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Claims  |
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What is claimed is:
1. Reinforced masonry construction for walls and slabs including
(a) a pair of skins spaced a predetermined distance apart in opposed
relation
(b) at least one of said skins comprising a plurality of preformed
elongated panels arranged with the longitudinal edges in contiguous
relationship
(c) each of said panels comprising a body portion of cementitious material
(d) the peripheral edge of said body portion being formed providing a
splineway
(e) said panel further including a reinforcing truss embedded in said body
portion, which truss is substantially coextensive with the length and
breadth of said body portion
(f) reinforcing means extending between, and engaged with, said skins
(g) said reinforcing means including a portion engaged with said skins for
interconnecting the same,
(h) one end of said reinforcing means being positioned in the splineway of
said panel, and
(i) an insulating agent in those spaced between said skins.
2. The reinforced masonry construction of claim 1, wherein:
(a) the body portion of each of said panels is constructed of cellular
concrete, and
(b) said insulating agent is cellular concrete.
3. The reinforced masonry construction of claim 1, wherein:
(a) one of said skins includes a cementitious topping applied to the
cementitious material between the skins.
4. The reinforced masonry construction of claim 1 wherein:
(a) said reinforcing means includes a tie extending between said skins.
5. The reinforced masonry construction of claim 1, wherein:
(a) said reinforcing means includes a truss chord.
6. The reinforced masonry of claim 5, wherein:
(a) said truss chord includes an elongated reticulate portion
(b) edge members engaged with the longitudinal edges of said reticulate
portion
(c) said edge members being of tubular conformation
(d) reinforcing rods extending through said tubular edge members
(e) hanger clips engaged with said truss chord
(f) a portion of each of said hanger clips being engaged with said
elongated panels, and
(g) composite clips carried by said hanger clips and including portions
engageable with the skin in opposed relation to said elongated panels.
7. The reinforced masonry construction of claim 5, wherein:
(a) said truss chord includes a pair of sections arranged in back-to-back
relation
(b) each of said sections including a reticulate portion
(c) edge members engaged with the longitudinal edges of said reticulate
portion
(d) said edge members being of J-shaped conformation in cross section
(e) hanger clips engaged with said pair of sections
(f) a portion of each of said hanger clips being engaged with said
elongated panels, and
(g) composite clips carried by said hanger clips and including portions
engageable with the skin in opposed relation to said elongated panels.
8. The reinforced masonry construction of claim 5, wherein:
(a) said truss chord includes a plurality of sections
(b) each of said sections including an elongated reticulate portion
(c) edge members engaged with the longitudinal edges of said reticulate
portion
(d) the outermost portions of said edge members being notched at intervals
for interfitting engagement with adjacent sections
(e) rods inserted through the notched portion of adjacent sections for
hingedly connecting the same together
(f) hanger clips engaged with the end truss chord sections
(g) a portion of each of said hanger clips being engaged with said
elongated panels, and
(h) composite clips carried by said hanger clips and including portions
engageable with the skin in opposed relation to said elongated panels.
9. Reinforced masonry construction for walls and slabs, including
(a) permanent forms spaced apart a predetermined distance to provide a
structural section
(b) each of said opposed forms comprising a plurality of elongated,
preformed panels arranged in rows with the longitudinal edges in
contiguous relationship
(c) the outer face of one panel being prefinished with a facing design
(d) each of said panels including a body portion of cellular concrete, the
peripheral edges of which are provided with a splineway
(e) a reinforcing truss embedded in said body portion, which truss is
substantially coextensive with the length and breadth of said body portion
(f) said reinforcing truss including a reticulate body portion
(g) edge members engaged with the longitudinal edges of said retriculate
body portion
(h) ties engaged with opposed panels of said forms and spanning the void
therebetween, said ties being in vertically aligned relationship
connecting each row of opposed panels for positioning said panels and
spanning the void therebetween
(i) each of said ties including a flat body portion having spaced openings
(j) the ends of said flat body portion having angular tabs for insertion
into the splineways of adjacent panels for positioning the latter
(k) a pair of reinforcing rods extending through the openings of said body
portion and extending transversely of the forms, and
(l) cementitious material in the void between said forms.
10. The reinforced masonry construction of claim 9, wherein:
(a) said cemetitious material comprises low density cellular concrete.
11. The reinforced masonry construction of claim 9, with the addition of:
(a) means for fixedly securing form sections at a right angle to each
other.
12. The reinforced masonry construction of claim 11, wherein:
(a) said means includes a right angle corner section interposed between
said form sections
(b) lugs cast in place in said form section and right angle corner section
adjacent the lateral extremities thereof, and
(c) connectors extending between, and engaged with, the lugs of said corner
section and form sections, for fixedly securing said sections together.
13. The reinforced masonry construction of claim 11, wherein:
(a) said means includes lugs cast in place in said form sections, adjacent
proximate edges thereof, and
(b) angular connectors extending between and engaged with, the lugs of said
form sections for fixedly securing said sections together.
14. The reinforced masonry construction of claim 13, with the addition of:
(a) a corner member inserted between the ends of the form sections and a
body portion, and
(b) extension members extending outwardly from said body portion into the
panel splines of the form sections for holding the corner member in
position.
15. The reinforced masonry construction of claim 13, wherein:
(a) said lugs and connectors are located interiorly of the right angle form
sections.
16. The reinforced masonry construction of claim 13, wherein:
(a) said lugs and connectors are located exteriorly of the right angle form
sections.
17. Reinforced masonry construction for walls and slabs, including
(a) permanent forms spaced apart a predetermined distance in opposed
relationship, leaving a void therebetween
(b) each of said opposed forms comprising a plurality of elongated,
preformed panels arranged in rows with the longitudinal edges in
contiguous relationship
(c) each of said panels including a body portion of cementitious material
(d) a reinforcing truss embedded in said body portion
(e) ties in vertically aligned relationship connecting each row of opposed
panels for positioning said panels and spanning the void therebetween
(f) each of said ties including a flat body portion
(g) the ends of said body portion being adapted for engagement with opposed
panels
(h) the body portion of said tie being provided with at least one opening
(i) a reinforcing rod extending through the vertically aligned ties for
substantially the entire transverse dimension of the forms, and
(j) An insulating agent between said forms engaged with said ties and
reinforcing rod to provide a structure of high compression strength.
18. The reinforced masonry construction of claim 17, wherein
(a) the body portion of each of said panels is high density cellular
concrete.
19. The reinforced masonry construction of claim 17, wherein
(a) the insulating agent between said panels is low density cellular
concrete.
20. The reinforced masonry construction of claim 17, with the addition of
(a) a truss positioned between, and engaged with, adjacent ties.
21. The reinforced masonry construction of claim 20, wherein
(a) said truss includes a reticulate body portion of rectangular shape
(b) edge members of U-shape cross section into which tie longitudinal edges
of said reticulate body portion are inserted
(c) said U-shape edge members and portions of said reticulate body portion
inserted therein being crimped and rolled to form tubular portions
(d) each of said tubular portions having a central opening adapted to
receive said reinforcing rods.
22. The reinforced masonry construction of claim 17, with the addition of
(a) means for fixedly securing together said panels, tie means and
reinforcing rods comprising the forms, whereby said forms may be
prefabricated and then moved to the site.
23. The reinforced masonry construction of claim 22, with the addition of
(a) lifting means detachably engaged with said forms for transporting the
same.
24. The reinforced masonry construction of claim 23, wherein
(a) said lifting means includes a pair of spaced tie members positioned
beneath the lowermost panels
(b) the ends of said tie members having upstanding tabs extending into the
splineways of said panels
(c) inverted U-shaped hooks secured to said tie members and extending
upwardly between said spaced panels
(d) spaced rods extending downwardly between said panels
(e) the lower ends of said spaced rods being provided with bills adapted
for detachable engagement with said inverted U-shaped hooks
(f) a transverse lifting rod, and
(g) means connecting said transverse lifting rod with the upper end of said
rods.
25. The reinforced masonry construction of claim 17, wherein
(a) said tie is provided with a second opening in spaced relation to the
first opening, and
(b) a second reinforcing rod extending through the second opening of the
vertically aligned ties.
26. The reinforced masonry construction of claim 25, wherein
(a) each of said reinforcing rods includes a plurality of short rod
members, the length of each of which is substantially the same as the
width of said panels and arranged in end-to-end relationship, and
(b) means for joining adjacent ends of said rod members together, whereby
both of the spaced forms may be readily erected from one side thereof.
27. The reinforced masonry construction of claim 26, wherein
(a) said means for joining said short rod members includes a tubular member
for receiving the ends of adjacent rod members.
28. A precast panel including:
(a) a rectangular body portion of cementitious material
(b) the peripheral edges of said body portion being provided with a
splineway, and
(c) a reinforcing truss embedded in said body portion, which truss is
substantially coextensive with the length and breadth of said body portion
(d) said reinforcing truss including a reticulate body
(e) said reinforcing truss further including edge members engaged with the
longitudinal edges of said reticulate body
(f) a portion of said edge members defining one side of the splineway.
29. The precast panel of claim 28, wherein
(a) said rectangular body portion is precast of lightweight cellular
concrete of high density.
30. The precast panel of claim 28, wherein
(a) one face of said body portion is prefinished with a facing design.
31. The precast panel of claim 28, wherein
(a) said edge members include elongated clips of U-shape cross section into
which the longitudinal edges of said reticulate body are placed
(b) said U-shape edge members and portions of said reticulate body
contained therein being crimped and bent to form the side of the
splineway.
32. The precast panel of claim 31, wherein
(a) said edge members are bent into a J-shape conformation in cross section
(b) said J-shape edge members including a main portion, an angular portion
and a reversely turned flange portion
(c) said main portion defining one side of the splineway of said body
portion
(d) said angular portion extending rearwardly of the body portion and
forming a part of the edge of said panel
(e) said reversely turned flange portion being in spaced, parallel relation
to said main body portion and forming a part of the rear face of said
panel.
33. Reinforced masonry construction for walls and slabs, including
(a) permanent forms spaced apart a predetermined distance to provide a
structural section
(b) each of said forms comprising a plurality of elongated panels arranged
in edge-to-edge relationship
(c) the edges of said elongated panels having splineways
(d) tie members engaged with opposed panels of said forms and spanning the
void therebetween, said tie members being aligned transversely of the
forms
(e) each of said tie members including a flat body portion having spaced
openings
(f) the ends of said flat body portion having angular tabs for insertion
into the splineways of adjacent panels for positioning the latter
(g) a pair of reinforcing rods extending through the openings of said body
portion, and extending transversely of the forms
(h) cementitious material in the void between said forms, and
(i) means for fixedly securing form sections at a right angle to each other
(j) said means including lugs cast in place in the form sections adjacent
proximate edges thereof
(k) angular connectors extending between, and engaged with, the lugs of the
form sections for fixedly securing the sections together
(l) said means further including a corner member inserted between the ends
of the form sections and including a body portion
(m) extension members extending outwardly from said body portion into the
panel splineways of the form sections for holding the corner member in
position.
34. Reinforced masonry construction for walls and slabs including
(a) permanent forms spaced apart a predetermined distance to provide a
structural section
(b) each of said forms comprising a plurality of elongated panels arranged
in edge-to-edge relationship
(c) the edges of said elongated panels having splineways
(d) tie members engaged with opposed panels of said forms and spanning the
void therebetween, said tie members being aligned transversely of the
forms
(e) each of said tie members including a flat body portion having spaced
openings
(f) the ends of said flat body portion having angular tabs for insertion
into the splineways of adjacent panels for positioning the latter
(g) a pair of reinforcing rods extending through the openings of said flat
portion, and extending transversely of the forms
(h) cementitious material in the void between said forms, and
(i) means for fixedly securing form sections at a right angle to each other
(j) said means including lugs cast in place in the form sections adjacent
proximate edges thereof
(k) angular connectors extending between, and engaged with, the lugs of the
form sections for fixedly securing the sections together
(l) said lugs and connectors being located exteriorly of the right angle
form section. |
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Claims |
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Description |
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BACKGROUND OF THE INVENTION
In the construction of reinforced masonry walls and/or concrete slabs, it
has been conventional practice in the past to erect spaced temporary
forms, between or upon which standard reinforcing members are placed,
following which approximatey 150 pcf. density of high structural strength
concrete is poured between or upon the forms, and vibrated.
After the forms are erected, or as they are in the process of being
erected, portions thereof are cut out for mechanical or electrical egress
and door and window frames are attached for openings by means of built-in
bucks. Cutting these forms results in costly repair if the forms are to be
reused.
After the concrete cures, the forms are removed, requiring a time element
which is costly, and finishes are usually applied to one or both outer
faces of the resulting section. If the exposed face is to be used as a
flat finish, the surfaces must be pointed up where snap ties are broken
off, which hole areas are noticeable without a supplementary finish, and
act as a capillary conduit for moisture through the wall.
If the walls are to be considered waterproof, an additional treatment must
be applied to the face exposed to the elements. If the walls are a part of
a residence, architectural concrete finishes must be applied or provided
by form liners, resulting in additional expense in time and material, and
damage thereto.
Since conventional concrete walls or slabs do not provide sufficient
insulation value to meet today's standards for energy conservation,
additional applications of insulation must be applied requiring an
additional application to the interior face for a finished wall surface,
involving even greater time and expense. In the case of roof slabs,
additional insulation and wearing surface must be added. Any use of
conventional concrete automatically dictates 30% additional weight (as
compared to the same section in structural grade cellular concrete) is
added to the dead load imposed upon the reinforcing, structural framework
and/or foundations.
In the construction of conventional masonry walls, the physical time and
cost factors are even less favorable than set out above. Finishes are
usually restricted to exposed brick or hollow block, or applied finishes
such as stucco or additional precast finishes. The thickness of the
load-bearing walls must be greater than concrete and reinforced concrete
beam and column sections must be provided within the masonry section
resulting for it to be considered load-bearing. This involves extra trades
in addition to the wet trades, which slow down a job to a considerable
degree and also increase its costs both in material and labor.
Besides a marked inferiority in load bearing capability as compared to
reinforced concrete, conventional masonry construction has little or no
resistance or lateral stress. Hollow block masonry is particularly
susceptible to moisture invasion, as well as vermin, and has little value
in fire rating or as an insulating factor against sound or thermal
conduction. In consideration of these defects, conventional masonry must
be reinforced, and additional applications be made to its surfaces, both
inside and outside, to overcome its weaknesses and gain some portion of
the aesthetic and physical properties noted above.
SUMMARY OF THE INVENTION
The present invention relates to reinforced masonry construction for walls
and slabs which, although constructed as a composite section of
lightweight, low and high density concrete, is stronger than conventional
high density concrete structures, while at the same time characterized by
superior insulating, waterproofing, sound and fireproofing qualities, and
very appreciable savings in deadweight of the sections resulting.
The present reinforced masonry construction basically comprises spaced
permanent forms in the case of walls, and a permanent form and a topping
in the case of slabs, the space between the forms or forms and topping
being filled with low density cellular concrete. In the case of slabs, the
monolithic topping, or skin, of high strength, lightweight cellular
concrete acts as the opposite composite face to the form panel below.
Each form includes a plurality of elongated panels joined in edge-to-edge
relation, opposed panels being connected by ties and composite connectors
which span and engage the panels to hold them in position. Each panel
comprises a body portion which is preferably made of structural grade
cellular concrete reinforced by a truss positioned therein. The peripheral
edges of the panels are provided with splineways which are engaged by a
portion of the ties to position the panels. The outer faces of one or both
forms may be prefinished.
The ties connecting the panels are vertically or horizontally aligned, and
reinforcing rods of unitary or multi-part construction, and need for
outside scaffolding is obviated in the erection of walls. Trusses may be
inserted between adjacent ties and engaged with the reinforcing rods for
added structural strength. If desired, the elongated panels, ties and
reinforcing rods may be welded, or secured together in any other suitable
fashion to provide a gang-formed wall or slab form which may be
prefabricated and transported to a building site.
The reinforcing rods, ties and reinforced panels of the present invention
are interconnected in a manner to form walls and slabs of superior
strength. When lightweight cellular concrete is poured between the forms
of a wall, or onto a form of a slab, the reinforced form panels, ties and
reinforcing rods form a composite structure of lightweight, yet strong
construction. The present construction further permits greater versatility
by using lightweight cellular concrete through its entire density range,
resulting in an almost unlimited range of physical benefits in weight,
sound, thermal insulation, fire, shock, etc.
Locking plates are provided to effect securement of adjacent panels
together in uniplanar or angular relationship to prevent separation
thereof during pouring of the concrete into the void between forms.
DESCRIPTION OF FIGURES OF THE DRAWINGS
FIG. 1 is a perspective view illustrating the manner of constructing a
masonry wall in accordance with the present invention;
FIG. 2 is a fragmentary longitudinal sectional view of wall and floor slab
sections constructed in accordance with the present invention;
FIG. 3 is an end elevational view of a horizontal truss member, that may be
employed in the floor slabs of the present invention;
FIG. 4 is a view similar to FIG. 3 showing an alternate truss;
FIG. 5 is an end view illustrating a further modified form of truss for a
floor slab;
FIG. 6 is a plan view of the truss of FIG. 5;
FIG. 7 is an enlarged perspective view of a portion of a slab showing the
advantage of a hanger clip;
FIG. 8 is a perspective view of a precast wall panel constructed in
accordance with the present invention, a portion thereof being broken away
to show details thereof;
FIG. 9 is an end elevational view of the arrangement of parts for making
the reinforcing truss used in the wall panel and flood slab of the present
invention;
FIG. 10 is an end elevational view similar to FIG. 9, showing the completed
truss;
FIG. 11 is an end elevational view similar to FIG. 7 of the arrangement of
parts for making the truss for use in a wall, or as slab reinforcing;
FIG. 12 is an end elevational view showing the completed truss of FIG. 11;
FIG. 13 is an enlarged fragmentary transverse sectional view of the wall
illustrated in FIG. 1, showing details of construction;
FIG. 14 is a perspective view of a tie member and reinforcing rods
constructed in accordance with the present invention;
FIG. 15 is a perspective of a tie member adapted for placement on a slab or
footing and at the top of a wall constructed in accordance with the
present invention;
FIG. 16 is a perspective view of a truss forming a part of the present
invention, and illustrating the application thereof in a wall section;
FIG. 17 is a perspective view of a gang-form wall section comprising a
modified form of the present invention;
FIG. 18 is an enlarged top plan view of a corner section employed to
connect wall sections at right angles to each other;
FIG. 19 is an enlarged perspective view of a connector plate employed to
join the corner section of FIG. 18 to wall sections arranged at right
angles to each other;
FIG. 20 is an enlarged top plan view of a modified form of the corner
section shown in FIG. 16;
FIG. 21 is an enlarged perspective view of a connector plate employed in
connection with the corner section of FIG. 18;
FIG. 22 is an enlarged top plan view of another modified form of the corner
section for joining interior wall sections at right angles to each other,
and
FIG. 23 is an enlarged perspective view of a connector plate employed with
the corner section of FIG. 20.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a reinforced masonry system and its
ability to provide walls and slabs by the utilization of a unique
interconnected series of component parts acting as connection devices and
structural trusses in concert with both low and high density cellular
concrete over the full range of its density, which is capable of providing
greater strength to its resultant section than the same section in
conventional high density reinforced concrete, while at the same time
being characterized by superior insulation, waterproofing, sound and fire
proofing qualities at considerably less weight and at less cost in time
and money.
This system for building walls and slabs employs a minimum of components,
including spaced-apart exterior and interior permanent wall forms as well
as the form for slabs, which preferably comprise a plurality of precast
panels of uniquely reinforced cellular concrete of equally high
compressive strength as compared to conventional high density structural
grade concrete, but at 30% saving in weight and the ability to have the
surfaces prefinished in a very wide range of aesthetic choice. These
panels may be cut, drilled or sawed easily with conventional masonry
tools, which elminates the requirement for fixed modular construction.
The exterior and interior wall forms, as well as the slab form, comprise a
plurality of elongated panels of a size and weight to be manually
positioned to erect the wall or slab forms, the opposed panels of the wall
form and the undersurface of the slab forms being interconnected by a
plurality of metal ties which engage the longitudinal edges of adjacent
panels to position successive rows of prefinished panels comprising each
wall form, or to suspend the panels forming the underside form of the slab
as well as its prefinished surface. The wall ties engaged in the panels
are arranged in aligned groups, vertically for walls and horizontally for
slabs, and reinforcing members through the wall ties from the top to the
bottom of the wall to form a structural column. In slabs, the same
procedure may be followed and connected to the beam or wall support by
positive engagement to horizontal and vertical reinforcement.
The formation of these wall or slab sections can be prefabricated off the
job site into what is known as a "gang-form" section if desired, and large
sections set in place by cranes. These sections can actually be welded
together internally, an ability inherited from the unique truss member
reinforcing each plank. If manual erection for walls is preferred, or is
required in order to eliminate the need for hoisting equipment, it is
possible to completely eliminate the need for outside scaffolding and
avoid the interference that might be caused by full length vertical
reinforcing by employing short sections of rod furnished with tubular
sections on one end, so that the rods may be coupled together with
positive structural splicing means to "grow" vertically as the wall is
erected. This eliminates the need for outside scaffolding in the erection
of a wall section.
The composite section of walls, or slabs, if the core is designed as a low
density type, is completed by pouring or pumping in a preferred fill of
low density cellular concrete. This density is usually at the opposite end
of the density range to that making up the panels, rendering the system
unique in the use of a single material used in its widest density range to
create all the physical characteristics required to offer waterproofing,
strength, fireproofing, sound and thermal insulation, as well as aesthetic
choice in finished surfaces. This composite arrangement enables the
construction of masonry walls and slabs, wherein the forms become a
permanent part of the wall or slab, and wherein, by virtue of the
arrangement of the structural components, a load-bearing wall or slab of
superior strength may be constructed with the composite section of high
and low density cellular concrete rather than entirely high density
concrete, thus achieving superior physical properties and values except
for strength.
Naturally, the strength of the wall is vastly increased as the density of
fill is increased, but this is not required by the system since the unique
trusses and their interrelationship with the other structural components,
permits the lightest weight to strength ratio available, one which far
exceeds the normal strength factors for building walls and slabs today.
When greater strength is needed in walls or slabs, e.g., in multi-level
structures or for high concentrated loading, trusses or additional trusses
as in the case of horizontal beams or columns, may be inserted between the
tie members, or used in continuous forms, which trusses are engaged with
the ties by means of threading the reinforcing through the holes therein
and at the same time passing through the circular heads of the trusses'
cords to create what could be considered small reinforced Lally columns
when cellular concrete is poured between or upon the form. Since the
composition of the material is very fluid, it is permitted to run inside
the circular head of the truss as well as all about it and the reticulated
web of the truss. This ability permits the section's strength to be
increased at a miniscule extra weight and retain the extra physical
qualities of the low density fill.
The composite section of the system provides greater durability in that it
has markedly superior stability in freeze-thaw durability and the
advantage to work in cold weather that would prevent conventional concrete
or masonry construction, since cellular concrete has the lowest free water
and very low water absorption, hence superior weatherability. It is the
lightest in weight to any other structurally comparable system which
reflects added savings in structural framework and to foundations.
Cellular concrete has been proven far more resistant to the effects of
salt than conventional concrete, and also has better impact, blast and
seismic energy absorption and shock mitigation reaction.
In certified comparable tests, cellular concrete has been rated as
impermeable by hydrostatic tests and building code acceptance, wherein
conventional dense structural grade, as well as ferro-concrete, failed.
The system in its composite section offers far greater and proven
protection against moisture penetration, thermal conductivity, fire
resistance and sound apsorption as well as complete freedom of design in
aesthetics. It is faster, cheaper and stronger than comparable
conventional means due to the unique design of its trusses and their
interrelation with the other components of the system. These factors are
all enhanced in the final composite creation by the additional of the
cellular concrete fill placed within the forms, which addition also
completely braces the structural and/or reinforcing means, adding extra
strength thereto, since, in the case of walls, the unsupported length of
the vertical column members is reduced virtually to zero.
The system is structurally unique in its composite form inasmuch as it can
be easily urged that it can be considered in any one of three structural
categories, i.e., as a "reinforced sandwich panel", as "reinforced
concrete", or as a "structural framed wall" braced by the fill completely
through and around all its parts and members. The fill greatly enhances
the value of the systems, components, and vice-versa. One of the
structural phenomena of the system is that it is in itself a combination
of the three means outlined above, receiving contributions from each to
achieve it ultimate, superior strength, and related physical criteria
advantages.
DESCRIPTION OF FIGURES OF THE DRAWINGS
In FIG. 1, there is illustrated the manner of constructing a masonry wall
for a building structure on a slab 30. In accordance with this invention,
there is provided an exterior wall form 32 and an interior wall form 34.
Exterior and interior wall forms 32 and 34 include a plurality of precast
panels 36 of basically the same construction, but wherein the outer
surface of one or both forms may be prefinished in a virtually unlimited
variety of finishes, such as a brick finish or a shiplap finish as
illustrated.
Referring to FIGS. 8, 9, 10 and 13, it will be seen that precast panels 36
are of elongated rectangular configuration and of a size to permit them to
be manually set in position in a wall or slab section. A panel of 12
inches high, 10 feet long and 11/4 inches thick has proven satisfactory in
use.
Panel 36 includes a body portion 38 which is precast of lightweight
cellular concrete of high density, i.e. above 60 pcf. One face of body
portion 38 is prefinished by providing a shiplap design as shown, or other
suitable facing design.
It is a salient part of the present invention to provide a reinforcement
truss 40 which is integrally formed in body portion 38. Truss 40 includes
an elongated reticulate body 42 of expanded metal construction, the
longitudinal edges of which are engaged by an imperforate J-shaped metal
member which includes a main portion 44, an angular portion 46 extending
outwardly at a 90.degree. angle to main portion 44, and an upturned flange
portion 48 issuing from the angular portion and lying in spaced, parallel
relation to reticulate body 42.
Referring now to FIG. 9, it will be seen that truss 40 is formed by placing
the longitudinal edges of reticulate body 42 into elongated metallic clips
50 of U-shaped cross section. Members 50 and the edges of reticulate body
are then crimped together and bent to the J-shaped configuration shown in
FIG. 8. No welding or other securing means is necessary to bond the clips
to the reticulate body.
Referring to FIGS. 8 and 13, it will be seen that truss 40 is substantially
coextensive with the height and length of body portion 38 and is
positioned in the body portion in greater proximity to the rear face
thereof. As shown in FIG. 13, main portion 44 is so located to form one
side of a splineway 52 which extends around the entire periphery of body
portion 38. Also angular portion 46 forms the outer top and bottom surface
of body portion 38 and lies upwardly of the upper and lower limits of the
concrete portion of the panel for reasons which will be hereinafter more
fully set out. Also flange portion 48 forms the limit of the inner face of
panel 36. This arrangement of the truss in the body portion maintains the
integrity of the concrete body portion and permits welding of the panel to
other metal components of the composite structure. If desired, the
J-shaped member may be perforate to effect a better bond with concrete to
and through it.
In order to hold the wall panels comprising the exterior and interior wall
forms in predetermined spaced relation, and to support the panels, there
are provided ties 54 which are adapted for placement on slab 30, and ties
56 for positioning between superjacent panels.
As shown in FIG. 15, tie 54 is of generally U-shaped configuration and
includes a body portion 58, the ends of which are bent upwardly to provide
tabs 60 adapted for insertion into splineway 52 of panels 36. Spaced
circular openings 62 are provided in body portion 58 between which is a
hook 64, the ends of which are fixed to body portion 58.
Tie 56 is shown to advantage in FIG. 12 and includes a body portion 66,
each end of which is bent to provide opposed upwardly extending tabs 68
and opposed downwardly extending tabs 70. Body portion 66 is provided with
a pair of spaced circular openings 72.
As shown to advantage in FIG. 1, base ties 54 are placed on slab 30 in
spaced relation to each other, following which exterior form panel 36,
either finished or unfinished, is placed thereon so that a tab 60 engages
splineway 52 of the panel. A second panel, either finished or unfinished,
comprising a part of the interior wall form is engaged with tab 60 at the
opposite end of base tie 54. This spaces the panels, comprising part of
the interior and exterior wall forms, a predetermined distance apart, such
as 6 or 8 inches, thereby forming a void therebetween. Ties 56 are then
placed on exterior and interior form panels to connect the same,
engagement being effected by inserting tabs 70 into splineway 52 of panels
36.
In accordance with the present invention, reinforcing rods are adapted to
be trained through openings 62 of ties 54 and openings 72 of ties 56.
These reinforcing rods may be of unitary construction, but, in order to
facilitate erection of the interior and exterior wall forms from one side
of the wall, and thereby avoid exterior scaffolding, it is preferable that
a plurality of short rods 74 be employed, the length of each rod being
substantially equal to the height of panels 36. In connection with rods
74, there are provided short tubular members 76 into which the ends of
superjacent rods 74 are placed, the tubular members being adapted to
extend through opening 52 of ties 54 and 72 of ties 56. Weld 78 are other
suitable stop means is located at approximately the midpoint of the
interior of the tubular members 76 to limit the degree of entry rods 74
into the same. Therefore, after panel 36, which is farthest removed from
the installer, is positioned on tabs 70 of ties 56, short rods 74 are
inserted into tubular members 76, following which the near panel 36 is
positioned in opposed relation to the first panel. In this way, the
reinforcing rods do not interfere with the installation of panels farthest
away from the installer.
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