Static structures (e.g. – buildings) – Footing or foundation type – For a wall
Reexamination Certificate
1999-02-01
2001-06-12
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Footing or foundation type
For a wall
C052S250000, C052S293300, C052S169900, C052S742100, C249S019000, C249S022000, C249S034000
Reexamination Certificate
active
06244005
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to the construction industry. More particularly it addresses a modular wall system based upon precast concrete panels and accessory elements that may be erected on a site to provide a concrete wall suitable for a building.
BACKGROUND TO THE INVENTION
Construction techniques based upon the use of precast panels for forming walls are known. This includes panels which are tipped-up for positioning on a foundation and then fastened together by various means.
A number of prior art references that describe precast concrete wall panels are referred-to in U.S. Pat. No. 5,864,999, the contents of which are adopted herein by reference. None of those references, nor the prior art cited with respect to U.S. Pat. No. 5,864,999, show a precast wall panel with rearwardly extending flange portions having reinforcing members protruding for embedment in a linear footing member having a U-shaped trough filled with concrete grout.
The aforesaid invention presupposes that the flanges on the precast panel are precast with the panel, or are precast to be fitted to the panel at the job site. The present invention is premised on the formation of such flanges at the job site, rather than by precasting in advance.
As a further feature of the prior invention the flanged wall panels may be surmounted by a precast lintel having a grout-receiving trough and pierced openings to permit reinforcing members to extend upwardly from the flanges through the lintel bottom for embedment in the grout or anchoring filler. The present invention is based upon casting the lintel pieces on-site.
A need exists for an improved system for supporting and fastening precast wall panels in position. This invention addresses such a need by providing a modular wall structure that can quickly be erected on a job site providing a full load-bearing and weather-tight wall.
The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a precast construction member has a form bonded thereto that contains an open interior for subsequent filling with a binder material such as concrete. This form, when applied to a flat panel suited for use as a wall element can be shaped in a longitudinal format that will produce a flange on the panel, once the open hollow interior of the form is filled with the binder material.
By a further feature, the form may provide an open, horizontal trough-like volume along a surface of the construction member which volume is filled with binder to provide a stiffening support to the member. In the case of a wall panel, a lintel can be cast along its upper edge.
The invention in another aspect is directed to a modular wall system comprising:
(a) a wall panel having a wall portion and a form mounted thereon for casting a outwardly extending flanged portion;
(b) a footing member having a footing trough defined by first and second trough sidewalls positioned beneath and supporting said wall panel; and
(c) lower coupling means protruding downwardly from the lower ends of each of the forms of the flanged portions of said panels;
wherein the wall portion of each of said wall panel is dimensioned to be placed to extend along the top of the first of the trough side walls of said footing trough, with the form for casting the flanged portion of the wall panel extending outwardly from said panel across the footing trough in order to subsequently support said wall panel when erected in an upright position and when the lower coupling means is imbedded in a binder or grout such as concrete within the footing trough when the form for casting the flange and the footing trough are filled with binder.
Preferably, the form for the flange is of sheet material, e.g. galvanized steel or plastic which is fastened, as by embedment, to the precast wall panel. To improve coupling between this form and the binder with which it is eventually to be filled, portions of the wall of the form may be depressed or deformed inwardly to provide dimples or tabs to be embedded within the binder when the binder is poured into the form.
The lower coupling means may consist of reinforcing bar that protrudes upwardly into the interior volume sufficiently to ensure that it is properly anchored therein when the form is filled with binder. Such reinforcing bar is preferably tied or hooked at its lower end to a similar bar laid in the footing trough before it is filled with binder. Once the form and footing trough are filled with binder, the wall panel will be anchored in place.
By a further feature of the invention a lintel member may be provided for positioning along the tops of said panel member, overlying the wall and flanged portions, the lintel member having a lintel trough formed therein with perforations formed along the lower surface of the lintel trough. Upper coupling means may then protrude upwardly from the upper ends of each of the panels, preferably from the forms for the flanged portions, for penetration into the lintel trough through the perforations. Such upper coupling means are then imbedded in a grout or binder, such as concrete, when the lintel trough is filled with binder.
Optionally, a panel may have a second or more longitudinal form for casting second or additional flanged portions positioned for overlying the footing trough when the panel is erected into an upright position. This provides a panel of multiples of “F”-shaped cross-section.
Instead of providing a precast lintel, the precast panel of the invention may have a second form, a lintel form, attached near or along the upper face portion of the panel. This lintel form may be of sheet metal that is coupled to the panel, as by being embedded therein along its lower edge. This lintel form then extends upwardly and outwardly between the flange forms to provide a receiving trough to support binder, such as concrete. In this manner a cast-in-place lintel may be created spanning the top of the precast panel.
Again, for strength, reinforcing bar may be used as the upper coupling means, such bar extending up into the interior volume of the lintel from the core of the flange forms. This upper coupling means is then anchored in place when the lintel trough and flange form are both filled with binder.
As with the lower coupling means, the upper coupling means preferably engages with horizontal lintel reinforcing imbedded within the binder being used to fill the lintel trough. The reinforcing, such as steel bars, present within such troughs ideally extends between adjacently located footings and/or lintel members.
The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
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French David J.
Friedman Carl D.
Yip Winnie
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