Prefab Utility Wall

Abstract

The invention presents a 7 foot by 6 inch wide utility wall. This prefab wall simplifies the installation of water/drain pipes and electric service for low cost housing and comprising complete plumbing and electric installation. The wall is comprised of a shower base or bathtub, toilet, sink, water heater, lighting, washing machine and dryer hook-up, as well as a complete electric service including a breaker box, electric outlets and light fixtures. The wall also contains pipes for a sink drain and for hot/cold water for an attached kitchen. The utility wall requires no underground plumbing.

Description

DESCRIPTION OF PRIOR ART

Most residential and commercial buildings are built on concrete slab foundations. Some residential buildings are still constructed on concrete piers, and in coastal areas, they are often built on wooden piers, but seldom concrete piers.

Buildings on concrete slab foundations require underground plumbing. The plumbing is placed after the channels for the grade beams are dug and the forms are set in place. After that procedure, the entire area of the slab, including the grade beam channels, are covered with thick plastic sheeting. The next step involves carefully installing the underground PVC plumbing pipes. After installation, the pipes have to be sealed and plugged as they will be tested for leaks by filling them with water. The final step of the slab preparation process involves the installation of the steel reinforcing bars required for the foundation. Before the concrete can be poured for the foundation, the governing agency, usually the City or County, will inspect the plumbing work, the reinforcing steel, the final measurements for the correct location of the concrete slab and perform the leak test.

Building on piers is an easier task, as there is no underground plumbing. The installation of plumbing can be done at a later time. However, all of the before-mentioned steps of preparing the work before the concrete can be brought in and even the pouring of the concrete for the slab foundation is dependent on favorable weather conditions.

When an unsuspected rain shower or sudden downpour occurs during the placing of the concrete, it can cause serious problems, as rain water can destroy the concrete work. Concrete washes out, which means that at least some of the cement from the concrete mixture will run out with the rain water, depending on the amount of rainfall. As the cement is the binder between the sand and gravel, the integrity, and therefore the desired strength of the concrete, is negatively impacted. This can then turn into an expensive repair job, and sometimes the concrete mixture has to be replaced. To prevent rain from negatively impacting a concrete installation, work has to sometimes be performed at night with special lighting and special delivery ready mix concrete. Moreover, during rainy periods, concrete trucks cannot drive on the rain-softened ground close to a foundation site in order to prevent from getting stuck in the mud, resulting in the foundation contractor or builder to have to bring in a concrete pump, adding to the expense of building the foundation. There are many other problems when a concrete job goes bad. Water has to be pumped out, forms may need to be replaced, steel reinforcing bars have to be re-set, and the plastic sheeting may have to be repaired, adjusted or replaced.

This is part of the construction business. If the entire concrete slab is not poured at the same time, money will surely be lost in the operation. During the construction of the building slab, it is much more unlikely that problems will arise if underground plumbing is not necessary.

Some claims of solutions to this problem have previously been published:

• 1. Alexander Barrenburg, U.S. Pat. Nos. 4,919,164 and 5,076,310 presented a plumbing wall which does require underground plumbing. The plumbing wall is unfinished and consists of an open wall without installed fixtures.
• 2. McLuskey, Patent Application # US 2010/0126082 A1 presents various ideas in different assemblies. There is no mention of above-floor drain pipes.
• 3. L. Barrett, Patent Application # US 2009/0100769 A1 presents a heavy steel structure with labor-intensive assembly work which requires specially trained workers to assemble the wall. Again, there are no above-floor drain pipes.
• 4. N. Herzog, Patent Application # US 2003/0140572 A1 is a design which requires extensive assembly work and well-trained workers to assemble the plumbing wall. The invention does not contain above-floor drain pipes.
• 5. A European system (see enclosed picture) was studied which consists of a labor-intensive system and which requires a pony wall. This system also needs separately designed assembly wall sections for the toilet, sink, bath tub, and the shower base. It can have above-floor or under-floor drainage pipes. This system is designed for buildings without wood or steel frame work, so it is proposed for solid stone or brick walls.

The before-mentioned five solutions/inventions are not applicable for low-cost housing, apartment buildings, motels/hotels, etc. The building industry has not adjusted to these designs, as they were proposed between 2003 and 2010, and we found no instances of them being used successfully in any applications. These inventions are more expensive and most of them require specialized assembly on site.

The plumbing pipe installation process in the building industry has remained virtually unchanged over the past few decades. Only some of the material has changed, i.e. stronger, more temperature-resistant PVC pipes, for instance. Plumbing pipes still have to be cut, assembled and adjusted on the job site. Cupplings and elbows still must be joined and glued together on-site and holes/pipe openings must be cut in floors, ceilings, and wall frames. Before the walls are closed/finished, the pipes need to be tested for leaks, and the builder must schedule and wait for an inspector to come and inspect the plumbing installation.

A pre-fabricated plumbing wall is faster to install and it can be installed by mostly unskilled workers. It is less expensive to install compared to other options. It can be handled and transported similar to pre-fabricated trusses, pre-fabricated joists, pre-fabricated windows and doors, and the toilet outlet is always 12 inches from the wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The above general description of the method and the following detailed description are merely illustrative of the subject invention and modes, advantages and particulars of this invention (can) be readily suggested to those skilled in the art without departing from the spirit and scope of the invention.

In accordance with the present invention, the Prefab Utility Wall System, FIG. 1, consists of a partial enclosure of 7 feet 6 inches by 3 feet made of either a wood or steel frame. FIG. 2, which is covered on three vertical sides 10, 11, 12; FIG. 3 and the floor, FIG. 3-8, covered with structural plywood or equivalent material. The floor frame is designed so as to provide a space for the drain and water pipes and, if requested, also gas lines. The back wall, 10, or plumbing wall in FIG. 3 also comprises the electric service and wire connections for the water heater as well as the electric outlets for water heater and clothes washer/dryer. The drain pipes for the shower base or bathtub and toilet are underneath the subfloor FIGS. 1-3, “7”. Therefore there is no underground piping necessary for the exterior pipe connection.

The utility wall has been designed so as to fit inside a standard 8 foot shipping container, FIGS. 5 and 7 or on a truck bed which is 8 foot wide. All electricals, plumbing, and appliance components are designed in accordance to the International Residential Code (IRC).

After connecting the water supply and electric power all appliances will be immediately functional. Likewise after connecting the sewer pipe, FIG. 3-14 to the city sewer or septic system it will also be functional.

The utility wall can easily be connected with other walls for bathrooms of many sizes and finishes, FIG. 12.

The presented invention of the Prefab Utility Wall System, FIG. 1, has unlimited use in various building applications, such as in homes, apartments FIG. 5, 6,7; hotels, shelters FIGS. 5-7; housing on oil rigs, low-cost housing, hospitals (multi-stories if requested, and FEMA housing. Using the latter as an example, FEMA could convert and steel or masonry building with water and sewer connection into an emergency shelter rapidly and without large cost outlays.

Also on existing concrete foundation slabs that remain after a house has been destroyed by tornados, hurricanes or by fire, the present invention offers a faster and cost-saving solution to rebuilding a destroyed building. Furthermore, it would not matter if sewer drain(s) FIG. 6; 1, 2, 3 are located at the perimeter of the concrete slab, FIGS. 6; 1 and 2, as the Prefab Utility Wall would have a 10 to 12 inch offset from the outside edge of the concrete slab FIG. 7-14. In case of FIG. 7-2, it would be easy to frame around.

Due to the design of a partial subfloor, FIGS. 3-7, underneath the shower base or bathtub the toilet is raised about 4 inches off the floor. This makes it more comfortable for tall, elderly and handicapped persons. Although extra-high toilets are usually more costly, they occasionally required.

Overall, the Prefab Utility Wall System is unique in that it can be utilized with or without underground plumbing, is comprised of an electric breaker box already wired for outlets, light fixtures, hot water heater, washer and dryer, and other electrical appliances; and it offers substantial cost savings in both labor and material.

DETAILED DESCRIPTION OF DRAWINGS

FIG. 1 demonstrates a three-sided enclosure, consisting of floor 8, back wall 10, right wall 11 and left wall 12. The figure shows all appliances in place: shower base 2, toilets 3, sink 4, electric breaker box 9, and water heater 10.

The toilet, 3 and shower base 2 mount on a 3½ inch high subfloor. The subfloor 7 is comprised of drain pipes, FIGS. 3, 14 and 14A. For bathtub installation, water connections, FIGS. 1 and 33-, 30 and 31, are prepared.

FIG. 2 shows the framework for the partial enclosure. The frame design is made from wood or steel studs and screw together. Then the outside wall covering, 10, 11 and 12 are screwed to the frame. Structural plywood or equivalent material should be used. The floor parts 7 and 8 are made from heavy plywood. Supports of the subfloor 15, are made from 2×4 studs. For a bathtub application instead of a shower base the subfloor 7, and the exterior wall 11, will be extended by 2 feet so a standard size, 5 foot long bathtub can be set: FIG. 6, and extended detail 50 (interrupted lines).

FIG. 3 shows a set-up of the appliances with the drain pipes. Most pipes, 14 and 16 are mounted in the back wall, 10. The pipes 14 and 14A are in cavity between floor 8 and subfloor 7. The drain pipe 16A for the washing machine and kitchen sink are inside wall 12. 15A shows the siphon for the shower or bathtub.

FIG. 4. The drawing shows a house with an installed Prefab Utility Wall unit. On a new as well as on an existing building a 3′ 3″×8′ opening is necessary. The backside of the utility wall has to face the exterior wall in order to connect to a sewer drain pipe.

FIG. 5 shows the Prefab Utility Wall with a shower base used in a standard 8 foot by 20 foot shipping container. The installation of the Prefab Utility Wall can easily be performed by opening the two container doors on any standard shipping container.

FIG. 6 shows the Prefab Utility Wall will be installed with a standard 5 foot long bathtub.

FIG. 7 demonstrates the use of the Prefab Utility Wall on an existing slab, A: for example following a tornadic or similar event has leveled a structure. In picture 1 there are three drain pipe outlets. The utility wall can be easily set next to any drain outlet. Instead of just using the Prefab Utility Wall, another option is to place a standard shipping container, FIG. 5 or 6, with the Prefab Utility Wall already installed inside of the container, on top of the slab.

FIG. 8 demonstrates the method of the Prefab Utility Wall with a bathtub instead of a shower base, where 7A is the subfloor and 11A is the sidewall. If a whirlpool is favored in lieu of a bathtub, a whirlpool pump can be connected at 9AA, electrical outlet. The water connections 30, 31+ will be the same as those for the shower stall.

FIG. 9 demonstrates the integration of the Prefab Utility Wall as installed in a shipping container, efficiency apartment, or oilfield housing or other structures. The drawing depicts a three-dimensional view of a fully-furnished, standard 20 foot long shipping container. The utility wall will be installed in the same way as mentioned in FIGS. 5+6, through the existing container doors.

FIG. 10 shows a regular building on a concrete slab foundation, A. The building—a small house—has a 3′ 3″×by 8′ opening cut-in for installation of the Prefab Utility Wall. The opening can be vertical or horizontal.

FIG. 11 demonstrates the installation of the Prefab Utility Wall in a 2-story building, II. The 1^st floor I, is identical to the 2^nd floor, with 10 a cut-out showing partial view of the Prefab Utility Wall. For installation on buildings with more than 2 stories, the drawing for the next stories would be equivalent to the first and second stories as shown in FIG. 11.

FIG. 12 demonstrates two different bathroom layouts. Picture I illustrates a larger bathroom than picture II. Picture I suggests 3 different access door possibilities. Picture II demonstrates a low-cost design with an attached kitchen sink 19 and 20 being the exterior building walls. Layouts for custom designs with the use of basic utility wall is unlimited. This drawing shows only two designs.

Claims

1. Prefab Utility Wall System consists of a wall that combines plumbing and electric service, and which connects plumbing appliances with fixtures.

2. Prefab Utility Wall System after claim 1 comprises a subfloor underneath the shower or bathtub and toilet, that does not exceed 4 inches in extra height.

3. Prefab Utility Wall System after claim 1 uses the subfloor to house waste pipes for the shower base or bath tub and toilet.

4. Prefab Utility Wall System after claim 1 has all drain pipes above the floor.

5. Prefab Utility Wall System after claim 1 has a maximum weight of 200 pounds.

6. Prefab Utility Wall System after claim 1 has two horizontal support walls each 3 feet long for transportation purposes.

7. Prefab Utility Wall System after claim 1 has a round or oval drain pipe.