Abstract:
A method for constructing factory prefabricated and finished load bearing wall panels and monolithic ceiling/floor sections and modules comprised of the same for use in a single family or single story building as well as a multi-level and multi-unit building. The integrally formed wall panels are constructed of modified steel studs, rigid insulating material, and metal lathe and are factory finished with plaster or stucco like material. A void is defined by the modified steel studs window casings and door jambs. Upon erection and assembly at the job site, steel rebar is placed in such voids that are then filled with concrete, thereby eliminating the need for any additional concrete form work.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims the benefit of previously filed co-pending Provisional Patent Application, Ser. No. 60/513,675. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention relates generally to a method of construction and more specifically to constructing factory prefabricated and finished forms for load bearing wall panels, ceiling/floor sections, roof sections and modules comprised of the same for use in a single family or single story building as well as for use in a multi-level and multi-unit building. 
     BACKGROUND OF THE INVENTION 
     Noncombustible, building construction typically is of one of five basic structural types or combinations thereof: 1) reinforced concrete frame; 2) reinforced wall bearing masonry; 3) structural steel framework; 4) precast concrete framework; or 5) light gage steel bearing wall. Each of these methods of construction is subject to cost disadvantages due to one or more of: time, labor, materials, weight, and complexity of assembly. Reinforced concrete frame construction requires the on site labor and time to build forms for the wet concrete, waiting for it to harden, and then time and labor to remove the used forms. Thereupon, the building is completed and finished on site with expensive job site labor and materials. Reinforced wall bearing masonry uses concrete block walls held together with mortar, then reinforced with steel rods and filled with concrete to produce the bearing walls. This approach is used extensively in residential construction but is limited to a few stories high. The biggest disadvantage has to do with adding plumbing, wiring and finishing material with job site labor, at prime cost. Structural steel or pre-cast concrete framework construction is commonly used in high-rise work, but require the heavy steel or concrete supporting frame structure; the ceilings, walls and all the interiors and exteriors to be completed and finished with on site labor and materials, a costly construction. 
     Light gage steel bearing wall construction employs framing partitions of light gage steel members assembled into panels. These members are load bearing and can be assembled into panels at the job site, prior to erection, but can be assembled more economically in a controlled factory environment. However, the remainder of the building then is completed and finished with costly job site labor and materials. 
     U.S. Pat. No. 4,409,764 by Wilnau discloses a system for constructing the structural framework of a building or other structure of reinforced concrete that is characterized by column and beam forms of sheet metal which remain in place as permanent parts of the framework after being filled with concrete. These forms are factory-assembled, together with the necessary internal metal reinforcing skeletons, and shipped to the building site ready for erection of the column forms and interconnection thereof by the beam forms. When the column and beam structure is complete, the curtain walls must be assembled and finished on site. This current invention describes a system of load bearing walls which function as curtain walls as well as the super structure. 
     U.S. Pat. No. 5,048,257 by Luedtke discloses a method of constructing multiple story buildings, particularly detention structures, whereby the framing members are lightweight steel channel members that are generally similar and in certain applications, interchangeable. The walls and floors of the building are framed with the channel members and lathe sheathing is applied, with cementitious fill there between. This specification does explain a stay in place forming system. It describes the placement of the fill as being observed through the lath to assure a solid fill. Luedtke later explains the subsequent application of cement plaster or stucco like material. This terminology necessarily infers that the plaster or stucco like material is applied after the concrete has cured, possibly to assure a straight wall that bowed during the placement of plastic concrete. The Luedtke design discusses a method of concrete delivery consisting of a fill hose as pictured in  FIG. 6  of the patent. This practice is not practical and probably not possible, at least not at the low slump mentioned and required to achieve the strength provided by the proper water to cement ratio. 
     While both Wilnau and Luedtke combine the advantages of reinforced concrete and steel framework by using portions of the steel framework as non-removable forms for the poured concrete columns and beams, these inventions do not take full advantage of the efficiencies and cost savings that can be obtained by factory prefabrication of not only the structural wall panel, but also of the window casings and door jambs contained in the wall panels that also serve as an integral form for receiving the poured concrete. Further, these inventions do not take advantage of the cost-savings that can be achieved by factory pre-finishing the wall panels with plaster or stucco like material and paint or wallpaper. 
     Another invention, U.S. Pat. No. 3,983,368 by Perrin discloses an invention whereby a wall is formed as by spraying cementitious material through and around two panels of sheet material thus to produce a composite wall with a hollow core therebetween, such core to be filled with a rigid material. This design is a sandwich panel where the core is described as a cellulostic material referred to as corrugated paperboard or cardboard. The voids within the core appear to be very small at least as compared to the current invention which is a forming system for achieving conventional steel reinforced concrete in a more economical fashion. Although Perrin&#39;s wall panel contemplates a sprayed plaster or stucco like material finish, just as in Wilnau and Luedtke, it also does not take advantage of prefabricating window and door jambs as an integral part of the framing structure. Further, Perrin&#39;s invention relies on the use of a reinforced rigid core for its load-bearing properties. While suitable for residential housing, such construction will not provide the load-bearing capacity that the use of conventional steel reinforced concrete provides as disclosed in the present invention. 
     The Anderson U.S. Pat. No. 5,996,293 describes a window buck devoted to providing an opening. The current invention does define an opening but the hollow metal jamb also functions as an integral part of the structural framework, provides a stop for the mounting of doors and windows and is ideally suited as a termination device for the finished surfaced surfaces. 
     SUMMARY OF THE INVENTION 
     The present invention discloses a method that overcomes the disadvantages of prior art by taking full advantage of the efficiencies and cost savings that can be obtained by factory prefabrication of a much larger unit of construction with far more value added under industrialized conditions where both cost and quality can be controlled. All effort is to be expended at the time and place where the benefit can be maximized while the cost is minimized. Everything that is ever to go inside a wall, ceiling or roof section is to be added as the section is being assembled on the framing table, except the steel reinforcement (rebar) and concrete. Every surface of every section that should ever be finished will be finished on the framing table in the horizontal position with the side to be finished facing up. Notable exceptions are the surfaces that must be left open to place the steel and concrete. In the case of wall sections, the top surface will never be exposed. The top surface of the floor section will be exposed but it is much less costly to field apply the concrete from the top and finish the floor than apply the concrete from the bottom and finish the ceiling. The roof section is a different matter; it is much less expensive to apply the concrete from the bottom and finish the ceiling than to finish the roof surface. Finished surfaces include paint, wall paper, veneer of every type and roof covering. 
     The integrally formed wall panels are constructed of modified steel studs, rigid insulating material, and metal rib-lathe imbedded in plaster or stucco like material or stucco type material. The three elements of the side wall function as a composite material of structural integrity sufficient to withstand the forces of the plastic concrete added at the job site. The primary function of the steel stud is to hold the two composite sides in place during hauling, erection and the placement of concrete. A second objective is to hold the rigid insulation in place until the plaster or stucco like material or stucco type material has been applied. The primary function of the insulation is to act as a thermal resistance, but it also acts as a back stop for the plaster or stucco like material or stucco type application and as an integral part of the composite side wall. The rib-lathe is steel reinforcement for the plaster or stucco like material or stucco type but the rib is also the member that holds the studs in place during the fabrication of the wall section. Notice that top and bottom plates, as is normally used in conventional construction to hold the studs in place, must be avoided in this design in order to keep the void open for easy access at the top, and for interconnection at the bottom. 
     The integrally formed monolithic ceiling/floor panels are constructed of U-shaped “gull wing” steel joists, rigid insulation, “C” channels, metal lathes, and plaster or stucco like material. As in the wall section, the insulation, lathe and plaster or stucco like material are combined to create a composite material, sufficient to withstand the forces of hauling, erection and the application of the finished floor. The joists are placed in position first and must be of sufficient size and strength to span the required distance and support the application of reinforcement steel, and the concrete, which is, field applied later. The insulation is installed second and then the “C” channels are placed at the ends of the joists. These are necessary to hold the system together for assembly, hauling and erection. This section is fabricated on the framing table in the upside down position, which is with the ceiling facing up. Next the lathe is added and the plaster or stucco like material is applied and finished. 
     In general sections are made up of parts. Sections are assembled to create modules. A module is made up of four wall sections and one ceiling/floor section. The ceiling of one module will function as the floor of the module above. Each is a five-sided cube. The module, which is hauled and erected at the job site, does not have either a bottom or a floor. This configuration of a 5 sided cube allows the wheels of the carrier to come up inside the module thus lowering the center of gravity and allowing a higher ceiling while still allowing clearance under highway overpasses. The ceiling/floor section, serving as the top, provides a work platform for tradesmen in lieu of scaffolding. 
     Finally, the roof section is made up of a sheet metal covering, joists that function as rafters, and rigid insulation. The sheet metal is stamped or roll formed and pre-finished to achieve the correct appearance and functions as an integral part of the structural system. The joists are placed into position with the opening facing down and the insulation is then added. A ridge beam and cornice are added. The roof covering is then installed. The mechanical fasteners holding the roof covering membrane should always be at the high point of the membrane rather than in the trough where water would flow. The final roof assembly is field installed so that the rebar can be added and interconnected with adjacent sections before the zero slump concrete is shot into place. The rib-lathe and plaster or stucco like material are then applied and finished. 
     The primary objective of this specification is to describe Integral Forming Technology in terms of sections and modules where wall, ceiling and roof surfaces are machine finished and internally complete except for the steel reinforcement and concrete. These forms receive the concrete without distortion and remain as useful, functional and integral parts of the final product. It is important to note that every wall, including the smallest closet wall, is constructed the same way; every wall is structural and load bearing and functions as an integral part of the entire structure. Storm like forces are transmitted from any element to every adjoining element to the extent that every force is distributed equally throughout the monolithic whole. 
     It is therefore an object of the present invention to provide a method for constructing a unit of construction that, compared to traditional concrete and steel construction methods, has far more “value added” under industrialized conditions where cost and quality can be controlled. 
     It is therefore a further object of the invention to provide for a method of construction for factory prefabrication of load bearing wall panels and monolithic ceiling/floor sections for use in multi-story buildings. 
     It is a further object of the invention to provide a method of construction for constructing a wall panel consisting of studs and window casings and door jambs that creates an integral form for the concrete core thereby eliminating the need for any additional concrete form work on the job site. 
     It is a further object of the invention that the lighter-weight elements of standard construction methods that are labor and skill intensive are to be assembled and pre-finished in the factory taking advantage of automated machinery. After the integral forms have been transported to the site and erected, the heavy elements, re-bars and concrete, are placed in the forms. 
     It is a further object of the present invention to realize cost savings, efficiencies, and improved quality control by factory finishing both sides of the wall panels, the ceiling of the ceiling/floor section, and the top roof surface. 
     It is also an object of the present invention to create a construction system where the pre-finished forms are made up of individual materials combined to function as composites, which act in unity and therefore create a homogenous whole. The formed sections and modules provide ample access to field install steel reinforcement and place concrete to achieve a monolithic superstructure where every section mutually supports every adjoining section. 
     It is an object of the present invention to create a monolithic, ceiling/floor section structural unit that is more cost-efficient and has better structural integrity than individually constructed floor and ceiling elements. 
     It is an object of the present invention to create pre-finished sections useful for building anything that should be steel reinforced concrete, including but not limited to fences and walls of every type. 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, together with the description, serve to explain the principles of the invention. The description of the preferred embodiment of this invention is given for purposes of explaining the principles thereof, and is not to be considered as limiting or restricting the invention since many modifications may be made by the exercise of skill in the art without departing from the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The following figures set forth the preferred embodiment of the present invention: 
         FIG. 1  depicts an overview of the concept; 
         FIGS. 2   a ,  2   b ,  2   c , and  2   d  depicts views of a metal stud, modified to facilitate the manufacture of integral forms as described by this specification; 
         FIGS. 3   a  and  3   b  depicts a gull-wing metal joist to function as a floor joist or roof rafter and facilitate the manufacture of integral forms as described in the specification and a single wing metal joist respectively; 
         FIG. 4  depicts a rib lathe, a standard product currently in production and readily available; 
         FIG. 5  depicts a hollow metal door and window jamb frame; 
         FIG. 6  shows a plaster or stucco like material stop; 
         FIG. 7  depicts a “C” channel to hold the gull-wing joist in place; 
         FIG. 8  depicts an assembly of wall section; 
         FIG. 9  shows a ceiling/floor section assembly; 
         FIG. 10  depicts addition of “C” channel to ceiling/floor section assembly; 
         FIG. 11  shows a cross section of the assembly of a ceiling/floor section; 
         FIG. 12  depicts the attachment of walls to each other; 
         FIG. 13  depicts the ceiling/floor section attachment to exterior walls below; 
         FIG. 14  shows a stack and arrangement of modules and sections on site; 
         FIG. 15  depicts a party wall juncture; 
         FIG. 16  shows a plan view of party wall; 
         FIG. 17  shows a roof section assembly; and 
         FIG. 18  depicts a roof section installation. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Integral Forming Technology (IFT) describes a method of factory finishing wall, ceiling and roof sections where all of the internal elements are included. The sections can be assembled into modules in the plant or erected on the site. The sections and or modules appear to be finished except the steel reinforcement (rebar) and concrete has not been placed. Integral forms are best described as a much larger unit of construction, with far more value added under industrialized conditions, where both cost and quality can be controlled. The integral forms can be stacked and arranged with the flexibility to achieve virtually any architectural effect. Integral forming is a method of constructing steel reinforced concrete buildings of any size and for any purpose. The disclosed system has been designed to enclose more space that is more desirable, more attractive and more comfortable, is more structurally significant; and, is less expensive to build, operate and maintain than any currently available. To better explain the preferred embodiment of the invention the following numbering system is used:
           1 . Modified Stud     2 . Rigid Insulation     3 . Rib lathe     4 . Concrete     5 . The Void     6 . Steel reinforcement     7 . Gull wing joist     7 . a  Single wing joist     8 . Opening jamb frame     9 . Plaster or Stucco like material stop     10 . “C” channel     11 . Wall section assembly     12 . Ceiling/floor section assembly     13 . Module     14 . Pre-finished sheet steel roof membrane     15 . Steel reinforcement holes     16 . Wiring/plumbing holes     17 . Attachment clips     18 . Mechanical fastener     19 . Plaster or Stucco like material     20 . Tabs     21 . Cornice       

     Referring now to the drawings  FIG. 1  discloses an overview of the concept showing how the pre finished sides of the integral form will be held in place relative to each other by the modified studs ( 1 ) creating the voids ( 5 ) which are readily accessible to receive the field placement of the steel reinforcement ( 6 ) and concrete ( 4 ). 
       FIGS. 2   a ,  2   b , and  2   c  discloses views of modified studs ( 1 ); Unmodified studs are currently produced in large quantity and in a number of sizes and gauges of sheet metal that are well known in the art. The standard studs are easily modified with tabs and voids as shown in the figures. The modified studs ( 1 ) are in a wall section assembly ( 11 ), as shown in  FIG. 8 , in the vertical position and are to resist loads, both compressive and tensile. As far as an Integral Form is concerned, the primary function of the modified studs ( 1 ) is to hold the two composite sides in place until the concrete ( 4 ) has cured. Modified as shown, the tabs ( 20 ) in the modified studs ( 1 ) are to hold the rigid insulation ( 2 ) in place until the rib lathe ( 3 ) has been added and the plaster or stucco like material ( 19 ) has been applied. The plaster or stucco like material ( 19 ) is sprayed on under pressure and bonds with both the rib lathe ( 3 ) and the rigid insulation ( 2 ). The three, properly bonded together, function as a composite side. The steel reinforcement holes ( 15 ) in the center of the modified studs ( 1 ) are to allow the passage of steel reinforcement ( 6 ) and hold it near the center of the concrete ( 4 ) to be added later. The much larger oblong holes on the centerline of the modified studs ( 1 ) are to allow free passage of the concrete ( 4 ) in the horizontal direction. The wiring/plumbing holes ( 16 ) to the side are to allow passage of pipe, conduit and wiring of every type through the modified studs ( 1 ) and rigid insulation ( 2 ) which will be notched as required. 
       FIGS. 3   a  and  3   b  discloses the gull wing joist ( 7 ). The primary function of a joist is to span a distance between two supporting elements. This gull wing joist ( 7 ) is designed to create a void for steel ( 6 ) and concrete ( 4 ) that will be poured on site. The gull wings on the gull wing joist ( 7 ) are to hold the rigid insulation ( 2 ) in place. Note that the wing must be removed from one side of the end gull wing joist ( 7 ), effectively resulting in a single wing joist ( 7 . a ). Notice also that the gull wing joist ( 7 ) used in the upside down position functions as a roof rafter. 
       FIG. 4  discloses the rib lathe ( 3 ). The rib lathe ( 3 ) is steel and effectively acts as reinforcement for the plaster or stucco like material ( 19 ). The ribs of the rib lathe ( 3 ) itself is solid, meaning not perforated, and is a more structural element serving to provide rigidity in the horizontal position which is perpendicular to the modified studs ( 1 ) and intended to hold the modified studs ( 1 ) in the proper position. 
       FIG. 5  is an isometric view of an opening jamb frame ( 8 ). This standard opening jamb frame ( 8 ) is used to frame door and window openings, and facilitate the mounting of same. This opening jamb frame ( 8 ) must be installed during the framing stage to define the opening and provide a stop for applying the plaster or stucco like material ( 19 ). All window and door opening jamb frames ( 8 ) are installed while the wall section is still lying flat on a framing table (not shown). 
       FIG. 6  discloses a plaster or stucco like material stop ( 9 ) that is used to provide a connection device for the wall section assembly ( 11 ) to the floor/ceiling section assembly ( 12 ), and provide a reference for placement of the plaster or stucco like material ( 19 ). 
       FIG. 7  discloses a C channel ( 10 ) used to hold the floor/ceiling section assembly ( 12 ), which is more fully disclosed in figure ( 9 ), together while assembly and installation of the finished module ( 13 ) and/or while hauling and erection of the module ( 13 ) at the job site. The modules ( 13 ) are more fully disclosed in  FIG. 14 . 
       FIG. 8  shows how the parts will be assembled to make a wall section assembly ( 11 ). The first modified stud ( 1 ) is put in place on a framing table. The bottom rigid insulation ( 2 ) is then put in place, and the top rigid insulation ( 2 ) and the second modified stud ( 1 ) is added simultaneously. This sequence is repeated starting with the bottom rigid insulation ( 2 ). All piping, wiring, conduit and opening jamb frames ( 8 ) must be added at this time. Rib lathe ( 3 ) is added next and then the plaster or stucco like material stop ( 9 ). With everything in place the plaster or stucco like material ( 19 ) is then added to one side of the wall section assembly ( 11 ). The wall section assembly ( 11 ) is then turned over and the plaster or stucco like material ( 19 ) is added to the other side of the wall section assembly ( 11 ). 
       FIG. 9  discloses the floor/ceiling section assembly ( 12 ) manufacture wherein the first gull wing joist ( 7 ) will be laid in place and then the first rigid insulation ( 2 ). This sequence will be repeated as required. 
       FIG. 10  discloses how the C channel ( 10 ) is added to hold the floor/ceiling section assembly ( 12 ) together during fabrication and erection. 
       FIG. 11  further discloses part of the assembly of the floor/ceiling section assembly ( 12 ). With the floor/ceiling section assembly ( 12 ) in the upside-down position, the rib lathe ( 3 ) is added and then the plaster or stucco like material ( 19 ) is applied and finished. 
       FIG. 12  discloses how angled attachment clips ( 17 ) are attached to the abutting wall section assembly ( 11 ), and then the two wall section assemblies ( 11 ) are to be placed in the proper position and the attachment clips ( 17 ) are attached to the abutment wall section assembly ( 11 ). 
       FIG. 13  shows how the floor/ceiling section assembly ( 12 ) is attached to an exterior wall section assembly ( 11 ). This condition is the same for module ( 13 ) assembly in the plant or field erection of walls and floors on site. Notice that the outermost wall of the exterior wall section assembly ( 11 ) is higher than the innermost wall, this extension is to act as a rim beam as used in conventional construction. Also, the plaster or stucco like material ( 19 ) may not be applied all the way to the edges of the wall section assemblies ( 11 ) and floor/ceiling section assemblies ( 12 ) which allows for the addition of a corner piece of wire lathe (not shown) to be added as a part of the module assembly in the factory or while assembling in the field for additional structural integrity. The plaster or stucco like material ( 19 ) would then be added to the areas where it was left off after assembly. 
       FIG. 14  shows a possible sequence for stacking and arranging modules ( 13 ), wall section assemblies ( 11 ), and floor/ceiling section assemblies ( 12 ) on the job site. Note that the greatest stacking and arranging advantage is achieved when an odd number of modules ( 13 ) are used. The odd numbered modules ( 13 ) are full modules ( 13 ), while the additional sections ( 11  and  12 ) create enclosed spaces between the modules ( 13 ). 
       FIG. 15  shows floor/ceiling connection to the party wall section assembly ( 11 ) section below. The party wall section assembly ( 11 ) and the right floor/ceiling section assembly ( 12 ) are delivered to the site as part of a module ( 13 ) while the left floor/ceiling section is installed at the site as a section. 
       FIG. 16  is a plan view of  FIG. 15 . Note the accessibility of the voids ( 5 ) within the wall section assembly ( 11 ) and interconnectivity with the voids ( 5 ) within the interior of the gull wing joist ( 7 ). 
       FIG. 17  shows how the gull wing joists ( 7 ) are to be installed on a framing table in the upside-down position such that they will function as roof rafters. The rigid insulation ( 2 ) is added next and then the pre-finished sheet steel roof membrane ( 14 ) as a water proofing membrane. The assembly is designed for a mechanical fastener ( 18 ) to penetrate the pre-finished sheet steel roof membrane ( 14 ) at the high point. 
       FIG. 18  shows the roof section, complete with the cornice ( 21 ), being installed atop a wall section assembly ( 11 ) on the site. With the roof section in its final position, the interconnecting steel reinforcement ( 6 ) will be added and zero slump concrete ( 4 ) will be shot into place within the interior voids ( 5 ) of the gull wing joist ( 7 ). Next the rib lathe ( 3 ) will be added and the plaster or stucco like material ( 19 ) will be installed on the ceiling and finished as appropriate.