Fully integrated precast concrete construction including provisions for insulation and all services-HVAC, plumbing, lighting etc.

Abstract

The integrated precast building system provides for all construction elements. The walls, floor, and roof form an integrated structure of module length (FIG. 3). Passages for HVAC, electrical wiring and piping are provided. Inserts for decorative panels and lighting are easily installed and removed. The sloped roof requires no covering. A flat roof can be made with the floor panel but the roof would not be as waterproof as the recommended sloped roof. The system is applicable to homes thru large commercial buildings. The building goes together faster and is completed quicker because all details of the structure are integrated. Life cycle costs are minimized because the structural elements need no painting and do not deteriorate. The basic structure is fireproof. Modifications are easy. Removing the inserts, installing the changes and replacing the inserts facilitate modifications. The buildings can withstand earthquake 4 requirements when post tensioned.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

NONE

FEDERALLY SPONSORED RESEARCH

NONE

SEQUENCE LISTING OR PROGRAM

NONE

1. Prior Art

1. U.S. Pat. No. 1,123,261 Jan . 5, 1915 by T. A. Edison

Mold for Concrete Construction

This is the best example of fully integrated building system to date. It wasn't precast but was cast as one unit in a single pour. The model shown at the Edison National Historic Site shows how the building was to look. The nearest example of the model home is 18 concrete homes built about 1915 in Newark, Ohio. They are similar in appearance to the model but the construction is not with the Edison forms. About the same time 1919, cement homes were built in one day using wood forms in Union, N.J. All of the houses are still lived in and the owners in Newark, Ohio are very happy with their homes.

The homes were not insulated and did not provide for utilities. Edison could not give away the patent because the cost of the forms precluded making a profit. No historical record was found of how the Newark, Ohio homes were constructed but the developer was purported to be a friend of Edison and some of Edison's forms may have been used. Conventional large concrete blocks were used in the foundation work. The owners of the Union, N.J. homes complain of leaky roofs. This is not surprising because the roofs were flat.

2. U.S. Pat. No. 1,144,038 Sep. 28, 1915 by W. C. Broughton—Concrete Building.

This is an example of a simple concrete structure made of precast concrete parts. It is not reinforced to modern standards and has no provisions for utilities.

3. U.S. Pat. No. 1,479,557 Jan. 1, 1924 by W. R. Raymond—Building Construction.

This is another example of simple concrete construction. It is makes no provisions for utilities.

4. U.S. Pat. No. 1,924,801 Aug. 29, 1933 by R. C. Olmsted—Concrete building

This is a more advanced precast concrete system. It makes no provisions for utilities or insulation.

5. U.S. Pat. No. 4,071,984 Feb. 7, 1978 by Larrow—House assembly with prefabricated elements.

This is a more advanced system that does make provisions for insulation but not utilities. It would not pass the latest earthquake requirements. It is not fireproof and is not of cast elements of precast concrete.

6. U.S. Pat. No. 4,114,333 Sep. 19, 1978 by Jones et al.—Wall Panel Unit

This is a limited use panel and does not represent an integrated building system.

7. U.S. Pat. No. 4,127,971 Dec. 5, 1978 BUILDING CONSTRUCTED OF PRECAST L-SHAPED CONCRETE UNITS.

This is a limited system for one-story buildings. It makes no provisions for insulation or utilities. It is not earthquake resistant or adapted to a wide range of structures.

8. U.S. Pat. No. 4,142,340 Mar. 6, 1979 by Howard BUILDING ENCLOSURE MADE FROM STANDARD CONSTRUCTION UNIT IN SIDE WALLS AND ROOF DECK

This is another limited system for one-story buildings. It makes no provision for insulation or utilities. It is not earthquake resistant or adapted to a wide range of structures.

9. U.S. Pat. No. 4,158,941 Jun. 26, 1979 by Silvio Diano PRECAST BUILDING STRUCTURE AND METHOD OF ASSEMBLY

This is a circular structure that makes no provision of insulation or utilities. A much superior circular precast structure was built in the early 60s by Don Johnson (Architect and builder) which required no central support but joined the roof sections by a post tensioned circular beam. Don has built several precast circular buildings but they were not fully integrated with built in channels for utilities. Circular buildings are difficult to scale and forms have to be built for each diameter. This is very limiting and costly.

10. U.S. Pat. No. 4,252,767 Feb. 24,1981 by Matthew R. Piazza, Nichols; David E. Zimmer COMPOSITE BUILDING MODULE

This system makes no provision for utilities. It is not earthquake proof. It has very limited applicability.

11. U.S. Pat. No. 4,669,240 Jun. 2, 1987 by Gluseppe Amormino PRECAST REINFORCED WALL PANELS AND METHOD OF ERECTING SAME.

This system makes no provision for utilities. It is not earthquake proof. It has very limited applicability.

12. U.S. Pat. No. 5,072,554 Dec. 17, 1991 by Lowell K. Hayman PREFABRICATED MODULAR STORAGE BUILDING

This is a limited system for buildings that makes no provisions for insulation or utilities.

13. U.S. Pat. No. 5,103,604 Apr. 14, 1992 by William Teron MODULAR BUILDING SYSTEMS

This is an expansion of patent 4,127,971 and is a small improvement but makes no provision for insulation or utilities except at special modules. It is not a complete building system and would not be earthquake resistant.

14. U.S. Pat. No. 5,150,552 Sep. 29, 1992 by Davis-Arzac BUILDING SYSTEM FOR EXTENSION OF PROGRESSIVE HOUSING

This is a limited application system for building extensions.

15. U.S. Pat. No. 5,230,191 Jun. 27, 1993 by Paul Mayrand PRECAST CONCRETE PANEL FOR PREFABRICATED BUILDING STRUCTURE

This is a sophisticated wall system that combines with floor slabs to erect buildings. Provision for utilities and rework after construction is not provided. Connections do not seem to be strong enough to meet earthquake 4 requirements.

16. U.S. Pat. No. 5,440,845 Aug. 15,1995 by Maher K. Tadros; David C. Salmon; Amin Einea; Todd D. Culp PRECAST CONCRETE SANDWITCH PANELS

This is not a building system. It is a complex wall structure that would require skilled labor to construct.

17. U.S. Pat. No. 5,697,189 Dec. 16, 1997 by John F. Miller; Andrew J Miller LIGHTWEIGHT INSULATED CONCRETE WALL

This is not a building system. It is a complex wall structure that would Require skilled labor to construct.

18. U.S. Pat. No. 6,076,319 Jun. 20, 2000 by Gary K. Hendershot, Gregory E. Cook PRECAST CONCRETE CONSTRUCTION AND CONSTRUCTION METHOD

This is an elaborate system that makes no provision for insulation and utilities. Erection is not simple and connections are varied and may not meet earthquake 4 requirements.

BACKGROUND OF THE INVENTION

OBJECTS and ADVANTAGES

1. Satisfy the needs of buildings from modest homes through multistory commercial buildings of the most common configurations.

2. Be fireproof.

3. Be compatible with earthquake prone locations without extensive modifications.

4. Blend well with existing structures at the building locations.

5. Provide the ability to have unique appearances that will be attractive and useful.

6. Allow the owners considerable choices for customizing the appearance and functionality of the building.

7. Require minimum maintenance.

8. Initial construction cost shall be no more than existing construction as a requirement and considerably less than conventional as a goal.

9. Construction time is minimized.

10. Skilled craftsmen requirements are minimized.

11. Training of the construction crew is easily accomplished with workmen of minimum skills supervised by a permanent small skilled workforce.

12. Quality control shall be inherent in the process and easily inspected.

13. All system elements shall be compatible with the uniform building code.

14. Structural members shall provide the finished surfaces of the building. No cladding shall be required.

15. The floors and roofs shall be free span up to 42 feet. Larger spans are possible but not considered. For very large free span buildings other building systems are more appropriate.

16. Insulation shall be designed into the structural modules.

17. Doors and windows openings shall be precision sized with all surfaces finished during the casting process.

18. Lighting shall be indirect, efficient and capable of adequate switching.

19. The electrical system is designed into the structural modules.

20. HVAC shall be incorporated into the building design and not tacked on later. All ductwork, controls etc. shall be included in the detail design of the building.

21. The system uses a seven-foot module but other modules could be accommodated. The uniqueness of the system is in its completeness and not in the module size.

22. The basic modules are wall, floor and roof.

23. The system can be erected in 7-foot increments up to 42 foot in width. The length of the building is N×7 feet.

24. The roof can be flat or sloped. The sloped roof can be designed to any desired pitch. No roof covering is required for any slope over 2/12. The roof life is unlimited and maintenance free. The preferred embodiment shows a 4/12 slope.

25. The foundation is designed for each site and depends on soil conditions, height of the building and other building unique features. It will be part of each building unique engineering design certification.

26. Cavities under the basement floor and in the building modules provide connectivity for all the utilities, electrical, HVAC, and communications.

Further objects and advantages of my invention will become apparent from a consideration of the drawings and ensuing description.

SUMMARY

1. The building system is fully integrated. Walls, floors, and roof are designed to join each other and provide passages for heating, lighting, air conditioning, and plumbing. Such passages can be used after the building is finished. Modifications can use the wall, roof and floor passages for economical changes without disturbing the existing building tenants. Lighting fixtures are designed to fit the floor and roof modules. Floor, and roof coffers are designed to receive the lighting fixtures and standard decorative ceiling tile. Wall coffers can receive decorative panels of varying designs. All modules can receive electrical outlets, switches, etc.

2. All structural elements of the building are fireproof.

3. The building system can produce multiple types of buildings from homes to high rise buildings.

BRIEF DESCRIPTION OF DRAWINGS

1. FIG. 1—Prototype house isometric

a. FIG. 1a—Main floor plan

b .FIG. 1b—Lower floor plan

2. FIG. 2—Large building

a. FIG. 2a—Condo building project

3. FIG. 3—Basic modules

a. FIG. 3a—Foundation floor cross section

4. FIG. 4—Wall module details.

a. FIG. 4a—Wall sections AA & CC

b. FIG. 4b—Wall section BB details 1, 2, & 3

5. FIG. 5—Floor module details

a. FIG. 5a—Floor cross sections

6. FIG. 6—Roof module details

a. FIG. 6a—Roof cross sections

b. FIG. 6b—Roof cross sections

c. FIG. 6c—Roof overhang cross section

d. FIG. 6d—Roof assembly details

7. FIG. 7—Jointing modules partial isometric

8. FIG. 8—Partial isometric with roof in place

a. FIG. 8a—Roof detail isometric

9. FIG. 9—Stair module

a. FIG. 9a—Stairs—Isometric cut away to show stairs

10. FIG. 10—Wall module with door

11. FIG. 11—Wall module with 4′×4′ window

12. FIG. 12—Wall module with 30″×4′ casement window

13. FIG. 13—Interior module

14. FIG. 14—Interior module with door

15. FIG. 15—Lighting details—Flat ceiling

a. FIG. 15a-2 Lamp ceiling light

b. FIG. 15a1—Single lamp details

b. FIG 15b—Cathedral ceiling light

c. FIG. 15c—Cathedral ceiling light-design details

d. FIG. 15d—Lighting sketch

e. FIG. 15d1—Wall lighting

f. FIG. 15d2—Sidewall lighting flat ceiling

16. FIG. 16—Heat, plumbing & electrical routing

17. FIG. 17—Heating and cooling under lower floor.

a. FIG. 17a—Heating and cooling under lower floor

18. FIG. 18—Post tensioning

DETAILED DESCRIPTION

Preferred Embodiment—FIGS. 1-18

FIG. 1 shows an isometric of the prototype house to be built on a sloped lot. This embodiment illustrates most of the system modules. It illustrates the versatility of the system to accommodate terrain elevations over the building length. Surface textures can be varied. As an example, a rock surface is easily applied while the wall section is curing in a horizontal position in the form during the curing process. This is easily done with unskilled labor using rock rubble that is the most economical rock to buy. Don Johnson and his children rocked the surfaces of his precast concrete home in this manner in a few hours very economically. No skilled masons were present to help. Stamping of the outside surface during curing is also a possibility. There are numerous patterns available. Staining of the surface eliminates the need for painting. White and colored concrete can also be used in the process. These processes are in the public domain and are not part of this patent. This patent does allow economical use of many available surface finishes in an economical manner.

FIG. 1A is the first floor plan of the prototype house. Because of the 42-foot free span interior arrangements can be easily accommodated. Cabinetry is used for most of the walls. Where the internal wall system is used, the walls are placed on the module lines that form a 3.5-foot×3.5-foot grid. Opening the floor panel accommodates the installation of the stairs. Some of the upper stairs are located in the floor beam that supports the upper end of the stairs. FIG. 9 illustrates the installation of the stairs in the floor opening. The cross passage thru the floor is routed to the adjacent passage in the same floor module thru openings blocked out of the central leg of the floor panel along the neutral axis of the structural leg.

FIG. 1B is the lower floor plan of the prototype house. The 3.5 foot grid is adhered to in placing the internal walls. Utility and HVAC connecting passages are located under the floor. FIGS. 17 and 17A show standard construction under the floor of a rectangular building. FIG. 17b shows the passages under the floor in the prototype house allowing the HVAC unit to be located in the utility and laundry room under the garage. Each building HVAC would be designed to meet the requirements of that building but would be consistent with the system design as illustrated in the patent application.

FIG. 2 and FIG. 2A show sketches of large buildings that are possible. Large buildings such as stores, warehouses, shops, office buildings, and any other rectangular building is possible. The practical limitation on height is probably about 10 stories.

FIG. 3 illustrates a basic 7-foot module of walls, floor and roof. A 7-foot module is used in the preferred embodiment but other module sizes using the system are possible. The system uniqueness is in its completeness and not in the module size.

FIG. 3A shows a generic foundation and the composition of the lower floor. The rock bed is used as a passive element in the HVAC system. Each building HVAC would be designed to use passive heat and cooling as much as possible depending on the site conditions. Standard HVAC elements would be used and could adequately condition any building economically.

FIG. 4 shows the wall section of the 2-story prototype building.

FIG. 4A shows the wall cross sections in greater detail.

FIG. 4B shows the wall section BB details.

FIG. 4C shows a 3 story wall section. 5 story wall sections are practical using a 60-foot mold. Taller buildings are best erected with the upper walls erected from the 5th floor. The system is practical up to 15 floors restaging every 5 floors. Buildings over 10 stories require more study. They fit into the system but very tall buildings have special problems and other systems might be more economical.

FIG. 5 shows the floor module. The length shown is 42 feet but any modular size up to 42 feet can be made in the mold.

FIG. 5a shows the cross sections of the floor.

FIG. 6 shows the roof module. The roof and floor modules are similar and can be made in the same mold bed. The module shown is for 42 foot clear span. Shorter modular spans can be made in the same mold.

FIG. 6a shows the roof cross sections and they are similar to the floor cross sections.

FIG. 6b shows the roof cross sections at the angle they will be installed to make the roof.

FIG. 6c shows the roof overhang cross-section.

FIG. 6d shows the assembly of the roof. The center tie post-tensioned cable allows the erection of the roof without a ridge beam. This makes it possible to make almost any length of building desired because each modularly assembled section is self-supporting. The cross tensioning done after the building is erected ties the whole building together and keeps all the concrete surfaces in compression. This compression makes the surfaces waterproof. It also makes it possible to design the building to earthquake 4 stresses.

FIG. 7 shows the jointing modules that complete the building and also allow all the walls to be the same height. It is possible to design a building with varying height wall sections and eliminate the gussets. It would be more costly and complicate the erection and post tensioning process.

FIG. 8 shows the roof in place with the overhang and jointing modules.

FIG. 8a shows the special overhang module and filler module over the connection wall to the garage.

FIG. 9 shows the stair module shown right and left hand. Prefabricated stairs have been used since the early 1900s. The attachment to the floor is made by blockouts in the floor module as shown in phantom.

FIG. 9a shows the installation of the stairs in the prototype building.

FIG. 10 shows the wall module with a door installed.

FIG. 11 shows the wall module with a 4′×4′ window installed.

FIG. 12 shows the wall module with a 30″×4″ casement window installed.

FIG. 13 shows the interior wall module. The interior wall module is designed to continue the wall panel design of the exterior walls. It is designed to accept electrical outlets and switches.

FIG. 14 show the interior wall module with a door installed.

FIG. 15 shows the basic preferred lighting for a flat ceiling in the bottom of the floor module.

FIG. 15a shows the technical details of the collimated light fixture for a flat ceiling. The efficiency of the unit is the % of the light that is collimated. The rest of the light is not lost but is radiated in a standard manner and its intensity diminishes with the square of the distance from the light element.

FIG. 15a1 shows the technical details of a single lamp installation. This design is utilized for the roof overhang and illumination of the outside walls where desired.

FIG. 15b shows the light used in the cathedral ceiling.

FIG. 15c shows the technical details of the cathedral ceiling light.

FIG. 15d shows the illumination of the outside walls where desired.

FIG. 15d1 shows the wall lighting detail at the cathedral ceiling level.

FIG. 15d2 shows the wall lighting detail at the flat ceiling level.

FIG. 16 shows the routing channels for HVAC, plumbing and electrical. All openings in the walls, floor, and ceilings are covered with standard panels, decorative panels, and lighting panels. Great flexibility in allowed in decorating. Large selections of decorative ceiling panels are available. The wall panels are standardized as much as possible and on large projects the panels can be ordered in the custom size to eliminate the cost of waste and reduce on site labor. All modern surface treatments can be accommodated without excessive costs. During modifications, necessary panels are removed without disturbing the building tenants to the degree that standard building construction modifications cause.

FIG. 17, 17a & 17b show the ductwork that has to be made in the basement floor. The rock bed under the floor is used for cooling assistance in the summer. Low heat loss in the building allow for economical HVAC to be installed.

FIG. 18 illustrates the post tension channels available in the structure. Each building is engineered for site conditions and the modules used. Standard post tension engineering is used to make the building earthquake resistant to earthquake zone 4 requirements.

Conclusion, Ramification, Scope

The invention is an integrated building system that will cut construction costs, reduce lifetime costs and greatly reduce modification costs. The basic structure is fireproof and makes provisions for HVAC, lighting, plumbing and most surface finishing techniques.

The system is applicable to most residential and commercial construction. It requires a reasonable sized project to accommodate construction on site. The cost of setup and termination must be factored into the overall cost of the project. The forms and machinery would be moved from project to project and their cost amortized over the life of the forms and machinery. All maintenance supplies, engineering, labor and site dependent costs would be charged to each project. Low cost housing would be possible with the system and would make many projects cost effective. Standard and luxury projects would benefit by providing many extras at the cost of comparable projects without the extras. All projects would benefit by extended life and durability of the concrete structure.

The scope of the system is universal and when demonstrated would be imitated. A major change in building technique is required as land becomes more costly and the population grows. Present demand is great but the cost for first time homebuyers is a real barrier to good housing. Many commercial enterprises would benefit by lower cost buildings and insurance reductions because of the buildings basic fire resistance and durability. Changes in usage would be accommodated easily and encourage business to modify their operations for greater efficiency.

Claims

1. The building system is fullly integrated. Walls, floors, and roof are designed to join each other and provide passages for heating, lighting, air conditioning, and plumbing. Such passages can be used after the building is finished. Modifications can use these passages for economical changes without disturbing the existing building.

2. All structural elements of the building are fireproof

3. The building system can produce multiple types of buildings from homes to high rise buildings.