U.S. patent application number 10/473913 was filed with the patent office on 2004-06-03 for building structure and modular construction method.
Invention is credited to Bergqvist, Tonny.
Application Number | 20040103601 10/473913 |
Document ID | / |
Family ID | 3828229 |
Filed Date | 2004-06-03 |
United States Patent
Application |
20040103601 |
Kind Code |
A1 |
Bergqvist, Tonny |
June 3, 2004 |
Building structure and modular construction method
Abstract
A building structure comprising one or more modular panels (5);
a wall locating member (12) positioned between a base (2) and the
one or more modular panels (5); a top member (19) placed on top of
the modular panels (5); and a plurality of tie rods (14). The
modular panels (5) when adjoining to form a wall create
longitudinal cavities (16) within the wall. The plurality of tie
rods (14) extend through said longitudinal cavities (16) and secure
said top member (19), walls (3) and wall locating member (12) to
the base (2).
Inventors: |
Bergqvist, Tonny;
(Maroochydore, AU) |
Correspondence
Address: |
Fish & Richardson
Suite 500
4350 La Jolla Drive
San Diego
CA
92122
US
|
Family ID: |
3828229 |
Appl. No.: |
10/473913 |
Filed: |
October 3, 2003 |
PCT Filed: |
May 30, 2001 |
PCT NO: |
PCT/AU01/00642 |
Current U.S.
Class: |
52/284 ; 52/157;
52/293.3 |
Current CPC
Class: |
E04D 3/363 20130101;
E04B 1/14 20130101; E02D 5/801 20130101; E04B 2001/3583 20130101;
E04D 3/355 20130101; E04D 3/366 20130101; E02D 27/12 20130101; E04D
3/352 20130101 |
Class at
Publication: |
052/284 ;
052/293.3; 052/157 |
International
Class: |
E02D 005/74; E04B
001/00; E04B 005/00; E04B 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 5, 2001 |
AU |
PR 4229 |
Claims
1. A building structure comprising: one or more modular panels; a
wall locating member positioned between a base and the one or more
modular panels; a top member placed on top of the modular panels;
and a plurality of tie rods; wherein, said modular panels when
adjoining to form a wall create longitudinal cavities within the
wall; and wherein, the plurality of tie rods extend through said
longitudinal cavities and secure said top member, walls and wall
locating member to the base.
2. The building structure of claim 1, wherein the top member is a
capping member.
3. The building structure of claim 1, wherein the top member is a
compression member.
4. The building structure of claim 1, wherein the top member
comprises a capping member and a compression member.
5. The building structure of claim 1, wherein the modular panels
comprise recesses on opposing longitudinal sides of the adjoining
panels, thereby defining, in use, the longitudinal cavity between
the adjoining modular panels.
6. The building structure of claim 1, wherein the wall locating
member and the top member are both C section channelling.
7. The building structure of claim 1, wherein an upright channel
member is fixed to one face of a modular panel for locating modular
panels to form a comer or internal wall.
8. The building structure of claim 1, wherein the tie rods are
releasably engageable with mounts provided at predetermined
positions along the base.
9. The building structure of claim 1, wherein the modular panels
are of a laminated construction.
10. The building structure of claim 9, wherein the modular panels
are formed from foamed plastics laminated panels having at least
one outer skin member.
11. The building structure of claim 1, wherein the modular panels
comprise an additional longitudinal aperture, located inwardly from
the longitudinal recess, for accommodating a tie rod in the
formation of a comer or join.
12. The building structure of claim 1, wherein the base includes a
floor structure, which may optionally be of modular construction,
also employing laminated panels.
13. The building structure of claim 12, wherein the laminated
panels for the floor comprise a ribbed outer steel skin, a foamed
plastic core and a ribbed inner skin, and preferably the floor is
lined with composite flooring, waterproof ply or timber floor.
14. The building structure of claim 1, further comprising a roof
structure supported by the walls.
15. The building structure of claim 14, wherein the roof structure
is also of modular construction, and employing further laminated
panels.
16. The building structure of claim 15, wherein the laminated
panels for the roof comprise a ribbed outer steel skin, a foamed
plastic core and a ribbed inner skin and are preferably lined with
fibre-cement board, plasterboard, random grooved ply or timber.
17. A method of construction including the steps of: placing one or
more wall locating members on a base; erecting one or more modular
panels on the wall locating members to form one or more walls;
engaging adjacent modular panels to define longitudinal cavities
between longitudinal recesses formed on upright sides of said
modular panels; placing a top member on the upper edge of the
modular panels; inserting tie rods through the top member and
longitudinal cavities; connecting the tie rods to the base to
secure the top member, modular panels and wall locating member
thereto, to form walls.
18. The method of construction of claim 17, wherein the step of
placing the top member on the upper edge of the modular panels
comprises the steps of; placing a capping member on the upper edge
of the modular panel; and placing a compression member on top of
the capping member.
19. A modular panel for use in the building structure of claim 1 or
method of construction of claim 17, wherein said modular panel
comprises: a core of foamed plastics material; at least one outer
skin member bonded to said core; two longitudinal recesses on
opposing longitudinal sides of the modular panel which define, in
use, a longitudinal cavity extending along the junction between
adjoining modular panels.
20. The modular panels of claim 19, wherein the modular panel
further comprises an additional longitudinal cavity, sized so as to
receive a tie rod; wherein the longitudinal cavity is located
toward an end of the modular panel but in from the longitudinal
recess.
Description
[0001] THIS INVENTION relates to building structures employing
modular structural panels and also to an improved construction
method for assembling such modular panels to form such a
building.
BACKGROUND TO THE INVENTION
[0002] The prior art is replete with modular building structures
and associated construction methods, many of which suffer from a
variety of problems. Amongst such problems are included the
complexity of assembling elaborate framing systems to which modular
panels are attached, the inconvenience attendant the use of plural
individual fasteners to fix structural panels to one another, and
the poor structural strength of some modular structures.
[0003] An example of a prior art modular construction arrangement
which employs a plurality of fasteners is U.S. Pat. No. 4,858,398
in the name of Ricchini. Ricchini discloses a structure using
proportionally sized panels secured together by turn-lock fasteners
inserted through aligned openings in adjacent sides of panels.
[0004] A further exemplary prior art construction arrangement is
that disclosed in French Patent Document Number 2389724 in the name
of Batimpro S A. This document discloses a modular building using
panels having adjacent vertical sides of complementary shapes. The
panels are joined together by screws and are reinforced with metal
plates at the location of the joints.
[0005] Reference may also be made to the method and apparatus for
manufacturing foamed plastics laminated panels for modular building
applications as disclosed in the applicant's Australian Patent No.
620338. Panels manufactured in the manner described therein are an
example of those suitable for use with the present invention. One
particular advantage of the applicant's previously disclosed method
is that the panels may be conveniently fabricated at the building
site.
OBJECT OF THE INVENTION
[0006] It is an object of the present invention to provide a
building structure employing modular panels which overcomes or
ameliorates at least some of the problems associated with the prior
art.
[0007] It is a further object of the invention to provide a
construction method employing modular panels which is simple but
maintains the structural integrity of a completed building
structure, thus providing a more convenient alternative to those
presently available.
[0008] A yet further object of the invention is to provide a
laminated modular panel adapted for use with the building structure
and/or construction method which may also be expediently
fabricated.
[0009] Further objects will be evident from the following
description.
DISCLOSURE OF THE INVENTION
[0010] In one form, although it need not be the only or indeed the
broadest form, the invention resides in a building structure
comprising:
[0011] one or more modular panels;
[0012] a wall locating member positioned between a base and the one
or more modular panels;
[0013] a top member placed on top of the modular panels; and
[0014] a plurality of tie rods;
[0015] wherein, said modular panels when adjoining to form a wall
create longitudinal cavities within the wall; and
[0016] wherein, the plurality of tie rods extend through said
longitudinal cavities and secure said top member, walls and wall
locating member to the base.
[0017] It is preferable that the modular panels comprise recesses
on opposing longitudinal sides (herein after referred to as the
longitudinal recess) of the adjoining panels, thereby defining, in
use, the longitudinal cavity between the adjoining modular
panels.
[0018] The top member provides a capping and/or compression feature
to the walls of the building structure. The top member may comprise
a capping member and/or a compression member.
[0019] Suitably the wall locating member and the top member, when
it is a capping member, are both C section channelling. For the
wall locating member the C channelling is placed so as to form a U
and for the capping member the C channelling is placed so as to
form an inverted U over the top of the modular panels.
[0020] In one form an upright channel member may be fixed to one
face of a modular panel for locating modular panels to form a
corner or internal wall.
[0021] In preference the tie rods possess high tensile
strength.
[0022] The tie rods may be releasably engageable with mounts
provided at predetermined positions along the base.
[0023] In preference the modular panels are of a laminated
construction.
[0024] The modular panels are suitably formed from foamed plastics
laminated panels having at least one outer skin member.
[0025] The modular panels may comprise an additional longitudinal
aperture for accommodating a tie rod, located some distance in from
the longitudinal recess, for the formation of a corner or join.
[0026] It is preferable that the base includes a floor structure,
which may optionally be of modular construction, also employing
laminated panels. Suitably the laminated panels for the floor
comprise a ribbed outer steel skin, a foamed plastic core and a
ribbed inner skin. The laminated floor panels made of a ribbed
construction are preferably lined with composite flooring,
waterproof ply or timber floor.
[0027] The building structure may also include a roof structure
supported by the walls, which roof may also be of modular
construction, employing further laminated panels. The laminated
panels for the roof may comprise a ribbed outer steel skin, a
foamed plastic core and a ribbed inner skin. The ribbed roof panel
construction is preferably lined with fiber-cement board,
plasterboard, random grooved ply or timber.
[0028] In a further form the invention resides in a method of
construction including the steps of:
[0029] placing one or more wall locating members on a base;
[0030] erecting one or more modular panels on the wall locating
members to form one or more walls;
[0031] engaging adjacent modular panels to define longitudinal
cavities between longitudinal recesses formed on upright sides of
said modular panels;
[0032] placing a top member on the upper edge of the modular
panels;
[0033] inserting tie rods through the top member and longitudinal
cavities;
[0034] connecting the tie rods to the base to secure the top
member, modular panels and wall locating member thereto, to form
walls.
[0035] The step of placing the top member on the upper edge of the
modular panels may comprise the steps of;
[0036] placing a capping member on the upper edge of the modular
panel; and
[0037] is placing a compression member on top of the capping
member.
[0038] In a yet further form, the invention resides in a modular
panel for use in the abovementioned building structure or method of
construction, wherein said modular panel comprises:
[0039] a core of foamed plastics material;
[0040] at least one outer skin member bonded to said core;
[0041] two longitudinal recesses on opposing longitudinal sides of
the modular panel which define, in use, a longitudinal cavity
extending along the junction between adjoining modular panels.
[0042] The modular panels may have an additional longitudinal
cavity, sized so as to receive a tie rod, wherein the longitudinal
cavity is located toward an end of the modular panel but inwardly
from the longitudinal recess.
BRIEF DETAILS OF THE DRAWINGS
[0043] To assist in understanding the invention, preferred
embodiments will now be described with reference to the following
figures in which:
[0044] FIG. 1A is a front elevation of an exemplary building
structure;
[0045] FIG. 1B is an end elevation of the building structure;
[0046] FIG. 1C is a schematic plan view of the building structure
showing the arrangement of modular panels comprising the walls;
[0047] FIG. 2A is an enlarged partial sectional view of the
structure's base showing the junction of the floor structure with
an outer wall;
[0048] FIG. 2B is an enlarged sectional view of the portion of FIG.
2A in the circle.
[0049] FIG. 3A is an exploded isometric view illustrating the
erection of modular panels to form a wall, wherein the top member
is a capping member;
[0050] FIG. 3B is an exploded isometric view illustrating the
erection of modular panels to form a wall, wherein the top member
comprises a capping member and a compression member;
[0051] FIG. 3C is an enlarged detail view of an optional
arrangement for locating the bottom side of the modular panels;
[0052] FIG. 4 are enlarged sectional plan views of the aligned
laminated panels showing the configuration of the positive
positioning profiles on the laminated panels;
[0053] FIG. 5 is an enlarged partial sectional view of the roof
area showing an arrangement of the fascia;
[0054] FIG. 6A is an end elevation of a modular roof panel;
[0055] FIG. 6B is an enlarged detailed view of the showing the
positioning profiles on the roof panels;
[0056] FIG. 7 is an exploded isometric view showing the arrangement
of corner junctions and tee-junctions of the walls; and
DETAILED DESCRIPTION OF THE DRAWINGS
[0057] In general, FIG. 1 shows a building structure 1 in the
nature of a small dwelling which may be constructed in accordance
with the invention. The structure includes a base 2, a number of
walls 3 and a roof 4. The walls, whether external or entirely
internal, are composed of modular panels 5. The modular panels are
fabricated to a typical module size of 900 mm wide by 3.0 m high.
In some situations larger panels may be used, particularly to
accommodate the pitch of a roof. The modular panels are secured to
the base by tie rods (described later) which are disposed along the
walls at 900 mm centres 6. Additional tie rods are disposed at the
sides of openings in the walls 7 and at the comers 8 of the
building structure.
[0058] The wall panels may be erected on a concrete or timber floor
or, as illustrated in FIG. 2A, on a floor comprised of further
laminated panels attached to screw-in foundations. In the later
arrangement, the base 2 comprises floor panels 9 supported by an
inverted T member 10 mounted on screw-in foundations 11.
[0059] FIG. 2A also shows floor panels 9 are mounted to the other
half of the inverted T member 10 (the inner most horizontal face).
The floor panels 9 are generally attached via screws 17A.
[0060] FIG. 2B shows a wall locating member 12, in the form of a C
section channel, mounted on the outermost half of the inverted T
member 10. The modular wall panels 5 are located in the wall
locating member 12. Threaded studs 13, for securing respective tie
rods 14, are fastened to the horizontal face of the outer most half
of the inverted T member 10 by welding, screwing or the like and
protrude through the wall locating member 12 and into longitudinal
cavity 16 for engagement with a nut 15 fastened to the end of each
tie rod 14. The tie rods 14 extend through respective longitudinal
cavities 16 provided in the upright wall panels 5. The studs
project through the wall locating member 12, via an aperture
17.
[0061] The overall arrangement of wall panels may be better
understood by reference to the exploded view of the base 2 and
partially completed wall 3 shown in FIG. 3A and 3B. In accordance
with the invention, individual wall panels 5 are erected and
aligned such that the longitudinal cavities 16, which are defined
when the panels adjoin one another, correspond to the studs 13 and
cooperating apertures 18 in the wall locating member 12.
[0062] Each tie rod 14 is inserted into a respective longitudinal
cavity 16 and engaged with a stud 13 disposed at the lower
extremity of the cavity 16. The top member 19 is then placed so as
to form an inverted U over the top side of the wall panels.
Apertures 22 in the top member 19, are sized to accommodate the
shaft of the tie rods 14 and are spaced so as to correspond to the
studs 13. Thus the upper ends of the rods protrude through said
apertures 22 in the top member 19 when they are positioned on the
modular wall panels. The upper end of the tie rods 14 may be screw
threaded and engageable with a nut 23 to facilitate the tensioning
thereof. The nuts 23 are engaged with the rods and tightened
against the top member 19.
[0063] FIG. 3B illustrates the partial completion of a wall,
similar to that of FIG. 3A, but wherein the top member 19 comprises
a capping member 20 and a compression member 21. The compression
member 21 is placed on top of the capping member 20. Apertures 22
and 22A in both the capping member 20 and compression members 21
respectively, are sized to accommodate the shaft of the tie rods 14
and are spaced so as to correspond to the studs 13. Thus the upper
ends of the rods protrude through said apertures 22 and 22A in the
capping member 20 and the compression member 21 when they are
positioned on the modular wall panels. The upper end of the tie
rods may be screw threaded and engageable with a nut 23 to
facilitate the tensioning thereof. The nuts 23 are engaged with the
rods and tightened against the compression member 21.
[0064] FIG. 3C illustrates in detail the locating the modular
panels 5 placed in the wall locating member 12, so that the cavity
16 is aligned with the cooperating aperture 18 in the wall locating
member 12, to allow the tie rods 14 to engage with the base 2.
[0065] For ease of description the subsequent embodiments will
describe the top member comprising a capping member and a
compression member. It will be appreciated by the person skilled in
the are that the exact nature of the top plate may vary depending
on the building type under construction and the exact location of
the top plate(s) within the building construction.
[0066] In an alternative embodiment (not illustrated), the rods are
externally screw threaded at both lower and upper ends thereof. The
lower end engages with an internally screw threaded stud adapted,
for example, for friction fitting in holes drilled into a concrete
floor. Further alternatives for securing the tie rods will be
apparent to the skilled addressee. The use of tie rods, preferably
of high tensile strength, in accordance with the invention
overcomes problems with fasteners, such as screws or the like,
being pulled out of the modular panels in high wind load
conditions. The invention also overcomes any requirement for local
reinforcement of the modular panels which might otherwise add to
the cost and complexity of panel fabrication.
[0067] FIG. 4 shows in plan a schematic of one form of the
longitudinal recesses formed on the upright sides of the wall
panels. The lightweight panels 5 comprise a core 25 of foamed
plastics, such as polyurethane and outer skins, such as
fiber-cement sheeting 26. The core is typically 66 mm thick whilst
the skins are between 4.5 and 7.5 mm. The modular panels may be
made of a thinner inner skin and a thicker outer skin. The thinner
inner skin is typically 4.5 mm while the thicker outer skin is
typically 7.5 mm. The thicker outer skins may suitably be stucco
fiber, whilst the inner skins may suitably be a plasterboard or
timber finish. The longitudinal cavity 16 is formed from the two
recesses 27 and 27A on the facing edges of the panels, as shown on
the panels which are aligned with one another in FIG. 4A.
[0068] When the panels are adjoined, see FIG. 4B, a longitudinal
cavity 16 is formed between the recesses 27 and 27A. The cavity is
sized for accommodating a tie rod 14. Further subsidiary cavities
29 may be provided immediately under the panel skins for
accommodating building services such as electrical wiring (not
shown).
[0069] A first embodiment of a roof for the building structure is
illustrated in FIG. 5. In this embodiment the roof 4 has a minimum
pitch, typically of from 3 to 10 degrees, and is supported directly
by the external walls 30 and by the internal walls 31. The roof may
also be comprised of modular panels as discussed in more detail
below in relation to FIG. 6A.
[0070] The roof panels 33 are secured at one end to the external
walls 30 by screws 34 which pass through the roof panels 33,
compression member 21 and capping member 20 before engaging with
the modular wall panel 5. At the other end, near the ridge, the
screws 34 securing the roof panels engage with supporting internal
walls 31 in the same manner as with the external walls 30. The peak
portion of the roof panels is covered by ridge capping 36 which
extends over the roof panel securing screws 34, which capping is
secured to the roof by further screws 36A.
[0071] As shown in FIG. 6A, the modular roof panels 33 in this
embodiment include a 25 mm ribbed steel outer skin 37 and an
injected polyurethane foam core 38 which has a 25 mm ribbed steel
inner skin 39, the panel is typically 100 mm thick. The underside
of the roof panel is lined (39A). The roof lining (39A) may be 4.5
mm fiber-cement board, 10 mm plasterboard, random grooved ply or a
timber ceiling screwed directly onto the ribbed steel inner skin.
Suitably the roofing panel is hi-tensile spandeck steel sheeting.
Wooden support blocks 40 are embedded in the core at spaced
locations along one side of the roof panel to provide mounting
points for the fascia panel 41, shown in FIG. 5.
[0072] The floor panels described in FIG. 2 may also be made of a
similar panel construction as the roof panels described above and
in reference with FIG. 6. More preferably the floor panels are also
formed from hi-tensile spandeck steel sheeting. When formed by the
hi-tensile spandeck steel sheeting, the floor panels are lined with
either composite flooring, waterproof ply or a timber floor applied
directly onto the sheeting by screws or glueing.
[0073] The use of hi-tensile spandeck sheeting for roof and floor
panels has the advantage of having high strength, light weight, and
being able to span up to 7 metres, thereby providing easy of
construction whilst reinforcing the building strength.
[0074] The enlarged detail view of the roof panel joint in FIG. 6B
shows the arrangement of a projection 42 and cooperating recess 43
formed in the sides of the foam core 38 of a roof panel 33. The
enlargement shows a ridge 37A of the outer roof skin extending
laterally past the core such that, when two cooperating roof panels
are engaged, the extended ridge 37A clips over the ridge nearest
the side of an abutting roof panel. The core may also be undercut
in the vicinity of the projection so as to produce a longitudinal
cavity 44 when the roof panels are clipped together. This cavity
may accommodate building services in the same manner as the
subsidiary cavities provided in the wall panels.
[0075] Returning to FIG. 5, the outer roof skin is turned-up 45 at
the peak end edge thereof to minimise any leakage. The roof skin
also extends past the foam core 38 and coplanar embedded wooden
blocks 40, so as to overhang the guttering 46 at the fascia end 47.
The wood or metal fascia panel 41 is suspended under the valleys of
the overhung roof skin by screws 48 and attached to the embedded
support blocks 40 by a further series of screws 49. The screws
which are sunk into the fascia support blocks also pass through
gutter brackets 50 which brackets in turn support the guttering
46.
[0076] The drawings in FIG. 7 show the arrangement of the corners
and tee-junctions of walls, in particular, the alternative
arrangements of the capping and compression members at these
junctions. A completed outer wall 30 is shown in place upon the
base 2, with a capping member 20 and compression member 21 on the
top side thereof engaged by tie rod nuts 22. The wall junctions
commonly include positioning profile members 51 which are attached
upright to the completed wall 30 at selected positions by screws
52. Wall locating members 12 are fixed upon the floor surface or
base 2 to locate the modular panels making up the walls.
[0077] An outer wall panel 53 is shown ready to be positioned at
the corner of the structure, whereby the recess 53A in the upright
side of the outer wall panel cooperates with the nose 51A of the
positioning profile member. At a corner the capping member 20 to be
placed on one of the walls will have about 75 mm removed from the
inner side of the C channelling. The remaining horizontal and outer
side faces of the C channelling capping member then run to the
outer edge of the corner.
[0078] The capping member 20 on the joining wall simply adjoins or
overlaps the capping member with a side partially removed. The
compression members 21 at the comer joint are machined to half
thickness for the length of the comer joint, thus forming half
thickness tongues. These half thickness tongues are arranged so
that the compression members interlace or overlap, resulting in an
even thickness of the compression members at the comer. One of the
modular panels forming the comer join has an additional
longitudinal cavity, capable of receiving a tie rod 14. This
additional longitudinal cavity is located so as to be at the centre
of the corner join. Apertures 55 and 55A are provided on the
capping members 20 and compression members 21 to facilitate fixing
the members together and corresponding to the additional
longitudinal cavity of the modular panel, thereby contributing to
the structural integrity of the building.
[0079] FIG. 7 also shows the tee-junction arrangement of an
internal wall where a tie rod in an intersecting wall is not in
immediate proximity, but is provided at the intersecting end of the
internal wall. The internal wall panel 57 (shown in fragmentary
form) engages with the respective positioning profile member 51, in
a similar fashion as two engaging panels (recall FIG. 4B), thereby
defining a longitudinal cavity. The capping member 58 and
compression member 59 include apertures 60 & 60A at their
extremities. The capping member 58 and compression member 59 are
then disposed on the top side of the internal wall comprised of
like panels 57. The tie rod 14, provided for the end of the
internal wall, may then be inserted through the apertures 60 and
60A and down into the cavity for securing the internal wall 57.
[0080] Throughout the specification the aim has been to describe
the preferred embodiments of the invention without limiting the
invention to any one embodiment or a specific collection of
features.
* * * * *