U.S. patent application number 10/239774 was filed with the patent office on 2004-02-05 for sandwich wall construction and dwelling.
Invention is credited to Calderan, Roberto, Martella, Vincent.
Application Number | 20040020147 10/239774 |
Document ID | / |
Family ID | 4165641 |
Filed Date | 2004-02-05 |
United States Patent
Application |
20040020147 |
Kind Code |
A1 |
Martella, Vincent ; et
al. |
February 5, 2004 |
Sandwich wall construction and dwelling
Abstract
A construction wall system having, rigid inner an outer
rectangular panels on either side and end edges on ends. The panels
spaced apart from one another, with parallel junction strips
between the inner and outer panels, with end junction strips
secured between the panels. End junction strips define junction
channels along the side edges between the panels, with inwardly
spaced spacer strips secured between the inner and outer panels
relative to the end edges of the panels to define end junction
channels between the inner and outer panels. Panels and strips all
being formed of polymer-modified fibre reinforced concrete
material, with synthetic plastic foam material filling the spaces
between the inner and outer panels.
Inventors: |
Martella, Vincent;
(Schomberg, CA) ; Calderan, Roberto; (Toronto,
CA) |
Correspondence
Address: |
George A Rolston
Miller Thomson
Suite 2500
20 Queen Street West
Toronto
ON
M5H 3S1
CA
|
Family ID: |
4165641 |
Appl. No.: |
10/239774 |
Filed: |
September 25, 2002 |
PCT Filed: |
March 23, 2001 |
PCT NO: |
PCT/CA01/00381 |
Current U.S.
Class: |
52/261 ;
52/272 |
Current CPC
Class: |
E04B 2/8635 20130101;
E04C 2/288 20130101; E04B 1/6108 20130101; E04B 1/14 20130101; E04B
1/6179 20130101; E04B 7/22 20130101; E04B 1/165 20130101 |
Class at
Publication: |
52/261 ;
52/272 |
International
Class: |
E04B 001/00; E04B
005/00; E04B 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 27, 2000 |
CA |
2,302,137 |
Claims
1. A construction wall system comprising; an inner rigid panel and
an outer rigid panel of rectangular shape and defining length and
breadth dimensions and defining side edges on either side and end
edges on ends thereof said panels being spaced apart from one
another; a plurality of intermediate junction strips having a
predetermined width secured between said inner and outer panels,
and said junction strips having a length less than the length of
said panels, and being arranged in parallel spaced apart relation,
at spaced intervals between said inner and outer panels; a
plurality of end junction strips having a predetermined width equal
to said intermediate junction strips secured between said inner and
outer panels adjacent opposite side edges thereof, and spaced
inwardly from said side edges whereby to define junction channels
along said side edges between said inner and outer panels, a
plurality of spacer strips having a predetermined width equal to
the width of said junction strips and secured between said inner
and outer panels transverse to said junction strips and adjacent
thereto, said spacer strips being spaced inwardly relative to said
end edges of said panels whereby to define end junction channels
between said inner and outer panels, said panels and said strips
all being formed of polymer-modified fibre reinforced concrete
material.
2. A wall system as claimed in claim 1, and including a synthetic
plastic foam material filling the spaces between said side walls
and said end walls and said intermediate junction strips.
3. A wall system as claimed in claim 2 and including a plurality of
foam filling openings in one of said end walls, and foam filled
into the spaces defined between the intermediate channels after the
wall system has been assembled.
4. A wall system as claimed in claim 3 and including a plurality of
such wall systems erected side by side, and defining a continuous
open junction channel at the upper ends of said wall construction,
and including concrete filling said continuous open topped junction
channel.
5. A wall system as claimed in claim 3 and including a shallow
locating channel formed along the lower edge of each said wall
system, and including registering strip means secured to a
construction footing, adapted to fit within said shallow
registering channel, whereby to register all of said wall systems,
and secure their lower ends against movement.
6. A wall construction having a plurality of such wall structures
and each said wall structure comprising, inner and outer rigid
panels of polymer-modified fibre reinforced concrete material, and
means bonding said panels together in spaced apart relation with
their planes parallel, junction channels formed along the sides and
ends of said wall structure, and, concrete filling in said junction
channels between adjacent sides and adjacent ends of said structure
said concrete extending integrally from one said junction channel
into the adjacent junction channel of two adjacent wall
structures.
7. A wall construction as claimed in claim 6 and wherein same said
wall panels are formed at adjacent ends with a shorter end edge and
a longer end edge, and wherein, when said shorter and longer end
edges are placed adjacent one another, they enclose a rectangular
enclosure, and concrete received in said rectangular enclosures
thereby bonding said wall panels together to form a corner.
8. A dwelling or other housing structure having walls and a
transverse covering and a plurality of wall structures all being
composed of composite wall structures and each said wall structure
comprising; inner and outer rigid panels of polymer-modified fibre
reinforced concrete material and means bonding said panels together
in spaced apart relation with their planes parallel; junction
channels formed along the sides and ends of said wall structure;
and, concrete filling in said junction channels between adjacent
side and adjacent ends of said structure said concrete extending
integrally from one said junction channel into the adjacent
junction channel of two adjacent wall structures.
9. A dwelling structure as claimed in claim 8 and including a
plurality of transverse panels, each consisting of upper and lower
rigid panels of polymer modified concrete material, and steel
reinforcing channels located between said upper and lower panels
and bonded thereto, said upper and lower panels and said
reinforcing channels defining open spaces therebetween, and foam
plastic material filling said open spaces, and connection means
extending upwardly from said walls through said transverse
structure, and being secured in said transverse structure
panels.
10. A dwelling structure as claimed in claim 9 wherein said
connection means are in the form of generally cone shaped openings
formed in said transverse panels, and being located and adapted to
receive reinforcing bars extending upwardly from said walls, and
concrete material filling said cone shaped recesses and bonding
around said reinforcing bars and securing said transverse structure
in position.
11. A dwelling structure as claimed in claim 10 and including a
plurality of relatively narrow transverse panels, each of the
transverse panels having interlocking male and female formations at
their respective side edges, whereby said roof panels may be mated
together, to form a transverse structure spanning the space of a
building.
12. A dwelling structure as claimed in claim 11 wherein said
transverse panels form a floor for a second storey of said dwelling
structure.
13. A method of constructing a wall panel structure having an inner
rigid panel and an outer rigid panel of rectangular shape and
defining length and breadth dimensions and defining side edges on
either side and end edges on ends thereof said panels being spaced
apart from one another and, a plurality of intermediate junction
strips having a predetermined width secured between said inner and
outer panels, and said junction strips having a length less than
the length of said panels, and being arranged in parallel spaced
apart relation, at spaced intervals between said inner and outer
panels and, a plurality of end junction strips having a
predetermined width equal to said intermediate junction strips
secured between said inner and outer panels adjacent opposite side
edges thereof, and spaced inwardly from said side edges whereby to
define junction channels along said side edges between said inner
and outer panels, a plurality of spacer strips having a
predetermined width equal to the width of said junction strips and
secured between said inner and outer panels transverse to said
junction strips and adjacent thereto, and comprising the steps of;
securing said spacer strips and said intermediate junction strips
between said inner and said outer panels, said spacer strips being
spaced being spaced inwardly relative to said end edges of said
inner and outer panels panels whereby to define end junction
channels between said inner and outer panels, said panels and said
strips all being formed of polymer-modified fibre reinforced
concrete material; and, filling the spaces between said spacer
strips and said inner and outer panels with synthetic plastic foam
material.
14. A method of constructing walls, and a dwelling using wall
structures having an inner rigid panel and an outer rigid panel of
rectangular shape and defining length and breadth dimensions and
defining side edges on either side and end edges on ends thereof
said panels being spaced apart from one another, and a plurality of
intermediate junction strips having a predetermined width secured
between said inner and outer panels, and said junction strips
having a length less than the length of said panels, and being
arranged in parallel spaced apart relation, at spaced intervals
between said inner and outer panels, and a plurality of end
junction strips having a predetermined width equal to said
intermediate junction strips secured between said inner and outer
panels adjacent opposite side edges thereof, and spaced inwardly
from said side edges whereby to define junction channels along said
side edges between said inner and outer panels, a plurality of
spacer strips having a predetermined width equal to the width of
said junction strips and secured between said inner and outer
panels transverse to said junction strips and adjacent thereto,
said spacer strips being spaced inwardly relative to said end edges
of said panels whereby to define end junction channels between said
inner and outer panels, said panels and said strips all being
formed of polymer-modified fibre reinforced concrete material; and,
comprising the steps of; erecting a plurality of said wall
structures end to end to form dwelling walls; pouring concrete in
said junction channels between adjacent said wall structures to
secure the same together, and, erecting a plurality of transverse
structures spanning said walls and forming a floor, roof or the
like.
Description
TECHNICAL FIELD
[0001] The invention relates to a sandwich-type wall structure and
to a wall construction using a plurality of sandwich wall
structures, and to a dwelling constructed from such sandwich wall
structures.
BACKGROUND ART
[0002] Conventional construction of walls involves the erection of
framing and the exterior is then covered in with some form of
sheathing, drywall, stucco and/or bricks or siding. Insulation is
placed between the framing or studs, and the interior wall is then
covered in usually with plaster board of some kind. This involves a
large number of different operations, using on site labour, which
is paid at relatively high hourly rates. Materials were often
subject to damage by insects, and by rot.
[0003] Clearly it is desirable to provide for a low cost
construction technique in which portions of a building may be
pre-built and finished in a factory, and which use durable, long
lasting materials not subject to attack by rot, weather or insects.
It is further clearly desirable that such building components shall
be capable of being manufactured by relatively unskilled factory
labour, and may be erected to form a low cost dwelling or other
building, in a speedy, efficient manner, using a minimum of on-site
labour with minimum skills, and requiring only a minimum of heavy
equipment. The buildings using this system will preferably be
capable of withstanding hurricane winds and earthquake shocks.
[0004] A partial solution is to use wall panel systems, in which
wall panels can be prefabricated to standard sizes. The panels are
then simply put together to erect the completed walls. These
systems however suffer from a variety of disadvantages such as the
use of various different materials, having differential rates of
expansion and contraction, and the use of some materials which may
be subject to deterioration, rot, or attack by insects and the
like.
[0005] In co-pending U.S. application Ser. No. 09/024,656, Title:
Composite Wall Construction and Dwelling therefrom, and assigned to
the assignee of this application, there is described a wall
structure and dwelling meeting many of these objectives.
[0006] It is found however, that a sandwich like wall structure,
which is somewhat less costly, but retains many useful qualities
comparable to the earlier wall structure, can be made without
significant loss of strength. In particular, in the system
described in the aforesaid application, the system provided for the
use of front and rear spaced apart panels, and partition walls
extending between the front and rear panels of the wall structure,
defining interior cavities and further called for the use of
expanded polyurethane foam insulation material in the cavities.
While this was relatively expensive, the walls resulting from such
wall structures were strong and well-insulated and were otherwise
satisfactory. It has been found that in practice significant
economies can be made in cost, without any significant loss of
properties, and at the same time production both at the factory,
where the wall structures are produced, and also in the erection of
such wall structures, can be substantially speeded up.
DISCLOSURE OF THE INVENTION
[0007] With a view to achieving the foregoing advantages the
invention provides a sandwich wall structure comprising, an inner
rigid panel and an outer rigid panel of rectangular shape formed of
polymer-modified fibre reinforced concrete material and defining
length and breadth dimensions and defining side edges on either
side and upper and lower end edges on ends thereof said panels
being spaced apart from one another, an insulation block formed of
rigid expanded polystyrene thermal insulation material bonded
between said inner and outer panels, the block defining upper and
lower and end surfaces all such surfaces being spaced inwardly
relative to the side and end edges of said panels whereby to define
side and upper end junction channels, and lower registering
channels, between said inner and outer panels.
[0008] The invention further comprises a wall construction having a
plurality of such sandwich wall structures, and concrete filling in
said side channels and said upper end junction channels between
adjacent sides and extending between adjacent upper ends of said
panels, said concrete extending integrally from one said junction
channel into the adjacent junction channel of two adjacent wall
structures.
[0009] The invention further comprises a rectangular composite wall
which comprises a plurality of such sandwich wall structures
erected side by side, and defining continuous horizontal junction
channels at the upper ends of said wall structures, and including
concrete filling said continuous horizontal junction channels and
further concrete filling vertical junction channels between
adjacent sides of adjacent panels.
[0010] The invention further comprises a wall construction as
described and including a shallow locating channel formed along the
lower edge of each said sandwich wall structures and including
registering strip means secured to a construction footing, adapted
to fit within said shallow registering channel, whereby to register
said sandwich wall structures, and secure their lower edges against
movement. Preferably there will also be a matching reinforcing
strip within the interior of the locating channel secured along the
downwardly directed surface of the insulation block, for contacting
the registering strip means.
[0011] Reinforcing bars of steel may typically be incorporated in
the vertical and upper horizontal junction channels and embedded in
the concrete.
[0012] The invention further comprises a corner construction
consisting of interlocking panels, formed at adjacent ends of
adjacent sandwich wall structures with a shorter end edge and a
longer end edge, and wherein, when said shorter and longer end
edges are placed adjacent one another, they enclose a generally
rectangular enclosure and metallic L-shaped angles secured to
adjacent end edges of said inner and outer panels, and securing
adjacent inner and adjacent outer panels together and concrete
received in said generally rectangular enclosures thereby bonding
said wall structures together at said corner. Preferably the
rectangular enclosures will be of truncated L-shape in section.
[0013] The invention further comprises a dwelling or other housing
structure having walls and a roof and said walls being formed of a
plurality of sandwich wall structures each said wall structure
comprising, inner and outer rigid panels of polymer-modified fibre
reinforced concrete material and an insulation block formed of
rigid expanded polystyrene between said panels and means bonding
said panels to said insulation block with their planes parallel,
junction channels formed along the sides and upper ends of each
said wall structure, and, concrete filling in said junction
channels between adjacent sides and extending between adjacent ends
of said sandwich wall structures said concrete extending integrally
from one said junction channel into the adjacent junction channel
of an adjacent wall structure.
[0014] The roof preferably comprises a plurality of roof structures
each consisting of upper and lower rigid panels of polymer modified
concrete material, and a block of expanded polystyrene thermal
insulation material bonded therebetween and steel reinforcing
channels located between said upper and lower panels and bonded
thereto, said upper and lower panels and said reinforcing channels
defining open spaces therebetween, and connection means extending
upwardly from said walls through said roof, and being secured in
said roof panels.
[0015] The roof panels may be joined by stepped ledge formations in
a form of "ship-lath" connection.
[0016] The invention further comprises the provision of a dwelling
or other housing structure having both walls and the roof as
described above, and further having an intermediate floor structure
composed of floor structure panels substantially as described in
connection with the roof structure panels.
[0017] The invention further comprises that said connection means
are in the form of generally cone shaped openings formed in said
roof panels, and being located and adapted to receive reinforcing
bars extending upwardly from said walls, and concrete material
filling said cone shaped recesses and bonding around said
reinforcing bars and securing said roof in position.
[0018] Preferably the roof will be comprised of a plurality of
relatively narrow roof panels, each of the roof panels having male
channel formations and interlocking female channel formations at
their respective side edges, whereby said roof panels may be mated
together with said male and female channel formations interengaged,
to form a roof spanning the space of a building.
[0019] The invention further comprises a method of constructing a
wall panel structure having the foregoing advantages, and a method
of constructing walls, and a dwelling using the wall structures
according to the foregoing.
[0020] The various features of novelty which characterize the
invention are pointed out with more particularity in the claims
annexed to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages and
specific objects attained by its use, reference should be made to
the accompanying drawings and descriptive matter in which there are
illustrated and described preferred embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective illustration partially cut away of a
sandwich wall structure illustrating one form of the invention;
[0022] FIG. 2 is a section along the line 2-2 of FIG. 1;
[0023] FIG. 3 is a section along the line 3-3 of FIG. 1;
[0024] FIG. 4 is a side elevational view partially cut away showing
two composite wall structures erected on a concrete foundation, and
showing them assembled together using poured concrete as the
joining medium;
[0025] FIG. 5 is a section along the line 5-5 of FIG. 1 greatly
enlarged to show the method of securing the portions of the
composite wall structure together;
[0026] FIG. 6 is a section along the line 6-6 of FIG. 4;
[0027] FIG. 7 is a section along the line 7-7 of FIG. 4;
[0028] FIG. 8 is a schematic side elevational view of a simple
dwelling illustrating the use of the invention in construction;
[0029] FIG. 9 is a top plan view of the building plan of the
dwelling of FIG. 8;
[0030] FIG. 10 is a section along the line 9-9 of FIG. 9, showing
joining two side walls at a right angular corner;
[0031] FIG. 11 is a section along the line 9-9 of FIG. 9 greatly
enlarged showing joining side walls and a partition wall together
at a Tee junction;
[0032] FIG. 12 is a section of a junction of four walls;
[0033] FIG. 13 is a sectional illustration illustrating the
attachment of a floor panel between two upright walls;
[0034] FIG. 14 is a section illustrating the construction of a
plurality of roof panels placed edge to edge in interlocking mating
relation;
[0035] FIG. 15 is a section through the end edge of a typical roof
or floor panel;
[0036] FIG. 16 is an exploded cut away view of another form of roof
panel connection;
[0037] FIG. 17 is section along the line 16-16 of FIG. 8,
illustrating the attachment of a roof panel to a side wall,
and,
[0038] FIG. 18 is a section showing the junction of two roof panels
at a ridge, where two portions of the roof meet one another,
typically along the axis of an interior partition wall.
MODES OF CARRYING OUT THE INVENTION
[0039] As already indicated the invention relates generally to a
modular sandwich-type wall structure, which is modular in nature
and which is factory built. The modular wall structures can be
transported in large numbers to a building site and then can be
erected basically by hand labour, and using simple poured concrete
facilities.
[0040] The basic wall structure is illustrated in FIGS. 1 through
3. It will be seen to comprise a modular sandwich wall structure
illustrated generally as 10. The wall structure 10 has an outer
panel 12 and an inner panel 14. They are both of rectangular shape
and of the same size, and typically may be in the region of four
feet by eight feet, or more depending upon the height of the
dwelling, or other building to be erected.
[0041] Panels 12 and 14 are spaced apart from one another, and,
between the panels 12 and 14, there is secured and a block of
insulation material 16. The block of insulation material 16 is of
rectangular shape being in the form of a flattened solid body,
defining side edge walls 18 and 20, and top and bottom edge walls
22 and 24.
[0042] The block of insulation material 16 is formed of
thermoplastic material, typically being expanded polystyrene bead
material, of a type well known in the art, and requiring no special
description or formulation.
[0043] The panels 12 and 14 are bonded together on opposite sides
of the block 16 by any suitable adhesive means. The side edge and
top and bottom edge dimensions of the block 16 are somewhat reduced
in relation to the dimensions of the side edges and the top edges
of the panels 12 and 14.
[0044] In this way, it will be seen that along either side of the
sandwich wall structure, there are defined a generally open sided
rectangular vertical channels 26, and along the top edge a
horizontal channel 28. Along the lower edge of the wall structure
there is defined a shallow lower rectangular channel 30 which it
will be seen, is of reduced depth dimension in relation to the
channels 26 and 28.
[0045] Each of the panels 12 and 14 are of identical construction.
They will be seen to comprise sheets 32 of polymer-reinforced
concrete material, typically having a thickness of about one half
to three quarters of an inch. On at least one side of the
polymer-reinforced concrete material, there are located fibre
reinforced matting sheets 34. Such sheets of polymer-reinforced
concrete, reinforced with fibre matting, typically resin fibre
matting, form a structure of great strength and bending resistance
and load carrying capacity.
[0046] The insulation block 16 is bonded to the interior of the
inner and outer panels 12 and 14 by any suitable adhesive means.
This will bond securely to the inner surfaces of the panels 12 and
14, defined by the fibre resin mesh reinforcement 34, thereby
bonding the panels 12 and 14 together with the block 16 to make a
homogenous integral solid sandwich wall structure.
[0047] All of these functions can be carried out in the factory
with great precision, and also with a minimum of instruction. The
wall structures 10 being largely formed of lightweight material are
relatively light, and can be handled by manual labour without the
use special mechanical lifting devices.
[0048] Referring now to FIGS. 4, 5, 6 and 7, the wall structures 10
can be associated together to form a wall shown generally as 40 in
FIG. 4. The wall 40 illustrated in FIG. 4 is merely illustrative of
the way in which the wall structures 10 can be used to be construct
and erect a wall. Typically the wall of a single storey building or
dwelling, will be defined by the height, i.e. the length dimension
of each panel 10. As shown in FIG. 4, the panels 10 are erected on
a concrete base or slab or foundation indicated as F. In order to
locate the wall structures 10 a locating strip 42 is secured on the
surface of the slab F by nails or other fastenings. The locating
strip 42 in this embodiment is typically formed by a metal channel
but may also be a strip of the polymer-reinforced concrete panel
material. It fits within the channels 30 between the front and rear
panels 12 and 14.
[0049] The lower channel 30 (FIG. 2) is arranged so that it has a
sufficient height to fit over the locating strip 42, and make a
snug fit thereon.
[0050] In order to join two adjacent wall structures 10 together,
in edge to edge abutting relation, concrete material M is poured
down through the channels 26 and 26, between two adjacent
structures 10. Additional bracing is usually temporarily required
adjacent the joints between the panels 12 and 14 of the adjacent
wall structures 10, and this of course may be provided in any
suitable manner. For example metal bracing channels 44 secured by
wire clips 46 may be used. Such temporary bracing may be required
in order to prevent the pressure of the concrete from distorting
the edges of the panels 12 and 14 where they define the channels
26. However, the bracing can usually be removed after twenty-four
hours as the concrete material M cures.
[0051] Usually, there will be a plurality of vertical reinforcing
rods R placed in the channels 26 prior to pouring of the concrete,
in accordance with well known construction techniques.
[0052] In order to provide a horizontal top beam, for supporting
the roof concrete M is also poured in the horizontal channels 28
along the top of the wall structures 10. Generally speaking, since
the depth of this concrete is only a few inches, there will be no
additional bracing required at this point.
[0053] Such concrete M will usually be reinforced with suitable
reinforcing rods. When the wall is finished, the individual wall
structures 10 are joined edge to edge in abutting relation, and the
wall is supported by vertical columns of cured concrete M, and by
horizontal beams of concrete M, which are all poured integrally at
the same time and form a structure of great strength. Additional
rebars may be placed at intervals extending upwards for attachment
of a roof.
[0054] It will now be apparent from the foregoing description that
the sandwich wall structures 10 can be assembled together to
provide walls for a dwelling or other building. Referring now to
FIGS. 8 and 9, such a building is illustrated generally as 50. FIG.
8 is a schematic side elevation of such a building, typically a
small, low cost dwelling, and FIG. 9 is a floor plan of such a
building.
[0055] It will be seen that the building 50 is provided with four
exterior walls 52, and a central partition wall 54, extending
between two of the side exterior walls 52. All of the walls 52 and
54 are made of sandwich wall structures 10 as described in FIGS. 1
through 3, and all of the wall structures are joined by means of
poured concrete columns. In FIG. 9 the poured concrete columns are
indicated as C. The junction between the exterior side walls and
the partition walls is achieved by means of a generally Tee-shaped
poured corner containing concrete column C, illustrated in more
detail in FIG. 11. Portions of the inner panels 14 of two abutting
wall panels may be cut away as shown to allow concrete to flow into
the Tee junction.
[0056] The corners of the walls 52 in this embodiment require
modified wall structures shown in FIG. 10.
[0057] These modified wall structures are formed with outer panels
12A which are extended somewhat along one edge as at 56, and have
modified interior panels 14A , which are cut somewhat shorter as at
58.
[0058] Two wall structures 10-10 as shown, may be formed into a
corner by placing the longer and shorter edges 12A and 14A in edge
abutting relation as shown in FIG. 10. This forms a right angular
corner. Reinforcing corner angles 60 are secured whereas the
interior at the junctions of the outer panels 12A and remain in
place. Suitable reinforcing rods are placed down the L-shaped space
defined by the longer and shorter portions 56 and 58, and concrete
is poured down in the space. The rebars are interlocked by straps
as needed. The concrete will form a generally L-shaped column,
extending around the corner, and holding both wall structures
securely together and holding them upright.
[0059] At this point, reviewing the simple dwelling structure of
FIGS. 8 and 9 it will be seen that the four walls and the central
partition wall are all constructed of the sandwich wall structures
10 as illustrated generally in FIG. 1, and that they are joined
edge to edge to form the complete walls by means of poured concrete
columns. The entire structure thus has great integral strength, and
at the same time has great resistance to thermal transmission.
Being provided with a plurality of vertical supporting concrete
columns, reinforced as described, the structure will have great
resistance to earthquake and other shocks. At the same time it is
apparent that it can readily be erected, by manual labour simply
taking the sandwich wall structures 10 illustrated in FIG. 1 and
erecting them side by side and comer to corner, supporting them
vertically, and pouring concrete using relatively primitive
equipment such as will be readily available even in remote
locations.
[0060] A floor can be constructed, in multi-storey dwelling, (not
illustrated), by taking somewhat modified sandwich structures 70,
and attaching them between lower and upper walls 72 and 74.
[0061] In this case, from the near upper channel 26 of the lower
wall 72, a connecting rebar 76 extends upwardly.
[0062] The panel 70 is formed with a generally frusto-conical
opening or recess 78. The rebar 76 fits within the recess, and
concrete is then poured down into the recess and bonds the rebar
thereby holding the floor in position.
[0063] The upper wall 74 is attached once again in the manner shown
in connection with FIGS. 4 and 5.
[0064] Reference may now be made to the roof 80 of the
dwelling.
[0065] The roof is best illustrated in FIGS. 14, 15, 16, 17 and 18.
It will be made up of a plurality of elongated relatively narrow
roof sandwich members 82. The roof members 82 comprise upper and
lower panels 84 and 86 formed of polymer modified concrete,
sandwiched around a polystyrene panel of induration 87.
[0066] A plurality of steel C channels 88 are bonded between the
interior surfaces of the panels. The panels 84 and 86 are otherwise
formed in the same way, with reinforcing fibre glass mesh, as
described in connection with the panels of FIG. 1.
[0067] Along one side edge of each of the sandwich members 80,
(FIG. 14) a metal C section 90 is recessed inwardly between the
panels 82 and 84 so as to leave a shallow channel. Along the other
side edge of the member 80, a C section 92 is secured flush with
the ends of the roof members 80. A mating strip member 94 is bonded
to the exterior of the C section 92 , and is dimensioned so as to
make a snug fit between the space defined within C channel 90 along
the other side edge.
[0068] In this way the roof members 82 can be set side by side
together with a form of tongue and groove interconnection between
them.
[0069] FIG. 15 illustrates and alternate form of interconnection.
In this case two roof panels have identical edge portions formed by
inwardly faced C channels 96.
[0070] The surfaces of the C channels can be bonded together by
adhesive.
[0071] FIG. 16 illustrates a further form of roof panel
junction.
[0072] In this case modified C channels 98 are used. These channels
are formed with offset portions 100. They are turned to face
upwardly along one edge and downwardly along the opposite edge of
each panel. When the panels are placed edge to edge, the channels
98 will interfit and form a type of "ship lath" joint, having great
strength and being weather proof. For added security a screw 102
can be inserted at spaced intervals along each joint.
[0073] In order to secure the roof panels to the walls vertically
extending rebars 104 are located and dimensioned so as to interfit
with generally conically shaped recesses 106 , formed at each end
of each of the roof members or panels (FIGS. 17 and 18).
[0074] With this arrangement, concrete is then filled in around the
conical recess thereby bonding to the rebars and holding the roof
firmly in position.
[0075] Similar arrangements can be made for the pitched roof shown
in FIG. 10, the details of which require no special
description.
[0076] It will also be understood that, in a two storey structure,
the floor members can be provided to serve as the floor of the
second storey (FIG. 13).
[0077] The floor structures will be somewhat similar to the roof
structures described above, but will usually be somewhat thicker,
ie. in the region of seven inches overall, with a half inch panel
top and bottom, and a six inch core of insulation block.
[0078] The floor structures will be reinforced along with side
edges by metal reinforcing channels, and also similar reinforcing
channels along their end edges.
[0079] Along one side edge, the channel will be turned outwardly so
that it defines a U-shaped recess. Along the other edge the channel
will be turned inwardly and simply fits over the insulation block.
Alternatively the "ship lath" type of joint can be used as in the
roof (FIG. 16).
[0080] Along the exterior of the wall a rectangular strip of
polymer reinforced concrete material.
[0081] The foregoing is a description of a preferred embodiment of
the invention which is given here by way of example only. The
invention is not to be taken as limited to any of the specific
features as described, but comprehends all such variations thereof
as come within the scope of the appended claims.
* * * * *