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BACKGROUND OF THE INVENTION
The invention relates to arrangements of the construction of concrete walls
and particularly to construction of composite walls made of double or
multiple single walls with empty or usable space between single units, the
walls made of partially prefabricated and prefabricated parts.
In the conventional arrangement of erecting walls most of the construction
elements are made on the construction site while the erection of the wall
is carried on. It is known that this arrangement is costly and not too
efficient because preparation of molds, time for setting of the concrete
in the molds, or of mortar used in columns, beams, etc., cannot be
considered a really productive time, during which inevitable costs are
involved such as wages and material which become scrap after the
construction has been finished. Furthermore, the individual work performed
at the construction site is more expensive than the use of certain
prefabricated and standardized parts.
It is also known in the trade that a single concrete wall does not provide
adequate insulation when used in a building for housing and it normally
requires the application, in the inside face of the wall, of insulating
materials covered with drywall or the like that weaken the interior
surface of the wall and make it a fire hazard.
In other concrete wall applications, such as bearing walls, noise barriers,
retaining walls, anti-terrorist barriers, safety walls for correctional
institutions, core walls for reservoirs, training walls in river beds, and
the like, the construction process is generally cumbersome, slow and
costly for the reasons mentioned above.
On the other hand, the erecting of walls by using exclusively prefabricated
parts is subject to certain disadvantages practically insurmountable,
particularly both in transportation and handling, which usually require
special equipment. In addition, to withstand handling and transportation,
large prefabricated panels require more reinforcing steel integrated in
the panels than otherwise required for structural purposes alone.
This invention has been made to solve these and similar problems through
the use of composite double or multiple walls constructed with simple,
easy to handle elements.
SUMMARY
The invention consists in such novel features, construction arrangements,
combination of parts and improvements as may be shown and described in
connection with the apparatus herein disclosed by way of example only, and
as illustrative of a preferred embodiment. The advantages of the invention
are qualitative improvements of construction component parts, improved and
expeditious handling of such parts and timesaving prefabrication of some
of such parts and fabrication of other such parts in the construction site
itself in order to fabricate composite walls made of two or more single
walls, with pre-determinable separation between walls, resulting in a
construction of great structural strength and relatively light weight.
The composite wall is designed so as to absorb structurally its maximum
gravitational strength without the need of using reinforcing material
integrated into the concrete panels of which the walls are constructed.
The flanges in the columns of the wall, between which the panels are
inserted, are sufficient to keep the panels in their vertical position,
preventing the shear effect that otherwise might crack the panels
prematurely. The anchorage of the columns absorbs the forces perpendicular
to the wall.
The construction is of reduced cost because of the ability to use the space
between walls for placing insulation or sealant materials or concrete or
hazardous waste or any other material adequate to the purpose of each
specific construction.
A further object of the invention is to provide for molds for fabrication
of construction parts for composite walls, which molds are noncorrodible
and constitute integral members of such parts.
Furthermore, it is an object of the invention to provide facilities for
constructing of composite walls for substantially reducing the time
required for the constructing and erecting work of the wall.
Various further and more specific purposes, features and advantages will
clearly appear from the detailed description given below taken in
connection with the accompanying drawing which forms part of this
specification and illustrated merely by way of example one embodiment of
the device of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the following description and in the claims, parts will be identified by
specific names for convenience, but such names are intended to be as
generic in their application to similar parts as the art will permit. Like
reference characters denote like parts in the several figures of the
drawing, in which
FIG. 1 is a sideview of three wall panels in the superimposed position in
which they form a basic single wall section.
FIG. 2 is a sideview of a double wall with confined insulation, consisting
of two walls made of prefabricated panels of a size small enough not to
require reinforcement or special machinery for handling, and any type of
insulation as it may be required.
FIG. 3 is a front view of the composite double wall section shown in FIG.
2.
FIG. 4 is a front view of a composite double wall section in FIG. 3 with
columns and beam joining the same.
FIG. 5 is a section of the front view shown in FIG. 4 taken along the line
5--5.
FIGS. 6 and 7 are isometric views of portions of two different mold pieces
for fabricating or building columns.
FIG. 8 is an isometric view of a variation of mold piece shown in FIG. 7
used in columns that are provided with electrical outlets or switches.
FIG. 9 is a cross section of a composite double column showing four wall
panels and insulation joining the same.
FIG. 10 is a cross section of a composite double column showing five wall
panels and insulation joining the same. This arrangement occurs when a
composite double wall is combined with a single wall partition.
FIG. 11 is an isometric view of the metal piece used to connect adjacent
panels when regular column is not required or used.
FIG. 12 is an isometric view of metal pieces shown in FIG. 11 assembled to
be used in a composite double wall.
FIG. 13 shows the tying plate used to join the connecting metal pieces
shown in FIG. 11.
FIG. 14 is a cross section of a composite connecting metal piece shown in
FIG. 11, showing four wall panels and insulation joining the same.
FIG. 15 is a side view along line 15--15, FIG. 14, of the composite
connecting metal piece showing the assembly of the elements of the metal
parts.
FIGS. 16 and 17 are isometric views of portions of two different mold
pieces for fabricating of corner columns in the composite double wall
arrangement.
FIG. 18 is a cross section of a corner column in the composite double wall
arrangement.
FIG. 19 is an isometric view of a portion of the metal mold piece for
fabricating a tie beam on top of the composite double wall.
FIG. 20 is a cross section, along line 20--20 of FIG. 4, showing the tie
beam, the metal mold pieces, the wall panels, the confined insulation, and
the roof slab and metal decking in a composite double wall arrangement in
a building.
FIG. 21 is a cross section of the tie beam along line 21--21 of FIG. 4,
showing the tie beam, the metal mold pieces, the composite double column,
the confined insulation, and the roof slab and metal decking in a
composite double wall arrangement in a building.
FIG. 22 is a cross section of a plan view of the composite double wall
showing several of the elements presented in this description of the
drawing in their assembled position.
FIG. 23 is a section of the plan view shown in FIG. 22 taken along line
23--23.
FIG. 24 is a section of a composite double wall showing a post-tensioning
arrangement in the area of the wall where the connecting metal piece is
used.
FIG. 25 is a cross section of the post-tensioning arrangement taken along
line 25--25 of FIG. 24.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in more detail to the drawing illustrating a preferred
embodiment by which the invention may be realized, there is shown in FIG.
1 a portion of a single wall consisting of prefabricated panels 10 which
are conveniently fitted together. Each one of panels 10 is made of
concrete or the like hardenable noncombustible material which becomes
solid and strong after setting. The panel is manufactured by pouring
concrete in a metal mold so that the panel walls 11, after the hardening
of the concrete and the panel having been removed from the mold, have a
smooth finish making unnecessary the use of stucco or plaster before
painting them. The interlocking tongue and groove 12 and 13 arrangement of
the panels is positioned in a manner that, when panels 10 are assembled
for forming a wall, no water can penetrate through the seams, not even in
the case of a strong storm.
Shown in FIGS. 2 and 3 is a composite double wall made of panels 10 and
insulation 20 which is confined within the wall, becoming thus
incombustible.
FIG. 4 presents a front view of the composite wall showing the general
arrangement of panels 10, composite columns 90, beams 190 and roof 203.
FIG. 5 is a section along line 5--5 of FIG. 4 view showing the arrangement
of panels 10, insulation 20, and composite columns 90.
Shown in FIGS. 6, 7 and 8 are isometric views of molds 60, 70 and 80 for
parts of which columns are made, which can be composed for fabricating
various kinds of columns on the construction site. Mold piece 60 is the
basic element for the standard column and is made of extruded aluminum or
any other appropriate noncorroding material. Mold piece 70, made of the
same material, is manufactured in sections of a length substantially equal
to half the height of the column or any other convenient length consistent
with the requirements of the erection process as per following
description: Mold pieces 70 are the cover of the front side of the column.
They are put in their place by sliding them from the end of the column
along grooves 61 of mold piece 60. Thus loosely preassembled, the column
is placed in its final position in a predetermined place on the floor
slab. After the lower section of mold piece 70 rests by its edge on the
floor slab, the lower half of the column is filled with concrete by any
appropriate means, such as using a concrete pump, or gunite or the like.
To allow for the passage of the nozzle of the concrete-applying device so
that it can be positioned on top of the section in order to fill the lower
half of the column, the upper section of mold piece 70 is raised
temporarily along grooves 61. Once the lower part has been filled, the
upper section of mold piece 70 is released so that its lower edge rests
again on the upper edge of the first section. Then, the filling device is
brought to the top of the column and the upper half is filled in the same
manner as described for the lower section. The purpose of filling the
column in two or more separate states is to prevent the presence of
unfilled air pockets which, given the small section of the columns, would
be present should the column be filled from its top in one only operation.
A dowel imbedded in the floor slab and pointing upward where the column is
to rest, strengthens the union between column and foundation. Likewise, a
dowel is placed on top of the column to improve the joining of column and
tiebeam.
Mold piece shown in FIG. 6 has two pairs of flanges 62 symmetrically
located in its outer opposite sides, each pair forming a channel 63 where
wall panels will be inserted to forming the wall. When only two panels are
joining each mold 60 as it is the case in arrangement shown in FIG. 9,
cover mold piece 70 is placed with its flanges facing inwards in such a
manner that the flat surface 73 of the cover becomes the outer finish of
the column. The assembly of two columns with an appropriate fastening
device 91 becomes the composite column 90. The fastening device 91 is of a
length that will determine the separation between the single columns.
Shown in FIG. 10 is the arrangement provided for a third wall panel joining
the column as a part of a single wall meeting perpendicularly the
composite double wall. In this arrangement, cover mold 70 is placed with
flanges 71 facing outwards in such a way that the third wall panel 10 is
inserted in the channel 72 formed by the pair of flanges 71 of the cover
piece 70.
Shown in FIG. 8 is cover mold piece 80 which is identical to cover mold
piece 70 except for a prepunched opening 82 provided in cover mold 80
where the electrical box 83 for the electrical outlets and switches will
be attached. Cover piece 80 is used in columns provided with electrical
conduits and boxes 83. The installation procedure for cover mold piece 80
is the same as for cover mold piece 70. When sections of cover mold 80 are
slid downwards along grooves 62 of mold piece 60, the electrical boxes and
conduit 83 have already been fastened to mold 80 between flanges 81. When
concrete is poured to fill the column section where cover mold piece 80 is
installed, the electric box and conduit remain cast in their final
position in the construction.
FIG. 11 shows an isometric projection of piece 110, made of noncorrodible
metal or any other appropriate strong noncorrodible material, which is
used to join panels 10 when no standard composite column 90 is needed for
structural purposes. Piece 110 is I-shaped forming two opposite channels
111 where panels 10 are inserted. The flanges 113 forming the channels
have prepunched openings 112 in whatever quantities and positions are
required in each specific arrangement, to allow for the passage of
connecting plate 120 that ties two or more I-shaped pieces 110 for the
assembling of composite walls, as shown in FIG. 12. Connecting plate 120,
seen in FIG. 13, is fastened to the bottom of the channel 111 of piece 110
allowing for setting variable and predetermined separations between pieces
110, in accordance with the specifications of the composite wall to be
constructed.
FIG. 14 is a plan section of a composite double wall illustrating the
arrangement of metal pieces 110, connecting plate 120, panels 10, and
insulation 20. FIG. 15 is a section along line 15--15 of FIG. 14. Plates
120 are spaced at different heights, as shown in FIG. 15, in accordance
with the specifications of the composite wall.
FIGS. 16 and 17 present isometric views of mold pieces 160, 110 and 170
used for fabricating the corner column in the composite double wall
arrangement. Mold pieces 110 and 170 are made of extruded aluminum or
other appropriate noncorrodible material. Mold piece 160 is made of
galvanized steel or other appropriate noncorrodible material. Piece 160 is
bent at a 90 degree angle at its outside corner 161. Its edges 162 are
bent at approximately 45 degree angles. Mold piece 160 may have lengthwise
ribs 163 in the two sides for added strength and rigidity. The column mold
ensemble, as shown in FIG. 18, is completed with two mold pieces 110 and
one mold piece 170 tied together by means of plates 120. The edges of mold
piece 160 are fastened 182 to flanges 113 of mold pieces 110 to complete
the mold, or shell, of the corner column. The mold is then placed in its
final position in the wall under construction; panels 10 are slid into
position, and insulation 20 (or other appropriate material) is also
introduced in the composite wall between panels. Reinforcing and anchorage
steel 183 is placed within the empty column, and concrete or other
appropriate strong hardenable filling material is poured in. Once the
concrete has set, metal molds 110, 160 and 170 remain as an integral part
of the column.
Tiebeams on composite double walls are fabricated by using a mold as shown
in isometric projection FIG. 19, and further illustrated in FIGS. 20 and
21. Mold piece 190 has the appropriate length and width and consists of a
substantially L-shaped form made of noncorrodible material, having
downward flanges 191 and 192 creating a recess where panels 10 are
inserted, as shown in FIG. 20. Two molds 190 facing each other are placed
on top of panels 10, as it is depicted in FIG. 20 and are kept in place by
any appropriate mechanical means, prior to placing reinforcing steel rods
201 and to pouring concrete in the U-shaped trough formed by the two mold
pieces 190. In practice, when erecting a building with concrete roof, the
tiebeam is filled with concrete 202 when concrete is poured in to
fabricate roof slab 203. Once the concrete has set, molds 190 become an
integral permanent part of the beam.
FIG. 21 illustrates the manner in which the tiebeam becomes integrated with
the composite column 90 upon pouring the concrete to fabricate the beam.
Mold piece 190 is provided with prepunched openings 193 spaced in such a
way as to coincide with the top of the columns 90. The dowels 211,
embodied into the column 90 pass through openings 193. When concrete is
poured to form the beam, it descends through opening 193 thus filling the
empty space 212 between the top of column 90 and the base of mold piece
190. Dowels 211 act as the tying link between beam and column.
FIGS. 22 and 23 further illustrate the position and function of some of the
elements described in this section.
FIG. 24 shows a cross-section of a post-tensioned composite double wall
assembly used in combination with connecting pieces 110. This embodiment
is applied when the double wall section is intended to bear permanent
overloads and there are no other specific reasons to use the composite
column 90 shown in FIG. 9.
FIG. 25 shows a plan section of said arrangement in the composite double
wall along line 25--25 of FIG. 24.
The post-tensioning rod 240 is bent at its lower end 241 and is imbedded in
the floor slab thus providing for a secure anchorage. Rod 240 is
positioned between the two single wall panels and as near as feasible to
tie-up plate 120. The top end of rod 240 is threaded 243 so that nut 244
can be inserted downward thus tightening plate 245 against the upper
horizontal surfaces of beam mold pieces 190 which, in turn, exert a
downward pressure against wall panels 10. Once nut 244 has reached its
lowest point, the tiebeam is completed by pouring concrete in.
The remaining elements of this arrangement are as shown and described in
FIG. 14. The elements used in the post-tensioning arrangement can be a
steel rod, as described in this preferred embodiment, or any other of the
usual elements available in the marketplace for this or similar purposes.
While this invention has been described and illustrated with respect to a
certain example which gives satisfactory results, it will be understood by
those skilled in the art after understanding the principle of this
invention, that various other changes and modifications may be made
without departing from the spirit and scope of the invention.
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