Non-combustible reinforced cementitious lightweight panels and metal frame system for building foundations
First Claim
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1. A method of building a foundation system in a building, comprising the step of:
- assembling an exterior vertical wall by attaching reinforced, lightweight, dimensionally stable structural cementitious panels to vertical metal studs of a metal frame to form a first vertical shear diaphragm;
locating at least a portion of the first vertical shear diaphragm below ground level and in contact with ground;
providing below ground level footings, the footings in contact with the ground below the footings;
the frame further comprising upper horizontal members above the studs and lower horizontal members below the studs, the studs attached to the upper and lower horizontal members, the lower horizontal members resting on the footings, the studs attached to the upper and lower horizontal members, the upper and lower horizontal members selected from at least one member of the group consisting of a C- joist and a plate;
wherein the cementitious panel is attached to the metal framing member by metal screws with winged drillers to provide a shear load bearing wall system, wherein the winged drillers are located above the point and below the threads of the screws, and protruding laterally from the shaft of the screws,wherein, the cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis,49 to 68 weight % reactive powder,23 to 36.1 weight % lightweight filler particles comprising ceramic microspheres having a particle density of 0.50 to 0.80 g/ml and an average particle size of about 10 to 500 microns (micrometers), and5 to 20 weight % glass fibers comprising alkali-resistant glass fibers, the continuous phase being reinforced with the glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm), andoptional superplasticizer,wherein the reactive powders comprise, on a dry basis,45 to 75 wt. % calcium sulfate alpha-hemihydrate,20 to 40 wt. % Portland cement,0.2 to 3.5 wt. % lime, and5 to 25 wt. % of an active pozzolan comprising silica fume,wherein the structural cementitious panel has a flexural strength, after being soaked in water for 48 hours, of at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003, and wherein the structural cementitious panel has a thickness of about ½
to 1 ½
inches.
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Abstract
A foundation system includes metal framing members that support a reinforced, lightweight, dimensionally stable cementitious panel. The foundation system is non-combustible, water durable, mold and rot resistant, and termite resistant. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, for example, calcium sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime. The continuous phase is reinforced with glass fibers and contains lightweight filler particles, for example, ceramic microspheres.
97 Citations
20 Claims
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1. A method of building a foundation system in a building, comprising the step of:
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assembling an exterior vertical wall by attaching reinforced, lightweight, dimensionally stable structural cementitious panels to vertical metal studs of a metal frame to form a first vertical shear diaphragm; locating at least a portion of the first vertical shear diaphragm below ground level and in contact with ground; providing below ground level footings, the footings in contact with the ground below the footings; the frame further comprising upper horizontal members above the studs and lower horizontal members below the studs, the studs attached to the upper and lower horizontal members, the lower horizontal members resting on the footings, the studs attached to the upper and lower horizontal members, the upper and lower horizontal members selected from at least one member of the group consisting of a C- joist and a plate; wherein the cementitious panel is attached to the metal framing member by metal screws with winged drillers to provide a shear load bearing wall system, wherein the winged drillers are located above the point and below the threads of the screws, and protruding laterally from the shaft of the screws, wherein, the cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 49 to 68 weight % reactive powder, 23 to 36.1 weight % lightweight filler particles comprising ceramic microspheres having a particle density of 0.50 to 0.80 g/ml and an average particle size of about 10 to 500 microns (micrometers), and 5 to 20 weight % glass fibers comprising alkali-resistant glass fibers, the continuous phase being reinforced with the glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm), and optional superplasticizer, wherein the reactive powders comprise, on a dry basis, 45 to 75 wt. % calcium sulfate alpha-hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, wherein the structural cementitious panel has a flexural strength, after being soaked in water for 48 hours, of at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003, and wherein the structural cementitious panel has a thickness of about ½
to 1 ½
inches. - View Dependent Claims (2, 3)
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4. A foundation system for a commercial or residential building, the foundation system comprising:
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at least one vertical exterior wall comprising a first exterior vertical wall diaphragm, a metal frame, and a second interior vertical wall diaphragm;
the metal frame comprising vertical metal studs, the first diaphragm and the second diaphragm supported on opposed sides of the metal frame studs,ground in contact with at least a below ground level portion of an outer surface of the at least one exterior wall diaphragm, footings in contact with ground below the footings, the at least one exterior vertical wall diaphragm comprising at least one reinforced, lightweight, dimensionally stable structural cementitious panel, and the frame further comprising upper horizontal members above the studs and lower horizontal members below the studs, the studs attached to the upper and lower horizontal members, the lower horizontal members resting on the footings, the studs attached to the upper and lower horizontal members, the upper and lower horizontal members selected from at least one member of the group consisting of a C-joist and a plate; metal screw fasteners with winged drillers for fastening the structural cementitious panel to the metal studs, the winged drillers located above the point and below the threads of the screw and protruding laterally from a shaft of the screw; the structural cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 49 to 68 weight % a blend of reactive powders, 23 to 36.1 weight % lightweight filler particles comprising uniformly distributed ceramic microspheres, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer, the continuous phase being uniformly reinforced with the glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm), the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), wherein the reactive powders comprise, on a dry basis, 45 to 75 wt. % calcium sulfate alpha-hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, wherein the structural cementitious panel has a flexural strength, after being soaked in water for 48 hours, of at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003, wherein the structural cementitious panel has a thickness of about ½
to 1 ½
inches. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A foundation floor system for a commercial or residential building, the foundation floor system comprising:
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below ground level footings, ground below the footings, the footings in contact with the ground below the footings; a foundation floor diaphragm comprising at least one exterior horizontal reinforced, lightweight, dimensionally stable structural cementitious panel, wherein the floor diaphragm has a horizontal design shear capacity of 300 to 1000 pounds per linear foot, a horizontal metal frame having opposed upper and lower surfaces, the at least one structural cementitious panel supported on the upper surface of the metal frame, the lower surface of the metal frame opposed to ground below the metal frame; at least a portion of the at least one structural cementitious panel being below ground level; and the metal frame comprising a perimeter of horizontal metal rim joists resting on the footings and horizontal metal floor joists attached to the metal rim joists; a lower surface of the at least one structural cementitious panel supported on the metal floor frame, the at least one structural cementitious panel attached to the metal floor frame, the horizontal exterior foundation floor diaphragm having a lower surface directly facing ground underneath the metal floor frame; and metal screw fasteners with winged drillers, wherein the winged drillers are located above the point and below the threads of the screw, and protruding laterally from the shaft of the screw; the at least one structural cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising water and, on a dry basis, 49 to 68 weight % a blend of reactive powders, 23 to 36.1 weight % lightweight filler particles comprising uniformly distributed ceramic microspheres, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer, the continuous phase being uniformly reinforced with the glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm), the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), wherein the blend of reactive powders comprise, on a dry basis, 45 to 75 wt. % calcium sulfate alpha-hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, wherein the panel has a flexural strength, after being soaked in water for 48 hours, of at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003, and wherein the structural cementitious panel has a thickness of about ½
to 1 ½
inches. - View Dependent Claims (19, 20)
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Specification