System and method of foamed cementitious construction

Abstract

A building system and method. A construction method and system is disclosed. The system includes panel members composed of foamed cement containing perlite as the only material aggregate. Each lightweight cement body is encased around its perimeter edges by a rigid frame preferably fabricated from steel C-channel or beams. Once cured, a plurality of such panels vertically disposed, arranged upon building footings, and inter-connected to serve as structure walls. The use of a special foamed cementitious mix containing expanded perlite provides lightweight panels of reliable strength and durability yet excellent thermal and sound insulation. The frames of abutting panels may be joined by welding. Reinforced concrete footings according to this disclosure are provided with a special channel running longitudinally there-along. An exposed anchor bar runs along the inside of the longitudinal channel. The wall panels have reinforcing conduits extending top to bottom in the panel frame. Tie rods situated in the conduit interiors extend beyond the conduit ends. The upper end of each tie rod is adjustably engaged with the end of the corresponding conduit, while the tie rod lower end is connected to the anchor rod on the footing. With the tie rod attached to the footing's anchor rod, the controlled tightening of the engagement of the tie rod and conduit upper ends pulls the tie rod into tension to secure the panel to the footing.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/718,409 entitled “Foamed Cementitious Building Material and Method of Use,” filed on Sep. 16, 2005, and the specification thereof is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention (Technical Field)

The present invention relates to construction methods and materials, generally to methods and materials for constructing building structures, particularly concrete construction, and specifically to a cementitious composition and method of using it to erect structures.

2. Background Art

It has been known for centuries that structural elements may be fashioned from cement, and reinforced concrete has been used in structural design and erection for nearly a century. Modern concrete structures typically are reinforced with steel rods (“rebar”), and the concrete mix includes Portland cement, sand, and aggregates.

Reinforced concrete structural elements pose certain challenges and disadvantages. Two leading challenges are the comparatively heavy weight (vis-a-vis lumber post and beam construction) and thermal conductivity. The weight of concrete, both while wet and when cured, demands careful planning and operation during the placement of the mix, as well as design considerations to provide for a self-supporting structure that also can withstand further active loading. Concrete, especially dense and heavily reinforced concrete, also is a less than optimal thermal insulator; in cold climates, concrete walls and floors can serve to conduct heat from a building interior to the ground and outdoor air.

There is known in the art of concrete construction generally the use of foaming agents to affect the material characteristics of concrete. The following patents, the disclosures of which are incorporated herein by reference, offer background information regarding the preparation of foamed concrete compositions:

U.S. Pat. No. 4,057,608 to Hashimoto, et al.;

U.S. Pat. No. 4,268,558 to Boardman;

U.S. Pat. No. 4,270,329 to Moore;

U.S. Pat. No. 4,373,955 to Bouchard, et al.;

U.S. Pat. No. 4,419,134 to Ishijima, et al.;

U.S. Pat. No. 4,789,244 to Dunton, et al.;

U.S. Pat. No. 4,872,913 to Dunton, et al.;

U.S. Pat. No. 5,413,633 to Cook, et al.;

U.S. Pat. No. 5,596,860 to Hacker;

U.S. Pat. No. 5,605,570 to Bean, et al.;

U.S. Pat. No. 5,795,060 to Stephens;

U.S. Pat. No. 6,046,255 to Gray, et al.;

U.S. Pat. No. 6,210,476 to Chatterji, et al.;

U.S. Pat. No. 6,153,005 to Welker, et al.;

U.S. Pat. No. 6,833,091 to Johansson, et al.; and

U.S. Patent Publication No. 2005/0133221 to Chatterji, et al.

SUMMARY OF THE INVENTION

A construction method and system is disclosed. The system includes panel members composed of foamed cement containing perlite as the only material aggregate. Each lightweight cement body is encased around its perimeter edges by a rigid frame preferably fabricated from steel C-channel or beams. Once cured, a plurality of such panels vertically disposed, arranged upon building footings, and inter-connected to serve as structure walls. The use of a special foamed cementitious mix containing expanded perlite provides lightweight panels of reliable strength and durability yet excellent thermal and sound insulation. The frames of abutting panels may be joined by welding.

Reinforced concrete footings according to this disclosure are provided with a special channel running longitudinally there-along. An exposed anchor bar runs along the inside of the longitudinal channel.

The wall panels have reinforcing conduits extending top to bottom in the panel frame. Tie rods situated in the conduit interiors extend beyond the conduit ends. The upper end of each tie rod is adjustably engaged with the end of the corresponding conduit, while the tie rod lower end is connected to the anchor rod on the footing. With the tie rod attached to the footing's anchor rod, the controlled tightening of the engagement of the tie rod and conduit upper ends pulls the tie rod into tension to secure the panel to the footing.

Roof decking is placed upon and secured to the plurality of erected wall panel members. Wet concrete is then placed, in a monolithic pour, down the reinforcing conduits and into the footing's longitudinal channel to fill the channel, fill the conduits, and to cover the roof deck to a design depth. This singular pour, besides providing a concrete roof cap and a bond beam along the tops of the panels, integrates the roof with the footing by bonding the tie rods and conduits to the roof and footing.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a part of the specification and, together with the description, serve to explain the principles of the invention. The drawings, all views and portions of which are not necessarily to uniform or consistent scale, are only for the purpose of illustrating a preferred embodiment of the invention and are not to be construed as limiting the invention. In the drawings:

FIG. 1 is an exploded top perspective view of a basic panel member and footing segment according to the present disclosure, with dashed directional lines indicating the placement of the panel upon the footing. Portions of the cementitious panel body, which in a complete installation extend the full length of the panel member, are broken away to permit illustration of panel frame elements.

FIG. 2 is an enlarged top perspective view of an upper outside corner showing the welded juncture of two wall panel members according to the present disclosure.

FIG. 3 is an exploded side perspective view of segments of top and bottom panel frame members, and a portion of a footing, according to this disclosure. A portion of the footing is broken away to illustrate the provision of an anchor rod, and means for anchoring the anchor rod to the footing, within the footing's longitudinal top channel. Major portions of an associated panel member are omitted from the view for clarity of illustration. The upper ends of a conduit and a tie rod are associated with the top frame member, and the lower ends of the same conduit and tie rod are associated with the bottom frame member, and the dashed directional lines suggest the positional relationships of the frame, tie rod and conduit members, and their installation upon the footing and the hooked engagement of the tie rod with an anchor bar in the footing.

FIG. 4 is an enlarged schematic end view of an upper portion of a panel member according to this disclosure.

FIG. 5 is a sectional end view of a panel member according to the present disclosure, showing its conjuncture with a roof.

FIG. 6 is an enlarged partially sectional end view of a lower portion of a panel member, shown connected to a portion of a footing by means of a hooked engagement between a tie rod in the panel member and an anchor bar in the footing.

FIG. 7 is a multiply exploded side schematic view of two stacked panel members according to the present disclosure, illustrating how the inventive system may be modified for utility in a two-story structure.

FIG. 8 is a perspective and partially sectional view of two panel members according to the present disclosure placed end-to-end and installed upon a footing. A roof is shown in section, with a portion broken away to reveal a section of a panel frame and the roof deck.

FIG. 9 is an end sectional view of two panel members stacked vertically in the erection of a two-story building.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Best Modes for Carrying Out the Invention

There is disclosed hereby a construction system and methods for erecting structures, especially including but not limited to residential dwellings of either single- or multiple-family types. The information of the present disclosure is most readily understood in the context of constructing a single-family home; however, it is to be understood that the principles and teachings hereof may be adapted to the erection of nearly any type of building, including commercial and industrial structures. Teachings are offered for a system and method of construction. A lightweight foamed cementitious composition also is disclosed from which structural elements may be fabricated.

The building system and method of erection employ a somewhat modular approach, whereby a plurality of panel components are fabricated and then assembled at the building site. Fundamental panel components are fabricated, either on- or off-site, for subsequent installation upon specially devised footings. The panel components may be constructed in a wide variety of sizes and shapes for use in and at different locations within a structure, to fulfill identified particular structural needs, or to accommodate architectural aesthetics as well as building systems (plumbing, electrical, heating, ventilation, air conditioning, etc.) function.

Accordingly, the depiction and description of particular panel components herein is not intended to be limiting as to the specific shape or size of panels, but rather to typify panel components within the ambit of the present invention. The construction of a building according to the present disclosure may involve the fabrication of many panel components, with no two panels being the same in size and form. As mentioned, a plurality of differing panels according to the invention are fabricated and assembled to erect a building, whether small and simple or large and complex. The versatility of this system and methodology permit the design and construction of any of a nearly limitless variety of building types and sizes.

A panel member according to the present disclosure has a body incased within a rigid framework. Each panel features a frame that defines the perimeter—the top, two ends, and bottom—of the panel. Panels are assembled and interconnected to constitute the main structural elements, most generally the vertical walls, of the building. The volume within each frame is occupied by a poured and cured foamed cementitious material that defines the body of the panel. The body of the panel typically has two parallel sides or faces, corresponding to the exterior and exterior sides of a wall, which sides are separated by a dimension corresponding to the panel thickness (which in turn serves as the basis for the thickness of the wall).

A panel framework features a frame preferably constructed from steel elements, but the frame alternatively may include elements of wood and/or synthetics, including wood-plastic composites. A panel's frame defines its shape and overall size, including thickness. The frame encases the cementitious panel body along its perimeter, while the broad faces of the body are exposed (e.g., for further covering or finishing, as with stucco, brick, siding, etc., on the exterior, and gypsum board, decorative paneling, or the like on the interior). An advantage of the invention is the low thermal conductivity of the panel body, although the invention may be practiced in a manner permitting installation of additional insulating materials on either face of the panel body.

The cementitious panel body is poured within a formwork including the frame (i.e., with the framework disposed horizontally upon the ground and allowed to cure. The material of the panel body is a foamed, perlite-containing cement, described further hereinafter.

The structural integrity of each panel is provided primarily by the frame, which in the preferred embodiment is constructed of 8-25 gauge steel C-channel. Each panel also features at least one, and preferably two or more, internal conduit reinforcements. The internal conduits preferably are 8-25 gauge steel pipe, preferably of at least 2-inch diameter, and more preferably between about 3 inches and 5 inches in diameter. The reinforcing conduits are disposed parallel to the ends of the panel, such that when a panel is vertically oriented upon a footing, the reinforcing conduits are parallel at a minimum of 24-inch on-center spacing along the horizontal extent of the panel. The upper end of each reinforcing conduit intersects with, and in the preferred embodiment is welded to, the top element of the frame; likewise the lower end of a conduit is secured to the bottom element of the frame.

In construction, individual panels are placed end-to-end to constitute building walls and corners. In the preferred embodiment, the end of each panel is defined by a vertically disposed length of steel C-channel. Accordingly, the ends of adjacent panels contact one anther, and preferably are welded (e.g., stitch welded) along vertical corners (exterior and interior). Further, a top weld preferably is installed along the “seam” defined by the tops of the abutting panels.

In a preferred embodiment, each panel is secured to its footing by means of tie rods situated within and extending beyond both ends of, the reinforcing conduits. The footing is provided with a horizontal anchor bar exposed within a longitudinal channel in the top of the footing. The bottom end of the tie rod is attached to the anchor bar, as by a hook means (on the end of the tie rod) engagable practically anywhere along the anchor bar. The top end of the tie rod is engaged with the upper end of the reinforcing conduit. This engagement preferably is accomplished by means of a rigid strap bracket disposed across the conduit upper end, and having a central aperture through which the tie rod is passed. The top end of the tie rod is threaded, and a tie nut is screwed down the tie rod until the nut contacts the strap bracket; thereafter, continued rotation of the tie nut tightens the nut to press down on the strap bracket while also drawing the tie rod into tension between the strap bracket and the anchor bar. Tightening the tie nut against the strap bracket secures the panel to the footing, via the connection provided by the tie rod extending between the footing's anchor bar and the strap bracket on the top end of the reinforcing conduit.

Upon the completion of panel installation to provide the structure's vertical walls, a roof is placed. The system utilizes commercially available lightweight polystyrene roof deck product that is disposed upon the tops of the vertical panels to provide a form and support for a reinforced poured concrete roof. This roof deck spans between supporting walls, and is secured to the wall tops. The roof, wall panels, and footing are then set by a monolithic concrete pour. The pour fills the channel in the footing (and thus encases the anchor bar), also fills the reinforcing conduits (thus surrounding the tie rods), and then covers the polystyrene roof deck to the desired depth to define the roof panel. This monolithic pour is permitted to cure without cold joints, thus integrating the roof, walls, and footings to provide an extremely strong, thermally insulated building shell.

Reference now is made to FIG. 1, showing generally, but by basic illustration, the practice of the apparatus and method. A reinforced concrete footing 20 is provided upon the ground. A prefabricated panel member 30 is then placed upon the top of the footing, as indicated by the dashed directional lines of the exploded view of FIG. 1.

Referring both to FIG. 1 and FIG. 8, the footing 20 is constructed generally according to known and accepted principles of reinforced concrete design and engineering, except as otherwise explained herein. A longitudinal channel 22 is defined along the entire length, or at least a substantial length, of each footing 20 in the top surface thereof. As seen in FIG. 1, the longitudinal channel 22 preferably but not necessarily is centrally located on the top of the footing 20, generally parallel to the footing's sides. The longitudinal channel 22 may be created or defined by laying a metal C-channel 23 (FIG. 6), legs and open side facing up, in the top surface of the footing 20 after pouring but before curing the footing.

Referring to FIGS. 3, 5, 7, and especially 6, it is seen that the preferred form of footing 20 includes an exposed anchor bar 24 within and along the longitudinal channel 22. The anchor bar 24, which may be steel rebar, is disposed in the channel in a position spaced-apart from the channel walls and bottom. As particularly suggested in FIGS. 3 and 6, the anchor bar 24 is intermittently but well anchored to the footing 20. Any of a variety of means for anchoring the anchor bar to the footing 20 may be used. In one preferred embodiment, a plurality of securing eye-bolts 25 are integrated with the footing 20, so to have their eyes aligned approximately along the axis of the longitudinal channel 22. Alternative to the use of closed-eye bolts, open-hook bolts may be used to facilitate easy engagement of the length of anchor bar 24 with the plurality of linearly aligned bolts 25. Other means for anchoring the anchor bar 24 to the footing 20 may be used without departing from the scope of this invention. FIGS. 3 and 6 show how the eyebolts 25 or other anchoring means may extend into the volume of the longitudinal channel 22, either from the sides of the bottom of the channel 22, and preferably are placed or shortly after the footing 20 is poured. The anchor bar 24 thus may be secured by integrating with the footing 20 a securing bolt 25 that extends into the longitudinal channel 22, and then threading or hooking the bar 24 through the exposed business end of the securing bolt 25. Furthermore, each end of the horizontally disposed anchor bar 24 preferably extends into the footing 22, e.g., is bent abruptly to extend into the bottom of the channel 22 before the footing solidifies.

Combined reference is made particularly to FIGS. 1 and 8. A panel member 30 has two main features, the frame 32 and the panel body 40. Assembling a frame 32 ordinarily involves assembling elements to define at least a top 34, two ends 36, and a bottom 38 of the panel 30. Door and window sub-frames, not shown in the figures for simplicity of illustration, may be assembled and attached within the main panel frame 32, and their provision is within ordinary skill in the art. In a preferred embodiment, the frame has a plurality (e.g., four) of rectilinear members 34, 36, 38 contiguously interconnected to define a generally rectangular frame 30 as seen in FIG. 1. The rectilinear members providing the top 34, two ends 36, and bottom 38 preferably are segments of steel C-channel cut to the selected design lengths. The segments of C-channel defining the frame 32 are arranged and disposed such that the “legs” of the C-channel face “inward” toward the center of the (typically rectangular or square) panel member 30. The joints whereat adjacent and adjoining frame members 34, 36, 38 abut are permanently connected by welding according to convention.

Frames of panel members according to the invention are arranged and configured according to the particular structure design plan; an advantage is that adjoining panel frames may be welded to significantly promote structural integrity. For example, FIG. 2 shows the top outside corner of two conjoined panel members according to this disclosure, having abutting respective frames 32, 32′. The C-channel end 36 of one panel frame 32 contacts the C-channel end 36′ of the other frame 32, while the corresponding frame tops 34, 34′ also are in contact. A long weld 71 is placed along the joint between the panel tops 34, 34′. Along the exterior seam of a corner, the two frame ends 36, 36′ are in contact for their complete common length (e.g., the height of a panel member). Accordingly, stitch welds 70, placed intermittently along the juncture of the ends 36, 36′ are adequate. Welded connections among the contiguous panel frames of a building provides for an overall structural system of tremendous strength and load-bearing capability.

FIG. 8 shows two panel members 30 placed end-to-end upon a footing 20, and conjoined in a manner according to the present invention.

Reference is made to FIGS. 1, 3, and 5. At least one, preferably more, hollow reinforcing conduits 42 are situated within the frame 32. Each conduit extends from an upper conduit end 43 penetrating the top 34 of the frame 32 to a lower conduit end 44 penetrating the bottom 38 of the frame 32 to provide fluid communication between the top 34 and bottom 38 of the frame. The conduit 42 may be cylindrical, or have any other radial cross-sectional shape, but is composed of a strong, rigid material resistant to both bending and axially compressive loading. The conduits 42 preferably are design lengths of steel pipe; situating any particular conduit 42 in the frame preferably involves the welding the steel pipe to at least the top steel C-channel member 34. Very preferably, the upper conduit end 43 is welded to the steel top 34 and the lower conduit end 44 likewise is welded to the steel C-channel bottom 38.

Notably, and as seen in the drawing figures, especially FIGS. 3 and 4, the upper conduit end 43 may extend above the top 34 a short distance (e.g., about six inches). The lower conduit end 43, however, while penetrating the bottom 38 does not extend beyond the bottom but is flush therewith so that the bottom of the frame 32 may rest in flush contact upon the top surface of the footing 20.

The foamed cementitious panel body 40 is formed within the frame 32; the panel body 40 has two sides (e.g. an exterior face and an interior face, typically both planar), with the frame defining the overall perimeter and thickness of the body (FIGS. 1 and 5). During erection of a dwelling, an assembled frame 32 may be laid horizontally upon the ground, with a planar form beneath to delimit an exterior side of the panel body to be poured. The wet foamed cementitious material may then be poured into the molding form thus provided, stricken and floated flat on its upper surface to define an “interior” side of the body 40, and allowed to cure. After the material of the body panel 40 has adequately cured, and thus is a lightweight solid, the entire panel member 30 may be moved to storage, transported to the job site, etc. With the composition of the body 40 cured, the panel member 30 can withstand stresses associated with being shipped and manipulated about, including being placed in a vertical orientation upon a suitable footing 20.

The cementitious mixture for the panel body 40 preferably is prepared and poured into a frame 32 at a central manufacturing facility. The cured panels may then later be transported to various jobsites as needed. Alternatively but less desirably, the panel body 40 may be poured and cured at the building construction site.

The panel body's cementitious mix includes as main ingredients Portland cement, foaming agent, expanded perlite, and water. To prepare one cubic yard of wet mix, the dry ingredients are mixed in the following ranges:

Portland cement: about 325 lbs to about 950 lbs, preferably between 450 lbs and 600 lbs, and most preferably about 540 lbs (to make about 1.0 yd³wet mix).

Expanded perlite: about 3 lbs to about 270 lbs, preferably between 20 lbs and 100 lbs, and most preferably about 50 lbs (to make about 1.0 yd³ wet mix).

The dry ingredients are mixed with water at a water/cement ratio of approximately 0.5, to which wet mix the foaming agent is added. Foaming agents may be either synthetic or organic; a very suitable agent is available commercially from Cellular Concrete, LLC of Allentown, Pa., USA, under the trademark MEARLCRETE. Foam liquid concentrate is added to the mix at rates of between approximately 1.5 and 2.0 lbs per cubic yard of wet mix, which typically yields a foam volume of between about 16 ft³/yd³ and about 21 ft³/yd³. The foregoing material measures and weights are recited for a single cubic yard, approximately, of cellular concrete. Persons skilled in the art know to multiply amounts by a number corresponding to the total number of cubic yards required in a given batch of wet mix.

Further, it is contemplated that newer “catalyzed” foaming agents may be used in the disclosed system and method. Catalyzed agents result in rapid setting of the cellular foam to maintain a lightweight pour while the concrete cures (which also may contain admixtures to accelerate curing). Catalyzed foam liquid products are available from Allied Foam Tech Corporation, Montgomeryville, Pa., USA.

The resulting wet batch is well-mixed to activate the foaming agent, and then quickly poured and finished, as with floating and screeds known in the art of concrete construction. Once poured to design thickness within a formed frame 32, the foamed cementitious mix is allowed to cure; adequate curing, at ambient temperatures (preferably above 70° F.) and humidity, to permit panel transportation to a job site, typically requires about four days. However, if catalyzed foaming agents and accelerating admixtures are included in the mix, curing times can be reduced to as little as twelve hours.

The cementitious mix according to this disclosure cures to have a dry density of less than approximately 44 lbs/ft³ , and a thermal conductivity believed to be less than about 1.0 Btu in/hr per square foot per degree Fahrenheit.

Referring to FIGS. 1, 3, 7, and 8, and as best seen perhaps in FIG. 4, a rigid frame flange 55 is attached along the outside length of a frame top 34 by welding, bolting or any other suitable means. The frame flange 55 serves as a form for a poured bond beam 68 (FIG. 5) and roof 60, to be further described hereinafter. A frame flange 55 preferably but not necessarily is composed of the same or similar steel gauge as comprises the frame members 34, 36, 38. The frame flange 55 projects perpendicularly (for example, about 12 inches) from the frame top 34, and is secured thereto along one edge (i.e. an “outside” edge) as indicated in the drawing figures. There preferably are provided a plurality of gussets 56 at spaced intervals along the top 34, situated orthogonally to both the top 34 and the frame flange 55, to reinforce the connection between frame flange and top, and to contribute structural integrity to the overall panel member 30. A gusset 56 may be penetrated, as needed, with a pour aperture 57 (FIG. 1) to permit wet cement to flow through from one side of the gusset to the other.

Optionally but often, electrical conduit 75 and switch boxes 73 (FIG. 1) generally according to known art are incorporated within a frame 32 prior to the pouring of the cementitious panel body 40 therein. Wiring is pulled through the conduits 75 as a cured panel member 30 is set in place upon a footing 20. Wiring also ordinarily is pulled before the pouring of the roof cap and upper bond beam on the frame, as described further herein. Certain plumbing stubs and conduits likewise may be blocked out or pre-installed within a frame 32 prior to the pouring of the panel body 40 there around.

Attention is invited to FIGS. 3, 6 and 7. Further erection of a structure according to this disclosure includes the placement of a cured panel member 30 upon the footing 20. Placing the panel member 30 upon the footing 20 includes registering the panel member bottom 38 with the longitudinal channel 22 while also placing the lower conduit end 44 in fluid communication with the channel 22.

The frame bottom 38 is placed in flush contact with the top of the footing 20, laterally spanning the longitudinal channel 22. The panel member 30 thus is aligned with the longitudinal channel; panel bottom 38 is in registration with the channel and proximate to (and roughly parallel to) the anchor bar 24. The panel member 30 then is attached to the footing 20 by securing the panel member 30 to the anchor bar 24.

Referring to FIGS. 3 and 7, it is seen that securing the panel member 20 to the anchor bar 24 includes situating a tie rod means 46 along the interior length of each reinforcing conduit 42, connecting the lower end of each tie rod 46 to the anchor bar 24, and engaging the upper end of each tie rod with the upper end of the conduit 42. Each conduit 42 of a particular panel member 30 has a tie rod 46 therein; each tie rod has an effective length exceeding the length of its surrounding conduit, so that the tie rod upper end 48 extends (e.g., a few inches) beyond the conduit upper end 43, and also extends (e.g. several inches) below the panel frame bottom 38.

As best seen in FIG. 6, the lower end 47 of the tie rod 46 features or is provided with a connecting means, such as a hook 49, for connecting the lower end 47 of the tie rod to the anchor bar 24. The lower end 47, bearing the hook connector 49, extends from the lower end 44 of the conduit 42 thus to project below the bottom 38 of the frame. By engaging around the anchor bar 24 all the hook means 49 associated with a given panel member, the panel member can be secured to the footing.

The upper end of the tie rod 46 is engaged to the upper end of the conduit 42. One means for realizing this engagement is shown in FIGS. 3 and 4. There it is seen that the projecting portion of tie rod upper end 48 is threaded to receive a complementarily threaded locking nut 50. For each and every conduit and tie rod, 42, 46, there is provided a rigid strap bracket 51. The length of the bracket 51 exceeds the diameter of the conduit 42. The metal alloy planar strap bracket 51 has a central aperture 52 through which is passed the threaded upper end 48 of the tie rod 46. Upon placement around the tie rod 46, the strap bracket 51 is then disposed across the conduit upper end 43 in contact therewith. Notably, the short-dimension width of the bracket 51 is considerably less than the diameter of the conduit 42, so that wet concrete may flow past the installed strap bracket and into the open upper end 43 of the conduit, thereby to permit the conduit to be filled with concrete. Preferably, concrete can flow freely through the conduit 42 in either direction, as both the upper and lower ends 43, 44 thereof are open (FIG. 3). Screwed tightening of a locking nut 50 against the strap bracket 51, while the connector 49 is engaged with the anchor bar 24, draws the tie rod 46 into tension; continued tightening of all the locking nuts arranged along a given panel member 30 pulls the panel member into extremely reliable and secure connection to its underlying footing 20.

A noteworthy benefit and significant advantage of the present system is the versatility of the afore-described mode of connecting a panel member to its associated footing. Because the anchor bar 24 is exposed and available along a major portion, or the entirety, of the length of the footing 20, there is little difficulty aligning each hook connector 49 with the anchor bar for engagement therewith. Without regard for the number or spacing of the conduits 42 (and thus the tie rods 46) in a particular panel member 30, the anchor bar is available directly below the lower end 47 of each tie rod 46. The step of engaging the hook means 49 around the anchor bar 24 thus beneficially involves engaging the hook at substantially any location along the full length of the anchor bar 24. This provides tremendous flexibility and facility in locating panel members 30 along a footing 20 for proper installation. In sum, the system's anchor bar running axially along the footings permits construction workers to position the panel members on the footings according to design plan, but with minimal concern for assuring the availability of an anchor point aligned directly below each hook connector 49.

The system also includes the placement of a roof 60 atop a collection of erected panel members 30. Referring to FIGS. 5 and 8, the preferred roof installation involves the disposition of a reinforced plastic deck 62 upon the tops 34 of erected panel members, so as to span from panel-to-panel, i.e., from wall to wall, according to the configuration of the particular structure. A lightweight cement is then poured and approximately leveled (or pitched to provide drainage, per specific design) onto the roof deck 62, so that, after the cement cures, a durable, generally planar cement roof cap 63 is the exposed upper surface of the roof 60.

Roof deck 62 is any of a number of products available commercially “off-the-shelf,” which are devised to be the reinforced substrata and supporting form for suspended pours of lightweight layers of concrete. Such concrete roof decking products include the LITE-DECK product available through Lite-Form International of South Sioux City, Neb., USA; or the QUAD-DECK product available from Quad-Lock Building Systems Ltd. of Surrey, British Columbia, Canada. Such products generally are fabricated from reinforced polystyrene, and are engineered to support and form poured concrete roofs (and floors in upper stories of multi-storied structures). A deck 62 according to this disclosure is reinforced both by its design moment of inertia as well as metal strips and cables integrated within the plastic deck. Further, an upper surface of the deck 62 preferably features a plurality of parallel longitudinal troughs or channels into which reinforcing rods may be placed. Such troughs may have a “dove-tail” shape, such that wet concrete flows through a narrower upper neck and into a broader lower volume, thereby securely integrating the deck 62 with a concrete cap 63 poured thereupon.

Referring particularly to FIGS. 5 and 7, it is seen that an end of a deck 62 is lowered upon an inside portion of the upper surface of the frame top 34, and there secured by bolting or other known means. In the preferred embodiment, the lateral width of the top 34 (i.e., the thickness of the panel member 30) and the diameter of the reinforcing conduit 42 are such that the end of the deck 62 can abut the upper ends of the conduits 42 projecting above the frame top 34, and yet substantially overlap the frame top to rest thereupon. By way of non-limiting example, if the frame top 34 is one foot wide and the conduits 42 along the axis of the top 34 each have a diameter of four inches, the flush overlap of the bottom of the deck 62 upon the frame top 34 is approximately four inches. This secured overlapping connection of deck 62 to frame top 34 is best seen in FIG. 7.

With adequate decking 62 installed upon a plurality of vertically oriented panel members configured according to design, a roof cap 63 may be placed. A final one of the principal steps and components of the method and system is the pouring of wet concrete to fabricate the roof cap 63, which pour is simultaneous to the pouring of concrete into the reinforcing conduits 42 and the longitudinal channel 22 in the footing. Such a monolithic pour serves to securely interconnect further the various modules of the structure, as the curing concrete bonds not only with the roof deck 62, but also the interior of the reinforcing conduits 42, the surfaces of the tie rods 46, the anchor bar 24, and the footing 20. Further, as the concrete fills the volume above the frame top 34 and between the end of the deck 62 and the frame flange 55, a concrete upper “bond beam” 68 is created along the frame top 34.

The wet concrete mix is poured (or pumped, as needed) atop the structure and onto the roof deck 62. Pouring continues for sufficient time and volume to cover the entire deck 62 to the design depth; the thickness of the concrete roof cap 63 may be determined by the elevation of the top edge of the frame flange, as suggested in FIG. 5.

As wet concrete is poured onto the deck 62, it also is poured into the open upper ends 43 of the conduits 42. Flowing down through each conduit, the wet mix discharges from the lower ends 44 of the conduits, which are adjacent to and in fluid communication with the associated footings' respective longitudinal channels 22. The mix accordingly flows by gravity into, along, and through the channels 22 until the channels are filled and the anchor bars 24 are surrounded and encased with wet concrete. Further, the points of engagement between the hooks or other connector means 49 and the anchor bars 24 likewise are fully submerged. Each concrete-filled longitudinal channel 22 thus serves, after cure, as a sort of bottom bond-beam for a panel member 30 directly above.

After the longitudinal channels are full of concrete mix, pouring continues to fill each conduit 42 with concrete. The conduits 42 fill, surrounding the tie rods 46 with wet mix. Once all the conduits are full, the pouring continues to fill to the design elevation of the top of the roof cap 63. A volume above the top 34 of each panel member, and defined between the frame flange 55 and the roof deck 62 fills with concrete to provide, when cured, an upper bond beam 68 integrated with the roof cap 63. Pouring is not interrupted until all the decks 62 are covered to the design depth to provide a layer of concrete defining the roof cap 63 when cured. Notably, the monolithic pour means that the concrete extends from footing 20 to roof cap 63 via the reinforcing conduits 42 without any undesirable intermediate “cold joints.” FIG. 5 shows that the monolithically poured concrete 64 fills each reinforcing conduit 42 and the channel 22 there below, and extends from the top of the conduit to be integral with the concrete upper bond beam 68 and roof cap 63.

Dimensions and specifications for a system according to this disclosure are subject to design engineering according to principles known in the art. However, some illustrative dimensions may be offered by way of example, rather than illustration.

Panel members 30 defining exterior walls are fabricated to a preferred minimum thickness of six inches, and more preferably from between about twelve inches and about twenty-four inches thick. Panel members 30 serving as interior and/or non-weight-bearing walls may be fabricated to a thickness of from about four to about nine inches. Such dimensions, with foamed perlite cement in the panel body 40, permit benefits of four-hour fire resistance, mold proof, and termite-proof.

A panel member 30 typically has a height of at least two feet and a length of at least about four feet, although vertical and longitudinal extents are adaptable without departing from the scope of the invention. A typical standard panel member is about ten feet long and from seven to ten feet high, with a preferred height of around eight feet. Panel members exceeding dimensions of 16 feet by 16 feet are not recommended. Panel members according to this disclosure have a minimum crush resistance rating of 50 psi, and a minimum lateral shear load rating of 20 psf. The maximum load rating of a panel member 30 on edge is approximately 10,000 pounds per linear foot.

FIGS. 7 and 9 indicate how the concepts of this system and method of this may be utilized to erect a two-story building. The lower panel member 30 is completed and installed upon the footing substantially as described hereinabove. In a two-story construction, the tie rods 46 extend well beyond the upper ends 43 of the bottom panel's conduits 42, and indeed project well above the first-story bond beam 68, as seen in FIG. 7. The bottom 38 of the frame 32′ for the second story is placed upon the ground story's upper bond beam 68. The lower tie rods 46 extend into the interior of the second story conduits 42. Second-story tie rods 46′ within the second story conduits 42′ are secured end-to-end with the lower story tie rods 46 by means of, for example, a coupling nut 65. The process described above for the erection of the ground story can then be repeated essentially step-by-step to provide the second story of the dwelling, including the placement of any desired type of roof components 62′. FIGS. 7 and 9 show that the system of the invention accommodates a variety of architectural features and flourishes, such as parapet walls 67.

It is immediately appreciated that the method and system are well-suited for fabrication in modules. A collection of modular panel members of selected sizes and configurations may be mass-produced and cataloged for use in erecting mass-manufactured buildings. A collected kit of modular components according to this system may be bulk shipped to a building site, where a structure of a selected design is then assembled according the particular kit's fixed plan.

The panel frames 32 and reinforcing conduits 42 may be manufactured separately to a standard panel member dimension with a minimum length of four feet and a minimum height of two feet. The frames can then be modified to fit blueprints for specific structures, including but not limited to electrical, plumbing, windows, and doors.

Assembled frames are filled with the foamed cementitious material described above. Poured panels 30 are cured in ambient air at a temperature preferably between about 50° F. and 110° F. for a minimum of about four days. Thereafter, individual panel members may be moved onto flatbed trailers or train cars, and may be so loaded as to be unloaded in the appropriate order of assembly at a job site. Panel members may continue curing in transit to the building site, or during storage, until such time as they are delivered, erected, and installed at the project site. Panel members are unloaded at the building site and erected using a crane, forklift, or the like.

The footing 20 according to the foregoing descriptions is placed in the ground according to project site design specifications, and allowed to cure prior to erection of any panel members thereon. Once a kit or requisite collection of selected panel members 30 and roof deck 62 and auxiliary components are delivered to the site, they are erected, bolted, and welded. The plumbing is stubbed and the wiring pulled. The deck 62 is installed, and the monolithic concrete pour filling the channels 22, reinforcing conduits 42, and defining the roof cap 63 with integral bond beam is accomplished using conventional transit-mix trucks and mix pumping as needed. The basic assembly of a residential structure of around 3,500 square feet may be accomplished in only a few days.

It should be appreciated that buildings according to the invention are intended to be permanent structures. However, for buildings that are to be portable, the monolithic final (roof) concrete pour is not done, so that the panel connecting welds can be cut, the panel components unbolted, and the building relocated elsewhere.

The speed with which the present building system can be manufactured, delivered, and installed offers tremendous opportunities for contractors to reduce the cost of delays relating to standard framing and drywall. The system and method additionally provides increased value to homeowners through a building system that is fire resistant, mold proof, termite proof, and is up to forty percent more energy efficient than customary two-by-six lumber framed structures. Moreover, the advantages of this building system can be realized at costs equal to or less than that of conventional building materials and practices.

Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents.

Claims

1. A method for erecting a structure comprising the steps of:

disposing a reinforced concrete footing, comprising the steps of: defining along a substantial length of the footing a longitudinal channel in a top surface thereof; and disposing an anchor bar within and along the longitudinal channel and securing the anchor bar to the footing;

preparing a panel member, comprising the steps of: assembling a frame to define at least a top, two ends, and a bottom of the panel; situating at least one conduit within the frame, extending from an upper conduit end penetrating the top of the frame to a lower conduit end penetrating the bottom of the frame to provide fluid communication between the frame top and frame bottom; forming within the frame a foamed cementitious panel body, the panel body having two sides and the frame defining the body perimeter;

placing the panel member upon the footing and proximate to the anchor bar;

securing the panel member to the anchor bar; and

filling the at least one conduit with concrete.

2. The method of claim 1 wherein the step of defining a longitudinal channel comprises laying a metal C-channel in the top surface of the footing prior to curing the footing.

3. The method of claim 1 wherein the step of securing the anchor bar comprises the steps of integrating with the footing a securing bolt extending into the longitudinal channel.

4. The method of claim 1 wherein the step of assembling a frame comprises contiguously interconnecting segments of steel C-channel.

5. The method of claim 1 wherein the step of placing the panel member upon the footing comprises:

registering the panel member bottom with the longitudinal channel; and

placing the lower conduit end in fluid communication with the longitudinal channel.

6. The method of claim 5 wherein the step of securing the panel member to the anchor bar comprises:

situating rod means along the interior length of the at least one conduit;

connecting the lower end of the rod means to the anchor bar; and

engaging the upper end of the rod means with the upper conduit end.

7. The method of claim 6 wherein the step of connecting the lower end of the rod means comprises:

providing a hook means on the lower end of the rod means; and

engaging the hook means around the anchor bar.

8. The method of claim 7 wherein the step of engaging the hook means around the anchor bar comprises engaging the hook means at substantially any location along the length of the anchor bar.

9. The method of claim 5 wherein the step of filling the at least one conduit with concrete comprises permitting wet concrete to flow from the lower conduit end into the longitudinal channel.

10. The method of claim 4 wherein the step of situating at least one conduit member comprises welding a steel pipe to at least the top steel C-channel member.