CA1052121A - Insulated studded concrete wall - Google Patents
Insulated studded concrete wallInfo
- Publication number
- CA1052121A CA1052121A CA276,018A CA276018A CA1052121A CA 1052121 A CA1052121 A CA 1052121A CA 276018 A CA276018 A CA 276018A CA 1052121 A CA1052121 A CA 1052121A
- Authority
- CA
- Canada
- Prior art keywords
- concrete
- studs
- wall
- embedded
- insulation
- 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.)
- Expired
Links
Classifications
-
- 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
- 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
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The present invention relates to the construction of fire resistant concrete walls. The walls have wood and/or metal studs embedded therein when the wall is being made, and as well, insulation may be inserted between the studs before or after the pouring of the concrete. The method for making the walls consists basically of laying insulation, studs and brackets in the base of a form, pouring concrete thereover, and while still wet, embedding a second set of studs in the concrete.
A second layer of insulation may then be added either before or after the concrete sets. Finished panelling may be attached to the concrete walls after the concrete is set using the embedded studs as a means for receiving nails or screws.
The present invention relates to the construction of fire resistant concrete walls. The walls have wood and/or metal studs embedded therein when the wall is being made, and as well, insulation may be inserted between the studs before or after the pouring of the concrete. The method for making the walls consists basically of laying insulation, studs and brackets in the base of a form, pouring concrete thereover, and while still wet, embedding a second set of studs in the concrete.
A second layer of insulation may then be added either before or after the concrete sets. Finished panelling may be attached to the concrete walls after the concrete is set using the embedded studs as a means for receiving nails or screws.
Description
~5~
1 This invention relates generally to a method of making fire resistant concrete walls and more particularly such walls which have embedded therein studs to which finished panelling and the like can be easily attached such as with common nails or screws.
In the past, whenever one wanted to attach finished panelling to poured conçrete walls it was very unsatisfactory ~; to txy and use ordinarily used means to attach the panelling to the concrete. Concrete is very difficult to hammer nails into and as well the nails do not often grip as well as ~hey would in wood or the like. Therefore, a rather elaborate and time ~ ;
consuming placement of studs on the concrete walls is the usual first step in finishing the wall. The finished panelling, insulation or w~atever is then attached to the studs.
Accordingly it is an object of the present invention to at least partially overcome these dlsadvantages by providing - a method of making a studd~d concrete wall wherein studs are ~ :-embedded in the concrete when the concrete is pouredO This .JI allows the panelling, or whatever, to be easily attached to the 20 bare concrete wall without the need of first attaching studs tothe concrete. If desired one might additionally incorporate the attachment of the insulation to the concrete at the same tlme ~ as the studs are being embedded in the uncured concrete.
;~ To this end, in one of it~ aspects, the invantion provides a method of forming a studded concrete wall to be ~ ~
used in the construction of a building comprising the steps of: }
horizontally locating a form having a floor completely bordered by upright perimeter members, positioning a first plurality ;, . ~
- of studs on the floor of the form in a predetermined arrangement, 30 each of the studs having a flat face akutting on the floor of ~
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1 the form, pouring concrete into the form completely covering the first plurality of studs to a pred~termined level, emhedding a second plurality of studs, each of which have a flat face,into the concrete before it sets whereby their flat faces are coplanar and facing upwardly but are not covered by the concrete, allowing the concrete to set and removing the wall from the form.
In another of its aspects, the invention further provides as a preferred embodiment the laying of insulation between the studs before the concrete is poured. The insulation is one which will not substantially alter its shape when the concrete is poured over it. When inserting the concrete at this stage of the construction one must ensure that each ~f the studs of the first plurality protrude above the surface of the insulation.
Further objects and advantages of the invention !
will appear from the following description taken together with the accompanying drawings in which: `~
.,~ .
Figure 1 is a cut-away vlew of a wall according , 2~ to the present invention showing several preferred embodiments.
Figure 2 is a cross section of the wall in `~
Figure 1. `
Figure 3 is a diagram showing a corner conætructed from two walls showing several preferred embodiments.
Figure 4 is a view o a side wall bracket used in the preferred embodiment to connect two wall units together ;
to make a longer wall. ~`
' -
1 This invention relates generally to a method of making fire resistant concrete walls and more particularly such walls which have embedded therein studs to which finished panelling and the like can be easily attached such as with common nails or screws.
In the past, whenever one wanted to attach finished panelling to poured conçrete walls it was very unsatisfactory ~; to txy and use ordinarily used means to attach the panelling to the concrete. Concrete is very difficult to hammer nails into and as well the nails do not often grip as well as ~hey would in wood or the like. Therefore, a rather elaborate and time ~ ;
consuming placement of studs on the concrete walls is the usual first step in finishing the wall. The finished panelling, insulation or w~atever is then attached to the studs.
Accordingly it is an object of the present invention to at least partially overcome these dlsadvantages by providing - a method of making a studd~d concrete wall wherein studs are ~ :-embedded in the concrete when the concrete is pouredO This .JI allows the panelling, or whatever, to be easily attached to the 20 bare concrete wall without the need of first attaching studs tothe concrete. If desired one might additionally incorporate the attachment of the insulation to the concrete at the same tlme ~ as the studs are being embedded in the uncured concrete.
;~ To this end, in one of it~ aspects, the invantion provides a method of forming a studded concrete wall to be ~ ~
used in the construction of a building comprising the steps of: }
horizontally locating a form having a floor completely bordered by upright perimeter members, positioning a first plurality ;, . ~
- of studs on the floor of the form in a predetermined arrangement, 30 each of the studs having a flat face akutting on the floor of ~
. . ' ~ ' :'` ' '' . ' ~ ` -~: ' : . , -`, , ~
1~5'~2~
1 the form, pouring concrete into the form completely covering the first plurality of studs to a pred~termined level, emhedding a second plurality of studs, each of which have a flat face,into the concrete before it sets whereby their flat faces are coplanar and facing upwardly but are not covered by the concrete, allowing the concrete to set and removing the wall from the form.
In another of its aspects, the invention further provides as a preferred embodiment the laying of insulation between the studs before the concrete is poured. The insulation is one which will not substantially alter its shape when the concrete is poured over it. When inserting the concrete at this stage of the construction one must ensure that each ~f the studs of the first plurality protrude above the surface of the insulation.
Further objects and advantages of the invention !
will appear from the following description taken together with the accompanying drawings in which: `~
.,~ .
Figure 1 is a cut-away vlew of a wall according , 2~ to the present invention showing several preferred embodiments.
Figure 2 is a cross section of the wall in `~
Figure 1. `
Figure 3 is a diagram showing a corner conætructed from two walls showing several preferred embodiments.
Figure 4 is a view o a side wall bracket used in the preferred embodiment to connect two wall units together ;
to make a longer wall. ~`
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105Z12~
1 Figure 5 is a view of a corner bracket used in the preferr~d embodiment to connect two wall units together 1 r to form a corner.
Figure 6 is a plan view showing corners and is . .
, located on the same page as Figure 4 Reference is made to Figures 1 and 2 which show a wall 10 formed according to the present invention. Several preferred embodiments are displayed in the drawings, although they are not necessary to work the present invention.
To maXe a wall according to the present invention, one first selects the proper form (not shown). Attention should be directed to the size and shape of wall desired and -` also as to whether any window or door spaces are desired. In ~. .. . - .:,:;
!; the bottom of the form a first plurality of ~tuds are arranged. The studs can be made out o~ any material into ~.
which common attaching means - nails, screws, staples, etc. -~-~ can be easily and readily applied to for attaching panelling, i insulation or whatever. The shape of the studs and their - arrangement on the floor o~ the form need simply be one which 20 would accommodate the a$taching o~ the exterior surface, such as finished panellings 18, thereto. In most aases
105Z12~
1 Figure 5 is a view of a corner bracket used in the preferr~d embodiment to connect two wall units together 1 r to form a corner.
Figure 6 is a plan view showing corners and is . .
, located on the same page as Figure 4 Reference is made to Figures 1 and 2 which show a wall 10 formed according to the present invention. Several preferred embodiments are displayed in the drawings, although they are not necessary to work the present invention.
To maXe a wall according to the present invention, one first selects the proper form (not shown). Attention should be directed to the size and shape of wall desired and -` also as to whether any window or door spaces are desired. In ~. .. . - .:,:;
!; the bottom of the form a first plurality of ~tuds are arranged. The studs can be made out o~ any material into ~.
which common attaching means - nails, screws, staples, etc. -~-~ can be easily and readily applied to for attaching panelling, i insulation or whatever. The shape of the studs and their - arrangement on the floor o~ the form need simply be one which 20 would accommodate the a$taching o~ the exterior surface, such as finished panellings 18, thereto. In most aases
3 this would mean that long 2-~by 4-type studs would be used, although this is not necessary, and that they would be arranged in a horizontal and~or vertical orientation. It would ~~ also be possible to use any other suitable shape o~ studs.
~ ~
'l Small irregular pieces capable of acting as studs can be used ~
, so long as the arrangement allows the panelling to be affixed ;
thereto when the wall is finished.
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Concrete 14 is then poured sver the studs 12 to a depth sufficient to completely cover them. It may be helpful to use some means to retain the studs in a prefixed position so that the concrete does not disturb them when it is being poured into the form. This could be accomplished by nailing the studs together if they are arrang~d in a horizontal and vertical arrangement as they are in the preferred embodiment.
Other methods could also be used to ke~p the studs positioned. . . .
Of course, if a random positioning of the studs 12 is acceptable, then there is no need to worry about this matter.
After the concrete has been poured, a ~econd plurality of studs 16 is arranged partially embedded in the wet concrete. As with the studs 12, the studs 16 are arranged in whatever malmer is preferred by the builder so that a finished ' panelling 20 may be attached thereby.
- By using this method, one is able to build a i concrete wall to which finished panelling may be directly attached without the need of using concrete nails and the like as,the panelling can be nailed, screwed, stapled or however ~
20 attached to the wall b~ attaching the panelling to the studs ' '' ' instead of to the concrete.
;, In choo~ing which type of studs to use in this con~
stxuction, one must consider ~everal factors. ~he portion of the '~ studs facing out from the concrete should be flat and coplanar to allow ~or an easy attachment of an exterior panelling thereto. ~ ~;
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As well, the studs must be of a proper construction to allow screws, nails and the like to be easily insèrted therein. In embedding the studs 16 into the concrete, and when pouring the concrete over the studs 12, it must be remembered that the concrete cannot completely surround the stud as there must be at least the flat face of the stud exposed to allow the scraws or nails to be insexted therein.
There is no reason however why the studs may not protrude from ~he concrete. This is what is done in a preferred-j 10 embodiment such as is shown in Figure 2. When the studs 16are embedded in the wet concrete ~hey are only partially inserted.
This allows for the use of thin-metal studs 16 as there will ; then be a hollow beneath the stud 16 into which the nail or . - . , screw 22 can enter without going into the concrete. As well, insulation 24 could also be inserted between the studs 16 before the panelling 20 is attached to the wall.
If one wished to have insulation on the other side of the concrete as well, then insulation 26 could be laid between the studs 12 before the concrete is poured. Of course this insulation 26 would have to be o~ a type which is rather resistant to a changing of shape from the pressure of the poured concrete.
A stif insulation such as Styrofoam would be easy to lay in large cut-to-size sheets and would also hold its form under the weight of the wet concxete. The insulation ~4 about the other studs 16 would not have to meet this physical requirement ` as it is laid on top of the concrete and often af~cr it has dried. This is obviously not possible with the insulation 26. A
fibre glass insulation would therefore be a satisfactory type of insulation 24.
j 30 Another improvement which may be made to the wall * Trade Mark .
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1 would be the inclusion of a reinforcing mesh 28 of some kind to strengthen the concrete. One might also hammer nails 30 or ; other like protrusions into the faces of the studs directed into the concrete before pouring the concrete. This would result in a better attachment of the studs to the concrete.
Figures 1 and 3 show preferred smbodiments of the present invention where a horizontal stud 32 has been placed across the top of one side of the wall. This stud can be used to hold a ceiling 36 in place. ~s well, a horizontal stud 34 has been laid across the ~ase of the wall to prevent chipping of the concrete when raising the set concrete out of the form and onto its end. These horizontal studs 32, 34 would also help to keep the other studs 12 in place when the concrete is poured by nailing the vertical and horizontal studs together.
If one wished to make the walls substantially fire- ¦~
proof, then the studs could all be made of non-burningImaterial such as thin metal sheeting. It is this type of construction which is shown on the interior side of the walls in Figure 3.
In constructing a building it may be that the wall ~0 units are for some reason built not as long as the desired wall ,: . ~. ...
of the building. Two or more wall units would then have to be joined end to end. Instead of just standing them up side by side, it may be preferable to join adjacent wall units in some way.
Figure 4 shows a side bracket unit 38 suitable for this purpose.
These side brackets 38 are inserted into the mold before the concrete is poured. Any obstructing matter, such as ~ -putty or even a rag, may be inserted about the central portion of the side bracket 38 to prevent the concrete from completely covering it. When the concrete is poured, the bracket 38 should .. . .
30 be open in this central portion in the upper and side directions.
(Fig. 3) This results in a hole 40 being formed when the . ' .~
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1 obstructing matter is ramoved from the dried concrete. In the portion of the bracket exposed there is a notch 42 into which a nut and bolt 44 can be inserted. To assist in retaininy the bolt in the notch, the notch can be upwardly extending as shown in Figure 4. These side brackets 38 must naturally be all placed at fixed positions in order that side brackets on ad~acent walls meet when the walls are positioned side-by-side.
Reinforcing rods 46 may be welded to the side brackets 38 before they are embedded in the concrete to make them even more ~O strongly secured in the concrete 14~ The hole 40 may be filled in with putty or insulation after the nut and bolt have been inserted to produce a smooth surface.
As when two walls are attached to form a longer wall~
so when two walls are attached to form a corner a corner bracket 48 is preferred to hold the wall~ together. Figures 3 and 5 show a corner bracket 48 being used to hold together two wall seotions in a preferred embodiment.
Before the concrete is poured, or while the concrete is still wet, the corner brackets are placed in the ~orm. The ~ ~
2~ complete bracket 48 consists of two L-shaped units, side portion 60 ~ -' and end portion 62, although it may also have welded thereto reinforcing rods 50 to help secure the bracket in the concrete. ~ ;
The description of the use of corner brackets in this embodiment ` of the invention is aided by the designation of wall sections as being either side walls 52 or end walls 54. In any building there will be only one end wall 54 for Pach corner constructed.
There may be many more side walls 52 if the wall sections prove not to be long enough and two or more must be joined together to form a longer wall. End walls 54 are the walls which have an exposed edge 56 not adjacent the edge of the adjacent wall. The ;
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1 abutting edge 58 of this adjacent wall, the side wall 52, abutsinstead against the face of the end wall 54. An exposed edge 56 and abutting edge 58 are shown in Figure 3. If only one wall rl unit i5 needed to act as a complete wall, then one end o~ the wall unit will act as a side wall 52 and the other as an end wall 54. (Fig. 6) :
In building the side wall 52, the portion of the cor~er bracket inserted therein, side portion 60, is set with flat faces against the bottom and side of the form and extends a distance above the height of the poured concrete. In the building of the end wall 54, the portion of the corner bracket inserted therein, end portion 62, is laid a predetermined distance rom the end of the mold in a manner which exposes a ~ace of the L-shaped bracket in the concrete wall. The positioning o~ end portion 62 is such that this exposed face o~
the end portion 62 overlaps the extended portion of the side portion 60 in such a manner that a hole in each part of the over-lapping portions ovarlap to allow access to a hollow (not shown) ~` in the end wall S4 defined by a suf~iciently long threaded nut, or nuts, which bolt 64 can be inserted into. The hollow may be kept free of concrete simply by placing adhesive tape or other similar obstructing matter o~er the internally directed end of the nut. ~-All of the diagrams show views of preferred - ;~
embodiments of the present invention. The studs 12 in these preferred embodiments are laid first in the form and are `` eventually to be on the exterior face of the wall structure. The second plurality of studs 16 will be on the interior side. The ;
outside studs 12 are wood or any other appropriate material. To reduce fire hazard, the studs 16 on the inside should be non-~'.,' ' ' ~' , , .:
., ~, ~s~
1 flamable material such as thin-metal studs into which screws and nails can be inserted.
The inside studs 16 are located so that they will be as close to the inside corner of the building as possible (Figure 3) and then every fixed unit of distance, say 18 or 24 inches apart. This allows for the interior panelling 20 to be affixed to the wall as close into the corners as is ; possible. This is generally the most satisfactory way of attaching the panellingO This does however create a problem for inserting bolt 64 into the corner bracket. Therefore a hole 66 is drilled thxough the adjacent stud 16 in the side panel and the bolt is inserted with a thin wall socket wrench.
When the end walls 54 are being built, the preferred embodiment shown in Figures l and 5 include laying the vertical ~tuds 12 and the horizontal studs 32, 34 in ~he form before pouring ~he concrete~ The vertical studs 12 are spaced apart at some fixed distance, say every 18 or 24 inches, whatever is convenient starting from the edges of the form. These studs 12 -~
,, run f rom the top stud 32 to the bottom stud 34.
~ ~ The ~tud 32 extends somewhat above the height of the finished wall to act as a cover for a ceiling which would rest upon the upper surface of the walls 52, 54. This is shown in Figure l.
When constructing the wall units, a corner stud 68 is placed at one end o the mold adjacent the end stud 12 (Fig. 6) against what will be the exposed edge 56 o~ the end wall 54. In each case the corner stud 68 must be at the same end, either the right or left end of the wall. In this way there will be one corner stud 68 on each corner of the building.
30 ~ These corner studs 68 are only incorporated into those walls 9 _ ~
f~.
1 which will form a corner in the finished building. The corner stud 68 extends flush with the top of the horizontal stud 32, is as wide as the insulation 26 and concrete 14 combined, and is as thick as the insulation 26 on t?ne adjacent wall. Corner stud 68 may be attached to the concrete 14 in the same manner as studs 12.
In building these walls, it is preferable that the studs 12, 16 should not extend comple~ely through the concrete even if they could still be securely placed therein for if the 10 wall is to be ~ire-resistant, then the studs would likely be ~-metal. However, the use of metal studs which extend completely through the concrete wall would result in heat loss in cold weather because of the extremely superior thermal conductivity of metal as compared to concrete. The wall would also likely be weakened along such a stud as the concrete-concrete bonding is generally stronger than the concrete-stud bonding.
If the walls are to also contain windows and doors, then provision must be made for them at the beginning of the construction o~ the wall. The form should be shaped to have the appropriate spacings for the door and window holes. Reinforc-ing rods and windows and door frames should be laid in thc appropriate places be~ore the concrete is poured. ;
When the concxete is being poured, it can be shaped so that the concrete is thicker at what will be the top of the wall. It is preferred that the extended width of the ~`
concrete at this point be at least enough so that the studs 16 are flush with the concrete, they may even be embedded therein. -~
Fig. 3 shows this extended portion 70. This allows for greater ;; ;
. .
support of the ceiling 36 and also simplifies the fitting of 33 shoring by the contractor on the walls should he decide to .,~ ~, .
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1 have a poured conc.rete ceiling.
Although the disclosure of this invention has largely been given w.ith respect to preferred embodiments, this should not at all be construed in a limiting sense so as to detract ..
from the broad disclosure of the invention therein or as claimed in the appended claims. It is to be understood that the invention is not restricted to the preferred embodiments.
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'l Small irregular pieces capable of acting as studs can be used ~
, so long as the arrangement allows the panelling to be affixed ;
thereto when the wall is finished.
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Concrete 14 is then poured sver the studs 12 to a depth sufficient to completely cover them. It may be helpful to use some means to retain the studs in a prefixed position so that the concrete does not disturb them when it is being poured into the form. This could be accomplished by nailing the studs together if they are arrang~d in a horizontal and vertical arrangement as they are in the preferred embodiment.
Other methods could also be used to ke~p the studs positioned. . . .
Of course, if a random positioning of the studs 12 is acceptable, then there is no need to worry about this matter.
After the concrete has been poured, a ~econd plurality of studs 16 is arranged partially embedded in the wet concrete. As with the studs 12, the studs 16 are arranged in whatever malmer is preferred by the builder so that a finished ' panelling 20 may be attached thereby.
- By using this method, one is able to build a i concrete wall to which finished panelling may be directly attached without the need of using concrete nails and the like as,the panelling can be nailed, screwed, stapled or however ~
20 attached to the wall b~ attaching the panelling to the studs ' '' ' instead of to the concrete.
;, In choo~ing which type of studs to use in this con~
stxuction, one must consider ~everal factors. ~he portion of the '~ studs facing out from the concrete should be flat and coplanar to allow ~or an easy attachment of an exterior panelling thereto. ~ ~;
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:
; 30 .
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As well, the studs must be of a proper construction to allow screws, nails and the like to be easily insèrted therein. In embedding the studs 16 into the concrete, and when pouring the concrete over the studs 12, it must be remembered that the concrete cannot completely surround the stud as there must be at least the flat face of the stud exposed to allow the scraws or nails to be insexted therein.
There is no reason however why the studs may not protrude from ~he concrete. This is what is done in a preferred-j 10 embodiment such as is shown in Figure 2. When the studs 16are embedded in the wet concrete ~hey are only partially inserted.
This allows for the use of thin-metal studs 16 as there will ; then be a hollow beneath the stud 16 into which the nail or . - . , screw 22 can enter without going into the concrete. As well, insulation 24 could also be inserted between the studs 16 before the panelling 20 is attached to the wall.
If one wished to have insulation on the other side of the concrete as well, then insulation 26 could be laid between the studs 12 before the concrete is poured. Of course this insulation 26 would have to be o~ a type which is rather resistant to a changing of shape from the pressure of the poured concrete.
A stif insulation such as Styrofoam would be easy to lay in large cut-to-size sheets and would also hold its form under the weight of the wet concxete. The insulation ~4 about the other studs 16 would not have to meet this physical requirement ` as it is laid on top of the concrete and often af~cr it has dried. This is obviously not possible with the insulation 26. A
fibre glass insulation would therefore be a satisfactory type of insulation 24.
j 30 Another improvement which may be made to the wall * Trade Mark .
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. ~
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1 would be the inclusion of a reinforcing mesh 28 of some kind to strengthen the concrete. One might also hammer nails 30 or ; other like protrusions into the faces of the studs directed into the concrete before pouring the concrete. This would result in a better attachment of the studs to the concrete.
Figures 1 and 3 show preferred smbodiments of the present invention where a horizontal stud 32 has been placed across the top of one side of the wall. This stud can be used to hold a ceiling 36 in place. ~s well, a horizontal stud 34 has been laid across the ~ase of the wall to prevent chipping of the concrete when raising the set concrete out of the form and onto its end. These horizontal studs 32, 34 would also help to keep the other studs 12 in place when the concrete is poured by nailing the vertical and horizontal studs together.
If one wished to make the walls substantially fire- ¦~
proof, then the studs could all be made of non-burningImaterial such as thin metal sheeting. It is this type of construction which is shown on the interior side of the walls in Figure 3.
In constructing a building it may be that the wall ~0 units are for some reason built not as long as the desired wall ,: . ~. ...
of the building. Two or more wall units would then have to be joined end to end. Instead of just standing them up side by side, it may be preferable to join adjacent wall units in some way.
Figure 4 shows a side bracket unit 38 suitable for this purpose.
These side brackets 38 are inserted into the mold before the concrete is poured. Any obstructing matter, such as ~ -putty or even a rag, may be inserted about the central portion of the side bracket 38 to prevent the concrete from completely covering it. When the concrete is poured, the bracket 38 should .. . .
30 be open in this central portion in the upper and side directions.
(Fig. 3) This results in a hole 40 being formed when the . ' .~
.;-. ~ ~ . . . .
~05~
1 obstructing matter is ramoved from the dried concrete. In the portion of the bracket exposed there is a notch 42 into which a nut and bolt 44 can be inserted. To assist in retaininy the bolt in the notch, the notch can be upwardly extending as shown in Figure 4. These side brackets 38 must naturally be all placed at fixed positions in order that side brackets on ad~acent walls meet when the walls are positioned side-by-side.
Reinforcing rods 46 may be welded to the side brackets 38 before they are embedded in the concrete to make them even more ~O strongly secured in the concrete 14~ The hole 40 may be filled in with putty or insulation after the nut and bolt have been inserted to produce a smooth surface.
As when two walls are attached to form a longer wall~
so when two walls are attached to form a corner a corner bracket 48 is preferred to hold the wall~ together. Figures 3 and 5 show a corner bracket 48 being used to hold together two wall seotions in a preferred embodiment.
Before the concrete is poured, or while the concrete is still wet, the corner brackets are placed in the ~orm. The ~ ~
2~ complete bracket 48 consists of two L-shaped units, side portion 60 ~ -' and end portion 62, although it may also have welded thereto reinforcing rods 50 to help secure the bracket in the concrete. ~ ;
The description of the use of corner brackets in this embodiment ` of the invention is aided by the designation of wall sections as being either side walls 52 or end walls 54. In any building there will be only one end wall 54 for Pach corner constructed.
There may be many more side walls 52 if the wall sections prove not to be long enough and two or more must be joined together to form a longer wall. End walls 54 are the walls which have an exposed edge 56 not adjacent the edge of the adjacent wall. The ;
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o~
1 abutting edge 58 of this adjacent wall, the side wall 52, abutsinstead against the face of the end wall 54. An exposed edge 56 and abutting edge 58 are shown in Figure 3. If only one wall rl unit i5 needed to act as a complete wall, then one end o~ the wall unit will act as a side wall 52 and the other as an end wall 54. (Fig. 6) :
In building the side wall 52, the portion of the cor~er bracket inserted therein, side portion 60, is set with flat faces against the bottom and side of the form and extends a distance above the height of the poured concrete. In the building of the end wall 54, the portion of the corner bracket inserted therein, end portion 62, is laid a predetermined distance rom the end of the mold in a manner which exposes a ~ace of the L-shaped bracket in the concrete wall. The positioning o~ end portion 62 is such that this exposed face o~
the end portion 62 overlaps the extended portion of the side portion 60 in such a manner that a hole in each part of the over-lapping portions ovarlap to allow access to a hollow (not shown) ~` in the end wall S4 defined by a suf~iciently long threaded nut, or nuts, which bolt 64 can be inserted into. The hollow may be kept free of concrete simply by placing adhesive tape or other similar obstructing matter o~er the internally directed end of the nut. ~-All of the diagrams show views of preferred - ;~
embodiments of the present invention. The studs 12 in these preferred embodiments are laid first in the form and are `` eventually to be on the exterior face of the wall structure. The second plurality of studs 16 will be on the interior side. The ;
outside studs 12 are wood or any other appropriate material. To reduce fire hazard, the studs 16 on the inside should be non-~'.,' ' ' ~' , , .:
., ~, ~s~
1 flamable material such as thin-metal studs into which screws and nails can be inserted.
The inside studs 16 are located so that they will be as close to the inside corner of the building as possible (Figure 3) and then every fixed unit of distance, say 18 or 24 inches apart. This allows for the interior panelling 20 to be affixed to the wall as close into the corners as is ; possible. This is generally the most satisfactory way of attaching the panellingO This does however create a problem for inserting bolt 64 into the corner bracket. Therefore a hole 66 is drilled thxough the adjacent stud 16 in the side panel and the bolt is inserted with a thin wall socket wrench.
When the end walls 54 are being built, the preferred embodiment shown in Figures l and 5 include laying the vertical ~tuds 12 and the horizontal studs 32, 34 in ~he form before pouring ~he concrete~ The vertical studs 12 are spaced apart at some fixed distance, say every 18 or 24 inches, whatever is convenient starting from the edges of the form. These studs 12 -~
,, run f rom the top stud 32 to the bottom stud 34.
~ ~ The ~tud 32 extends somewhat above the height of the finished wall to act as a cover for a ceiling which would rest upon the upper surface of the walls 52, 54. This is shown in Figure l.
When constructing the wall units, a corner stud 68 is placed at one end o the mold adjacent the end stud 12 (Fig. 6) against what will be the exposed edge 56 o~ the end wall 54. In each case the corner stud 68 must be at the same end, either the right or left end of the wall. In this way there will be one corner stud 68 on each corner of the building.
30 ~ These corner studs 68 are only incorporated into those walls 9 _ ~
f~.
1 which will form a corner in the finished building. The corner stud 68 extends flush with the top of the horizontal stud 32, is as wide as the insulation 26 and concrete 14 combined, and is as thick as the insulation 26 on t?ne adjacent wall. Corner stud 68 may be attached to the concrete 14 in the same manner as studs 12.
In building these walls, it is preferable that the studs 12, 16 should not extend comple~ely through the concrete even if they could still be securely placed therein for if the 10 wall is to be ~ire-resistant, then the studs would likely be ~-metal. However, the use of metal studs which extend completely through the concrete wall would result in heat loss in cold weather because of the extremely superior thermal conductivity of metal as compared to concrete. The wall would also likely be weakened along such a stud as the concrete-concrete bonding is generally stronger than the concrete-stud bonding.
If the walls are to also contain windows and doors, then provision must be made for them at the beginning of the construction o~ the wall. The form should be shaped to have the appropriate spacings for the door and window holes. Reinforc-ing rods and windows and door frames should be laid in thc appropriate places be~ore the concrete is poured. ;
When the concxete is being poured, it can be shaped so that the concrete is thicker at what will be the top of the wall. It is preferred that the extended width of the ~`
concrete at this point be at least enough so that the studs 16 are flush with the concrete, they may even be embedded therein. -~
Fig. 3 shows this extended portion 70. This allows for greater ;; ;
. .
support of the ceiling 36 and also simplifies the fitting of 33 shoring by the contractor on the walls should he decide to .,~ ~, .
; ~ :
-. :
1()5;~
1 have a poured conc.rete ceiling.
Although the disclosure of this invention has largely been given w.ith respect to preferred embodiments, this should not at all be construed in a limiting sense so as to detract ..
from the broad disclosure of the invention therein or as claimed in the appended claims. It is to be understood that the invention is not restricted to the preferred embodiments.
. .
O
.
~':
~:' :
Claims (13)
1. A studded concrete wall comprising a panel of poured concrete in which are embedded on a first face a plurality of first studs and on a second face a plurality of second studs, wherein the first studs are long thin-metal sheets folded along their lengths at two places so as to form a top and two sides of a substantially rectangular unit in cross-section, the two sides only partially embedded in the concrete with the top extended out from the first face, and wherein the second studs are wood lengths with protrusions extending from a face thereof, the wood lengths oriented so that the protrusions are embedded in the panel, most of the wood length being not embedded in the panel except for the face with the protrusions extending thereinto.
2. A wall as claimed in claim 1 wherein rigid insulation is located between and around the studs on each face of the panel.
3. A wall as claimed in claim 2 wherein the panel has two end surfaces and there is embedded in at least one end surface a side wall connecting means comprising a length of metal with its ends folded backwards from a centre portion which is coplanar with the end surface, the folded ends of the metal length being embedded in the panel, the concrete panel extending inwardly about the centre portion to fully expose it, the centre portion having a slot therein to receive a bolt sideways.
4. A wall as claimed in claim 3 wherein a first wall has an end surface which will abut the first face of a second wall, there being embedded on the second face of the first wall
4. A wall as claimed in claim 3 wherein a first wall has an end surface which will abut the first face of a second wall, there being embedded on the second face of the first wall
Claim 4 continued:
an L -shaped metal length which has one portion coplanar with the second face of the first wall and another portion coplanar with the end surface and extending therebeyond, the second wall having embedded therein an L -shaped metal length having one portion embedded in the second wall and another portion coplanar to the first face of the second wall, the two L-shaped lengths located so as to overlap and holes in each along the part of the overlap adapted to receive a bolt which will screw into a nut partially embedded at the bottom of a cavity behind the overlap portion in the second wall.
5. A process for constructing an insulated studded concrete wall comprising:
(a) horizontally locating a form having a floor completely bordered by upright perimeter members, (b) positioning a plurality of wood studs on the floor in a predetermined position, the lengths having protrusions extending upwards therefrom, (c) placing a first layer of rigid insulation around and between the wood studs, the insulation being of such a thickness so that when the concrete is poured thereover only a small portion of the wood stud is embedded in the concrete, (d) pouring concrete into the form to completely cover the wood studs, protrusions and insulation, (e) partially embedding a plurality of metal studs into the still-wet concrete, the studs being long, thin-metal sheets folded along their lengths at two places to form a top and two sides of a substantially rectangular unit in cross-section, wherein only a part
an L -shaped metal length which has one portion coplanar with the second face of the first wall and another portion coplanar with the end surface and extending therebeyond, the second wall having embedded therein an L -shaped metal length having one portion embedded in the second wall and another portion coplanar to the first face of the second wall, the two L-shaped lengths located so as to overlap and holes in each along the part of the overlap adapted to receive a bolt which will screw into a nut partially embedded at the bottom of a cavity behind the overlap portion in the second wall.
5. A process for constructing an insulated studded concrete wall comprising:
(a) horizontally locating a form having a floor completely bordered by upright perimeter members, (b) positioning a plurality of wood studs on the floor in a predetermined position, the lengths having protrusions extending upwards therefrom, (c) placing a first layer of rigid insulation around and between the wood studs, the insulation being of such a thickness so that when the concrete is poured thereover only a small portion of the wood stud is embedded in the concrete, (d) pouring concrete into the form to completely cover the wood studs, protrusions and insulation, (e) partially embedding a plurality of metal studs into the still-wet concrete, the studs being long, thin-metal sheets folded along their lengths at two places to form a top and two sides of a substantially rectangular unit in cross-section, wherein only a part
Claim 5 continued:
of each of the stud sides are embedded in the concrete, the top sitting predetermined distance above the surface of the concrete, (f) allowing the concrete to set, and (g) removing the wall from the form.
of each of the stud sides are embedded in the concrete, the top sitting predetermined distance above the surface of the concrete, (f) allowing the concrete to set, and (g) removing the wall from the form.
6. A method as claimed in claim 5 wherein a second layer of insulation is inserted between the second plurality of studs.
7. A method as claimed in claim 5 including the additional step of positioning a reinforcing mesh over the first plurality of studs and insulation, before the concrete is poured, such that the mesh will lie substantially in the centre of the concrete.
8. A method as claimed in claim 7 further comprising the step of fixing the first plurality of studs before pouring the concrete so as to prevent their movement when the concrete is poured thereover.
9. A method as claimed in claim 8 wherein the insulation and first plurality of studs completely cover the floor of the form.
10. A method as claimed in claim 9 further comprising the steps of inserting side brackets at predetermined positions along the sides of the form before the concrete is poured into the form, the side brackets having a removable obstructing matter inserted about a central portion of the brackets to prevent concrete when later poured from entering therein, and removing the obstructing matter after the concrete has set.
11. A method as claimed in claim 10 further comprising the steps of inserting corner brackets at predetermined positions along the sides of the form before the concrete sets, and inserting receiving means into the still-wet concrete, whereby an attachment means may be inserted through the corner bracket and into the receiving means.
12. A method as claimed in claim 11 wherein the receiving and attachment means are nuts and bolts.
13. A method as claimed in claim 12 wherein the form has door and window openings therein and further comprising the steps of laying door and window frames about the door and window openings before the concrete is poured.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA276,018A CA1052121A (en) | 1977-04-07 | 1977-04-07 | Insulated studded concrete wall |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA276,018A CA1052121A (en) | 1977-04-07 | 1977-04-07 | Insulated studded concrete wall |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1052121A true CA1052121A (en) | 1979-04-10 |
Family
ID=4108374
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA276,018A Expired CA1052121A (en) | 1977-04-07 | 1977-04-07 | Insulated studded concrete wall |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1052121A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0392610A2 (en) * | 1989-04-10 | 1990-10-17 | Bruce Harrington | Wall units for constructing buildings |
| CN107366449A (en) * | 2017-06-29 | 2017-11-21 | 温州海跃食品有限公司 | The adjustable freezer of heat insulation effect |
-
1977
- 1977-04-07 CA CA276,018A patent/CA1052121A/en not_active Expired
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0392610A2 (en) * | 1989-04-10 | 1990-10-17 | Bruce Harrington | Wall units for constructing buildings |
| EP0392610A3 (en) * | 1989-04-10 | 1991-09-04 | Bruce Harrington | Wall units for constructing buildings |
| CN107366449A (en) * | 2017-06-29 | 2017-11-21 | 温州海跃食品有限公司 | The adjustable freezer of heat insulation effect |
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