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Publication numberUS3747287 A
Publication typeGrant
Publication dateJul 24, 1973
Filing dateMay 4, 1971
Priority dateMay 4, 1971
Publication numberUS 3747287 A, US 3747287A, US-A-3747287, US3747287 A, US3747287A
InventorsFinger E
Original AssigneeFinger E
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Modular building construction
US 3747287 A
Abstract
A modular building construction and method having relatively thin, reinforced concrete wall and roof panels with means exposed at spaced intervals at the edges of the wall and roof panels for joining together adjacent wall and roof panels as by welding or the like at said spaced means, with adjacent wall panels and adjacent roof panels disposed at an angle relative to one another to impart structural rigidity and strength to the building structure while enabling the use of said relatively thin wall and roof panels and eliminating the necessity for separate frame or support means.
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Description  (OCR text may contain errors)

United States Patent Finger MODULAR BUILDING CONSTRUCTION Ernest G. Finger, 1203 Vesper Dr., Fort Myers, Fla. 33901 221 Filed: May4, 1911 211 App]. No; 140,131

[76] inventor:

[52] US. Cl. 52/18, 52/293, 52/583, 52/601 [51] Int. Cl. E04b 7/12, E04c 2/50 [58] Field of Search 52/18, 90, 91, 601, 52/600, 583, 587, 730

[ 56] r References Cited UNITED STATES PATENTS 1,998,448 4/1935 Crowe 52/583 2,126,301 8/1938 Wo1cott..... 52/600 X 2,497,887 2/1950 Hilpert 52/601 X 2,592,634 4/1952 Wilson 52/601 X 2,635,450 4/1953 Orzel 52/587 [111 3,747,287 [451 July 24, 1973 2,706,538 4/1955 Schumann 52/73 3,494,092 2/1970 .lohnson.... 521583 3,555,763 1/1971 Bloxom 52/745 Primary Examiner-John E. Murtagh Attorney-Shoemaker & Mattare [57] ABSTRACT A modular building construction and method having relatively thin, reinforced concrete wail and roof panels with means exposed at spaced intervals at the edges of the wall and roof panels for joining together adjacent wall and roof panels as by welding or the like at said spaced means, with adjacent wall panels and adjacent roof panels disposed at an angle relative to one another to impart structural rigidity and strength to the building structure while enabling the use of said relatively thin wall and roof panels and eliminating the necessity for separate frame or support means.

27 Claims, 26 Drawing Figures PAIENIEUMZMWB SHEET 1 BF 5 30 INVENTOR ERNEST cs. FINGER FIG. 6

ATTORNEYS PAIENTEU Jul sum 2 OF 5 NTOR ERNEST G. FINGER ATTORNEYS PAIENTED 24'975 3.747. 287

sum 3 or 5 9v VII/149iy I I INVENTOR ERNEST G. FINGER ATTORNEYS PAIENIED JUL 2 4 ms SHEEI U [1F 5 F/G.ZO.

INVEIFTER ERNEST G. FINGER ATTORNEYS minimum 3.747.287

SHEEF 5 0F 5 FIG. 22.

INVENTOR ERNEST G. FlNGER ATTORNEYS 1 MODULAR BUILDING CONSTRUCTION BACKGROUND OF THE INVENTION to one another in a zig-zag arrangement. The wall penels are also welded or otherwise suitably connected along their bottom edges to a suitable foundation means.

Each panel includes reinforcing means adjacent both the front and back surfaces thereof for imparting'a high tensile strength to the panels, and. the joining together of adjacent panels is accomplished by means of a plurality of spaced apart reinforcing means embedded in the concrete of the panel and exposed at the edges of the panel for welding to a similarly exposed reinforcing means in an adjacent panel.

The roof panels are rectangular in shape and are constructed similarly to, the wall panels in that reinforcing means is embedded therein adjacent the top and bottom surfaces thereof with reinforcing means embedded in the concrete of the roof panels and exposed at the. edges of the roof panels at spaced intervals therealong for welding plate means to the roof panels forjoining a roof panel to an adjacent roof panel by welding the plate means on one roof panel to the plate means on an adjacent roof panel. Complementary means are provided at particularlocations on the roof panels and wall panels for joining the roof panels to the wall panels, and

in the completed building structure, adjacent roof panels as well as adjacent wall panels are disposed at an angle relative. to one another in a zig-zag arrangement to impart structural rigidity to the building. Suitable sealing means is provided at the joints between adjacent wall panels and between adjacent roof panels for making the building weather tight.

The reinforcing means adjacent the surfaces of the wall panels and roof panels and the angular disposition of adjacent wall panels relative to one another and of adjacent roof panels relative to one another enables the use of a relatively thin material and yet the building is strong and able to resist large static and dynamic loads. Moreover, the modular building is exceptionally simple to assemble and eliminates the need for skilledlabor in the construction thereof. The building is accordingly economical in. comparison with conventional building constructions. The use of reinforced concrete makes the. building corrosion resistant and requires substantially noupkeep. if a wall panel or root panel is dam-- aged or broken, it can be easily repaired or replaced and the damage will not spread to adjacent panels nor will the damage to an individual panel spread within that panel beyond the localized area of damage. The wall panels and rood panels can be easily cast at the site of the building and allowed town and then positioned to construct the building. This eliminates the possibility of damage to the panels which might occur during shipment or the like if the panels are cast at a plant and then shipped to the building location.

Due to the unique construction of the building, with the angular relationship of adjacent'roof panels and of adjacent wall panels, the opposite. end walls are the major load carrying walls and one or even both of the side walls of the building can bev eliminated, if desired. Further, up to 60 percent of the material in the roof panels can be omitted for provision of skylights or the like without rendering the roof panels structurally unsound.

By means of the present invention, a building can be constructed in as little as. three weeks, including the time requiredv for casting and curing of the wall and roof panels, and the building will give exceptional service in even the most corrosive environments such as, for example, adjacent bodies of salt water or the like wherein the building might be used for boat storage or the like.

All welds and connections are made on the inside surface of the building, thus resulting in a clean external surface and a pleasing appearance of the building. Electrical wiring, plumbing and the like are also disposed on the inside surfaces of the building. Accordingly, all welded connections, wiring, plumbing and the like may be easily covered with insulation or panelling or the like in the completed building, thus completely hiding such elements from view. Further, the outside surfaces of the building may be given various. textures or designs by casting stones or the like into the con. crete on the outside surfaces of the panels when casting the panels and the completed building may be painted, if desired, to give it a desired color.

In assembling the building, the foundation is first poured and then allowed to cure. A form or forms may then be constructed on the foundation from 2 X 4 s, for example, and the wall and roof panels cast in the forms on the foundation.

A plurality of panels can be cast in stacked relationship one upon the other with means inserted between adjacent panels to facilitate separation thereof once the panels are cured. When the panels are cured, they are removed one at a time from the stack and assembled in position on the foundation. The foundation includes a notch or shoulder means about the periphery thereof which automatically positions and aligns the wall panels when they are placed therein. The panels are first assembled in their respective positions and fastened therein by means of suitable temporary fasteners such as bolts or the like. When the panels have been properly aligned and positioned, they are permanently welded together and the bolt means or other fastening means removed. Suitable caulking or sealing means is then placed between adjacent panels, and flashing or grout means are put on the roof to effect a weather tight structure.

osiacrs or THE lNVENTlON and yet in which relatively thin and inexpensive material is used.

A further object of this invention is to provide a modular building which is simple to assemble and which may be constructed with the use of unskilled labor.

An even further object of this invention is to provide a modular building comprising a plurality of panels of reinforced concrete which can be cast at the location of the building.

A still further object of this invention is to provide a modular building made of reinforced concrete or the like which is corrosion resistant and which requires substantially no upkeep.

Yet another object of this invention is to provide a modular building construction in which if a portion thereof is damaged or broken, the building can be easily repaired or the damaged part repalced.

A still further object of this invention is to provide a method of assembling a modular building by welding adjacent panels of reinforced concrete together at spaced intervals along adjacent edges thereof.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view in elevation of a building in accordance with the present invention.

FIG. 2 is an end view of the building shown in FIG. 1. FIG. 3 is a plan view of the building shown in FIG. 1 with a portion thereof broken away to show details of construction thereof.

FIG. 4 is a plan view of a typical wall panel used in constructing the building of FIG. 1 with a portion thereof broken away to show the internal construction thereof. An end wall panel is shown in full lines and the relative size and shape of a sidewall is indicated in phantom line.

FIG. 5 is a sectional view of the wall panel shown in FIG. 4 and is taken along the line 5-5 in FIG. 4.

FIG. 6 is a top perspective view of the stirrup or reinforcing bar used about the periphery of the roof panel in the building of FIG. 1.

FIG. 7 is a top perspective view of the stirrup or rein forcing bar used in the wall panel of FIG. 4.

FIG. 8 is a top perspective view of a welding bar or plate which is embedded in the foundation and to which the lower edge of the wall panels are fastened.

FIG. 9 is a plan view, partly broken away, of a typical roof panel.

FIG. 10 is a view in section of the roof panel of FIG. 9 and is taken along the line 10-10.

FIG. 11 is a view in section of the roof panel of FIG. 9 and is taken along the line 11-11.

FIG. 12 is an end view in section taken along the line 12-12 in FIG. 1.

FIG. 12A is a view in section of a modified structure of that shown in FIG. 12 and is taken at the vertical connection between panels joining adjacent edges of roof panels.

FIG. 13 is an enlarged sectional view of the manner of connecting adjacent roof panels at the peak thereof and is taken along line 13-13 in FIG. 1.

FIG. 14 is an enlarged sectional view of the valley portion of the roof of the building and shows the manner of joining adjacent roof panels at the valley thereof and is taken along line 14-14 in FIG. 3.

FIG. 15 is an enlarged sectional view of a portion of the structure shown in FIG. 3 and is taken along line 15-15 and shows the manner in which the side wall panels are joined to the overhanging roof portion.

FIG. 16 is a sectional view of the structure shown in FIG. 15 and is taken along the line 16-16 in FIG. 15.

FIG. 17 is a sectional view of a portion of the wall of the building showing the manner in which adjacent wall panels are joined together and is taken along line 17-17 in FIG. 2.

FIG. 18 is an enlarged sectional view of a portion of a wall panel and the foundation showing the manner in which the wall panels are connected to the foundation and is taken along line 18-18 in FIG. 17.

FIG. 19 is a view in elevation looking from inside the building toward the joint between the wall panels in FIG. 17.

FIG. 20 is a view in section of the structure shown in FIG. 19 and is taken along line 20-20.

FIG. 21 is a view in section of the joint between the side wall panels and the roof and is taken along line 21-21 in FIG. 3.

FIG. 22 is a view in section of the joint of FIG. 21 and is taken along the line 22-22.

FIG. 23 is a view in section of the connection between the wall panels and the roof at the corner of the building and is taken along line 23-23 in FIG. 3.

FIG. 24 is a view in section of the joint shown in FIG. 23 and is taken along line 24-24.

FIG. 25 is a perspective view of a completed building constructed in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings, wherein like reference numerals refer to like parts throughout the several views, a building in accordance with the present invention is indicated generally at 1 in FIGS. 1, 2, 3 and 25 and comprises end walls 2 and 3, opposite side walls 4 and 5, a roof 6 and a foundation 7.

Referring now particularly to FIGS. 3, 12, 18, and 25, the construction of the foundation 7 is seen. The construction of the foundation is generally conventional in that it comprises a bed of stone 8 or the like placed in a recess 9 formed in the surface of the ground G to a desired depth. A suitable vapor bearer means 10 such as a fluid impervious plastic sheet or the like is placed over the stone bed 8 and suitable reinforcing such as wire mesh or reinforcing bars 11 or a combination thereof is then placed over the vapor bearer 10 and concrete is poured thereover to form a monolithic slab 12 preferably having a thickness of approximately 4 inches.

A plurality of weld bars or plates 13 are cast in the slab 12 with one end thereof projecting downwardly in an angle into the slab and the other end 14 extending vertically upwardly beyond the upper surface of the slab 12 to define a means for attaching the side walls thereto. The weld bars or plates are preferably spaced apart approximately 5 feet about the periphery of the foundation in one example.

As best seen in FIGS. 12 and 18, a peripheral portion of the foundation includes a first, inclined part 15 and a peripheral, thickened portion 16 having a thickness approximately equal to the combined thickness of the stone bed 8 and slab 12. Suitable reinforcing means such as bars 17 or the like are embedded in the thickened portion 16. The upper marginal edge of the thickened portion 16 includes a relatively short, sloping surface 18, at the upper edge of which is formed a shoulder or recess 19 for receiving the lower ends of the wall panels.

The end walls 2 and 3 comprise a plurality of substantially identically constructed panels 20 joined together in edge-to-edge abutting relationship with adjacent panels disposed at an angle relative to one another in a zig-zag pattern. The side walls 4 and 5 are similarly comprised of a plurality of identically constructed panels 21 joined together in edge-to-edge relationship with adjacent panels disposed at an angle relative to one another in a zig-zag pattern.

As can be seen in FIGS. 1 and 2, the end wall panels 20 are longer than the side wall panels 21 and have more steeply inclined upper ends. 7

The construction of a wall panel 20 is shown in FIGS. 4 and 5 and since each of the wall panels is substantially identically constructed, only one panel will be described in detail, description of that panel sufficing for all of the panels. Each panel 20 is trapezodial in shape and has a pair of parallel, vertically extending elongate edges 22 and 23, with the edge 22 being longer than the edge 23, a bottom edge 24, and inclined top edge 25. Each panel 20 has an inside surface 26 and an outside surface 27 and the elongate side edges 22 and 23 are inclined in the same direction so that when adjacent panels 20 are placed in position in angular relationship relative to one another, the edges 22 and 23 of adjacent panels will be in abutting relationship.

Each panel is comprised of reinforced concrete and has a pair of spaced apart wire mesh reinforcing means 28 and 29 therein adjacent the inner and outer surfaces thereof, respectively A reinforcing perimeter bar or rod 30 is cast in the panel about the periphery thereof and is disposed approximately mid-way between the inner and outer surfaces of the panel. A plurality of spaced apart reinforcing stirrups or bars 31 are also cast into each panel along the edges thereof and each reinforcing stirrup 31 is bent generally in the shape of a U with and end portion 32 thereof bent or deflected upwardly from the plane of the U and extending outwardly beyond the concrete at the juncture of the inner surface 26 with the edges 22 and 23. The stirrups 31 are welded to the perimeter rod 30 and together with the perimeter bar or rod 30 and the wire mesh 28 and 29 serve to reinforce and substantially increase the tensile or beam strength of the panel. Angle members 33 and 34 are cast with the panel at the upper corners thereof and are suitably secured to the panel by means of a pair of generally U-shaped stirrup members 35 and 36 welded at one end to the back surfaces of the angle members and embedded at their other ends in the concrete panel.

Ths side wall panels 21 are constructed substantially identically to the end wall panels 20 except that the uper sloping edge is inclined less steeply than the edge 25 of the end wall panels as indicated in phantom line at 25' in FIG. 4 and this edge is also inclinedrelative to the plane of the panel as seen in FIG. 15, and the side wall panels 21 will accordingly not be described in further detail.

A typical end wall panel 20 constructed in accordance with the above is approximately 17 feet long at edge 22 and 13 feet long at edge 23. The panel is approximately 5 feet wide and 1% inches thick with a one-quarter inch cover of concrete over each of the wire mesh reinforcing means 28 and 29. The mesh reinforcing means typically comprises 2 inches X 2 inches number 12/12 mesh and the reinforcing perimeter bar 30 and reinforcing stirrups 31 are made of number 3 reinforcing bar which has a diameter of approximately three-eighths of an inch. The panels could have any other size as desired and the thickness and other dimensions changed accordingly.

Referring now to FIGS. 9, 10 and 11, details of construction of a typical roof panel 37 are seen, and since each of the roof panels is identically constructed, only one roof panel will be described in detail, description of that panel sufficing for all. Each panel is generally rectangular in shape and has an upper surface 38 and a lower surface 39. Each panel includes opposite, parallel end edges 40 and 41 and opposite, parallel elongate side edges 42 and 43. A pair of spaced apart wire mesh reinforcing means 44 and 45 are cast into the concrete adjacent the upper and lower surfaces thereof, respectively. A plurality of generally U- shaped, spaced apart reinforcing stirrups 46 are cast into the concrete along the opposite longitudinal edges .42 and 43 of the panel with the bight portions or ends 37 thereof extending to and exposed at the longitudinal edges 42 and 43 of the panel. A pair of generally U- shaped reinforcing bars 48 and 49 are also cast into the panel at the opposite ends 40 and 41 thereof with the legs 50 and 51 thereof welded to the end stirrups 46 along the edges 42 and 43. A pair of longitudinally extending edge plates 52 and 53 are on opposite edges 42 and 43 of the panel and are welded to the exposed ends of the stirrups 46 along the opposite edges thereof.

In addition to the panels 37, the roof includes a pair of upturned, relatively narrow edge panels 54 and 55 extending along opposite edges of the roof. These panels are constructed substantially the same as the panels 37 except that they are only about one-third as wide as the panels 37 and they do not have an edge plate 52 along the outer or upper edge thereof. Each panel 54 and 55 also includes a pair of spaced apart wire mesh reinforcing means 56 and 57 adjacent the upper and lower surfaces 58 and 59 thereof, respectively, and a plurality of transversely extending reinforcing bars 60 are cast into the panels 54 and 55 at spaced intervals along the length thereof. The reinforcing bars 60 include a portion 61 in approximately the middle thereof bent toward the bottom edge surface of the panel, and a generally rectangular plate 62 is welded to the portion 61 of the reinforcing bars 60. The plate 62 and reinforcing bars 60 are cast into the concrete with the outer surface of the plate 62 flush with the surface 59 of the panel. The spacing of the reinforcing bars 60 and plates 62 is determined by the spacing of the joints between adjacent side wall panels 21 with a plate 62 positioned in the roof panels 54 and 55 at each point where the longest edges 22 of a pair of side wall panels 21 meet.

In constructing a modular building in accordance with the present invention, the foundation is first constructed using suitable form means to provide the irregular shape as seen best in FIGS. 3 and 25 and to provide the sloping surface 18 and shoulder 19 about the periphery thereof. The weld plates or anchor bars 13 are cast with the foundation with the portion 14 thereof extending upwardly above the surface of the peripheral portion 16 of the foundation and exposed at the shoulder 19. The upwardly extending portion 14 of the plate 13 may extend a substantial distance above portion 12 and be provided with opening means therethrough for receiving a bolt or the like.

After the foundation has cured, suitable form or framing means made, for example, from 2 X 4'5 or the like cut at an angle along one side thereof, are positioned on the foundation and a roof panel and a wall panel cast in a respective form means, with the angle provided by the 2 X 4s or the like forming the angled edges 22 and 23 on the wall panels and the angled edges 42 and 43 on the roof panels. A suitable means is placed over each panel after it is cast and a further panel is then cast on top of the previous panel, with the means disposed therebetween aiding in separating the panels when they are cured. When the desired number of panels have been cast and allowed to cure, suitable lifting means (not shown) is connected to one end of a panel and a crane or the like is used to lift the panel from the stack of cured panels. The panel is then positioned in place on the foundation with the sloping surface 18 and shoulder 19 serving to align the panel in its proper place. Temporary fastening means, such as bolt means or the like, are used to temporarily secure the panel in position. Each of the remaining panels are then lifted into their respective positions and temporarily secured therein and the roof panels are positioned on the top edges of the wall panels and temporarily secured thereon. Once the panels have all been properly aligned and placed in their respective proper positions, they are permanently fastened together by welding as seen in FIGS. 12-24.

The exposed portions 32 of stirrups 31 at the bottom edges of the wall panels 20 and 21 are welded to the vertically extending portions 14 of bars 13 and adjacent, aligned portions 32 of the stirrups 31 along the vertically extending side edges 22 and 23 of wall panels 20 and 21 are welded together.

'The adjacent side edges of the roof panels 37 are welded together by making approximately 2 inch long weld beads spaced about 12 inches apart along the length of the roof panels between a pair of adjacent, abutting plates 52 at the peaks of the roof and between plates 53 at the valleys of the roof.

The roof panels are welded to the wall panels 20 at the ends of the building by making approximatelyl inch long weld beads between the bottom edges of angle members 33 at the peaks of the roof. A 1 inch long weld bead is also made between adjacent abutting edges of angle members 33 at the upper end of edges 22 of end wall panels 20.

At the valleys of the roof, a 1 inch long weld bead is made between the bottom edges of adjacent abutting side plates 53 on the roof panels and the upper edges of angle members 34 at the upper ends of side edges 23 of panels 20. A 1 inch long weld bead is also made between adjacent abutting edges of the angle members 34 between adjacent wall panels 20.

At the corners of the building, angle member 34' on a side wall panel 21 is welded to an adjacent abutting angle member 34 on the adjacent abutting end wall panel 20 by means of a 1 inch long weld bead therebetween. The angle members 34 and 34' are also welded to the bottom edges of plate 53 on side edge roof panels 54 and 55 and plate 53 on roof panel 37.

The side wall panels 21 are welded to the side edge roof panels 54 and 55 by welding angle members 33' on the side wall panels 21 at the upper end of edge 22 thereof to the bottom surface of plate 62 in the side edge roof panels 54 and 55. The angle members 33 at adjacent abutting edges of adjacent side wall panels 21 are also welded together. These welds comprise 1 inch long weld beads W as previously described.

All welds are made on the inside surface of the building, thus leaving a clean exterior surface, and when all welds have been completed, the temporary fastening means is removed and a suitable caulking material 63 such as, for example, plastic rope caulking is packed into the joints between adjacent panels. A suitable grouting material 64 is then placed in the valleys of the roof, the grouting material varying in thickness from approximately one-half inch at one end of the building to 3 inches at the other end of the building, thus providing a 2% inch slope for drainage of water or the like from the roof of the building. Suitable flashing material 65 such as copper flashing or the like, or asphalt or other suitable material is placed at the peaks of the roof for effecting a weather seal thereat.

Suitable door means such as an overhead door 66 or the like as seen in FIG. 1 may be provided at desired locations in the building. Also, suitable windows or other openings, not shown, may be provided in the building, or one or both of the side walls 4 and 5 may be omitted if desired, the end walls 2 and 3 being the major load bearing walls of the building structure. Up to percent of the roof may be used for skylights or other openings or the like as desired without having any deleterious effect on the structural soundness of the roof.

In the event one or the other of the side walls 4 and 5 is omitted, the side edge roof panels 54 and 55 must be provided in order to prevent excessive deflection of the roof panel 37 at the edge of the building since these side edge roof panels 54 and 55 offset the tendency of the roof panels 37 at the edge of the building to bend or deflect.

When the building is completed, it may be painted or the like on the outside thereof, if desired, to give it a desirable color. The weld connections and electrical wiring and plumbing and the like on the interior of the building may be covered with insulation or other materials used in finishing the interior of the building such as panelling or the like. Firring strips may be attached directly to the interior surface of the building for attachment of panelling or the like.

The exterior surface and the interior surface, if desired, may be given a suitable finish in stone or the like simply by placing a layer of stone or other desirable material upon the surface on which the individual panels of the wall are cast; and when the panels are cast over the stone or other material, the stone or other material will be embedded in the panels to give a desired pleasing effect to the building.

The building could obviously be given other dimensions and shapes, as desired, or as required for a particular installation. For example, the side walls 4 and 5 could be made straight without the zig-zag pattern or arrangement of panels, as desired, or the side walls could be omitted.

A building constructed in accordance with this invention and having a length of approximately 50 feet, a width of approximately 21% feet and a side wall height of approximately l2 feet was tested for static and dynamic loading and was found to undergo very slight deflection under both types of load. For example, a wind load test was carried out by applying a load gradually over a 5 minute period and then reading the deflection of the building. A load equivalent to a 200 miles per hour wind was applied to the building by means of a test apparatus comprising a frame means positioned against one end of the building and pulled against the building by means of a cable or the like connected with a crane having gauge means thereon for measuring the amount of load applied to the building. The load was held for 2 hours and the deflection was recorded at 30 minute intervals. The load was released instantly and the deflection read and then the load was applied gradually over a 5 minute period and the deflection was again read. This load was held for minutes and the deflection was read, after which the load was released and the deflection again read. The maximum deflection encountered with the building was one-quarter inch.

An alternate means of joining together adjacent roof panels is seen in FIG. 12A and comprises a plurality of generally U-shaped hook members 65, substantially the same as members 31, cast into the roof panels 37 along opposite edges thereof in spaced apart relationship, with the bight portions 66 thereof welded together. The plates 52 and 53 are omitted in this form of the invention.

As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the metes and bounds of the claims or that form their functional as well as conjointly cooperative equivalents, are therefore intended to be embraced by those claims.

I claim:

1. A modular building construction having a foundation, opposite side walls, opposite end walls, and a roof, said side walls and end walls each comprising a plurality of individual, elongate, flat, trapezoidal-shaped, reinforced concrete panels secured together in edge-toedge relationship and at an angle to one another in a zig-zag pattern, each panel having a long vertical side edge surface, a spaced, short vertical side edge surface, a bottom edge, an inclined top edge, and front and rear surfaces, the side edge surfaces being parallel to one another and inclined to the plane of the panel so that adjacent side edge surfaces of adjacent, secured together, angularly disposed panels are in flat abutting contact with one another, a plurality of spaced, metallic. reinforcing means embedded in each panel along the edges thereof and a portion of each reinforcing means exposed at the edges of the panels, the exposed portion of the reinforcing means in one panel edge aligned with the exposed portion of the reinforcing means in an adjacent panel edge and welded thereto to secure the panels together, the long side edge surfaces of. adjacent panels secured together and the short side edge surfaces of adjacent panels secured together so that the upper edges of the wall panels define a series of peaks and valleys, said roof comprising a plurality of substantially flat, rectangularly shaped, elongate reinforced concrete panels each having a width substantially equal to the length of said inclined top edge of an end wall panel and secured together in edge-to-edge relationship and to the top inclined edges of the wall panels in a zig-zag pattern in said peaks and valleys, thus resulting in a strong, substantially corrosion-free, self-supporting building structure.

ill)

2. A modular building structure as in claim 1, wherein said spaced reinforcing means along the edges of said panels are cast in said panels.

3. A modular building structure as in claim 1, wherein each of said panels has a plurality of separate, additional reinforcing means therein.

4. A modular building structure as in claim 3, wherein said separate reinforcing means comprises a pair of spaced apart wire mesh reinforcing means disposed closely adjacent the front and rear surfaces of said panels with a relatively thin cover of concrete thereover.

5. A modular building structure as in claim 4, wherein said cover of concrete over said wire mesh reinforcing means is approximately one-fourth inch.

6. A modular building structure as in claim 4, wherein the reinforcing means in said wall panels includes a reinforcing perimeter bar cast in the panel and extending about the periphery thereof spaced inwardly from the edges of the panel.

7. A modular building structure as in claim 6, wherein the spaced reinforcing means along adjacent edges of the wall panels for securing the panels together comprises a plurality of spaced apart, generally U-shaped reinforcing bars cast in the panels and extending at the bight portions thereof to the surface of the panel at the edge thereof.

8. A modular building structure as in claim 7, wherein said U-shaped reinforcing bars are welded to the perimeter bar.

9. A modular building structure as in claim 8, wherein a metallic angle member is cast on each wall panel at the opposite upper corners thereof.

10. A modular building structure as in claim 1, wherein said foundation includes shoulder means about the edge thereof, said wall panels being received at their lower ends on said shoulder means, said shoulder means serving to align said wall panels in the desired position with respect to said foundation.

11. A modular building structure as in claim 10, wherein a metallic angle member is cast on each wall panel at opposite upper corners thereof, and an elongate metallic plate is secured on each of said roof panels along opposite longitudinal edges thereof, said plates being commensurate in length with the panel,

' and said angle members on said wall panels being welded to said plates on the edges of said roof panels.

12. A modular building structure as in claim I, wherein spaced metallic means are cast in said roof panels at spaced intervals along opposite edges thereof with a portion of the metallic means exposed at the edges of the panels, the means in one panel disposed in alignment with the means in an adjacent panel and welded; thereto to secure the roof panels together in edge-to-edge relationship with adjacent panels dis-' posed at an angle relative to one another.

13. A modular building construction as in claim 1, wherein each of said roof panels has means along opposite longitudinal edges thereof for securing adjacent edges of adjacent roof panels together.

14. A modular building structure as in claim 13, wherein said means on said roof panels along opposite longitudinal edges thereof comprises an elongate plate on each edge, said plates being commensurate in length with said panel.

15. A modular building structure as in claim 14, wherein the plates on adjacent edges of adjacent panels are welded together to secure the adjacent panels together.

16. A modular building structure as in claim 15, wherein said plates are welded together at spaced intervals along the length thereof.

17. A modular building structure as in claim 14, wherein said roof panels include a pair of relatively narrow, upturned side edge roof panels along opposite sides of the building.

18. A modular building structure as in claim 17, wherein metallic means are cast into said foundation about the edge thereof with at least a portion of said means exposed above said foundation, said means being in alignment with adjacent U-shaped reinforcing bars in the bottom edge of said wall panels, said reinforcing bars in said wall panels being welded to said means in said foundation.

19. A modular building structure as in claim 18, wherein a plurality of spaced apart U-shaped reinforcing bars are cast in each said roof panel along the opposite edges thereof with the bight portions of said U- shaped members welded to said plates on the opposite longitudinal edges of said roof panels for anchoring said plates-to said roof panels.

20. A modular building structure as in claim 19, wherein rectangular plate means are cast into said side edge roof panels at spaced intervals along the bottom surface thereof, said plate means being in alignment with the joints between adjacent side wall panels.

21. A modular building structure as in claim 20, wherein the angle members at the opposite upper corners of said side wall panels are welded to the rectangular plate means on the undersurface of said side edge roof panels.

22. A modular building structure as in claim 21, wherein flashing means is on said roof at the peaks thereof to effect a weather tight seal.

23. A modular building structure as in claim 22, wherein grout means is on said roof at the valleys thereof for effecting a weather tight seal.

24. A modular building structure as in claim 23, wherein said grout means varies in thickness from one end of the building to the other end thereof to provide a slope for drainage of water or the like from the roof of said building.

25. A modular building construction having a foundation, side walls, end walls, and a roof, said side walls, end walls and roof each comprising a plurality of individual panels of reinforced concrete having front and rear surfaces and joined together along adjacent edges, with adjacent panels disposed at an angle to one another, a pair of spaced apart wire mesh reinforcing means disposed adjacent the front and rear surfaces of each panel, a reinforcing perimeter bar cast in each wall panel and extending about the periphery thereof spaced inwardly from the edges of the panel, and a plurality of spaced apart, generally U-shaped reinforcing bars cast in each of the panels and extending at the bight portions thereof to the surface of the panel at the edges thereof, the reinforcing bar in the edge of one panel aligned with the reinforcing bar in the edge of an adjacent panel and welded thereto to secure the panels together.

26. A modular building construction having a foundation, side walls, end walls, and a roof, said side walls, end walls and roof each comprising a plurality of individual panels of reinforced concrete having front and rear surfaces and joined together along adjacent edges, with adjacent panels disposed at an angle to one another, a pair of spaced apart wire mesh reinforcing means disposed adjacent the front and rear surfaces of each panel, an angle member cast on each wall panel at the opposite, upper corners thereof, an elongate metallic plate along opposite longitudinal edges of each roof panel and commensurate in length with said panel, a plurality of spaced apart U-shaped reinforcing bars cast in each roof panel along opposite longitudinal edges thereof, with the bight portions of said U-shaped reinforcing bars welded to said plates on opposite longitudinal edges of said roof panels for anchoring said plates to said roof panels, adjacent plates on adjacent edges of adjacent roof panels welded together to secure the roof panels together, said roof panels including a pair of relatively narrow, upturned side edge roof panels along opposite sides of the building, and metallic means cast into said foundation about the edge thereof with at least a portion of said means exposed above said foundation, said means in alignment with adjacent, U- shaped reinforcing means in the bottom edge of the wall panels and welded thereto to secure the wall panels to the foundation.

27. A modular building construction having a foundation, side walls, end walls, and a roof, said side walls and end walls each comprising a plurality of elongate reinforced concrete panels having opposite, spaced apart vertical side edges, a bottom edge, and an inclined top edge, the wall panels fixed together with the side edges of adjacent panels abutting and adjacent panels disposed in angular relationship to one another in a zig-zag pattern, the inclined top edges of adjacent panels being inclined in opposite directions, the roof comprising a plurality of elongate, reinforced concrete, rectangularly shaped panels each having a width substantially equal to the length of the inclined top edge of the end wall panels and fixed to the top edges of the side and end wall panels with adjacent roof panels oppositely inclined at an angle to one another in a zig-zag pattern to define a series of peaks and valleys, the inclined upper edges of the end wall panels conforming to the zig zag shape of the roof and engaged with the underside of respective, adjacent, oppositely inclined roof panels to define a strong, substantially corrosionfree building construction.

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Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US4320606 *Dec 6, 1979Mar 23, 1982Home Crafts CorporationReinforced concrete panels and building constructed therewith
US4388874 *Nov 26, 1980Jun 21, 1983Stone Frank KPrefabricated concrete vault
US6009677 *Jul 29, 1997Jan 4, 2000Strathclyde Technologies, Inc.Building panels for use in the construction of buildings
US6508043 *Feb 11, 2000Jan 21, 2003Art BondBuilding construction system and method
US6540445 *Mar 1, 2001Apr 1, 2003Eldon Boyd Evans, Jr.Made of very thin, steel reinforced concrete panels that are aligned side by side and fixed in a trench; fence will visibly deflect when design loading is applied but will resume its original configuration without incurring damage
US8225564Jan 23, 2004Jul 24, 2012Moprec S.A.Modular construction system
US8627620Jul 23, 2012Jan 14, 2014Moprec S.A.Modular construction system
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Classifications
U.S. Classification52/18, 52/293.1, 52/601
International ClassificationE04B1/04, E04C2/06, E04B7/20, E04B7/00, E04B1/02
Cooperative ClassificationE04C2/06, E04B7/20, E04B1/04
European ClassificationE04C2/06, E04B1/04, E04B7/20