Method for interlocking molded building panels

Abstract

A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel and adjacent panel edges form a generally horizontal beam channel, atop a poured foundation or other supporting structure to fabricate a building wall, which includes the steps of: placing into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, a first rebar that extends at least partially into the joint post channel; inserting a second rebar into the joint post channel so that a first end is juxtaposed with the extending end of the first rebar, and a second, opposite end extends from the joint post channel; bending the second, extending end of the second rebar so that once bent, it lies in the generally horizontal beam channel intersecting with the joint post channel; and, filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete. Further disclosed is a method for creating openings useful for window and door frames in such construction.

What is claimed is:  
     
         1 . A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each generally vertical panel edge and the top panel edge, so that abutting panel edges form a generally vertical joint post channel and adjacent panel edges form a generally horizontal beam channel, atop a foundation or other supporting structure, to fabricate a building wall, comprising the steps of: 
 placing into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, a first rebar that extends at least partially into the joint post channel;    inserting a second rebar into the joint post channel so that a first end is juxtaposed with the extending end of the first rebar, and a second, opposite end extends to the top of the joint post channel and bends so that it lies in the generally horizontal beam channel intersecting with the joint post channel; and,    filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete.    
     
     
         2 . A method as in  claim 1  further comprising the step of: 
 inserting a third rebar in the generally horizontal beam channel across the joint post channel.  
 
     
     
         3 . A method as in  claim 1  wherein the step of placing a first rebar into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, further comprises the steps of: 
 marking a drill point on the supporting structure where the joint post channels are formed between abutting panels;  
 drilling a hole into the supporting structure at the drill point;  
 injecting an epoxy holding compound into the drilled hole; and,  
 inserting the first rebar into the drilled hole so that it partially extends in a generally vertical direction from the supporting structure.  
 
     
     
         4 . A method as in  claim 1  wherein the step of placing a first rebar into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, further comprises the steps of: 
 marking an embedding point on the supporting structure where the joint post channels are formed between abutting panels; and,  
 embedding the first rebar into the supporting structure while the supporting structure is being poured so that it partially extends in a generally vertical direction from the supporting structure.  
 
     
     
         5 . A method as in  claim 1  wherein the step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of: 
 pumping the concrete into both the generally vertical joint post channel and the generally horizontal beam channel.  
 
     
     
         6 . A method as in  claim 5  wherein the step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of: 
 using a pressurized hose to pump the concrete into both the generally vertical joint post channel and the generally horizontal beam channel.  
 
     
     
         7 . A method as in  claim 5  wherein the step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of: 
 pumping sufficient concrete to fill both the generally vertical joint post channels and the generally horizontal beam channels in one continuous pour.  
 
     
     
         8 . A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel, where the abutting edges of the panels are of unequal length, so that a portion of the channel formed in the longer panel edge is exposed, comprising the steps of: 
 covering the exposed portion of the channel formed in the longer panel edge with a mold to form a sealed joint post channel;    filling the sealed joint post channel with concrete; and,    removing the mold from the exposed portion of the channel formed in the longer panel edge once the concrete filling the sealed joint post channel has hardened.    
     
     
         9 . A method as in  claim 8  further comprising the step of: 
 inserting and releasably retaining fittings for anchoring bolts on the inside of the mold; and,  
 embedding the fittings on the inside of the mold in the concrete filling the joint post channel.  
 
     
     
         10 . A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel, where the abutting edges of the panels are of unequal length, so that a portion of the channel formed in the longer panel edge is exposed, comprising the steps of: 
 covering the exposed portion of the channel formed in the longer panel edge with a mold to form a sealed joint post channel;    Drilling a hole in the grout dam or mold that covers the exposed portion of the vertical or horizontal post channel in an opening creating a door or window frame;    Inserting a hollow tubing in the vertical or horizontal post channel so that a first end of the tubing protrudes through the hole in the grout dam or mold, and a second, opposite end extends out of the channel, the tubing providing a passageway for wiring through the channel once the channel is filled with concrete;    filling the sealed joint post channel with concrete; and,    removing the mold from the exposed portion of the channel formed in the longer panel edge once the concrete filling the sealed joint post channel has hardened.