Abstract:
There is provided an engineered wall system which comprises at least one monolithic precast concrete foundation wall panel having top, bottom and opposing side edges. Each of the panels comprises a plurality of integral ribs, evenly spaced along a length of the panel between the side edges. The ribs are vertically oriented and project inwardly when the panel is in position as part of a building wall and a first and second outermost rib form each of the opposing side edges. There is a plurality of sleeve apertures located in the top edges and axially aligned in the opposing side edges and ribs and alignment means on the first and second outermost ribs to align adjacent ones of the panels. Attachment means on the first and second outermost ribs to secure together the aligned adjacent panels is also provided, as well as installation support pads attachable to the panels.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to a precast engineered wall system comprising monolithic precast concrete panels suitable for foundation walls and above ground applications, including commercial buildings.  
         BACKGROUND OF THE INVENTION  
         [0002]    The construction of foundations for residential and commercial building is a time and labour intensive process. It is often subject to the prevailing weather and often accounts for a significant portion of the delay in building projects.  
           [0003]    Tilt slab construction, on site at building locations, has been used in recent years to attempt to circumvent some of the problems involved in the construction of building walls, both residential and commercial. However, tilt slab construction has been shown to have certain limitations, most notably the cost of material involved, since the slab will be solid concrete with steel reinforcing throughout.  
           [0004]    There is thus a need to devise a system of constructing walls, including foundation walls, which eliminates some of the limitations of traditional construction techniques and which reduces the cost involved in tilt slab construction.  
           [0005]    In that regard, there have been attempts made to develop a system of manufacturing walls using discreet wall panel sections. Many of those systems involve a precast wall panel to be manufactured on site or off and then installed together at the work site to form the foundation walls, as well as the other walls of the building. Theses systems have met with very limited commercial success, however, due to a variety of technical deficiencies. In particular, many of the existing panel systems require that the floor be poured before the foundation can be backfilled. If this is not done, the wall will not be adequately supported. This is contrary to normal building practice, however, in which the pouring of the floor is typically one of the last steps to be done. It is crucial, in the commercial success of any building product, but in particular a product for foundation walls, that the normal building sequence be disturbed as little as possible. Builders, most notably large builders working on tract housing, sub-divisions or the like will typically not accept a product or step which upsets their normal routine.  
           [0006]    The existing systems have also failed commercially because of the increased cost associated with the system. Builders may accept a more expensive system if the cost can be passed on to the ultimate buyer. That buyer, however, is generally not prepared to accept a higher price for a house where the increase is associated with something unseen like the construction of a foundation. It is the applicant&#39;s experience that buyers are prepared to pay extra for features such as hardwood floors or bay windows but not for a foundation.  
           [0007]    Thus, foundation wall systems which require expensive bolts or connectors and insulation as an integral part of the system, for example, increase the cost of the foundation to a point that render the systems commercially unacceptable.  
           [0008]    The applicant is presently aware of the following patents and applications describing systems which suffer from many of these deficiencies:  
           [0009]    Canadian Patent application 2,107,070 of Mion, “Panel System for Construction of Building Foundations”;  
           [0010]    Canadian Patent 1,272,929 granted to Superior Walls of America Ltd., “Prefabricated Concrete Wall Structure”;  
           [0011]    Canadian Patent 1,238,201 also granted to Superior Walls of America Ltd., “Sprayed Concrete Basement Structure”;  
           [0012]    U.S. Pat. No. 4,605,529 also of Zimmerman, “Method of Constructing a Prefabricated Concrete Wall Structure”;  
           [0013]    U.S. Pat. No. 4,934,121 of Zimmerman, “Integrated Reinforced Concrete Wall Structure”; and  
           [0014]    U.S. Pat. No. 5,055,252 also of Zimmerman, “Method of Constructing an Integrated Concrete Wall Structure”.  
           [0015]    Other references of background interest to the present invention include: Canadian Applications 2,169,527; 2,169,572; 2,191,491; 2,191,514; 2,297,515; 2,240,098; 2,274,287; and Canadian patent 1,167,272.  
         SUMMARY OF THE INVENTION  
         [0016]    It is thus an object of the present invention to provide an engineered wall system which uses discreet precast panels which do not include the structural limitations that result in the commercial deficiencies of previous systems discussed above.  
           [0017]    In one aspect of the invention, there is provided an engineered wall system which comprises at least one monolithic precast concrete wall panel having top, bottom and opposing side edges. Each of the panels comprises a plurality of integral ribs, evenly spaced along a length of the panel between the side edges. The ribs are vertically oriented and project inwardly when the panel is in position as part of a building wall and a first and second outermost rib form each of the opposing side edges. There is a plurality of sleeve apertures located in the top edges and axially aligned in the opposing side edges and ribs and alignment means on the first and second outermost ribs to align adjacent ones of the panels. Attachment means on the first and second outermost ribs to secure together the aligned adjacent panels is also provided, as well as installation support pads attachable to the panels.  
           [0018]    In another aspect of the invention, the top, bottom and side edges are bevelled.  
           [0019]    In another aspect of the invention, the top, bottom and side edges and an outermost face of the ribs further comprise steel studs fixed thereto.  
           [0020]    In another aspect of the invention, there is a series of footings cast in place below the panels and between the pads, when the panels are in place to form a foundation wall.  
           [0021]    In another aspect of the invention, the alignment means comprises a tongue and groove configuration on an outer surface of the side edges, from top to bottom of the side edges, constructed such that the tongue and groove configuration of one side edge of one panel cooperatively mates with the tongue and groove configuration of one side edge of an adjacent panel.  
           [0022]    In another aspect of the invention, there is provided a method of constructing a foundation wall comprising the steps of:  
           [0023]    clearing and leveling an area of ground on which the foundation is to be supported;  
           [0024]    affixing at least two installation support pads to a plurality of monolithic precast concrete foundation wall panels;  
           [0025]    placing the panels in position on the cleared and leveled area to form the foundation wall;  
           [0026]    aligning adjacent of the panels and affixing all of the adjacent panels together;  
           [0027]    leveling the installation pads;  
           [0028]    pouring a concrete footing between the installation pads; and  
           [0029]    backfilling around the foundation wall, so that the foundation wall is then ready to accept service cables, wires, plumbing therethrough, insulation, a top plate to support a floor thereabove and so that a concrete floor can then be poured around a bottom of the foundation wall. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0030]    These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:  
         [0031]    [0031]FIG. 1 is a perspective view of a portion of an engineered wall system manufactured with the panels of the present invention.  
         [0032]    [0032]FIG. 2 is a front elevation view of the panel of the present invention.  
         [0033]    [0033]FIG. 3 is a cross-sectional view taken along line  3 - 3  of FIG. 2.  
         [0034]    [0034]FIG. 4 is a plan view of a corner detail of the engineered foundation wall system.  
         [0035]    [0035]FIG. 5 is a plan view of a detail of a rib of the panel of the present invention.  
         [0036]    [0036]FIG. 6 is a sectional view taken along line  6 - 6  of FIG. 2.  
         [0037]    [0037]FIG. 7 is an exploded sectional view of the top and bottom detail of the panel.  
         [0038]    [0038]FIG. 8 is detail view of a foundation installation section.  
         [0039]    [0039]FIGS. 9 a to  9   c  are each a detail view of the footing for the panel.  
         [0040]    [0040]FIGS. 10 a  to  10   d  are each a detail view of an alternate embodiment of the invention. 
     
    
       [0041]    While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0042]    In the following description, similar features in the drawings have been given similar reference numerals.  
         [0043]    Turning to the drawings, FIG. 1 illustrates a perspective view of a corner portion of a building wall  2 , (shown for illustrative purposes as a foundation wall) constructed with precast panels  10  of the present invention. FIG. 2 is a front elevation view of the panel  10 . The panel  10  has top  12 , bottom  14 , and opposing side  16  and  18  edges. The panel  10  is further characterized by a plurality of integral ribs  20  running vertically between the top  12  and bottom  14  edges. When the panel  10  is in position within a building wall  2 , those ribs  20  project inwardly, as seen in FIG. 1. For any given panel the outermost ribs  22  and  24  form the side edges  16  and  18  respectively of the panel  10 .  
         [0044]    The panel is preferably cast of concrete in a single pour. Embedded within the concrete may be a welded wire mesh  26  in order to add strength and rigidity to the concrete, without an appreciable increase in mass, or cost of manufacture.  
         [0045]    The panel  10  will also include a series of apertures, preferably in the form of sleeves  30  in the top edge  12  and sleeves  32  in the ribs  20 ,  22  and  24 . Additional sleeves  34  may be included in the outermost ribs  22 ,  24 . Those additional sleeves may function as part of the attachment means for attaching adjacent panels  10 .  
         [0046]    With reference to FIG. 3, the joining of two adjacent panels  10  and  10 ′ is illustrated (the designation ‘will be used to denote the common features between the two adjacent panels). The panels are arranged so that the first outermost rib  22  of one panel  10  mates with the second outermost rib  24  of the adjacent panel  10 ′. The sleeves  34  and  34 ′ would align to create a though hole between the adjacent panels. A bolt  36 , or other suitable anchor may be used to fix the two panels together.  
         [0047]    The ribs  20  will preferably include reenforcing metal bars  38  through the concrete. Similar reinforcing bars  39  will be in the top  12  and bottom  14  edges of the panel  10 .  
         [0048]    The outermost ribs  22 ,  24  will include an alignment system in order to accurately align the adjacent panels  10  and  10 ′. Preferably that alignment system will comprise a double tongue  40  and groove  42  configuration. The rib  22  will typically include the grooves  42  in an outermost surface of the rib  22 , while the rib  24  will include the mating tongues  40  on an outermost surface thereof. That arrangement can be reversed without an adverse effect on its functionality.  
         [0049]    In a preferred embodiment, the tongues  40  will be longer than the depth of the grooves  42 . In this way a gap  44  will be left between adjacent panels. That gap can then be filled with caulking, gasketing or other waterproofing material. An exterior waterproofing membrane  46  will be applied over the joint of the two panels  10 ,  10 ′ to further seal the joint.  
         [0050]    A corner detail is shown in FIG. 4, wherein a panel  10  is mating to an adjacent panel  10 ′ at a corner of the wall. In that configuration, only one of the tongues  40  will mate with a groove  42 . A bolt  48  is still used to join the panels, but an additional anchor bolt  50  will preferably be used to secure that bolt  48  to the panel  10 ′, as illustrated.  
         [0051]    FIGS.  5  to  7  show detail views of a preferred embodiment of the construction of the panel  10  of the present invention. In that preferred embodiment, the panel  10  includes steel studs on the ribs  20 , top  12  and bottom  14  edges. In FIG. 5, the steel stud  60  is shown on the top edge  12  and would preferably be of 26 gauge steel. The studs  62 ,  64  is shown along the side of the rib  20  and would similarly be preferably of 26 gauge steel. A similar steel stud  66  would be included on the bottom edge  14 .  
         [0052]    As seen in FIG. 6, the steel studs  62 ,  64  are joined and covered by a covering layer, depicted as a sheet of asphenite  68 . Similarly, a sheet of ashpenite  70  would join and cover the top and bottom studs  60 ,  66 . The covering could alternately be formed of plywood or drywall, or any other suitably rigid material which could be used to join the studs and which would provide some thermal bridge between the studs as well. With the coverings  68 ,  70  in place on the panel, there would be no concrete or steel visible to a person viewing the panel  10 .  
         [0053]    The manner in which the panel  10  is installed on the ground in a typical foundation wall installation is depicted in FIGS. 8 and 9 a  to  9   c . The skilled person in the art will appreciate that there will be minor differences in the installation of the panels as part of an above-ground commercial wall. Those differences will, however, be largely determined by the building requirements and the nature of the differences inherent in building above-ground walls, as compared to foundation walls. The method of installing and particularly joining and sealing the panels will be essentially the same as that to be described.  
         [0054]    The panel  10  rests on a plurality of precast installation pads  80 . That pad  80  is of a width of preferably about 32 inches and houses an anchor bolt  82  in order to affix the panel  10  to the pads  80 . It is contemplated that there will be approximately 2 pads  80  for each standard 16 to 20 foot wall section, although more pads can be used for longer sections. The panel  10  will typically be affixed to the pads  80  off site, but in any event, before installation of the panels  10  on site.  
         [0055]    Once the panels have been installed and leveled, a concrete footing  84  can be poured, on site, between the pads  80 . This footing  84 , in combination with the pads  80 , allow backfill  86  to be poured before the conventional floor  88  has to be poured. This represents a significant commercial improvement over many of the prior art systems known to the applicant. Once that is complete the wall is ready to accept a top plate  90  and a finished floor  92  in the conventional manner.  
         [0056]    In operation, therefore, the panels  10  would be precast and a series of panels would be brought on site to complete the wall  2 . Some of those panels  10  will include beam pockets  94  and window cutouts  96  (as shown in FIG. 1) in order to accommodate different foundation wall designs. The skilled person in the art will appreciate that other cutouts and modifications can be made to the panels  10  to accommodate design requirements.  
         [0057]    The panels  10 , attached to the pads  80  will be brought to building site. The area for the foundation wall will be cleared and leveled and a panel  10  will be placed on the area and leveled. An adjacent panel  10 ′ will then be aligned with panel  10  and the two will be attached, with the gaps filled as required. This will be repeated until the wall  2  is complete, with leveling throughout as required. Once the wall  2  is level, the footing  84  can be poured in place in between the pads  80  and the area can be backfilled. If necessary, a form can be inserted into the pads  80  to guide the pour of the footing  84 . Once complete, work on the building can then continue in the normal fashion.  
         [0058]    In an alternate embodiment of the invention, the steel studs are replaced on the top and bottom edges and the ribs by bevelled edges as shown in FIGS. 10 a  to  10   d . As seen in FIG. 10 a , adjacent panels  100 ,  100 ′ are joined by the through bolt  160 , preferably locked with a nut and bevelled washer. The ribs  122 ,  124  are each bevelled at  104 ,  106  respectively. A gap can be introduced between the adjoining panels by means of a spacer, such as plywood shims  108  as shown, or a thermal spacer such as a gasket or the like. Caulking, gasketting or other waterproofing material can also be used to fill the gap, and the joint is then covered with an exterior waterproofing membrane  146 .  
         [0059]    As seen in FIG. 10 b , each rib  120  in this embodiment of the invention is bevelled on either side, as depicted at  150 ,  152 . This double beveling has been found to be advantageous, particularly in the forming of the panels as it allows easy separation between the panel and the forming mould (not shown). Single beveling, on either side of the rib  120 , as with the outermost ribs  122 ,  124  is also contemplated as an option for this embodiment.  
         [0060]    [0060]FIG. 10 c  illustrates the corner detail in which an anchor bolt  162  is used to adjoin the panel  100 , by its outermost rib  124 , with the adjacent corner panel  101 , with its bevelled top edge  112 .  
         [0061]    [0061]FIG. 10 d  illustrates the beveling on the top  112  and bottom  114  edges, as depicted at  164 ,  166  respectively. There remains a sleeve  130  in the top edge  112 , as with the other embodiment. Optional loop lifting inserts  170  can be used to lift the panel  100  into position, such as at the work site.  
         [0062]    It will be appreciated that the amount of reinforcing metal bars and overall dimensions of the panels will vary given the lateral and vertical load requirements of the building to be constructed, without departing from the overall structure of the panels.  
         [0063]    Thus, it is apparent that there has been provided in accordance with the invention an engineered wall system that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention.