Wall panel and method

Abstract

The disclosure provides a system and method for constructing support structures in buildings or other projects, which can support molds for use when pouring reinforced concrete slabs. The disclosed structures can accommodate more than one molds stacked vertically one over the other, and can remain in place to define walls or other separators in the completed structure. In one embodiment, the disclosed structure is a wall panel including a frame and vertical support members. The wall panel includes features allowing the vertical stacking of multiple wall panels. The wall panel includes a load distribution member in the form of a T-beam with a web portion disposed between the vertical support members.

1 . A wall panel configured as a load bearing structure for supporting vertical loading in a building, the wall panel comprising:
 a box frame having a generally rectangular shape, the box frame including:
 a load distribution member disposed at a top of the box frame, 
 a bottom member, and 
 two sets of side rails interconnecting the load distribution member and bottom member, wherein each set of side rails includes two side rail members extending parallel to one another and defining a gap therebetween; 
   a plurality of vertical supports disposed parallel to one another and to the side rails extending between the load distribution member and bottom member of the box frame, each vertical support including two vertical support members extending parallel to one another and defining an additional gap therebetween that is substantially aligned along the length of the wall panel with the gaps defined the side rail pairs;   wherein the load distribution member includes a T-beam having a flange connected to the side rails and the vertical supports and having a web extending down from the flange and disposed within each gap between the respective sets of side rails and within each additional gap between the respective vertical support members of each support, the load distribution member being configured to distribute loading applied vertically from above the load distribution member substantially evenly along the length of the bottom member.   
     
     
         2 . The wall panel of  claim 1 , wherein the side rails and vertical support members are made of rectangular steel tube stock. 
     
     
         3 . The wall panel of  claim 1 , wherein the bottom rail is made of cold-formed steel sheet having a U-section. 
     
     
         4 . The wall panel of  claim 1 , wherein each set of side rails includes a first side rail disposed along a first outer edge of the wall panel and a second side rail disposed along a second outer edge of the wall panel. 
     
     
         5 . The wall panel of  claim 1 , wherein the respective gaps and additional gaps provide a passageway for conduits or pipes extending through the wall panel. 
     
     
         6 . The wall panel of  claim 1 , further comprising a bridging rail extending horizontally along the length of the wall panel and disposed at about the midsection of the wall panel. 
     
     
         7 . The wall panel of  claim 1 , further comprising an interconnection device adapted to interconnect the wall panel with an additional wall panel, wherein the interconnection device includes two blocks, each block having a hole and disposed on either end of the wall panel atop respective ends of the load distribution member, wherein each block is made of a section of rectangular tube stock, wherein each hole extends through a top side wall of each block to accommodate a fastener therethrough for connecting the additional panel. 
     
     
         8 . The wall panel of  claim 7 , further comprising two angled brackets, each disposed, at a respective end of the wall panel along an inner horizontal surface of the bottom member, wherein the two angled brackets are configured to provide structural reinforcement around a hole formed in the bottom member that is aligned with the hole in the corresponding block. 
     
     
         9 . The wall panel of  claim 1 , further comprising two cross braces which extend in an “X” configuration between the four corners of the box frame. 
     
     
         10 . A building system, comprising:
 a plurality of inter-connectable wall panels configured to be assembled into a load bearing structure for a building;   each wall panel comprising a box frame having a generally rectangular shape, the box frame including:
 a load distribution member disposed at a top of the box frame and including a T-beam having a flange and a web, 
 a bottom member, and 
 two sets of side rails interconnecting the load distribution member and bottom rail, wherein a top of each side rail abuts the flange of the T-beam and each set of side rails includes two side rail members extending parallel to one another, disposed on respective opposite sides of the web of the T-beam and defining a gap therebetween; 
 a plurality of vertical supports disposed parallel to one another and to the side rails and extending between the load distribution member and bottom member, each vertical support including two vertical support members extending parallel to one another, disposed on respective opposite sides of the T-beam and defining an additional gap therebetween that is substantially aligned along the length of the wall panel with the gaps defined by the side rails; and 
   an interconnection device adapted to interconnect each wall panel with an additional wall panel, wherein the interconnection device includes two blocks, each block having a hole and being disposed on either end of the wall panel atop respective ends of the load distribution member, wherein each block is made of a section of rectangular tube stock, wherein each hole extends through a top side wall of each block to accommodate a fastener therethrough for connecting the additional panel;   wherein the load distribution member of each wall panel is configured to distribute loading applied vertically from above the load distribution member substantially evenly along the length of the bottom member of the respective wall panel.   
     
     
         11 . The building system of  claim 10 , wherein the side rails and vertical support members of each wall panel are made of rectangular steel tube stock. 
     
     
         12 . The building system of  claim 10 , wherein the bottom member of each wall panel includes a light gage track made of cold-formed steel sheet having a U-section and a support plate below the light gage track. 
     
     
         13 . The building system of  claim 10 , wherein each set of side rails of each wall panel includes a first side rail disposed along a first outer edge of the wall panel and a second side rail disposed along a second outer edge of the wall panel. 
     
     
         14 . The building system of  claim 10 , wherein each gap provides a passageway for conduits or pipes extending through the respective wall panel. 
     
     
         15 . The building system of  claim 10 , wherein each wall panel includes a bridging rail extending horizontally along the length of the wall panel and disposed at about the midsection of the wall panel. 
     
     
         16 . The building system of  claim 10 , wherein each wall panel includes two angled brackets respectively disposed at each end of the respective wall panel along an inner horizontal surface of the bottom member, wherein the two angled brackets are configured to provide structural reinforcement around a hole formed in the bottom member that is aligned with the hole in the corresponding block. 
     
     
         17 . The building system of  claim 10 , wherein the vertical support members of a first of the plurality of interconnectable wall panels are formed of a stronger structural member than the vertical support members of a second of the plurality of interconnectable wall panels.