CA1086090A - Building system and method - Google Patents
Building system and methodInfo
- Publication number
- CA1086090A CA1086090A CA274,624A CA274624A CA1086090A CA 1086090 A CA1086090 A CA 1086090A CA 274624 A CA274624 A CA 274624A CA 1086090 A CA1086090 A CA 1086090A
- Authority
- CA
- Canada
- Prior art keywords
- panels
- shell
- concrete
- building
- wire mesh
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/166—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with curved surfaces, at least partially cast in situ in order to make a continuous concrete shell structure
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/35—Extraordinary methods of construction, e.g. lift-slab, jack-block
- E04B1/3505—Extraordinary methods of construction, e.g. lift-slab, jack-block characterised by the in situ moulding of large parts of a structure
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B2001/3217—Auxiliary supporting devices used during erection of the arched structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B2001/3258—Arched structures; Vaulted structures; Folded structures comprised entirely of a single self-supporting panel
- E04B2001/3264—Arched structures; Vaulted structures; Folded structures comprised entirely of a single self-supporting panel hardened in situ
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B2001/327—Arched structures; Vaulted structures; Folded structures comprised of a number of panels or blocs connected together forming a self-supporting structure
- E04B2001/3276—Panel connection details
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B2001/327—Arched structures; Vaulted structures; Folded structures comprised of a number of panels or blocs connected together forming a self-supporting structure
- E04B2001/3288—Panel frame details, e.g. flanges of steel sheet panels
Abstract
"BUILDING SYSTEM AND METHOD"
ABSTRACT
A system of constructing buildings by connecting together expanded plastic panels with reinforcing strips bonded thereto and wire mesh attached to the exterior surfaces thereof upon a foundation with at least a portion of the panels having a curved configuration to maximize structural strength of the combination of panels. Concrete is applied to the exterior of the combined panels with the wire mesh then forming reinforcing in the resultant concrete wall upon the panels and the interior is coated with plaster to form a low cost structure with very good insulating properties,
ABSTRACT
A system of constructing buildings by connecting together expanded plastic panels with reinforcing strips bonded thereto and wire mesh attached to the exterior surfaces thereof upon a foundation with at least a portion of the panels having a curved configuration to maximize structural strength of the combination of panels. Concrete is applied to the exterior of the combined panels with the wire mesh then forming reinforcing in the resultant concrete wall upon the panels and the interior is coated with plaster to form a low cost structure with very good insulating properties,
Description
20 ~ BACKGROUND OF INVENTION
;~ 22 -. secause of the high cost of constructing conventional 24 wood frame buildings of small and medium size and steel and ~ 25 concreLe buildings of larger size, there have been many attempts 26 to manufacture prefabricated structures~ Commonly such :~ 27 structures include some type of wall modules which can be manu~
;~ 22 -. secause of the high cost of constructing conventional 24 wood frame buildings of small and medium size and steel and ~ 25 concreLe buildings of larger size, there have been many attempts 26 to manufacture prefabricated structures~ Commonly such :~ 27 structures include some type of wall modules which can be manu~
2~ factllred in a plant and joined together. at construction sites.
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''. ' lV86090 1 The advanta~e oE mass produ~ing buildings or building modules are 2 well recognized; however, this type of construc~ion has had only
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''. ' lV86090 1 The advanta~e oE mass produ~ing buildings or building modules are 2 well recognized; however, this type of construc~ion has had only
3 Limited acceptance. An alternative to the foregoing has been ~he 41 so-called balloon building wherein a rubber bag or the like is in1ated upon a concrete slab to comprise an inner form upon which 61 concrete is sprayed. After setting of the concrete the bag is 71 deE:Lated and removedO While this approach to building structures 81 overcomes many prior art problems, there are numerous limitations 9¦ ~hich are disad~antageous.
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11¦ The present invention provides a substantial departure 12¦ ~r~m noxmal. building construction in that prefabricated insulatin~
~i 13¦ panels are joined together to form a rigid structure upon which 141 concrete or the like is applied to o~m a low cost structure - 15¦ ha~ing ver~ good insulating properties.
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18 ¦ SUMMARY OF :I:NVENT:l:ON
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20 ¦ q.'he present in~ention employs preormed panels adapted 21 ¦to be joined together at a construction site to form the shell of ~2 la bui:Ld:Lny or the li~e~ These panels have an expanded plastic ~3 ¦cor:e w;.th reinforcing strips on the front and back surEaces ~4 ¦ thexeo~. Pre~erably the panels are Eormed oE ex.panded poly-st~retle ha~ing a substantial ~ensity, as of the order of 2 lbs.
~6¦ pe~ cubic feet with thin metal strips bonded to the front and back 271 surfaces at least along the edges thereo and extending in part 28¦ ~rom two edges on the front face of each panelO The strip .' 311 '`` 32 ,~
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~ i 1¦ extensions are adapted to overlap strips of adjacent panels ~or 21 attaching the panels toge-thex. The panels employed in the buildiny system hereof have a con~ex outer sur~ace and are formed ¦ with a predetermined plurality of different sizes and configura-51 tions to fit together into a variety of building configurations.
61 Upon the outer surface of each panel there is mounted a wire mesh 71 in spaced rela-tion to the outer surface and contiguous panèls may be joined together by the use o sheet metal screws through over-9¦ lapping metal reinorcing stripsO
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The building s~stem hereof provides for the attachment 12¦ together of a plurality of predetermined panels as~described above 13¦ to form a shell of a resultant building structure. The panels ~ may be placed upon a concrete slab foundation, for example, and 15¦ the bottom panels affixed thereto. The present invention employs 16¦ panels tha~ aré curved in a single direction or two mutually 17¦ perpendicular directions which in combination form convex 18¦ exterior building surfaces to maximize the structural strength of ~9¦ -the shell. ~ ~
. 201 2,1 A~ter erection Oe the shel~, concrete or some substitute ~21 there~o~ is applied to the e~terior thereo as by spraying or ?3¦ tr~weling -thereon. The applled concrete envelopes the wire mesh 2~1 on -tho ex~erior o~ th~ shell panels and there is thus produced a 251 rein~orced concrete building having insulating panels on the ; ¦ interlox o~ the concrete walls. The inside o the building may 2/1 b~ ~inished by the application of plaster~ concxete, or the like ~8¦ coveriny the interior surfaces of the panels so that the panels `~ 29 remain in place as an insulating core or shellO
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During construction of a building in accordance ~ith the present invention the exterior wall and roof are maintained sub-stantially unbroken and windows, for example, are à~fixed to the ex~erior of the shell with suitable framing and the shell later cut out t~ expose the window after the concrete has set. Th~re may also be provided structural beams and appropria~e temporary bracing thereof, as required by large structures formed in accoraance with the present invention.
Particularly, the present invention provides in one aspect thereof a method of building fabrication.
According to the method, a plurality of expanded plastic panels with reinforcing strips bonded thereto are attached together to ~orm a building shell having integral walls and roof. The panels have wire mesh mounted on the outer faces thereof in offset relation thereto and lacing together the wire mesh of contiguous panels to form a wire mesh covering on said shell. Wet concrete is then applied to the exterior of said shell on said mesh to form an integral concrete wall and roof of a building with the shell attached thereto. A plaster coating is thereafter applied to the interior of said shell to completely seal said panels between concrete and plaster as an insulating core of the resultant building. -The present invention also provides in another aspect thcreoE an improved building structure. The structure comprises a foundation and a building shell mounted on the foundation and formed of a plurality of molded panels of expanded plastic having reinforcing strips on outer and inner faces thereof and attached together by overlapping reinforcing strips. The panels also have wire mesh mounted in offset relation to the outer faces thereof. The panels are disposed i~ adjacent : .
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contacting relationship and joined together to form a sub-stantially continuous expanded plastic unitary shell with said wire mesh being joined together to form a substantially continuous mesh over said shell. The structure further includes a concrete layer covering the outside of said shell with said wire mesh disposed in the concrete to form a single continuous rigid integral building wall and roof; and a plastic coating on the interior of said shell completely sealing said panels within the integral wall and roof of the bullding. :~
DESCRIPTION ~F FIGURES
The present invention is illustrated as to pa~ticular .
preerred embodiments thereof in the accompanying drawings wherein:
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Figure 1 is a plan view of a simple spherical structure ~ormed in accordance with the present invention;
Figure 2 is a side elevational vie~ of the structure of ; Figure l;
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Figures 3, 4 and 5 are illustrations of insulating panels o differ~nt configurations employed in the builaing . ~ . .
~ stxucture of Figures 1 and 2;
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" 1¦ Figure~ 6 and 7 are plan views o al~ernati~e building i 21 configura~ions which may be ~ormed in acco~dance with the present .. ~ 3¦ inventi.on;
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.. 51 Figure 8 is a partial view of a number of panels joined ¦
6¦ toge-~her i~ accordance with the presen~ invention for use in the 7 I bu:;lding system o~ the present invention;
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¦ Figure 8~ is a hori~ontal sec~ional view o a plurali~y - lOI o alternatively configured panels jolned together, ~,.'' 11 1 .. 12¦ Figure 9 is a partiaL vertical sectional view o a wall .
13¦ o~ the building system o the present .invention in process o 14¦ appl~ing concrete to the exterior thereo; .
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16 ¦ Figure 10 is a partial vertical sec~ional view of a 17¦ completed wall of a building in accordan~e with the presenlt .
18 ¦invention;
19 I .. ' . , . 20 ¦ Fi~ure 10~ is a partial vertical sectional view of an :~ 21 ¦a~.ternati~e wall conigurationi - .
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X3 ¦ Figure 11 i5 a partial seational view illustrating the 2~ ¦ mo~mting of a window unit during construction of a building in ~5 ¦~acordancc with the present in~ention, . ~6 l : 2~ ¦ Figure 12 is a partial per~pective illus-tration o~ the `~; 28 ¦ window mounting of Figure 11 ~:~ 29 ~
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-B6090) I ¦ Fiyuxe 13 .is a vertical se~tional VieW through a ~indo~
' 2 ¦unit in a building structure in accordance herewith prior to : 3 ¦applicati.on of ~he inkernal plaster coating;
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5 ¦ E'igure 14 iS a vertical sectional view o the upper 6 ¦por-tion of the building structure in a~cordance herewith showing tensioniny means fox increasing the load-resistant characteri~tic~
8 o-E one roof structure in accordance herewith;
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.Figure 15 is a floor plan view o a building formed in ll accordance wi.th the presen~ invention;
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13 Figure 16 iS a side elevational view of the building oE
14 Figure 15, -16Figure 17 is a verkical sectional View taken in the 17 plane 17~17 o Figure 15; and .
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19Figuxe 18 iS a partial sectional view illustratin~
20 plaaement of a stifening beam as may be employed in the roo~
21 ~9~ructure o~' the buildings oE Figures lS to 17.
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6~90 ;
DESCRIPTION OF PI~EFERRED EMBODIMENTS
~ , , Referring to Figures 1 a~ of the arawings, there will be seen to be shown a simple semispherical buiIaing shell 11 in laccordance with the present invention~ This shell is shown to be I placed upon a slab founda~ion ~2 and tobe formed o a plurality of panels joinea together, as noted below. ^'~ p~Y~-13 o~ F~-3 will be seen to have a triangular configuration in fro~t elevation ana the panels 14 ana 16 have rectangular configurations in front elevation. Panel 16 is curved in one airection while panels 13 and 14 are curved in two directions so thàt upon assembly~ as illustrated in Figure 2, a plurality of pane1s substantially forms half a sphere. Each of the panels is pro~idea as an expanded plastic coxe, such as expande~ polystyrene, having thin reinforc-ing trips ~ metal, for examplè,-bonded to front and back ~surfaces thereof. These strips are provided at least along the .:~ . . . , ~ , . .
edges of the front and back surfaces ana panel 13, ~or example, ;will be seen to have a strip 21 along ~he left edge o the front -,~. , ............................. , .~ ,, .
surface extending laterally outwara from this edge. Each of the longitudinal strips on the front surface ~f panel 13 also extenas ~~eyond the lower edge of the panei to form tabs 22. The ~nel 14 .. . . .
similarly has a strip 26 on the front surface along the left edge, as viewed in Figure 4, extending beyond the edge and also ha~ the vextical stxips extending below the bottom edge of the front face ",.,., .~ .'' ' ' . :
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, ' 1 to ox~ tabs 270 Panel 16 is formed in the same manner as panel . . 2 ¦ 14 with a v~r-tical strip 28 on ~he ron-t face extending latera~l~
3 ¦ou-tward of the le~t edge, as viewed in Figure 5, and the vert~cal ¦strips on the ~ront ~ace extending below the bottom edge of the 5 ¦panel to orm tabs 290 6 l .
7 ¦ ~n Figures 1 and 2 there i.s illus-trated a very simple 8 ¦semispherical shell for purposes of describing the present . ¦i~vention; however, it is noted that a wide VarietY of other 1 10 ¦configurations are also possible~ ~n Figure 6, for example, 11 ¦ there is illustrated a shel.l configuration wherein ~he corners 12 ¦are spherica~ segments and straight walls are provided therebetwee . 13 ¦to o.rm somewhat of a rectangular shapeO .For a shell of this 14 ¦confiyuration there are provided single radius panels w~ich are 15 ¦curved only inwardly ~or the straight wall sections. In Figure 7 : 16 ¦there is illustra-ted a further simple she~l con~iguration which is 17¦ generally triangular. In this confiyuration the "corners" are .
18¦ ormed as segmen~s of a spherical surface with straigh~ walls 19¦ interconnecti.ng them. In both Figures 6 and 7 the arrangement of 20¦ panels ls illustrated b~ the lines within the boundaries of the - 21¦ ~i.yures. .
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~ 23¦ In Figure 8 there is illustrated the attachment o `~1 241 panels together and it will be seen that a panel 13 is placed in 251 contiguous relation to the upper edye of the panel 14 wlth the ~; 26¦ tabs ~ overlapping the horizontal reinforcing strip on the front :. 2~¦ Eace oE the panel 14 at the top thereo0 The panels 13 and 14 ~ 28¦ are secured together by driving shee~ metal screws 31, for example , " 291 . .
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1 through the overlapping tahs 22 and the upper horiæontal strip on 2 panel 140 To the righ~ of panel 14 in Figure 8 there is illustr~
3 atea another like panel 14' with reinforcing strip 26' of panel 141 o~erlapping the vertical reinforcing strip on the right side 5 of panel 14/ Sheet metal screws 31 or the like are driven 6 through these overlapping s~rips t~ secure the panels 14 and 14' 7 together.. Successive panels are joined together in the manner 8 ¦aescribed above by screwing or otherwise attaching overlapping 9¦ strips on successive panels togethex~
' 10 1-11 ¦ IT1 huilding structures of the type generally 12 ¦illustratecl in Figures 6 and 7, there are included straight .
13 ¦sections o wall as well as curved sec~ions and, in order to :~ 14 ¦maximi~e the structural rigidi~y of the straight.section5, 15 ¦partic~larly for carrying an externa~ly applied load such as wet 16 ¦concrete, the straight sections may be made up o~ a plurali~y o~
. 17 ¦horizontally curved panels as indicated in ~igure 8A. This .
.~ 18 ¦figure illustrates a horizontal section taken through a plurality :~ 19 ¦oE contiyuous lower panels 16, 16', etci of a straight sèction of .
20 ¦Wa1L. It will be seen in Figures 8A ~hat the base panels 16, 16' . 21 eta. are curved in the i~lustrated horizontal plane and are .~. 22 com~ected together as by sheet metal screws through overlapping 23¦ reln~oxcing strips as described above. The curved configuration 2~1 o~ the ~ase panels in Figure 8A inareases the loading capability `. 25 ¦ ~ the generally.strai~ht wall thereof. It will be appreciated . 2~ ¦ that upper panels placed on the curved panels 16, 16', etc~ are - 271 simila.rly curved but do not have a tapered configuration, as 29~ indicated, for xample, in Figure 6.
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1~ In -the foxmation oE a shell 11, such as sho~ in ~igures 21 1 and 2, the lower panels 16 are first mounted upon the slab 12 by 31 bencling the ~ottom ~abs 2g ~utwardl~ and nailing or screwing the . ¦tabs to the slab. Panels 14 are then attached to the panel 16 atop same and panels 13 are then at-tached to panels 14 atop same.
¦In this manner the shell is complcted; howe~er, it is noted that 7 ¦each o the panels have wire mesh on the outer surface thereof in 8 ¦spaced relation to such surfaceO As the struc-ture is assembled .~. ¦from the panels, the wire mesh on adjacent panels is secured 10 ¦together as by Lacing a wire through the mesh along the joinder 11 ¦line to thus ~orm a substantially unbxoken ~Jire mesh cover on the . 12 ¦outside o~ ~he shell. With the shell construc-ted as desc~ibed `........... 13 ¦above, the system hereof is then in conaition or the applica-~ion 1~ lo~ concrete to the exterior o the she~l, as further described; 15 ¦beLow.
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17 ¦ Re~erence is now made to Figure 9 illustrating the -18 ¦ application o~ we~ or plastic concrete to a shell such as that 19 ¦shot~n in Figures 1 and 20 ~n this figure the mounting of the ; 20 ¦wire mesh is clearly illustrated and re~errin~ to panel 14, foxs~ 21 ¦ example, i-t ~lill be seen that spacer blocks 41 are provided on 22 ¦ the outer surEace of the panel on the reinforcing strips thereoE
23 ¦ with wire mesh 42 placed on the bLocks and nails or screws 4324 ¦ ~ecuring the mesh and blocks to the panel proper. Small washers ~ay be placedunder the he~ds o~ the screws to engage the mesh and 26 ¦ ho:Ld i~ against the blocks as the screws are drlven into the 27 ¦ blocks and panel. With the shell in place, as described above28 ¦ ana illustrated in part in Figure 9, there is applied concreke or ;`' ~'~ .. , .
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1 the like to the exterior thereo . Al though concrete is a 2 preferred coating applied to the shell~ ik will he appreciated 3 ~ that alternatives are possible such as an aggregate ~ith s~me other type of bi.nder or even a wet a~obe in locations wllere I concrete may not be readily available. In the following 6 ¦descrip~ion the term "concrete" is taken to include substitutes 7 ¦thereor. ~pplication of concrete is il~ustrated in Figure 9 as 8 ¦being accomplished by a nozz~e 51 through which plastic concrete ¦is pumped ~o emerge as a spray 52. Concrete is applied to the 10 ¦shell -Erom the bottom upwardly and is applied as a thick coatin~t 11 ¦i~e., a number o~ inches thick, to comprise a solid concrete wall 12 ¦ upon the exterior o~ the shell. It will be seen that the 13 ¦ concrete 53 envelopes khe mesh 42 which ~hen forms reinforcing 14 bar or wire in the concrete. In ac~ordance wikh genexal praatice, the wire mesh is spaced outwardly of the shell a 16 distance about one-third of the thickness of concrete coating to 17 ¦ be applied to the shell. The shell 11 has sufficient structural 18 ¦ rigidity to carry the weight o the concrete applied thereko.
19 ¦ ~'hus the concrete is applied either by spraying or troweling on 20 ¦ ~o a substantially rigid form comprising the shell ana upon 21 ¦ hardeni.ng or setting will form a concr~te wall 56~ ~s illustxated 22 ¦ in E'igure 10. Prefera~ly this ~oncrete wall has a somewhak 23 ¦ ~reater thickness at the bottom thereo upon the slab foundation 2~ ¦ 12 and, of course, means may be employed to tie the concrete wall 25 ¦ to the ~oundation as, for example, by the provision of iron or 26 ¦ ste~l bars embedded in the foundation and extending upwardly into 27 ¦ the lower portion of the wall about tlle shell~ ~he curved con-2~ ¦ figur~tion of the shell provides maximum load-carryin~ capacity ¦ thereof so as to readily accommodate the application o a substan-tial ~nount o concrete to the extexior surace of the shell.
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lV~il6090 1 The interiox of the structure is finished ~y the 2 application of an interior coating 57 of plaster or the like.
3 The interior suraces of the panels are appropriately conditioned
',` 101 . .
11¦ The present invention provides a substantial departure 12¦ ~r~m noxmal. building construction in that prefabricated insulatin~
~i 13¦ panels are joined together to form a rigid structure upon which 141 concrete or the like is applied to o~m a low cost structure - 15¦ ha~ing ver~ good insulating properties.
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18 ¦ SUMMARY OF :I:NVENT:l:ON
' 19 I .~ , .
20 ¦ q.'he present in~ention employs preormed panels adapted 21 ¦to be joined together at a construction site to form the shell of ~2 la bui:Ld:Lny or the li~e~ These panels have an expanded plastic ~3 ¦cor:e w;.th reinforcing strips on the front and back surEaces ~4 ¦ thexeo~. Pre~erably the panels are Eormed oE ex.panded poly-st~retle ha~ing a substantial ~ensity, as of the order of 2 lbs.
~6¦ pe~ cubic feet with thin metal strips bonded to the front and back 271 surfaces at least along the edges thereo and extending in part 28¦ ~rom two edges on the front face of each panelO The strip .' 311 '`` 32 ,~
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~ i 1¦ extensions are adapted to overlap strips of adjacent panels ~or 21 attaching the panels toge-thex. The panels employed in the buildiny system hereof have a con~ex outer sur~ace and are formed ¦ with a predetermined plurality of different sizes and configura-51 tions to fit together into a variety of building configurations.
61 Upon the outer surface of each panel there is mounted a wire mesh 71 in spaced rela-tion to the outer surface and contiguous panèls may be joined together by the use o sheet metal screws through over-9¦ lapping metal reinorcing stripsO
- 101 . ' ' .
The building s~stem hereof provides for the attachment 12¦ together of a plurality of predetermined panels as~described above 13¦ to form a shell of a resultant building structure. The panels ~ may be placed upon a concrete slab foundation, for example, and 15¦ the bottom panels affixed thereto. The present invention employs 16¦ panels tha~ aré curved in a single direction or two mutually 17¦ perpendicular directions which in combination form convex 18¦ exterior building surfaces to maximize the structural strength of ~9¦ -the shell. ~ ~
. 201 2,1 A~ter erection Oe the shel~, concrete or some substitute ~21 there~o~ is applied to the e~terior thereo as by spraying or ?3¦ tr~weling -thereon. The applled concrete envelopes the wire mesh 2~1 on -tho ex~erior o~ th~ shell panels and there is thus produced a 251 rein~orced concrete building having insulating panels on the ; ¦ interlox o~ the concrete walls. The inside o the building may 2/1 b~ ~inished by the application of plaster~ concxete, or the like ~8¦ coveriny the interior surfaces of the panels so that the panels `~ 29 remain in place as an insulating core or shellO
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During construction of a building in accordance ~ith the present invention the exterior wall and roof are maintained sub-stantially unbroken and windows, for example, are à~fixed to the ex~erior of the shell with suitable framing and the shell later cut out t~ expose the window after the concrete has set. Th~re may also be provided structural beams and appropria~e temporary bracing thereof, as required by large structures formed in accoraance with the present invention.
Particularly, the present invention provides in one aspect thereof a method of building fabrication.
According to the method, a plurality of expanded plastic panels with reinforcing strips bonded thereto are attached together to ~orm a building shell having integral walls and roof. The panels have wire mesh mounted on the outer faces thereof in offset relation thereto and lacing together the wire mesh of contiguous panels to form a wire mesh covering on said shell. Wet concrete is then applied to the exterior of said shell on said mesh to form an integral concrete wall and roof of a building with the shell attached thereto. A plaster coating is thereafter applied to the interior of said shell to completely seal said panels between concrete and plaster as an insulating core of the resultant building. -The present invention also provides in another aspect thcreoE an improved building structure. The structure comprises a foundation and a building shell mounted on the foundation and formed of a plurality of molded panels of expanded plastic having reinforcing strips on outer and inner faces thereof and attached together by overlapping reinforcing strips. The panels also have wire mesh mounted in offset relation to the outer faces thereof. The panels are disposed i~ adjacent : .
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contacting relationship and joined together to form a sub-stantially continuous expanded plastic unitary shell with said wire mesh being joined together to form a substantially continuous mesh over said shell. The structure further includes a concrete layer covering the outside of said shell with said wire mesh disposed in the concrete to form a single continuous rigid integral building wall and roof; and a plastic coating on the interior of said shell completely sealing said panels within the integral wall and roof of the bullding. :~
DESCRIPTION ~F FIGURES
The present invention is illustrated as to pa~ticular .
preerred embodiments thereof in the accompanying drawings wherein:
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Figure 1 is a plan view of a simple spherical structure ~ormed in accordance with the present invention;
Figure 2 is a side elevational vie~ of the structure of ; Figure l;
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Figures 3, 4 and 5 are illustrations of insulating panels o differ~nt configurations employed in the builaing . ~ . .
~ stxucture of Figures 1 and 2;
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" 1¦ Figure~ 6 and 7 are plan views o al~ernati~e building i 21 configura~ions which may be ~ormed in acco~dance with the present .. ~ 3¦ inventi.on;
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.. 51 Figure 8 is a partial view of a number of panels joined ¦
6¦ toge-~her i~ accordance with the presen~ invention for use in the 7 I bu:;lding system o~ the present invention;
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¦ Figure 8~ is a hori~ontal sec~ional view o a plurali~y - lOI o alternatively configured panels jolned together, ~,.'' 11 1 .. 12¦ Figure 9 is a partiaL vertical sectional view o a wall .
13¦ o~ the building system o the present .invention in process o 14¦ appl~ing concrete to the exterior thereo; .
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16 ¦ Figure 10 is a partial vertical sec~ional view of a 17¦ completed wall of a building in accordan~e with the presenlt .
18 ¦invention;
19 I .. ' . , . 20 ¦ Fi~ure 10~ is a partial vertical sectional view of an :~ 21 ¦a~.ternati~e wall conigurationi - .
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X3 ¦ Figure 11 i5 a partial seational view illustrating the 2~ ¦ mo~mting of a window unit during construction of a building in ~5 ¦~acordancc with the present in~ention, . ~6 l : 2~ ¦ Figure 12 is a partial per~pective illus-tration o~ the `~; 28 ¦ window mounting of Figure 11 ~:~ 29 ~
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```~ 3~ I
-B6090) I ¦ Fiyuxe 13 .is a vertical se~tional VieW through a ~indo~
' 2 ¦unit in a building structure in accordance herewith prior to : 3 ¦applicati.on of ~he inkernal plaster coating;
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5 ¦ E'igure 14 iS a vertical sectional view o the upper 6 ¦por-tion of the building structure in a~cordance herewith showing tensioniny means fox increasing the load-resistant characteri~tic~
8 o-E one roof structure in accordance herewith;
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.Figure 15 is a floor plan view o a building formed in ll accordance wi.th the presen~ invention;
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13 Figure 16 iS a side elevational view of the building oE
14 Figure 15, -16Figure 17 is a verkical sectional View taken in the 17 plane 17~17 o Figure 15; and .
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19Figuxe 18 iS a partial sectional view illustratin~
20 plaaement of a stifening beam as may be employed in the roo~
21 ~9~ructure o~' the buildings oE Figures lS to 17.
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6~90 ;
DESCRIPTION OF PI~EFERRED EMBODIMENTS
~ , , Referring to Figures 1 a~ of the arawings, there will be seen to be shown a simple semispherical buiIaing shell 11 in laccordance with the present invention~ This shell is shown to be I placed upon a slab founda~ion ~2 and tobe formed o a plurality of panels joinea together, as noted below. ^'~ p~Y~-13 o~ F~-3 will be seen to have a triangular configuration in fro~t elevation ana the panels 14 ana 16 have rectangular configurations in front elevation. Panel 16 is curved in one airection while panels 13 and 14 are curved in two directions so thàt upon assembly~ as illustrated in Figure 2, a plurality of pane1s substantially forms half a sphere. Each of the panels is pro~idea as an expanded plastic coxe, such as expande~ polystyrene, having thin reinforc-ing trips ~ metal, for examplè,-bonded to front and back ~surfaces thereof. These strips are provided at least along the .:~ . . . , ~ , . .
edges of the front and back surfaces ana panel 13, ~or example, ;will be seen to have a strip 21 along ~he left edge o the front -,~. , ............................. , .~ ,, .
surface extending laterally outwara from this edge. Each of the longitudinal strips on the front surface ~f panel 13 also extenas ~~eyond the lower edge of the panei to form tabs 22. The ~nel 14 .. . . .
similarly has a strip 26 on the front surface along the left edge, as viewed in Figure 4, extending beyond the edge and also ha~ the vextical stxips extending below the bottom edge of the front face ",.,., .~ .'' ' ' . :
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, ' 1 to ox~ tabs 270 Panel 16 is formed in the same manner as panel . . 2 ¦ 14 with a v~r-tical strip 28 on ~he ron-t face extending latera~l~
3 ¦ou-tward of the le~t edge, as viewed in Figure 5, and the vert~cal ¦strips on the ~ront ~ace extending below the bottom edge of the 5 ¦panel to orm tabs 290 6 l .
7 ¦ ~n Figures 1 and 2 there i.s illus-trated a very simple 8 ¦semispherical shell for purposes of describing the present . ¦i~vention; however, it is noted that a wide VarietY of other 1 10 ¦configurations are also possible~ ~n Figure 6, for example, 11 ¦ there is illustrated a shel.l configuration wherein ~he corners 12 ¦are spherica~ segments and straight walls are provided therebetwee . 13 ¦to o.rm somewhat of a rectangular shapeO .For a shell of this 14 ¦confiyuration there are provided single radius panels w~ich are 15 ¦curved only inwardly ~or the straight wall sections. In Figure 7 : 16 ¦there is illustra-ted a further simple she~l con~iguration which is 17¦ generally triangular. In this confiyuration the "corners" are .
18¦ ormed as segmen~s of a spherical surface with straigh~ walls 19¦ interconnecti.ng them. In both Figures 6 and 7 the arrangement of 20¦ panels ls illustrated b~ the lines within the boundaries of the - 21¦ ~i.yures. .
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~ 23¦ In Figure 8 there is illustrated the attachment o `~1 241 panels together and it will be seen that a panel 13 is placed in 251 contiguous relation to the upper edye of the panel 14 wlth the ~; 26¦ tabs ~ overlapping the horizontal reinforcing strip on the front :. 2~¦ Eace oE the panel 14 at the top thereo0 The panels 13 and 14 ~ 28¦ are secured together by driving shee~ metal screws 31, for example , " 291 . .
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1 through the overlapping tahs 22 and the upper horiæontal strip on 2 panel 140 To the righ~ of panel 14 in Figure 8 there is illustr~
3 atea another like panel 14' with reinforcing strip 26' of panel 141 o~erlapping the vertical reinforcing strip on the right side 5 of panel 14/ Sheet metal screws 31 or the like are driven 6 through these overlapping s~rips t~ secure the panels 14 and 14' 7 together.. Successive panels are joined together in the manner 8 ¦aescribed above by screwing or otherwise attaching overlapping 9¦ strips on successive panels togethex~
' 10 1-11 ¦ IT1 huilding structures of the type generally 12 ¦illustratecl in Figures 6 and 7, there are included straight .
13 ¦sections o wall as well as curved sec~ions and, in order to :~ 14 ¦maximi~e the structural rigidi~y of the straight.section5, 15 ¦partic~larly for carrying an externa~ly applied load such as wet 16 ¦concrete, the straight sections may be made up o~ a plurali~y o~
. 17 ¦horizontally curved panels as indicated in ~igure 8A. This .
.~ 18 ¦figure illustrates a horizontal section taken through a plurality :~ 19 ¦oE contiyuous lower panels 16, 16', etci of a straight sèction of .
20 ¦Wa1L. It will be seen in Figures 8A ~hat the base panels 16, 16' . 21 eta. are curved in the i~lustrated horizontal plane and are .~. 22 com~ected together as by sheet metal screws through overlapping 23¦ reln~oxcing strips as described above. The curved configuration 2~1 o~ the ~ase panels in Figure 8A inareases the loading capability `. 25 ¦ ~ the generally.strai~ht wall thereof. It will be appreciated . 2~ ¦ that upper panels placed on the curved panels 16, 16', etc~ are - 271 simila.rly curved but do not have a tapered configuration, as 29~ indicated, for xample, in Figure 6.
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1~ In -the foxmation oE a shell 11, such as sho~ in ~igures 21 1 and 2, the lower panels 16 are first mounted upon the slab 12 by 31 bencling the ~ottom ~abs 2g ~utwardl~ and nailing or screwing the . ¦tabs to the slab. Panels 14 are then attached to the panel 16 atop same and panels 13 are then at-tached to panels 14 atop same.
¦In this manner the shell is complcted; howe~er, it is noted that 7 ¦each o the panels have wire mesh on the outer surface thereof in 8 ¦spaced relation to such surfaceO As the struc-ture is assembled .~. ¦from the panels, the wire mesh on adjacent panels is secured 10 ¦together as by Lacing a wire through the mesh along the joinder 11 ¦line to thus ~orm a substantially unbxoken ~Jire mesh cover on the . 12 ¦outside o~ ~he shell. With the shell construc-ted as desc~ibed `........... 13 ¦above, the system hereof is then in conaition or the applica-~ion 1~ lo~ concrete to the exterior o the she~l, as further described; 15 ¦beLow.
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17 ¦ Re~erence is now made to Figure 9 illustrating the -18 ¦ application o~ we~ or plastic concrete to a shell such as that 19 ¦shot~n in Figures 1 and 20 ~n this figure the mounting of the ; 20 ¦wire mesh is clearly illustrated and re~errin~ to panel 14, foxs~ 21 ¦ example, i-t ~lill be seen that spacer blocks 41 are provided on 22 ¦ the outer surEace of the panel on the reinforcing strips thereoE
23 ¦ with wire mesh 42 placed on the bLocks and nails or screws 4324 ¦ ~ecuring the mesh and blocks to the panel proper. Small washers ~ay be placedunder the he~ds o~ the screws to engage the mesh and 26 ¦ ho:Ld i~ against the blocks as the screws are drlven into the 27 ¦ blocks and panel. With the shell in place, as described above28 ¦ ana illustrated in part in Figure 9, there is applied concreke or ;`' ~'~ .. , .
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1 the like to the exterior thereo . Al though concrete is a 2 preferred coating applied to the shell~ ik will he appreciated 3 ~ that alternatives are possible such as an aggregate ~ith s~me other type of bi.nder or even a wet a~obe in locations wllere I concrete may not be readily available. In the following 6 ¦descrip~ion the term "concrete" is taken to include substitutes 7 ¦thereor. ~pplication of concrete is il~ustrated in Figure 9 as 8 ¦being accomplished by a nozz~e 51 through which plastic concrete ¦is pumped ~o emerge as a spray 52. Concrete is applied to the 10 ¦shell -Erom the bottom upwardly and is applied as a thick coatin~t 11 ¦i~e., a number o~ inches thick, to comprise a solid concrete wall 12 ¦ upon the exterior o~ the shell. It will be seen that the 13 ¦ concrete 53 envelopes khe mesh 42 which ~hen forms reinforcing 14 bar or wire in the concrete. In ac~ordance wikh genexal praatice, the wire mesh is spaced outwardly of the shell a 16 distance about one-third of the thickness of concrete coating to 17 ¦ be applied to the shell. The shell 11 has sufficient structural 18 ¦ rigidity to carry the weight o the concrete applied thereko.
19 ¦ ~'hus the concrete is applied either by spraying or troweling on 20 ¦ ~o a substantially rigid form comprising the shell ana upon 21 ¦ hardeni.ng or setting will form a concr~te wall 56~ ~s illustxated 22 ¦ in E'igure 10. Prefera~ly this ~oncrete wall has a somewhak 23 ¦ ~reater thickness at the bottom thereo upon the slab foundation 2~ ¦ 12 and, of course, means may be employed to tie the concrete wall 25 ¦ to the ~oundation as, for example, by the provision of iron or 26 ¦ ste~l bars embedded in the foundation and extending upwardly into 27 ¦ the lower portion of the wall about tlle shell~ ~he curved con-2~ ¦ figur~tion of the shell provides maximum load-carryin~ capacity ¦ thereof so as to readily accommodate the application o a substan-tial ~nount o concrete to the extexior surace of the shell.
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lV~il6090 1 The interiox of the structure is finished ~y the 2 application of an interior coating 57 of plaster or the like.
3 The interior suraces of the panels are appropriately conditioned
4 to ~eceive the coating 57 as described, for example, in our ah~ve-S noted copending U.S. patent application. Piping for the building 6 i~ provided through the foundation slab 12 pxior to building construction and internal electrical wiring may be readily 8 accomplished by insetting conduit into the in~erior of the shell prior to plastering. Reinforcing strips are cut along conduit lines ancl tht3 core depressed as by heat or routing so that the 11 concluit fits into the she~l. Additional metal tabs or short 12 s-trips ma~ -then be attached over -the cut strips to hold the 13 condui-~ in place. Subsequent plastering or coating of the ~ in~erior of the shell covers the conduits and strips to form a smooth inner surface. The finished walls entirely seal the 16 panels therein to preclude any possible fire hazard and to ach~eve 17 ver~ good insulatlon. It is no~ed that ~arious diferent 18 interiox coatings may be employed including concrete and, if 19 necessary, wire mesh may be employed interiorly for the lattèr type oE coating, although this is not normally necessary. The 2l ~erm "plaster" lS herein ta~en to include substitutes therefor.
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~3 It will be appreciated that the provision of inwaxdly ving walls in the buildlng system o the present invention is ~5 advantageous in maximizing the load-carrying capability of the ~h~ Ll; however, it will a~so be n~ted that such curvature ~7 causes some loss of head room adjacent the outer walls~ This may 2$ be m:inimized in the manner ilLus~rated in Figure lOA n ~eferring . ' .
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~ ' ' lO~ljO90 1 to the ~igure, it will be seen tha~ the hase panel 16 is moun-ted 2 on the slab 12 as previously described; ho~ver, the panel 14 3 atop -the base panel 16 is swung outwardly about the bottom edge of the panel 14. rrhe result o~ this arrangement is clearl~
S illustrated in Figure lOA, wherein the panel 14 is shown to be - 6 pivotea, às noted above, and the dashed line 15 indicates the ori.yinai or unpivoted posi~ion of the panelc The distancè x 8 indicates ~he amount tha~ the top of the panel 14 is moved ; 9 outwardly from unpivoted position and the distance y indicates the resultant increase in head room interioxly o~ the shell 11 because o~ this change in position of ~he panel 14. It will be 12 seen tha~ the distances x and y are about equal so that moving the -~op o~ the panel laterally outward 6 inches~ ~or example, will 14 increase the head room at the top of the panel by about the same amoun-t. This is a rather signi~icant lmprovementO The upper 16 panel 13 remains attached to the panel 14 in the same manner as - 17 described above and it will be appreciated that, in order to 18 complete the top of the structure, it is either necessary to 19 elongate the total lengths of the panels 13 and 14 or to provide an a:l.terna-ti.ve or cap structure at the center o the shell, as 21 Eur~ler descrlbed below. The configur~ti~n illustrated in 22 Figure lOA and briefly described above has a further advantage in 23 yrovidin~ the shell w.ith a slightly outwardly curved configuxation 2~ above the base panels 16 to Eurther maxi.mize the load-carrying capabilities of the shell. App~icat.ion of concrete to the shell 26 o.E FicJure lOA may be carried out as described above with the lower 2/ por-tion o~ the concrete being thicker than the upper portions, 28 ¦ somewhat as illustra-ted by the dashed line to the le~t of ` 30 ` 31 3ZlI
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1 ¦Figure 10~. In this manner the exterior ~all of the resultant 21 building structure provides no indication of the diEference in 31 shell arrangement from that of Figure 10, for exampleO It will 4¦ be appreciated -that the amount by which the panels 14 are pivoted S ¦is exaggerated in Figure lOA for the purpose of emphasizing the 6 ¦results thereof.
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8 ¦ While the foregoing description sets forth the general 9 ¦concepts and steps in the building system of the present invention, 10 ¦-there are certain details worthy of particular note. As stated 11 ¦above, the curved shell configuration maximizes the capability 12 ¦thereof to carry an exterior load of concrete when it is applied.
13 ¦ In order to maintain maximum load-carrying capacit~ it is 14 ¦preferable that the shell not be pierced by openings prior to the 15 ¦application and hardening of the concreteO It is, however, 16 ¦normally necessary to provide windows and doors in a building and 17 ¦this is accomplished in the manner described belowO
19 ¦ The provision of a window, for example, in a building 20 ¦structure in accordance with the present invention, may be 21 ¦accomplished in the manner illustrated in Figures ll to 13 of the 22 Idrawings. A conventional window and frame 61 is mounted exteriorl 23 ¦of the shell 11 by means of a frame 62 preferably formed of the 2~ ¦same material as the shell and shaped to fit the exterior of the shell. This frame 62 mounts the window and integral frame 61, as 26 shownr and generally comprises a box-like structure having the 27 interior edges of the walls thereof curved -to fit against the 28 exterior of the shellO The frame 62, and window 61 carried thereb ~.; ' .
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10E~60~
1¦ is mounted in the appropriate position on the shell as by means ¦ of tie ~ires 63 plac~d about the frame and extending through the 31 she]l~ The wires interiorly of the shell extend through a pad or 41 washer or the like 64 and are there expanded as indicated at 66,
2~
~3 It will be appreciated that the provision of inwaxdly ving walls in the buildlng system o the present invention is ~5 advantageous in maximizing the load-carrying capability of the ~h~ Ll; however, it will a~so be n~ted that such curvature ~7 causes some loss of head room adjacent the outer walls~ This may 2$ be m:inimized in the manner ilLus~rated in Figure lOA n ~eferring . ' .
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~ ' ' lO~ljO90 1 to the ~igure, it will be seen tha~ the hase panel 16 is moun-ted 2 on the slab 12 as previously described; ho~ver, the panel 14 3 atop -the base panel 16 is swung outwardly about the bottom edge of the panel 14. rrhe result o~ this arrangement is clearl~
S illustrated in Figure lOA, wherein the panel 14 is shown to be - 6 pivotea, às noted above, and the dashed line 15 indicates the ori.yinai or unpivoted posi~ion of the panelc The distancè x 8 indicates ~he amount tha~ the top of the panel 14 is moved ; 9 outwardly from unpivoted position and the distance y indicates the resultant increase in head room interioxly o~ the shell 11 because o~ this change in position of ~he panel 14. It will be 12 seen tha~ the distances x and y are about equal so that moving the -~op o~ the panel laterally outward 6 inches~ ~or example, will 14 increase the head room at the top of the panel by about the same amoun-t. This is a rather signi~icant lmprovementO The upper 16 panel 13 remains attached to the panel 14 in the same manner as - 17 described above and it will be appreciated that, in order to 18 complete the top of the structure, it is either necessary to 19 elongate the total lengths of the panels 13 and 14 or to provide an a:l.terna-ti.ve or cap structure at the center o the shell, as 21 Eur~ler descrlbed below. The configur~ti~n illustrated in 22 Figure lOA and briefly described above has a further advantage in 23 yrovidin~ the shell w.ith a slightly outwardly curved configuxation 2~ above the base panels 16 to Eurther maxi.mize the load-carrying capabilities of the shell. App~icat.ion of concrete to the shell 26 o.E FicJure lOA may be carried out as described above with the lower 2/ por-tion o~ the concrete being thicker than the upper portions, 28 ¦ somewhat as illustra-ted by the dashed line to the le~t of ` 30 ` 31 3ZlI
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1 ¦Figure 10~. In this manner the exterior ~all of the resultant 21 building structure provides no indication of the diEference in 31 shell arrangement from that of Figure 10, for exampleO It will 4¦ be appreciated -that the amount by which the panels 14 are pivoted S ¦is exaggerated in Figure lOA for the purpose of emphasizing the 6 ¦results thereof.
7 I .
8 ¦ While the foregoing description sets forth the general 9 ¦concepts and steps in the building system of the present invention, 10 ¦-there are certain details worthy of particular note. As stated 11 ¦above, the curved shell configuration maximizes the capability 12 ¦thereof to carry an exterior load of concrete when it is applied.
13 ¦ In order to maintain maximum load-carrying capacit~ it is 14 ¦preferable that the shell not be pierced by openings prior to the 15 ¦application and hardening of the concreteO It is, however, 16 ¦normally necessary to provide windows and doors in a building and 17 ¦this is accomplished in the manner described belowO
19 ¦ The provision of a window, for example, in a building 20 ¦structure in accordance with the present invention, may be 21 ¦accomplished in the manner illustrated in Figures ll to 13 of the 22 Idrawings. A conventional window and frame 61 is mounted exteriorl 23 ¦of the shell 11 by means of a frame 62 preferably formed of the 2~ ¦same material as the shell and shaped to fit the exterior of the shell. This frame 62 mounts the window and integral frame 61, as 26 shownr and generally comprises a box-like structure having the 27 interior edges of the walls thereof curved -to fit against the 28 exterior of the shellO The frame 62, and window 61 carried thereb ~.; ' .
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10E~60~
1¦ is mounted in the appropriate position on the shell as by means ¦ of tie ~ires 63 plac~d about the frame and extending through the 31 she]l~ The wires interiorly of the shell extend through a pad or 41 washer or the like 64 and are there expanded as indicated at 66,
5 Iso as to firmly hold the frame 62 on the exter~or of the shell.
6 The pads or washer 64 provide a sufficient area of contact with
7 ¦the shell to ensure that the ~ires are not pulled out of ~he shell
8 ¦~lhen concrete is applied to the exterior of the building. If ¦desirea, wire mesh ma~ also be placed on the frame ~2 and if the 10 ¦frame is of any substantial size reinforcing strips may be bonaed 11 ¦ thereto during the formation of the frameO The frame 62 may in 12 ¦ ~act comprise a prefabricated part which need only be positioned 13 on the exterior of the shell and wired thereto, with the window 61 14j being carried by the frame. During the application of concrete 15¦ to the e~terior of the shell the frame 62 is covered with concrete 16¦ except for the window 61 therein. After the concrete has .71 hardened to form the concrete wall 56, the shell is cut away ~rom 1~¦ -the inside thereof as indicated at 67 to expose the interior of 19 ¦ the frame 6~ and window 61, as illustrated in Figure 13. This 201 may be readil~ accomplish~d with a saber saw, ~or example, ~or 21¦ the core and reinforcing strips are relatively easi~y cut with a 22¦ saw or the like. When the interior plaster coating 57 is applied, 231 it :ls extended into the intexior of the frame 62 across the cut 2~ ¦ surfaces oE ~he shell so as to provide a smooth interior surface 25 ¦ covering the cut out surEaces of the shell. In this manner the ~6 ~ ructural integrity oE the shell is not reduced prior to se~ting 27 1 o the concrete so that the shell retains its full load-carr~ing 28 ¦ capability dur~ng the time that this is required. It is noted 29 ¦ that the portions of the wire covered by concrete remain in p]ace 30 ¦ and the remainder of the wire is cut o after the concrete sets 32 with the wire ends being -then sealed. It ~ill, o~
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1 ¦course, be appreciated that at leas~ one small opening is to be 2 ¦formea in the shell prior to application--of the concrete so th~t 3 ¦i-t is possible Eor workmen to enter the shell for cutting the 4 ¦necessary openings to expose windows and doors. The above-5 ¦described manner of formin~ window openings in the building is 6 ¦also suited to the formation of door openings.
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8 ¦ For some roof structures in accordance with the present
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1 ¦course, be appreciated that at leas~ one small opening is to be 2 ¦formea in the shell prior to application--of the concrete so th~t 3 ¦i-t is possible Eor workmen to enter the shell for cutting the 4 ¦necessary openings to expose windows and doors. The above-5 ¦described manner of formin~ window openings in the building is 6 ¦also suited to the formation of door openings.
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8 ¦ For some roof structures in accordance with the present
9 ¦invention, it is preferable to increase the load-carrying capacity
10 ¦and to provide means preventing any possible dislocation of shell
11 ¦panels as s~bstantial amounts of wet concrete are applied to the
12 ¦roo. In Figure 14 there is illustrated a sectional view of a
13 ¦pair of roof panels 71 and 72 which may be rectangular in plan
14 ¦view a~ld are curved, as illustrated, in side elevation. These
15 ¦panels 71 and 72 are mounted upon and attached to wall panels
16 ¦beneath same in the manner previously described and are herein
17 ¦provided with tension wires 73 to prevent any possible outward ¦movement of the lower eclges of ~hese roof panels with the ~
19 ¦application of an exterior load of concrete thereto. The tension 20 ¦wlre~ 73 are shown to extend through the reinforcing strips at 21 ¦-the lower corners o~ each of the panels 71 and 72o The tension 22 ¦wires 73` also extend through washers or the like 74 placed on the 23 ¦exter:ior of these washers. It will be seen that the appllcation 2~ ¦oE concrete or other loading to the roof panels will tend to ~5 ¦ Eorce the lower edges thereof outwardly because of the curvature 26 lo~ ~he panels; however, the tension wire or wires 73 take up this ¦~oacl and prevent such movementO The concrete applied to the 28 ~exterior of the shell wil~ entlrely cover the washers 74 and the 32 ~ ` -.~ ,. .
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wire ends so that a~-ter the concre~e has hardened, it is onl~
2 necessary to cut off the wires in the interior of the shell and 3 plaster o~er -them so that there is no subsequent evidence that the : 4 wires were ever employed. In the roof structure of Figure 14 there is also shown the application of additional reinforcing strips 76 and 77 on the inner and outer sides oE the joint between the roo~ panels 71 and 72 in order to Eurther strengthen this 8 joint~ These strips 76 and 77 may be attached to the panels by g sheet metal screws, for example, driven through the overlapping stri.ps 76 and 77 and reinforcing strips on the panels. The type 11 ¦oE roof structure illustrated in Figure 14 is the type that may be 12 ¦employed, for example, in ~he building configuratio~ of Figure 6.
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1~ In Figures 15 to 18 there is illus-trated one possible : lS building con-figuration in accordance with -the present invention.
16 It will be seen that partial spherical surfaces and curved - 17 surfaces are employed in order to maximize the structural rigidity
19 ¦application of an exterior load of concrete thereto. The tension 20 ¦wlre~ 73 are shown to extend through the reinforcing strips at 21 ¦-the lower corners o~ each of the panels 71 and 72o The tension 22 ¦wires 73` also extend through washers or the like 74 placed on the 23 ¦exter:ior of these washers. It will be seen that the appllcation 2~ ¦oE concrete or other loading to the roof panels will tend to ~5 ¦ Eorce the lower edges thereof outwardly because of the curvature 26 lo~ ~he panels; however, the tension wire or wires 73 take up this ¦~oacl and prevent such movementO The concrete applied to the 28 ~exterior of the shell wil~ entlrely cover the washers 74 and the 32 ~ ` -.~ ,. .
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wire ends so that a~-ter the concre~e has hardened, it is onl~
2 necessary to cut off the wires in the interior of the shell and 3 plaster o~er -them so that there is no subsequent evidence that the : 4 wires were ever employed. In the roof structure of Figure 14 there is also shown the application of additional reinforcing strips 76 and 77 on the inner and outer sides oE the joint between the roo~ panels 71 and 72 in order to Eurther strengthen this 8 joint~ These strips 76 and 77 may be attached to the panels by g sheet metal screws, for example, driven through the overlapping stri.ps 76 and 77 and reinforcing strips on the panels. The type 11 ¦oE roof structure illustrated in Figure 14 is the type that may be 12 ¦employed, for example, in ~he building configuratio~ of Figure 6.
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1~ In Figures 15 to 18 there is illus-trated one possible : lS building con-figuration in accordance with -the present invention.
16 It will be seen that partial spherical surfaces and curved - 17 surfaces are employed in order to maximize the structural rigidity
18 o~ the shell prior to application of the exterior concrete. With
19 ¦the building~oE Figures 15 to 18 having an interior area of 1,600
20 ¦square feet, for example, the central roof 81 has a fairly
21 ¦~ub~antial extent. Under such circumstances, it may be preferabl .
~2 ¦-to provide structural beams for supporting this rooE structure.
.l 23 ¦In this respect reference is made to F:igure 18 wherein there is 2~ ¦shown a portlon of an upper shel.l panel 82 witl~ an L-shaped 2S ¦collcrete or steel beam 83 disposed along the upper inner edge 26 ¦thereoE. The beam 83 is formed as a continuous rectangle about ~` 27 ¦th~-~ opening upon which the roof 81 is to be mounted and short 28 Ivertical panels 84 are employed to box the opening for the roof `~. 3 .. - 17 - .
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1~6090 1 ¦with the roof 81 then resting upon these panels 84. Reinforcing 2 ¦bars 86 eY.ten~ from the beam 83 into the concrete wall 56 to lock 3 ¦-the beam into the concrete wall and roof. The manner of locking 4 the beam to the concrete wall and roof may be varied; however, some type of attachment is to be provided so thak the beam and 6 wall become an integral unit in the finished structureO With this rei.nforcement, it is preferable ~o provide temporary bracing 8 interiorly of the shell to hold the weight o~ the beam 83 and 9 concrete to be applied on the exterior of the shell, as indicated at 87. This -temporary bracing is removed after the exterior 11 concrete is set It will be appreciated that the application of 12 concrete to the exterior of the shell and plaster to the interior 13 of the shell entirely seals the panels and core material thereof 1~ and furthermore covers up any and all minor protuberances or the like which ~ay exist on the shell surface because of the nature 16 oE same or the attachment of elements thereto.
17 ;
18 The building 91 illustrated in Figures 15 to 17, for 19 example, comprises a shell assembled in accordance with the present invention and operated upon to form a concrete wall on 21 the exterior and a plaster coating on the interior. This
~2 ¦-to provide structural beams for supporting this rooE structure.
.l 23 ¦In this respect reference is made to F:igure 18 wherein there is 2~ ¦shown a portlon of an upper shel.l panel 82 witl~ an L-shaped 2S ¦collcrete or steel beam 83 disposed along the upper inner edge 26 ¦thereoE. The beam 83 is formed as a continuous rectangle about ~` 27 ¦th~-~ opening upon which the roof 81 is to be mounted and short 28 Ivertical panels 84 are employed to box the opening for the roof `~. 3 .. - 17 - .
, .
- : ' ' ' . . : .
.
.
1~6090 1 ¦with the roof 81 then resting upon these panels 84. Reinforcing 2 ¦bars 86 eY.ten~ from the beam 83 into the concrete wall 56 to lock 3 ¦-the beam into the concrete wall and roof. The manner of locking 4 the beam to the concrete wall and roof may be varied; however, some type of attachment is to be provided so thak the beam and 6 wall become an integral unit in the finished structureO With this rei.nforcement, it is preferable ~o provide temporary bracing 8 interiorly of the shell to hold the weight o~ the beam 83 and 9 concrete to be applied on the exterior of the shell, as indicated at 87. This -temporary bracing is removed after the exterior 11 concrete is set It will be appreciated that the application of 12 concrete to the exterior of the shell and plaster to the interior 13 of the shell entirely seals the panels and core material thereof 1~ and furthermore covers up any and all minor protuberances or the like which ~ay exist on the shell surface because of the nature 16 oE same or the attachment of elements thereto.
17 ;
18 The building 91 illustrated in Figures 15 to 17, for 19 example, comprises a shell assembled in accordance with the present invention and operated upon to form a concrete wall on 21 the exterior and a plaster coating on the interior. This
22 building structure is adapte~ to have interior partltions and
23 the like 92 ~ormed therein in order to complete the building
24 structure .into a single Eamily dwelling, for example. These lnterior partitions and the like may be conventionally constructed 26 or alterna-tively may be preEabricated along the general lines o~
27 the present inven-tion. Non-load bearing interior walls 92 may be 28 formed oE panels of the present invention having only plaster 29 .
~` 301 . 32 .``'' - 1~ -.. .. . .
.
I 3~0~6~9~ ~
applied to opposite sides thereof and under these clrcumstances it is not necessary to apply the wire mesh to the panels. The preformed panels o-~ the present invention are highly advantageous ¦
4 in building const~uction because of the ease and low cost o~
5 ¦manufacture of the panels and the very good insulating properties 6l of the panels which remain as a part of ~he final structure. It 7 ¦will be appreciated that, although only a few building con~figu-3 ¦rations are illustrated, many others are possible. Additionally ¦there are many architectural features which may be incorporated 10 ¦in -the buildings constructed in'accordance herewith such as, for 11 ¦example1 cathedral windows 93 at the ends of the roof 81 o~ the 12 ¦building illustrated in Figures 15 to 17. It is recognized that ¦the s-tructure of the present building system does not have the 1~ square or angular look of many conventional buildings and,'to the exten~ -that this may be considered objectional, modifications 16 which are not necessarily structural ma~ be provided such as 17 details about windows 94 and doors 960 ; 19 The present invention has been described above with respect to particular preferred embodiments of the invention, 21 however, it will be apparent to those skilled in the art that 22 modl~icatiolls and variations are possible within the scope o 23 the present invention. It is thus not intended to limit the 2~ present invention to the precise terms of description nor details oE illustration. ' ' 2`~
~ 22~ ' ~
33o .
,
27 the present inven-tion. Non-load bearing interior walls 92 may be 28 formed oE panels of the present invention having only plaster 29 .
~` 301 . 32 .``'' - 1~ -.. .. . .
.
I 3~0~6~9~ ~
applied to opposite sides thereof and under these clrcumstances it is not necessary to apply the wire mesh to the panels. The preformed panels o-~ the present invention are highly advantageous ¦
4 in building const~uction because of the ease and low cost o~
5 ¦manufacture of the panels and the very good insulating properties 6l of the panels which remain as a part of ~he final structure. It 7 ¦will be appreciated that, although only a few building con~figu-3 ¦rations are illustrated, many others are possible. Additionally ¦there are many architectural features which may be incorporated 10 ¦in -the buildings constructed in'accordance herewith such as, for 11 ¦example1 cathedral windows 93 at the ends of the roof 81 o~ the 12 ¦building illustrated in Figures 15 to 17. It is recognized that ¦the s-tructure of the present building system does not have the 1~ square or angular look of many conventional buildings and,'to the exten~ -that this may be considered objectional, modifications 16 which are not necessarily structural ma~ be provided such as 17 details about windows 94 and doors 960 ; 19 The present invention has been described above with respect to particular preferred embodiments of the invention, 21 however, it will be apparent to those skilled in the art that 22 modl~icatiolls and variations are possible within the scope o 23 the present invention. It is thus not intended to limit the 2~ present invention to the precise terms of description nor details oE illustration. ' ' 2`~
~ 22~ ' ~
33o .
,
Claims (5)
OR PRIVILEGE IS CLAIMED, ARE DEFINED AS FOLLOWS:
1. A method of building fabrication comprising the steps of (a) attaching together a plurality of expanded plastic panels with reinforcing strips bonded thereto to form a building shell having integral walls and roof;
(b) said panels having wire mesh mounted on the outer faces thereof in offset relation thereto and lacing together the wire mesh of contiguous panels to form a wire mesh covering on said shell;
(c) applying wet concrete to the exterior of said shell on said mesh to form an integral concrete wall and roof of a building with the shell attached thereto, and (d) applying a plaster coating to the interior of said shell to completely seal said panels between concrete and plaster as an insulating core of the resultant building.
(b) said panels having wire mesh mounted on the outer faces thereof in offset relation thereto and lacing together the wire mesh of contiguous panels to form a wire mesh covering on said shell;
(c) applying wet concrete to the exterior of said shell on said mesh to form an integral concrete wall and roof of a building with the shell attached thereto, and (d) applying a plaster coating to the interior of said shell to completely seal said panels between concrete and plaster as an insulating core of the resultant building.
2. The method of Claim 1 further defined by attaching said panels together by sheet metal screws driven through over-lapping reinforcing strips on contiguous panels.
3. The method of Claim 1 further defined by applying said wet concrete to the shell by spraying the concrete onto the shell from the bottom up with the concrete being applied thickest at the bottom of the shell and the concrete having a thickness of the order of a few inches to form upon hardening a rigid integral wall and roof of the building.
4. An improved building structure comprising a foundation;
a building shell mounted on said foundation and formed of a plurality of molded panels of expanded plastic having reinforcing strips on outer and inner faces thereof and attached together by overlapping reinforcing strips, said panels also having wire mesh mounted in offset relation to the outer faces thereof, said panels being disposed in adjacent contacting relationship and joined together to form a substantially continuous expanded plastic unitary shell with said wire mesh being joined together to form a substantial-ly continuous mesh over said shell;
a concrete layer covering the outside of said shell with said wire mesh disposed in the concrete to form a single continuous rigid integral building wall and roof; and a plaster coating on the interior of said shell completely sealing said panels within the integral wall and roof of the building.
a building shell mounted on said foundation and formed of a plurality of molded panels of expanded plastic having reinforcing strips on outer and inner faces thereof and attached together by overlapping reinforcing strips, said panels also having wire mesh mounted in offset relation to the outer faces thereof, said panels being disposed in adjacent contacting relationship and joined together to form a substantially continuous expanded plastic unitary shell with said wire mesh being joined together to form a substantial-ly continuous mesh over said shell;
a concrete layer covering the outside of said shell with said wire mesh disposed in the concrete to form a single continuous rigid integral building wall and roof; and a plaster coating on the interior of said shell completely sealing said panels within the integral wall and roof of the building.
5. The building structure of Claim 4 further defined by adjacent panels being joined together by screws extending through overlapping reinforcing strips and into the panels.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US670,057 | 1976-03-24 | ||
| US05/670,057 US4094110A (en) | 1976-03-24 | 1976-03-24 | Building system and method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1086090A true CA1086090A (en) | 1980-09-23 |
Family
ID=24688804
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA274,624A Expired CA1086090A (en) | 1976-03-24 | 1977-03-23 | Building system and method |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US4094110A (en) |
| CA (1) | CA1086090A (en) |
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-
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- 1976-03-24 US US05/670,057 patent/US4094110A/en not_active Expired - Lifetime
-
1977
- 1977-03-23 CA CA274,624A patent/CA1086090A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| US4094110A (en) | 1978-06-13 |
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