Abstract:
A prefabricated wall system used in constructing a structure, the system including a wall segment configured to be lightweight and easily handled manually while constructing the structure, and a securing system configured to secure the wall segment in place on the structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/983,773 filed Oct. 30, 2007, and incorporated herein by reference in its entirety. 
         [0002]    This application claims the benefit of U.S. Provisional Application No. 61/060,946 filed Jun. 12, 2008, and incorporated herein by reference in its entirety. 
     
    
     FIELD OF INVENTION 
       [0003]    The present invention relates to building construction and, more particularly, to a prefabricated building wall section system for use in replacing concrete blocks. 
       BACKGROUND OF THE INVENTION 
       [0004]    Typical building construction uses concrete blocks that are individually set in mortar to construct walls of a building. These blocks are nominally 8×8×16 inches when measured with the associated mortar joints. Each block weighs about 40 pounds and the laying of the blocks to create a wall is a labor intensive task. Various methods have been proposed to overcome the labor issues involved in laying block, including creating forms and pouring solid concrete walls. Other proposals have used prefabricated wall panels such as foam core panels that can be put in place and then sprayed with a concrete surface. It has also been proposed to prefabricate a foam core panel with outer concrete surfacing that can be lifted in place using lifting apparatus at the job site. However, recent changes in building codes have required that building walls have sufficient strength to withstand winds associated with hurricanes and tornados. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0005]    A prefabricated wall system used in constructing a structure is disclosed. The system has a wall segment configured to be lightweight and easily handled manually while constructing the structure. A securing system is disclosed being configured to secure the wall segment in place on the structure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, exemplary embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
           [0007]      FIG. 1  is a composite view of all of the individual elements that are joined together to form a prefabricated wall section; 
           [0008]      FIG. 2  shows the components of the wall section of  FIG. 1  as they are assembled to form a wall section; 
           [0009]      FIG. 3A  shows an exemplary embodiment of the components of another wall section as components are assembled to form the wall section; 
           [0010]      FIG. 3B  shows an exemplary embodiment of additional components of the wall section illustrated in  FIG. 3A  as components are assembled to form the wall section; 
           [0011]      FIG. 4A  shows an exemplary embodiment of the components of another wall section as components are assembled to form the wall section; 
           [0012]      FIG. 4B  shows an exemplary embodiment of additional components of the wall section illustrated in  FIG. 4A  as components are assembled to form the wall section; 
           [0013]      FIG. 5  shows an exemplary embodiment of the components of another wall section as components are assembled to form the wall section; 
           [0014]      FIG. 6  illustrates an assembly of the wall sections to form a wall; 
           [0015]      FIG. 7  illustrated an assembly of the wall section upon a floor; 
           [0016]      FIG. 8  illustrates a final wall assembly; 
           [0017]      FIG. 9  is a partial cutaway and external view of a wall assembly using a concrete post and beam application; 
           [0018]      FIG. 10  is a partial cutaway and external view of a wall assembly using a steel post and beam application; 
           [0019]      FIG. 11  illustrates a wall assembly with a window; 
           [0020]      FIG. 12  illustrates details of a portion of the wall assembly; 
           [0021]      FIG. 13  is a cross-sectional view of the window installation in the wall assembly; 
           [0022]      FIG. 14  illustrates a starter block used to minimize water incursion into a structure; 
           [0023]      FIG. 15  illustrates the use of the starter block in a wall structure; 
           [0024]      FIG. 16  is an enlarged cross-sectional view of the starter block and wall assembly; 
           [0025]      FIG. 17  shows one form of sill board for use in the window structure of  FIG. 13 ; 
           [0026]      FIG. 18  is a cross-sectional view of a wall segment arrangement of  FIGS. 3A and 3B . 
           [0027]      FIG. 19  is a cross-sectional view of a wall segment arrangement of  FIGS. 4A and 4B . 
           [0028]      FIG. 20  is a cross-sectional view of a wall segment arrangement of  FIG. 5 . 
           [0029]      FIG. 21  is a cross-sectional view of another exemplary wall segment; 
           [0030]      FIG. 22  is a cross-sectional view of another exemplary wall segment arrangement; and 
           [0031]      FIG. 23  is a cross-sectional view of another exemplary wall segment arrangement. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    Reference will now be made in detail to the embodiments consistent with the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals used throughout the drawings refer to the same or like parts. 
         [0033]    Though exemplary embodiments of the present invention are described with respect to concrete post and beam construction, the exemplary embodiments disclosed herein are also applicable for steel post and beam construction. Towards this end, the exemplary embodiments of the present invention is applicable for a plurality of uses, including but not limited to high rise structural construction other uses, where improved wind load tolerances and reduced effects of seismic activity is realized. 
         [0034]    Turning now to  FIG. 1 , the various components that make up the inventive wall section are each illustrated as individual items in this figure. Each of the items are previously cut or sized to fit a particular desired dimensional wall section, such as but not limited to a 5×9 or 4×8 section. As shown in  FIG. 1 , the individual pieces comprise a metal stud  10  which extends through the longest length of the wall section and a metal track  12  which is used to join the completed sections or panels. The panels use metal channels  16  and angle bars  14  to join the metal studs  10  into a rectangular configuration. The components also include a corrugated galvanized steel panel  18  between the metal studs. The remaining components include a thermal ply layer  20  which is attached to one side of the assembled metal studs. A rib lathe  22  is fastened to the outer exposed area of the thermal ply layer to form a surface for receiving stucco or other outer material such as lightweight concrete. Insulation  24  is placed between the studs  10 . A lightweight concrete drywall panel  26  may be poured in situ over the rib lathe  22  to form the panel. 
         [0035]    Referring to  FIG. 2  at  30  there is shown an assembly of the metal studs  10  fastened together at opposite ends by transverse angle bars  14 . In addition, the center studs  10   a  and  10   b  are fastened together by means of the metal track  12 . The combination of the studs  10 , track  12 , and angle bars  14  forms a skeleton structural unit  30  which is the basis for the wall panel. The bars  14  are fastened to the studs along one edge and then the assembly  30  is inverted to receive the thermal ply outer panel  20 . The panel  20  is attached to the framework  30  by screws or other suitable means well known in the art. The rib lathe  22  is then attached to the thermal ply layer by screws to form a bonding surface for the lightweight concrete panel  26 . The lightweight concrete panel indicated at  26  in  FIG. 1  is formed on the assembly  32  by placing the assembly in a form and pouring the concrete over the rib lathe. 
         [0036]      FIGS. 3A and 3B  show exemplary embodiment of the components of another wall section as components are assembled to form a wall section. As illustrated in  FIG. 5A , a vapor barrier, such as but not limited to Visqueen®, stretched over a mold  99 . The framework  30  is secured to the mold  99 . Foam insulation  100  is inserted into the openings in the framework  30 . Plumbing and electrical conduits  62 , such as but not limited to cold rold channels and electrical chases, are installed into the framework  30 . As illustrated holes  104 , or openings, are formed through the framework  30  to accommodate the conduits  102 . 
         [0037]    Turning to  FIG. 3B , a thermal ply layer  108  is attached over the opening where the conduits  102  are visible between the framework  30 . A second layer of foam insulation  110  is attached to the thermal ply layer  108  and the framework  30 . A third piece of foam insulation  112  is installed over the framework  30 . Whereas the first and second layers of foam insulation  100 ,  110  are multi-faceted pieces configured to fit within openings in the framework  30 , the third layer of insulation  112  is a solid piece configured to cover the exposed edge of the framework  30 , furthest away from the mold  99 . As further illustrated, a home wrap, Visqueen® or another coating,  114  is stretched and secured to the third layer of foam insulation  112 . A lath  116  is then placed over the home wrap  114  and attached to the framework  30  and/or third layer of insulation  112 , collectively forming a wall segment  118 . 
         [0038]      FIGS. 4A and 4B  show exemplary embodiment of the components of another wall section as components are assembled to form the wall section. As illustrated in  FIG. 6A , a mold  120  is coated with a lightweight concrete coating  122 , such as but not limited to the lightweight concrete coating disclosed in U.S. patent application Ser. No. 12/166,494, filed Jul. 2, 2008, herein incorporated by reference. A mesh panel  124  is inserted into the poured concrete  122 . The mesh panel  124  may be made of a metal and/or a plastic material. The mesh panel  124  is further covered with the lightweight concrete  122  and the concrete is then leveled off. A framework  30  is fixed within the concrete  122 . The framework  30  has threaded rods  126 , such as but not limited to steel rods, inserted through the framework  30 . The threaded rods  126  are provided to apply tension within the core of the finished wall segment. Application of tension to the rods  126  significantly increases strength and surface impact resistance. A temporary mold  128  is formed by placing a removable material, such as but not limited to Styrofoam® beneath the threaded steel rods  126 . Though Styrofoam® is disclosed, the type of material used is a material to define an area during construction of the wall. 
         [0039]    Turning to  FIG. 4B , a second layer of mesh  130  is placed in the openings of the framework  30 , over the threaded rods  126 . Another layer of lightweight concrete  122  is then poured within the openings of the framework  30 . A thermal ply  20 , such as but not limited to a single piece, is secured over the framework  30 . A lathe  132  is fastened to the framework  30 , over the thermal ply. A foam board  134  is installed and then a final layer of the lightweight concrete  122  is applied. After the concrete  122  has set, the formboards  134  and Styrofoam molds  128  are then removed, forming the wall segment  136 . This configuration has no foam insulation. Therefore, toxic fumes are eliminated in case of a fire. 
         [0040]      FIG. 5  shows exemplary embodiment of the components of another wall section as components are assembled to form the wall section. A mold  140  is provided. Either lightweight concrete or another type of board, such as but not limited to a Magnesium Oxide board,  142  is installed in the mold  140 . Foam insulation  144  is attached to the concrete/board  142 . A top surface of the wall segment has a concrete layer and/or the magnesium oxide board  144 . Such a wall segment  150  is lightweight and has a high R-value rating. An R-value rating is based on a measure of thermal resistance used to compare insulating values. The higher the R-value of a material, the better its insulating capability. Additionally, such a wall segment  150  has high impact resistant qualities while being flexible. 
         [0041]    At a construction site, the individual panels indicated at  34  in  FIG. 6  are assembled by joining the ends of the panels together using the metal tracks  12 . The tracks  12  are screwed to the studs  10  using conventional metal screws designed for this purpose. As shown at  40  in  FIG. 6 , the initial panel stands on end and is positioned over a vertically extending reinforcement bar and then rotated around the rebar and slid into position so that the panel is actually connected to the reinforcing bar indicated at  42 . A plurality of the panels  40  is then sequentially placed adjacent each other and joined together by the metal tracks  12  as indicated at  44 . The corrugated galvanized steel indicated at  18  in  FIG. 1  is inserted into the wall panels between each of the pair of parallel studs  10 . Once the corrugated galvanized steel panels  18  are positioned between the studs  10 , a one and one-half inch metal channel is slid through the holes that are conventionally formed in the metal studs and rotated to lock the studs and corrugated steel in place as shown at  46 . As each of the preformed panels is slid into place and attached to an adjacent panel by means of the six inch track  12 , a space is formed between the adjacent panels that can be used to receive concrete so that the wall is joined by formed in place concrete piles between each of the pairs of panels. 
         [0042]    The individuals panels, or wall segments indicated at  34 , in  FIG. 2 ,  118  in  FIG. 3B ,  136  in  FIG. 4B , and  150  in  FIG. 5  can be installed in a similar manner as disclosed above. In another exemplary embodiment, illustrated in  FIG. 7 , once a floor  152  is laid for a building structure, the track  156 , such as but not limited to a steel track, is secured to the floor  152 . The steel track  156  is segmented by tenants  158 , such as but not limited to steel tenants. The wall segments  34 ,  136 , and  150  are positioned on the tracks  156  therebetween the tenants  158 . A tubing  160 , such as but not limited to a vertical steel tubing, is placed between adjacent wall segments, and a horizontal tubing  162 , such as but not limited to a steel horizontal tubing, is secured above the wall segment. 
         [0043]    Turning now to  FIG. 8 , at  50 , in another exemplary embodiment, there is shown upper and lower reinforcing bars  52  extending lengthwise across the top of the assembled panels so that a concrete tie-beam can be poured in place across these panels and joined by the reinforcing bar extending crosswise of the panels. The reinforcing bars  52  are conventional reinforcing bars used in wall construction. At  54  there is shown a further step in the assembly in which the insulation material  24  is pushed in place between the vertical studs  10 . Note that the insulation  24  is in two pieces, one long piece and one short piece to accommodate the joint formed at the top of the studs by the crossing angle bar  14 . Once the insulation has been placed between the studs as indicated at the assembly  56 , the concrete reinforcement can be pumped into the down cells formed between adjacent panels by tracks  12  and into the top area in which the reinforcing bar  52  is located so that the down cells and cross tie-beam are integrally joined. Finally, the wall  58  can be completed by conventional attachment of a drywall panel  60  to the inside of the walls overlaying the insulation material  24 . 
         [0044]    As disclosed herein, the wall segments are utilized with a concrete and/or steel post and beam application.  FIG. 9  discloses a wall where a concrete post and beam application is used. Once the walls are in place, such as secured to the track  156 , concrete, reinforced concrete, is poured therebetween adjacent wall segments to form the post  165 . A concrete beam  166 , with reinforced concrete, is poured horizontally across the top of the wall segments. An upper track  157  is provided to define the location where the cement is poured forming the concrete beam  166 . 
         [0045]      FIG. 10  discloses a wall where a steel post and beam application is used. In this embodiment, the steel posts  170  are secured in place after the floor is poured. The wall segments are lifted over the steel posts and are lowed down into position. The walls are then bolted to the steel beam  172  once it is placed on top of the wall segments. Those skilled in the art will readily recognize that a plurality of various wall segments, such as but not limited to those disclosed herein, may be utilized for the wall segments. 
         [0046]      FIG. 11  shows how a window and hurricane shutter assembly can be incorporated in the wall section. In this example, the wall section is formed of two spaced cementious panels  70  and  72  with Styrofoam filler  76  between the panels. A poured concrete tie beam across the top of the wall at  74  provides structural strength. Again, those skilled in the art will readily recognize that a plurality of various wall segments, such as but not limited to those disclosed herein, may be utilized for the wall segments. 
         [0047]      FIG. 12  shows detail of another form of the wall structure in which the wall is made up of multiple segments each defined by a concrete header, footer and side beams. Between these concrete elements, the wall is formed by a corrugated steel panel  78  mounted to the vertically oriented metal studs  80 . 
         [0048]      FIG. 13  is a cross-sectional view of the window arrangement of  FIG. 11  illustrating a structure in which the building base is built on a footer  82  and raised to ground level or above by conventional concrete blocks  84 . A starter block  86  is placed on the blocks  84  at the level of the concrete slab  88 . The wall panels  58  are then erected on the starter block  86  with a beveled mud set at  90 . Along the bottom of the window opening there is beveled window sill  92  and a buck strip  94 . Details of the sill  92  are shown in  FIG. 17 . The sill forces the penetrating water to drain to the exterior. Details of the starter block  86  are shown in  FIG. 14 . This block serves as a formboard and a recessed trap to catch water that penetrates through the outer wall. The starter block is formed of a material that absorbs the water and releases it below ground level.  FIG. 15  provides a better view of the arrangement of the starter blocks  86  along a support wall. 
         [0049]      FIG. 16  is an enlarged view of the interface of the wall section  58  with the starter block  86  at slab level. It should be noted that the beveled concrete insert  90  locks the bottom of the wall panel to the slab. 
         [0050]      FIG. 18  is a cross-sectional view of a wall segment arrangement of  FIGS. 3A and 3B .  FIG. 19  is a cross-sectional view of a wall segment arrangement of  FIGS. 4A and 4B .  FIG. 20  is a cross-sectional view of a wall segment arrangement of  FIG. 5 .  FIG. 21  is a cross-sectional view of another wall segment. This wall segment  180  has a thermal ply barrier  20  next to the framework  30 . Foam insulation  144  is next to the other side of the framework  30  and the last layer is a vapor barrier  190 . As disclosed herein with respect to the other wall segments, opening  104  for electrical connections and plumbing are also provided.  FIG. 22  is a cross-sectional view of another wall segment arrangement. This wall segment  194  has a lightweight concrete coating  122  next to a foam insulation  144 . The next layer is a thermal ply  20 , followed by the framework  30 . A vapor barrier  190  is the final layer.  FIG. 23  is a cross-sectional view of another wall segment arrangement. This wall segment  196  has a lightweight concrete coating  122  next to corrugated steel  191 . A thermal ply layer  20  is then provided. Foam insulation  144  is then provided, followed by the framework  30 . As illustrated two levels of foam insulation  144  are used. A vapor barrier  190  is the final layer. Also displayed in  FIGS. 18  though  23  are rebar  201 , the concrete beam  166 , the steel upper track  157 , and a top plate  203 . In each configuration, the wall segment is fixed to the starter block  86  and to the foundation or floor  152 , including Z-flashing  206  between the foundation  152  and wall segment. 
         [0051]    While the invention has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes, omissions and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another.