US3785095A

US3785095A - Multi-unit folding slab construction

Info

Publication number: US3785095A
Application number: US00163462A
Authority: US
Inventors: E Verner
Original assignee: Individual
Current assignee: Individual
Priority date: 1971-07-16
Filing date: 1971-07-16
Publication date: 1974-01-15
Anticipated expiration: 1991-01-15

Abstract

A structural support for supporting two ceiling panels upon a base wall panel. One edge of each ceiling panel has protuberances rigidly conjoined thereto which span outwardly and over the upward edge of the wall panel for supporting the ceiling panels. The protuberances of one ceiling panel are hingeably conjoined to the wall panel to allow pivotal movement therebetween during the erection procedure. The supporting interconnection provided by the protuberances and underlying supporting walls permits successive building units to be stacked in columnar relation with abutment between overlying walls, and grout to be placed between the supported panels to integrally conjoin the wall panels of the joint as erected.

Description

States Patent 1 1 Werner Edwin Abercrombie Verner, 2922 Derby, Berkeley, Calif.

[22] Filed: July 16, 1971 [21] Appl. No.: 163,462

Related US. Application Data [63] Continuation of Ser. No. 842,322, July 16, 1969,

[76] Inventor:

abandoned.

[52] 11.8. C1 52/70, 52/122, 52/745, 52/236, 52/583 [51] Int. Cl E041) 1/344 [58] Field of Search 52/745, 122, 125, 52/236, 583, 251, 69, 71, 79; 16/128 [56] References Cited UNITED STATES PATENTS 3,494,092 2/1970 Johnson et a1 52/745 1,886,962 11/1932 LaRoche 52/236 X 2,897,668 8/1959 Graham 52/583 X 3,331,181 7/1967 Schmidt.... 52/745 X 1,361,831 12/1920 Crew 52/281 1,886,962 11/1932 LaRoche... 52/236 X 1,957,026 5/1934 Lasker 52/236 3,226,894 l/l966 Burchardt et al 52/236 X [4 1 Jan. 15, 1974 3,494,092 2/1970 Johnson et al 52/236 X 3,500,595 3/1970 Bennett 52/236 X FOREIGN PATENTS OR APPLICATIONS 1,032,666 6/1966 Great Britain 52/236 1,480,252 3/1966 France 52/251 Primary ExaminerFrank L. Abbott Assistant ExaminerH. E. Raduazo Att0rney-Alvin E. Hendricson et al.

[57] ABSTRACT A structural support for supporting two ceiling panels upon a base wall panel. One edge of each ceiling panel has protuberances rigidly conjoined thereto which span outwardly and over the upward edge of the wall panel for supporting the ceiling panels. The protuberances of one ceiling panel are hingeably conjoined to the wall panel to allow pivotal movement therebetween during the erection procedure. The supporting interconnection provided by the protuberances and underlying supporting walls permits successive building units to be stacked in columnar relation with abutment between overlying walls, and grout to be placed between the supported panels to integrally conjoin the wall panels of the joint as erected.

15 Claims, 15 Drawing Figures Pmminm 15 m4 SHEET 1 OF 4 INVENJOR.

EDWIN A BERCROMBIE VERNER lownSendlownsend PNEWH] JAN 15 I974 SHEET 2 BF 4 INVENTOR.

EDWIN ABERCROMBIE VERNER jmunsend /ownsend PATENWJM I 5 mm SHL'ET 3 BF 4 INVENTOR.

EDWIN ABERCROMBIE VERNER BY Vownsend w lawns end PMENTEUJAM 15 mm 3. 785095 SHEET a 0? 1 INVEN TOR.

EDWIN ABERCROMBE VERNER L Zownsend loumsend MUlL'lll-UNIT FOLDING SLAB CONSTRUCTION This application is a continuation of Ser. No. 842,322 filled July 16, 1969 and now abandoned.

This invention relates to prefabricated building structures and more specifically discloses an improved building joint usable with a folding slab construction in such prefabricated building structures.

The improved building joint of this invention is utilized with those construction techniques described in application Ser. No. 651,166, filed July 5, 1967, now US. Pat. No. 3,494,092 entitled Integrated Folding Slab Construction. In the construction techniques therein illustrated, two panels, typically poured and cured in coplanar relation, are joined at the time of curing with embedded hinge members. When the hinges are firmly incorporated in the panels as a result of the curing process, one pane] is elevated and the remaining panel depended therefrom. Typically, the elevated panel comprises the ceiling member and the depended panel, or panels, the wall members. When the hinged panels are placed on a building site, the wall panel edgeunderlies the ceiling panel in wall-side to ceiling-slabedge supporting relation.

in the construction of multi-unit dwellings using this hinged panel technique, three major areas of construction difficulty have been encountered. First, where two separate units of folded slabs are adjoined in side-byside relation, it has been found highly desirable to support abutting ceiling panels on a common wall panel. Such a construction not only reduces the number of wall panels necessary to form the completed building structure, but additionally reduces the weight and material of the finished building structure.

Secondly, when such folding slabs have been adapted to multi-story construction, it has been necessary to design joints intcrconnecting ceiling and wall panels that will receive and support the overlying structure and sustain the weight thereof. Moreover, the wall and ceiling panel sections must be hinged and supported with respect to one another so that they can be brought into position, placed in plumb and level relation with respect to one another and prevented from bending or warping due to uneven positioning of the walls.

Thirdly, it has been found necessary to make the load bearing interfaces between conjoined wall panels horizontal wherever possible. These horizontal interfaces resist slipping of the panels with respect to one another and prevent shear forces from being generated immediately within the hinge at the point of conjoinder between such adjacent panels.

An object of this invention is to disclose a building joint wherein a common and underlying wall panel, hinged in abutting relation protuberance or support bars extending from to a first ceiling panel can be adapted to support a second ceiling panel.

An advantage of this invention is that through the use of a single underlying wall panel to support two ceiling panels, the weight of a building structure can be greatly reduced.

A still further advantage of this joint construction is that the supporting interface between the hinged wall and ceiling panel hinge elements is not inclined, a construction which eliminates the tendency of the panels to move with respect to one another after placement and prevents high tension and shear forces from being generated at the point of panel conjoinder- A still further object of this invention is to disclose a joint construction for folding slabs wherein successive building units fabricated of folding slabs can be stacked in overlying relation to form a multi-story structure.

An advantage of this invention is that the underlying and supporting wall members of each successive stacked building unit of a multi-story building structure are in overlying relation with respect to walls below and without ceiling slabs interstitially placed between the abutted wall slabs and hence provide common walls extending vertically for the entire height of the finished multi-story structure.

An advantage of the spanner members of the hinge construction of this invention is that the spanners when extending between overlying and abutting wall panels can readily be inserted in small notches defined at the interstitial area between the walls, thus preventing substantial interruption of the continuity of the designed wall-to-wall abutment.

A further object of this invention is to provide the underlying and supporting wall members with embedded, reinforcing columnar members extending vertically within the wall panels of the finished structure. These columnar members enable the stacked wall panels of this invention to be supported at preselected points wherein the respective wall and ceiling panels of conjoined units can be both plumbed and leveled.

An advantage of the columnar members of this invention is that they provide points between the adjoined wall sections where the panels can be fixed in spatial relation.

A further object of this invention is to disclose a technique for providing a supporting interface of grout between the panels of successively stacked walls in multistory buildings.

An advantage of this grout is that it effectively and simultaneously seals the conjoined wall and ceiling panels into an integrally finished structure.

A still further advantage of the integral finished structure provided by the grout placed between the abutting panel edges is that conventional posttensioning techniques can be used for reinforcement of the finished building structure.

A still further object of this invention is to disclose a joint between the abutted ceiling panels which will permit prestressing the ceiling panels.

An advantage of this prestressed construction is that the thickness of the abutted ceiling and wall panels can be substantially reduced as in conventional prestressed concrete construction.

Other objects, features, and advantages of this invention will be more apparent after referring to the following specification and attached drawings in which:

FIG. 1 is a perspective view of successive building units of folded slabs disposed in coplanar relation adjoining a building site, with the underlying central building unit being elevated by a spreader attached to a lifting apparatus (not shown);

FIG. 2 is a perspective view of the finished building structure with all but the last building unit in place;

FIG. 3 is a perspective view of a hinge construction suitable for use with this invention, the outline of the poured and cured slabs relative to the hinge construction being shown in their unerected relation as broken lines;

FIG. 4a is a perspective view of a hingeably joined ceiling and wall panel in the erected position;

FIG. 4b is a perspective view of the erected panels of FIG. 4a with an abutted ceiling panel supported by the common or party wall panel;

FIG. 40 is a perspective view similar to FIG. 4b herein showing the wall panel of an overlying building unit abutted at the bottom edge thereof to the joint illustrated in FIG. 4b;

FIG. 5 is a detailed perspective view of the hinged ceiling panel and abutted ceiling panel as supported by the common underlying wall panel;

FIG. 6 is a perspective view of the columnar support between abutted overlying and supporting wall panels;

FIG. 7a is a cross-sectional elevation of the channel formed by the conjoined wall panel and abutted ceiling panels illustrating the disposition of grout within the channel immediately prior to the placement of an overlying wall panel;

FIG. 7b is a view similar to FIG. 7a showing the overlying wall panel after placement and the grout as extruded;

FIG. 8 is a perspective and exploded view of an alternate embodiment of the hinge and joint construction of this invention;

FIG. 9a is a perspective view of conjoined ceiling and wall panels incorporating an alternate grout channel and lapped bar construction;

FIG. 9b is a detail of an integral form material preparing the side edges of the alternate grout channel construction disclosed in FIG. 9a;

FIG. 10 is a schematic diagram illustrating a technique for predeflecting the abutted ceiling panels; and

FIG. 11 is a side elevation section through the abutting wall and ceiling slabs illustrating a technique for post-tensioning the abutted ceiling and wall panels.

With reference to FIG. 1, building site or foundation A is shown having stacked adjacent thereto the hingedly joined wall and ceiling slabs of end building units B1 through B4 and central building units C1 and C2. The central building unit C1 is illustrated being elevated by a spreader D through lifting apparatus (not shown).

As stacked adjoining the building site, the slabs of building unit B1 are placed in overlying relation to the slabs of building unit B2. Similarly, the slabs of unit B3 overlie the slabs of unit B4 and slabs of unit C1 overlie the slabs of unit C2.

With reference to FIG. 2, the hinged slabs of building units B1 through B3, and C1 and C2 are shown in the erected position on building site A. As here shown, unit C1, placed on foundation at its central portion immediately underlies unit C2. Likewise, unit Bl immediately underlies unit B2. Unit B4 is illustrated in its unplaced disposition.

Building units Bl through B4 each include a ceiling panel 11 with hingedly

conjoined wall panels

13, 14 and 15. These wall panels abut the rectangular ceiling panel on three edges thereof with the remaining or exposed edge 18 having no wall panel hingedly joined thereto.

Central units Cl and C2 are similar to end units Bl through B4. In these units, however, all edges of the ceiling panels are adjoined by hinged walls. Typically, ceiling panel 21 is provided with two end-

wall panels

22 and 23 and two

sidewall panels

25 and 26.

Referring again to FIG. 2, it will be noted that when end unit B4 is placed into stacked relation on top of end unit B3, support of the ceiling panel 11 by the wall panels 12', 14' and 15' of unit B4 will occur only along three of its four rectangular edges. Exposed edge 18 will remain unsupported. Accordingly, to provide exposed edge 18 of ceiling panel 11' with support, wall 23 of building unit C2 must be utilized. This support between the abutted ceiling panel 11 of unit B4 and ceiling panel 21' of unit C2 is provided by the building joint hereinafter described.

With reference to FIG. 3, hinge E is illustrated conjoining end wall panel 23' to a ceiling panel 21 of central unit C1, the panels here being shown in broken lines to fully illustrate the details of the hinge. Typically, end wall panel 23 has embedded therein a single hinge leaf or bar 30. Hinge bar 30 protrudes outwardly into a rectangular recess defined in the edge of wall panel 23. Likewise, ceiling panel 21 has embedded therein two hinge leafs or bars 34.

Hinge bars 30 and 34 are here shown with a rectangular cross section protruding outwardly from the edge of their respective wall and ceiling panels. Bars 34 are spaced so as to straddle therebetween bar 30. As is common in the hinge art, a pin 36 (here shown as a nut and bolt) penetrates aligned apertures within the

bars

30 and 34 to provide pivoted connection of the hinge.

Securing the hinged members to the

panels

21 and 23, respectively, is effected with reinforcing bars or rebars embedded within the slabs. Typically, hinge bar 30 has two pigtailed re-bars 38 butt welded to the end thereof. Likewise, bars 34 have welded therebetween two pigtailed re-bars 40. Typically, these pigtailed rebars are provided with that irregular surface common in reinforcing bars and are bent at their respective ends to enhance their grip with the cured concrete of the

panels

21 and 23.

It will be noted that the diameter of the bars 40 is selected to maintain the desired spatial separation between hinge bars 34 to allow hinge bar 30 to fit therebetween; one pigtailed re-bar 40 being between the upper adjoined portion of bars 34 and the remaining pigtailed re-bar 40 being between the lower adjoined sections of bars 34.

To reinforce further the embedded relation of the hinge bars within

slabs

21 and 23, a series of diagonal bracing re-bars is provided transverse of the hinge bars. These re-bars include upper and lower horizontal rebars 42 which extend horizontally outward from a welded joinder to hinge

members

30 and 34, respectively, into an embedded disposition with

slabs

23 and 21. Attachment of hinge bars 30 and 34 is further reinforced by V-shaped re-bars 44. These re-bars are welded at the bottom central portion of the

hinge members

30 and 34. At their respective ends removed from the hinge bars 30 and 34, V-shaped re-bars 44 are welded to horizontal re-bars 42. As is apparent from FIG. 3, the V-shaped re-bars 44 are inverted when rebars 44 attach to the top of hinge bars 30 and 34 and right side up when re-bars 44 attach to the bottom of the hinge bars 30 and 34.

At the surface which is to become the bottom surface of recess 32 in the as-erected position, hinge bar 30 penetrates the central portion of a rectangular support plate 46. As will hereinafter become more apparent with reference to FIGS. 4a through 5, support plate 46 provides a supporting interface between wall panel 23 and subsequently conjoined ceiling panel 1 1 of an adjacent building unit.

Referring to FIG. 4a, disposition of the conjoined panels is illustrated after erection. Typically, when ceiling panel 21 of building unit C1 is raised, wall panel 23 rotates from the position shown in FIG. 3 downwardly to underlie the protruding hinge rigidly embedded in ceiling panel 21 in supporting relation.

Referring to FIG. 4b, the placement of adjoining building structure B1 is illustrated. Typically, unit B1 is lowered so that ceiling panel 11 at exposed edge 18 is in relative juxtaposition and abutted to that corresponding edge of ceiling panel 21 of building unit C1, with only the wall slab 23 standing between. In this position, support bars 50 protruding outwardly of exposed edge 18 of ceiling panel 11 of unit Bl, come to rest on support plate 46 at either side of the hinge members B so as to transfer the load of panel 11 at edge 18 onto wall 23 of unit C1. A detail of this supporting interconnection is shown in FIG. 5.

Referring to FIG. 5, support bars 50 are illustrated protruding horizontally outward from the exposed edge 18 of ceiling panel 11 in building unit Bl. Typically, bars 50 are embedded within ceiling panel 11 and embraced by re-bars similar to those

re-bars

38, 40, 42 and 44 previously illustrated in FIG. 3. For purposes of brevity, the disposition of the re-bars will not be further discussed herein.

Bars 50 are each given a spatial separation relative to hinge E so that they can come to rest on either side of the conjoined hinge bars 30 and 34. Support bars 50 rest on their lower protruding surface upon the upper surface of support plate 46. Plate thus provides a metal-to-metal interface with bars 50 so as to bear the vertical load of ceiling panel 11 at exposed edge 18.

With reference to FIG. 4c, the placement of vertical wall 23 of unit C2 overlying a wall 23 of unit Cl is illustrated. Typically, unit C2 will be lifted upwardly by spreader D so that its ceiling and

wall panels

21, 22, 25, and 26' of unit C2 overlie the corresponding ceiling and

wall panels

21, 22, 23, 25, and 26 of unit C1. Thereafter, unit C2 will be lowered on top of unit C1; the panels together forming the joint illustrated in FIG. 4c.

In forming the final joint illustrated in FIG. 4c, two features of the interconnection between the walls 23 and 23' of units C1 and C2, must be noted. First, the walls are provided with a positive metal-to-metal contacting surface at landing pads F. Second, the remainder of the contact between the two wall panels occurs at a grouted interface G within the joint defined by the wall structure of this invention.

In the placement of the building units it has been found that the wall and ceiling slabs must be movable relative to either the building site A onto which they are placed or the lower and supporting units on which they are stacked. Preferably the wall and ceiling panels must be plumb and level, respectively. Moreover, these panels must precisely overlie their corresponding points on either the building site A or their supporting building unit. Finally, the panels must be provided with a firm base from which they can be adjusted. To these ends it is preferred that each of the walls be provided with two positive points of contact with either the supporting building site A or an underlying and supporting building unit. This function is served by the landing pads F illustrated in FIGS. 1, 2, 4c and 6.

With respect to FIG. 6, the junction between two

vertical walls

23 and 23 of building units Cl and C2 is illustrated. Typically, each of the walls 23 and 23' has extending vertically therein two

columnar re-bars

52 and 52. These re-bars have welded at the upper surface of their panel 23 steel landing 54 of expanded section. Typically, landing bar 54 is embedded interior of the slab so as to expose its upper surface flush with the upper edge of the wall slab 23.

Protruding downwardly from the corresponding overlying portion of wall 23' of unit C2, the overlying columnar re-bar 52 is illustrated. This bar protrudes from a recess 57 provided with beveled edges 58 permitting access to the interface between the landing pad 54 and the lower end of the columnar re-bar 52.

With reference to FIGS. 1 and 2, it will be seen that columnar re-bars 52 and 52' each extend vertically of the wall slabs of building units C1 and C2, respectively. This disposition permits the columnar re-bars to become vertical, load bearing column members the instant that the units are placed on either building site A or on a supporting and underlying building unit. Moreover, it is seen that each wall panel is provided with two such columnar reinforcing bars, each bar being located approximately adjacent and parallel to the vertically extending edges of each wall panel. These two columnar reinforcing bars permit positive contact of the wall at two points, provide precise positioning of the wall members with respect to either the building site or an underlying and supporting building unit, and provide embedded columnar supporting members extending the entire building height.

Referring again to FIG. 6, it can be seen that the expanded and upwardly exposed surface of landing pad 54 (or plate) provides for movement of overlying columnar re-bars 52' with respect to underlying columnar re-bars 52. This movement permits wall panel 23 of building unit C2 to be adjustably moved with respect to the wall panel 23 of building unit Cl. With such movement, precise alignment of the wall sections can occur when the building units C1 and C2 are placed. When such alignment is made, typically columnar re-bar 52' at its protruding lower portion is welded to the upwardly exposed surface of landing bar 54 and the length of, and expanded dimension of re-bar 52 provides smooth flow of stress vertically in a near concentric line in spite of job site aberration in dimension.

Columnar re-bar member 52 extends downwardly of wall panel 23 a distance beyond the plane of lower edge 60 of the wall panel 23. This distance is chosen so that edge 60 remains separated by a preselected spatial interval 61 from the upper edge 62 of wall 23 of building unit C1. It is within this interval that grout G is squeezed in this process of placing overlying building unit C2. Alternately, grout may be intruded as by pumping.

In the construction of the building structures herein illustrated, it has been found that landing pads F cannot conveniently wholly bear the weight of the building units. This is particularly true when the structure has more than one level or story requiring support along the joint between overlying wall panels as in the lower stories of tall buildings. To provide this additional support, grout G is placed between the vertically overlying and supporting wall sections.

With reference to FIGS. 4b, 4c, 7a and 7b, placement of grout G is illustrated. In FIGS. 4b and 7a, it will be seen that the conjoined ceiling panel 21 and wall panel 23 of building Cl form, in cooperation with the exposed edge 18 of ceiling panel 11 of building unit B1, a channel or trough. Typically, this channel or trough is sealed at the bottom by the placement of caulking seal 64 between the lower edge of the

respective ceiling panels

11 and 12 and the side surface of the wall panel 23. As illustrated in FIGS. 4b and 7a, before the overlying wall unit is placed, this trough is filled with grout G. The grout placed may or may not be of the variety that expands upon curing and is placed in a quantity that slightly exceeds that quantity necessary to fill the spatial interval when the walls have come to rest on their respective landing pads F.

With reference to FIGS. 4c and 7b, the final disposition of grout G forming the interface between the wall panels 23 and 23' is illustrated. Wall panel 23' of building unit C2 will compress grout G when it is placed. This compression will cause excess grout G to be extruded from between the abutting wall panels 23 and 23' outwardly and to the sides of the trough formed between the

abutted ceiling panels

11 and 21. After wall panels 23 are placed, grout G will be trimmed flush with the upper surface of the abutted

ceiling panels

11 and 21.

Referring again to FIG. 6, it is often desired to prevent the grout interface G from extruding into the concavity formed by the recess 57 of the landing pads. Such extrusion can be prevented by the insertion of a small grout dam 66 between the grout interface and the applicable recess as shown in FIG. 6.

In the practice of this invention, alternate embodiment of the hinge members can be used. Referring to FIG. 8, such an alternate hinge construction E is illustrated.

A ceiling hinge member 70 and a wall hinge member 72 are illustrated in their erected disposition. Ceiling hinge member 70 is provided wtih two protruding hinge leaves 73 extending outwardly on either side of an intermediate hinge leaf 74 attached to and extending upwardly from wall hinge member 72.

When the hinge E of FIG. 8 is used, an abutment member 76 is attached to the exposed edge 18 of abutting ceiling panel 11. Abutment member 76 is provided with two straddle bars 78, which lap outside of the hinge construction E and permit the supported abutment of its attached ceiling panel on the hinge.

Hinge members

70 and 72 and abutment member 76 are herein shown provided with a construction which readily permits their embedded placement interior of the wall sections. Typically, each of the members is provided with a solid cast construction integrally joining the block 80 of the members to their protruding bars or hinge members. The backside of this block is embedded within its attached panel and provided with a plurality of ridges 82 defining valleys 83 therebetween. This ridge and valley construction, preferably extending horizontally of both block 80 and the attached panel edge permits the concrete of the slab when poured and cured to key between the ridges and valleys strengthening the embedded placement of the members in shear.

To prevent the

members

70, 72 and 76 from being pulled from the slab, it is necessary that their respective blocks 80 be attached to reinforcing bars 85 extending away from the hinge members into an embedded relation interior of the slab. To this end, there is provided a plurality of saddles 84 aligned in two rows from near the top valley and bottom valley, respectively, of each of the blocks 80. These saddles, have welded thereto re-bars 85 and provide requisite anchoring of the hinge members interior of the slab.

In the construction of the drop leaf wall panels herein illustrated, the hinge member attached to, embedded in, and protruding upwardly from the wall panels is formed with two types of apertures. Typically, one aperture is formed as illustrated in FIG. 3, the aperture being sized with respect to the hinge pin so as to prevent all wall panel movement relative to the hinged axis between the ceiling and wall panels. Alternatively, the wall panel can be provided with an aperture elongated within the plane of the wall as illustrated in FIG. 8. This permits the wall to move upwardly and downwardly while being maintained in a positive lateral position with respect to the hinge axis at the line of fold between the ceiling and wall panel.

These two types of hinge apertures can be combined to provide an improved support of the ceiling panel. Typically, in the support of a ceiling panel, it is preferred that the panel rest on only two lines of support, one line of support underlying one panel edge, the other line of support preferably being at an opposite edge. Such support can be provided by fastening the two wall panels on opposite edges of the ceiling panels with hinge apertures of the variety shown in FIG. 3. These apertures, permitting no movement of the wall transverse to the hinge axis, firmly support the ceiling slab along the two opposite edges. Typically, where the ceiling slab is square the wall panels selected for the support can be at any two opposite edges of the ceiling panel; alternately where the ceiling slab is rectangular, the wall panels selected for support will be preferably at the elongate opposite edges of the rectangle (such edges in closer proximity to each other than the other two shorter edges).

The remaining wall panels will be provided with elongate hinge apertures as illustrated in FIG. 8. These elongate apertures will permit the remaining wall panels to be adjusted upwardly and downwardly into their defined elevational relationship with the ceiling panel and yet held in positive lateral position relative to the hinge axis.

With reference to FIGS. 9a and 9b, an alternate construction of the grout trough defined within the improved joint construction of this invention is illustrated. Typically, wall 23 at its upper edge is provided with an upwardly extending ridge of rectangular cross section. Each of the abutting

ceiling slabs l

1 and 21 is provided with tapered slopes 92, which diverge away from the juncture between the wall slab 23 and the bottom of

ceiling slabs

11 and 21.

Protruding normally outward from the upper portion of sloping surfaces 92 of

ceiling panels

11 and 21 into the concavity defined by the joined ceiling and wall slabs there are a plurality of reinforcing bars 93. These bars 93, embedded within the panels at one end, extend into the concavity defined by the edges of the slabs and fasten to the poured and cured grout by becoming embedded therein. Such bars 93, in order to engage the embedding grout would preferably be terminated with hooks reaching as near as possible to tapered slope 92 on opposite sides of the trough or concavity.

It will be noted that the surface provided at the edges of the slabs is irregular. Typically, this irregularity is produced by folded and perforated sheet metal plates illustrated in FIG. 9b.

With reference to FIG. 9b, an exemplary section of the sheet metal is shown formed with a plurality of intersecting ridges 96 and valleys 98. These intersecting ridges and valleys incorporate within the sheet metal a plurality of surfaces wherein the poured and cured grout can become keyed upon curing.

In addition to or in place of the irregular surfaces provided by ridges 96 and valleys 98 of the sheet metal, the metal is punctured at numerous intervals on each plane surface. This puncturing flares the metal in an irregular and jagged manner about the aperture so as to form a surface not unlike the surface of a cheese grater. Some apertures are punctured so as to open downwardly; another equal number of apertures are punctured so as to open upwardly. This alternate upward and downward opening permits the sheet metal to key to concrete or grout on either side thereof.

The apertures within the sheet metal serve to accomplish four separate functions. First, when the slab is originally poured, the apertures permit air if entrapped between the ridges and valleys to escape. The escape of this air permits the concrete to flow into and fill completely the irregular surface defined by the sheet metal.

Secondly, the apertures are selected in their size so as to prevent appreciable amounts of concrete from escaping therethrough. In this manner they can form the sidewalls of the mold into which the panel is formed.

Thirdly, the irregular surfaces provided by the aperture boundaries further key the sheet metal to the grout layer or interface between the abutting panels. This effects a further improved, embedded adhesion of the panel edges.

Fourthly, such formed surfaces, by functioning integrally with the poured concrete, permit the lifting and folding operation to proceed without the necessity of removing forms from the side edges of the panel which form the grout channel.

The particular construction of the grout trough illustrated in FIG. 9, particularly with the whisker-bars'93, has the advantage of permitting the ceiling panel to be effectively prestressed as they are embedded within the joint construction herein illustrated. Such prestressing is schematically illustrated in FIG. 10.

With reference to FIG. 10, building units C1 and B1 are illustrated in side elevation section as adjoined on building site A. Typically, before grout G is inserted in the trough defined between the abutting edges of ce'iling slabs ll and 21 and wall slab 23, a portion of the load of the ceiling slabs is removed by jacking. To this end, jacks 99 are placed between the building site A and

overlying ceiling slabs

11 and 21. Thereafter, the jacks are extended to predeflect the

ceiling panels

11 and 21 and to thus remove a portion of the vertical load of these ceiling slabs from their underlying and supporting wall slabs. Typically, the jacks together support one-half the total weight of the ceiling panels with the remaining one-half of the weight of these ceiling panels supported by the wall panels at the edges of the ceiling panels. It is to be understood, however, that the weight of the ceiling panels assumed by the jacks can be varied; the optimum weight carried by the jacks will 'be dependent upon the slab geometry, the live load to dead load ratio and other considerations common to engineering or to the prestressed concrete art.

When the jacks have assumed the desired load, grout is poured in channel G. If the structure is to be a multistory dwelling, the overlying units are placed. After the grout G has cured and thus embedded the protruding re-bar members 93, the jacks are removed. This removal effectively fixes the ends of the supported

ceiling slabs

11 and 21 at the protruding re-bar members 93, prestressing the slabs at their point of conjoinder to the wall panels, and beyond.

In addition to the prestressing technique illustrated with respect to FIG. 10, the building joint of this invention easily lends itself to post-tensioning. Such a posttensioning technique is illustrated with respect to FIG. 1 1.

Referring to FIG. 11, a sectional view of the ceiling slab 21 and

end wall slabs

22 and 23 of building unit C1 is shown in supported side-by-side relation to ceiling slab 11 and wall slab 14 of building unit B1. As is apparent, poured and cured grout G at the interstices of the abutting ceiling and wall panels have integrally fastened the walls in supported relation.

Typically, where post-tensioning of the walls is desired, a plurality of tubes 102 encasing cables 103 will be inserted in the ceiling panels. As shown in FIG. 11, tube 102 and cable 103 extend across the length of ceiling slab 21 through a notch 104 provided in the upper edge of wall slab 23 of building unit Cl and thence into adjoined ceiling slab ll of building unit B2. As is common in the post-tensioning art, a plurality of anchors 106 are provided at either end of the conjoined posttensioned ceiling slabs and 21.

Typically, tubes 102 and each of the individual ceiling slabs and notch 104 and wall slab 23 will be aligned in anticipation of the erected disposition of the folded slabs. Thereafter, tubes will be connected across the grout channel or trough before grout G is poured. When the slabs are erected and the grout poured and cured, the aligned and continuous tubes will be threaded with cable. This tension will effectively prestress the ceiling slabs to provide additional slab loading in anticipation of the live and/or dead weight loads of each of the ceiling slabs l1 and 21. As in the case of conventional prestressing, such loading will permit the slabs to be substantially reduced in weight and thickness.

In addition to the post-tensioning of the

ceiling slabs

11 and 21, it may be additionally desired to tension the walls in their erected relation. Accordingly, each of the walls here illustrated is provided with vertically extending tubes 102 and cables 103, their respective anchors being not shown.

As is common in the art of post-tensioning, grout can be forced along the length of tubes 103 after posttensioning of cables 102 and after such tubes have been completely sealed as they cross the interstitial spatial interval between adjoined slabs.

These and other modifications of my invention may be practiced, it being understood that the form of my invention as described above is to be taken as a preferred example of the same. Such description has been by way of illustration and example for purposes of clarity and understanding. Changes and modifications may be made without departing from the spirit of my invention.

What is claimed is:

1. A structural support comprising: a base wall panel; two ceiling panels, each ceiling panel having one edge juxtaposed to the upper edge of said base wall panel on opposite sides of said base wall panel, said juxtaposed edge of each ceiling panel terminating at a boundary which does not overlie the edge of said base wall panel; a plurality of first rigid support bars rigidly connected to a first one of said ceiling panels at said juxtaposed edge thereof extending outwardly in overlying relation to said upper edge of said base wall panel, a plurality of second support bars rigidly connected to the second one of said ceiling panels in extension outwardly from said juxtaposed edge and overlying said upper edge of said base wall panel and resting on said edge of said base wall panel; interconnecting means connecting said first support bars on said first ceiling panel and said base wall panel, said interconnecting means including means for hingeably connecting the support bars on said first ceiling panel and said base wall panel to allow pivotal movement between said first ceiling panel and said base wall panel during erection of the structure, said means for hingeably connecting being located within the interstitial volume between said base wall panel and said two ceiling panels.

2. A structural support comprising: a planar base wall panel, said base wall panel on the upper edges thereof defining a plurality of areas substantially normal to the plane of said panel for receiving vertical loads; two ceiling panels, each ceiling panel having one edge juxtaposed to the upper edge of said base wall panel on a different side of said base wall panel from the other, said juxtaposed edge of each ceiling panel terminating at a boundary which does not overlie and is spaced from said upper edge of said base wall panel; a plurality of first rigid support bars rigidly conjoined to said juxtaposed edge of a first one of said ceiling panels and extending outwardly therefrom overlying said upper edge of said base wall panel; interconnecting means connecting said first support bars on said first ceiling panel and said base wall panel, said interconnecting means including means for hingeably conjoining said first support bars on said first ceiling panel and said base wall panel to allow pivotal movement between said first ceiling panel and said base wall panel from a substantially parallel disposition between planes of said ceiling panel and said base wall panel to a right angle position between planes of said ceiling panel and said base wall panel wherein the plane of said base wall panel is substantially vertical and said load bearing areas of said base wall panels are substantially horizontal with respect to said ceiling panel, said means for hingeably conjoining further being located at one of said areas for receiving vertical load on the edge of dais base wall panel to permit said area to receive a vertical loading and said means for hingeably conjoining being disposed with its hinge axis in the interstitial area between said base wall panel and said two ceiling panels; and a plurality of second rigid support bars rigidly conjoined to said juxtaposed edge of a second one of said ceiling panels and extending outwardly therefrom overlying the upper edge of said base wall panel at one of said areas for receiving a vertical load and resting on said area of said base wall panel to vertically load said panel,

3. The invention of claim 2 and wherein, said wall panel has defined in the upper edge thereof a plurality of recesses, said recesses each being spaced along said upper edge at the location of an area for receiving vertical loading for receiving at least one support bar from one of said ceiling panels and having said interconnecting means contained therein.

4. The invention of claim 2 and wherein said interconnecting means includes poured and cured grout between said panel edges.

5. The invention of claim 2 and wherein, said ceiling panels and said base wall panel define at the juxtaposed edges thereof a trough and said trough is filled with poured and cured grout.

6. The invention of claim 2 and wherein said structural support further comprises an overlying wall panel supported at the bottom edge thereof by said base wall panel at at least one of said areas for receiving vertical loading.

7. A structural support comprising: a planar base wall panel, said base wall panel on the upper edge thereof defining a plurality of areas substantially normal to the plane of said panel for receiying vertical loads; said base wall panel including Hnbiidioiiiiihi"P511- forcing members; said columnar members of said base wall panel extending vertically from a bottom edge of said panel to a top edge of said panel to form a continuous column extending upwardly through said base wall panel and each terminating at a different one of said areas for receiving vertical loads; two ceiling panels, each ceiling panel having one edge juxtaposed to an edge of said base wall panel on the opposite side of said base wall panel from the other; said juxtaposed edge of each ceiling panel terminating at a boundary which does not overlie and is spaced from the edge of said base wall panel; a plurality of first support bars rigidly conjoined to the juxtaposed edge of a first one of said ceiling panels and extending outwardly therefrom overlying the upper edge of said base wall panel; interconnecting means connecting said first support bars on said first ceiling panel and said base wall panel, said interconnecting including means for hingeably conjoining said first support bars on said first ceiling panel and said base wall panel to allow pivotal movement between said first panel and said base wall panel from a substantially parallel disposition between planes of said ceiling panel and said base wall panel to a right angle position between planes of said ceiling panel and said base wall panel wherein the plane of said base wall panel is substantially vertical and the load bearing areas of said base wall panel are substantially horizontal with respect to said ceiling panel, said means for hingeably conjoining being located at one of said areas for receiving vertical load on the edge of said base wall panel; and, a plurality of second protuberances rigidly joined to said juxtaposed edge of the second of said ceiling panels extending outwardly therefrom overlying said upper edge of said base wall panel at one of said areas for receiving vertical load and resting on the edge of said base wall panel to vertically load said panels.

8. The invention of claim 7 and wherein said structural support further comprises an overlying wall panel supported at the bottom edge thereof by said base wall panel at at least one of said areas for receiving vertical loading.

9. The invention of claim 8 and wherein said overlying wall panel includes embedded columnar reenforcing members; said embedded columnar reenforcing member of said overlying wall panel contacting at said bottom edge an area for receiving vertical loading and extending upwardly of said overlying wall panel to form a continuous column to said overlying wall panel.

10. The invention of claim 9 and wherein, each wall panel has two of said vertically extending columnar members embedded therein, each said columnar members being adjacent to one of the vertical side edges of said panel.

11. The invention of claim and wherein, embeddable members are attached to the edges of said ceiling panels for embedment within said poured and cured grout.

12. A structural support comprising: a base wall panel, said base wall panel having two vertical side edges defining spaced apart parallel planes and major surfaces defining on the upper edge thereof a plurality of areas substantially normal to the planes of said panel for receiving vertical loads; two ceiling panels, each of said ceiling panels being juxtaposed to the upper edge of a different one of said major surfaces of said base wall panel at a position spaced from the one of said major surfaces associated therewith; an overlying wall panel placed overlying the upper edge of said base wall panel; said overlying and base wall panels including embedded columnar reenforcing members extending vertically above said overlying and base wall panels, said embedded reenforcing members terminating at the upper edge of said base wall panel in a load receiving area, and terminating at the lower edge of said overlying wall panel at a load receiving area, one of said columns providing an expanded surface for the placement of the other of said columns from the other of said wall panels; a plurality of first rigid protuberances rigidly conjoined to the juxtaposed edge of a first one of said ceiling panels and spanning outwardly overlying the upper edge of said base wall panel; interconnecting means connecting said first protuberances on said first ceiling panel and said base wall panel, said interconecting means including means for hingeably conjoining the first protuberances on said first ceiling panel and said base wall panel to allow pivotal movement between said first ceiling panel and said base wall panel from a substantially parallel disposition between planes of said ceiling panel and said base wall panel to a right position between planes of said ceiling panel and said base wall panel wherein said planes of said base wall panel are substantially horizontal relative to said ceiling panel; said means for hingeably conjoining being located at one of said areas for receiving vertical load on the edge of said base wall panel to permit said area to receive vertical loading with the interstitial area between said parallel planes, and a plurality of second protuberances rigidly conjoined to the juxtaposed edge of said second one of said ceiling panels and spanning outwardly overlying the upper edge of said base wall panel at one of said areas for receiving vertical load and resting on said edge of said base wall panel to vertically load said panel.

13. The invention of claim 12 and wherein, said support means includes a layer of grout between said wall panels.

14. A multi-story folding slab construction comprising a first ceiling panel having a plurality of straight edges; a plurality of first protuberances embedded with said first ceiling panel and spanning outwardly from said panel at said straight edges; a plurality of first wall panels, said wall panels on the upper edge thereof defining a plurality of areas substantially normal to the plane of said panels for receiving vertical loads; means for hingeably mounting each of said wall panels to said protuberances on a different one of said plurality of edges of said first ceiling panel, said means for hingeably mounting being disposed at locations on said protuberances wherein said wall panels will not underlie said ceiling panel and each of said protuberances will overlie an area for receiving vertical loads on said wall panels, said hinge mounting means further permitting pivotal movement between each of said plurality of wall panels relative to said ceiling panels between a parallel disposition of said panels to a right angle disposition of said panels; a second and overlying ceiling panel having a plurality of straight edges, each of said plurality of straight edges of said second ceiling panel overlying a corresponding one of said plurality of straight edges of said first ceiling panel; a plurality of second protuberances embedded within said second ceiling panel and spanning outwardly from said panel at said straight edges; a plurality of second wall panels, said second wall panels on the upper edge thereof defining a plurality of areas substantially normal to the plane of said panels for receiving vertical loads; means for hingeably mounting each of said plurality of second wall panels to said second protuberances on a different one of said plurality of edges of said second ceiling panels, said means for hingeably mounting said wall panels permitting movement of said second wall panels relative to said second ceiling panels between a parallel position between said panels and a normal position between said panels, said means for hingeably mounting each being at an area for receiving vertical loads on said second wall panels; and, interstitial support means extending between the bottom edge of each of said plurality of second wall panels and the top edge of a different one of said plurality of first wall panels independent of said first and second protuberances, said interstitial support means including a plurality of first column members embedded in said first wall panels and extending to the top edge of said first wall panels, and a plurality of second columnar members embedded in said second wall panels and extending to the bottom edge of said second wall panels, each said second column members spaced along said second walls to overlie a first column for supporting said wall panels.

15. The invention of claim 14 and wherein, said interstitial support means is adapted to maintain a preselected spatial interval between the top edge of said first wall panels and the bottom edge of said second wall

Claims

2. A structural support comprising: a planar base wall panel, said base wall panel on the upper edges thereof defining a plurality of areas substantially normal to the plane of said panel for receiving vertical loads; two ceiling panels, each ceiling panel having one edge juxtaposed to the upper edge of said base wall panel on a different side of said base wall panel from the other, said juxtaposed edge of each ceiling panel terminating at a boundary which does not overlie and is spaced from said upper edge of said base wall panel; a plurality of first rigid support bars rigidly conjoined to said juxtaposed edge of a first one of said ceiling panels and extending outwardly therefrom overlying said upper edge of said base wall panel; interconnecting means connecting said first support bars on said first ceiling panel and said base wall panel, said interconnecting means including means for hingeably conjoining said first support bars on said first ceiling panel and said base wall panel to allow pivotal movement between said first ceiling panel and said base wall panel from a substantially parallel disposition between planes of said ceiling panel and said base wall panel to a right angle position between planes of said ceiling panel and said base wall panel wherein the plane of said base wall panel is substantially vertical and said load bearing areas of said base wall panels are substantially horizontal with respect to said ceiling panel, said means for hingeably conjoining further being located at one of said areas for receiving vertical load on the edge of dais base wall panel to permit said area to receive a vertical loading and said means for hingeably conjoining being disposed with its hinge axis in the interstitial area between said base wall panel and said two ceiling panels; and a plurality of second rigid support bars rigidly conjoined to said juxtaposed edge of a second one of said ceiling panels and extending outwardly therefrom overlying the upper edge of said base wall panel at one of said areas for receiving a vertical load and resting on said area of said base wall panel to vertically load said panel.

7. A structural support comprising: a planar base wall panel, said base wall panel on the upper edge thereof defining a plurality of areas substantially normal to the plane of said panel fro receiving vertical loads; said base wall panel including embedded columnar reinforcing members; said columnar members of said base wall panel extending vertically from a bottom edge of said panel to a top edge of said panel to form a continuous column extending upwardly through said base wall panel and each terminating at a different one of said areas for receiving vertical loads; two ceiling panels, each ceiling panel having one edge juxtaposed to an edge of said base wall panel on the opposite side of said base wall panel from the other; said juxtaposed edge of each ceiling panel terminating at a boundary which does not overlie and is spaced from the edge of said base wall panel; a plurality of first support bars rigidly conjoined to the juxtaposed edge of a first one of said ceiling panels and extending outwardly therefrom overlying the upper edge of said base wall panel; interconnecting means connecting said first support bars on said first ceiling panel and said base wall panel, said interconnecting including means for hingeably conjoining said first support bars on said first ceiling panel and said base wall panel to allow pivotal movement between said first panel and said base wall panel from a substantially parallel disposition between planes of said ceiling panel and said base wall panel to a right angle position between planes of said ceiling panel and said base wall panel wherein the plane of said base wall panel is substantially vertical and the load bearing areas of said base wall panel are substantially horizontal with respect to said ceiling panel, said means for hingeably conjoining being located at one of said areas for receiving vertical load on the edge of said base wall panel; and, a plurality of second protuberances rigidly joined to said juxtaposed edge of the second of said ceiling panels extending outwardly therefrom overlying said upper edge of said base wall panel at one of said areas for receiving vertical load and resting on the edge of said base wall panel to vertically load said panels.

11. The invention of claim 10 and wherein, embeddable members are attached to the edges of said ceiling panels for embedment within said poured and cured grout.

15. The invention of claim 14 and wherein, said interstitial support means is adapted to maintain a preselected spatial interval between the top edge of said first wall panels and the bottom edge of said second wall panels.