WO1998012396A1

WO1998012396A1 - Construction assembly and method

Info

Publication number: WO1998012396A1
Application number: PCT/AU1997/000602
Authority: WO
Inventors: Andrea Mario Stodulka
Original assignee: Andrea Mario Stodulka
Priority date: 1996-09-20
Filing date: 1997-09-12
Publication date: 1998-03-26
Also published as: AUPO247096A0

Abstract

In a first aspect the invention resides in a construction assembly disclosed which includes: a nestable structural member (10) substantially channel shaped in cross section; a panel member (16); and panel connecting means (13) connected to the panel member along one edge thereof, the connecting means extending outwardly of the one edge for connection to an adjoining panel member, the panel connecting means being adapted to engage the nestable structural member to be supported thereby. In a further aspect a roofing/ceiling construction assembly is disclosed which includes: a plurality of nestable structural roof members (27, 28, 29, 30); a plurality of ceiling panel members (31); and a plurality of roofing panel members (32); said structural roof members being substantially channel shaped in cross section and of varying channel depth, the variation in channel depth defining the roof pitch.

Description

"CONSTRUCTION ASSEMBLY AND METHOD"

Technical field

This invention relates to a construction assembly and to a method of construction.

The invention has particular but not exclusive application to the construction of buildings and building components. The buildings may be dwellings such as low cost houses, and the building components may be walls, partitions, floors, and ceilings or panels for these.

The meaning of the expression "construction assembly" as used herein includes buildings and building components .

Background of Invention

Prefabricated and modular construction methods and assemblies are well known. It is known for buildings and building components to be prefabricated off site and transported to a building site to be erected. In known systems prefabricated frame members are at least partially constructed and consequently considerable space is required for their transportation.

Summary of Invention The present invention aims to provide an alternative to known construction assemblies and methods of construction.

This invention in one aspect resides broadly in a construction assembly including:- a nestable structural member; a panel member, and panel connecting means connected to said panel member along one edge thereof, said connecting means extending outwardly of said one edge for connection to an adjoining panel member, said panel connecting means being adapted to engage said nestable structural member to be supported thereby.

As used herein the expression "nestable member" means that the members are adapted to nest within each other.

It is preferred that the structural member is substantially channel shaped in cross-section. The panel connecting means may be any means suitable for connection to adjoining panel members and adapted to support a nestable structural member. Thus the panel connecting means could be a series of ties connectable along the edges of adjoining panel members to which the nestable structural member can be fixed. However it is preferred that the panel connecting means includes a plate member connectable to the face of a panel member along one edge and to the face of an adjoining panel member along an edge of the adjoining panel member, and support means for supporting the structural member. In a preferred embodiment the support means are located along opposite edges of the plate member.

The support means can take various forms . Thus in one form of the invention the support means extend outwardly from edges of the plate member. Alternatively, the support means return inwardly from edges of the plate member .

The support means could be tabs or the like about which or by means of which the structural member is supported. However it is preferred that the support means are flanges.

The structural member may include engagement means for engagement by the support means .

The engagement means can be of any suitable form and could for example be tabs corresponding with the tabs associated with the panel connecting means. However it is preferred that the engagement means comprise flanges extending outwardly from the edges of the sidewalls of the channel shaped structural member. In one form of the invention these flanges are single flanges adapted to engage within support means which return inwardly from edges of the plate member. Alternatively, the flanges can be return flanges adapted to engage about support means which extend outwardly from edges of the plate member.

In another aspect this invention resides broadly in a method of construction including: - connecting adjoining panel members having panel connecting means located along one edge by connecting an edge of one panel member to the panel connecting means of an adjoining panel, and structurally supporting adjoining panels by a nestable structural member supported by the panel connecting means.

It is preferred that the structural member (s) support a structure exoskeletally .

In a further aspect this invention resides broadly in a roofing/ceiling construction assembly including :- a plurality of nestable structural roof members; a plurality of ceiling panel members, and a plurality of roofing panel members; the structural roof members being substantially channel shaped in cross-section and of varying channel depth, the variation in channel depth defining the roof pitch.

It is preferred that the ceiling panel members have panel connecting means along one edge thereof for connection to an adjoining ceiling panel member, the panel connecting means being adapted to be suspended from a structural roof member.

In another aspect this invention resides broadly in a method of constructing a roof including :- supporting in substantially parallel alignment a plurality of nestable structural members which are substantially channel shaped in cross-section and of varying channel depth, the structural members being supported at a substantially horizontal level and positioned such that the variation in channel depth of adjacent structural members defines the roof pitch, and fixing roofing panels to the structural members. In yet another aspect this invention resides broadly in a building construction assembly including :- a plurality of wall panel members; a plurality of roofing panel members; a plurality of nestable structural wall members substantially channel shaped in cross-section; a plurality of nestable structural roof members substantially channel shaped in cross -section and of varying channel depth, the variation in channel depth defining the roof pitch; a plurality of structural member connecting means for connecting an end of the structural roof members to an upper end of a structural wall member, and a plurality of wall corner connecting means for connecting adjoining panels of two walls meeting at a corner.

The building assembly may also include a plurality of ceiling panel members have panel connecting means along one edge thereof for connection to an adjoining ceiling panel member, the panel connecting means being adapted to be suspended from a structural roof member.

In a further aspect this invention resides broadly in a method of constructing a building including: - connecting adjoining wall panel members having panel connecting means located along one edge by connecting an edge of one panel member to the panel connecting means of the adjoining panel; structurally supporting adjoining wall panels by a nestable structural wall member supported by the panel connecting means; supporting in substantially parallel alignment a plurality of nestable structural roof members which are substantially channel shaped in cross-section and of varying channel depth, the structural roof members being supported at a substantially horizontal level and positioned such that the variation in channel depth of adjacent structural members defines the roof pitch, and fixing roofing panels to the structural members.

It is preferred that the structural roof members are supported by connecting an end thereof to an upper end of a structural wall member by a structural member connecting means.

It is preferred that the method of constructing the building includes connecting the adjoining panels of two walls meeting at a corner by wall corner connecting means. The method may also include fixing in the building a ceiling comprising a plurality of ceiling panel members have panel connecting means along one edge thereof for connection to an adjoining ceiling panel member, the ceiling being fixed in the building by suspending the panel connecting means from the structural roof members .

In another aspect this invention resides broadly in a construction assembly including :- a panel member, and panel connecting means connected to said panel member along one edge thereof, said connecting means extending outwardly of said one edge for connection to an adjoining panel member, said panel connecting means being adapted to engage a nestable structural member so as to be supported thereby.

It is preferred that the panel connecting means is connected to the panel member substantially continuously along the one edge.

Description of Drawings

In order that this invention may be more easily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention, wherein: -

FIG 1 is a perspective view of a first embodiment of a nestable channel shaped structural stud, joist or beam; FIG 2 is a perspective view of a connector piece for joining building panels and supporting the structural member of FIG 1;

FIG 3 is a perspective view of a building panel with a connector piece attached along one edge; FIG 4 is a section view of a pair of wall panels or a pair of ceiling panels connected by the connecting piece, with the wall stud or ceiling joist illustrated in FIG 1 being supported by the connecting piece; FIG 5 is a section view of a pair of wall panels at a corner in the wall connected by a corner connector;

FIG 6 is a perspective view of a second embodiment of a nestable channel shaped structural stud, joist or beam; FIG 7 is a perspective view of the connector piece for joining building panels and supporting the structural member of FIG 6;

FIG 8 is a section view of a pair of wall panels or a pair of ceiling panels connected by the connecting piece illustrated in FIG 7, with the wall stud or ceiling joist illustrated in FIG 6 supported by the connecting piece;

FIG 9 is a perspective view of a structural connector connecting the upper end of a wall stud to the outer end of a ceiling joist;

FIG 10 is a cross sectional elevation through a building constructed in accordance with the invention, and

FIG 11 is an elevation showing the support for a load-bearing wall.

Description of Preferred Embodiment of Invention

As can be seen in FIG 1, a structural stud, joist or beam member 10 is substantially channel shaped with a pair of tapering flanges or sidewalls 11 and a web or base 13. Structural members 10 can nest together. A pair of flanges 12 extend outwardly from the edges of sidewalls 11.

FIG 2 illustrates a connector piece 13 having a longitudinally extending plate 14. A pair of return flanges 15 return inwardly from the edges of plate 14. As seen in FIG 3, connector piece 13 can be attached along an edge of panel 16 by fasteners 17. Alternatively, connector piece may be glued or otherwise bonded to panel 16. Panel 16 can be a wall panel or a ceiling panel.

As can be seen in FIG , when assembled in a manner subsequently to be described, connector piece 13 connects adjoining panels 16 and also supports structural member 10.

To construct a wall in accordance with this aspect of the invention, one of adjoining panels 16 is connected to connector piece 13 by means of fastening screws or nails or staples or other suitable fasteners 19, or alternatively a connector piece 13 may already have been connected to each panel. The other panel is then connected to connector piece 13 along the face adjoining an edge of the other panel. If the panels already have connector pieces affixed along one edge, the connector pieces of each panel are attached to adjoining panels along the edge opposite the affixed connector piece in a shiplapped manner.

One flange 12 of channel shaped structural member 10 is then positioned in connector piece 13 by location in the groove formed between plate 14 and a return flange 15. Channel shaped structural member 10, which has a degree of resilience, is then compressed along its length and the other flange 12 similarly located at the entrance to the groove formed at the other return flange 15. Upon releasing the compressed connector piece, this flange 12 will be captured within this groove. Fasteners 18 are then fixed to retain flanges 12 of the structural member within the grooves. It will be seen that connector piece 13 supports structural member 10 by the engagement of flanges 12 within support means constituted by the grooves formed by return flanges 15.

In an embodiment not illustrated, a second connector piece can be attached centrally to the panel to provide the capacity for doubling the number of structural members. Thus 1200 mm wide walling panels with both central and edge connector pieces can be used to provide walling with 600 mm spaced studs.

As can be seen in FIG 5, adjoining walls may be structurally connected at their corners in a manner similar to that described above by an angled connector piece 20 and a nestable channel shaped wall corner structural member 21 in which the engagement flanges extend outwards at an angle of 45 degrees.

An alternative structural member and connecting piece to that described above is illustrated in FIGS 6 to 8.

As can be seen in FIG 6, a nestable substantially channel shaped structural stud, joist or beam member 22 is similar to that illustrated in FIG 1 except that flanges 23 which extend outwardly from the edges of the sidewalls are doubled by returning underneath.

FIG 7 illustrates a connector piece 24 having a longitudinally extending plate 14. A pair of flanges 25 step outwardly from the edges of plate 14.

As can be seen in FIG 8, connector piece 24 connects adjoining panels 16 and also supports structural member

22. One flange 23 of channel shaped structural member 22 is then positioned on connector piece 24 by locating the groove formed by the return of flange 23 over stepped flange 25. Channel shaped structural member 22, which has a degree of resilience, is then opened along its length and the opening to the groove formed by the other flange 23 is similarly located at the edge of the other stepped flange 25. Upon releasing the opened structural member 22, the other flange 23 will be captured about the other stepped flange 25.

It will be seen that connector piece 24 supports structural member 22 by the engagement of double return flanges 23 about support means constituted by flanges 25.

The structural members can be made from any suitable material. Preferably the members are formed from rolled galvanised steel strip. The gauge of the steel strip will depend on the application but typically can be between approximately 0.6 and 1.8 mm. The top hat section of the structural members provides an excellent strength to weight ratio. Sections of 250 mm depth made from 1.8 mm gauge material placed at 600 mm centres have the capacity to span 7 metres with flooring loads. A building can be constructed in accordance with the method and assemblies of the present invention by connecting a plurality of adjoining wall panels in the manner described above. A wall made from a plurality of wall panels can be assembled on the ground and then elevated or alternatively, two wall panels can be joined on the ground, elevated to a vertical position and propped, with successive panels in the wall being fixed to the standing wall in a vertical position. The standing walls can also be supported by connecting a return wall panel at a corner by means of a corner connector.

Structural roof members 27 are then attached to structural wall members 10 by means of a structural member connecting bracket 26 as seen in FIG 9. As can be seen in FIG 10, structural roof members 27 to 30 are of varying depth. They are supported at the same horizontal level on at the upper ends of the structural wall members. The structural roof members are spaced from each other in accordance with the roofing pitch required. It will be appreciated that the trigonometric tan of the angle of roof pitch is the ratio of the differential in depth between adjacent roof members to their spacing. Thus the structural roof members 27 to 30 are separated in accordance with the depth differential of adjoining members so that their upper surfaces form the plane of the roof at the required pitch.

Corner brackets 26 are configured to house structural roof members of varying depth. With the structural roof members secured in place by brackets 26, roofing panels 32 are connected to the roof. Ceiling panels 31 can be suspended from the structural roof members by connector pieces in a manner described above. It will be appreciated that the structural roof members serve as roofing beams and do not require ceiling or roofing battens as both ceiling and roof panels can be affixed directly to the structural roof member. FIG 10 also illustrates how the structural members may be used as flooring joists 33 with flooring panels 34 affixed thereto.

FIG 11 illustrates how the load-bearing walls are supported on the building foundations. A bearer such as angle beam 40 is supported by posts 41 or the like on foundations 42. Flooring joists 43 span across to another bearer. Wall base plate 44 is located along the ends of flooring joists 43 and the walls erected as described above with structural wall members 45 positioned on plate 44 above a joist 43. Structural ceiling members 46 are then connected to the upper end of wall members 45 by structural connectors 47 as described above .

The construction assembly and method of the present invention has a number of advantages in comparison with known systems.

It will be appreciated that buildings constructed in accordance with the present invention are simple to erect and require minimal skilled labour. The top hat section of the structural members allows for stacking, has the strength and structural rigidity to span relatively long distances and has the resiliency to permit a simple time-saving slide and click operation for assembly. Furthermore, in single skin construction the top hat section structural members provide a concealment for services such as plumbing and electrical wiring.

Buildings constructed in accordance with the invention have a number of desirable structural characteristics. The connector pieces act as shear plates transferring load shear from one panel to another. The structural member connecting brackets provide a portal connection between floor and roof rather than a connection via the walling stud top plates. Furthermore, the structural members of a building constructed in accordance with the invention comprise studs, purlins and floor joists which thus form an integral part of the building frame which is well adapted to withstand cyclonic conditions.

It will also be appreciated that the present invention results in considerable space savings during transportation. In known systems, considerable space is occupied by structural members such as beams, studs, joists and bearers, and in the case of prefabricated walls etc, by the space between the studs. In the present invention the nestable structural members result in space savings during transportation. This space saving is particularly significant when prefabricated dwellings are being transported between countries or by air to meet emergency situations.

It will of course be realised that whilst the above has been given by way of an illustrative example of this invention, all such and other modifications and variations hereto, as would be apparent to persons skilled in the art, are deemed to fall within the broad scope and ambit of this invention as is herein set forth.

Claims

1. A construction assembly including :- a nestable structural member substantially channel shaped in cross-section; a panel member, and panel connecting means connected to said panel member along one edge thereof, said connecting means extending outwardly of said one edge for connection to an adjoining panel member, said panel connecting means being adapted to engage said nestable structural member to be supported thereby.

2. A construction assembly as claimed in claim 1, wherein said panel connecting means includes a plate member connectable to the face of said panel member along said one edge and to the face of an adjoining panel member along an edge of the adjoining panel member, and support means for supporting said structural member.

3. A construction assembly as claimed in claim 1, wherein said structural member is substantially channel shaped in cross-section.

4. A construction assembly as claimed in claim 2, wherein said support means are located along opposite edges of said plate member.

5. A construction assembly as claimed in claim 4, wherein said support means extend outwardly from edges of said plate member.

6. A construction assembly as claimed in claim 4, wherein said support means return inwardly from edges of said plate member.

7. A construction assembly as claimed in claim 5 or claim 6, wherein said support means are flanges.

8. A construction assembly as claimed in claim 1, wherein includes engagement means for engagement by said support means .

9. A construction assembly as claimed in claim 8, wherein said engagement means comprise flanges extending outwardly from the edges of the sidewalls of said channel shaped structural member.

10. A construction assembly as claimed in claim 9, wherein said flanges are single flanges adapted to engage within support means which return inwardly from edges of said plate member.

11. A construction assembly as claimed in claim 10, wherein said flanges are return flanges adapted to engage about support means which extend outwardly from edges of said plate member.

12. A method of construction including :- connecting adjoining panel members having panel connecting means located along one edge by connecting an edge of one panel member to said panel connecting means of the adjoining panel, and structurally supporting adjoining panels by a nestable structural member supported by said panel connecting means.

13. A method as claimed in claim 12, wherein said structural member (s) support a structure exoskeletally.

14. A roofing/ceiling construction assembly including : - a plurality of nestable structural roof members; a plurality of ceiling panel members, and a plurality of roofing panel members; said structural roof members being substantially channel shaped in cross-section and of varying channel depth, the variation in channel depth defining the roof pi tch .

15. A roofing/ceiling construction assembly as claimed in claim 14, wherein said ceiling panel members have panel connecting means along one edge thereof for connection to an adjoining ceiling panel member, said panel connecting means being adapted to be suspended from a structural member.

16. A method of constructing a roof including :- supporting in substantially parallel alignment a plurality of nestable structural members which are substantially channel shaped in cross-section and of varying channel depth, said structural members being supported on a substantially horizontal level and positioned such that the variation in channel depth of adjacent structural members defines the roof pitch, and fixing roofing panels to said structural members.

17. A building construction assembly including :- a plurality of wall panel members; a plurality of roofing panel members; a plurality of nestable structural wall members substantially channel shaped in cross-section; a plurality of nestable structural roof members substantially channel shaped in cross-section and of varying channel depth, the variation in channel depth defining the roof pitch; a plurality of structural member connecting means for connecting an end of said structural roof members to an upper end of a structural wall member, and a plurality of wall corner connecting means for connecting adjoining panels of two walls meeting at a corner .

18. A building construction assembly as claimed in claim 17 and including a plurality of ceiling panel members have panel connecting means along one edge thereof for connection to an adjoining ceiling panel member, said panel connecting means being adapted to be suspended from a structural roof member.

19. A method of constructing a building including :- connecting adjoining wall panel members having panel connecting means located along one edge by connecting an edge of one panel member to said panel connecting means of the adjoining panel; structurally supporting adjoining wall panels by a nestable structural wall member supported by said panel connecting means; supporting in substantially parallel alignment a plurality of nestable structural roof members which are substantially channel shaped in cross-section and of varying channel depth, said structural roof members being supported at a substantially horizontal level and positioned such that the variation in channel depth of adjacent structural members defines the roof pitch, and fixing roofing panels to said structural members.

20. A method as claimed in claim 19, and including connecting the adjoining panels of two walls meeting at a corner by wall corner connecting means.

21. A method as claimed in claim 20, wherein said structural roof members are supported by connecting an end thereof to an upper end of a structural wall member by a structural member connecting means.

22. A method as claimed in claim 21, and including fixing in the building a ceiling comprising a plurality of ceiling panel members have panel connecting means along one edge thereof for connection to an adjoining ceiling panel member, the ceiling being fixed in the building by suspending said panel connecting means from said structural roof members .

23. A construction assembly including :- a panel member, and panel connecting means connected to said panel member along one edge thereof, said connecting means extending outwardly of said one edge for connection to an adjoining panel member, said panel connecting means being adapted to engage a nestable structural member so as to be supported thereby.

24. A construction assembly as claimed in claim 23, wherein said panel connecting means is connected to said panel member substantially continuously along said one edge .