CA2174876A1 - Prefabricated building panel and method of making the same - Google Patents
Prefabricated building panel and method of making the sameInfo
- Publication number
- CA2174876A1 CA2174876A1 CA 2174876 CA2174876A CA2174876A1 CA 2174876 A1 CA2174876 A1 CA 2174876A1 CA 2174876 CA2174876 CA 2174876 CA 2174876 A CA2174876 A CA 2174876A CA 2174876 A1 CA2174876 A1 CA 2174876A1
- Authority
- CA
- Canada
- Prior art keywords
- panel
- frame
- studs
- lath
- scratch coat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
- E04B2/845—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising a wire netting, lattice or the like
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
A cost effective panel and method of manufacture is disclosed where the panel includes temporary reusable supports for curing of a scratch coat. The scratch coat includes a lath substrate attached to a metal frame of the panel. The panel is inexpensive to manufacture and, if desired, can be assembled on site using a production line process or merely transported to the site for assembly in the building or manufactured as part of the building. A
finish coat is applied once the panel is in place.
finish coat is applied once the panel is in place.
Description
~-~OCA ~17487G
TITLE: PREFABRICATED BUILDING PANEL AND
METHOD OF MAKING THE SAME
FIELD OF THE INVENTION
The present invention relates to a wall stud construction system covered by a cement substrate. The construction system can be used to manufacture prefabricated building panels at a remote location or to manufacture walls on site. The construction system provides versatility and is cost effective.
BACKGROUND OF THE INVENTION
A number of prefabricated panels have been proposed, as to address the need for more efficient, low cost housing and the ability to construct various dwellings using unskilled labour.
Some systems have used extruded hollow sections of plastic to define interior and exterior surfaces of a panel and then fill the hollow cavities of the extrusion on site.
Another approach is to build sections of an entire wall.
and ship these basically finished wall panels. There r~m~' n.s a need for a more cost effective and easily varied building panel system.
SUMMARY OF THE INVENTION
A rectangular prefabricated building panel, according to the present invention, comprises a lath substrate attached to a perimeter metal frame with the lath reinforcing a scratch coat of a cement type material, preferably reinforced with glass fibers. The panel is produced by providing temporary back support for the lath and scratch coat during application of the scratch coat to the lath. The scratch coat and lath are self-supporting once the scratch coat has cured.
It is also possible to build the wall on site. In this case the stud frame is built, the lath is attached thereto, the vapour or air barrier is attached, the temporary back support is positioned and the scratch coat OCA 2i7~876 ~ .
is applied. Shortly thereafter the temporary back supports are removed.
According to an aspect of the invention, the perimeter frame is defined by metal channels.
According to a further aspect of the invention, the panel has a number of studs intermediate the height of the panel which support the lath.
According to a further aspect of the invention, the panel includes means for maintaining the spacing of the studs, particularly for use during shipping to avoid bending of the combined lath and scratch coat.
According to an aspect of the invention, the panel includes guide members projecting outwardly from the scratch coat with the guide members collectively defining a predetermined depth used to assist in applying a finish coat to the panel.
According to a further aspect of the invention, a vapour or air barrier is positioned between the studs and the scratch coat.
A method of manufacturing a wall or panel structure, according to the present invention, comprises providing a perimeter frame of metal channels and metal studs with at least some of the studs being intermediate the width of the structure and extending the length thereof, attaching a lath substrate to one face of the metal studs, positioning temporary support members between the studs, applying a cement type scratch coat to the lath substrate supported by the temporary support members, the studs and the lath substrate, allowing the scratch coat to dry and stiffen, and removing the temporary support members.
With this method and panel, the backing members necessary for supporting the scratch coat during the application thereof are removed when the scratch coat has cured sufficiently to be self-supporting. In this way, the cost for these support members in each final panel is avoided and the support members are reused.
O~ ~17487~
'_ Bracing of the studs avoids buckling or racking of the scratch coat during shipping of a panel and, if necessary, when installed. The panel during installation is reinforced by an interior surface, such as drywall, applied to the panel. The scratch coat even if it cracks during shipping is maintained by the lath and is covered by a final coat when the panel is finally installed.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
Figure 1 is a sectional view showing a portion of a panel being manufactured;
Figure 2 is a partial perspective view of a finished building panel with the bracing removed;
Figure 3 is a partial perspective view of the panel prior to application of the scratch coat; and Figure 4 is a partial perspective view illustrating how temporary supports are maintained in place to support the scratch coat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The general concept of the prefabricated building panel is shown in Figures 1, 2, 3 and 4. The building panel 50 includes on the rear surface thereof a number of metal studs 11 which are captured at the base of the panel and at the top of the panel by opposed 'U' shaped members 15. The metal studs 11 and the channel members 15 cooperate to form a frame about the panel and to reinforce the panel at intermediate positions due to a number of the studs being intermediate the frame. The panel 50 has a scratch coat 3 which forms one surface of the panel and this scratch coat is made up of a cement type material, preferably reinforced with glass fibers, with a lath type substrate 4 which has been previously secured to the studs.
The back of the panel, which is the 'up' side shown in Figures 2 and 4, is open and will be sent to the building site typically in this manner. A vapour or air barrier 1 ~ o~ 2174~7~
is preferably provided between the studs and the scratch coat. This barrier also serves to protect the temporary supports from the scratch coat when it is applied.
Additional reinforcing members 55 for shipping are used to maintain the spacing of the studs 11 and to avoid bending or flexing of the panel frame and thereby protect scratch coat 3. The reinforcing members 55 pass through ports 57 in the studs and frames. These reinforcing members 55, as shown in Figure 4 press wedges 10 against temporary supports 8. These supports 8 and wedges 10 are removed after curing of the scratch coat 3.
The front face 52 of the panel includes a plastic or metal 'J' mold 2 installed on the perimeter frame of the panel to allow a final coat to be applied in a level manner and to protect the edge thereof. In addition, a further intermediate guide 6 is attached to the intermediate studs and is partially embedded in the scratch coat. The intermediate guide 6 simplifies levelling of the final coat which will be applied in the field. Various ports 57 are provided in the studs and in the channels for allowing securement of panels in the field or to provide ports through which wiring can pass. The panels in the field are assembled on footings and are grouped to define a wall. A
finished coat is then applied to the exterior of the secured panels. The members 2 and 6 simplify the levelling of the final coat which provides an uninterrupted final surface, except for any expansion joints required therein.
The interior of the panels will still be open and any insulation can be added on site. The open backed panels are easily wired on site. The metal studs 11 include ports 57 along their length and these ports are aligned to allow reinforcing member 55 (Figure 4) to be inserted therethrough to provide stiffening during the manufacturing of the panel and during shipping of the finished panel.
In order to manufacture the panel of Figure 2, it is required to provide support for the scratch coat intermediate the studs 11. Temporary reusable support members 8, shown in Figure 1, provide this support and are ~17~876 ~-- OCA
shown in Figure 1 being supported above the stiffener or reinforcing member 11 which passes through the ports and the channel. Wedge blocks 10 position the temporary support in the desired position, and as shown, the temporary supports are generally flush with the face of the channels. It can be seen that the lath substrate 4, preferably of metal or nylon, is positively attached to the channels by rivets or screws and preferably has plastic washers to distribute the force of attachment to the substrate. The guides 6 and the perimeter frame 8 are also attached to the studs. The scratch coat can be applied with the temporary supports 8 in position, as shown in Figure 1, and the scratch coat is then allowed to dry and stiffen. Once the scratch coat has stiffened, the panel does have significant structural stability due to the scratch coat and due to the channels and the integration of these components. The structural integrity is further improved by maintaining the spacing of the studs and this can be accomplished by the stiffener, shown as 9 and 55.
The temporary supports 8 can be removed, as they are no longer necessary to directly support the scratch coat.
These supports are then reused.
In some cases, it is desirable to provide an air or vapour barrier and such a barrier is shown as 1 in Figure 1.
With the structure as shown in Figure 1, it can be seen that the panel can be made in substantial widths which is a significant benefit if manufactured as a wall of the building or is manufactured as large panels onsite and then put in position. The size and configuration of the panels can be preengineered and designed for the specific application. The back surface of the panels are fully open to allow wiring and/or the addition of any insulation materials, if necessary, and the final interior surface can be attached to the studs on site. The temporary stiffeners 9 can provide protection to the panel during the shipping thereof. It has been found that the reusable aspect of the temporary supports 8 and allowing this material to be ~ OCA ~17~876 removed from the finished panel significantly reduces the costs of the panel or wall. The panel is not particularly vulnerable to damage during shipping and the final panel will be further reinforced by the finished layer, which is applied to the exterior of the building panels on site and by an interior surface.
This particular panel is easily manufactured at an offsite location and shipped to a job site. It is also possible to manufacture the panel onsite, if desired, using a production line type process. It is also possible to manufacture on site as part of the building by assembly of the stud frame of the building and then apply the other components.
The panel or wall has been primarily described with respect to metal studs and metal channels, however, wood studs, and wood top and bottom plates can also be used.
Basically, the studs provide the support for the scratch coat, and therefore, the studs and frame can be of any suitable material.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
TITLE: PREFABRICATED BUILDING PANEL AND
METHOD OF MAKING THE SAME
FIELD OF THE INVENTION
The present invention relates to a wall stud construction system covered by a cement substrate. The construction system can be used to manufacture prefabricated building panels at a remote location or to manufacture walls on site. The construction system provides versatility and is cost effective.
BACKGROUND OF THE INVENTION
A number of prefabricated panels have been proposed, as to address the need for more efficient, low cost housing and the ability to construct various dwellings using unskilled labour.
Some systems have used extruded hollow sections of plastic to define interior and exterior surfaces of a panel and then fill the hollow cavities of the extrusion on site.
Another approach is to build sections of an entire wall.
and ship these basically finished wall panels. There r~m~' n.s a need for a more cost effective and easily varied building panel system.
SUMMARY OF THE INVENTION
A rectangular prefabricated building panel, according to the present invention, comprises a lath substrate attached to a perimeter metal frame with the lath reinforcing a scratch coat of a cement type material, preferably reinforced with glass fibers. The panel is produced by providing temporary back support for the lath and scratch coat during application of the scratch coat to the lath. The scratch coat and lath are self-supporting once the scratch coat has cured.
It is also possible to build the wall on site. In this case the stud frame is built, the lath is attached thereto, the vapour or air barrier is attached, the temporary back support is positioned and the scratch coat OCA 2i7~876 ~ .
is applied. Shortly thereafter the temporary back supports are removed.
According to an aspect of the invention, the perimeter frame is defined by metal channels.
According to a further aspect of the invention, the panel has a number of studs intermediate the height of the panel which support the lath.
According to a further aspect of the invention, the panel includes means for maintaining the spacing of the studs, particularly for use during shipping to avoid bending of the combined lath and scratch coat.
According to an aspect of the invention, the panel includes guide members projecting outwardly from the scratch coat with the guide members collectively defining a predetermined depth used to assist in applying a finish coat to the panel.
According to a further aspect of the invention, a vapour or air barrier is positioned between the studs and the scratch coat.
A method of manufacturing a wall or panel structure, according to the present invention, comprises providing a perimeter frame of metal channels and metal studs with at least some of the studs being intermediate the width of the structure and extending the length thereof, attaching a lath substrate to one face of the metal studs, positioning temporary support members between the studs, applying a cement type scratch coat to the lath substrate supported by the temporary support members, the studs and the lath substrate, allowing the scratch coat to dry and stiffen, and removing the temporary support members.
With this method and panel, the backing members necessary for supporting the scratch coat during the application thereof are removed when the scratch coat has cured sufficiently to be self-supporting. In this way, the cost for these support members in each final panel is avoided and the support members are reused.
O~ ~17487~
'_ Bracing of the studs avoids buckling or racking of the scratch coat during shipping of a panel and, if necessary, when installed. The panel during installation is reinforced by an interior surface, such as drywall, applied to the panel. The scratch coat even if it cracks during shipping is maintained by the lath and is covered by a final coat when the panel is finally installed.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
Figure 1 is a sectional view showing a portion of a panel being manufactured;
Figure 2 is a partial perspective view of a finished building panel with the bracing removed;
Figure 3 is a partial perspective view of the panel prior to application of the scratch coat; and Figure 4 is a partial perspective view illustrating how temporary supports are maintained in place to support the scratch coat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The general concept of the prefabricated building panel is shown in Figures 1, 2, 3 and 4. The building panel 50 includes on the rear surface thereof a number of metal studs 11 which are captured at the base of the panel and at the top of the panel by opposed 'U' shaped members 15. The metal studs 11 and the channel members 15 cooperate to form a frame about the panel and to reinforce the panel at intermediate positions due to a number of the studs being intermediate the frame. The panel 50 has a scratch coat 3 which forms one surface of the panel and this scratch coat is made up of a cement type material, preferably reinforced with glass fibers, with a lath type substrate 4 which has been previously secured to the studs.
The back of the panel, which is the 'up' side shown in Figures 2 and 4, is open and will be sent to the building site typically in this manner. A vapour or air barrier 1 ~ o~ 2174~7~
is preferably provided between the studs and the scratch coat. This barrier also serves to protect the temporary supports from the scratch coat when it is applied.
Additional reinforcing members 55 for shipping are used to maintain the spacing of the studs 11 and to avoid bending or flexing of the panel frame and thereby protect scratch coat 3. The reinforcing members 55 pass through ports 57 in the studs and frames. These reinforcing members 55, as shown in Figure 4 press wedges 10 against temporary supports 8. These supports 8 and wedges 10 are removed after curing of the scratch coat 3.
The front face 52 of the panel includes a plastic or metal 'J' mold 2 installed on the perimeter frame of the panel to allow a final coat to be applied in a level manner and to protect the edge thereof. In addition, a further intermediate guide 6 is attached to the intermediate studs and is partially embedded in the scratch coat. The intermediate guide 6 simplifies levelling of the final coat which will be applied in the field. Various ports 57 are provided in the studs and in the channels for allowing securement of panels in the field or to provide ports through which wiring can pass. The panels in the field are assembled on footings and are grouped to define a wall. A
finished coat is then applied to the exterior of the secured panels. The members 2 and 6 simplify the levelling of the final coat which provides an uninterrupted final surface, except for any expansion joints required therein.
The interior of the panels will still be open and any insulation can be added on site. The open backed panels are easily wired on site. The metal studs 11 include ports 57 along their length and these ports are aligned to allow reinforcing member 55 (Figure 4) to be inserted therethrough to provide stiffening during the manufacturing of the panel and during shipping of the finished panel.
In order to manufacture the panel of Figure 2, it is required to provide support for the scratch coat intermediate the studs 11. Temporary reusable support members 8, shown in Figure 1, provide this support and are ~17~876 ~-- OCA
shown in Figure 1 being supported above the stiffener or reinforcing member 11 which passes through the ports and the channel. Wedge blocks 10 position the temporary support in the desired position, and as shown, the temporary supports are generally flush with the face of the channels. It can be seen that the lath substrate 4, preferably of metal or nylon, is positively attached to the channels by rivets or screws and preferably has plastic washers to distribute the force of attachment to the substrate. The guides 6 and the perimeter frame 8 are also attached to the studs. The scratch coat can be applied with the temporary supports 8 in position, as shown in Figure 1, and the scratch coat is then allowed to dry and stiffen. Once the scratch coat has stiffened, the panel does have significant structural stability due to the scratch coat and due to the channels and the integration of these components. The structural integrity is further improved by maintaining the spacing of the studs and this can be accomplished by the stiffener, shown as 9 and 55.
The temporary supports 8 can be removed, as they are no longer necessary to directly support the scratch coat.
These supports are then reused.
In some cases, it is desirable to provide an air or vapour barrier and such a barrier is shown as 1 in Figure 1.
With the structure as shown in Figure 1, it can be seen that the panel can be made in substantial widths which is a significant benefit if manufactured as a wall of the building or is manufactured as large panels onsite and then put in position. The size and configuration of the panels can be preengineered and designed for the specific application. The back surface of the panels are fully open to allow wiring and/or the addition of any insulation materials, if necessary, and the final interior surface can be attached to the studs on site. The temporary stiffeners 9 can provide protection to the panel during the shipping thereof. It has been found that the reusable aspect of the temporary supports 8 and allowing this material to be ~ OCA ~17~876 removed from the finished panel significantly reduces the costs of the panel or wall. The panel is not particularly vulnerable to damage during shipping and the final panel will be further reinforced by the finished layer, which is applied to the exterior of the building panels on site and by an interior surface.
This particular panel is easily manufactured at an offsite location and shipped to a job site. It is also possible to manufacture the panel onsite, if desired, using a production line type process. It is also possible to manufacture on site as part of the building by assembly of the stud frame of the building and then apply the other components.
The panel or wall has been primarily described with respect to metal studs and metal channels, however, wood studs, and wood top and bottom plates can also be used.
Basically, the studs provide the support for the scratch coat, and therefore, the studs and frame can be of any suitable material.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
Claims (8)
1. A rectangular prefabricated building panel comprising a lath substrate attached to one side of a metal frame, said lath cooperating with a scratch coat of a cement type material, said metal frame including studs intermediate said frame, each stud at a base thereof being captured in a metal channel of the frame and each stud at a top thereof being captured in a metal channel, said panel further including means for maintaining the spacing of said studs intermediate the height of the frame to stiffen the frame against bending.
2. A rectangular panel as claimed in claim 1 including guide members projecting outwardly from said scratch coat, said guide members collectively defining a predetermined depth used to assist in applying a finish coat.
3. A panel as claimed in claim 1 or 2 including a vapour or air barrier between said studs and said scratch coat.
4. A panel as claimed in claim 1 or 2 wherein said lath is of a metal or nylon.
5. A method of manufacturing a panel or wall structure comprising providing a perimeter stud frame having at least some intermediate studs reinforcing the structure, attaching a lath substrate to one face of said stud frame and intermediate studs, positioning temporary support members between said studs, applying a cement type scratch coat to said lath substrate supported by said temporary support members, said frame, said studs and said lath, allowing said scratch coat to dry and stiffen, and remove said temporary support members.
6. A method as claimed in claim 5 including bracing said studs to avoid movement therebetween during shipping of said panel.
7. A method as claimed in claim 5 including providing a vapour or air barrier between said lath and said stud frame.
8. A method as claimed in claim 5 used to build a wall of a building wherein said frame is built as part of said building and said scratch coat is applied to said frame when said frame is vertically orientated.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2174876 CA2174876A1 (en) | 1996-04-24 | 1996-04-24 | Prefabricated building panel and method of making the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2174876 CA2174876A1 (en) | 1996-04-24 | 1996-04-24 | Prefabricated building panel and method of making the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2174876A1 true CA2174876A1 (en) | 1997-10-25 |
Family
ID=4158052
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2174876 Abandoned CA2174876A1 (en) | 1996-04-24 | 1996-04-24 | Prefabricated building panel and method of making the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2174876A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109794768A (en) * | 2019-03-15 | 2019-05-24 | 衡水中铁建环保工程有限公司 | A kind of noise barrier structure frame set installing is standby |
-
1996
- 1996-04-24 CA CA 2174876 patent/CA2174876A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109794768A (en) * | 2019-03-15 | 2019-05-24 | 衡水中铁建环保工程有限公司 | A kind of noise barrier structure frame set installing is standby |
| CN109794768B (en) * | 2019-03-15 | 2024-02-09 | 衡水中裕铁信环保工程有限公司 | Sound barrier structure frame equipment |
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| Date | Code | Title | Description |
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| FZDE | Dead |