AU2009101292A4

AU2009101292A4 - A joining system for erecting walls of a building structure

Info

Publication number: AU2009101292A4
Application number: AU2009101292A
Authority: AU
Inventors: Jonathon Godsiff Nott
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-12-15
Filing date: 2009-12-15
Publication date: 2010-01-28
Anticipated expiration: 2017-12-15

Description

P/00/012 Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION INNOVATION PATENT Invention Title: "A JOINING SYSTEM FOR ERECTING WALLS OF A BUILDING STRUCTURE" The following statement is a full description of this invention, including the best method of performing it known to me: 1 TITLE A JOINING SYSTEM FOR ERECTING WALLS OF A BUILDING STRUCTURE 5 FIELD OF THE INVENTION The present invention relates to a joining system for erecting walls of a building structure. In particular, but not exclusively, the present invention relates to a joining system having interlocking male and female joining parts for erecting pre-engineered walls of a building structure. 10 BACKGROUND TO THE INVENTION Pre-engineered buildings erected using pre-engineered walls are well known for temporary housing and low cost housing. These buildings including pre-engineered walls have the benefit of being easy to transport and relatively quick to erect when compared to traditional housing structures. 15 In order for the erected building to be structurally sound, it is necessary for the walls to be securely joined to each other and to the floor. To aid in the quick erection of the building, it may be beneficial if the planned location of the walls on the floor of the building is clearly set out. This is especially so where more than mere external walls on the periphery of a floor is required. 20 It is preferable to have the pre-engineered walls finished (clad, painted and utility service switches installed) before they are erected, thereby to speed up the time to completion of the building from the start of erection of the walls. US4284051 describes a building system having modular walls with horizontal passages. Interposed between adjacent walls are fins having 25 projecting tubes which are receivable in the horizontal passages to locate the 2 walls relative to each other. Rope or the like is threaded through adjoining walls and the tubes to fix the walls relative to each other. The building system of US4284051 is complicated to erect and little guidance is given as to where on the floor the walls must be erected, other than being on the 5 periphery. In this specification, the terms "comprises", "comprising" or similar terms are intended to mean a non-exclusive inclusion, such that a system and/or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed. 10 OBJECT OF THE INVENTION It is a preferred object of the present invention to provide an improved joining system for erecting walls of a building structure that addresses or at least ameliorates one or more of the aforementioned problems of the prior 15 art and/or provide the consumer with a useful or commercial choice. SUMMARY OF THE INVENTION According to one aspect, although not necessarily the broadest aspect, the 20 present invention resides in a joining system for erecting walls of a building structure, the joining system comprising: a rail fixable to a first building element; a channel section defining a channel, the channel section fixable to a second building element, wherein the channel section and the rail are 25 dimensioned and configured so that at least part of the rail is receivable in 3 the channel of the channel section to locate the first building element relative to the second building element; and fasteners for fastening the rail in the channel section. Optionally, the channel section is integrally formed with the second 5 building element. Preferably, the rail comprises a web which is locatable against the first building element and through which the fasteners may extend to fix the rail to the first building element, two parallel walls extending from lateral sides of the web, and inwardly extending guide formations projecting towards each 10 other from distal ends of the parallel walls. The first building element may be a floor or a post and the second building element may be a wall. The wall preferably has the channel section along its foot and sides. According to another aspect of the invention there is provided a 15 method of erecting a building structure, the method including: fixing a number of rails to a floor in an arrangement according to the wall plan for the building structure; and standing a number of walls on the floor with the rails received in channel sections of the wall panels. 20 BRIEF DESCRIPTION OF THE DRAWINGS By way of example only, preferred embodiments of the invention will be described more fully hereinafter with reference to the accompanying drawings in which like features have like reference numerals, wherein: 4 FIG 1 shows a perspective view of a joining system according to an embodiment of the present invention, joining a pre-engineered wall to a rail fixed to a floor; FIG 2 shows a perspective view of a floor having the rails fixed thereto 5 in an arrangement according to the wall plan of a building structure; FIG 3 shows a detailed perspective view of a corner of the floor to which the rails are fixed; FIG's 4 to 5 shows the stages of erection of a pre-engineered wall joined by the joining system of FIG 1; 10 FIG 6 shows an end view of a pre-engineered wall erected by lowering the wall onto a rail of the joining system in accordance with the invention; FIG 7 shows a perspective view of the joining system, joining ends of pre-engineered walls to a post; FIG 8A shows a side view of a stud wall having channel sections 15 integrally formed at the bottom and ends of the stud wall, in accordance with another embodiment of the invention; FIG 8B shows an end view of the bottom of the stud wall of FIG 7A; FIG 8C shows an end view of the head of the stud wall of FIG 7A; FIG 9 shows a sectional side view of part of a building structure 20 erected using an embodiment of the joining system of the present invention; FIG 10 shows a sectional view of a ridge connector and roof panels received in channels of the connector as part of a building structure erected using an embodiment of the joining system of the present invention; and FIG 11 shows sectional top view of part of a building structure erected 5 using an embodiment of the joining system of the present invention. For the sake of clarity, like reference numerals are employed for like features throughout the drawings. 5 DETAILED DESCRIPTION OF THE INVENTION Embodiments of the present invention will be described with reference to improved pre-engineered building structures suitable for temporary and permanent accommodation. However, it should be appreciated that embodiments of the present invention can be used to provide 10 accommodation relating to many different applications such as holiday accommodation, camping accommodation and other temporary accommodation. It will be appreciated that variations may need to be made as required. The present invention is particularly useful for erecting building structures quickly using unskilled labour. 15 FIG 1 shows a joining system 10 in accordance with embodiments of the present invention. The joining system 10 comprises a rail 12 fixed to a floor 14 and a channel section 16 fixed to a floor plate 36 of pre-engineered wall 18. The channel section 16 has a channel 20 in which part of the rail 12 is received. The rail 12 and channel section 16 are of roll-formed steel 20 sheet. The channel section 16 is fastened to the rail 12 by screws 38 where respective walls of the channel section 16 and the rail 12 overlap. The joining system 10 joins a first building element in the form of the floor 14 to a second building element in the form of the wall 18. FIG 2 shows the rails 12 fixed to the floor 14 in an arrangement 6 according to the wall plan of a building structure. The rails 12 are fixed to the floor 14 by screws. The rails 12 may be screwed to the floor 14 on site in accordance with a wall plan marked on the floor, or may be fixed to the floor before being transported to site. The broken lines 22 marked on the floor 14 5 indicate where rails 12 are still to be fixed to the floor 14. The broken lines 22 are drawn on the floor 14 to guide an unskilled laborer to fix the rails 12 on the floor 14 in accordance with the wall plan of the building structure. FIG 3 shows a detailed view of the rails 12 where they are fixed to a corner of the floor 14. The rails 12 each comprise a web 24, two parallel 10 walls 26 extending from lateral sides of the web 24, and inwardly extending guide formations 28. The rails 12 have a height "h" measured from the underside of the web 24 to the highest point of the guide formations 28. The rails 12 have an external diameter "De4" measured between the outsides of the parallel walls 26. The rails 12 are screwed to the floor 14 by screws 30 15 which extend through the web 24 and into the floor 14. FIG 4 shows the pre-engineered wall 18, having the channel section 16 fixed thereto, lying flat on the floor 14. The channel section 16 butts against the rail 12. The channel section 16 is generally U-shaped in cross section, having a flange 32 and two parallel walls 34. The channel section 20 16 is fixed to the floor plate 36 at the underside of the pre-engineered wall 18 by screws 37. The floor plate 36 is substantially the same as the channel section 16. The channel section 16 and floor plate 36 are fixed back-to back. The channel section 16 has a depth "d" which is the height of the parallel walls 34.

7 The height "h" of the rail 12 is less than the depth "d" of the channel section 16. As such, the wall 18 is supported by the channel section 16 when the wall 18 is erected. The wall 18 stands on the bottom edges of the parallel walls 34 when erected. A gap is left between the between the guide 5 formations 28 of the rail 12 and the flange 32 of the channel section 16 when the rail 12 is received in the channel 20 of the channel section 16. The channel sections 16 have an internal diameter "Dint" measured between the insides of the parallel walls 34. The internal diameter Dint of the channel section 16 is the same or slightly less than the external diameter Dext of the 10 rails 16 so that the rails 12 are received in the channel sections 16 in an interference fit. The wall 18 is pre-finished prior to erection in that it is already clad, painted and utility service switches are installed. FIG 5 shows how the pre-engineered wall 18 is erected by pivoting the 15 wall 18 about the rail 12. A distal edge of one of the walls 34 of the channel section 16 abuts the rail 12 to create a fulcrum about which the wall 18 pivots. The guide formations 28 guide the walls 34 of the channel section 16 to capture the rail 12 between the walls 34. FIG 6 shows how the pre-engineered wall 18 is erected by lowering 20 the wall 18 straight onto the rail 12. The guide formations 28 still act as guides down which the walls 34 ride if the wall 18 and rail 12 are slightly out of alignment when lowering the wall 18 onto the rail 12. FIG 6 also shows fasteners in the form of screws 38 which fasten the walls 34 of the channel sections 16 to the walls 26 of the rail 12. Once the wall 18 is erected, the 8 screws 38 are screwed into the overlap between the walls 34 and the walls 26. FIG 7 shows a perspective view of the joining system 10, joining ends of the pre-engineered walls 18 to a building element in the form of a post 40. 5 FIG 7 shows a corner connection where two walls 18 meet. The walls 18 have studs 35 along their ends. The post 40 is a square hollow section. The rails 12 extend along the length of the post 40. The rails 12 are fixed to orthogonal sides of the post 40 by screws 30. The channel sections 16 are fixed to the studs 35 by screws 37. The walls 18 are located relative to the 10 post 40 by receiving the rails 12 in the channels 20 of the channel sections 16. The guide formations 28 of the rail 12 guide the walls 34 of the channel section into side-by-side location next to the walls 26 of the rails 12. The channel sections 16 are then fastened to the rails 12 by screws where the walls 34 of the channel sections 16 overlap with the walls 26 of the rails 12. 15 A hip receiver channel (not shown) is fixed to the top of the post 40. A square hollow section stump is welded to the bottom of the hip receiver channel to be nestingly received in the post 40. The square hollow section stump is screw fixed in the post 40 by screws extending through the post 40 and the stump. 20 FIG 8A shows a side view of a pre-engineered stud wall 50. The wall 50 has opposite ends 44, a foot 46 and a head 48. The wall 50 comprises a number of studs 52, end studs 54 at the opposite ends 44, a floor plate 56, noggins 58 and braces 60. A window 62 is formed in the wall 50. Cross sections of the studs 52 and 54 are depicted in FIG 8A, spaced below their 9 position in the wall 50. The stud wall 50 further comprises channel sections 64 integrally formed with the end studs 54. The channel sections 64 are the same as the channel sections 16 described with reference to FIG's 1 to 7, except that they are integrally formed with the end studs 54. The floor plate 5 56 also has a channel section 64 integrally formed therewith, which is more particularly illustrated in FIG 8B. The channel sections 64 are the same as the channel sections 16 described with reference to FIG's 1 to 6, except that they are integrally formed with the end studs 54 and the floor plate 56. FIG 8B shows an end view of the floor plate 56 including the channel 10 section 64. The floor plate 56 forms part of the wall 50. FIG 8C shows an end view of the head 48 of the wall. The ends of the studs 52 are notched at an angle which is the angle of the roof pitch. FIG 9 shows a sectional side view of part of a pre-engineered house 100 using the joining system 10. The house 100 includes a sub floor 15 structure 102. The sub floor structure 102 comprises top-hat sections 104 which sit on top of Z-purloins 106. The Z-purloins mount to square hollow section stumps cast into concrete footings and screw-fixed to the Z-purloins. A plywood floor 108 is screwed down onto the top hat sections 104. A C section 118 covers the end of the top hats 104 and floor 108 to protect the 20 floor. A rail 12 as described with reference to FIG's 1 to 6 is fixed to the floor 108 with screws. A wall 50 as described with reference to FIG 8 stands on the floor 104 with the rail 12 received in the channel 20 of the floor plate's 56 channel section 64. The wall 50 is screw fixed to the rail 12 by screws extending through the walls of both the channel section 64 and the rail 12.

10 The wall 50 has external cladding 110 on the outside and internal cladding 112 on the inside. The bottom 140mm of the inside of the wall 50 is left free of internal cladding to allow access to the cavity 113 in the wall. Services such as plumbing and electrical wiring may be installed in the cavity 5 113. A rebated skirting board 114 is fixed to a lower foot region of the wall 50 to close off the cavity 113. The house 100 further includes roof panels 130 which are fixed to the upper end of the studs 52 via a top plate 116. The top plate 116 is fixed at the upper end of the stud 52. The roof panel 130 is fixed to the top plate 116 10 by roof screws. The roof panel 130 has pre-drilled holes 132 though which 150mm long screws can extend to fix the roof panel 130 to the top plate 116. FIG 10 shows the roof panels joined at a ridge by a ridge connector 140. The ridge connector 140 has two receiver channels 142 which are fixed to one another and which define an acute angle a between them. Ends of 15 the roof panels 130 are received in the channels 142 and screw fixed in the channels by screws 144. FIG 11 shows a sectional top view of part of the house 100. Depicted are two walls 120, 121 joined to a corner post 122 by the joining system 10 and an internal wall 124 joined to one of the walls 121 by the joining system 20 10. The corner post 122 is the same as the post 40 described with reference to FIG 7. The corner post 122 has two rails 12 fixed thereto. The walls 120,121 are similar to the wall 50 described in FIG 8 A-C and includes integrated channel sections 64 in which the rails 12 are received. The wall 121 further includes a rail 12.1 fixed to a side thereof intermediate its ends.

11 The rail 12.1 is fixed to two studs 52 of the wall 121. The rail 12.1 provides means for the internal wall 124 to be joined to the wall 121. The internal wall 124 is similar to the wall 50 described in FIG 8 A-C and includes integrated channel section 64 in which the rail 12.1 is received. 5 The house 100 can be rapidly, easily and intuitively assembled with limited or no instructions and without the need for skilled labour or resources, such as specialized assembly tools. Because the walls 18 are pre-finished prior to erection, the house 100 can be completed rapidly once the walls 18 are erected. The accessible cavity 11 3in the wall 18 makes it quick and easy 10 to install the plumbing and electrical wiring for the house 100. The joining system 10 allows for pre-engineered walls to be are pre-finished prior to erection. Although the joining system 10 is specifically described for joining walls to each posts and to a floor, the joining system may similarly be used to 15 join walls stacked one on top of the other. Throughout the specification the aim has been to describe the invention without limiting the invention to any one embodiment or specific collection of features. Persons skilled in the relevant art may realize variations from the specific embodiments that will nonetheless fall within the 20 scope of the invention.

Claims

1. A joining system for erecting walls of a building structure, the joining system comprising: 5 a rail fixable to a first building element; a channel section defining a channel, the channel section fixable to a second building element, wherein the channel section and the rail are dimensioned and configured so that at least part of the rail is receivable in the channel of the channel section to locate the first building element relative 10 to the second building element; and fasteners for fastening the rail in the channel section.

2. The joining system of claim 1, wherein the channel section is integrally formed with the second building element. 15

3. The joining system of claim 1 or claim 2, wherein the rail comprises a web which is locatable against the first building element and through which the fasteners may extend to fix the rail to the first building element, two parallel walls extending from lateral sides of the web, and inwardly extending 20 guide formations projecting towards each other from distal ends of the parallel walls.

4. A method of erecting a building structure, the method including: fixing a number of rails to a floor in an arrangement according to a 13 wall plan for the building structure; and standing a number of walls on the floor with the rails received in channel sections of the walls.

5. A joining system for erecting walls of a building structure and a 5 method of erecting a building structure as substantially herein described with reference to the drawings.