US2159991A - Prefabricated building unit and wall - Google Patents

Description

y 30, 1939- Mi (5. HILPERT EREFABRICATED BUILDING UNIT AND WALL Filed Feb. 5, 1957 4 Sheets-Sheet 1 y l L J I l I gwvq/wbob fleierGeo. Hi/Q a May 30, |L RT 2,159,991

' PREFABRICATED BUILDING UNIT AND WALL Filed Feb. 3, 1957 4 Sheets-Sheet 2 ig;g .az 34 ,5

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OHM/wag May 30, I G. RT I PREFABRICATED BUILDING UNIT AND WALL Filed Feb. 5, 1957 4 Sheets-Sheet 3 Meier Gemflilbezd? May 1939- A M. G. HILPERT 2,159,991

PREFABRICATED BUILDING UNIT AND WALL Filed Feb. 5, 19s? 4 Sheets-Sheet 4 Me ifergeouHi/pert, v I

Patented May 30, 1939 UNITED STATES PATENT OFFICE J 8 Claims.

This invention relates to slabs, capable of varied uses but especially intended for use in forming the walls, floors and roofs and the floors plus ceilings and the roofs plus ceilings, of pre-fabricated building constructions preferably having steel frames and if desired, stucco, or Gunite,

or brick veneer exterior finishes, and has gen-' the accompanying drawings and defineddn the appended claims.

In the drawings:

Figure l is a plan view of a grid-like rein-. forcement for the top or outer wall of a slab.

Figure 2 is a plan view of a grid-like rein-- forcement for the bottom or inner portions of the 25 side and end walls and the ribs of a slab, including chairs for the attachment of additional reinforcements.

Figure 3 is a longitudinal sectional view showing the relative arrangement of the reinforcing so elements of Figures 1 and 2 and cell forming core elements within a form preparatory to pouring the body portion of one of the present slabs. Figures-4 and 5 are fragmentary sectional and plan views, respectively, of a combined clip and as chair used in the constructionof the present slab. Figure 6 isa plan view of a completed body portion of a floor or roof slab.

Figure 7 'is a longitudinal-section through a completed body portion of a floor .or roofslab it) with the cell forms and exterior forms removed and provided with thermal insulation.

. Figure 8 is a longitudinal section through a v 'flnished floor or roof slab showing the plastic cast ceilingforming closures for the cells thereof. Figure 9 is a fragmentary-sectional view showing a joint between two adjacent floor or roof slabs.

Figure 10 is a view similar to Figure 9 illusm trating an alternative slab and jointcon'struction. I

, Figure 11 is a plan'view of a wall slab equipped with a hole for the reception of a lifting device and with anchors for retaining a stucco, Gunite or brick weneer exterior finish.

(c1. 'zzi) Figure 12 is a transverse section on the line. |2- -l2 of Figure 11.

Figure 13 is a view similar to Figure 12 showing a modification in applying thermal insulation.

Figure 14 slab.

Figure 15 is an elevation of a wall having slab load and locking elements extending between the slabs forming said wall. 10

t Figure 16 is a horizontal section through the wall joint showing the loading and locking elements in elevation.

Figure 17 is a sectional, perspective view of a portion-of a building constructed with slabs and elements in their proper relation to a steel frame all in accordance with the invention.

Referringto the drawings in detail, first with particular reference to the floor or roof, or floor plus ceiling, or roof plus ceiling, slab illustrated in Figures 6 to 10, A designates, generally, the slab body which in accordance with the invenis a sectional view through a wall tion, is of rectangular shape and may be formed from any suitable material such as ordinary concrete or the like, or cinder concrete, Haydite" or the like having thermal insulating value in itself.

The body A may be of any desired length, breadth and thickness and is of closed-top, cellular construction having the cells thereof opening through its bottom. That is to say, the body A comprises a top wall in, side walls II and end walls l2, and has depending from its top wall to the plane of its bottom, one or more strengthening ribs- I3 extending longitudinally from end to end thereof, and one or more strengthening IlDS l4 extending transversely from side to side thereof, the said ribs cooperating with each other and with the side and end walls to define the cells,' designated as l5, which open through the bottom of the body A as stated.

In the top wall I0 is embedded suitable reinforcing means which conveniently may comprise a plurality of rods I 6 and I1 extending longitudinally and transversely of said wall, said rods l6 and Il preferably. but not necessarily, being suitably joined together at the points where they extend across or intersect each other. In addition, other reinforcing rods i 8 and I9 are embedded in the bottoms of the ribs [3 and. i4, respectively, and extend longitudinally thereof, said rods l8 and I9, as in the case of rods l6 and Il, also preferably, but not necessarily, being suitably joined together at the points where they extend across or intersect eaehother.

clips 20 from side to side of the slab body A are -rods 22 which serve as reinforcements for a relatively thin slab bottom closure 23 of cement or the likehaving at the bottom thereof additional transversely extending reinforcingrods 22'.

In some casesit may not be necessary or desirable to have finished ceilings at the under sides of the floor or root slabs A. On that event, in forming the slabs, the rods l8 need not be equipped with the clips 20 for holding the rods 22 and said rods 22 and the bottom closure 23 need not be provided. In other words, the cells l5 may remain open at their bottoms. On the other hand, in cases where it is necessary or desirable to have finished ceilings at the under sides of the slabs A, the bottom closures 23 therefore and the reinforcing rods 22 held by the clips 20 or their equivalent are provided, the said bottom closures forming the finished ceilings as is apparent. 1

Preferably the cells l5 are lined with metallated paper or other suitable material 26 whereby the heat losses of the slab are greatly reduced and moisture and air are prevented from finding their way through the slab. Alternatively, the cells l5 may be filled, or partly filled, with other suitable heat and sound insulating material such, for example, as bulk insulation, designated as 25, which may be retained in said cells in any suitable manner, as, for example, by being stuck to the interior cell walls before applying the closure 23, or by means of bowed rods or wires 26 engaged at their ends against the cell side and, or,

,end walls, as illustrated in connection with the wall slab shown in Figure 12, or alternatively, the bulk insulation may be carried on a sheet of paper resting on the rods 22 and provided with upturned edges, or it may be placed on top of and around the sides of the core elements employed in forming the slab, prior to the pouring of the material to comprise the slab over said core elements.

, The slabs A are adapted to be suitably supported in side to side and end to end relationship with their ends resting upon the flanges of beams or girders, and are adapted to have the spaces between them filled by concrete or other suitable material which may present either the same surface color as the slabs or any contrasting color to form an atttractive fioor design. In any event, to adapt the slabs, when disposed in side to side and end to end relationship, to have spacesformed therebetween for the reception of slab binding fillers of concrete or the like, the outer faces of the side and end walls of the slabs, according to one practical form of the invention, are downwardly and outwardly inclined as indicated at 21. This results in the forming, between any two adjacent slabs, of a V-shaped channel for the placing of I-beam tie rods and for the reception of a binding material designated as 28, which may, if desired, be covered by a reinforced layer 29 of the same material as the slab body. Moreover, this beveling or inclining of the side and the end walls of the slab body provides for the forming of a binding material re-.

or the like on the flange of which the side or end of the slab 'rests, the I-beam or the like being thus fireproofed by said binding material.

Obviously, instead of beveling the sides and ends of the slab body to provide for the forming of binding material receiving channels between the slabs, the same result may be obtained by forming the bottom portion of the slab body at its sides and ends with an outwardly directed flange 30, in which event the outer faces of the slab body above said flange may be either perpendicular to the plane of the slab body, or inclined, as may be desired. In either case, when the flanges of any two slabs are brought into edge to edge abutting relationship, as illustrated in Figure 10, a binding material receiving channel is formed between the slabs as is apparent. Also, it is apparent that in the case of any terminal slab resting upon the flanges of I-beams, or the like, there is formed a binding material receiving channel between the adjacent wall or girder and the side of the slab body.

In Figures ll to 16 of the drawings are illustrated wall slabs, designated as B, which are of generally the same construction as the fioor or roof, or floor plus ceiling, or roof-plus ceiling slabs illustrated in Figures 6 to 10. That is to say, the bodies of said wall slabs are of rectangular shape and may be formed from any of the extending ribs, l3 and M respectively, integral with and extending inwardly from their closed outer sides l0. At their inner sides they may be either left open or unfinished or they may be closed by thin walls 23' as in the case of the slabs A. Moreover, the cells I5 may be lined with metallated paper or may be filed, or partly filled, with bulk insulation which may be retained in said cells in any suitable or desired manner. Instead of the edges of the slabs B being beveled or stepped as in the case of the slabs A, the edges of said slabs B preferably are fiat and are disposed perpendicularly to the planes of the slabs.

As it is intended that the wall slabs B are to be made of considerable size they may be quite heavy and, in the absence of special means to facilitate their handling, they may be difiicult to handle. Accordingly, and as illustrated in Figures 11 and 12 of the drawings, there preferably is formed through each slab B, transversely thereof, a hole 3| through which a rod, pipe or the like may be passsed for use in lifting or otherwise handling the slab. This hole may be formed at any desired point. Preferably, however, it is formed approximately midway between the ends of the slab, through one of the ribs l3' or M or ata point where a pair of these ribs intersect. Moreover, the concrete or other material comprising the slab body preferably is reinforced adjacent to said hole as illustrated, for example, in Figure l2, by means of a rod or wire 32 bent upon itself and embedded in one of the ribs l3 7 cells and is suitably secured therein as by placing flat bottom or is disposed upon a suitable flat surface s. In addition, there is provided, as illustrated in Figure l, a section of the crossed rods or wires I6, I 1 substantially corresponding in length and width to the top wall III of the slab body to be formed, and, as illustrated in Figure 2, a section of the crossed'rods or wires l8, I9 spaced correspondingly to the spacing of the ribs l3 and I 4 to be formed, the wires or rods of said sections being wire tied together so that they may readily be adjusted'relatively to each other for use in forming slabs of different sizes. Moreover, there are provided a number of closed-top, closed-side, pan-like elements 35 to serve as cores for forming the cells l5. At points suitably spaced along the wires l8 or l9, depending upon whether it is desired that the bottom closure reinforcing rods 22 shall extend transversely, or longitudinally of the completed slab, are placed the clips 20 in alined rows transversely or longitudinally of the rods 18 and I9 slightly above said surface.-

Within the rectangular space between each two adjacent rods 18, I8 and I 9, I9 is placed one of the pan-like core elements 35, the same resting on the surface s and having downwardly and outwardly sloping side and end walls of which the side walls engage the ends of the clips 20, whereby said core elements-are held properly positioned relative to the rods l8. As is understood, the pan-like elements 35 are arranged in rows longitudinally and transversely with the elements spaced apart corresponding to the width of the ribs l3 and I4 to'be formed. For either of the slabs A or B there may be disposed in covering relationship to each core-element a sheet of the metallized paper or the like 24. Supported in any suitable manner at suitable distances above the tops of the core elements 35 is the grid-like section of crossed rods or wires l3, II. In addition, if the slabis to be provided with the hole 3| a suitable core, such as an ordinary paper mailing tube, is placed in upright position at the point where the hole is to be located and the reinforcing wire or rod 32 is supported in proper position by means of said core. The concrete or other material from which the slab is to be formed then is mixed, or, already mixed and in plastic condition, is poured into the form F until it fllls the spaces between the core elements 35, therebyforming the ribs I 3' and I4, or I 3' and I4, as the case may be, and until it rises suitably above the tops of the core elements toform the top wall I0 or lfl' of the slab body, A or B as the case may be. Thereby, the reinforcing rods or wires l6, l1 beco'me embedded in the top wall l0, and the rods or wires I8, 19 become centrally embedded in the bottoms of, the ribs l3, l4 with the eyes 2| of the clips- 20 presenting openings at the bottom of and through said ribs to receive the wires or rods 22. Thereafter, the wires 34, if same are used, are forced in the plastic top of the slab body.

After hardening of the concrete or other material from which the slab body is formed, the form F is removed, the slab body is lifted from the surface s, and the core elements are re- ,moved, leaving within the cells li for wall slabs the metallized paperor equivalent linings 24. If anlalternatethermal insulation is to be used and the cells are to be filled or partiallyfllled with insulating material asfqrroof or over basement slabs, this material then is placed within said stucco and plaster.

on paper and resting on rods 22 or by means of the rods or wires 26. The bottom closure reinforcing rods 22 then are inserted through'the eyes 2| of the clips 20 and the bottom closure 23 is applied in any suitable manner, becoming united with the slab body through the instrumentality of the rods 22 and the clips 2| and serving effectively to close the bottom of the slab. In

this connection one suitable manner of applying I the bottom closure 23 is to providea form corresponding in length and width to the bottom of the slab body; to pour into this form a quantity of the material in plastic form from which the bottom closure is to be formed until the material assumes the form of a sheet of the desired depth or thickness; then to lower the slab body into said form until the bottom of the slab body embeds in the plastic material, and finally to permit the plastic material to harden. This obviously results in the rods or wires 22 becoming embedded in and reinforcing the bottom closure and, at the same time results in the bottom closure becoming securely bonded to the slab body in effective closing relationship to the bottom thereof. As a result the finished slab is of hollow, cellular form, light in weight, strong, weatherit is important that all of the prefabricated wall units be capable of expeditious assembly to promptly provide all exterior and interior surfaces for finishing, as afollowingoperation, and that all joints shall be well bonded as against contractive and expansive forces and other forces such as the weight of'the units or wind pressure against the wall slabs, or even earthquake forces. fore, the wall slabs are provided with flat sides Thereperpendicular to their planes and wire mesh or rods or the like 33 having T-shaped or equivalent ends, is or are employed between adjacent slabs as illustrated in Figures 15, 16 and 17. The rods 36 extend transversely between the slabs at suit-- ably spaced apart intervals and their T-shaped or equivalent ends overlie the inner and the outer faces of the slabs. Thereby, the slabs are supported in slightly spaced ,apart relationship and are interlocked against lateral movement relative to each other, especially, when the T-shaped or equivalent ends of the rods are embedded in 9 Moreover, when stucco or the like is applied to the outer sides of the wall slabs and plaster is applied to the innersides of said slabs, it is pushed into the spaces between the slabs and providesadditional bearing, area betweenlthe slabs and insulating air spaces within the joints. The rods 38, moreover, assure uniform,- thin joints between the slabs andpermit slabs staple-like anchors preferably of several pieces of galvanized wire twisted together for greater bonding value for both the exposed portion and the embedded portions. As the "exterior finish is applied, that is, as the brick veneer wall is laid up, the usual brick wall galvanized wall anchors are made to engage the slab staples and are moztared into the brick wall joints and thus the exterior finish is thoroughly tied to the locked wall slabs and shored against same by the excess veneer mortar bridging, at places, the usual insulating air space between the wall slabs and the veneer wall. The wall slab staples also act as accurate spacers for the width of the air space between the slab wall and the veneer wall, since the staples are placed in the prefabricated wall slabs by shop methods so as to extend exact distances beyond the exterior surfaces of slabs.

For veneer walls it will be provided that the veneer wall be founded slightly below the bottom slab joint and said slab joints thoroughly mortared exteriorly so that moisture invading the air space between the veneer wall and the slab wall will escape through the lower and exterior veneer wall joint, thus avoiding a serious defect of the ordinary veneer wall of brick, stone or tile.

' Without further description it is thought that the features and advantages of the invention will be readily apparent to those skilled in the art,

and it will of course, be understood, that changes in the form, proportion. and minor details of construction may be resorted to, without departing from the spirit of the invention or scope of the appended claims.

I claim: r

1. A building slab comprising a body portion having a top or outer wall, side and end walls, and ribs extending inwardly from the top or outer wall and cooperating with the side and end walls to form cells within said body portion, metallized paper linings for said cells, and a bottom or inner side closure for said slab body.

2. A building slab' comprising a body portion of closed top hollow form, clips embeddedinsaid cooperating with said faces to hold the slabs against inward or outward movement relative to each other.

4. A building slab having a top or outer wall, side and end walls, and ribs extending from the top or outer wall and cooperating with said side and end walls to form cells within the slab, re-

lnforcement means within the ribs near the bottom or inner ends thereof, and eyed clips, cariied by said reinforcement means and extending beyond the bottom or inner faces of said ribs for holding reinforcement means for a bottom or inner side closure for said slab.

5. A wall comprising superimposed pre-formed slabs, slab spacing elements extending transversely of said wall between adjacent slabs holding the latter spaced apart, and formations at the ends of said spacing elements overlying the inner and the outer faces of the slabs and providlng retaining and reinforcing means for plaster at the inner side of the wall and a finishing veneer or stucco at the outer side of the wall.

6.'A wall as set forth in claim 5 having a finishing veneer or stucco at its outer side and plaster at its inner side, the veneer or stucco and the plaster extending into the spaces between the slabs.

7. A building slab having a hole formed transversely therethrough and opening at opposite sides thereof for the reception of a lifting element, and slab reinforcing means embedded in said slab in surrounding relationship to said hole.

8. A building slab comprising a body portion having a top or outer wall, side and end walls, and ribs extending inwardly from the top or outer wall and cooperating with the side and end wall, to form cells within said body portion, heat and sound insulating material within. said cells, yielding means sprung into the cells from the open side thereof to hold the insulation material against said top or outer wall and the side walls of said cells, said yielding means engaging the opposite walls of the cells thereby to be held in place, and a bottom or inner side closure for said body portion and closing said cells.

MEIER GEO. HILPERT.

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