U.S. patent application number 11/122792 was filed with the patent office on 2005-12-01 for concrete foundation wall with a low density core and carbon fiber and steel reinforcement.
Invention is credited to Messenger, Harold G., Rotondo, Thomas.
Application Number | 20050262786 11/122792 |
Document ID | / |
Family ID | 46304490 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050262786 |
Kind Code |
A1 |
Messenger, Harold G. ; et
al. |
December 1, 2005 |
Concrete foundation wall with a low density core and carbon fiber
and steel reinforcement
Abstract
A fabricated concrete foundation wall is provided with a
plurality of insulation panels and reinforcing ribs to improve
strength and reduce the density of the wall panel. The foundation
wall panels are easily placed and interconnected together to
quickly provide a foundation adapted to support the main walls of a
home, for example. The foundation panels in one embodiment
generally include a facewall that may have at least one carbon
fiber band positioned horizontally therethrough to provide
additional stiffness.
Inventors: |
Messenger, Harold G.;
(Rehoboth, MA) ; Rotondo, Thomas; (Harwinton,
CT) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
|
Family ID: |
46304490 |
Appl. No.: |
11/122792 |
Filed: |
May 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11122792 |
May 4, 2005 |
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11096705 |
Apr 1, 2005 |
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11096705 |
Apr 1, 2005 |
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10772148 |
Feb 3, 2004 |
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10772148 |
Feb 3, 2004 |
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10423286 |
Apr 24, 2003 |
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6898908 |
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10423286 |
Apr 24, 2003 |
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10150465 |
May 17, 2002 |
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6729090 |
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10150465 |
May 17, 2002 |
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10093292 |
Mar 6, 2002 |
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6701683 |
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Current U.S.
Class: |
52/309.12 |
Current CPC
Class: |
E04C 2002/045 20130101;
E04C 2/044 20130101; E04C 2/288 20130101; E04C 2/049 20130101; E04C
2/382 20130101; E02D 27/02 20130101; E04C 2/2885 20130101; E04C
2/06 20130101; E04C 2002/046 20130101 |
Class at
Publication: |
052/309.12 |
International
Class: |
E04C 001/00 |
Claims
What is claimed is:
1. An insulative wall panel comprising: a concrete exterior face
wall having an upper edge, a lower edge, and lateral edges
therebetween, said face wall having at least one carbon fiber strip
extending between said lateral edges; a plurality of ribs extending
from said concrete exterior face wall, wherein said plurality of
ribs are reinforced with a reinforcing rod and are interconnected
to said concrete exterior face wall with a carbon fiber stirrup;
and a plurality of insulation panels placed adjacent to a plurality
of ribs, thereby providing a lightweight, strong and highly
insulative foundation wall panel.
2. The insulative wall panel of claim 1, further comprising a
footer on said lower edge; and a bearing pad for engagement with a
building foundation interconnected adjacent to said lower edge of
said face wall.
3. The insulative wall panel of claim 1, wherein said carbon fiber
strip is tensioned during concrete placement so that the exterior
facewall is in compression after fabrication.
Description
[0001] This application is a continuation-in-part of pending U.S.
patent application Ser. No. 11/096,705, which is a
continuation-in-part of pending U.S. patent application Ser. No.
10/772,148, filed Feb. 3, 2004, which is a continuation-in-part of
pending U.S. patent application Ser. No. 10/423,286, filed Apr. 24,
2003, which is a continuation-in-part of U.S. patent application
Ser. No. 10/150,465, now U.S. Pat. No. 6,729,090, filed May 17,
2002, which is a continuation-in-part of U.S. patent application
Ser. No. 10/093,292, now U.S. Pat. No. 6,701,683, filed Mar. 6,
2002, each of the pending applications or issued patents being
incorporated by reference in their entirety herein.
FIELD OF THE INVENTION
[0002] The present invention relates to building components, and
more specifically lightweight concrete foundation walls that are
manufactured in a controlled environment and can be selectively
interconnected on-site to fabricate modular buildings.
BACKGROUND OF THE INVENTION
[0003] Due to the high cost of traditional concrete components and
the expensive transportation and labor costs associated therewith,
there is a significant need in the construction industry to provide
lightweight, precast, composite building panels that have superior
strength and insulative properties. Previous attempts to provide
these types of building panels have failed due to the expensive
transportation costs and less than ideal insulative and thermal
conductivity properties associated with prefabricated concrete
wire-reinforced products. Further, due to the brittle nature of
concrete, many of the previously used building panels are prone to
cracks and other damage during transportation.
[0004] The relatively large weight per square foot of building
panels of the prior art has resulted in high expenses arising not
only from the amount of materials needed for fabrication, but also
the cost of transporting and erecting the modules. Module weight
also places effective limits on the height of structures, such as
stacked modules e.g., due to load limitations of the building
foundations, footings and/or lowermost modules. Furthermore, there
is substantial fabrication labor expense that can arise from
design, material, and labor costs associated with providing and
placing reinforcement materials. Accordingly, it would be useful to
provide a wall panel system for modular construction that is
relatively light, can be readily stacked to increased heights and,
preferably, inexpensive to design, manufacture, transport and
erect.
[0005] In many situations panels or modules are situated in
locations where it is desirable to have openings therethrough to
accommodate doorways, windows, cables, pipes and the like. In some
previous approaches, panels were required to be specially designed
and cast so as to include any necessary openings, requiring careful
planning and design, thus increasing costs due to the special,
non-standard configuration of such panels. In other approaches,
panels were cast without such openings and the openings were formed
after casting, e.g. by sawing or similar procedures. Such
post-casting procedures such as cutting, particularly through the
thick and/or steel-reinforced panels as described above, is a
relatively labor-intensive and expensive process. In many processes
for creating openings, there is a relatively high potential for
cracking or splitting of the panel or module. Accordingly, it would
be useful to provide panels and modules wherein openings such as
doors and windows may be integrated in desired locations with a
reduced potential for cracking or splitting.
[0006] One other problem associated with metallic wire or bar
materials used in conjunction with concrete is the varying rates of
expansion and contraction. Thus, with extreme heating and cooling
the embedded metallic materials tend to separate from the concrete,
thus creating cracks which may lead to exposure to moisture and the
eventual degradation of both the concrete and wire reinforcement
due to corrosion.
[0007] One example of a composite building panel that attempts to
resolve the aforementioned problems inherent in modular panel
construction of the prior art is described in U.S. Pat. No.
6,202,375 to Kleinschmidt (the '375 patent), which is incorporated
by reference in its entirety herein. In this invention, a building
system is provided that utilizes an insulative core with an
interior and exterior sheet of concrete and which is held together
with a metallic wire mesh positioned on both sides of an insulative
core. The wire mesh is embedded in concrete, and held together by a
plurality of metallic wires extending through the insulative core
at a right angle to the longitudinal plane of the insulative core
and concrete panels. Although providing an advantage over
homogenous concrete panels, the composite panel disclosed in the
'375 patent does not provide the necessary strength and stiffness
properties required during transportation and in high wind
environments. Further, the metallic wire mesh materials are
susceptible to corrosion when exposed to water during fabrication,
and have poor insulative qualities due to the high heat transfer
properties of metallic wire. Thus, the panels disclosed in the '375
patent may be more susceptible to failure when exposed to stresses
during transportation, assembly or subsequent use.
[0008] In addition, attempts have been made to employ improved
building materials that incorporate carbon fiber. For example, in
U.S. Pat. No. 6,230,465 to Messenger, et al., which is incorporated
herein in its entirety by reference, discloses concrete with a
carbon fiber and steel reinforced precast frame. Unfortunately, the
insulative properties of this invention are relatively poor due to
the physical nature of the concrete and steel. Further, the
excessive weight of the panels and inherent problems associated
with transportation, stacking, etc. are present. Previously known
prefabricated building panels have also not been found to have
sufficient tensile and compressive strength when utilizing only
concrete insulative foam materials or wire mesh. Thus, there is a
significant need for a lightweight concrete building panel that has
increased tensile and compressive strength, and which utilizes one
or more commonly known building materials to achieve this
purpose.
[0009] Furthermore, there is a need for a precast concrete
foundation wall system that can be directly positioned on a
prepared soil gravel or sand surface and interconnected to one or
more foundation walls. After interconnection, a concrete floor can
be poured which is operatively interconnected to the foundation
walls and provides additional support.
[0010] Accordingly, there is a significant need in the construction
and building industry to provide a composite building panel and
foundation wall that may be used in modular construction and which
is lightweight, provides superior strength and has high insulative
values. Further, a method of making these types of building panels
is needed that is inexpensive, utilizes commonly known
manufacturing equipment, and which can be used to mass produce
building panels for use in the modular construction of warehouses,
low cost permanent housing, hotels, and other buildings. Finally
there is a significant need for a precast foundation wall system
that can be positioned on a prepared soil or gravel surface and
operably interconnected to a poured concrete floor without
utilizing onsite forms or other expensive building techniques.
SUMMARY OF THE INVENTION
[0011] It is one aspect of the present invention to provide a
composite wall panel that has superior strength, high insulating
properties, is lightweight for transportation and stacking purposes
and is cost effective to manufacture. Thus, in one embodiment of
the present invention, a substantially planar insulative core with
interior and exterior surfaces is positioned between concrete
panels that are reinforced with carbon fiber grids positioned
substantially adjacent to the insulative core. In a preferred
embodiment of the present invention, the interior layer of concrete
is comprised of a low-density concrete. Furthermore, as used
herein, insulative core may comprise any type of material that is
thermally efficient and has a low heat transfer coefficient. These
materials may include, but are not limited to, Styrofoam.RTM.-type
materials such as expanded polystyrenes, extruded polystyrenes,
extruded polypropylene, polyisocyanurate, combinations thereof and
other materials, including wood materials, rubbers, and other
materials well known in the construction industry.
[0012] It is yet another aspect of the present invention to provide
a superior strength composite wall panel that utilizes carbon fiber
materials that are oriented in a novel geometric configuration that
interconnect the insulative core to both the interior and exterior
concrete panels. In one embodiment of the present invention, a
plurality of carbon fibers are oriented in a substantially diagonal
orientation through the insulative core and which may be operably
interconnected to carbon fiber mesh grids positioned proximate to
the interior and exterior surfaces of the insulative core and which
operably interconnect both the interior and exterior concrete
panels to the insulative core. Preferably, the carbon fiber mesh
grid is comprised of a plurality of first carbon fiber strands
extending in a first direction that are operably interconnected to
a plurality of second carbon fiber strands oriented in a second
direction. Preferably, the carbon fiber mesh grids are embedded
within the interior and exterior concrete panels.
[0013] It is a further aspect of the present invention to provide a
lightweight, composite concrete foundation wall panel that is
adapted to be selectively interconnected to a structural steel
frame. Thus, in one embodiment of the present invention attachment
hardware is selectively positioned within the foundation wall panel
during fabrication that is used to quickly and efficiently
interconnect the panel to a structural frame.
[0014] It is another aspect of the present invention to provide a
low density concrete foundation wall panel that has sufficient
compressive strength to allow a second building panel to be stacked
in a vertical relationship, on which can support a vertical load in
the form of a floor truss or other structural member. Alternately,
it is another related aspect of the present invention to provide a
composite lightweight foundation wall panel that can be utilized in
a corner adjacent to a second foundation wall panel, or aligned
horizontally with a plurality of foundation wall panels in a side
by side relationship.
[0015] It is a further aspect of the present invention to provide a
composite foundation wall panel with at least a portion with
insulative material that has superior compressive strength than
typical composite materials comprised of Styrofoam.RTM. and other
similar materials. Thus, in another aspect of the present
invention, a plurality of structural metallic reinforcing members
are placed throughout the insulative core and which extend
substantially between an upper end and lower end of the insulative
core. Preferably, these reinforcing members are comprised of steel
carbon-fiber or other materials.
[0016] It is still yet another aspect of the present invention to
provide a composite foundation wall panel that can be easily
modified to accept any number of interior textures, surfaces or
cladding materials for use in a plurality of applications. Thus,
the present invention is capable of being finished with a stucco,
siding, drywall other type of interior surface.
[0017] It is yet another aspect of the present invention to provide
a composite modular foundation wall panel that can be used to
quickly and efficiently construct modular buildings and temporary
shelters and is designed to be completely functional with regard to
electrical wiring and other utilities such as telephone lines, etc.
Thus, the present invention in one embodiment includes at least one
utility line which is positioned at least partially within the
composite wall panel and which accepts substantially any type of
utility line which may be required in residential or commercial
construction, and which can be quickly interconnected to exterior
service lines. This utility line may be oriented in one or more
directions and is generally positioned near the interior surface of
the foundation wall panel.
[0018] It is yet another aspect of the present invention to provide
a novel configuration of the insulative core that assures a
preferred spacing between the insulative core and the reinforcing
ribs. More specifically, the spacing is designed to provide a gap
between the insulative core panels to assure that concrete carbon
fiber stirrups and metallic reinforcing bars are properly
positioned between the insulative core panels. This improved and
consistent spacing enhances the strength and durability of the
foundation panel
[0019] It is still yet another aspect of the present invention to
provide an insulated concrete foundation panel that is comprised of
a exterior face wall with a plurality of reinforcing ribs emanating
therefrom. The space between the ribs receives foam insulation,
thereby increasing the insulative properties of the foundation wall
and reducing the overall density of the foundation wall. The
exterior face in one embodiment of the invention is additionally
strengthened with at least one carbon fiber grid that generally
extends horizontally therethrough. During fabrication, the carbon
fiber band is preferably tensioned between about 500-3000 lbs. so
that once released the carbon fiber band will retract somewhat,
thus placing the hardening concrete in a compressed state. The
foundation wall panel may also include a footer positioned adjacent
to a top edge and a bearing pad positioned at a bottom edge. The
footer provides a location for the placement of main building walls
and the bearing pad is designed to increase the footprint of the
wall panel on a soil or pea stone, and which subsequently becomes
operably interconnected to the concrete floor surface.
[0020] It is still yet another aspect of the present invention to
provide an insulative foundation panel that is quickly manufactured
and durable. More specifically, one embodiment of the present
invention is manufactured in an exterior face up configuration. As
used herein, "face up" configuration refers to the exterior surface
of the foundation wall panel being in an uppermost portion of the
casting form during fabrication. This configuration allows for the
efficient placement of the insulative foam panels, reinforcing
strands and carbon fiber grid material. Since the foundation wall
is substantially comprised of a concrete base material, the
finished product is fire resistant, substantially maintenance free,
mold resistant, insect proof, wind resistant and projectile
resistant. To increase the fire and smoke resistance of the panel,
a fire and smoke resistant surface may be affixed to the insulative
foam. In addition, the use of insulation in-between the ribs
provides a foundation wall panel that is insulated, in one
embodiment having an R factor of about 20 or more. Further, with
proper treatment of the concrete, the foundation wall panel is
substantially water resistant.
[0021] Thus, in one embodiment of the present invention, an
insulative wall panel is provided, comprising:
[0022] a concrete exterior face wall having an upper edge, a lower
edge, and lateral edges therebetween, said face wall having at
least one carbon fiber strip extending between said lateral
edges;
[0023] a plurality of ribs extending from said concrete exterior
face wall between said upper edge and said lower edge, said
plurality of ribs reinforced with a reinforcing rod and
interconnected to said concrete exterior face wall with a carbon
fiber material; and
[0024] a plurality of insulation panels placed adjacent to said
plurality of ribs, thereby providing a lightweight, strong and
highly insulative foundation wall panel.
[0025] The Summary of the Invention is neither intended nor should
it be construed as being representative of the full extent and
scope of the present invention. The present invention is set forth
in various levels of detail in the Summary of the Invention as well
as in the attached drawings and the Detailed Description of the
Invention and no limitation as to the scope of the present
invention is intended by either the inclusion or non-inclusion of
elements, components, etc. in this Summary of the Invention.
Additional aspects of the present invention will become more
readily apparent from the Detail Description, particularly when
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate embodiments of
the invention and together with the general description of the
invention given above and the detailed description of the drawings
given below, serve to explain the principles of these
inventions.
[0027] FIG. 1 is a top sectional plan view of an insulated
founation panel of one embodiment of the present invention;
[0028] FIG. 2 is a perspective view of interconnected insulated
foundation panels positioned on a pea stone base;
[0029] FIG. 3 are top plan views of various configurations of
interconnected walls;
[0030] FIG. 4 are front elevation and top plan views of foundation
panels as contemplated by the present invention;
[0031] FIG. 5 is a top sectional plan view of an insulated
foundation similar to that shown in FIG. 1;
[0032] FIG. 6 are top plan views of various embodiments of the
present invention that includes reinforcing bars that span the
entire height of the foundation wall panel;
[0033] FIG. 7 are views of one embodiment of the present invention
that includes lifters and inserts for transporting;
[0034] FIG. 8 are views similar to that shown in FIG. 7; and
[0035] FIG. 9 are partial top plan views illustrating various
interconnection methods in one embodiment of the present
invention.
[0036] To assist in the understanding of the present invention the
following list of components and associated numbering found in the
drawings is provided herein:
1 # Component 2 Foundation panel 4 Exterior face wall 6 Carbon
fiber strip 8 Reinforcing rib 10 Upper edge 12 Lower edge 14
Reinforcing bar 16 Carbon fiber stirrups 18 Foam insulation 20 Wood
strip 22 Channel 24 Shoe 26 Plate 28 Foundation material 30 Lip 32
Concrete floor 34 Utility conduit 36 Outlet 38 Bolt 40 Foam plug 42
End column 44 Fire and smoke resistant surface 46 Aperture 48
Lifters and inserts 50 Bolt pockets 52 Steel plate
[0037] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary for an understanding of the invention or that render
other details difficult to perceive may have been omitted. It
should be understood, of course, that the invention is not
necessarily limited to the particular embodiments illustrated
herein.
DETAILED DESCRIPTION
[0038] Referring now to FIGS. 1-9, one embodiment of an insulated
foundation wall panel 2 is shown. More specifically, an insulated
foundation panel 2 is provided that includes an exterior face wall
4 with one or more embedded carbon fiber strips 6. Interconnected
to the exterior face wall 4 are a plurality of reinforcing ribs 8
running generally from an upper edge 10 to a lower edge 12 of the
foundation panel 2. Tying the ribs 8 to the foundation wall 2 are
reinforcing bars 14 and carbon fiber or metallic stirrups 16.
Preferably, the space between each rib 8 is filled with foam
insulation 18, thus providing a foundation panel 2 that is strong,
light, and that has superior insulative properties. Optionally,
some embodiments of the present invention employ wood, foam or
metal strips 20 running substantially the length of the ribs 8 to
provide a location for nails, screws, etc. such that sheet rock or
other wall finishings may be applied to the foundation panel 2.
[0039] Referring again to FIG. 1, an insulative foundation panel 2
is provided that includes the face wall 4 having a plurality of
ribs 8 emanating therefrom. The space between each rib 8 is filled
with foam insulation 18, preferably 8" thick EPS regrind foam. The
foam insulation 18 may also include channels 22 running its length
that provide locations for the placement of utility conduits for
electrical wiring, water pipe, etc.
[0040] The ribs 8 of one embodiment of the present invention run
substantially the height of the insulative foundation panel 2 and
are approximately three inches thick. The ribs 8 preferably are
tied into the face wall 4 with metal or carbon fiber stirrups 16
that are located adjacent to the upper edge and the lower edge of
the insulated face wall 2 and, which provide shear loading
capability. However, one skilled in the art will appreciate that
the face wall and ribs may be placed in one continued operation. In
addition, steel reinforcing bars 14 vertically reside in each rib 8
adjacent to the front surface thereof to add additional strength
and stiffness.
[0041] The face wall 4 of one embodiment of the present invention
is two inches thick and may range in height from about 5 feet to
about 9 feet, thus providing an insulative foundation panel for
crawl spaces and/or full basements, respectively. In addition, the
insulative foundation panel 2 may include a plurality of eight inch
wide carbon fiber strips 6 that lie horizontally within the face
wall 4 about 36 inches above the lower edge. The carbon fiber strip
6 may also be tensioned when the concrete of the insulated
foundation panel 2 is placed, thus yielding a wall panel that is
pre-stressed compressively after set. One example of a carbon fiber
grid material which may be used in the present invention is the
"Mec-Grid.TM." carbon fiber material manufactured by Hexcel
Clark-Schwebel and as described in U.S. Pat. No. 6,236,692, which
is incorporated herein in its entirety by reference. Here, also
shown is an optional wood screw strip 20 that runs substantially
the length of each rib 8. The wood screw strip 8 is generally
spaced the same distance as each rib, in one embodiment 24 inches
apart, and provides a location for the introduction of nails or
other fastening devices to interconnect finishing materials, such
as sheet rock, onto the insulated foundation panel 2. One skilled
in the art will appreciate that the robustness of the manufacturing
process allows the spacing of the ribs 8 and the optional wood
screw strips 20 to be varied depending on the desires of the
manufacturer, and including alternative materials.
[0042] Referring now to FIG. 2, a pair of interconnected foundation
panels are shown. Here, the facewall 4 is shown with a footer 24
interconnected adjacent to the upper edge 10 and a bearing pad 26
located at its lower edge 12. The footer 24 is adapted to receive
other walls, wall panels, bricks, stones, etc. The bearing pad 26
is provided to increase the foot print of the foundation panel 3
upon the building foundation, such a bed of tamped material 28.
Preferably, in one embodiment of the invention, six inches of 3/8"
pea stone is used that provides a foundation for the bearing pad
26. The bearing pad 26 also may include a lip 30 that interfaces
with a concrete floor 32 that will bear down on the lip 36 of the
bearing pad 26 to help stabilize the finished assembly. In
addition, utility channels 22 are provided wherein portions of the
insulation 18 have been removed to provide a location for conduits
34 and electrical outlets 36. One skilled in the art will
appreciate that once the conduits 34 and other utilities installed,
the insulation 18 may be used to fill the channel 22 to increase
the insulative properties of the wall.
[0043] Adjacent foundation panels 2 are generally interconnected in
one embodiment with bolts 38. In order to provide a location for
the bolts 38, the insulation 18 must be cut away to reveal
apertures integrated into the wall panel 2. Once the bolts 38 or
other fasteners are in place, a foam plug 40 ay be added to the
insulation panel 18 to increase the insulative properties of the
foundation panel 2.
[0044] Referring now to FIG. 3, views are shown of adjacent
foundation wall panels 2 in a variety of configurations. For
example, with specific reference to FIG. 3A, adjacent foundation
wall panels 2 are shown interconnected wherein the bolts are driven
through the rib 8 of one wall panel 2 into an end column 42 of an
adjacent wall panel 2. Alternatively, bolts may be used to
interconnect the face wall 4 of the wall panel 2 into the end
column 42 of an adjacent foundation panel 2, as shown in FIG. 3B.
Further, as shown in FIG. 3C, bolts may be used to interconnect the
rib 8 of one wall panel 2 into the face wall 4 of another wall
panel 2. One skilled in the art will appreciate that many different
wall panel arrangements and assemblies may be utilized without
departing from the scope of the invention. In addition, after the
adjacent wall panels 2 are in place, additional insulation, such as
two inch foam strips may be field installed to ensure that
substantially all concrete faces of the finished wall are covered,
thus increasing the insulative property of the system as a
whole.
[0045] Referring now to FIG. 4, foundation wall panels 2 are shown
in a variety of embodiments. More specifically, foundation wall
panels may be formed in a variety of shapes and sizes depending on
the application and design criteria. In addition, the foundation
wall panels 2 may be arranged such that they are interconnectable,
or have a bend integrated therein, such that a plurality of angled
walls are provided by one panel. Further, it should be understood
by one skilled in the art that a plurality of apertures 46 may be
integrated into the wall panel(s) 2 so that conduits for electrical
lines, sewage lines and/or water lines may be accommodated.
[0046] Referring now to FIG. 5-8, another embodiment of an
insulated foundation wall panel 2 is shown, More specifically, an
insulated foundation panel 2 is provided similar to that shown and
described above with respect to FIG. 1. However, this embodiment of
the present invention includes a cylindrical channel 22 as opposed
to a prismatic rectangular channel for the receipt of the fluid or
electrical conduit. In addition, a fire and smoke resistant surface
44 is shown affixed to the foam insulation 18. The fire and smoke
resistant surface 44 may be glued to the foam panel 18 or otherwise
interconnected using methods well known by those skilled in the
construction trades. The wood strips 20 are also shown
interconnected to the ribs 8 of the insulated foundation panel 2,
wherein a small piece of insulative material may be added between
the wood strip 20 and the rib 8 to enhance the insulative
properties of the system.
[0047] In addition, the reinforcing bars 14 preferably span
substantially the entire height of the foundation wall panel 2.
More specifically, one embodiment of the present invention includes
reinforcing bars 14 that are integrated into the ribs 8 of the
panel from the plate 26 to the shoe 24, thus tying them into the
rib 8 to provide additional strength and rigidity.
[0048] Other embodiments of the present invention include
reinforcing bars integrated horizontally within the plate 26 and/or
the shoe 24. One skilled in the art will appreciate that the
horizontal reinforcing bars and the longitudinal reinforcing bars
14 may be interconnected to increase strength and rigidity. In
addition, carbon fiber may be added to the ribs 8, the shoe 24,
and/or the plate 26, in conjunction with steel reinforcing bars 14
or alone, to increase wall panel strength 2. Further, foundation
wall panels as contemplated by the present invention may also
include lifters and inserts 48 that receive a lifting device to
facilitate transportation and erection of the foundation wall
panels 2.
[0049] Referring now to FIG. 9, an interconnection scheme employed
by one embodiment of the present invention is shown. More
specifically, one embodiment of the foundation wall panels 2 may be
interconnected via a bolt 38. Preferably, the foundation wall
panels 2 include an angled outer edge that engages a matching
angled edge of an adjacent foundation wall panel 2. These edges are
similar to that of miter joints as known in the art. Bolt pockets
50 may also be provided that are located adjacent to the upper edge
and the lower edge of the foundation wall panels 2 for
interconnection. The bolt pockets 50 allow for the insertion of a
fastener, such as a bolt 38, through coincident apertures on each
wall panel 2. The adjacent foundation wall panels 2 can then be
securely interconnected by a nut or other attachment hardware known
in the art. Alternatively, welding may be utilized to prevent
movement of the two panels. In addition, steel plates 52 may be
included, affixed to either an inner corner or an outer corner of
the finished interconnected joint, to add increased strength
thereto. These plates 52 are interconnected to the foundation wall
panels 2 via fasteners, such as bolts, or alternatively welded.
[0050] Referring again to FIG. 1, one method of constructing the
insulative foundation panel 2 is shown and described. Embodiments
of the present invention are constructed "face up", which is
believed novel. Initially, the insulation panels 18 are placed in
the casting form, wherein the reinforcing ribs 8 defined by the
spaces between the insulative panels 18. Reinforcing bars 14 and
carbon fiber stirrups are then positioned within the space for the
reinforcing ribs 8. Concrete is then poured into the space. One or
more carbon fiber strips 6 are placed at a predetermined location
within the exterior face wall 4. One skilled in the art will
appreciate that additional steps, such as vibration, may be
employed to ensure that the consistency of the concrete is per
specification, and to improve the density of the concrete. Finally,
wood, foam, or metal screw strips 20 may be applied along the edges
of the ribs 8. One skilled in the art will also appreciate that
lifting devices may also be formed into the wall panel 2 to aid in
the transportation or lifting thereof. Although not shown, the
insulative foundation panel 2 will include a footer and a bearing
pad that is placed when the ribs 8 are formed, and which may be
tied into the face wall 4 with reinforcing bar 14 and stirrups as
well. The footer is subsequently covered at least partially with
concrete when the concrete floor is poured during installation at
the building site, thus providing additional structural
support.
[0051] With regard to the concrete utilized in various embodiments
of the present application, the face wall and associated ribs may
be comprised of a low density concrete such as Cret-o-Lite.TM.,
which is manufactured by Advanced Materials Company of Hamburg,
N.Y. This is an air dried cellular concrete that is nailable,
drillable, screwable, sawable and very fire resistant. In a
preferred embodiment, the face wall is comprised of a dense
concrete material to resist moisture penetration and in one
embodiment is created using VISCO CRETE.TM. or equal product, which
is a chemical that enables the high slumped short pot life
liquification of concrete to enable the concrete to be placed in
narrow wall cavities with minimum vibration and thus create a high
density substantially impermeable concrete layer. VISCO-CRETE.TM.
is manufactured by the Sika Corporation, located in Lyndhurst, N.J.
The face wall is preferably about 2 inches thick. This concrete
layer has a compression strength of approximately 5000 psi after 28
days of curing.
[0052] Positioned within the ribs is one or more reinforcing bars
"rebar", which are generally manufactured from carbon steel or
other similar metallic materials. Preferably, the reinforcing bar
has a diameter of at least about 0.25 inches, and more preferably
about 0.75-1.50 inches. As appreciated by one skilled in the art,
the reinforcing bars 14 may be any variety of dimensions or lengths
depending on the length and width of the wall panel 2, and the
strength requirements necessary for any given project. As
additionally seen in FIG. 1, the stirrups 16 that tie the ribs 8
into the face wall 4 are comprised of carbon fiber grid material,
or alternatively metallic materials.
[0053] The foregoing description of the present invention has been
presented for purposes of illustration and description.
Furthermore, the description is not intended to limit the invention
to the form disclosed herein. Consequently, variations and
modifications commenced here with the above teachings and the skill
or knowledge of the relevant art are within the scope in the
present invention. The embodiments described herein above are
further extended to explain best modes known for practicing the
invention and to enable others skilled in the art to utilize the
invention in such, or other, embodiments or various modifications
required by the particular applications or uses of present
invention. It is intended that the dependent claims be construed to
include all possible embodiments to the extent permitted by the
prior art.
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