U.S. patent application number 11/459462 was filed with the patent office on 2008-01-24 for building modular and panel system and method of construction thereof.
Invention is credited to PAUL R. RHEAUME.
Application Number | 20080016802 11/459462 |
Document ID | / |
Family ID | 38970097 |
Filed Date | 2008-01-24 |
United States Patent
Application |
20080016802 |
Kind Code |
A1 |
RHEAUME; PAUL R. |
January 24, 2008 |
BUILDING MODULAR AND PANEL SYSTEM AND METHOD OF CONSTRUCTION
THEREOF
Abstract
A building modular and panel system for construction using
prefabricated modular panels. The system includes top and bottom
plates connected to metal studs. A high rib metal lath with
moisture barrier backing can be secured to and covers the metal
studs. A light weight gas injected concrete/plaster seizer mix is
sprayed over the metal lath to create the structural panel. The
structured panel is preferably bolted to the slab. To provide
further support, especially in a commercial setting, one or more
lateral wall channel bracing can be attached to the metal
studs.
Inventors: |
RHEAUME; PAUL R.; (NAPLES,
FL) |
Correspondence
Address: |
DANIEL S. POLLEY, P.A.
1215 EAST BROWARD BOULEVARD
FORT LAUDERDALE
FL
33301
US
|
Family ID: |
38970097 |
Appl. No.: |
11/459462 |
Filed: |
July 24, 2006 |
Current U.S.
Class: |
52/220.1 |
Current CPC
Class: |
E04C 2/26 20130101; E04C
2/384 20130101 |
Class at
Publication: |
52/220.1 |
International
Class: |
E04C 2/52 20060101
E04C002/52 |
Claims
1. A structural panel for a building comprising: a frame assembly
comprising a bottom plate, a top plate and a plurality of studs,
each of said plurality of studs having a bottom end and a top end,
wherein the bottom end of the each stud is secured to the bottom
plate and the top end of each stud is secured to the top plate, the
frame assembly having an exterior side and an interior side; a high
rib mesh lath secured to the exterior side of the frame assembly; a
concrete mixture applied to the mesh lath to form an a structural
exterior wall; and an interior wall member secured to the interior
side of the frame assembly.
2. The structural panel of claim 1 wherein the interior wall member
is selected from a group consisting of sheetrock, drywall and
gypsum board.
3. The structural panel of claim 1 wherein each of said plurality
of studs is constructed from galvanized metal steel.
4. The structural panel of claim 1 wherein said high rib mesh lath
having a plurality of small openings for receiving the applied
concrete mixture.
5. The structural panel of claim 1 wherein said concrete mixture
comprises: an amount of Portland cement, sand and a plaster
seizer.
6. The structural panel of claim 5 wherein said concrete mixture
further comprises a cement accelerator.
7. The structural panel of claim 1 wherein said frame assembly
having an interior areas defined between said interior wall member,
said high rib mesh lath and adjacent studs which is substantially
filled with insulation having a rating of at least R19.
8. The structural panel of claim 7 wherein each of said insulation
is provided in batt form.
9. The structural panel of claim 1 wherein said bottom plate is
secured to a concrete slab of the building by anchor bolts.
10. The structural panel of claim 1 wherein said lath constructed
from metal.
11. The structural pane of claim 1 wherein at least one of said
plurality of studs having an aperture.
11. A structural wall for a building, comprising: a frame assembly
having a top track, a bottom track and a plurality of metal wall
studs secured at a top end to the top track and at a bottom end to
the bottom track, each of said metal wall studs having a plurality
of spaced apart apertures, said frame assembly having an exterior
side and an interior side; a high rib metal lath secured to said
metal wall studs on an exterior side of said frame assembly; a
concrete mixture applied over and covering the metal high rib lath;
and an interior member secured to the metal studs on the interior
side of said frame assembly and selected from the following group:
sheet rock, gypsum board or drywall.
12. The structural wall of claim 1 wherein said bottom track of
said frame assembly is secured to concrete slab of a building by a
plurality of anchor bolts.
13. The structural wall of claim 11 wherein said metal high rib
lath having a herringbone meshed pattern and substantially V-shaped
ribs running approximately the length of said rib lath.
14. The structural wall of claim 11 wherein said frame assembly
defining an internal area between each adjacent pair of metal
studs, said top track and said bottom track; wherein the structural
wall further comprising a piece of R-19 or higher rated insulation
inserted within each internal area of said frame assembly.
15. The structural wall of claim 14 wherein each piece of
insulation having a moisture barrier backing paper.
16. The structural wall of claim 11 further comprising a moisture
barrier backing paper secured to the metal high rib lath.
17. The structural wall of claim 14 further comprising wiring and
plumbing disposed within one or more internal areas of said frame
assembly and inserted through one or more apertures of said metal
studs.
18. The structural wall of claim 17 further comprising grommets
disposed within the apertures of said metal studs to avoid any
inserted wiring or plumbing from directly contacting the metal
studs.
19. The structural wall of claim 11 wherein said concrete mixture
having a thickness applied over said lath of about two inches.
20. The structural wall of claim 11 wherein each metal stud is
secured to the top track by two screws on the interior side of the
frame assembly and two screws on the exterior side of the frame
assembly and each metal stud is secured to the bottom track by two
screws on the interior side of the frame assembly and two screws on
the exterior side of the frame assembly.
21. The structural wall of claim 11 wherein said metal lath is a
metal lath 3/8'' high rib lath having a herringbone mesh pattern
with 3/8'' V-shaped ribs running the length of said lath at 41/2''
intervals and 3/16'' intermediate ribs.
22. The structural wall of claim 11 wherein said interior member is
a 5/8'' type gypsum board.
23. The structural wall of claim 11 wherein said metal studs are
constructed from galvanized steel.
24. A structural wall for a building, comprising: a frame assembly
having a substantially U-shaped top track, a substantially U-shaped
bottom track and a plurality of galvanized steel wall studs secured
at a top end to the top track and at a bottom end to the bottom
track, each of said wall studs having a plurality of spaced apart
apertures, said frame assembly having an exterior side and an
interior side, said frame assembly defining an internal area
between each adjacent pair of wall studs, said top track and said
bottom track; a metal high rib lath secured to said metal wall
studs on an exterior side of said frame assembly; a concrete
mixture applied over and covering the metal high rib lath; a piece
of 5/8'' type gypsum board secured to the metal studs by a
plurality of screws on the interior side of said frame assembly; a
piece of R-19 or higher rated insulation inserted within each
internal area of said frame assembly; and wiring and plumbing
disposed within one or more internal areas of said frame assembly
and inserted through one or more apertures of said wall studs.
25. The structural wall of claim 24 wherein said bottom track of
said frame assembly is secured to concrete slab of a building by a
plurality of anchor bolts.
26. The structural wall of claim 24 wherein each piece of
insulation having a moisture barrier backing paper.
27. The structural wall of claim 24 further comprising a moisture
barrier backing paper secured to the metal high rib lath.
28. The structural wall of claim 24 further comprising grommets
disposed within the apertures of said metal studs to avoid any
inserted wiring or plumbing from directly contacting the metal
studs.
29. The structural wall of claim 24 wherein said concrete mixture
having a thickness applied over said lath of about two inches.
30. The structural wall of claim 24 wherein each wall stud is
secured to the top track by two screws on the interior side of the
frame assembly and two screws on the exterior side of the frame
assembly and each metal stud is secured to the bottom track by two
screws on the interior side of the frame assembly and two screws on
the exterior side of the frame assembly.
31. The structural wall of claim 24 wherein said metal lath is a
metal lath 3/8'' high rib lath having a herringbone mesh pattern
with 3/8'' V-shaped ribs running the length of said lath at 41/2''
intervals and 3/16'' intermediate ribs.
32. A method for constructing a structural wall for a building
comprising the steps of: (a) securing a plurality of metal wall
studs to a bottom track and a top track to provide a frame assembly
having an interior side, an exterior side and a plurality of
internal areas defined between adjacent wall studs, the bottom
track and the top track; (b) securing a high rib metal lath to the
plurality of metal wall studs at the exterior side of said frame
assembly; (c) applying a concrete mixture over said high rib metal
lath; (d) installing insulation within each internal area of said
frame assembly; (e) installing any required wiring or plumbing
within one or more internal area of said frame assembly; and (f)
and securing an interior panel selected from a group consisting of
sheet rock, drywall or gypsum board to said metal wall studs at the
interior side of said frame assembly.
33. The method of claim 32 further comprising the step of attaching
moisture barrier backing paper to the insulation.
34. The method of claim 32 further comprising the step of attaching
moisture barrier backing paper to the high rib metal lath.
35. The method of claim 32 wherein said concrete mixture is applied
over the high rib metal lath in three coats to a thickness of about
2 inches.
36. The method of claim 32 further comprising the step of securing
the bottom track to a concrete slab of the building.
37. A method for constructing a structural wall for a new building
remote from the building site and not exposed to outside elements
during its construction, said method comprising the steps of: (a)
while inside an existing structure and not exposed to outside
weather conditions securing a plurality of metal wall studs to a
bottom track and a top track to provide a frame assembly having an
interior side, an exterior side and a plurality of internal areas
defined between adjacent wall studs, the bottom track and the top
track; (b) securing a high rib metal lath to the plurality of metal
wall studs at the exterior side of said frame assembly; (c)
applying a concrete mixture over said high rib metal lath; (d)
installing insulation within each internal area of said frame
assembly; (e) installing any required wiring or plumbing within one
or more internal area of said frame assembly; (f) and securing an
interior panel selected from a group consisting of sheet rock,
drywall or gypsum board to said metal wall studs at the interior
side of said frame assembly; (g) transporting the frame assembly
with secured metal lath having applied concrete mixture, secured
interior panel and installed insulation, wiring and plumbing from
the existing structure to a building site for a new building; and
(h) securing the bottom track to a concrete slab present at the
building site.
38. The method of claim 37 further comprising the step of attaching
moisture barrier backing paper to the insulation prior to
installing the insulation in the internal areas of the frame
assembly.
39. The method of claim 37 further comprising the step of attaching
moisture barrier backing paper to the high rib metal lath prior to
securing the metal lath to the metal studs of the frame
assembly.
40. The method of claim 37 wherein said concrete mixture is applied
over the high rib metal lath in three coats to a thickness of about
2 inches.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to building
construction and building materials and more particularly to a
novel modular and panel system for a building and novel method of
construction of the building.
[0003] 2. Description of the Prior Art
[0004] The three basic components for residential construction
shells generally are the foundation, the frame or skeleton and the
skin. The foundation includes contiguous structural elements
typically set on contiguous concrete footing poured into
excavations in the ground beneath. The frame includes the floor,
the exterior walls, and the roofing joists. The skin has both
exterior and interior applications and includes whatever materials
or layers that are applied or connected to the frame. The skin also
includes insulation, drywall, roofing systems, etc. The house or
other building (collectively referred to as "building") is put
together piece by piece outdoors where all of the raw materials for
the building and the building processes are subject to all of the
elements of nature.
[0005] Successful construction, in any climate, is always dependent
upon the availability of weather suitable to the type of
construction. Thus, a relevant factor is the suitability of the
construction materials and methods to the available weather.
Conventional construction is limited to those types of materials
which pass the stringent fire safety codes. Most often, this is
usually some form of masonry. While the materials of which blocks
and bricks are comprised are not specifically susceptible to the
exigencies of cold and heat extremes, or even to the particular
presence or absence of moisture, the methods for bringing the
blocks and bricks together are.
[0006] Conventional construction typically has at least five
distinct parts or phases to it, each of which is separate and must
be concluded before the next can be started. They are: (1) site
prep, which includes the clearing of the land and the excavation of
the slab and/or footers; (2) foundation, which is the pouring of
the concrete for footers and the pouring of any basement or slab
flooring; (3) framing, usually of wood studs and joists (often
referred to as "stick built") covered with plywood chip board, or
some similar material; (4) sheathing, which, is the block or
masonry outer "skin" (which may or may not include a "moisture
barrier" and the roofing; and (5) finishing, which is all of the
interior trades. Four of these five phases are conducted
exclusively outdoors, where temperatures and conditions limit the
circumstances under which they can be affected. While these items
are worked out, all other trades are at a standstill until the
building (house) is declared to be "in the dry". In view of these
delays, there are often long periods of weeks and months each year
when traditional builders are idle and construction is halted or
intermittent at best in the northern climate.
[0007] Home ownership slips further and further from the grasp of a
growing proportion in the United States and elsewhere. The
conventional building materials and methods of construction
described above do not lend themselves to a workable solution for
the needs of affordable housing. It is to the effective resolution
of these and other problems associated with conventional building
materials and methods of construction that the present invention is
directed.
SUMMARY OF THE INVENTION
[0008] The present invention generally provides a building modular
and panel system for construction using prefabricated modular
panels and method for construction the building primarily offsite,
such as, but not limited to, indoors at a factory. The system
includes a frame having top and bottom plates and a plurality of
metal studs, preferably constructed from galvanized steel. The top
and bottom plates are connected to the metal studs. The studs can
be provided with one or more holes or apertures for running
electrical wiring, cable, computer wiring, plumbing, etc., as well
as for bridging purposes.
[0009] A high rib metal lath with or without a moisture barrier
backing can be secured to and covers the metal studs. A light
weight gas injected concrete/plaster seizer mix can be sprayed over
the metal lath to create the structural panel. The structured panel
is preferably bolted to the slab, such as, but not limited to, by
the use of anchor bolts. To provide further support, especially in
a commercial setting, one or more lateral wall channel bracing can
be attached to the metal studs.
[0010] In one non-limiting embodiment, the concrete mixture sprayed
on to the metal lath can consist of an amount of Portland Type 1
cement, an amount of sand (40-60 screen size), and a plaster
seizer, with or without a cement accelerator. In one embodiment,
three coats are spray applied to the lath preferably by using a
three-coat machine. The exterior finish can be approximately in
thickness, though such is not considered limiting.
[0011] Any required electrical and rough plumbing items can then be
installed, as well as any other items such as, but not limited to,
cables, computer wiring, etc. At this point the insulation material
can also be installed within the interior area. Grommets can also
be installed in the stud apertures to isolate or prevent the
installed electrical wiring or plumbing from directly contacting
the metal studs. The internal area of the final panel can be
preferably filled with insulation material. Though not limiting, in
the preferred embodiment, R-19 or R-20 rated insulation can be used
for the insulation. The insulation can be provided with a Kraft
paper backing to provide a moisture barrier. Additionally or
alternatively, a paper backing can also be provided on high rib
lath.
[0012] The interior side of the panel can be completed by the
attachment of drywall or gypsum board to the metal studs.
Alternatively, a lath assembly can also be provided on this
(interior) side of the panel if so desired.
[0013] Using the materials and methods described herein, the
present invention provides a more cost effective way of producing
pre-site built modular and panel systems, which at the same time
produces a faster built, stronger and environmentally safer
commercial and/or residential building.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective partial cutaway view of a first
embodiment for a manufactured panel in accordance with the present
invention;
[0015] FIG. 2 is a perspective partial cutaway view of a second
embodiment for a manufactured panel in accordance with the present
invention;
[0016] FIG. 3 is a perspective view of a frame assembly for the
manufactured panel of FIG. 1;
[0017] FIG. 4 is a perspective view of the metal lath assembly for
the manufactured panel of FIG. 1 shown partially covering the frame
assembly on the exterior (outside) side of the frame assembly of
FIG. 3;
[0018] FIG. 5 is a perspective view of an exterior finish partially
applied to the metal lath disposed on the exterior (outside) side
of the intended structure, with the metal lath now shown fully
covering the metal studs of the frame assembly of FIG. 3;
[0019] FIG. 6 is a perspective view illustrating certain electrical
and plumbing components installed within the manufactured panel;
and
[0020] FIG. 7 is a perspective view illustrating drywall being
secured to the frame assembly on interior (inside) side of the
frame assembly of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] As seen in FIG. 1 a first embodiment for a manufactured
panel is disclosed and generally designated as panel 20. Panel 20
generally comprises a frame assembly 30, a metal lath 70, an
exterior finish 90 and an interior finish 96. Panel 20 can be
preferably attached to a concrete slab 25, which has been
previously been formed through conventional practices. FIG. 2
illustrates a second embodiment for the manufactured panel which is
highly similar to the first embodiment, with the addition of
lateral wall channel bracing provided, which can be preferably
equally spaced up the wall and attached to the metal studs of the
frame assembly 30. In one non-limiting embodiment, lateral bracing
can be spaced out in 1/3.sup.rd lengths of the wall height, though
such is not considered limiting. Though also not considered
limiting, the lateral bracing can be preferably provided for
commercial buildings and a panel 20 without bracing can be used for
residential buildings. The below description for the invention is
considered applicable to both the first embodiment (FIG. 1) and
second embodiments (FIG. 2) of the invention.
[0022] As best seen in FIG. 3, frame assembly 30 comprises a top
track 34, a bottom track 46 and a plurality of wall studs 60. In
one embodiment, top track 34 and bottom track 46 can both be a "U"
shaped channel runners, having a web 36 and 48, respectively of
approximately 6'' and leg (38 and 50, respectively) heights of
approximately 11/4''. Tracks 34 and 36 can be approximately 10' in
length. These disclosed dimensions for top track 34 and bottom
track 46, as well as all other dimensions discussed herein, are
given by way of example and are not considered limiting.
Accordingly, other dimensions for the various components of panel
20 can be used and are considered with the scope of the invention.
Tracks 34 and 46 can be preferably constructed from 18 gauge metal
though other gauges can be used and are considered within the scope
of the invention.
[0023] Wall studs 60 can also be preferably constructed from 18
gauge metal though again other gauges can be used and are
considered within the scope of the invention. Studs 60 can be "C"
shaped members which with top track 34 and bottom track 46 form
frame assembly 30 for the axial load bearing walls. Studs 60 can be
provided with one or more holes or apertures 62 for electrical
wiring, cable, computer wiring, plumbing, etc., as well as for
bridging purposes. In one non-limiting embodiment apertures 62 can
be approximately 24'' on center and have a knockout size of
approximately 11/2.times.approximately 4''. However, other
dimensions can be used and are considered within the scope of the
invention. The knockout can be punched at approximately 12'' from
the leading edge with additional knockout at approximately 24'' on
center. Again these dimensions are given by way of example and are
not considered limiting. As the knockouts (apertures 62) are used
for plumbing and electrical items it is preferred that they are
substantially aligned from studs 60.
[0024] Studs 60 are attached to top track 34 and bottom track 46
through conventional such as by fasteners 64. In a preferred,
though non-limiting embodiment, a powder actuated fastener
technique can be used to attached studs 60 to tracks 34 and 46. In
a preferred embodiment, two fasteners 64 on each side (interior and
exterior) of stud 60 for a total of four fasteners 64 attach stud
60 to top track 34. Similarly, two fasteners 64 on each side of
stud 60 for a total of four fasteners 64 attached stud 60 to bottom
track 46. Thus, in the preferred embodiment, a total of eight
fasteners 64 can be used for attaching each stud 60 to top track 34
and bottom track 46. However, it should be recognized that the
present invention is not limited to any particular number of
fasteners or that the same number of fasteners have to be provided
for attaching stud 60 to the top track 34 as for attaching stud 60
to bottom track 46. Accordingly, other number of fasteners can be
used and are also considered within the scope of the invention. In
one non-limiting, embodiment, fasteners 64 can be #10 self tapping
Philip head low profile or framing screws. However, other screws,
bolts, rivets, nails, etc. can be used for fasteners 64 can be used
and are also considered within the scope of the invention. Though
not preferred, other mechanisms for securing studs 60 to tracks 34
and 46 can also be used and are considered within the scope of the
invention, such as, but not limited to, welding, gluing, etc.
Though also not considered limiting, two screws at the top and two
screws at the bottom for each side of each stud 60 can be used for
attaching studs 60 to tracks 34 and 46.
[0025] Studs 60, top track 34 and bottom track 46 together comprise
frame or wall assembly 30. Frame assembly 30 can be preferably
fastened to concrete slab 25 preferably by using a power fastener.
In one non-limiting embodiment fasteners 48 can be anchor bolts,
preferably having a hex head formed with an integral washer. The
anchors can be preferably designed to be used with a matched
tolerance anchor bolt drill bit having the same tolerance and
dimensions as the anchor bolt for optimum fastening results.
[0026] FIG. 4 illustrates metal lath assembly 70 which can
preferably comprise a 3/8'' high rib lath 72 having herringbone
mesh pattern with 3/8'' V-shaped ribs running the length of the
sheet at 41/2'' intervals and inverted 3/16'' intermediate ribs.
The preferred dimensions are not considered limiting and other
dimensions can be used for metal lath 72 and are considered with
the scope of the invention. As seen in FIG. 4 high rib lath 72 is
placed against framing assembly 30 and attached to framing assembly
30 through fasteners 74, such as but not limited to #10.times.1''
self tapping Philip head screws at maximum 8'' on center. In one
non-limiting embodiment fasteners 74 can be provided at one or more
points of each stud 60. Lath 72 can be provided with a kraft paper
backing to serve as a moisture barrier. Lath 72 with its small
opening patters receives the relatively lightweight concrete which
causes the concrete and the lath 72 to join and become one with the
studs 60 to create a structural panel.
[0027] FIG. 5 illustrates the final step for the exterior side of
panel 20 in which a one or more coat concrete finish is applied to
high rib lath 72. In one embodiment, three coats are spray applied
to lath 72 using a three-coat machine. Exterior finish 90 can be
approximately 2'' in thickness, though such is not considered
limiting and other thicknesses can be used and are considered
within the scope of the invention. In the preferred three coat
finish 90, the first coat can serve as a scratch coat, the second
coat can service as a brown coat and the third coat can serve as a
finish coat. The concrete mixture can consist of a cement,
aggregate and admixture. In one non-limiting embodiment, the cement
can be a Portland type cement, the aggregate can be a sand and the
admixture can be a plaster seizer mix with or without an
accelerator or cement accelerator. The Portland cement can be of a
Type I kind and the maximum size for the sand can be about
40--about 60 screen size. One non-limiting ratio for the
ingredients or components of the concrete mixture given in
properties per cubic foot can be (i) 8 bags of Portland Type I
cement, (ii) 20 cubic foot of sand; (iii) 32 ounces of plaster
seizer mix and (iv) 32 ounces of accelerator. The plaster seizer
mix can be a composite of lightweight concrete, made lighter than
normal concrete by introducing gas bubbles into the plastic cement
mix to create a novel material with a cellular structure. The gas
or air bubbles can be produced by a chemical reaction which takes
place within the fresh mortar/cement mass. The structural concrete
produced by the present invention can be effective in controlling
both sound absorption and transmission. The structural concrete of
the present invention used in the modular and panel systems of the
present invention is lighter in weight, different in composition,
more controllable in production, more versatile in applications,
spreads easier, has more yield, better thermal, acoustical and
frost resistant properties, and costs less than standard
concrete.
[0028] FIG. 6 illustrates the step for installing the required
electrical and rough plumbing items, as well as any other items
such as, but not limited to, cables, computer wiring, etc. FIG. 6
also illustrates the installing of the insulation material within
the interior area that is defined inside panel 20. Grommets 66 can
be installed in apertures 62 of studs 60 to isolate or prevent the
installed electrical wiring or plumbing from contacting the metal
studs 60. The grommet 66 size can be 11/2'' or otherwise correspond
to the size of apertures 62. Grommets 66 can snap into or otherwise
be attached within apertures 62 in studs 60 and openings 38 and 50.
Where needed, one or more openings 38 can be provided in top truck
for feeding or running wiring, plumbing, etc. through. One or more
openings 50 can be provided in bottom track 46 for similar
purposes. Grommets 66 can also be provided for openings 38 of top
track 34 and openings 50 of bottom track 46. Any remaining void in
apertures 62 after installing the above-described electrical,
plumbing, etc. can be filled with a foam or other non-conductive
material.
[0029] As also seen in FIG. 6, the internal area of panel 20 can be
filed with insulation material. Though not limiting, in the
preferred embodiment, R-19 or R-20 rated insulation 68 can be used
for the insulation. However other rated insulation can also be used
and are considered within the scope of the invention. The
insulation can come in various forms, including, but not limited
to, batts, rolls, loose-fill, and rigid foam boards and all are
considered within the scope of the invention. Insulation 68 can be
provided with a kraft paper backing to provide a moisture barrier.
As mentioned above, the paper backing can also be provided on high
rib lath 72 in addition or as an alternative to insulation 68.
[0030] As seen in FIG. 7, the final step for he interior side of
the panel 20 is the attachment of drywall or gypsum board 96
(collectively referred to as "gypsum board") to studs 60.
Alternatively, a lath assembly can also be provided on this
(interior) side of panel 20. In a non-limiting preferred embodiment
the gypsum board can be 5/8'' in thickness, though other dimensions
can be used and are considered within the scope of the invention.
Standard fasteners 98, such as but not limited to, drywall screws
or self-tapping drywall screws can be used for attaching gypsum
board 96 to studs 60. In one non-limiting embodiment,
#6.times.11/4'' long with countersunk Philip head screws preferably
at a maximum of 8'' on center and minimum of 6'' on center.
However, other dimensions for the screws and other distances for
their location can be used and are considered within the scope of
the invention.
[0031] The joints of the present invention building system can be
"moment" connection, capable of resisting rotation. Steel and
galvanized light weight cement skin preferably forms "composite"
construction working together which can be performed in a factory
setting. All adjoining walls can be bolted and sealed together
using the concrete mixture of the present invention.
[0032] Preferably the entire concrete floor or slab is poured and
complete so that the modular or panel system of the present
invention can be attached thereto as discussed above. However, the
present invention can also be used to create a floor system as
well. In this embodiment, the lightweight concrete discussed above
can be installed in a thickness, such as, but not limited to, about
2'' over a floor joist or floor truss with the same high rib metal
mesh lath. The resulting floor can be significantly stronger than
floor systems created using industry standards.
[0033] Each member of the present invention frame resists force
placed on any other members and spreads the resistance over all
members. As all members add together they can be relatively
lighter. Thus, the present invention acts as a structural system.
With the present invention building system, rafters and trusses can
be become part of the wall system. Slab anchors (anchor imbedded in
slab) can also be imbedded in the wall. Each wall panel can have a
reinforced relatively light weight cement skin to resist sheer. As
there are preferably no overturning, truss or rafters can be on
2-foot centers. Additionally, lintels may not be required. The
present invention can provide for a screwed roof structure covered
with roof shingle to resist or reduce deformation. The preferred
cement skin of the wall can form a "stress-skin-panel", which can
provide an efficient structural form. From an appearance
standpoint, an attractive cement surface can be provided on the
outside wall. The cement can be light weight and waterproof and
thus little or no maintenance is needed.
[0034] As to the foundations and/or slabs, the present invention
provides for concrete strip footing or slabs. The steel panels can
be set right on footing or slab and can be at 33,000 psi. The
modular panel systems of the present invention can be bolted in the
floor slab. The walls can be anchored by steel bolts, such as, but
not limited to, 6'' steel bolts at 2' o/c. The present invention
can provide for a reinforced 3,000 psi "earth tempered" floor slab
which can conduct earth crust temperature into living areas (i.e.
crust typically varies from about 60.degree. F. to about 65.degree.
F. As the concrete slab--3,000 psi, any flooring may be
applied.
[0035] The exterior walls produced through the present invention in
a preferred embodiment provide for a 30,000 psi minimum galvanized
screwed steel frame. The walls can include metal studs, preferably
steel, such as, but not limited to, 6'' steel studs at 16'' o/c.
The walls can also include a galvanized structural metal lath
sheathing as reinforcing to light weight cement vertical mini-slab
monolithic shell (4,000 psi). The exterior walls can be fireproof
and resistant to mold, mildew, fungus, bacteria, termites, ants,
vermin, etc. The exterior walls can also be insulated to R19 or R20
and the preferred galvanized steel will not rust or burn. The
system can be designed to retain energy by using an insulated heat
reflecting barrier and high insulation values in walls and
roofs.
[0036] The exterior facing for the wall can provide a light weight,
textured, seamless cement-based weathercoat which "breathes" to
allow water vapor transmission to avoid damp wall cavities. The
cement coat can be impervious to ultra-violet sunlight exposure.
The cement coat is preferably unremovable manually, fireproof,
seamless, no air leaks, burglar resistant and 4,000 psi. As
referenced above, the structure can be preferably galvanized
screwed steel frame encased in reinforced light weight cement and
structural wall. The facing will not rust or deteriorate and does
not provide for a breeding ground for mold, mildew, fungus,
bacteria, termites, ants, vermin, etc. The exterior surfaces can be
tinted and weatherproofed with a finish coat cement mixture to
create the color and texture required. As the surface can be
impervious to moisture penetration, any shape or ornamentation can
be relatively inexpensively formed.
[0037] The joists, rafters and studs can be preferably pre-punched
for service runs. This permits easier installation at the factory
of electrical, plumbing, HVAC, etc. Grommets, such as but not
limited to, rubber or plastic grommets, can be inserted into
punch-outs to avoid contact items inserted through the punch-outs
(e.g. pipes, wires, etc.) with the frame (metal studs, galvanized
steel studs, etc.). The roof frame can preferably include 33,000
psi galvanized steel rafters screwed together to form a single
structural unit with the walls. These mini-slab roofs can create a
single unified structural skin, which preferably prevents or
reduces pull-outs or blow offs. Use of the present invention
provides for a roof having increased stability and rigidity in view
of the frame metal tiles being compatible with the steel frame.
Enameled galvanized metal screws preferably with rubber washers can
be used to join compatible materials.
[0038] The present invention provides for a monolithic seamless
structural shell made of compatible materials which allows for the
cement-steel bond to become a single structural piece. The average
material strength can be 25,000 psi and higher, which is
significantly stronger than conventional materials. The structural
is also durable in view of little or minimal deterioration of the
cement over an extended period of time (i.e. approximately 100
years, etc.) and the preferred use of galvanized steel to increase
lifespan of the steel and resulting unified structure. The
structure preferably is fireproof and non-combustible. The exterior
appearance can be of a stucco type and can include a wide variety
of tints and textures.
[0039] Significant environmental advantages are also achieved
through the present invention building system as the steel industry
used approximately 1/100.sup.th of land area as compared for that
needed for timbering; the system used approximately 1/10.sup.th of
an amount of cement as conventional masonry or concrete, the
construction steel industry typically recycles 100 percent, as the
building is pre-fabricated there is minimal if any trash at the
site.
[0040] The walls and roofs of the present invention building system
can be approximately two inches thick yet they provide significant
insulation and effect energy savings. Insulation batts can be
installed, sprayed and/or treated. In one non-limiting embodiment,
the insulation can be approximately 6'' fiberglass insulation
installed into the walls and/or attics.
[0041] Any cabinetry, shelves and/or accessories to be secured to
the wall can be provided with a blocking having a steel track for
securing to associated studs, such as, but not limited to, studs
associated with the bathrooms and/or kitchens.
[0042] The steel and lightweight cement components of the present
invention form a strong combination. The preferred steel framework
integrated with a continuous reinforced cement exterior surface,
provides the strength to resist storms, floods, earthquakes and
other natural disasters. The reinforced cement can form a right
shell encasing the steel frame. The cement coat can bond to the
frame creating a unified steel and lightweight structure. This
composite stress skin structure is very strong for its weight,
providing durability and disaster resistance using a fraction of
the material traditionally required.
[0043] Once built, the pre-engineered construction system can be
easily transported to the building site. The modular or panel
systems can be delivered to the site finished and installed on the
foundation or slab. All plumbing, electrical, air condition and
heating, cabinet and counter work can be done at the factor except
for utility connections. The system can include, but is not limited
to, panelized exterior walls, roofs, ceilings, intermediate floors,
partitions, and stairs. The panels are relatively lightweight and
can be easily placed with a minimum of on-site equipment. As no
cutting or framing is required, the present invention provides a
relatively fast and affordable construction building system.
[0044] When constructing a building using the present invention
building system, site prep becomes less critical as compared to
conventional building techniques since the combined weight of the
completed building is about 1/10.sup.th that of a conventional
building. With the present invention the footers can be poured at
about the same time as the site is being prepped, and thus,
reducing time frames significantly. The pouring of the concrete
slab, whether for a slab foundation or as part of the basement
floor, can be left until after a substantial part (if not all) of
the framing has been finished. Time requirements for framing are
thus substantially reduce, except possibly for erecting the frames
and attaching them from one to another. Furthermore, the framing
can be performed indoors under controlled climate conditions.
Additionally, with the present invention, framing and sheathing can
take place virtually simultaneously and the roofing can begin as
soon as the upper portion of the building has been erected into
place. This process is relatively rapid as compared to conventional
building techniques, such that the weather envelope does not have
to lengthy in order to get the building "in the dry". With the
framed "skeleton" of the building up, the entire structure can be
plumbed and electrical wiring can be installed. When finished with
all doors and windows in place, the structure can be inspected
under ideal conditions at the factory. Cold conditions do not
become a major issue as approximately 85% of the structure can be
built indoors at the factory.
[0045] The present invention can provide at least some, if not all
of the below objects and/or advantages:
[0046] (1) overcomes obstacles that have created and continue to
sustain affordable housing and building shortages;
[0047] (2) provides a finished, pre-engineered product;
[0048] (3) results in finished products which can meet and surpass
the highest building code standards;
[0049] (4) a completed building using the present invention,
whether residential or commercial, can be provided with superior
fire resistance;
[0050] (5) completed structure and structural components can be non
combustible and non friable;
[0051] (6) completed structure and structural components can have
zero smoke contribution and zero out gassing preferably without any
other coating or treatment;
[0052] (7) provide superior lightning resistance where the entire
frame of the building can be grounded with nothing flammable for
the lightning to ignite;
[0053] (8) the finished product can have a combined strength rating
of approximately 30,000 P.S.I.;
[0054] (9) the strength of the present invention building system
can allow for unusually long spans without trusses or load-bearing
walls, which can afford more open and innovative living designs
while mitigating costs;
[0055] (10) the completed pre-engineered structures can use
substantially less materials than are consumed in conventional
construction (i.e. approximately 1/8.sup.th of cement and
approximately 1/2.sup.th of steel, etc.);
[0056] (11) the completed structures can be relatively light weight
(i.e. approximately ten to approximately 20 percent of the weight
of a conventionally constructed building), and preferably employs
no relatively large/heavy components, which in the event of a
earthquake or other natural disaster could crash down on an
occupant of the building;
[0057] (12) the exterior shell can be designed so as not to
collapse under extreme force or blow out;
[0058] (13) the frame can be designed to give way on impact without
pulling down the exterior shell;
[0059] (14) the present invention building system can consume
little or no lumber in its construction, thus sparing approximately
150 trees typically used to build an average-sized house;
[0060] (15) the structure can be constructed without hydrocarbons
or resins and can use materials with a proven history of
longevity;
[0061] (16) the system can use materials that are readily,
abundantly and economically available to eliminate or reduce
possible market shortages;
[0062] (17) materials used in the building system can be compatible
with one another to reduce or eliminate any chance for reactions
which could cause deterioration;
[0063] (18) can reduce or eliminate rusting of metal;
[0064] (19) materials used can have relatively low and virtually
equal coefficients of thermal expansion and contraction such that
shrinkage is minimized, even under extreme temperature variances,
and the integrity of the material is not compromised;
[0065] (20) the building system becomes a unitized structure,
preferably able to meet and resist building, wind, precipitation
and movement leads as a unified whole rather than as separate
components fastened and attached together;
[0066] (21) a pre-engineered structure at one with its foundational
system, such as by being attached, strapped, bolted or fastened as
opposed to merely stuck to;
[0067] (22) a building system incorporating a roof deck and roof
system attached to the foundation and exterior walls such that no
known natural wind force up to approximately 180 mph can separate
the roof from the rest of the structure;
[0068] (23) completed structure preferably strong enough and
adaptable enough that choices for roofing are based on budget and
aesthetics;
[0069] (24) the strength of the finished building built to
withstand sustained wind loads in excess of 180 mph;
[0070] (25) a building system designed so that repairs can be
effected quickly and affordably;
[0071] (26) vertical and horizontal planes of the completed
structure are plumb and square;
[0072] (27) clearances and tolerances for the installation of
windows and doors can be kept relatively very low and not dependent
upon the use of caulks, fillers and weather stripping to achieve
proper fit;
[0073] (28) windows can be constructed using highly efficient high
impact glass or storm shuttered windows;
[0074] (29) window frames and doors can be of durable, waterproof,
non-combustible and/or non-decomposing material;
[0075] (30) the exterior weatherproof skin can be impervious to
water in droplet form, repelling and resisting it, and preferably
incapable of wicking or absorbing water into the interior of the
system;
[0076] (31) the surface skin can preferably be crack resistant,
color fast, resistant, shrink resistant and structurally
resilient;
[0077] (32) the skin can be preferably applied either by hand or by
spray;
[0078] (33) the materials used for the skin can be preferably
tailored for various climates, regardless of temperatures and
humidities;
[0079] (34) the system can be designed such that its strength can
preclude or reduce the necessity of floodgates in areas susceptible
to flash flooding;
[0080] (35) the system can be water and rust resistant such that in
the event of flooding there is preferably no permanent damage to
the structural components of the building;
[0081] (36) the system can be closed to climate intrusion,
including, but not limited to, wind infiltration, without the use
of moisture barriers and without trapping fumes, solvents,
hydrocarbons, vapors and/or gases environmentally hazardous to the
occupants;
[0082] (37) the wall system does not support the growth of mold,
mildew, bacteria, or fungus and preferably can "breathe" to allow
moisture vapor to be expelled while withstanding water
penetration;
[0083] (38) the system does not attract, feed or sustain termites
and burrowing insects, and the chosen materials for the system can
be thick and strong enough that none burrow in;
[0084] (39) the system does not attract, feed or sustain vermin or
roaches and the chosen materials for the system can be thick and
strong enough that none burrow in;
[0085] (40) the entire building system is relatively safe and offer
increase protection and safety from natural disasters;
[0086] (41) the finished product can be energy efficient, well
insulated both below and above grade and preferably designed to
take advantage of geothermal constants;
[0087] (42) the system can have installed a heat reflective thermal
break throughout the exterior surface of the structure;
[0088] (43) the finished structure can be relatively economical to
build and own, preferably coming in will within affordable housing
and building initiative guidelines;
[0089] (44) the pre-engineered system and its resultant structures
can be easily and adaptable to virtually any architectural
style;
[0090] (45) the system can easily lend itself to custom and upscale
designs as well as production runs of affordable housing and
construction;
[0091] (46) the finished structure has an attractive appearance
making it difficult to single out as "affordable housing";
[0092] (47) the design of the house can appear open, airy and
spacious and can boast high ceilings where practical and make good
use of available sunlight;
[0093] (48) the building system can be able to economically adapt
to difficult site situations incorporating basements where possible
or utilizing crawl spaces or slabs where necessary;
[0094] (49) the building system can be able to accommodate flexible
designs for single or multistory units and can be buildable as
single or multi-family construction;
[0095] (50) the building system is capable of providing rapid
construction, such as, but not limited to, being able to be erected
and ready for occupancy in approximately three weeks regardless of
weather conditions;
[0096] (51) the construction of the building leaves relatively
little or no waste at the construction site;
[0097] (52) the construction of the building can be non-polluting
at the job site;
[0098] (53) job site construction can be relatively low noise;
[0099] (54) building construction can be achieved with simple
tools, preferably without the use of cranes or other heavy
machinery;
[0100] (55) wall systems can be designed to receive plumbing and
electrical installations without drilling or punching, thus
eliminating approximately sixty percent of the time such trades
typically spend on site;
[0101] (56) the building system does not require new, difficult or
specially skilled labor which would make the building more
expensive to construct and/or leave the building project vulnerable
to worker shortages and/or labor slowdowns;
[0102] (57) the factory production nor the on-site construction
does not represent any unusual hazards or unsafe work conditions
which reasonable safety awareness and care should avoid; and
[0103] (58) raw materials can be non-toxic minerals, free from
urea-formaldehyde and allergens.
[0104] It should be noted that all figures, dimensions,
temperatures, amounts are considered to be in approximates and not
necessarily limited to the exact number provided. The present
invention provides a panelized cement modular pre-engineered
structural system and more particularly a steel and lightweight
cement pre-engineered structure. Any force applied to the structure
is resisted by the entire structural skin, reducing unit stress
throughout the frame.
[0105] The amount of cement in a building constructed by the
present invention building system can be approximately 1/10.sup.th
to approximately 1/5.sup.th of that used by traditional building
methods and about 1/2 of the steel traditionally needed. The
building can be built with no wood, no hydrocarbons, and no resins,
and can be built with all-mineral content materials that are
non-toxic. The walls, roofs and floors of the present invention
building do not support fungus, bacteria, mold or mildew and will
not deteriorate, rot, rust, attract termites or vermin, blow down
in storms, float away in rising waters, or become a maintenance
problem for the occupants. Additionally, the building site for the
present invention building has little or no waste left for pickup
as nothing needs to be actually fabricated at the building site.
Furthermore, by preferably producing the modular panel systems,
interior and exterior walls, retaining and foundational walls,
columns, girders, trusses, stair cases, roofs and intermediate
floors at the factory and not at the building site, frugal or
controlled use of materials can be exercised to help further reduce
waste and lessen strain on environmental resources. The
pre-fabricated panels are of light enough weight to be erected on
site without the use of large, energy consuming, and polluting
equipment.
[0106] Where a typical wall "R" values are 12, the present
invention can provide for "R" values of 20. In conjunction with the
floor or basement floor concrete slab, the present invention
building can pick up and hold the constant temperature of the
ground below the frost line, creating a thermal stabilizer which
can lower the amount of heating or cooling necessary to achieve
comfort in the house.
[0107] The present invention building can withstand extreme weather
conditions which routinely destroy conventional buildings. The
present invention light-gauge galvanized steel framework can be
comprised of modular and panel structures created from preferably
about 30,000 psi rust resistant galvanized steel imbedded in
concrete floor slabs at each level and then preferably coated with
a super-reinforced light weight cement structural skin (about 4,000
psi). Though lighter in weight then conventional construction
types, this unified and cohesive pre-engineered structure can be
many times stronger than its conventional counterparts, making it
relatively highly resistant to fires, floods, hurricanes,
tornadoes, mold, mildew, bacteria, fungus, termites, vermin
infestation, etc.
[0108] While the invention has been described and disclosed in
certain terms and has disclosed certain embodiments or
modifications, person skilled in the art who have acquainted
themselves with the invention, will appreciate that it is not
necessarily limited by such terms, nor to the specific embodiments
and modifications disclosed herein. Thus, a wide variety of
alternatives, suggested by the teachings herein, can be practiced
without departing from the spirit of the invention, and rights to
such alternatives are particularly reserved and considered within
the scope of the invention.
* * * * *