Patent EA-000200-B1 (EA)
Title: Prefabricated construction panels and modules for multistory buildings and methods for their use
IPC: E04B1/16
Filed: 1996-12-19
Abstract: 1. In a method for constructing a multi-level, multi-unit per level building with a framework comprising; creating said beams/ above the first level, without the use of removable forms by the steps of: erecting wall panels on a specific building level, wherein each said wall panel having a top; placing ceiling panels on top of said wall panels, characterized in that said ceiling panels having vertical ends; positioning said vertical ends of two said ceiling panels so as to lie spaced apart on said top of one of said wall panels; said vertical ends thereby defining the vertical, spaced apart sides of a volumetric beam void said top of said one wall panel defining the base of said volumetric beam void and the top surface of said beam void remaining exposed, and filling said beam void with concrete through open upper part to complete said beam. 2. In the method according to Claim 1, the step of: prior to filling said beam void with concrete installing reinforcing bars into said beam void, prior to said filling whereby said completed beam is of reinforced concrete; securing vertically rising, spaced apart supports to said top of said one wall panel, and mounting certain of said reinforcing bars onto said supports, affixing spacing members to said vertical ends of said ceiling panel, said spacing members being sized and shaped for abutting sides of said supports when said vertical ends of said ceiling panels are correctly spaced apart for defining said vertical sides of said beam void; and positioning said ceiling panels so that said spacing members abut said supports. 3. In the method according to Claim 1; each said wall panel having a bottom; securing to said bottom at least one guide member which projects downward from and along the length of said bottom; and creating a vertical groove along the top, exposed surface of said beam soon after said beam void is filled with concrete; the relative positions of said downward projecting guide member and said vertical groove being such that they will mate when a wall panel is positioned properly on top of said beam; whereby, such wall panel will lie on top of said beam and be vertically aligned with said one wall panel, which defined said base of said beam void. 4. In the method according to Claim 1, said ceiling panels and wall panels being constructed and arranged relative to said beam forming void and said resulting beam so that said beam lies exterior of said ceiling panels and said wall panels. 5. In the method according to Claim 1, employing light gage steel studs, the resulting loadbearing capability of said wall panels being at least sufficient to support the weight of said ceiling panels and concrete beams positioned at said top of said wall panels. 6. In the method according to any one of Claims 1-5, incorporating at least one column frame within each said wall panel; said column frame after being filled with concrete, becoming a loadbearing column. 7. In the method according to Claim 5, positioning certain of said column frames at the ends of said wall panels; affixing horizontally projecting anchors to some of those certain column frames for projecting into the column frames of other of those certain column frames; whereby, said anchors will become imbedded in the concrete of said other column frame and, after the concrete has hardened, said same' and other column frames and their respective wall panels will be secured to each other. 8. In the method according to Claim 6, constructing said column frame with an open top therebelow. 9. In the method according to Claims 1-8 accomplishing during a first part of a construction day, for a specific level, said erecting of said wall panels, and said placing and said positioning of said ceiling panels; and accomplishing during a second part of the same construction day, for said specific level said filling with concrete said beam voids and said column frames. 10. In the method according to Claim I prefabricating said wall panels and ceiling panels into a self-contained core module each said core module such that said base of said beam void is defined by said top of two said wall panels/ one such wall panel being in one volumetric core module, and the other wall panel lying back-to-back with said one such wall panel and being part of another volumetric core module. 11. In the method according to any of Claims 1-10 mounting vertical loadbearing reinforcing bars into said beam voids said reinforcement having a top portion and a bottom portion; said mounting being such that said bottom portion is in bearing surface contact with said top or said one wall panel, which defines said base of said beam void, and said top portion is in bearing surface contact with the bottom of another of said wail. 12. In the method according to any of Claims 1-10 fabricating a loadbearing, trussed wall panel said wall panel said wall panel including: a pair of metal tracks which define the top and bottom of said wall panel; top, bottom and diagonal metal truss chord members secured to each other/ with said top and bottom truss members being secured to said tracks; a plurality of interrupted vertical studs secured to said chord members. 13. In the method according to Claim 12 mounting vertically at least one lightweight column within said wall panel is open to said top and bottom of said wall panel; said column frame is constructed and arranged to receive reinforcing bars and concrete poured from said top of said wall panel; whereby after the concrete is hardened, there results a reinforced concrete column within said trussed wall panel. 14. In the method according to Claims 12 or 13 wherein a concrete beam underlying said wall panel; said beam having reinforcing bar portions projecting upward from a surface; said trussed wall panel constructed and arranged to securely receive said reinforcing bar portions/and thereby provide upward support to said beam.