Reusable and Recyclable Modular Wall System for a Construction Barrier
A modular wall system includes a plurality of wall panels, each with a core, a front skin, a rear skin, and at least one edging piece along at least one edge. The edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length. A floor track has a base flange and a substantially vertical panel-receiving channel. At least one vertically oriented H-spline is provided for resting on the floor track and being positioned between two adjacent wall panels. The H-spline has a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels. The lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web. The rear flange extends over a portion of the rear skins of the adjacent wall panels. A top channel is disposed along a top of the modular wall system and receives a plurality of the wall panels. A first side channel is disposed along a side of the modular wall system and receives at least one of the wall panels.
This application claims priority to provisional application 61/074,565, filed Jun. 20, 2008, entitled “Modular Temporary Construction Safety/Privacy Wall” which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCHNot Applicable.
BACKGROUND OF THE INVENTIONThe present invention relates in general to construction barriers, and, more specifically, to a modular wall system for temporary installations.
Temporary walls or partitions are often used at construction sites such as renovation or remodeling projects in malls, hotels, office buildings, and other public or private venues. The walls provide a safety and security barrier while the renovation or remodeling project is in progress. The walls also block dust and noise from entering public spaces in front of the wall.
Even though the need for a construction barrier is temporary, typical practice is to build walls using conventional metal stud and drywall structures. Such walls are expensive, time consuming, and are labor intensive to install and remove. In order to provide a finished look and to provide an acceptable surface for applying graphics (e.g., a “Coming Soon” message), the time and expense of finishing the drywall (i.e., taping, mudding, sanding, and painting) is necessary. The typical barrier walls generate large amounts of solid waste when torn down. An average wall 70 feet long and 12 feet high generates about one ton of debris that ends up in a landfill. Thus, there is a need for a temporary safety/privacy wall system that can be installed and removed quickly, with less labor, and lower cost while reducing solid waste.
SUMMARY OF THE INVENTIONA preferred embodiment of a modular wall of the invention employs a wall panel which may be comprised of a core bonded with a perimeter edge piece and a plastic skin of about 0.060 thickness or may be a single piece construction with the core, edge piece, and skin integrally formed. The core may have a honeycomb shape or a corrugated shape, for example. The wall panels may be comprised of a polymer such as polypropylene or acrylonitrile butadiene styrene (ABS). Top and bottom tracks of extruded aluminum receive the wall panels and allow for only 0.060 play after a panel is installed. A joiner spline between adjacent panels is comprised of an extruded H-channel that provides about 3″ support on the back side of the panels and about 2.0″ internal support via a groove in each edge piece. Panels at side and/or top ends of the wall are attached to the main section of the wall by a continuous hinge, thereby allowing them to be turned at an angle to the main section. The bottom track may be secured to the floor or ground or may rest in place. The bottom track may be provided with a non-slip rubber tape to protect the floor surface. Panels are stood up and slid into the bottom track with the H-splines being placed between adjacent panels. The top track is slid on and fastened to the panels approximately every 8′ with a through pin and cotter pin. The modular wall structure is tied back to existing structure of the site about every 4′ at the top or bottom of the wall with aluminum angle braces. The front plastic skins of the panels are in a flush abutment to provide a smooth surface that can be decorated with desired graphics. At the time of removal, the parts of the modular wall are easily disassembled and most of the parts can be reused to construct another barrier at a different construction site. The materials for any parts that were modified too much to be reused can be easily recycled.
More specifically, the modular wall system for temporary erection at a construction site comprises a plurality of wall panels. Each wall panel has a core, a front skin, a rear skin, and at least one edging piece along at least one edge, wherein the edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length. A floor track has a base flange and a substantially vertical panel-receiving channel. At least one vertically oriented H-spline is provided for resting on the floor track and being positioned between two adjacent wall panels. The H-spline has a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels. The lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web. The rear flange extends over a portion of the rear skins of the adjacent wall panels. A top channel is disposed along a top of the modular wall system and receives a plurality of the wall panels. A first side channel is disposed along a side of the modular wall system and receives at least one of the wall panels.
Referring to
The main wall section typically is placed out in front of the area being reconstructed (i.e., in a spot not being modified). Therefore, floor track 18 may include a resilient layer at the bottom thereof, such as a rubber tape, to protect floor 12 as is described in greater detail below. Furthermore, the wall will typically turn at the sides or top in order to tie back to existing structure. Thus, a side wall section includes a wall panel 27 received in a side channel 28 and a floor track extension 29. Side channel 28 is preferably connected via a continuous hinge with side channel 20. A top channel 30 and side channel 31 are also disposed around wall panel 27, which is locked in place by additional locking pins 32 and 33, for example. Side channel 31 may be attached to an existing wall of the construction site (e.g., by nails or screws) to help support the entire wall and to complete the barrier on the respective side. On the opposite end of wall 10, a wall panel 34 provides a similar end closure to the existing construction site and is retained in a side channel 35, top channel 36, and side channel 37, while being locked in place by a locking pin 38. A top of the wall may be formed in a similar fashion by providing top wall panels on channels hinged with the top channels of the other wall portions and attached to the existing construction site in a similar manner. If used, the side wall section(s) and top wall section(s) can also be interconnected with specially-cut pieces of wall panels (e.g., a triangular gable piece) mounted in appropriately cut side channels in order to close any resulting openings in the barrier.
The rear side of wall 10 is shown in
On the side section of wall 10,
Side or top wall sections may be added to a wall system using a pair of hinged C-channels as shown in
A higher wall can be achieved by stacking wall panels between vertical H-splines running continuously (i.e., when using wall panels of a lesser height than the full height of a wall). Thus, a wall 100 shown in
A door may be created within the modular wall as shown in
Claims
1. A modular wall system for temporary erection at a construction site, comprising:
- a plurality of wall panels each having a core, a front skin, a rear skin, and at least one edging piece along at least one edge, wherein the edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length;
- a floor track having a base flange and a substantially vertical panel-receiving channel;
- at least one vertically oriented H-spline resting on the floor track and positioned between two adjacent wall panels, the H-spline having a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels, wherein the lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web, and wherein the rear flange extends over a portion of the rear skins of the adjacent wall panels;
- a top channel disposed along a top of the modular wall system and receiving a plurality of the wall panels; and
- a first side channel disposed along a side of the modular wall system and receiving at least one of the wall panels.
2. The modular wall system of claim 1 further comprising:
- a hinge disposed along a substantial length of the top channel;
- a canopy channel attached to the top end channel via the hinge; and
- a top wall panel mounted within the canopy channel and adapted to be mounted to relatively permanent structure at the site.
3. The modular wall system of claim 1 further comprising:
- a hinge disposed along a substantial length of the first side channel;
- a second side channel attached to the first side channel via the hinge;
- a extension floor track having a base flange and a substantially vertical panel-receiving channel, the extension floor track extending non-parallel from the floor track; and
- a side wall panel mounted within the second side channel and the vertical panel-receiving channel of the extension floor track.
4. The modular wall system of claim 1 further comprising:
- a plurality of angle braces, each attached to a respective rear flange of a respective H-spline and to a relatively permanent structure at the site.
5. The modular wall system of claim 4 wherein the relatively permanent structure is comprised of a floor or ground underlying the modular wall.
6. The modular wall system of claim 4 wherein the relatively permanent structure is comprised of an upper structure of a building on the site.
7. The modular wall system of claim 1 further comprising:
- a locking pin mounted through aligned holes in the vertical panel-receiving channel and one of the plurality of wall panels.
8. The modular wall system of claim 1 further comprising:
- a locking pin mounted through aligned holes in the top channel and one of the plurality of wall panels.
9. The modular wall system of claim 1 further comprising:
- a plurality of locking pins including at least a first locking pin mounted through aligned holes in the vertical panel-receiving channel and one of the plurality of wall panels and a second locking pin mounted through aligned holes in the top channel and a different one of the plurality of wall panels.
10. The modular wall system of claim 1 including a pre-hung door section for installation between a pair of wall panels in the modular wall system, the door section comprising:
- a frame having outwardly extending C-channels at its sides and top and a sill at its bottom;
- a door panel hung within the frame; and
- a plurality of locking pins mounted through respective aligned holes in the C-channels and respective wall panels on each lateral side of the door section.
11. The modular wall system of claim 10 further comprising:
- a lintel wall panel inserted into the C-channel at the top of the frame; and
- a pair of H-splines mounted to the lateral sides of the lintel wall panel.
12. The modular wall system of claim 1 wherein the core, front skin, rear skin, and edging piece of each wall panel are comprised of recyclable plastic.
13. The modular wall system of claim 12 wherein the core is corrugated.
14. The modular wall system of claim 1 wherein the floor track, H-spline, top channel, and side channel are comprised of extruded aluminum.
15. The modular wall system of claim 1 wherein the floor track further comprises a resilient layer applied to the base flange.
16. A method of installing a modular wall system for temporary erection at a construction site, the method comprising the steps of:
- laying a floor track, wherein the floor track has a base flange and a substantially vertical panel-receiving channel;
- inserting a first wall panel into the panel-receiving channel, wherein the first wall panel has a core, a front skin, a rear skin, and at least a first edging piece along at least one edge, wherein the first edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining a first intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length;
- inserting an H-spline onto the first edging piece and resting on the floor track, wherein the H-spline has a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the first intermediate groove of the first edging piece of the first wall panel, wherein the lesser length of the second edgewise extensions of the first edging piece provides a gap for receiving the web, and wherein the rear flange extends over a portion of the rear skin of the first wall panel;
- inserting a second wall panel into the panel-receiving channel, wherein the second wall panel has a core, a front skin, a rear skin, and at least a second edging piece along at least one edge, wherein the second edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining a second intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length, wherein the front flange of the H-spline further receives the second intermediate groove of the second edging piece of the second wall panel, wherein the lesser length of the second edgewise extensions of the second edging piece provides a gap for receiving the web, wherein the rear flange extends over a portion of the rear skin of the second wall panel, and wherein there is substantially flush abutment of the front skins of the first and second wall panels;
- inserting a top channel over the first and second wall panels; and
- inserting a first side channel disposed along a side of one of the wall panels.
17. The method of claim 16 further comprising the step of:
- bracing the H-spline to a relatively permanent structure on the site.
18. The method of claim 16 further comprising the step of:
- bracing at least one of the top channel or first side channel to a relatively permanent structure on the site.
19. The method of claim 18 wherein the braced top channel or side channel is hinged to a C-channel, and wherein the bracing step is comprised of:
- inserting a third wall panel into the C-channel; and
- attaching the third wall panel to a relatively permanent structure on the site.
20. A modular wall system for temporary erection at a construction site, comprising:
- a plurality of wall panels each having a core, a front skin, a rear skin, and at least one edging piece along at least one edge, wherein the edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length;
- a floor track having a base flange and a substantially vertical panel-receiving channel;
- at least one vertically oriented H-spline resting on the floor track and positioned between two adjacent wall panels, the H-spline having a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels, wherein the lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web, and wherein the rear flange extends over a portion of the rear skins of the adjacent wall panels; and
- a brace for bracing the H-spline to a relatively permanent structure on the site.
Type: Application
Filed: Feb 4, 2009
Publication Date: May 28, 2009
Inventors: Douglas B. Spear (Clarkston, MI), Aaron D. Barnes (Whitelake, MI)
Application Number: 12/365,240
International Classification: E04B 2/18 (20060101); E04C 2/38 (20060101); E04C 2/20 (20060101);