Prestructured Building And Panels Therefor

Abstract

A prestructured building is assembled from manufactured panels, each of which includes parallel spaced-apart channel members having interposed therebetween and secured thereto sheet material. The panels are interconnected by the adjoining of adjacent channel members to form the walls and roof of the building whereby the channel members become the framework of the building and the sheet material becomes the siding and roofing thereof.

Description

BACKGROUND OF THE INVENTION

This invention relates to buildings and more particularly to prestructured buildings. In recent years the use of prestructured buildings, that is, buildings which are assembled from prefabricated panels have received a wide and ever-growing acceptance. One advantage of prefabricated buildings over commonly used part by part construction is the reduction of erection time which reduces field construction costs and also permits quick beneficial occupancy of the building.

One of the principle problems encountered in prestructed buildings is the damage to the prefabricated panel during transportation thereof from the manufacturing facility to the construction site. Unless the panels are elaborately crated, jolts incurred during shipment will cause the relatively fragile sheet portions of the panels which are usually juxtaposed in close proximity to each other to collide resulting in creases or indentures therein which detract from the pleasing appearance thereof. In some situations a hole may even by punched through the sheet portions necessitating the replacement or repairing thereof.

It is therefore an object of this invention to present prefabricated building panels which are so constructed that the same can be transported without being damaged and without requiring substantial crating procedures.

It is a second object of this invention to present prefabricated building panels incorporating rigid channel members which maintain a space between the sheet portions of the panels during shipment and which also provide the framework of the assembled building.

SUMMARY OF THE INVENTION

Generally the prestructured building is constructed from a plurality of wall and roof panels which are fabricated in a manufacturing facility and transported unassembled to the construction site. Generally the wall and roof panels consist of two vertical channels having interposed therebetween and secured thereto sheet material. The channel members also serve to protect the sheet material from damage during transportation, that is, during transportation the panels are positioned and interconnected in abreast relationship such that the legs of the channels maintain a space between the respective sheet materials to prevent collisions therebetween. At the construction site the individual wall and roof panels are joined at the junction of adjacent channel members such that the channel members become the framework of the building and the sheet material becomes the siding thereof.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of the building showing the overall configuration thereof.

FIG. 2 is an isometrical view of an individual panel which is an element of the invention.

FIG. 3 is a top view of a plurality of panels interconnected and ready for transportation thereof from the plant facility to the construction site.

FIG. 4 is a vertical cross section of the building taken along the line 4--4 of FIG. 1.

FIG. 5 is a cross-sectional view of a corner of the building taken along the line 5--5 of FIG. 1.

FIG. 6 is a cross-sectional view of the roof of the building taken along the line 6--6 of FIG. 1.

FIG. 7 is a horizontal cross-sectional view of the junction of the sidewall panel and the roof panel taken along line 7--7 of FIG. 1.

FIG. 8 is a partial sectional view taken along the line 8--8 of FIG. 1.

FIG. 9 is a partial perspective view of another embodiment of this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to FIG. 1, the prestructured building generally denoted as the numeral 10, embodies a plurality of interconnected sidewall panels 12, roof panels 14 and end wall panels 16, each of which is generally similar in construction to the sidewall panel shown in FIG. 2 of the drawings to which specific attention will now be given.

An individual sidewall panel 12 includes two rigid spaced-apart parallel beam members 18 and 20 which may be of a variety of shapes, such as commonly known wide flange or standard I-beams. However, it has been found that channel members having a web 22 and legs 24 perpendicular thereto are well suited for utilization in the panel. In subsequent discussions, the beam members will be referred to as channel members. The webs 22 of the beam or channel members are in facing relationship and have appropriately secured thereto sheeting 28 interposed therebetween in such a manner that there is a void 26 between the sides of the sheeting and the legs of the channel. The sheeting 28 may be fastened to the channel members by cross support members between channels or by using any well known type of fastener such as bolts, rivets, or screws, which are diagrammatically shown by the numeral 29 in the various views. Each of the legs 24 contains a plurality of paired transverse apertures 30.

The beam or channel members 18 and 20 generally are straight strips of rigid material such as steel formed either from hot rolled, cold rolled or cold formed manufacturing methods and the sheeting 28 interposed therebetween usually comprises a plurality of laminae sandwiched together to form a unitary sheet, the number and composition of which varies with the design specifications of each building. A typical panel will include an interior lining 32, a first insulation blanket 34, a vapor shield liner 36, a second insulation blanket 38, and an exterior protective covering 40. The composition of the individual laminae and the fabrication thereof are well known in the art and in no way limit the concepts of the invention.

Although the individual panels forming the sidewall panels 12, the end wall panels 16, and the roof panels 14 embody the same general principles of construction, each type panel does have individual characteristics which are necessary for achieving the specific function thereof.

Considering first the sidewall panels 12, the beam or channel members 18 and 20 thereof are elongated members, preferably straight along the lower portion thereof. Other configurations such as that shown in FIG. 9 is also inclusive of this invention. Received over the upper end thereof is a receiving plate 42 upon which the eave portion of the beam or channel members of the roof panels 14 rest when the building is assembled.

Turning now to the specific configuration of a roof panel 14 and in particular to such a panel used on a gable type roof, as can be seen in the cross-sectional view of FIG. 7, the channel members thereof slope upwardly at an acute angle relative to a horizontal plane and the eave portion thereof includes an abutting member 44 extending horizontally outwardly from the lower leg thereof and a vertical member 45 extending downwardly from the upper leg to meet the horizontal abutting leg at a right angle. The sheeting 28 of a roof panel slopes upwardly parallel with the channel member and at the eave end thereof the inner laminae 32, 34, 36 and 38 turn downwardly into transverse alignment with the vertical sidewall sheeting while the outermost protective covering 40 thereof progresses outwardly to form an overhang as at 46. Other roofing panels such as that used for a flat roof are constructed in a similar manner.

As is shown in the cross-sectional view of FIG. 5, the end wall panels 16 are similarly constructed to the sidewall panels 12 except that the corner post channels 48 thereof include a horizontal extension flange 50 progressing inwardly from the edge of one of the legs 24 thereof. In addition to typical parallel spaced-apart vertical channel members, each end wall panel 16 includes a transversing member 52 which connects at the top thereof the two vertical channel members and which is of a shape similar to the corner post as can be seen in FIG. 8 in that it also includes a horizontal inwardly progressing extension flange 53 on one of the leg portions thereof.

Once manufactured, the panels of the building are crated for shipment to the construction site in the manner depicted in FIG. 3. The panels are positioned in parallel relationship with the legs of adjacent channels 18 and 20 abutting each other and a bolt 54 is introduced into a sufficient number of apertures 30 onto which is threaded a nut to secure the panels together such that a space 57 is maintained between the layers of adjacent sheeting 28. A crane or other lifting means hooked to handling chains 56 which in turn are hooked to the channel members through eyelet plates 58 or other structural means is used to lift the connected panels onto a freight car or bed for the trip to the construction site. During shipment the channels so interconnected maintain the space 57 between neighboring relative fragile layers of sheeting 28 to prevent collision therebetween and resultant damage thereto. In addition the channels are of sufficient rigidity to independently support the weight of the panels and consequently eliminate the need for further crating.

Turning now to the assembling of the building, at the construction site where the foundation and floor which in some instances may have equipment installed thereon, have usually already been completed, the joined panels are unloaded from the freight car and disconnected by removal of bolts 54.

Referring now to the cross-sectional view of FIG. 4, there is shown a typical joining of two like panels, that is, the joining of a sidewall panel to a sidewall panel, end wall panel to an end wall panel, or a roof panel to a roof panel. The connecting of all three types of panels is accomplished in a similar manner and discussion will refer specifically to a sidewall panel but it is to be understood that the same applies to end wall and/or roof panels.

Two sidewall panels 12 are juxtaposed in horizontal alignment with the webs 22 of adjacent channel members 18 and 20 being back to back in a close proximity to each other. A first spacer plate 60 spanning between the legs 24 of the panel within the interior of the building and bolted thereto through utilization of a transverse aperture 30 on each of the legs 24 joins the juxtaposed panels. In like manner, a second spacer plate 62 joins the two channels along the exterior legs thereof. With the panels so joined, the sheeting 28 of the panels provides the siding of the building and the wedded channel members form the side framework thereof thereby eliminating the need for a spearate independently assembled structure framework and also eliminating the need for any structural beams within the interior of the building. Thus the entire interior space of the building can be utilized for positioning plate equipment. Flexible insulation 63 (e.g., acoustical, thermal or other) if required is introduced around the exterior leg of the channel members along the longitudinal length thereof and is retained therein by having the longitudinal ends thereof wedged between the outer protective covering laminae 40 and the second insulation laminae 38 of the sheeting 28.

To seal the wedded channel members from the elements, an elongated box enclosure 64, rectangular in cross section and which may be fabricated from the same material as the outer protective covering laminae 40 is installed over the flexible insulation and the junction of the channel members and is appropriately secured to the outer covering of the panels such as by means of sheet metal screws.

As before mentioned, the roof and end wall panels are joined in a similar manner along the longitudinal lengths of the channel members thereof. As with the side panels, the channel members of the roof panels form the roof framework or rafters and the sheeting 28 thereof provides a siding or roofing of the building. On the other hand as will become clearer in subsequent discussion, the end wall panels merely serve to enclose the end of the building and are not an integral part of the framework thereof.

Looking now at FIG. 6, on a gable type roof, the rafter channels besides being joined at and along the elongated legs 24 of the channel members are also joined at the upper transverse end 66. Appropriate openings may be arranged in the roof for vents, pipes, etc., as required. A cover plate 76 stretching longitudinally between the rafter channels and transversely between the sheeting 28 is received over and is contiguous with the upper end portion of the outer protective covering laminae 40.

Once the individual type panels have been connected, the sidewall panels 12 are properly positioned on the foundation of the building and the lower ends of the channel members 18 and 20 thereof are anchored and grouted thereto in a manner similar to present commonly used methods.

Looking now at FIG. 7, the connected roof panels are next lifted over and aligned with the sidewall panels such that the horizontal abutting member 44 of the rafter channels rests on and is bolted to the receiving plate 42 of the sidewall panels. A haunch bracket 78 having flanges 80 inserted in the gap between the joined channel members is bolted to the channel members to furnish additional structural strength to the junction. Connecting plate 83 also provides even additional strength to the junction of the rafter panel 14 and the sidewall panel 12. The eave portion of the sheeting of the roof panel 14 provides an extension to the sidewall siding which is protected from the elements by a shield 82 longitudinally extending between the panel members and overlapping the outer protective covering 40 of the sidewall. The joining of the entirety of the roof panels 14 to the sidewall panels 12 provides a self-supporting open-ended building having integral framework of sufficient strength and rigidity to independently support the building weight, all dead-weight loads, and design live-weight loads, such as overhead cranes and specified combinations thereof without the need for any additional bracing.

Enclosure of the building is obtained by abutting and connecting the end wall panels 16 around the periphery of the transverse extremities of the sidewall and the roof panels 12 and 14. FIG. 5 illustrates the connecting of the corner sidewall panel to the corner post of the end wall 16. The addition of the horizontal extension flange 50 onto a leg 24 of the corner post enables the web of the end panel 16 to be positioned perpendicular to the web of the sidewall 12 which results in the end wall sheeting turning the corner or as otherwise stated, the respective sidewall panels and end wall panels are mutually perpendicular. Since the end wall panels do not form an integral part of the framework of the building but are used merely to enclose the building and shut out the wind and elements, the joining thereof to the sidewall panels need be only at and along the leg portions of the channels protruding within the interior of the building. The connecting is done with spacer plates 60 bolted to the respective leg portions which have transverse apertures therein. Elongated insulating blankets 85 are wrapped around the channels from the top to the bottom thereof and are covered by first and second enclosures 84 and 86 each of which are secured along one longitudinal edge thereof to the outer protective covering 40 and which along the other longitudinal edges thereof mutually overlap and are secured to an L-shaped bracket 88 projecting outwardly from the back of the web of the corner post.

Turning now to FIG. 8, the gable connection of the roof panels 14 to the transversing members 52 of the end wall panels is shown. As in the joining of the end wall corner post to the sidewall, extension flange 53 extending inwardly from the member 52 permits a spacer plate 60 to connect the two members 20 and 52 such that the web of the end wall transversing member 52 is perpendicular to the web of the roof channel. Insulation blankets 85 and enclosures 84 and 86 are introduced and installed over the channels in a manner similar to that done at the corner post.

The construction herein explained is capable of permitting expansion. For example, removal of the end wall readily permits the addition of panels and roof panels to a new desired length.

During the detailed description of the preferred embodiment of the invention specific terminology has been used for the sake of clarity, however, it is to be understood that the words used are not words of limitation and include all equivalents which are operated in a similar manner to obtain a similar result. Obviously, the building could include various overhead and entry doors and also overhead cranes which are carried by and supported by the channel rafters of the building. Also even though the preferred embodiment described the assembly of the building by first referring to the sidewalls, the roof, and then the end walls, the steps in joining of the individual panels could just as easily be reversed or interchanged.

Claims

What is claimed is:

1. A panel for a prestructured building comprising:

two longitudinal parallel spaced-apart channel members each of said channel members having webs bordered by legs substantially perpendicular thereto, said members oriented such that said legs face each other;

sheeting interposed between said facing channel legs and secured thereto; and

means along said legs to interconnect with the leg of an adjacent panel when stacked in parallel relationship for transportation to a given site;

whereafter a plurality of said panels can be joined along abutting webs to form a building with said channel members being the framework thereof and the said sheeting being the siding thereof.

2. An apparatus as in claim 1 wherein said sheeting comprises a plurality of laminae sandwiched together; said laminae including an inner surface portion, an insulating portion and an outer protective portion.