US20120167504A1 - Precast insulated concrete wall assembly - Google Patents

Precast insulated concrete wall assembly Download PDF

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Publication number
US20120167504A1
US20120167504A1 US13/287,705 US201113287705A US2012167504A1 US 20120167504 A1 US20120167504 A1 US 20120167504A1 US 201113287705 A US201113287705 A US 201113287705A US 2012167504 A1 US2012167504 A1 US 2012167504A1
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United States
Prior art keywords
concrete
studs
stud
end caps
wall panel
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Abandoned
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US13/287,705
Inventor
John McKinney
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Individual
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Individual
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Application filed by Individual filed Critical Individual
Priority to US13/287,705 priority Critical patent/US20120167504A1/en
Publication of US20120167504A1 publication Critical patent/US20120167504A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/382—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of concrete or other stone-like substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/12—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of wood, e.g. with reinforcements, with tensioning members
    • E04C3/125—End caps therefor

Definitions

  • the present invention generally relates to a prefabricated concrete wall, and more specifically, to such a wall with a prefabricated concrete exterior with a structural skeleton formed from wood or composite framing lumber.
  • a prefabricated concrete wall panel may comprise a concrete top beam; a concrete bottom beam; studs interposed between the top and bottom beams; a concrete exterior interposed between the top and bottom beams; and protective end caps on one or more of the studs interposed between the studs and the top and bottom beams.
  • protective end caps for studs of a precast concrete wall panel with integral concrete beams may comprise a water impervious body configured to enclose an end of the stud and preclude direct contact between concrete and the stud within the integral concrete beams.
  • a method for producing precast wall panels may comprise the steps of applying protective end caps to end portions of studs, leaving mid portions of the studs unenclosed by the end caps; placing the studs in a pouring jig with spaces between the studs; applying covering over the mid potions portions of the studs and mid portions of the spaces between the studs; and pouring concrete onto the covering and around the protective end caps.
  • FIG. 1 is a perspective view of a precast wall panel in accordance with an embodiment of the invention
  • FIG. 2 is a partial sectional view of the wall panel of FIG. 1 taken along the line 2 - 2 ;
  • FIG. 3 is a perspective view of a protective end cap in accordance with an embodiment of the invention.
  • FIG. 4 is a partial cross sectional view of the wall panel of FIG. 2 taken along the line 4 - 4 ;
  • FIG. 5 is a partial cross sectional view of the wall panel of FIG. 1 taken along the line 5 - 5 ;
  • FIG. 6 is a partial cross sectional view of the wall panel of FIG. 1 taken along the line 5 - 5 ;
  • FIG. 7 is a partial cross sectional view of the wall panel of FIG. 1 taken along the line 7 - 7 ;
  • FIGS. 8 , 9 and 10 are elevation views of alternate embodiments of protective end caps in accordance with the invention.
  • embodiments of the present invention generally provide a wall system that uses conventional framing lumber incorporated within concrete top and bottom beams that have compressive and tensile properties.
  • Protective caps may be placed over the top and bottom of each conventional framing stud to protect the ends of the studs from direct contact with concrete of top and bottom beams.
  • a wall panel 10 may comprise conventional wood or composite studs 11 (referred to herein generally as studs 11 ), end protector caps 12 , intermediate sheeting 14 , blocks 15 , horizontal rebar 16 , wire reinforcement 17 , intermediate reinforcement 18 , a bottom beam 19 , a top beam 20 , and exterior wall concrete 21 .
  • Curved rebar 30 may be shaped for attachment to the horizontal rebar 16 and the wire reinforcement 17 .
  • the wall panel 10 may be constructed in the following steps. Each end of every stud 11 with may be enclosed with one of the end protective caps 12 , leaving a mid section 11 - 1 of the stud unenclosed.
  • the studs 11 may be aligned in a framing and pouring jig (not shown) with conventional spacing between the studs.
  • Intermediate sheeting 14 may be attached to each stud 11 .
  • Blocks 15 may be added between the studs 11 at the top and bottom of the wall panel 10 to prevent concrete from flowing into spaces between the studs 11 .
  • Horizontal rebar 16 may be installed as required into rebar cutouts 27 of end protector caps 12 .
  • Curved rebar 30 may be installed as required.
  • Horizontal rebar 16 may be attached to or through the intermediate clips 18 .
  • Wire reinforcement may be attached onto the horizontal rebar 16 . Concrete may be poured to create the top and bottom beam 19 and 20 and exterior wall concrete 21
  • an exemplary embodiment of the protective end cap 12 may comprise a body 13 with an opening 24 into which the stud 11 may be inserted and a tab 25 for engaging with a corresponding groove 11 - 2 formed on the stud 11 .
  • the end cap 12 may also comprise a bottom fin 26 with rebar cutouts 27 , a back fin 28 with rebar cutouts 29 and side fins 30 which may hold the blocks 15 in place while concrete is poured during construction of the wall panel 10 .
  • the tab 25 may be formed at an angle relative to a bottom plane of the wall panel 10 , i.e., not orthogonal to an axis of the stud 11 . Consequently, interaction of the tab 25 and the groove in the stud 11 may effectively lock the cap 12 and the stud 11 into the wall panel 10 .
  • FIG. 8 another exemplary embodiment of a protective cap 12 D is illustrated.
  • the cap 12 D may differ from the cap 12 of FIG. 3 in that the cap 12 D may have a sloped bottom 40 . It may be seen (in FIG. 8 ) that a portion of the concrete of the bottom beam 19 may fill in a space adjacent the sloped bottom 40 thus effectively locking the cap 12 D and the stud 11 into the wall panel 10 .
  • an end cap such as an end cap 12 B or 12 C, shown in FIGS. 9 and 10 may be provided with a chamfer 42 . Concrete may fill in a space adjacent the chamfer 42 thus effectively locking the end cap 12 C and the stud 11 into the wall panel 10 .
  • the protective end caps may be constructed from water impervious material (e.g., injection molded plastic or metal) so that they are tolerant of long-term contact with concrete.
  • the end caps may form a permanent protective barrier between the studs 11 and concrete within the wall panel 10 .

Abstract

A prefabricated concrete wall panel may include a concrete top beam, a concrete bottom beam, studs interposed between the top and bottom beams and a concrete exterior interposed between the top and bottom beams. Water-impervious protective end caps may be placed on ends of the studs to preclude contact between the studs and the concrete of the beams.

Description

    RELATED APPLICATIONS
  • This application claims the benefit of U.S. Provisional Patent Application No. 61460506 filed on Jan. 4, 2011.
    • BACKGROUND OF THE INVENTION
  • The present invention generally relates to a prefabricated concrete wall, and more specifically, to such a wall with a prefabricated concrete exterior with a structural skeleton formed from wood or composite framing lumber.
  • Various prefabricated and precast wall panels for construction of building foundations and structures are known. Typically such walls may be constructed with concrete or metal studs with sheet insulation sandwiched between concrete layers. Wood or composite studs, with their inherent desirable features, have not been used in such walls because direct contact with wet concrete during fabrication may have a deleterious effect on studs.
  • As can be seen, there is a need for a system of constructing precast insulated concrete walls with studs.
    • SUMMARY OF THE INVENTION
  • In one aspect of the present invention, a prefabricated concrete wall panel may comprise a concrete top beam; a concrete bottom beam; studs interposed between the top and bottom beams; a concrete exterior interposed between the top and bottom beams; and protective end caps on one or more of the studs interposed between the studs and the top and bottom beams.
  • In another aspect of the present invention, protective end caps for studs of a precast concrete wall panel with integral concrete beams may comprise a water impervious body configured to enclose an end of the stud and preclude direct contact between concrete and the stud within the integral concrete beams.
  • In still another aspect of the invention, a method for producing precast wall panels may comprise the steps of applying protective end caps to end portions of studs, leaving mid portions of the studs unenclosed by the end caps; placing the studs in a pouring jig with spaces between the studs; applying covering over the mid potions portions of the studs and mid portions of the spaces between the studs; and pouring concrete onto the covering and around the protective end caps.
  • These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a perspective view of a precast wall panel in accordance with an embodiment of the invention;
  • FIG. 2 is a partial sectional view of the wall panel of FIG. 1 taken along the line 2-2;
  • FIG. 3 is a perspective view of a protective end cap in accordance with an embodiment of the invention;
  • FIG. 4 is a partial cross sectional view of the wall panel of FIG. 2 taken along the line 4-4;
  • FIG. 5 is a partial cross sectional view of the wall panel of FIG. 1 taken along the line 5-5;
  • FIG. 6 is a partial cross sectional view of the wall panel of FIG. 1 taken along the line 5-5;
  • FIG. 7 is a partial cross sectional view of the wall panel of FIG. 1 taken along the line 7-7;
  • FIGS. 8, 9 and 10 are elevation views of alternate embodiments of protective end caps in accordance with the invention.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
  • Various inventive features are described below that can each be used independently of one another or in combination with other features.
  • Broadly, embodiments of the present invention generally provide a wall system that uses conventional framing lumber incorporated within concrete top and bottom beams that have compressive and tensile properties. Protective caps may be placed over the top and bottom of each conventional framing stud to protect the ends of the studs from direct contact with concrete of top and bottom beams.
  • Referring now to the Figures it may be seen that in an exemplary embodiment, a wall panel 10 may comprise conventional wood or composite studs 11 (referred to herein generally as studs 11), end protector caps 12, intermediate sheeting 14, blocks 15, horizontal rebar 16, wire reinforcement 17, intermediate reinforcement 18, a bottom beam 19, a top beam 20, and exterior wall concrete 21. Curved rebar 30 may be shaped for attachment to the horizontal rebar 16 and the wire reinforcement 17.
  • The wall panel 10 may be constructed in the following steps. Each end of every stud 11 with may be enclosed with one of the end protective caps 12, leaving a mid section 11-1 of the stud unenclosed. The studs 11 may be aligned in a framing and pouring jig (not shown) with conventional spacing between the studs. Intermediate sheeting 14 may be attached to each stud 11. Blocks 15 may be added between the studs 11 at the top and bottom of the wall panel 10 to prevent concrete from flowing into spaces between the studs 11. Horizontal rebar 16 may be installed as required into rebar cutouts 27 of end protector caps 12. Curved rebar 30 may be installed as required. Horizontal rebar 16 may be attached to or through the intermediate clips 18. Wire reinforcement may be attached onto the horizontal rebar 16. Concrete may be poured to create the top and bottom beam 19 and 20 and exterior wall concrete 21
  • Referring now to FIG. 3, an exemplary embodiment of the protective end cap 12 may comprise a body 13 with an opening 24 into which the stud 11 may be inserted and a tab 25 for engaging with a corresponding groove 11-2 formed on the stud 11. The end cap 12 may also comprise a bottom fin 26 with rebar cutouts 27, a back fin 28 with rebar cutouts 29 and side fins 30 which may hold the blocks 15 in place while concrete is poured during construction of the wall panel 10. The tab 25 may be formed at an angle relative to a bottom plane of the wall panel 10, i.e., not orthogonal to an axis of the stud 11. Consequently, interaction of the tab 25 and the groove in the stud 11 may effectively lock the cap 12 and the stud 11 into the wall panel 10.
  • Referring now to FIG. 8, another exemplary embodiment of a protective cap 12D is illustrated. The cap 12D may differ from the cap 12 of FIG. 3 in that the cap 12D may have a sloped bottom 40. It may be seen (in FIG. 8) that a portion of the concrete of the bottom beam 19 may fill in a space adjacent the sloped bottom 40 thus effectively locking the cap 12D and the stud 11 into the wall panel 10. Alternatively an end cap such as an end cap 12B or 12C, shown in FIGS. 9 and 10 may be provided with a chamfer 42. Concrete may fill in a space adjacent the chamfer 42 thus effectively locking the end cap 12C and the stud 11 into the wall panel 10.
  • The protective end caps may be constructed from water impervious material (e.g., injection molded plastic or metal) so that they are tolerant of long-term contact with concrete. The end caps may form a permanent protective barrier between the studs 11 and concrete within the wall panel 10.
  • It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims (10)

1. A prefabricated concrete wall panel comprising:
a concrete top beam;
a concrete bottom beam;
studs interposed between the top and bottom beams;
a concrete exterior interposed between the top and bottom beams; and
protective end caps on one or more of the studs interposed between the studs and the top and bottom beams.
2. The wall panel of claim 1 wherein the end caps comprise:
a water impervious body configured to enclose an end of the stud;
fins attached to exterior surfaces of the body; and
one or more rebar supports formed in one or more of the fins.
3. The wall panel of claim 1 wherein the protective end caps are plastic.
4. The wall panel of claim 1 further comprising rebar supported by the protective end caps.
5. Protective end caps for studs of a precast concrete wall panel with integral concrete beams, the end caps comprising a water impervious body configured to enclose an end of the stud and preclude direct contact between concrete and the stud within the integral concrete beams.
6. The protective end cap of claim 5 further comprising a tab configured to engage with a groove in the stud, the tab being oriented to be not orthogonal to an axis of the stud so that interaction of the tab and the groove in the stud lock the stud into the wall panel when the end cap is encased in the concrete beam.
7. The protective end cap of claim 5 further comprising a bottom having a chamfer, the chamfer being engageable with a portion of the concrete beam to lock the stud into the wall panel when the end cap is encased in the concrete beam.
8. The protective end cap of claim 5 further comprising:
fins attached to exterior surfaces of the body; and
one or more rebar supports formed in one or more of the fins.
9. A method for producing precast wall panels comprising the steps of:
applying protective end caps to end portions of studs, leaving mid portions of the studs unenclosed by the end caps;
placing the studs in a pouring jig with spaces between the studs;
applying covering over the mid potions of the studs and mid portions of the spaces between the studs; and
pouring concrete onto the covering and around the protective end caps.
10. The method of claim 9 further comprising the step of:
attaching rebar to the protective end caps prior to pouring the concrete,
wherein the step of pouring concrete includes pouring concrete around the rebar so that reinforced beams are produced in the wall.
US13/287,705 2011-01-04 2011-11-02 Precast insulated concrete wall assembly Abandoned US20120167504A1 (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
US201161460506P 2011-01-04 2011-01-04
US13/287,705 US20120167504A1 (en) 2011-01-04 2011-11-02 Precast insulated concrete wall assembly

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120233950A1 (en) * 2011-03-17 2012-09-20 Cemwall Systems Concrete wall systems and methods and spacers therefor
US20180347191A1 (en) * 2017-06-01 2018-12-06 9360-4742 Quebec Inc. Prefabricated concrete slab floor and method of fabricating the same
US10870990B1 (en) * 2019-05-10 2020-12-22 Peter Baruch Mueller Closed panel building systems

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US1008227A (en) * 1910-12-14 1911-11-07 Clarence G Welsz Portable fence-post.
US3774362A (en) * 1972-05-17 1973-11-27 Univiron Corp Structural corner post and framing system for buildings
US4742655A (en) * 1985-03-29 1988-05-10 Kabe Industrier Ab Device in concrete structures
SU1557330A1 (en) * 1987-01-07 1990-04-15 Всесоюзный научно-исследовательский и проектно-конструкторский угольный институт "КузНИУИ" Shield for mining thick steep beds
US5325651A (en) * 1988-06-24 1994-07-05 Uniframes Holdings Pty. Limited Wall frame structure
US5623804A (en) * 1995-01-06 1997-04-29 The Burke Group Concrete structure having load transferring insert and method for making same
US5625993A (en) * 1995-01-06 1997-05-06 The Burke Group Concrete structure having load transferring insert and method for making same
US5697196A (en) * 1992-08-11 1997-12-16 Unique Development Corporation Element based foam and concrete wall construction and method and apparatus therefor
US5819489A (en) * 1996-06-11 1998-10-13 Mckinney; John W. Pre-formed building studs and construction form system
US20040088934A1 (en) * 2002-11-09 2004-05-13 Don Kain Method and apparatus for protecting a substrate
US20050076600A1 (en) * 2003-10-08 2005-04-14 Moody Donald R. Thermal wall system
US6918213B2 (en) * 2002-04-29 2005-07-19 Stallion Fence Accessories Plastic pergola end caps of extended length
US20050166533A1 (en) * 2004-01-09 2005-08-04 Leroy Strickland Residential construction method and apparatus
US20050229515A1 (en) * 2004-03-25 2005-10-20 Ruston Wilbur R Liquid impervious apparatus for wallboard
US7076923B2 (en) * 2001-09-06 2006-07-18 Seldon William G Simulated exposed roof rafter end
US7107727B2 (en) * 2003-04-10 2006-09-19 Matthew James Nelsen Protective beam and joist cap
US20070119108A1 (en) * 2005-11-14 2007-05-31 Downard Evan M End cap for wood frame construction
US20080110121A1 (en) * 2006-11-13 2008-05-15 Phil Edmends Joist end cap
US20090047074A1 (en) * 2007-08-13 2009-02-19 Meyer John W Center beam connection assembly for temporary shoring
US7617648B2 (en) * 2003-08-25 2009-11-17 Nucon Steel Corporation Thermal framing component
US20100107549A1 (en) * 2008-11-05 2010-05-06 Tony Ingram Exterior Rafter And Beam Covering Sleeve

Patent Citations (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1008227A (en) * 1910-12-14 1911-11-07 Clarence G Welsz Portable fence-post.
US3774362A (en) * 1972-05-17 1973-11-27 Univiron Corp Structural corner post and framing system for buildings
US4742655A (en) * 1985-03-29 1988-05-10 Kabe Industrier Ab Device in concrete structures
SU1557330A1 (en) * 1987-01-07 1990-04-15 Всесоюзный научно-исследовательский и проектно-конструкторский угольный институт "КузНИУИ" Shield for mining thick steep beds
US5325651A (en) * 1988-06-24 1994-07-05 Uniframes Holdings Pty. Limited Wall frame structure
US5697196A (en) * 1992-08-11 1997-12-16 Unique Development Corporation Element based foam and concrete wall construction and method and apparatus therefor
US5623804A (en) * 1995-01-06 1997-04-29 The Burke Group Concrete structure having load transferring insert and method for making same
US5625993A (en) * 1995-01-06 1997-05-06 The Burke Group Concrete structure having load transferring insert and method for making same
US5819489A (en) * 1996-06-11 1998-10-13 Mckinney; John W. Pre-formed building studs and construction form system
US7076923B2 (en) * 2001-09-06 2006-07-18 Seldon William G Simulated exposed roof rafter end
US6918213B2 (en) * 2002-04-29 2005-07-19 Stallion Fence Accessories Plastic pergola end caps of extended length
US20040088934A1 (en) * 2002-11-09 2004-05-13 Don Kain Method and apparatus for protecting a substrate
US7107727B2 (en) * 2003-04-10 2006-09-19 Matthew James Nelsen Protective beam and joist cap
US7617648B2 (en) * 2003-08-25 2009-11-17 Nucon Steel Corporation Thermal framing component
US20050076600A1 (en) * 2003-10-08 2005-04-14 Moody Donald R. Thermal wall system
US20050166533A1 (en) * 2004-01-09 2005-08-04 Leroy Strickland Residential construction method and apparatus
US20050229515A1 (en) * 2004-03-25 2005-10-20 Ruston Wilbur R Liquid impervious apparatus for wallboard
US20070119108A1 (en) * 2005-11-14 2007-05-31 Downard Evan M End cap for wood frame construction
US20080110121A1 (en) * 2006-11-13 2008-05-15 Phil Edmends Joist end cap
US20090047074A1 (en) * 2007-08-13 2009-02-19 Meyer John W Center beam connection assembly for temporary shoring
US20100107549A1 (en) * 2008-11-05 2010-05-06 Tony Ingram Exterior Rafter And Beam Covering Sleeve

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120233950A1 (en) * 2011-03-17 2012-09-20 Cemwall Systems Concrete wall systems and methods and spacers therefor
US20180347191A1 (en) * 2017-06-01 2018-12-06 9360-4742 Quebec Inc. Prefabricated concrete slab floor and method of fabricating the same
US10870990B1 (en) * 2019-05-10 2020-12-22 Peter Baruch Mueller Closed panel building systems
US20210071421A1 (en) * 2019-05-10 2021-03-11 Peter Mueller Closed panel building systems

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