CAST WALL WITH MODULAR UNITS
A cast wall system comprising at least two modular units, each having a front surface, a back surface, and opposing edge surfaces. A first edge surface (e.g., an upper edge surface) of one modular unit is positioned adjacent to a second edge surface (e.g., a lower edge surface) of another modular unit. A compression system (e.g., a threaded rod under tension) and coupled to elongated beams) provides a force to compress the first edge surface of the one modular unit toward the second edge surface of the other modular unit, and a hardened backing (e.g., concrete) is positioned on the back surface of the at least two modular units. Preferably, the first and second edge surfaces are ground in order to improve the surface contact between those two edge surfaces. When producing the cast wall, the hardened backing is preferably poured onto the back of the modular units. Prior to and during the pouring, it is preferred to support a first end of the one modular unit and a second end of the other modular unit on a common rail. In one embodiment, the common rail includes a base portion and an upright portion (e.g., a T-rail), and the step of supporting includes positioning the base portion on a support surface, and setting the first end of the one modular unit and the second end of the other modular unit on the upright portion. Preferably, the second end of the one modular unit and the first end of the other modular unit are supported on rails different than the common rail.
The present invention generally relates to the field of concrete walls having veneered surfaces.
BACKGROUNDDue to the expense of building a conventional brick wall from brick, block, stone, or other hard modular unit, veneered building panels with a hardened backing (e.g., concrete) arc becoming more popular in building construction. In one common process, thin modular units, such as thin bricks or blocks, are laid out face down, and a concrete backing layer is poured into the track of the units to form a cast wall. The veneered brick building panels can either be pre-cast (i.e., constructed off-site and then transported to the building site) or tilt up (constructed on-site and tilted up into place) to be attached to an exterior wall.
In the past, simulated brick veneered building panels were made of thin modular units that are arranged on an object retention liner. U.S. Pat. No. 5,268,137 to Scott, et al. shows an object retention form liner that holds and transfers objects, such as thin bricks, to the finished surface of concrete structures. Thin bricks are placed in recesses in the form liner. Concrete is poured into the form liner to completely cover the backs of thin bricks. The concrete fills the spaces along the sides of the thin bricks and additional cavity areas to simulate the grout line in conventional masonry construction. Once the concrete has properly hardened, the wall is raised and the form liner can be pulled away from the outer surface of the concrete wall to expose the outer surface of the bricks having grout lines to give the appearance of a conventional masonry construction.
U.S. Pat. No. 5,009,387 to Scott, et al. shows a form liner with recesses that are closely sized to fit the face of a standard brick or a thin brick that is about one-half the depth of a standard brick. The recesses are arranged in staggered rows in the surface of the form liner to resemble the normal grout line between bricks. Ridges between the bricks fill the area around each side of the brick to a desired depth to form the grout recesses. Retainers such as clips hold the bricks in position in their individual recesses. The retainers are flexible and resilient enough to maintain proper spacing between bricks by absorbing the vibration that occurs during the cement pouring process.
SUMMARYAlthough the systems described above increase efficiency in the construction of walls, the thin modular units do not effectively transfer compressive loads. Therefore, the thin modular units are not able to be taken into account while measuring the load bearing capabilities and structural rigidity of the wall. The result is that the poured concrete must be sufficiently thick to take the full design load of the wall. In addition, some existing pre-cast systems allow concrete to leak between the modular units and into the front face of the modular units and onto the casting deck.
A need exists for a precast wall that is load bearing and can add to the structural rigidity of the wall. A precast wall whereby the concrete modular units act as an integral structure and where the concrete modular units absorb and transfer a compressive load to each other will allow the precast wall to be calculated as a load bearing structure. In addition, there is a need for a precast system that inhibits the leakage of concrete onto the front face of the modular units.
The present invention provides a cast wall system comprising at least two modular units, each having a front surface, a back surface, and opposing edge surfaces. A first edge surface (e.g., an upper edge surface) of one modular unit is positioned adjacent to a second edge surface (e.g., a lower edge surface) of another modular unit. A compression system (e.g., a threaded rod under tension and coupled to elongated beams) provides a force to compress the first edge surface of the one modular unit toward the second edge surface of the other modular unit, and a hardened backing (e.g., concrete) is positioned on the back surface of the at least two modular units. Preferably, the first and second edge surfaces are ground in order to improve the surface contact between those two edge surfaces.
The above-described cast wall system can be produced by positioning the first edge surface of the one modular unit adjacent to the second edge surface of the other modular unit, compressing the first edge surface toward the second edge surface, and pouring a backing (e.g., concrete) on the back surface of the at least two modular units. Preferably, the method also includes grinding the first and second edge surfaces prior to compressing.
In another aspect, the invention provides an improved method of forming a cast wall system that is made up of at least two modular units, each modular unit having at least a first end and a second end, and each end having an edge surface. The method comprises positioning an edge surface of the first end of one modular unit adjacent an edge surface of the second end of the other modular unit, supporting the first end of the one modular unit and the second end of the other modular unit on a common rail, and pouring a backing (e.g., concrete) onto the modular units. In one embodiment, the common rail includes a base portion and an upright portion (e.g., a T-rail), and the step of supporting includes positioning the base portion on a support surface, and setting the first end of the one modular unit and the second end of the other modular unit on the upright portion. Preferably, the second end of the one modular unit and the first end of the other modular unit are supported on rails different than the common rail.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
DETAILED DESCRIPTIONIn constructing the cast wall 10, a frame 24 having the dimensions of the desired cast wall 10 is placed on a generally horizontal surface, such as the ground. The frame 24 can be constructed of many different of materials, including without limitation steel, wood, rigid plastic, and other types of synthetic or non-synthetic materials, and any blend or combination thereof. The frame 24 should be rigid to withstand any shear or normal forces that may be present once the modular units 14 are placed inside the frame 24 and the concrete backing is poured.
The modular units 14 illustrated in
The edge surfaces 30 of the modular units 14 are qualified, or ground, to provide surfaces that will effectively mate with adjacent edge surfaces for transfer of loads. More specifically, in the illustrated embodiment, the top and bottom edge surfaces 30 are ground so that they are substantially parallel to each other, and the side edges are ground so that they are substantially parallel to each other and perpendicular to the top and bottom surfaces. Edge surfaces 30 that are not in contact with other surfaces can function properly without grinding. For example, the top edge 34 and left edge 38 of the modular unit 42 at the top left corner of the cast wall 10 may function properly without being ground.
The front surfaces 28 of the illustrated modular units 14 are commonly colored to provide a desired appearance. For example, the front surface 28 can be colored and textured to provide the appearance of brick, granite, and other building materials. The color of the modular units can be mixed throughout the modular units or, alternatively, can be at the surface only.
Referring to
In the embodiment illustrated in
The insert 18 includes a tongue portion 66, a stabilizer portion 70, and a receiving portion 74. The tongue portion 66 is dimensioned to fit securely into the groove 54. In the embodiment illustrated in
The stabilizer portion 70 is coupled to the tongue portion 66 and is designed to be positioned flush with the rear surface 26 of the modular unit 14 when the tongue portion 66 is inserted into the groove 54. The stabilizer 70 serves to inhibit excess bending of or torque on the insert 18 when the insert 18 is coupled to the connection bar 22. In the embodiment illustrated in
As illustrated in
In constructing the cast wall 10 illustrated in
After the top row 46, bottom row 50, and middle rows 118 have been arranged in the frame, the connection bars 22 can be installed. As illustrated in
In embodiments wherein both ends 106, 114 of the connection bar 22 are threaded and both apertures 94, 90 are threaded, a first end 106 of the connection bar 22 is inserted into a first aperture 94 and the second end 114 of the connection bar 22 is inserted into a second aperture 90. Because the first aperture 94 is threaded opposite to that of the second aperture 90, when the connection bar 22 is rotated, both ends 106, 114 of the connection bar 22 will engage the respective threads and thereby tighten and compress the cast wall 10. In this embodiment, the connection bar 22 can be threaded partially into the inserts 18 before the inserts 18 are engaged with the grooves 54.
In other embodiments of the invention wherein both ends 106, 114 of the connection bar 22 are threaded and the apertures 94, 90 are not threaded, the first end 106 of the connection bar 22 can be inserted into a first aperture 94 independent from or simultaneously with the second end 114 of the connection bar 22 being inserted into a second aperture 90. Stoppers 110 can then be screwed onto the threaded ends 106, 114 of the connection bar 22 until the modular units 14 are compressed. Other methods of compressing the modular units 14 are available in alternative arrangements of the connection bar 22 and inserts 18.
After compressing the modular units 14 with the connection bar 22, concrete 88 is poured into the frame 24 and onto the back of the assembled modular units 24. The concrete 88 is evenly spread on the rows 46, 50, 118 of modular units 14. The concrete 88 sits for a time period until the concrete 88 is hardened to a desired drying point. The cast wall 10 can then be tilted up to be used as a structural building wall. It should be understood that any other suitable hardened backing can be used instead of concrete.
Another embodiment of the invention is shown in
The modular units 214 have chamfered edges 229 that are aligned with the chamfered edges 229 of the adjacent modular unit 214. In the embodiment illustrated in
The chamfered edges 229 allow for a U-shaped chair, or riser 236, to be inserted into the chamfered edges 229. The riser 236 has two arms 240 that each fit within the chamfered edge 229 of a modular unit 214. A base portion 244 of the riser 236 rests on a flat surface 245 (e.g., the ground G) within a frame 252. As illustrated in
In the embodiment illustrated in
As illustrated in
The elongated beam 218 has apertures 294 that are spaced to align with the grooves 326, 330. The apertures 294 are located on either the first face 220 or the second face 222 of the elongated beam 218, depending on which face 220, 222 is adjacent the grooves 326, 330. The apertures 294 are large enough to receive a first end 306 or a second end 314 of the connection bar 322. The first end 306 and second end 314 of the connection bar 322 are threaded and can be connected to a threaded nut 310. In other embodiments, variations in the connection between the elongated beam 218 and the connection bar 322 can exist as long as the construction allows for compression of the modular units 214 by the connection bar 322.
The cross-section of the connection bar 322 illustrated in FIGS. 5 and 7-8 is generally round. The vertical grooves 326, 330 for receiving the connection bar 322 are of a round shape, or a shape that can fully accommodate the round connection bar 322. In other embodiments, the shape of the connection bar 322 and grooves 326, 330 can vary. The horizontal groove 254 has a more squared shape to receive at least one face 220, 222 of the elongated beam 218. However, the horizontal groove 254 can be shaped in various ways to receive alternative shapes of the faces 220, 222 of the elongated beam 218.
In constructing the cast wall 210 of
Upon the connection bar 322 being fully inserted within the vertical grooves 326, 330 of the modular units 214 and into the apertures 294 in the elongated beams 218, the threaded nuts 310 can now be screwed onto the first or second ends 306, 314 of the connection bar 322 to cause the connection bar 322 to compress the modular units 214 together. When the modular units 214 are compressed by the connection bar 322 to the desired force, the cast wall 210 is ready for concrete 288 to be poured. The concrete 288 is not shown to be entering grooves 326, 330 of cast wall 210 in
In should be understood that the vertical compression of the modular units structurally integrates the modular units as a structural component of the building wall, and further inhibits leakage of concrete between the top and bottom edges of adjacent modular units. The modular units can also be compressed in the horizontal direction in order to inhibit the leakage of concrete between the side edges of adjacent modular units. Because the side edges are precision ground, horizontal compression of the modular units will provide the desired seal to deter concrete leakage. The horizontal compression is not illustrated in the drawings, but can be performed in a manner similar to that described above for the vertical compression. For example, the horizontal compression can be performed using an apparatus similar to that illustrated in
In one embodiment, the horizontal compression is performed first, followed by the vertical compression. After the vertical compression is added, the apparatus for creating the horizontal compression can be removed. Due to the overlapping nature of the modular units, the vertical compression will maintain at least a portion of the horizontal compression. In this manner, only the apparatus that creates the vertical compression will be embedded into the concrete backing.
In a modification of this embodiment, a small vertical compression is applied first, followed by horizontal compression of each row (either simultaneously or sequentially). The horizontal compression of each row is strong enough to overcome the friction created by the vertical compression and move the units horizontally into intimate contact with each other. The horizontal compression is then removed, and the small vertical compression will hold the units in place. Concrete can then be poured into the back of the assembled units.
In another embodiment of the invention, the compression of the units can be performed by the frame 24. More specifically, the side rails of the frame can be designed to be movable so that a compressive force can be applied by the rails on the assembled units. For example, a pipe clamp can be applied to force the rails into contact with the units, or some other system (e.g., manual, hydraulic, pneumatic, etc.) can be used to move the rails and apply a compressive force to the units.
The embodiment of
The embodiment of
Thus, the invention provides, among other things, a cast wall having a veneered surface that is load bearing and able to transfer compressive loads. The invention further provides a system for building a cast wall wherein the amount of concrete leaking between the modular units is reduced. In addition, the invention provides a rail system that supports the modular units while a backing is being poured. Various features and advantages of the invention are set forth in the following claims.
Claims
1. A cast wall system comprising:
- at least two modular units, each modular unit having a front surface, a back surface, and opposing edge surfaces, wherein a first edge surface of one modular unit is positioned adjacent to a second edge surface of another modular unit;
- a compression system providing a force to compress the first edge surface of the one modular unit toward the second edge surface of the other modular unit; and
- a hardened backing distributed on the back surface of the at least two modular units.
2. The cast wall system of claim 1, wherein the first edge surface is an upper edge surface and the second edge surface is a lower edge surface.
3. The cast wall system of claim 1 wherein the first edge surface is a left side edge surface and the second edge surface is a right side edge surface.
4. The cast wall system of claim 1, wherein the first edge surface comprises a ground surface.
5. The cast wall system of claim 1, wherein both the first and second edge surfaces comprise ground surfaces.
6. The cast wall system of claim 1, wherein the compression system includes a connection bar under tension.
7. The cast wall system of claim 6, wherein the connection bar comprises a threaded rod.
8. The cast wall system of claim 6, wherein the compression system further includes an elongated beam coupled to at least one modular unit and coupled to the connection bar.
9. The cast wall system of claim 1, wherein the hardened backing comprises concrete.
10. A method of forming a cast wall system, the cast wall system made up of at least two modular units, each modular unit having a front surface, a back surface, an upper edge surface, and a lower edge surface, the method comprising:
- positioning a first edge surface of one modular unit adjacent to a second edge surface of another modular unit;
- compressing the first edge surface of one modular unit toward the second edge surface of the other modular unit; and
- pouring a backing on the back surface of the at least two modular units.
11. The method of claim 10, further comprising grinding the first edge surface prior to compressing.
12. The method of claim 10, further comprising grinding both the first and second edge surfaces prior to compressing.
13. The method of claim 10, further comprising supporting a portion of each modular unit on a common rail.
14. The method of claim 10, wherein compressing includes forcing the modular units toward each other.
15. A method of forming a cast wall system, the cast wall system made up of at least two modular units, each modular unit having at least a first end and a second end, each end having an edge surface, the method comprising:
- positioning an edge surface of the first end of one modular unit adjacent an edge surface of the second end of the other modular unit;
- supporting the first end of the one modular unit and the second end of the other modular unit on a common rail; and
- pouring a backing onto the modular units.
16. The method of claim 15, wherein the common rail includes a base portion and an upright portion, and wherein supporting includes:
- positioning the base portion on a support surface; and
- setting the first end of the one modular unit and the second end of the other modular unit on the upright portion.
17. The method of claim 15, wherein the common rail is a first rail, and wherein the method further comprises:
- supporting the second end of the one modular unit on a second rail; and
- supporting the first end of the other modular unit on a third rail.
18. The method of claim 15, wherein the backing comprises concrete, and wherein the method further includes hardening the concrete.
Type: Application
Filed: Jul 11, 2006
Publication Date: Aug 13, 2009
Applicant: UPKON WALL SYSTEMS, INC. (Appleton, WI)
Inventor: John S. Edwards (Weston, WI)
Application Number: 11/995,515
International Classification: E04B 2/16 (20060101);