The invention relates generally to modular building construction, and more particularly to modular wall panels used in the construction of foundation walls and upper floor exterior walls.
Building structures are often built upon perimeter wall foundations. Typical perimeter wall foundations have been formed from poured or modular concrete or built up by grouted blocks placed atop a concrete footing. The perimeter foundation walls, and any cross beams bridging across the walls, support the first floor and higher load bearing walls of the structure.
Structures such as manufactured and modular homes may be installed on interior piers as the primary foundation support rather than using the perimeter wall as the primary support. Even when using interior pier support, however, it often required by building code to provide some type of perimeter wall to reduce shear loads, seismic vibration effects and wind uplift, and to prevent flooding and pest invasion under the foundation. While a perimeter foundation in conjunction with these interior pier supports could be constructed as traditionally done with concrete or block before the building structure is lowered into position, the difficulties and expense of precise wall placement and leveling for this type of perimeter wall has led to the use of steel panels that can be hung from the perimeter floor boards of a manufactured or modular home, and then anchored at the bottom edge in a concrete-filled trench that serves as a footer for the foundation wall.
Panel assemblies for this type of steel panel perimeter foundation are known, such as the AnchorPanel® assemblies by Fast Track Foundation Systems. These are corrugated steel panels that can be cut to length and installed with lag screws hanging under the perimeter floor boards of a pier-supported structure. The corrugated shape provides stiffening against bending under vertical and side loads. The panels have the bottom 5 or 6 inches cut along the outfacing corrugation channel and bent inward at 90 degrees to form an anchorage flange that will be encapsulated in the concrete footer. While such steel panel foundations are easier to install than concrete or grouted block, the corrugated shape requires some external facing if it is to appear flat in areas exposed above ground or to be used to attach decorative surface finishing materials to make an attractive facade.
There is a need for more efficient and versatile wall panel assemblies for foundation walls, including panels with flat exterior wall surfaces, bottom anchorage for encapsulation in concrete slab floors, robust support for full foundation walls and cross wall beams, provisions for attached steel frame stairways, more variations of corners and curved panels, ease of thermal insulation, ease of drywall support, and reinforcing shear walls where much of the wall face is taken up by window and door cutouts.
Many of these objectives can be attained by using wall panel structures similar to those used in the construction of in-ground swimming pools, made from steel which can be galvanized or otherwise weather coated, with adaptations as necessary to serve as weight bearing foundation walls and shear walls for exposed foundations and upper floor exterior walls. The attainment of these and other objectives will become apparent in the description that follows.
According to one aspect of the invention, a perimeter foundation wall is constructed from modular wall panels with flat exterior wall surfaces. The panels are preferably made of steel. In one embodiment, the individual panels have a generally planar shape defining a wall face and a flange formed on each vertically extending side by bending the side edges of the panel at a right angle in the same direction. These side flanges have matching bolt holes to allow another panel to be joined to the panel on either side to form a section of vertical wall. The panels are also bent at the top and base into the same direction to the panel as the side flanges to form a top cap and base pan, as described more fully in the detailed description.
In an alternative embodiment, the individual panels have a generally planar shape defining a wall face, two vertical-side framing studs, a top cap and a bottom pan, that are all integrally constructed, preferably from a steel sheet. Each side framing stud of the panel extends at a right angle away from the wall face to a side depth distance to form a panel side wall. The side walls have matching bolt holes to allow similar panels to be joined to the panel on either side, as in the previous embodiment. Different from the previous embodiment, however, each side-framing stud then is bent and extends parallel to the wall face from the side depth distance toward the opposite side stud of the panel for a distance of about three quarter inch to two inches to form a surface for attaching a finishing strip. At the opposite end of the finishing strip surface the stud may be bent again to reflect back parallel to the panel side for a short distance toward the wall face.
In this embodiment, the top cap again extends at a right angle from the wall face in the same direction as the side panels, but may now extend to a distance from the wall face that is longer than the side depth by substantially the depth of the finishing strip. The top cap is then bent downward to form a top flange that will lie over the finishing strips. Similarly, the base pan extends at a right angle from the wall face in the same direction as the side panels to a distance from the wall face that is longer than the side depth distance by substantially the depth of the finishing strip, and then is bent upward to form a bottom flange to overlie the finishing strips
As small variations on the above embodiment, the top cap may only extend to the side depth before bending downward to form a flange over the side studs, so that the finishing strips provide a thermal barrier between the metal panel and any drywall or other wall covering. The bottom flange may also be longer than the top flange to provide a screed support for leveling a poured concrete floor pad.
The finishing strips are made from non-metallic material having good insulating properties to form a thermal barrier between the wall panel and any interior wall surface such as drywall or paneling. The strips also have sufficient strength to hold staples, screws, drywall nails or similar fasteners used to support interior wall surface materials or wall hangings on hangers passing through the drywall. While natural wood could be used, engineered wood or plastic composite provides sufficient strength and thermal barrier in narrow strips and are preferred for that reason. The finishing strips are attached to each side wall framing support and extend from the bottom pan to the top cap
In the first embodiment where the side walls are just flat side flanges extending from the wall face, the panel side walls may be reinforced as needed by vertical “C”-shaped support brackets bolted to one or both panel side walls along the seams where adjacent panels are bolted together. In the embodiment where the side walls are also integral framing supports with a finishing strip surface, no additional vertical support bracket is needed at the side wall seams. In both embodiments, the side walls and the vertical framing studs have aligned cutout chase-ways to accommodate the passage of electrical conduit and/or fluid piping along the wall.
The wall panels may also be reinforced by vertical reinforcement studs as interior framing studs spaced at regular intervals (e.g. at 16 inch centers on a 48 inch wide panel). The interior studs are generally “Z-shaped. In a preferred embodiment, the vertical reinforcement studs have a top and bottom plate for contact against the top cap and bottom pan of the panel and, similar to the side framing studs, extend parallel to the wall face for a distance of about three quarter inch to two inches to form a surface for attaching a finishing strip, and at the opposite end of the finishing strip surface reflect back a short distance toward the wall panel's face. In this embodiment a finishing strip is attached to each vertical framing stud and extends from the bottom pan to the top cap.
The top caps of the panels, supported by the framing studs, provide a base for a sill plate. The base pans of the panels provide an anchor that can be fastened to a concrete footer or be encapsulated in a concrete slab floor. The corners of the foundation wall may be formed by corner panels. The corner panels can form a right angle corner, or be curved corners of various radii. The right angle corners can be either inside corners (90 degree) or outside corners (270 degree). The corner panels have side walls that match with the flat wall panels, and bolt holes and conduit cutouts aligned with those in the wall panels. The corner pieces also have a top cap and base pan like the wall panels, and may have surfaces for attaching finishing strips.
A beam support post may be installed between adjacent wall panels to form a beam pocket in which to seat a beam extending across the foundation to a similar beam pocket located on an opposite side of the perimeter wall. Alternatively, a beam support post may be installed within a wall panel, with the panel's top cap having a gap to accommodate the beam.
A modular stair well may be placed between adjacent wall panels to form a basement walkout or egress. Windows, doors and egress windows may be formed in above grade sections of the wall. Where the windows or doors are in a shear wall, beam pockets may support a hollow beam over door or window openings for greater shear resistance.
The panels may have insulation material sprayed onto the inside of wall face. The panels may also be coated with a decorative protective finish, such as Rhino Lining™ finish.
Wall panels of the embodiment having two vertical-side framing supports and finishing strips are preferred when constructing the foundation walls of a full height basement. According to one exemplary method of using the panels to construct the foundation walls for a full height basement, a foundation outline box is laid out and the basement pit is excavated to below the frost line with an over-dig of at least about two feet wider than the outline box. A layer of crushed stone may be needed depending upon soil condition. Drainage piping and other filter or vapor membranes may be used under the area where the concrete slap floor will be poured. A perimeter footer wider than the width of the wall panels is poured and leveled in the outline of the foundation.
Wall panels pre-manufactured to the particular foundation wall specifications are then assembled together with bolts at the side wall seams. The assembly preferably starts at a corner section and works both directions from the corner. The corner panel is set in place and aligned on the footer. There are pre-punched anchor holes in the base pan of the corner panel through which anchor holes can be drilled into the footer. Concrete anchor screws (e.g. TAPCON™ screws) and washers are used to immobilize the panel on the footer as the other panels are assembled to it. At each side seam, a bead of urethane sealant is drawn about one quarter inch thick running along the top cap then down to the bottom pan in the surface between the wall face and the bolt holes. After checking alignment and level, more concrete anchor screws can be used to immobilize the wall section as the next adjacent panels are bolted on.
When all of the wall panels are joined and leveled, a continuous bead of urethane sealant is also placed at the seam between the concrete footer and the base pan at both the interior and exterior sides of the wall area. A concrete slap floor may be poured in the interior basement space between the walls. If the wall panels are intended to be encapsulates in the slab, the panels are made with a short flange on the bottom pan such that the poured concrete flows into the entire base pan. Alternatively, if the intention is to contain the slab along the inside perimeter formed by the base pan, the flange of the base pan is increased in height and serves as a screed support for leveling the poured concrete. Any cross beams or other support beams are placed into the beam pockets. A sill plate is then installed over the top cap to fix the top alignment of the panels and ready the foundation for support of upper levels.
Upper levels of the building structure may also use the wall panels of the present invention, particularly where the exterior walls may be subject to high shear forces or need increased weight bearing capacity.
Referring to the drawings, where like numerals identify like elements,
As shown in
Attached to the wall 10 is a steel stair well 16 with steps to provide a walkout exit. The wall 10 also includes two opposite beam pockets 18 to accommodate a cross wall support beam. A longer wall could have more than one cross beam. Cross beams can also be used with walls of different shapes and dimensions. The structural wall panels 12 have a generally flat or planner outside surface 20, although the panels can be curved for customized buildings where the foundation is not rectangular and yet retain a smooth outside surface. Standard panels are 4-foot wide and up to 10 foot in height, but custom panels can be made in various dimensions.
The panel can be constructed from a steel sheet by cutting or punching the dimensions and bolt holes and keyways, and then bending the edges to form the panel. As shown in
Depending upon how much load the perimeter wall be subjected to, the wall panels may require additional structure to resist bending. When the perimeter wall 10 is the main support structure of the foundation, as in the basement wall embodiment of
Vertical support brackets 38 are used to stiffen the wall panel connection between adjacent panels and to increase vertical support. A support bracket is preferably C-shaped in cross section as shown in
In an alternative embodiment as shown in
In a variant of this embodiment, the top cap 118 extends only to the side depth D before being bent downward to form a top flange 130. In this variation, the finishing strips. Similarly, the base pan 120 extends at a right angle from the wall face in the same direction as the side panels to a distance from the wall face that is longer than the side depth distance by substantially the depth of the finishing strips, and then is bent upward to form a bottom flange 132 over the finishing strips. In this variation, the finishing strips overlie the top cap flange to provide a thermal barrier between the metal pane and the dry way or other wall covering.
In another variation, the bottom flange may be longer than the top flange, for example a 3-inch high bottom flange as opposed to a 1-inch top flange. The longer bottom flange may be used when the concrete basement floor is to be contained within the inside perimeter of the base pan. A shorter flange is used when the concrete is intended to flow over the flange and into the base pan.
In this embodiment of panel having integral side-framing studs, the interior framing studs 134, similar to the previously described side framing studs 116, are preferably 14 gauge coated steel channels having a roughly Z-shaped cross section, as shown in
The finishing strips 128 are made of non-metallic material having good insulating properties to form a thermal barrier between the wall panel and any interior wall surface such as dry wall or paneling. The strips also have sufficient strength to hold staples, screws, dry wall nails or similar fasteners used to support interior wall material or wall hangings. While natural wood could be used, engineered wood or plastic composite provides sufficient strength and thermal barrier in narrow strips and are preferred for that reason. The finishing strips 128 are attached to each side wall framing support and extend from the bottom pan to the top cap.
As shown in
Alternatively, as shown in
A section of wall 200 as shown in
Windows and doors windows may be formed in above grade sections of the wall. Where large windows such as egress windows or doors form openings in a shear wall, a hollow support beam 230 (also shown in
A conventional sill plate (not shown) may be placed around the top caps of the wall panels and corner panels and over the cross beams. Floor joists are then placed across the walls transverse to the beam. To assist in locating and installing the floor joists, a joist anchor can be mounted on the sill plate. The joist anchor is an elongated 90 degree angle bracket formed from sheet steel of suitable thickness, such as 14 gauge. The sheet is cut to dimension and bent to a right angle at the bottom to form a short bottom flange having a width that is less than the width of the sill plate that will be laid on the foundation wall, and an upright flange having a height to make it approximately flush with the top of a floor joist placed in the anchor resting on the bottom flange. Holes may be drilled or stamped in the bottom flange to pass through anchor bolts extending from the foundation wall panels and cross beam though the sill plate. Holes may also be provided in the upright flange for screws attaching the end of the floor joist to the anchor, or the screws can self-drill these holes. Since the short bottom flange of the sill plate has a width that is less than the width of the sill plate, there is room behind the joist anchor to fit a trim board to cover the heads of the screws.
Although not shown in the drawings, insulation be sprayed or otherwise adhered to the inside surface of the wall panels and beam posts, preferably to an efficiency rating of R-14 or greater
According to one exemplary method of using the panels to construct the foundation walls for a full height basement, a foundation outline box is laid out and the basement pit is excavated to below the frost line with an over-dig of at least about two feet wider than the outline box. The pit is excavated to sufficient dimensions to accommodate the planned basement and allow working space around the exterior of the basement walls. A layer of crushed stone may be needed depending upon soil condition. Drainage piping and other filter or vapor membranes may be used under the area where the concrete slap floor will be poured. A concrete perimeter footer wider than the width of the wall panels is poured and leveled in the outline of the foundation, and includes the footer for a walkout stairwell if one will be installed. The footer should provide a smooth surface of about 8-12 inches (increased to three times the wall width under any cross beam posts) on which to erect and anchor the wall panels and stairwell.
If a steel stairwell is used, it is set in place and anchored first on the respective portion of the footer. If no stairwell is used, the assembly preferably starts at a corner section and works both directions from the corner. The wall panels made to the particular foundation wall specifications are then assembled together with bolts at the side wall seams. The vertical support studs preferably have been are fastened onto the wall panels at the proper spacing before the panels are connected together, the finishing strips have been installed on the side wall studs and vertical studs, and thermal insulation has been sprayed onto the inner wall surface prior to delivery of the wall panels to the site.
If starting a corner panel, it is set in place and aligned on the footer. There are pre-punched anchor holes in the base pan of the corner panel through which anchor holes can be drilled into the footer. Concrete anchor screws (e.g. TAPCON™ screws) and washers are used to immobilize the panel on the footer as the other panels are assembled to it. At each side seam, a bead of urethane sealant is drawn about one quarter inch thick running along the top cap then down to the bottom pan in the surface between the wall face and the bolt holes. After checking alignment and level, more concrete anchor screws can be used to immobilize the wall section as the next adjacent panels are bolted on. A wall panel having the beam post support column is used at the foundation location where a cross beam will span across opposite walls. Corner panels are used to make the inside and outside corners. Panels having window or door frames are placed in the intended locations. Preferably all of these pieces can be marked to indicate the order of installation and location prior to site delivery to reduce any likelihood of placing the wrong panel in a sequence.
When all of the wall panels are joined and leveled, a continuous bead of urethane sealant is also placed at the seam between the concrete footer and the base pan at both the interior and exterior sides of the wall area. A concrete slab floor may be poured in the interior basement space between the walls. In a preferred embodiment, the flange on the bottom pan is about three inches high and the depth of the slab is preferably poured up to the height of the flange, using the top of the flange as a screed support for leveling the concrete surface. Alternatively, the concrete could be allowed to flow into the base pan area and encapsulate the base of the panels. Any cross beams or other support beams are placed into the beam pockets. A sill plate is then installed over the top cap to fix the top alignment of the panels.
The outside surface of the wall structure may be sealed by caulking the seams and spraying a urethane sealing layer on the entire exterior wall before the pit is backfilled. The exterior surface may also be prepared for supporting a decorative facade. Support stakes may be attached to the wall to support a ledge or shelf mounted on the stakes at a height that will be below grade when the pit is back filled. The ledge can be used to support decorative facing, such as a brick stone facade. Other exterior surfaces visible above ground can be painted or covered with mesh and stucco or other decorative finish before or after backfilling the pit.
The wiring and any in-wall plumbing or conduit work can be installed through the keyway cutouts in the side walls and vertical supports. The dry wall or other surface cover can be hung on the finishing strips.
Although the use of the panels has been described above in relation to a foundation wall, it should be clear that the same panels could be used in upper floor exterior walls. The panels provide increased shear resistance and weight bearing capacity, and are easy to install by bolting side-by-side panels. The finishing strips provide ease of attachment for wallboard, and the keyways allow for wiring and other conduit. Thicker insulation may be required in upper floor wall panels. The outside surfaces of upper floor walls can be covered by siding or other facade material, or painted if an appearance other than the polyurethane coating is wanted.
This application is a continuation in part of Ser. No. 11/504,621 filed May 18, 2007, and through it claims priority of provisional applications No. 60/501,538 filed May 18, 2006 and No. 60/904,012 filed Feb. 28, 2007.
Number | Date | Country | |
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Parent | 11504621 | Aug 2006 | US |
Child | 12422680 | US |