Light weight sandwich panels

Abstract

Light weight structural wall panels are made of two layers of load bearing skins, separated by a light-weight concrete, using expanded materials such as Perlite, Pulverized Fuel Ash, Styrene or foam cement to form a sandwiched construction for structural strength. The load-bearing skins, which are sprayed into a mold, are made of glass fiber, sand and cement matrix in different thickness and mix ratios. All edges of the encapsulated panels are made of the same GFRC matrix. The distance between GFRC inner & outer layers dictates the required structural strength of overall finished panel to resist wind & earthquake loadings. The sprayed layers and the core are made/cast while the concrete is green, before its initial setting-time to ensure structural integrity of components after curing.

1 . A method of making a building panel, comprising the steps of: 
 providing a mold;    spraying sides and bottom of said mold with a stress skin material;    filling said mold with concrete immediately after said step of spraying said sides and bottom of said mold;    spraying said stress skin material onto said concrete while said concrete is in an initial stage of setting.    
   
   
       2 . The method according to  claim 1 , wherein: 
 said stress skin material comprises a fiberglass and cement matrix.    
   
   
       3 . The method according to  claim 2 , wherein: 
 said fiberglass is alkali resistant.    
   
   
       4 . The method according to  claim 1 , wherein: 
 said concrete comprises a light aggregate and cement matrix.    
   
   
       5 . The method according to  claim 4 , wherein: 
 said light aggregate comprises perlite.    
   
   
       6 . The method according to  claim 4 , wherein: 
 said light aggregate comprises styrene beads.    
   
   
       7 . A building panel, comprising: 
 a first stress skin;    a second stress skin;    a concrete core provided between said first stress skin and said second stress skin.    
   
   
       8 . The building panel according to  claim 7 , wherein: 
 at least one of said first and second stress skins comprises a fiberglass and cement matrix.    
   
   
       9 . The building panel according to  claim 8 , wherein: 
 said fiberglass is alkali resistant.    
   
   
       10 . The building panel according to  claim 7 , wherein: 
 said concrete core comprises a light aggregate and cement matrix.    
   
   
       11 . The building panel according to  claim 10 , wherein: 
 said light aggregate comprises perlite.    
   
   
       12 . The building panel according to  claim 10 , wherein: 
 said light aggregate comprises styrene beads.    
   
   
       13 . The building panel according to  claim 17 , wherein: 
 said building panel is a ceiling panel and comprises at least one I-beam and at least two structural beams;    said I-beam spanning between said structural beams.    
   
   
       14 . A system for supporting building panels, comprising: 
 at least one building panel provided with a groove in at least one edge thereof;    an adjustable hold-down device provided with a v-shaped shoe at a distal end thereof;    an anchor configured to attach said hold-down device to a slab at a proximal end thereof; and    a fastener configured to secure said shoe in said groove.    
   
   
       15 . The system according to  claim 14 , wherein: 
 said shoe is provided with a rubber surface on a side thereof facing said groove.    
   
   
       16 . The system according to  claim 14 , wherein: 
 said fastener is a bolt with an adjustable sleeve.    
   
   
       17 . The system according to  claim 16 , wherein: 
 said bolt is provided with a rubber washer.    
   
   
       18 . The system according to  claim 14 , wherein: 
 said anchor comprises an adjustable pulley.    
   
   
       19 . The system according to  claim 14 , further comprising: 
 at least one reinforcing bar placed in a space defined by said at least one groove in said building panel and a corresponding groove of an adjacent said building panel.    
   
   
       20 . The system according to  claim 19 , further comprising: 
 cement grout in said defined space.