U.S. patent number 3,662,506 [Application Number 05/002,177] was granted by the patent office on 1972-05-16 for unitized building structure utilizing precase components.
Invention is credited to Thomas J. Dillon.
United States Patent |
3,662,506 |
Dillon |
May 16, 1972 |
**Please see images for:
( Certificate of Correction ) ** |
UNITIZED BUILDING STRUCTURE UTILIZING PRECASE COMPONENTS
Abstract
A unitized building and a method of mass-producing the same that
features the use of percast wall and floor components with the wall
components being provided with vertical voids that are in registry
with the spacing between adjacent horizontal floor sections which
are, in turn, supported on said wall sections in spanning
relationship thereto. The floor components are precast prior to
delivery to the site so that upon in situ pouring of the floor
slabs to proper thickness, the cement being used is forced into the
voids of the wall panels to effectuate a concrete fusion between
wall and floor components.
Inventors: |
Dillon; Thomas J. (Cuyahoga
Falls, OH) |
Family
ID: |
26670044 |
Appl.
No.: |
05/002,177 |
Filed: |
January 12, 1970 |
Current U.S.
Class: |
52/251; 52/272;
52/262 |
Current CPC
Class: |
E04B
1/161 (20130101); E04B 5/38 (20130101); E04B
2/8629 (20130101) |
Current International
Class: |
E04B
1/16 (20060101); E04B 5/32 (20060101); E04B
5/38 (20060101); E04B 2/86 (20060101); E04b
001/16 (); E04b 005/16 () |
Field of
Search: |
;52/250,251,259,260,319-324,602,253,263,262,258,261,262,272 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
624,976 |
|
1963 |
|
BE |
|
39,809 |
|
1957 |
|
PO |
|
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Ridgill, Jr.; James L.
Claims
What is claimed is:
1. A modular building for use on a prepared foundation site of the
character described, comprising;
A. a plurality of precast unitary reinforced concrete wall
panels
1. at least two of which are arranged in parallel, spaced alignment
with each other
2. each having at least one vertical void centrally thereof that
extends from top to bottom;
B. a plurality of elongated solid precast floor panels
1. having the lower surface of the opposed end portions thereof
resting on the top of said spaced wall panels in non-covering
relationship to said voids and forming a preliminary structure;
C. field-positioned reinforcing means
1. at least some component portions of which are
a. received on top of said floor panels
b. received within the voids of said wall panels;
D. site-poured concrete simultaneously
1. filling said voids of said vertical wall panels
2. completely enveloping said reinforcing means
3. forming a floor surface on top of said wall panels
4. integrating said temporary structure into a monolithic modular
building structure defined by composite wall panels that are
structurally connected to composite floor panels through the medium
of reinforcing means that are integrally embedded in said
site-poured concrete.
2. The building structure of claim 9 further characterized by the
presence of interlocking means that prevent transverse and
longitudinal shifting between adjacent horizontal surfaces of
vertically adjacent wall panels.
3. The building structure of claim 9 further characterized by the
fact that said precast floor panels and said precast wall panels
each have elongate reinforcing rods embedded therein; said embedded
reinforcing rods coacting with the reinforcing means embedded in
said site-poured concrete to enhance the overall structural
characteristics of the monolithic structure.
Description
BACKGROUND OF THE INVENTION
This invention relates in general to the art of building
construction and more particularly to high-rise construction
adapted for office or other use and featuring the use of precast
concrete components.
DESCRIPTION OF THE PRIOR ART
High-rise construction of the type herein being discussed has long
been known in the building construction industry. In the past,
various methods and approaches have been taken to this subject with
the type of construction that has been and is being employed
varying considerably.
Because of rising wage and labor costs in the construction
industry, recent attempts have been directed to preforming as many
of the components as possible at factory locations so that the same
can be then erected at the site with minimal use of skilled
artisans, such as brick-layers, etc.
In this regard, it is known at the present time that floor panels
can be precast. However, at the present time weight and space
requirements have limited the degree to which precast components
can be employed. Weight in this regard is not only important from a
shipping standpoint but is important from the standpoint of the
ease of erection and handling that is involved at the building
site.
Thus it becomes axiomatic that while the use of precast components
is desirable, it is mandatory that such components be capable of
being supported and erected without unusual effort and expensive
equipment being required.
To this end, construction techniques at the present time presently
include the pouring or laying up of the vertical walls at the site.
The walls then receive precast floor components that are only
partially poured as regards thickness. Once these slabs are
positioned in place at the site, the remaining portion of the slab
is poured so that the finished product is completed.
While the above technique has resulted in a technical advance,
there still remains the difficulty of fusing the floors to vertical
wall components, and also there is an inability, in the known art,
to erect several stories before pouring.
SUMMARY OF THE INVENTION
It has been discovered that all essential components of the
building can be precast prior to delivery to the building site and
then assembled in situ followed by pouring in a fashion that in
effect "fuses" the wall and floor components together.
In this regard, the conventional wall panel is cast with a series
of vertical voids therein, with the voids serving the dual purpose
of lightening the precast components for shipping and erection
purposes, while simutaneously providing recesses within which the
finishing concrete used at the building site can be received so as
in effect create a fusion between the wall and floor components
following final pouring at the site.
It has further been discovered that if the wall component is
provided with appropriate horizontal undercuts on its lower edge
communicating with the vertical voids, that several floors can be
erected efficiently prior to any pouring.
These undercuts straddle the longitudinal ribs of the floor panels
so that as the finishing pour is taking place, cement can pass
through the void provided by these undercuts and thus into the
vertical voids that are connected thereto. By this arrangement the
finishing concrete not only cover the surface of the floor slab to
the desired thickness, but is also received within the vertical
voids of the wall panel so that wall panel and floor panel are
bonded or fused together by the same finishing concrete.
It is also contemplated that auxiliary mechanical fastening can be
employed between the components just described so as to insure
rigidity prior to the time of final pour. This auxiliary fastening
takes the form of angled rods which carried by the floor components
and can be tack welded to appropriate plates on the walls to
prevent shifting between the floor and walls as well as serving as
reinforcing members after the finish concrete has been poured.
Attainment of a building technique achieving the above described
objectives accordingly becomes the principal object of this
invention with other objects thereof becoming more apparent upon
the reading of the following brief specification considered and
interpreted in view of the accompanying drawings.
OF THE DRAWINGS:
FIG. 1 is a perspective view partly broken away and in fact, and
illustrating improved building construction method apparatus.
FIG. 2 is a plan view showing floor slabs in place on a vertical
wall section.
FIGS. 3, 4, and 5, are sectional views taken on the lines 3--3,
4--4, and 4--5 of FIG. 2.
FIG. 6 is a vertical section taken on the line 6--6 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIG. 1 thereof,
the improved building construction features the use of a precast
wall consisting of one or more precast wall panels 10, together
with a plurality of identical floor slabs 20,20 with each wall
panel 10 being disposed in a vertical mode while the floor slabs
20,20 span the spaces between adjacent the walls 10,10 so as to
form a floor and ceiling for adjacent floors of the building being
erected.
As best shown in FIG. 1, the panel 10 is generally rectangular in
elevational view and includes a top edge surface 11, bottom surface
12, and opposed planar faces 13 and 14. In accordance with known
building techniques the length of the panel 10 will be an even
multiple of the width of the floor slabs 20,20 so that a given
number of floor slabs will be supported in flush relationship to
the top surface of an individual wall panel 10. In practice it is
contemplated that the wall panel 10 will be approximately 24 feet
long by 8 feet high by 6 to 10 inches thick so as to support six
4-foot wide panels that can vary in length as desired. It should be
understood however that the invention is not intended to be limited
to any specific dimensions and the particular figures cited are for
illustration only.
Also and referring to FIGS. 1, 2, 3 and 4, the wall panels 10 have
a plurality of vertical voids 15,15 that are shown spaced
equi-distant between the opposed planar faces 13 and 14, and that
extend between the top surface 11 and the bottom surface 12 of the
panel. As pointed out earlier, the purpose of these voids 15,15 is
twofold in that their presence first, materially reduces the weight
of the panel in question, and that, secondly, these voids 15, 15
are subsequently filled with concrete during the final pouring
operations so as to effectuate fusion or bonding between the floor
and wall panels following erection.
The preferred embodiment of the invention shown herein also
contemplates erection of additional stories prior to the finish
pouring of the particular floor being built. In this fashion, for
example, the crew erecting the wall panels and laying in the floor
slabs can stay two or three stories ahead of the crew pouring the
concrete.
Accordingly, a series of transverse, horizontal grooves 16, 16 and
16a, 16a are provided in the bottom surface 12 of the wall panel
10, with these grooves extending transversely on the wall 10
between the planar surfaces 13 and 14. In the preferred embodiment
shown, the grooves 16,16 are shown having a greater depth than the
grooves 16a, 16a, with this arrangement being illustrated best in
the lower portion of FIG. 1. It is to be noted that the grooves
16,16 and 16a, 16a correspond in total number to the number of
voids 15,15, and further that these grooves are in vertical
alignment with such voids in all instances.
Again referring to FIG. 1, the floor slabs 20,20 are, as previously
indicated, identical in construction. These panels are pre-cast to
a rectangular configuration so as to include a base portion 20a, a
longitudinal edge portion 21, and a series of upwardly projecting
ribs 22,22 and 22a, 22a. The ribs 22 extend throughout the
longitudinal extent of slab 20 so as to have their ends flush with
the longitudinal end 21 of the slab, as clearly shown in FIG. 1 of
the drawings. The ribs 22a, 22a, on the other hand, terminate short
of the edge 21 for purposes that will be subsequently described.
Additionally, conventional reinforcing rods 40,40 are shown
extending longitudinally of floor panel 20 for known purposes of
reinforcing.
With reference to the method of connecting the floor panels on the
wall panels as preliminary to the final pouring operation, it is
believed apparent that several alternatives are available.
First, the units could be provided with tack pleats 41,41 and
42,42, which could be welded together on site. Alternatively, a
series of right angle rods 43,43 could be placed loosely in
position, as shown in FIG. 1, with the weight of the members
holding the same in place until such time as pouring operations
could be completed, at which time the members 43,43 would serve as
reinforcing units.
Finally, and in the event it is desired to build several stories
ahead and rigidity is required, a more rigid type of connection
could be used by employing welding components mechanically
interlocked the floor and wall panels together.
In this regard, and referring now to FIGS. 3 and 4, it will be seen
that the ribs 22,22 are provided with metal plates 23,23 that are
spaced inwardly from the outward ends of the slab, two inserts
being provided on each rib, as shown best in FIG. 4.
These inserts 23,23 serve as the point of attachment for certain
connecting elements 24, 25, 26 and 27, which will now be described.
In this regard, the elements 24 and 25 are right angle metal rod
components that respectively push against and pull against opposed
wall portions of the void 15, as best shown in FIG. 3. By this
arrangement, the slab 20 is locked in place against longitudinal
shifting with respect to the wall 10, once the components have been
fastened in place, as shown in FIG. 3 as by the use of tack weld
applied to the metal plate members 23,23. In this regard, it is
apparent that the plate members 23,23 may be cast in place or may
be attached as by the use of bolts or other fastening means. The
rods 26,27 are straight in profile and are intended to project
coextensively from one edge of slab 20 to connect with the adjacent
coextensive rod for attachment and alignment purposes. Such
attachment then precludes vertical or transverse shifting of the
floor slabs.
Once the floor slabs have been completely assembled as shown in the
upper portion of FIG. 1, it is believed apparent that another wall
panel can be positioned on the floor slabs 20,20 so as to start
construction of another floor. In this regard, the ribs 22,22 and
rods 24, 25, 26 and 27 will all be received within the void created
by the groove 16 so that the bottom surface 12 can be freely
received on the upper edge portions of the slabs 20,20, with this
condition being illustrated in the lower portion of FIG. 1 of the
drawings. While the rigs 22,22 are received within the grooves
16,16 as just described, the ribs 22a,22a are designed so as to be
in flush abutment with the planar faces 13 and 14 once the panel is
positioned in place. Further positioning, in effect, is achieved by
the use of centering pins 31,31 provided in the top and bottom
surfaces 11 and 12 of the wall panel 10. Thus, the pins 31, 31
preclude longitudinal or transverse shifting of the unit while the
flush abutment of the ribs 22a,22a with the opposed sides of the
wall panel 10 provides further support against transverse
shifting.
In this regard, the pin employed is preferably a tapered pin that
is received within a tapered pipe 32 that extends vertically and
opens into the surfaces 11 and 12 of the wall panel 10. The pin and
pipe which are illustrated are relatively short but they can be
extended to any desired length to give further stability to the
structure prior to the final pour if desired.
When a wall panel 10 has been assembled on positioned floor panels,
as shown in the bottom portion of FIG. 1, it is merely necessary
that the concrete be poured to the level indicated by the line "L"
in FIG. 1 of the drawings. During such pouring, the concrete will
pass through the grooves 16,16 and 16a,16a, and thence into the
vertical voids 15,15, with gravity insuring that the voids 15,15
will be completely filled so that a unitization or fusing of the
members together is insured by such pouring operation.
It is believed apparent, however, that prior to such pouring, it
would be very simple to install the utility conduits or openings on
top of the positioned slabs 20,20 with it being intended and
contemplated that all electrical and other outlets would be
positioned in place prior to completing the final pour.
In this regard, it will be noted that the finished floor line
indicated by the line "L" is above the uppermost surface of the
grooves 16,16 and 16a,16a, so that when final pour is completed, no
trace will remain of the grooves 16,16 and 16a,16a, which will have
been covered up during such pour. Additionally, and once the floor
and wall components have been assembled as just described, it is
believed apparent that corridor walls and other internal walls
could be readily positioned, using known techniques.
With reference to the pouring operations just mentioned, it is
believed apparent that several alternatives are also available
here, dependent upon strength requirements. For example, while a
solid pour of concrete may be required adjacent the point of
connection with the wall panel, it is apparent that the
intermediate portion of the floor panels could be provided with
voids that would be created as by laying a plate or wire mesh over
the upper surfaces of the ribs. Additionally, a honey-combing
arrangement could be employed in this regard if necessary.
It should be noted that where several floors are to be erected
before final pouring some additional reinforcement may be desired.
In that case it would be possible to position the corridor walls,
which run perpendicular to wall panels 10,10, before installing the
next floor slab 20. Also X-bracing or some similar means of
increasing stability may be employed if desired.
On the other hand if each floor is to receive the final pour before
adding the next, the "saw-tooth" bottom edge of panels 10,10 may be
eliminated by eliminating grooves 16,16 and 16a,16a. In this method
one series of wall panels is erected on the conventional foundation
(not shown) and the floor slabs 20,20 are placed in position. The
final pour of concrete is then accomplished so that a unitary
continuous structure is created. The second series of wall panels
are then erected and the process can be repeated for the second
floor.
While a full and complete description of the invention has been set
forth in accordance with the dictates of the Patent Statutes, it is
to be understood that the invention is not intended to be limited
to the specific form herein shown. Accordingly, modifications of
the invention may be resorted to without departing from the spirit
hereof or the scope of the appended claims.
* * * * *