Structure and formulation for manufacture of prefabricated buildings

• US 6,073,410 A
• Filed: 10/14/1998
• Issued: 06/13/2000
• Est. Priority Date: 10/14/1998
• Status: Expired due to Fees

• Current Assignee: Advanced Wall Systems LLC
• Original Assignee: ECO Buliding Systems Incorporated
• Inventors: Harrel, Marcus J., Schimpf, Michael J.
• Primary Examiner(s): Canfield, Robert
• Application Number:
  US09/172,741
• Time in Patent Office: 608 Days
• Field of Search: 52/483.1, 52/474, 52/434, 52/435, 52/801.1, 52/250, 52/319, 52/326, 52/327, 52/333, 52/335, 52/338, 52/341, 52/479, 52/481.1, 52/489.1, 156/71, 156/291, 428/294.7, 106/711, 106/724, 106/802, 106/810, 106/823
• US Class Current: 52/481.1
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]

Abstract

The present invention resides in a wall unit and formulation which is particularly advantageous for the manufacture of prefabricated buildings. The wall unit uses a uniquely formulated exterior wall panel that is bonded to a frame of tri-chord steel beams. The unique cementitious composition of the wall unit allows it to be fire and insect resistant and generally impervious to moisture.

Claims

1. A structure, comprising:

a cementitious panel;

a frame of steel beams having opposed triangular end portions; and

cementitious bonding pads that attach the frame, at one of the triangular end portions of the steel beans, to the panel.

2. A structure as defined in claim 1, wherein the cementitious panel and the cementitious bonding pads are formed of a composition, by weight, of greater than 25% cement, less than 55% sand, less than 5% glass fibers, greater than 1.6% acrylic polymer, and greater than 11% water.

3. A structure as defined in claim 1, wherein the cementitious panel and the cementitious bonding pads are formed of a composition, by weight, of about 40.3% cement, about 40.3% sand, about 2.9% glass fibers, about 4.0% acrylic polymer, about 0.4% super plasticizer and about 12.1% water.

4. A structure as defined in claim 1, wherein the cementitious bonding pads enclose segments of the triangular end portions of the respective steel beams.

5. A structure as defined in claim 1, further comprising a gravity strap that is attached to each beam at a location on the respective beam corresponding to the cementitious bonding pad that is closest to a bottom edge of the structure.

6. A structure as defined in claim 1, wherein the height of the structure along the beams is about 8 feet, the cementitious panel has a thickness of about 5/8 inches, and the cementitious bonding pads are spaced about 21 inches apart center-to-center.

7. A cementitious panel composition comprising (by weight) at least 25% cement, less than 55% sand, less than 5% glass fibers, at least 1.6% acrylic polymer, and at least 11% water.

8. A cementitious panel composition comprising (by weight) about 40.3% cement, about 40.3% sand, about 2.9% glass fibers, about 4.0% acrylic polymer, about 0.4% super plasticizer and about 12.1% water.

9. A structure comprising a cementitious panel formed of a composition as defined in claim 8, a frame of steel beams having opposed triangular end portions, and a cementitious pad that attaches the frame, at one of the triangular end portions of the steel beams, to the panel.