AU2017100806A4 - Prefabricated partition wall system and method - Google Patents

Abstract

A method of constructing a partition wall 10 in a building space between opposed upper 24 and lower 36 support structures. The lower support structure 36 defines a lower support surface in the building space, such as a slab floor and the upper support 5 structure 24 defines an upper height limit for the building space. The method includes securing a top member 12 to the upper support structure 24, wherein in the top member 24 defines a downwardly open recess 20 between spaced side walls 18 thereof. The method further includes providing one or more prefabricated wall frames 22, each frame 22 having a height which extends substantially between the upper and lower support 10 structures 24, 36. The method further includes installing the or each frame 22 in an upright manner such that the top thereof lies between the side walls 18 of the top member 12, with a clearance provided above the top of the or each frame 22 and with the side walls 18 extending below the top of the or each frame 22. 54mm 54mm 50mm Ec0 o 00 0 -12 121 E "14 E 4 E E E E 32 30 32 w5 50mm 54mm 54mm Fig. 1 Fig. 2

Description

Prefabricated partition wall system and method

Field of the invention 2017100806 21 Jun2017

The present invention relates to a prefabricated partition wall system and 5 method, in particular, although not exclusively, for office fit-outs or apartment buildings.

The application claims priority from AU2016902432, the contents of which are included by reference.

Background of the invention

In a typical office fit-out, the usable space is generally defined by between upper I0 and lower concrete slabs. This typically leaves a large open space for an office fit-out which is separated into smaller offices or rooms by non-load bearing partition walls. These partition walls are typically constructed from internal framing made up of a series spaced upright studs extending between a sole plate at the bottom and a top plate at the top. Because the height between slabs is often uneven, the height of the upright 15 studs often needs to be tailored accordingly and for this reason, the construction of the framing usually takes place on site. Following construction of the partition wall framing, cladding material is applied to the framing, such as plaster board.

One of the disadvantages of this system is that it is time-consuming and costly to custom-make the partition wall framing to suit the vagaries of the spacing between 20 slabs. An added shortcoming with this conventional system is that it is undesirable to fix the top plate and/or the sole plate to their respective slabs because this does not allow for slab deflection and thus contributes to cracking in the plaster work. However, fixing the top plate and the sole plate, while undesirable, generally occurs because it is otherwise difficult to maintain the framing in position. For example, an electrician will 25 typically dislodge the framing when he/she pulls wiring through.

Therefore, it is the object of the present invention to provide a prefabricated partition wall system and method which overcomes or at least ameliorates one of the abovementioned disadvantages.

Reference to any prior art in the specification is not an acknowledgment or 30 suggestion that this prior art forms part of the common general knowledge in any 1 1001843484 jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and/or combined with other pieces of prior art by a skilled person in the art. 2017100806 21 Jun2017

Summary of the invention 5 In accordance with the first aspect of the present invention, there is provided a method of constructing a partition wall in a building space between opposed upper and lower support structures, the lower support structure defining a lower support surface in the building space, such as a slab floor and the upper support structure defining an upper height limit for the building space, the method including: 10 securing a top member to the upper support structure, wherein in the top member defines a downwardly open recess between spaced side walls thereof; providing one or more prefabricated wall frames, each frame having a height which extends substantially between the upper and lower support structures; installing the or each frame in an upright manner such that the top thereof lies 15 between the side walls of the top member, with a clearance provided above the top of the or each frame and with the side walls extending below the top of the or each frame.

Thus the frames could be positioned directly onto the lower support structure. For example, lines could be marked out on the slab floor for the location of the frames, defining the ultimate location of the partition walls in the building space. 20 It will be appreciated that the clearance above the top of each frame will allow for slab deflection and other building movement. At the same time, the side walls of the top member will retain each frame in the upright orientation.

The method preferably further includes: securing a bottom member to the lower support structure, the bottom member 25 defining an upwardly open recess between spaced side walls, wherein the upwardly open recess of the bottom member faces the downwardly open recess of the top member. 2 1001843484

Where there is only a top member, then each frame can be inserted by tilting the frame so that the top is received within the recess of the top member and gradually adjusting the inclination until the frame is substantially upright. 2017100806 21 Jun2017

Where both a bottom member and a top member are provided, the frames are 5 preferably installed by inserting the top of each frame into the recess of the top member, while clearing the bottom member and then dropping the frame down to seat in the upwardly open recess of the bottom member.

The method may further include: sliding the frame along the top and bottom members until they reach respective 10 desired positions. Preferably a plurality of frames is arranged with the frames in spaced apart disposition.

The step of securing the top and/or bottom members may comprise: driving a fastener through the member into the corresponding support structure to inwardly flex the side walls of the member. 15 This flexing action of the side walls assists with retaining the frames firmly in position within the recesses of the top and bottom members. For this purpose, the top and bottom members may be constructed of a deformable material or at least a material which is resiliently deformable. Accordingly, the top and bottom members may be made of extruded aluminium, although some plastics material may also be suitable. Likewise, 20 it is preferred that the frames are also constructed of extruded aluminium profiles.

In order to flex the side walls evenly, the fastener is suitably located in a central location relative to the top and bottom members. Each of the top and bottom members may include a top/bottom wall between the side walls and the fastener may be applied in a central location relative to the top/bottom wall. There may be a series of fasteners 25 spaced along the length of the top and bottom members. In particular, a drive pin or a washered drive pin may be used.

Once the prefabricated wall frames are secured in position, wall cladding may be applied on one or both sides thereof. 3 1001843484

The top member may be in the form of an inverted channel and most preferably is a right-angled C-section. 2017100806 21 Jun2017

The bottom member preferably has a side wall height which is shorter than the side wall height of the top member. This enables the wall frames to be inserted first into 5 the top member, while clearing the bottom member. The frames are then dropped back down to seat in the bottom member.

Each prefabricated wall frame is suitably substantially planar in outline. The prefabricated wall frames are preferably in the form of framed units including upright studs and substantially horizontal top plates and sole plates. These framed units are 10 suitably made offsite, as understood by the term ‘prefabricated’. The frames are then delivered to the building site. The frames can therefore be made in a factory. Preferably, the frames come in a range of standard sizes. This achieves economies of scale and greatly decreases on-site labour costs. It is estimated that using factory produced prefabricated wall frames in a range of standard sizes will result in a reduction in labour 15 costs for partition wall construction of up to 70%.

The terms upper and lower support structure may refer to the floor slabs of a building. For example, at one particular building level there will be a lower floor slab as well as an upper floor slab. The lower floor slab could define the lower support structure while the upper slab could define the upper support structure. However, the partition >0 walls need not extend all the way between floor slabs. For example, a ceiling structure may be provided below the level of the upper floor slab. This is typically used to accommodate wiring and other services ducts. Thus, the partition wall need only extend up to ceiling structure. Accordingly, the ceiling structure may comprise the upper support structure to which the top members are secured. 25 In accordance with a second aspect of the present invention, there is provided a partition wall system for a building space between upper and lower support structures, the lower support structure defining a lower support surface in the building space and the upper support structure defining an upper height limit for the building space, the system including: 4 1001843484 a top member which defines an open recess between spaced side walls thereof, the top member being securable to the upper support structure; 2017100806 21 Jun2017 one or more prefabricated wall frames, each frame having a height which extends substantially between the upper and lower support structures, 5 wherein the or each frame is receivable between the side walls of the top member when secured to the upper support structure with the side walls depending, such that a clearance is provided above the top of the or each frame and with the side walls extending below the top of the or each frame.

The partition wall system may also include a bottom member which may include 10 all of the features described above in connection with the first aspect of the invention.

In accordance with a third aspect of the present invention, there is provided a partition wall incorporating the system described above in accordance with the second aspect, the partition wall including one or more top members secured to the upper support structure with the side walls thereof depending, and a plurality of said 15 prefabricated wall frames being spaced apart and received between the side walls of the top member such that a clearance is provided above the frames while the side walls extend below the top of each frame.

As used herein, except where the context requires otherwise, the term "comprise" and variations of the term, such as "comprising", "comprises" and 20 "comprised", are not intended to exclude further additives, components, integers or steps.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations 25 constitute various alternative aspects of the invention.

Further aspects of the present invention and further embodiments of the aspects described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings. 5 1001843484

Brief description of the drawings 2017100806 21 Jun2017

In order that the invention may be more fully understood, some embodiments will now be described, by way of example, with reference to the figures in which:

Figure 1 is a longitudinal sectional view of the top and bottom members 5 according to a first preferred embodiment of the present invention;

Figure 2 is a longitudinal sectional view of a partition wall system according to a first preferred embodiment;

Figure 3 is a longitudinal sectional view of top and bottom members according to a second preferred embodiment; I0 Figure 4 is a longitudinal sectional view of a partition wall system in accordance with the second preferred embodiment;

Figure 5 is a longitudinal sectional view of the top and bottom members according to a third preferred embodiment;

Figure 5A is a longitudinal sectional view of a partition wall system in accordance 15 with the third preferred embodiment;

Figure 6 is a longitudinal sectional view of the top and bottom members according to a fourth preferred embodiment;

Figure 6A is a longitudinal sectional view of a partition wall system in accordance with the fourth preferred embodiment; 20 Figure 7 is a longitudinal sectional view illustrating the securement of the top member to the upper support structure and the relative position of a prefabricated wall frame;

Figure 8 is a longitudinal sectional view showing the securement of the bottom member to the lower support structure and the relative position of the prefabricated wall 25 frame;

Figure 9 is a side view of a partly constructed partition wall illustrating the spacing of the prefabricated wall frame for 13mm or 16mm plasterboard applications; 6 1001843484

Figure 10 is a side view of a partly constructed partition wall showing the spacing of the prefabricated wall frames suitable for 10mm plasterboard applications; 2017100806 21 Jun2017

Figure 11 is a cross sectional view of a doorway showing the arrangement of the prefabricated wall frames;

5 Figure 12 is a cross sectional view of intersecting partition walls forming a U shape, showing the arrangement of prefabricated wall frames;

Figure 13 is a cross sectional view of a T-intersection of partition walls, showing the arrangement of prefabricated wall frames;

Figure 14 is a cross sectional view illustrating a right-angled corner of a partition I0 wall, showing the arrangement of prefabricated wall frames;

Figure 15 is a cross sectional view of a partition wall with an included oblique angle, showing the arrangement of prefabricated wall frames;

Figure 16 is a cross sectional view of a projecting partition wall showing the arrangement of a prefabricated wall frame; 15 Figure 17 is a cross sectional view of a length of partition wall, illustrating the arrangement of standard prefabricated wall frames at regular spacing;

Figure 18 is a diagram illustrating the relative dimensions; and

Figure 19 is a cross-sectional view of the stud profile.

Detailed description of the embodiments 20 Figures 1 and 2 illustrate the main components of the partition wall system in accordance with the first preferred embodiment of the present invention. The partition wall system 10 includes facing top and bottom members 12, 14. The top member 12 is in the form of an aluminium extruded right-angle C-section elongate channel as shown, having a top wall 16 and dependent side walls 18. The cross section is constant 25 throughout the length of the top member 12. The base metal thickness of the top member is 0.75mm. The top member 12 defines a downwardly open recess 20 into which the prefabricated wall frame 22 is inserted, as will be explained. 7 1001843484

As shown in figure 7, the top member 12 is secured to the upper support structure 24, in this case a concrete soffit 24. The top member 12 is secured to the concrete soffit 24 by means of 22mm drive washer pins 26. There is a series of spaced pins 26 along the length of the top member 12, through the top wall 16, in a central 5 location between the side walls 18. Since the top member 12 is constructed of a resiliently deformable metal extrusion, the location of the washer will cause slight bending or flexing of the top wall 16 so that the top wall 16 becomes concave relative to the recess 20. This causes the side walls 18 to flex inwardly and bear against the sides of the prefabricated wall frames 22 received in the recess 20. 2017100806 21 Jun2017 I0 Figure 1 also illustrates the bottom member 14 which is similar in many respects to the top member 12. The bottom member 14 is an elongate extruded aluminium profile of constant cross section shaped in a right-angled C-section. The bottom member 14 includes a bottom wall 30 and two spaced side walls 32. The bottom member 14 in position defines an upwardly open channel with an upwardly open recess 34 to receive 15 the prefabricated wall frames 22.

As shown in figure 8, the bottom member 14 is secured to the lower support structure, in this case a concrete slab 36 which defines a lower support surface such as a floor 38. The bottom member 14 is secured to the concrete slab 36 by means of 22mm drive washer pins 40. The drive washer pins 40 are spaced along the length of 20 the bottom member 14 to secure the bottom member 14 to the concrete slab 36 and to flex the side walls 32 inwardly to bear against the prefabricated wall frames 22 placed within the bottom member 14.

As shown in figure 1, the top member 12 has longer side walls 18 compared to the side walls 32 of the bottom member 14. The height of the side walls of the top 25 member 12 is 100mm as shown, whereas the bottom member 14 has a side wall height of only 30mm as shown. Additionally, the base metal thickness of the top member 12 is 0.75mm whereas the base metal thickness of the bottom member is 0.55mm. This is reflective of the fact that the bottom member 14 is subjected to lower loads whereby the side walls merely define the location of the prefabricated wall frames and the concrete 30 slab 36 (figure 8) bears the weight of the wall frames 22. On the other hand, the side walls 18 of the top member 12 may be subjected to higher loads because the side walls 8 1001843484 18 maintain the wall frame 22 in upright orientation and prevent the wall frame 22 from leaning over. 2017100806 21 Jun2017

The height of the top member 12 is approximately 3.3 times the height of the bottom member 14. 5 Figure 2 illustrates the basic form of the prefabricated wall frame 22 received within the top and bottom members 12, 14. Each prefabricated wall frame 22 has a top plate 42 and a sole plate 44. The top plate 42 is also in the form of an extruded aluminium right-angled C-section of constant cross section as shown. The top plate 42 is narrower in width than the top member 12. For example, whereas the top member 12 I0 may be 54/55mm, the top plate 42 is only 50/51 mm. This enables the wall frames 22 to move within the top and bottom members 12, 14, particularly to slide into position.

Each of the wall frames 22 will be comprised of a top plate 42 and a sole plate 44 with upright studs 46 extending therebetween. The top plate 42 and the sole plate 44 have facing recesses and the top and bottom and the studs 46 are received therein. 15 The prefabricated wall frames are prefabricated offsite in a different location from the building site where the partition walls are being formed. Typically, the prefabricated wall frames 22 will be constructed in a factory in a range of standardised sizes as will be described in this document. The prefabricated wall frames 22 thus come fully assembled, ready to be inserted into the top and bottom members 12, 14 on site. 20 The frames are produced in the factory in a range of standard frame widths.

However, the frames 22 are constructed according to the required height between the upper and lower support structures 24, 36. While the frames are customised and site-specific to the height of the building space, the play allowed by the clearance above the top of the frames will allow for a high degree of variation in the building space height. 25 Therefore, individual on-site customisation to suit varying building space height will not be required.

The form of the metal studs 46 is illustrated in figure 19 which is shown in the form of a channel with the open side of the channel having returns 48. The end wall 50 is profiled as shown to increase strength. This is merely one particular form of a metal 9 1001843484 stud 46 and other shapes are also possible. The base metal thickness of the metal stud is 0.55mm. 2017100806 21 Jun2017

While various component thicknesses are illustrated in the figures, this may vary depending upon the application. Suitable base metal thicknesses may include 0.55mm, 5 0.75mm and 1.15mm.

The mode of constructing the partition wall will now be described. In order to insert the wall frame 22 into the top and bottom members 12, 14, the wall frame 22 is tilted at an angle so that the top can be inserted into the downwardly open recess 20 of the top member 12. The angle of inclination may be gradually adjusted towards upright I0 while being gradually lifted so that the top of the wall frame 22 is gradually moved into the recess 20, towards the top wall 16. When the wall frame 22 is at or near the top of the top member 12, the bottom of the wall frame 12 should clear the bottom member 14 so that the wall frame 22 is able to be fully upright between the top and bottom members 12, 14. Once the bottom of the wall frame 22 clears the top of the bottom 15 member 14, the wall frame 22 may be dropped into position until the bottom of the wall frame 22 is seated on the bottom wall 30, between the side walls 32. In this position, the top of the wall frame 22 should still be disposed between the two side walls 18 of the top member 12 as shown in figure 18. In the seated position, there should be a clearance between the top of the wall frame 22 and the top wall 16 of the top member 20 12. This clearance allows for relative movement between the concrete soffit 24 and the concrete slab 36 which impacts on the top and bottom members 12, 14 because they are secured directly to these support structures. At the same time, the side walls 18 of the top member 12 bear against the sides of the wall frame 22, holding it firmly in position. 25 In order to facilitate the assembly as described, there is a dimensional relationship between the components. Where x is the height of the wall frame 22; a is the nominal or average height of the building space between the opposed upper and lower support structures 24, 36; 30 b is the height of the bottom member 14; and 10 1001843484 c is the height of the top member 12; then: 2017100806 21 Jun2017 x > (a - c) x < (a - b)

However, the above arrangement allows for 70mm of play which will allow for 5 variability in the building space height (a) while still allowing for functioning of this embodiment.

In extreme variations of building space height, it may be necessary to take further measures to take account of the variation in dimension a.

Figure 9 illustrates a partition wall 50 made up of opposing top and bottom I0 members 12, 14 with thick prefabricated walls frames 22 installed between the top and bottom members 12, 14. Each of the wall frames is 1,200mm and is separated from its neighbour by a gap of 600mm. Once the wall frames 22 have been inserted into position, they can be slid along tracks defined by the top and bottom members 12, 14 until they reach their desired location. The arrangement illustrated in figure 9 is suitable 15 for 13mm or 16mm thickness of plasterboard.

Figure 10 is a side view of a partition wall 52 similar to that shown in Figure 9. However, the prefabricated wall frames 22 are at spacings of 450mm and themselves have a width of 900mm. This is suited for 10mm plasterboard applications.

Figures 3 and 4 illustrate the second preferred embodiment where the width of 20 the top and bottom members 12', 14' is 80mm. In this embodiment, the top plate 42' and the bottom plate 44' have a width of 76mm as does the stud 46'.

In the third embodiment illustrated in figures 5 and 5A, the top and bottom members 12", 14" have a width of 68mm and the top plate 42" and the sole plate 44" have a width of 64mm. 25 In the fourth embodiment illustrated in figures 6 and 6A, the top and bottom members 12"', 14'" have a width of 96mm and the top plate 42'" and the sole plate 44"" have a width of 92mm. Otherwise, these components in the second, third and fourth embodiments are the same as those described for the first embodiment. 11 1001843484

As already explained in connection with figures 9 and 10, the wall frames 22 may come in a variety of standard widths such as 900mm or 1,200mm. Other standard widths also include 100mm, 150mm and 600mm. The shorter widths generally have application as doorjambs (figure 11) and corners (figures 12-14). 2017100806 21 Jun2017 5 The foregoing describes only one embodiment of the present invention and modifications may be made thereto without department from the scope of the invention. 12 1001843484

Claims (5)

1. A method of constructing a partition wall in a building space between opposed upper and lower support structures, the lower support structure defining a lower support surface in the building space, and the upper support structure defining an upper height limit for the building space, the method including: securing a top member to the upper support structure, wherein in the top member defines a downwardly open recess between spaced side walls thereof; providing one or more prefabricated wall frames, each frame having a height which extends substantially between the upper and lower support structures; installing the or each frame in an upright manner such that the top thereof lies between the side walls of the top member, with a clearance provided above the top of the or each frame and with the side walls extending below the top of the or each frame.

2. The method as claimed in claim 1 further including securing a bottom member to the lower support structure, the bottom member defining an upwardly open recess between spaced side walls, wherein the upwardly open recess of the bottom member faces the downwardly open recess of the top member.

3. The method as claimed in claim 2 further including sliding the frames along the top and bottom members until they reach respective desired positions with gaps between the frames.

4. The method as claimed in any one of the preceding claims where the step of securing the top and/or bottom members comprises: driving a fastener through the member into the corresponding support structure to inwardly flex the side walls of the member.

5. A partition wall system for a building space between upper and lower support structures, the lower support structure defining a lower support surface in the building space and the upper support structure defining an upper height limit for the building space, the system including: a top member which defines an open recess between spaced side walls thereof, the top member being securable to the upper support structure; one or more prefabricated wall frames, each frame having a height which extends substantially between the upper and lower support structures, wherein the or each frame is receivable between the side walls of the top member when secured to the upper support structure with the side walls depending, such that a clearance is provided above the top of the or each frame and with the side walls extending below the top of the or each frame.