Prefabricated Panel for Constructing Structures and Methods of Making Such Panels and Constructing Structures with Such Panels

Abstract

A prefabricated panel comprising autoclaved aerated concrete for constructing residential, commercial and industrial buildings and other structures including a first facing bonded to one side of the autoclaved aerated concrete, a second facing bonded to the other side of the autoclaved aerated concrete, and reinforcement members that provide structural integrity to the panel and enable the panel to be readily transported to the construction. A method for constructing residential, commercial and industrial buildings and other structures with the prefabricated panels, including constructing the prefabricated panels, transporting the prefabricated panels, and securing together the prefabricated panels with securement means.

1 . A prefabricated panel for constructing residential, commercial, and industrial structures comprising:
 a base panel formed from multiple sections of aerated concrete, the multiple sections coupled together with a binder;   a series of spaced apart reinforcing structures extending from a first end of the base panel to a second end of the base panel to aid in retaining the orientation of the multiple sections of aerated concrete to provide structural integrity;   at least one reinforcement base structure positioned at the first end of the base panel, the reinforcing structures configured to be coupled to the reinforcement base structure,   a second reinforcement structure positioned at the second end of the base panel; and   wherein the prefabricated panel is transportable as a single unit to a construction site and used with other prefabricated panels to form a structure.   
   
   
       2 . The prefabricated panel of  claim 1 , further including a first facing material covering a first side of the base panel. 
   
   
       3 . The prefabricated panel of  claim 2 , further including a second facing material covering a second side of the base panel. 
   
   
       4 . The prefabricated panel of  claim 2 , wherein the first facing material is a thin-set brick. 
   
   
       5 . The prefabricated panel of  claim 1 , wherein the base panel includes a base structure extending along the width of the panel, the base structure at least partially formed from aerated concrete and includes a reinforcement structure embedded in the concrete. 
   
   
       6 . The prefabricated panel of  claim 5 , wherein the base panel also includes a series of blocks stacked on the base structure, the blocks being coupled to the base and coupled together by use of the binder. 
   
   
       7 . The prefabricated panel of  claim 1 , wherein the reinforcing structures are in the form of steel rods that extend vertically through the base panel. 
   
   
       8 . The prefabricated panel of  claim 7 , wherein the rods are threaded and configured to accept fasteners. 
   
   
       9 . The prefabricated panel of  claim 8 , wherein the first and second reinforcement structures are coupled to the rods by use of the fasteners. 
   
   
       10 . The prefabricated panel of  claim 1 , further including a lifting beam that is coupled to the reinforcing structures to allow the base panel to be transported. 
   
   
       11 . The prefabricated panel of  claim 1 , wherein the base panel is configured to include channels along the edges that extend along the height of the base panel, the channels are configured to accept splices to allow adjacent base panels to be coupled together. 
   
   
       12 . The prefabricated panel of  claim 1 , wherein the base panel includes a base structure extending along the width of the panel, the base structure formed from a channel shaped block filled with mortar and rebar. 
   
   
       13 . A prefabricated panel for constructing residential, commercial, and industrial structures comprising:
 a base panel formed from multiple sections of aerated concrete, the multiple sections being stacked on one another and coupled together with a binder to form the base panel;   a series of spaced apart reinforcing rods extending through the multiple sections from a first end of the base panel to a second end of the base panel, the reinforcing rods configured to aid in retaining the orientation of the multiple sections of aerated concrete to provide structural integrity to the base panel;   at least one first reinforcement plate positioned at the first end of the base panel, the reinforcing rods configured to be coupled to the at least one first reinforcement plate,   at least one second reinforcement plate positioned at the second end of the base panel, the reinforcing rods configured to be coupled to the at least one second reinforcement plate; and   wherein the prefabricated panel is transportable as a single unit to a construction site and used with other prefabricated panels to form a structure.   
   
   
       14 . The prefabricated panel of  claim 13 , further including a first facing material covering a first side of the base panel. 
   
   
       15 . The prefabricated panel of  claim 14 , further including a second facing material covering a second side of the base panel. 
   
   
       16 . The prefabricated panel of  claim 14 , wherein the first facing material is a thin-set brick. 
   
   
       17 . The prefabricated panel of  claim 13 , wherein the base panel includes a base structure extending along the width of the base panel, the base structure formed at least partly from aerated concrete and includes a reinforcement structure embedded within the base structure. 
   
   
       18 . The prefabricated panel of  claim 17 , wherein the base panel also includes a series of blocks stacked on the base structure, the block being coupled to the base and together by use of the binder. 
   
   
       19 . The prefabricated panel of  claim 13 , wherein the rods are threaded and configured to accept fasteners. 
   
   
       20 . A building structure comprising:
 a series of prefabricated panels configured to be coupled at their ends to form a wall structure, each of the panels including:   a base panel formed from multiple sections of aerated concrete, the multiple sections being stacked on one another and coupled together with a binder to form the base panel;   a series of spaced apart reinforcing members extending through the multiple sections from a first end of the base panel to a second end of the base panel, the reinforcing members configured to aid in retaining the orientation of the multiple sections of aerated concrete to provide structural integrity to the base panel;   at least one first reinforcement plate positioned at the first end of the base panel, the reinforcing members configured to be coupled to the at least one first reinforcement plate,   at least one second reinforcement plate positioned at the second end of the base panel, the reinforcing rods configured to be coupled to the at least one second reinforcement plate;   a first facing material covering a first side of the base panel; and   a second facing material covering a second side of the base panel.