CA2412174A1

CA2412174A1 - Modular building apparatus and method

Info

Publication number: CA2412174A1
Application number: CA 2412174
Authority: CA
Inventors: Jorma Rauma; Salman Sayeed; Henry Yeo
Original assignee: Individual
Current assignee: MINAEAN BUILDING SOLUTIONS Inc
Priority date: 2002-11-20
Filing date: 2002-11-20
Publication date: 2004-05-20

Abstract

A new and unique construction system based on using a combination of modular components including load-bearing cold rolled Light Gage Steel (LGS) wall panels, floor decking, attachment means and other components, which are manufactured, pre-assembled and transported in kit form to the site, so as to enable the quick and simplified construction of calamity and theft resistant cost effective buildings, from single story single family residential buildings to multi-family housing residential buildings up to four stories in height, as well as commercial and industrial buildings with particular emphasis on applications in the developing countries of the world.

Description

MODULAR BUILDING APPARATUS AND METHOD
1. TECHNICAL FIELD
The present invention relates generally to modular home and commercial buildings and construction methods. More specifically, a modular construction method employing steel load-bearing panels, on-site poured concrete floor slabs and unique attachment means is disclosed.

2. BACKGROUND OF THE INVENTION
Construction methods and building materials have changed significantly during recent years in the industrialized and developed countries of the world. Less developed countries ("LDCs") have not kept pace with the new methods and materials due to cost and a lack of skilled labor, resulting in the widespread use of inefficient and environmentally damaging construction methods. LDCs are usually highly populated with a large and inexpensive labor force available. Recently, however, substantial increases in the population of LDC'.s, combined with urbanization, have rendered traditional labor intensive construction methods inadequate for meeting housing demands. Traditional construction materials such as wood, cement mortar, concrete, and bricks made of clay have proven to be wasteful of natural resources, energy inefficient, and time consuming to manufacture. The lack of standardized building products and industrialized manufacturing of housing components, combined with the explosion in population levels, has exacerbated the emergency in housing shortages.
Pressured by the internal demand for housing, while at the same time encouraged by foreign aid, many LDCs have now placed the improvement of housing conditions on top priority in their political agendas. There is an immediate need in LDCs for cost-effective construction systems and materials to efficiently address housing shortages. Such systems and materials must withstand natural calamities and disasters such as earthquakes, typhoons, and heavy rains that often afflict LDCs, particularly in the tropical and sub-tropical regions of the world. Security concerns are also important.
There has been a gradual shift to steel frame construction systems in North America and Canada. The competitive pricing of light gage steel components and its durability have made it a popular building material.
Steel has many inherent advantages as a construction material, including being lightweight, eco-friendly, 100% recyclable, and fire-resistant. The use of cold rolled steel as a construction material is a well established practice in the industrialized nations, particularly for lightweight steel framing systems such as studs and joists, etc.
Cold rolled steel sheets have been extensively used for sandwich wall panel systems which are not structural load-bearing walls. Such sandwich panels are typically used in conjunction with structural steelwork framing systems, usually for industrial buildings.
United States Patent No. 3,879,911 disclosed interlocking wall panels with interior corrugated heat insulating board for use as non-load-bearing partition walls sheathed in metal.
United States Patent No. 4,346,541 disclosed panels consisting of thin cardboard sheets with a trapezoidal corrugated cardboard interior for non load-bearing applications such as wall cladding and roofing. .
Recently, some wall panels have been developed which include sheet steel components which bear some of the load of the building, United States Patent No. 5,678,384 ('_384) discloses a construction system comprising of metal (either steel or aluminurn) corrugated wall panels and other components specifically for building two story burglar resistant buildings.
The wall panels use a system of longitudinal interlocking grooves, and are secured by vertical wall anchor bolts. The wall panels of the '384 patent are coated with insulation material (typically sprayed foam) and finished with conventional gypsum drywall on the interior surface and a conventional vinyl siding on the exterior surface.
The wall panels therefore have gaps in the interior insulation between the corrugations in the steel in the wall panels.
2.

US Patent No. 5,007,225 discloses composite metal panels with outer steel panels welded to an internal corrugated stiffener plate for application in shipbuilding.
The '225 patent describes a method of welding steel panels together which do not overlap.
The object of the present invention is t.o overcome the disadvantages of the prior art by providing an efficient system for assembling buildings, both for residential and industrial applications, using prefabricated load-bearing steel panels and attachment means. The assembled buildings arc calamity resistant, and stronger than existing panels due to the unique construction method and combination of steel, fiber cement board (FCB) and expanded or extruded polystyrene (EPS) boards. The present invention also provides the advantages of simple manufacture, packaging, transportation and assembly of the components.

3. SUMMARY OF THE INVENTION
It is an object of the present invention to provide a modular building construction system providing a method and apparatus which is quick and simple to erect with minimal materials, machinery and infrastructure.
Another object of the present invention is to provide prefabricated components that may be integrated and assembled at a building site with minimal skill and training and which can be manufactured, packaged and transported simply and easily.
In accordance with the present invention a building construction is disclosed.
The building includes a foundation, a plurality of load-bearing wall panels with corrugated metal cores, a plurality of metal corner panels connected to the wall panels at the corners of the building, a plurality of steel top elements disposed along the top edge of the wall panels and the corner panels, and a roof.
Advantageously, the building may comprise wall cladding, vertically corrugated wall panels, insulation disposed in the corrugations, and a plurality of bottom panels attached to the foundation.
The building may further comprise a,t least one interior wall, with a steel C-channel bottom element. attached to the foundation, a plurality of C-channel stud elements, a C-channel top element and cladding attached to each face of the interior wall.
Advantageously, the building may further comprise multiple stories with additional floors comprised of a plurality of "L" profile steel elements attached to the top elements, a plurality of joists extending across the building from the "L"
profile elements, corrugated steel decking spanning the building, and a concrete floor slab poured on the decking with anchoring members embedded in the slab such that the slab forms a foundation on which subsequent stories can be attached.
The invention also pertains to a modular building construction having a foundation, anchoring members disposed about the building perimeter, templates disposed about the perimeter to retain the anchoring members in alignment, steel elements attached to the anchoring members with a flange on the outer edge and a series of tabs on the inner edge, a generally rectangular steel corner panel attached at its base to the bottom plates and extending vertically to form the corners of said building, a plurality of top elements attached to the top of the corner panels and extending horizontally to form a frame for either the roof or additional stories, at least one door frame, and a plurality of corrugated steel wall panels.
The modular building can further comprise planar sheets of cladding material attached to an interior and exterior face of the wall panels, and a plurality of window frames. Furthermore, the modular components comprising panels, top elements and wall panels can be attached by either bolts, screws or welds, to each other at the building site by overlapping flanges disposed along the longitudinal edges of each the modular components.
The invention also pertains to a method of constructing a building comprising the steps of pouring a concrete foundation, placing a plurality of anchoring members in the foundation, installing a plurality of templates around the perimeter of the building, attaching a plurality of bottom plates on top of the templates, attaching a steel corner panel vertically to the bottom plates at each corner of the perimeter, attaching top plates on top of the corner panels thereby creating a single story frame for the building, inserting at least one steel prefabricated door frame, attaching a plurality of load-bearing wall panels comprised of corrugated steel sections to the bottom plates and the top plates to form a continuous wall around the perimeter, attaching planar sheets of wall cladding to both faces of the wall panels, and attaching a roof.
Furthermore, a kit for a modular building is disclosed comprising a plurality of steel bottom plates, a plurality of steel corner panels, a plurality of corrugated steel load-bearing wall panels with flanges at each longitudinal edge adapted to accept cladding, a plurality of C'-section top plates with flanges along each longitudinal edge, and a plurality of anchoring members to be placed in the foundation. The kit can further comprise a plurality of elongated steel elements, corrugated steel decking, a plurality of steel C-section joists whereby the steel elements, steel decking and joists are adapted for quick and easy construction of an additional story of said modular building.
The unique load-bearing wall unit for use in a modular building construction according to the invention comprises a corrugated steel core, cladding material attached to the corrugated steel core on both the interior and exterior surface of the wall panel, and insulation material disposed inside the wall panel such that the insulation material is generally contiguous with the cladding material and the corrugated steel core. The cladding material can be gypsum board, fiber cement board, oriented strand board or vinyl siding. The insulation material can be one of expanded polystyrene, extruded polystyrene, polyurethane foam, rock wool or glass wool.
The individual, unique modular components of the building system include a metal wall component comprising a generally rectangular, planar corner panel with a longitudinal groove and flanges disposed along each longitudinal edge; a load bearing metal wall component comprising a generally rectangular, corrugated panel having a flat, central, longitudinal ridge with two sides disposed along each longitudinal edge of said ridge al an oblique angle to the ridge, and flanges along the outer, longitudinal edge of the sides; a generally rectangular panel having a flat, central, longitudinal face disposed at an oblique angle to a flange along each edge; a generally rectangular elongated metal bottom panel; a generally rectangular elongated metal top panel; and a generally rectangular load bearing, metal, corrugated panel having a series of alternating, flat, central, vertical ridges and l;rooves and a flange disposed along each of the outer edges of the panel. The wall component preferably has 5 ridges and S

grOOVeS.
In a variation, a prefabricated buildin~; is provided in kit form for erection on an oil rig platform comprising a plurality of the above unique components, without the necessity of a foundation.
In a further variation, a radiation resistant modular building construction is disclosed comprising the above unique components wherein the corrugated metal core is comprised of lead sheeting to inhibit harmful radiation.
4. BRIEF DESCRIPTION OF THE DRAWINGS
The apparatus and method of the present invention will now be described with reference to the accompanying drawing figures, in which:
FIG. 1 is a perspective view of a completed typical single story residential building according to the invention.
FIG. 2 is an elevation view of a foundation and bottom plate according to the invention.
FIG. 3 is a plan view of a diagonal spacer bar attached to two templates according to the invention.
FIG. 4 is a perspective view of a bottom plate according to the invention.
FIG. 5 is an elevation view of two bottom plates abutting at a corner according to the invention.
FIG. 6 is perspective view of a corner panel according to the invention.
FIG. 7 is a plan view of a single wall panel according to the invention.
FIG. 8 is an elevation view of a single wall panel according to the invention.
FIG. 9 is a detail plan view of the connection between a corner panel and two single wall panels according to the invention.
FIG. 10 is a perspective view of a multi-wall panel according to the invention.
FIG. 11 is perspective view of a top plate according to the invention.
FIG. 12 is perspective view of a haat panel according to the invention.
FIG. l3 is perspective view of a half wall panel according to the invention.
(~

FIG. 14 is a perspective view of a C~channel according to the invention.
FIG. 15 is a detail of a window frame according to the invention, FIG. 16 is an elevation view of a window frame in a wall panel according to the invention.
FIG. 17 is a sectional view of Figure 16 along A-A.
FIG 18 is an elevation view of a doorframe according to the invention.
FIG 19 is a sectional view of Figure 18 along .A-A.
FIG. 20 is a perspective view of insulation cut to fit a wall panel according to the invention.
FIG 21 is a plan view of a wal! corner section with insulation, internal and exterior cladding installed according to the invention.
FIG ZZ is a plan view of an interior partition wall according to the invention.
FIG. 23 is a plan view of the top of the intersection of aai interior and exterior wall according to the invention.
FLG. 24 is a perspective view of a roof truss bracket according io the invention.
FIG. 25 is a perspective cut-away view of a roof truss on a wall section according to the invention.
FIG. 26 is an elevation view of a roof according to the invention.
FIG. 27 is a perspective view of a floor decking sheet according to the invention.
FIG. 28 is a perspective view o1~ an angle component according to the invention.
FIG. 29 is an elevation view of a floor slab for a multiple story building according to the invention.
FIG. 30 is a floor plan view of a typical single story residential building according to the invention.

5. DETAILED DESCRIPTION OF THE INVENTION
Referring to Figure 1, the preferred embodiment of the invention, a completed building 10 is shown in perspective. T'he building 10 is assembled from the novel modular building components according to the preferred method. The building 10 has a foundation 12, walls 20, roof 40 and other joinery such as doors 50 and windows 56.

The foundation 12 is typically constructed of concrete, and may consist of either a 'raft' type slab laid on well compacted grade, or isolated stub columns and pads with a 'plinth beam' along the perimeter of the building under the load-bearing walls (not shown). In all cases, the type and design of the foundations are dependent upon the nature of the soil conditions found at the respective site locations and will vary from project to project. All internal and external walls 20, doorframes 51, window frames 57 and roof trusses 63 are assembled from the modular components of the invention.
The first step of the preferred method is to construct a concrete foundation slab 12 according to individual design depending upon the ground conditions of the intended building 10 site. The site must be prepared by clearing off all debris, vegetation and topsoil. The building 10 dimensions must be laid out on the correct location. The ground or soil is then excavated to the required depth. The ground or soil should be prepared by leveling, watering and compacting. The form work for the foundation 12 must be installed followed by steel reinforcing as required. All drainage pipe work, water lines, and ducts for incoming electrical and telephone services and any other services connections must be placed before pouring the foundation as required.
Referring now to Figure 2, the first component of the modular building system, an attachment means, preferably anchor bolts. 70, are placed in the slab 12 or through the ground beams (not shown) as required along the line of the walls 20. Prior to pouring the concrete for the i-oundaiion 12, the anchor bolts 70 are held in place using any retainer known in the industry. The anchor bolts 70 are preferably J-bolts, which provide improved resistance to torsion or bending at the base of the walls 20.
The number of bolts 70 required is dependent on the dimensions of the building 10.
In the preferred embodiment, one bolt 70 per approximately 600 mm (23.64 in) of wall 20 is required. The bottom portion of the anchor bolts 70 are substantially immersed in the foundation 12, with the upper threaded portion protruding.
Longitudinal steel bars or templates 15 are inserted over the anchor bolts 70 in the wet concrete along the perimeter of the proposed building 10. Holes (not shown) are disposed at regular intervals to receive tine anchor bolts 70. The templates 15 act as a guide for the anchor bolts 70.

Referring now to Figure 3, a diagonal spacer bar 28 is attached at each corner of the building 10 between two bolts 70 in the templates 15, which are equidistant from the corner of the building 10. The spacer bar 28 must be disposed at the same angle from each of the two templates 15 to ensure that the corner panels 22 are straight and plumb.
Once the foundation 12 is dry, all the external and internal walls, doors and window positions should be marked out on the foundation 12, and checked with the drawings to ensure that all markings are correct.
Referring now to Figure 4, a bottom plate 14 is provided comprising a substantially rectangular steel plate with a thickness between 1.5 mm (0.0591 in) and 2.5 mm ( 0.0985 in), preferably consisting of light gage steel ("LGS"), as are the other modular components of the system, excluding the attachment means. A short, curved projection extends substantially vertically from one side of the bottom plate 14. There are a plurality of holes, each of a diameter sufficient to receive the attachments means, placed along the longitudinal axis of the bottom plate 14. In the preferred embodiment, for example, the holes are placed every 300 mm (1 1.82 in). The attachment means (not shown) may be anchor bolts 70. Alternatively, expanding bolts may be used. A
plurality of flaps or tabs 16 are punched in the bottom plate 14 along the longitudinal axis of the bottom plate 14, such that the flaps project at a substantially 90 degree angle from the surface of the bottom plate 14.
The bottom plate 14 is placed over the anchor bolts 70 and templates 15, using the holes provided in the bottom plate 14. Nuts 72 are tightened on the threaded ends of the anchor bolts 70 such that the bottom plates are tightly connected to and abutting the foundation 12. The bottom plates 14 should be level.
Referring now to Figure 5, the two bottom plates 14 abut at each corner at a substantially 45 degree angle. The nuts 72 on the anchor bolts 70 are tightened to securely attach the bottom plates l4 to the foundation I 2.
Once the bottom plates 14 for all the internal and external walls 20 are all installed on the foundation 12, the assembly and erecticm of the external walls 20 can commence.
c) Referring now to Figure 6, the next modular component required in the assembly process is the corner panel 22. The c;orncr panels 22 consist of metal, preferably LGS, with a thickness of between 1.2 mm (0.0473 in) and 2.5 mm (0.0985 in) according to loading requirements. In the preferred embodiment, each corner panel has a width of approximately 380 mm ( 14.972() in) and a height of approximately 2750 mm (108.35 in). The side edges of the corner panel 22 are angled inwards toward the interior face 23 of the corner panel 22 to form longitudinal flanges 32. A
notch or crimped section 25 runs longitudinally down the center of the corner panel 22.
The corner panels 22 are placed in a longitudinally vertical orientation on the bottom plates 14 at the four corners of the building 10, and fastened together using any commercially available fastening means. In the preferred embodiment bolts are used, although screws, welding or other means may be utilized. The interior face 23 of the corner panel 22 must be facing the interior of the building 10, such that the notch 25 of each corner panel 22 provides an interior corner of the building 10.
Top plates 18 (see Figure 11 ) are attached horizontally on top of each of the four corner panels 22 and above the perimeter of the building 10, such that a single story frame is created into which the next components such as door frames 51 and window frames 57 are inserted. The door frames 51 and window frames 57 are inserted between the bottom plates 14 and the top plates 18, and are fastened by bolts, welding or another commercially known fastening means. The preferred method is bolting the components together.
The next component ofthe modular system required is the single wall panel 30.
Figure 7 is an end view of a single wall panel 30, which has a flat central portion extending longitudinally, with the two edges extending at an angle of approximately 45 degrees from the sides of the flat central portion 31. A tlange 32 extends on each side parallel to the central portion 31.
Figure 8 is an elevation view of the single wall panel 30. Holes for electrical and plumbing services are puncheii or drilled in the single wall panel 30. The installation of single wall panels 30 is completed in two steps. First, one single wall panel 30 is installed on each side of the four corner panels 22. The wall panels 30 are bolted to the bottom plates 14 with attachment means of sufficient strength to meet structural design requirements and applicable seismic resistance standards.
The flanges 32 of the corner panels 22 and the single wall panels 30 are overlapped and attached to each other by any known means. In the preferred embodiment, the flanges 32 of the corner panels 22 and the single or multiple wall panels 34 are over-lapped and attached by means of self tapping screws placed every 3()0 mm ( 11.82 in). The tabs 16 on the bottom plates 14 are bent into position parallel with the surface of the wall panels 20, to provide a surface for connection to the walls 20. The walls 20 are then attached by screws, bolts or welds at the tabs 16 to the bottom plate 14.
Figure 9 is a detail plan view of the connection between a corner panel 22 and two single wall panels 30. The single wall panels 30 are aligned vertically and abutting the corner panel 22 with the flanges 32 overlapping. Holes are drilled and the flanges are bolted together.
Figure 10 is a perspective view of a mufti-wall panel 34, consisting of a single sheet of steel, preferably LGS, with a flange 32 on each outer edge. The mufti-wall panel 34 is corrugated in a series of ridges and grooves of similar profile to the single wall panel 30. In the preferred embodiment there are five ridges forming longitudinal flat portions or faces 36.
The walls 20 are constructed by inserting a series of single wall panels 30 and mufti-wall panels 34 as required. In the preferred embodiment, the mufti-wall panels are approximately 900 mm (35.46 in) wide and 2750 mm (108.35 in) high. The number of panels 30 is preset depending on the sire of building 10 desired, and the preset number of panels 30 is supplied in a kit.
Figure 11 is a perspective view of a tap plate 18 which is a length of C-section steel, preferably LGS, having a flange 32 disposed at substantially 90 degrees from the side of the C-section. The open end of the C-section top plate 18 is fitted over the top of the walls 20, with the flange projecting horizontally towards the interior of the building 10.
The wall panels 20 are fastened to the top plates 18 and bottom plates 14, using any known fastening means such as welding, screwing or bolting, ensuring that there are no gaps between the wall panels 29, the bottom plates 14, and top plates 18. In the preferred embodiment bolts are used. The top plates 18 are attached to the corner panels 22, door frames 51, and window frames 57, preferably with bolts, or alternatively by welding.
The wall panels 29 must fit snugly under the top plates 18. It is vital that there are no gaps between the top plates 18 and the top edge of the wall panels 29, as the roof loads must be distributed unifornlly all along the top of the walls 20.
Additionally, the wall panels 20 must be installed straight and plumb without any bends. All load-bearing wail panels 29 rest on, and are connected to, the bottom plate 14, which transfers the wall loads to the foundation 12.
Figure 12 is a perspective view of a hat panel 35 (which is a component known in the industry), having a flat central longitudinal surface or face 36, sides extended from the central surface at a steep angle, and flanges 32 extending parallel to the central flat surface 36 from the sides. The hat panel 35 is approx imately 1 J6 mm (7.7224 in) in the preferred embodiment, and can be used either to reinforce a wall 20 or to extend a wall 20 where non-standard dimensions are required. All flanges 32 of the modular components according to the invention arc of a consistent width and height such that they may be overlapped in a contiguous manner for easy and secure attachment.
Figure 13 is a perspective view of a half wall panel 37, which is half of a ridge found in the corrugated multi-wall panels 34, with a single angled surface and a flange 32 extending from each edge. The half wall panel 37 is used to extend walls 20 in the case of unusual dimensions.
The walls 20 are typically assembled in 9-foot or 2750 mm (108.35 in) high sections consisting of 3 multi-wall panels 34. An advantage of the invention is the provision of the modular components in quantities suitable to construct a building 10 which is of a standard size, thereby reducing; assembly time and difficulty.
Figure 14 is a perspective view of a C-channel 79, which is used as a bottom track 80, top track 82, and stud 84, all for interior, non load-bearing walls 21, or for window 56 and door 50 construction. 'fhe bottom tracks 80 have holes provided to receive the anchor bolts 70. The studs 84 have holes provided which are at the same elevation as the holes in the walls 20 for the insertion of electrical and plumbing services. The bottom tracks 80 and top tracks 82 are sized to fit snugly inside the studs 84.

In order to insert a window, the wall 20 edge must be capped with a stud 84.
Referring to Figure 15, one ann of the C-channel stud 84 overlaps and abuts the interior face 23 of the flange 32 on the single wall panel 30 or multi-wall panel 34.
Figure 16 is an elevation view of a window frame 57 in a wall 20. In the preferred embodiment, standard sized multi-wall panels 34 are cut to shorter lengths and placed one above thi; proposed window 56 and one below. The bottom and top edges respectively of the multi-wall panels 34 are then capped with a stud 84 bolted to the flat portions of the panel 34. A,ny commercially available window may be framed and inserted in the space provided.
Figure 17 is a section view of Figure 16 along A-A depicting how two back to back studs 84 are used below a window frame 57 in order to provide adequate reinforcing.
Figure 18 is an elevation view of a doorframe 51 section in a wall 20. The bottom plate 14 (bottom track 80 for internal doorframes S1 ) ends at each edge of the doorframe 51.
Figure 19 is a sectional view along A-A of Figure 18 showing how a door (not shown) can be framed by capping the edges of the wal l 20. One arm of the C-section 79 stud 84 overlaps and abuts the interior face 23 of the flange 32 on the single wall panel 30 or mufti-wall panel 34. The bottom and top edges respectively of the multi-wall panels 34 are then capped with a stud 84 bolted to the flat portions of the multi-wall panel 34. Doors 50 and v~rindows 56 are not components of the system.
Doorframes 51 and window frames 57 may be prefabricated and provided with the other modular components. The inside surfaces of the door frame 51 receives cladding material over which the interior (usually wooden) door frame is then installed.
Figure 20 is a perspective view of insulation 40 cut to fit a wall panel 29.
The insulation 40 is form cut to tit the grooves 38 in the corrugated wall panels 29, being a trapezoid in cross section with a flat base narrowing to a flat, longitudinal surface and a parallel, flat, horizontal top and bcottom. Expanded polystyrene (EPS), which is treated to be flame retardant, is the preferred material for the insulation means 40, although other commercially known types of insutat:ion 40 such as extruded polystyrene, polyurethane foam, rock-wool, and glass-wool may be used, whether pre-cut and inserted, or sprayed in. In the preferred embodiment the insulation 40 is cut in units 1371 tnm (54 in) high and stacked two high for each groove 38. The insulation 40 is form fitted to the grooves 38 in the wall panels 29, and glued in place where necessary.
While the insulation 40 is being installed, the installation of the electrical and plumbing services (not shown) should also commence. The electrical and telephone wiring should be installed in between the wall panel cavities as required, and the positions of the power outlet boxes, light and other appliance switches should all be marked and the conduit boxes installed. The main electrical panels should also be installed during this stage. Similarly, first stage installation of all plumbing and drainage lines should be completed during this stage. Electrical, plumbing and telephone installation are not part ol~the modular system and components are not provided.
Figure 21 is a plan view of a wall 20 corner with insulation 40 and an external wall cladding 42 and internal wall cladding 44 installed. The cladding may be of any commercial available product such as gypsum board, fiber cement board, oriented strand board or vinyl siding. Fiber cement board ("FCI3") is preferred for external and internal cladding 42 in LDC's.
The FCB external wall cladding 42 is installed by placing the cladding 42 against the flat surface 26 of the wall panel 29 , then screwing through the cladding 42 and into the flat surface 26 on the ridges 39 of the wall panels 29. 3 x 18 mm (0.1182 x 0.7092 in) self drilling screws are preferred.
The cladding 42 panels must fit properly and be straight and plumb. Where required, the panels may have to be trimmed and made to fit, particularly around the window frames 57 and doorirames S1. Any commercially available compound may be applied to the joints of the cladding panels 42 to seal the joints.
The inten~al cladding 44 is installed similarly to the external cladding 42, by screwing the cladding 44 to the interior face 23 ol~the flat surfaces 26 of the wall panels 29. Any commercially available cladding 44 may be used. Gypsum board is preferred for interior cladding 44.
Figure 22 is a plan view of an interior partition wall 21 as attached to an exterior wall 27. A bottom track 80 is bolted to the foundation l2 by anchor bolts 70 with a length as desired for the interior wall 21 length. Studs 84 are bolted to the bottom track 80 as required for loading. A top plate 18 is placed with the open end of the C-channel down over the top ends of the studs 84. Internal cladding 44 is screwed to the studs 84 and trimmed to fit.
Figure 23 is a plan view of the top portion of an interior partition wall 21 as attached to an exterior wall 27 by a connection means 74. The preferred connection means 74 is a flat rectangular steel plate having a plurality of holes drilled, (8 holes is preferred). The plate 74 is placed on top of the exterior wall 27 and interior wall Z1, such that the connection means 74 bridges the two walls 20 at each intersection of an interior wall 21 and exterior wall 27. The connection means 74 is then screwed down to the top track 82.
Referring again to Figure 9 , an angle; component 60, preferably 75 x 75 x 3 mm (3 x 3 x 0.1182 in), is placed vertically with the base at the outer corner of the bottom plates 14 and the top abutting the underside of the top plate 18. The angle components 60 are bolted to the top 18 and bottom 14 pl;rtes to provide a surface for fixing the edges of the external cladding 42 at a later stage.
For single story buildings 10, roof tr~.~ss brackets 64 are attached to the top plates 18 at regular intervals, depending on the roof 62 load. In the preferred embodiment, the brackets 64 are placed every 1200 mm (47.28 in).
Referring to Figure 24, the roof truss bracket 64 has a flat base with flaps extending downward from the front and rear- edges of the bracket to provide an attachment means to the top plate 18. Two flaps extend upward from the sides of the bracket 64.
Referring to Figure 25, roof trusses 63 are cut to size and placed transversely spanning between the exterior walls 27. Roof trusses 63 are cut from C-channels 79.
A second layer of roof trusses 63 are then attached to the brackets 64 with one end of the roof tnrss 63 extending to the exterior of the building 10 past the top plate 18, and the other end extending to the center of the building 10. The preferred angle for the second layer of roof trusses 63 is 19 degrees above horizontal. The roof trusses 63 abut at an oblique angle at the center of the building and are attached by any known means, such as bolts.

Figure; 26 is an elevation view of a roof according to the invention. Studs 84 are attached vertically between the first layer of horizontal roof trusses 63, and the second layer of roof trusses 63, in order to support the roof 62. Hat panels 35 are attached perpendicularly to the top surface of the roof trusses 63, preferably at 1200 mm (47.28 in) intervals to form purlins 66. The flange 32 of the purlin 66 is attached to the roof truss 63. Any commercially available roof sheeting 68 is then attached to the face 36 of the purlin 66 to form a waterproof roof 62. The preferred roofing material is conventional colored and galvanized steel roof sheeting. 'the galvanization provides a durable weather resistant surface to the. roof sheeting. Ridge flashing 69 made of the same materials as the roof sheeting 68 covers and weatherproofs intersections of the roof sheeting 68, and runs along the entire length of the building 10.
The eaves and gables (not shown) should overhang the building 10 edge.
Typical roof accessories such as ridge, cave and gable flashing may be installed as desired. An interior ceiling 61 is then added by cutting sheets of internal cladding 44 to fit and placing them on top of the flanges 32 of the top plates 18. Insulation 40 may then be placed on top of the ceiling 61.
For multiple story buildings, additional connponents and steps are required.
Following the steps above to construct a building 10, a floor slab 13 must be added rather than a roof 62. Figure 27 is a perspective view of a floor decking sheet 90 consisting of a sheet of corrugated steel, preferable I_CiS, with a profile similar to a single wall panel 30 but having different dimensions. In the preferred embodiment there are 7 ridges with centers 130 mm or approximately 127 mm (5 in) apart.
The use of floor decking 9U is dependent upon the structural design based on the loads which the floor slab 13 is required to carry. For smaller buildings 10 with room widths of up to 9'.0" or 275t) mm ( 108.35 in), floor decking sheets 90 of 2 mm (0.0788 in) in thickness are generally adequate to support the structural loads. In all cases, the longitudinal ridges of the decking sheet 90 should span across the shorter dimension of the room. However, for rooms of larger dimensions, the floor decking sheets are supported by LGS channels (not shown) which are placed beneath the decking sheets 90 and which act as joist > or beams to support the floor slabs 13.

Figure 28 is a perspective view of an angle component 60, which is an L shaped steel element. In the preferred embodiment the LGS angle component 60 is 9 feet or 2750 mm (108.35 in) long, and 101.6 mm (4 in) by 45 mm (().4445 in). The angle component 60 is used as an edge for poured floor slabs 13 in mufti-story buildings 10.
Refen-ing to Figure 29, angle components 60 are attached to the top surface of the top plates 18 around the periphery of the building 10, with the long side of the L of the angle component 60 projecting vertically. Floor decking sheets 90 are placed above the insulation 40 from the floor below, with a flat surface 36 of the decking 90 resting on the angle components 60. The decking sheets 90 cover the entire area of the building 10, and abut and are attached to the angle components 60. The decking sheets 90 are supported by trusses 63 (not shown byre) where applicable. Steel reinforcing 17 and anchor bolts 70 are placed suspended above the decking sheets 90 as required. The floor slab 13 of concrete is then poured with the decking sheets 90 forming the bottom of the slab 13, and the angle components 60 forming the sides. The top of the slab 13 is then leveled. Services and piping must be installed before the slab 13 sets.
The level or floor of the building 10 is then completed as for a single story building as described above. As many as three doors nnay be added in this manner. When the desired number of floors is reached, the roof 62 is added as described above for a single story building 10.
Concrete is then poured on top of the floor decking 90 to a depth appropriate for the structural loads.
Referring now to Figure 3(l, a standard single story building 10 .floor plan having a combined kitchen and living room 92 and one bedroom 94 is shown.
The table below indicates the strengths of an unsheathed wall panel for varying gages of steel sheeting. It can be seen that the walls 20, particularly when sheathed, can bear significant loads. The table may be used to determine what gage of LGS is required for a particular building 10. In the preferred embodiment, for a single story dwelling, 22 gage or 0.794 nnm (,0.0313 inch) LGS is used.

WALL SECTION PROPERTIES (Unsheathed Wall) Gauge (thickness [mm]) Strenl;th _. ~-_ -_-- __ (ASD
Design) Unsheathed ( )a Ga ! t is ( .a (ia 14(b)(ia Wall 2' 18 I (y 141 1 Z
x) (0. ( 1.2 ~ ( 1.44( 1 8 ( 1.8 (2.5 7 nu) nun) rnm) ntnr) mm) mm) ._ _. .___- ,.__ +~_____ _i.
-' A~ Inun'1 90.151 -183.28;28.93 482.35 566.70 815.11 _ __ __..__-I,~ Inlnt~l 233377 5(J7412j 611527.21761287.?8835582 1027225 Postive S (t) 4147 I t)3 ~ I 2583.63156(, 17195 21 1410 [nv'J 7 I .12 moment 8\(t,)(rrty17153 12684 15172,7818882.8120731 2584 i _. - -__, .~-_-__ _,-'~

" jrm ~

19?479 =110578507552.hU668883.90752702 9890608 Negatives"(t) 5228 05()(,', I I 14743.44I(i379 20692 [nmr'I 1521.74 ~

moment , 3624 S,~(b)[mm~~3U') 8982 11316.91153(,4.5117527 2 ~ '_- '-- _~-_--"' [nu~

1 281884 2818t>493662711.68j 5084266.865825077 7879591 Postivc 8;,.(I) IWI~) 2021$ 253(>5.54~ 33O90.IG37935 49387 Inuttjl I

monxnt >,a'k% (>059 14298 lul 31.9027669.7332256 45523 Lym'1 -_-.__1..-_.___-____._-_ .__._ , Imtl,yl 12x1883'R18649~ 3602711.685084266.865825077 7879591 Negative (,i)5~~14298 I~)131.9027159.7332256 45524 S,~tl) Lntnt'I

ntomcnt 8. H; Inl 20218 25365,54336!)0.1637935 49387 (ntnt'I 34 ___ _. _---_ -_-_ ;--_-_ Compression I ?.78 34.1 ~ =it,.(t2. 68.36 80.32 1 15.52 P,", I I:
V I
(1., m) Compression '.() 4.4 ~ 5.60 7.87 9.23 13.67 1'.~
IkNI
(L~

=2.75m : I.y ' =2.75nt ; I,,-2.75m) ~3.8:?813 23 1111.72 122.06 151.76 tension 43.27 I
~ ~I;N) ! ,,i).3'7~ 17..1927.76 33.86 42.49 , Shear 2.046 j V;"
IhNI
I

15,5'726.23 35.12 38.67 47.37 Shear J.U6 V;" 8 I I<Nl ' 1.58 1.J2 2.39 2.62 3.22 i Positive () (u3 I
moment ~1,""
IkN-ml I

I I .37 I %3 2.25 2.50 3.16 Negative (1.56a moment \f,.", [kN-rI

1.54 2.1)9 3,09 3.65 5.28 Positive Ir.635 moment (v1:~",lkN-ml j 1.54 ?.t)9 i 3,09 3.(i5 5.28 !.
Negative t~ 635 ~
moment ~-__. .__ !
Vl,""[kN-ntl I
_.

Note: 1. Use appropriate safety factor in accordance with relevant code to determine the actual allowable loads.
e.g. I'.~~,"":~,,n, = I'!y ; whcro !' is strength liwm table liw I,,tynp, -3.75 m 2. Buckling about weak axis and torsional bueklinf; are prevented by sheathing.
3. All values in table arc calculated for wall length of one foot (Icns~th of single wall panel section) l~

The table below indicates the strengths of a sheathed wall panel 29 for varying gages of steel sheeting. The novel load-bearing wall panels 29 result in rapid, easy construction of buildings 10 with minimal materials, which are provided in a prefabricated, modular format.
WALL SECTION PROPERTIES (Sheathed Wall) Gauge (thickness [mm]) Fully _ _ Braced Strength (ASD
Design) Sheathed (~a Cia (ix I6 (.a I4(a)Ga 14(b)Ga I2 Wall 22 I8 (0.7 1 I ( I .44 ( I .8 (2.U (2.5 mm) .2 mmj mm) mm) mm) mm) n~ [mm-I 90.1 .183.28328.93 482 35 566.70 815.1 I _ __ _-__-_- I
-2333~7507412 611527 761287.28835582 1027225 Postivc S"(t) ~mm'I414- IU377 12583.6315661.1217195 211410 moment S\L(b) 7153 12684 15172.7818882.8120731 2584 [rmm']

I';,.In1n111_.- -.-- --_- ._...__--I)24~9a1o57~ 50755260(ibi(st,3.9o7sz7oz 989obos NegativeS,~(t) 522s 9506 I 1521 14743.x416379 20692 ~mm'I 74 moment S". (b) 3O')' 8')82 I 131 I 536-1.5117527 23624 ~ nun' -_..-_-..._- (> ~> -.
~ I
__.

,.o. Ill7nlAl 1281884'81804<);(;(>27150842(,65825077 7879591 1.(.8 86 Postive S"(I) (mm'I1031 ?0218 25305.5-133690.1037935 49387 moment S" (r) 005'1 14298 191 31.0027059.7332256 45523 [mm's -- _ _.___.-__- _ h". [
mma l 1281883_'81804936(i2711.085084260-805825077 7879591 Negative (,05y 14?98 1')131-9()27659.7332256 45524 S,~(;) Imm'~

moment 8'~(nj IU134 20218 25305.5433690.1037935 49387 ~mm'~ i C'omprcssion 12.78 34.! 4(i.02 08.36 80.32 115.52 I',~a ~
~kNl (L.,=
U m) I
i ('ompression IU.28 2(,.73 30.00 52.50 61.45 87.12 I';, ~kNl (1..=2.75 m) I
tension 43.2' 73 82 88.23 I 10-72 122.06 151.76 I':~
IkNI
~

I
ShearV,~s-IkNI 2.0=1510.37 17.-tr) 2776 33.86 42.49 Shear 1.068 15.57 26.23 35.12 38.67 47.37 V," I I
IkNI I
~
I

, 0 03-~I 58 1.92 2.39 2.02 3.22 1'ositivc I
nu,ment M:"
~kN-m~
I!I

i Negative 0.504 I-3? I .73 2.25 2.50 3.16 moment , M:"~, I
IkN-ml I

Positive 0.925 2.18 2.92 4.23 4.92 6.95 moment i M,""IkN-m~

Negative 0 925 - 2.18 ~ 2.92 - 4.23 4.92 6.95 mnmwt -M,s-kN-ml ;

Note: I . Use appropriate safety factor in accordance with relevant code to determine the actual allowable loads.
1 ~) (e.g. P~u"";~t,a _= I'~y ; where 1' is slrcnpUh front table ti>r I..w =' 2.7s m) 2. E3uckling about weak axis and torsional buckling arc prevented by sheathing.
3. All values in table arc calculated for wall length of one foot (length of single wall panel section) The building 10 may be provided in kit fon~n containing the above detailed components, a component list, instructions, and drawings for easy assembly and erection. Further, a training manual is available for people using the invention.
The list will therefore contain a plurality of anchor bolts, templates, bottom plates, corner parcels, single wall panels, multi-wall panels, top plates, bottom tracks, top tracks, connectors, pre-assembled door frames, pre-assembled window and ventilator frames, studs and C-channels, hat profiles, fiber cement board external wall cladding sheets, fiber cement board (or gypsum board) internal wall cladding and false ceiling, EPS (or rockwool) insulation, and fasteners.
It should be understood that the various modular components of the invention integrate with each other and may be used in conjunction with other components described above which have not been described in detail, and additional prior art construction materials and components.
The construction manual provided to the user describes the steps of start-up, foundation installation, setting out walls, installing bottom plates, corner panels, wall panels, door and window frames, top plates, roof trusses, roofing panels, insulation, electrical wiring and plumbing, cxteo~al and internal cladding, the ceiling, door and windows, and other finishes and fixtures. The manual may form a component of the kit.
In an additional variation, the building 10 t~~ay be provided in a kit format for construction on an oil rig platform. to this case the bottom plates 14 are welded or bolted onto the rig platform, and the building 10 is then completed as described above.
In a further variation, the wal I panels 29 may be constructed from lead rather than LGS in order to act as a shield from radiation. The building 10 may then be constructed underground as a radiation-proofbunker, having wall panels 29 with corrugated lead sheeting as a core.
The preferred embodiments herein described are not intended to be exhaustive or to limit the scope of the invention to the precise forms disclosed. They are chosen '? 0 and described to best explain the principles of the invention and its application and practical use to allow others skilled in the art to comprehend its teachings.
As swill be apparent to those skilled in tile art in tile light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.

Claims

1. A building construction comprising:

a) a foundation having an exterior perimeter;
b) a plurality of load-bearing wall panels extending upward from said foundation, said wall panels comprising a corrugated metal core having an interior and exterior face;
c) a plurality of generally planar, metal corner panels connected to two said wall panels at the longitudinal edges of said wall panels such that said corner panels bisect the corners of said building;
d) a plurality of elongated steel top elements disposed along a top edge of said wall panels and said corner panels and connecting said wall panels and said corner panels; and e) a roof.

2. A building as in claim 1 wherein said corrugations form a series of parallel and alternating ridges and grooves oriented vertically.

3. A building as in claim 2 wherein said wall panel cores have various numbers of ridges and grooves such that any dimension perimeter of said building may be easily constructed from said cores.

4. A building as in claim 2 further comprising wall cladding attached co-planar to said corrugated steel core and on both said faces;

5. A building as in claim 4 further comprising insulation between said wall cladding and said core, said insulation being contiguous with said core and said cladding, thereby filling said grooves with said insulation.

6. A building as in claim 3 wherein said wall panels include a plurality of multi-wall panels having a plurality of alternating ridges and grooves, each said ridge being a flat portion and said grooves having obliquely angled walls in relation to said ridges, said wall panel having a flange disposed along each outer longitudinal edge of said panel.

7. A building as in claim 6 wherein said number of ridges is 5.

8. A building as in claim 2 wherein said corner panel has a planar, rectangular central face having a longitudinally notched central portion, a flange on each longitudinal edge of said central face which is co-planar to each face of said notch and adapted to overlap the flanges of said cores.

9. A building as in claim 8 wherein said flanges of said corner panels overlap and are attached to said flanges of said wall panels.

10. A building as in claim 3 wherein said wall panels include a plurality of single wall panels having a single flat ridge with an obliquely angled wall disposed along each longitudinal edge and a flange disposed along each longitudinal edge of each said wall whereby said flange is co-planar with said ridge.

11. A building as in claim 1 wherein said steel members are C-section light gage steel.

12. A building as in claim 1 further comprising a plurality of elongated bottom panels attached to said foundation, said bottom panels having a planar face with a flange projecting at substantially 90 degrees from proximal to an inner longitudinal edge.

13. A building as in claim 1 further comprising at least one interior wall, said interior wall having a steel C-channel bottom element attached to said foundation with two flanges projecting substantially vertically, a plurality of C-channel stud elements projecting vertically from said bottom element, a C-channel top element with two flanges projecting vertically downward, and planar cladding attached to each face of said interior wall.

14. A building as in claim 1 further comprising at least one additional story, each said additional story having a floor comprising:

a) a plurality of "L" profile steel elements attached to said top elements with one face of the "L" element contiguous with said top element and a second face projecting vertically at an exterior of said building;

b) a plurality of joists extending across said building from the "L" profile elements;

c) corrugated steel decking with corrugations aligned perpendicularly to said joists and spanning said building and having edges contiguous with said perimeter;

d) a concrete slab poured on said decking;

e) anchoring members embedded in said slab; such that said slab forms a foundation on which subsequent stories are attached.

15. A modular building construction having:
a) a foundation;
b) anchoring members in said foundation disposed about a perimeter of said building;
c) elongated templates disposed about said perimeter in said foundation adapted to retain said anchoring members in alignment;
d) elongated steel elements attached to said anchoring, members and having a continuous vertical projection along their outer longitudinal edge and a series of tabs projecting vertically proximal to an interior longitudinal edge;
e) a plurality of generally rectangular steel corner panels attached at its base to said bottom plates and extending vertically to form the corners of said building;
f) a plurality of elongated top elements attached to the top of said corner panels and extending horizontally to form a frame for one of a roof or a second story;

g) at least one door frame attached at its base to said bottom plates and at its top edge to said top elements;

h) a plurality of corrugated steel wall panels wherein said corrugations are disposed vertically;

16. A modular building as in claim 15 further comprising planar sheets of cladding material attached to an interior and exterior face of said wall panels.

17. The modular building of claim 16 further comprising a plurality of window frames attached at the base to said elongated steel elements and at their top to said top elements.

18. A modular building as in claim l O whereby the modular components comprising panels, top elements and wall panels are attached to each other at a site for said building by overlapping flanges disposed along the longitudinal edges of each said modular component and attached by an attachment means.

19. A modular building as in claim 18 wherein said attachment means is one of bolts, screws or welding.

20. A method of constructing a building comprising the steps of:
a) pouring a concrete foundation;
b) placing a plurality of anchoring members in said foundation before said foundation solidifies;
c) installing a plurality of elongated templates having holes adapted to guide and retain said anchoring members in a generally vertical orientation around a perimeter of said building;
d) attaching a plurality of elongated bottom plates on top of said templates and said foundation;

e) attaching a steel corner panel vertically to said bottom plates at each corner of said perimeter such that said corner panel extends substantially vertically from said bottom plates;

f) attaching a plurality of elongated top plates on top of said corner panels thereby creating a single story frame of said building;

g) inserting at least one steel prefabricated door frame such that said door frame extends vertically between said bottom plates and said top plates at said perimeter and is adapted to receive a door;

h) attaching a plurality of load-baring wall panels comprised of corrugated steel sections to said bottom plates and said top plates to forn~ a continuous wall about said perimeter;

f) attaching planar sheets of wall cladding. to both faces of said wall panels; and j) attaching a roof to said top plates such that said building is covered and protected from the elements.

21. A kit for a modular building comprising:
a) a plurality of generally rectangular elongated steel bottom plates adapted to be placed contiguously with the perimeter of said building on a foundation;
b) a plurality of generally rectangular steel corner panels having a central vertical notch adapted to act as a corner of said building and a flange along each longitudinal edge of said corner panel disposed at generally 45 degrees;
c) a plurality of corrugated steel load-bearing wall panels with flanges at each longitudinal edge adapted to accept cladding;
d) a plurality of generally rectangular elongated C-section top plates with flanges along each longitudinal edge of said top plate adapted to attach to said corner panels and said wall panels; and e) a plurality of anchoring members to be placed in said foundation and adapted to attach to said bottom plates, whereby said flanges are adapted to overlap and be attached thereby facilitating quick and easy on-site erection of said modular building.

22. A kit as in claim 21 further comprising:
a) a plurality of elongated steel elements;
b) corrugated steel decking;
c) a plurality of steel C-section joists whereby said steel elements, steel decking and said joists are adapted fur quick and easy construction of an additional story of said modular building.

23. A load-bearing wall unit for use in a modular building construction comprising:
a) a corrugated steel core;
b) cladding material attached to said corrugated steel core on both the interior and exterior surface of said wall panel; and c) insulation material disposed inside said wall panel such that said insulation material is generally contiguous with said cladding material and said corrugated steel core.

24. A wall unit as in claim 23 wherein said cladding material is selected from the group of gypsum board, fiber cement board, oriented strand board or vinyl siding.

25. A wall unit as in claim 24 wherein said insulation material is one of expanded polystyrene, extruded polystyrene, polyurethane foam, rock wool or glass wool.

26. A metal wall component for use in building construction comprising a generally rectangular, planar corner panel having a longitudinal groove with two sides disposed along the center of said panel and flanges disposed along each longitudinal edge of said panel which are substantially co-planar with said sides of said groove.

27 27. A load bearing metal wall component for use in building construction comprising a generally rectangular, corrugated panel having a flat, central, longitudinal ridge with two sides disposed along each longitudinal edge of said ridge at an oblique angle, each said side having a flange disposed along the; outer, longitudinal edge of said side.

28. A load bearing metal wall component for use in building construction comprising a generally rectangular, corrugated panel having a series of alternating, flat, central, vertical longitudinal ridges and grooves and a flange disposed along each of the outer, longitudinal edges of said panel.

29. A wall component as in claim 28 wherein said number of ridges is 5 and said number of grooves is 5.

30. A load bearing metal wall component for use in building construction comprising a generally rectangular panel having a flat, central, longitudinal face disposed at an oblique angle to a flange disposed along each longitudinal edge of said face, said flanges being substantially co-planar with each other.

31. A generally rectangular elongated metal bottom panel having a surface extending from a first longitudinal edge at substantially 90 degrees, and a plurality of metal tabs extending proximal to a second longitudinal edge at substantially 90 degrees.

32. A generally rectangular elongated metal top panel having a central longitudinal portion with a first and second surface extending from a first and second longitudinal edge of said central portion at substantially 90 degrees, and a second surface extending from a longitudinal edge of said second surface at substantially 90 degrees and coplanar to said central portion.

33. A prefabricated building in kit form for erection on an oil rig platform comprising a plurality of:

a) generally rectangular elongated steel bottom plates adapted to be placed contiguously with the perimeter of said building on said platform;

b) generally rectangular steel corner panels having a central vertical notch adapted to act as a corner of said building and a flange along each longitudinal edge of said corner panel disposed at generally 4S degrees;

c) generally rectangular load-bearing wall panels having corrugated steel interiors with flanges adapted to accept cladding; and d) generally rectangular elongated C-section top plates adapted to attach to the top edge of said corner panels and said wall panels.

34. A radiation resistant modular building construction comprising:
a) generally rectangular elongated steel bottom plates adapted to be placed contiguously with the perimeter of said building;

b) generally rectangular steel corner panels having a central vertical notch adapted to act as a corner of said building and a flange along each longitudinal edge of said comer panel disposed at generally 45 degrees;

c) generally rectangular load-bearing wall panels having corrugated lead interiors with flanges adapted to accept cladding; and d) generally rectangular elongated C-section top plates adapted to attach to top edge of said corner panels and said wall panels.