickly repositioned by
simply sliding them through the upper receptacles 112 into their
proper positions.
[0058] Each wall component 16 carries a longitudinal tongue 124
along one vertical side thereof. A longitudinal groove 126 is
formed in the opposite vertical edge of the exterior wall
component. The tongue and the groove have complementary tapered
cross sectional shapes similar to those previously described for
the tongue and groove formed in the foundation component. Adjoining
wall components 16 are interlocked by simply inserting the tongue
124 from one of the wall components into the groove 126 of the
adjoining wall component. The adjoining wall components thereby
abut in an aligned manner analogous to that previously described
for the foundation components shown in FIG. 9.
[0059] FIG. 1 depicts a representative corner wall component 22,
which contains a door D. It should be noted that doors and/or
windows may be formed in one or more of the wall components 16, as
well as in the corner wall component 22. Corner component 22 is
shown by itself in FIG. 13. In this version, the component
comprises a single unitary piece although, alternatively, multiple
pieces may be featured. More particularly, component 22 includes a
pair of wall panels 130 and 132 that are pre-cast or molded
together at an angle of 90.degree. or at other, non-perpendicular
angles. As a result, component 22 has a generally L-shaped cross
sectional configuration best shown in FIG. 13. A pair of
longitudinal upper receptacles 112a, which are analogous to the
previously described receptacle 112, are formed within the upper
surface 104a of component 22. One of the receptacles 112a extends
longitudinally through panel 130 and the other receptacle 112a
extends longitudinally through panel 132. The receptacles 112a
intersect and form an angle of 90.degree. that intersect at point
140 and define an angle of 90.degree.. The distal vertical end of
panel 130 includes a groove 126a and the distal end of panel 132
similarly includes a tapered tongue 124a. The tongue and groove of
the corner wall unit 122 have respective shapes and lengths that
correspond to the tongues 124 and grooves 126 carried by the
exterior wall components 16. As a result, adjoining wall components
are interlocked and interengaged with corner component 22. A first
wall component 16 abuts the distal end of panel 32 such that the
groove 126 in component 16 receives the tongue 124a of panel 132.
Similarly, an adjoining wall panel 16 abuts the distal end of panel
130 such that the tongue of the wall component is received by
groove 126a in panel 130. When the wall components are assembled in
this manner, the upper receptacles 112 in the wall components are
aligned with the receptacles 112a formed in the corner panels with
which the wall components abut. A continuous linear receptacle is
formed so that the truss tie downs can be freely adjusted along the
length of the walls of the building.
[0060] It should be understood that the pre-cast components
described herein may have various sizes and configurations other
than those shown herein. Additionally, the components may be
assembled in a wide assortment of arrangements within the scope of
this invention. A particular building project may utilize various
numbers and types of the components described herein. The corner
components may form angles other than 90.degree..
[0061] The use of the above described modular building components
permits a concrete building to be assembled quickly, precisely and
efficiently. Few, if any, delays are encountered. The modular
components may be assembled by a small crew of even unskilled or
semi-skilled workers. The individuals components are manufactured
at a factory rather than in the field. This improves quality
control and eliminates manufacturing miscalculations and costly and
time consuming construction errors. The secure, reliable
interconnection between the components achieves a building of
superior structural integrity. The building resists severe weather
conditions and is also quite fire resistant.
[0062] From the foregoing it may be seen that the apparatus of this
invention provides for a pre-cast building system. While this
detailed description has set forth particularly preferred
embodiments of the apparatus of this invention, numerous
modifications and variations of the structure of this invention,
all within the scope of the invention, will readily occur to those
skilled in the art. Accordingly, it is understood that this
description is illustrative only of the principles of the invention
and is not limitative thereof.
[0063] Although specific features of the invention are shown in
some of the drawings and not others, this is for convenience only,
as each feature may be combined with any and all of the other
features in accordance with this invention.
[0064] Other embodiments will occur to those skilled in the art and
are within the following claims:
* * * * *