CN116547432A - Building component, building structure formed by building component and construction method of building structure - Google Patents

Building component, building structure formed by building component and construction method of building structure Download PDF

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Publication number
CN116547432A
CN116547432A CN202180073166.4A CN202180073166A CN116547432A CN 116547432 A CN116547432 A CN 116547432A CN 202180073166 A CN202180073166 A CN 202180073166A CN 116547432 A CN116547432 A CN 116547432A
Authority
CN
China
Prior art keywords
beams
wall
building
building structure
wall panel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202180073166.4A
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Chinese (zh)
Inventor
郑品华
西蒙·普瑞特
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Quantum Architecture Co ltd
Original Assignee
Quantum Architecture Co ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2020903926A external-priority patent/AU2020903926A0/en
Application filed by Quantum Architecture Co ltd filed Critical Quantum Architecture Co ltd
Publication of CN116547432A publication Critical patent/CN116547432A/en
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34321—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/026—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of prefabricated modules, e.g. box-like or cell-like units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34326—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by longitudinal elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E04B1/6137—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface the connection made by formlocking
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E04B1/6141—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface the connection made by an additional locking key
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7448—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with separate framed panels without intermediary posts, extending from floor to ceiling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/024—Sectional false floors, e.g. computer floors
    • E04F15/02447—Supporting structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/024—Sectional false floors, e.g. computer floors
    • E04F15/02447—Supporting structures
    • E04F15/02464—Height adjustable elements for supporting the panels or a panel-supporting framework
    • E04F15/0247—Screw jacks
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/005—Modulation co-ordination
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34317—Set of building elements forming a self-contained package for transport before assembly
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34869—Elements for special technical purposes, e.g. with a sanitary equipment
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/14—Load-carrying floor structures formed substantially of prefabricated units with beams or girders laid in two directions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling

Abstract

A panel for forming part of a frame of a building structure, comprising: (a) a pair of opposed longitudinally extending beams; (b) spaced apart transverse joists interconnecting the beams; and (c) a layer of lightweight insulating material under the joists.

Description

Building component, building structure formed by building component and construction method of building structure
Technical Field
The present invention relates to building components, building structures formed from these components, and methods of constructing the building structures.
Background
Existing construction methods and building components for building structures, such as houses and the like, suffer from a number of drawbacks. At least in australia, housing construction is burdened with regulations, inefficient construction methods, legislation, costs of lengthy financing requirements, relatively high numbers of litigation cases, etc., which all have the effect of throttling out building and construction innovations that might otherwise be:
-reducing construction cycle and costs and OHS hazards;
-improving the quality, size and/or level of precision of the process and construction;
-improving on-site labor management and productivity;
-improving the efficiency of construction;
facilitating less complex installation requirements; and
enhancing the flexibility, creativity and simplicity of houses that can be designed and constructed.
The modular construction of the house attempts to solve these problems, whereby the different sections of the house to be built are prefabricated off site. The prefabricated sections are then transported and hoisted in place, connected, assembled and trimmed to form the complete house.
However, modular house design can be quite restrictive due to limitations such as road conditions, regulations and capacity, truck size, site access, and crane capacity. Furthermore, in many cases, the additional costs associated with crane use, the additional built-in structure required for transportation and lifting operations, and the transport damage reduce the cost effectiveness of the modular building structure.
There is a need to solve the above problems and/or at least to provide a useful alternative.
Disclosure of Invention
According to a first aspect of the present invention there is provided a panel for forming part of a frame of a building structure, the panel comprising:
(a) A pair of opposed longitudinally extending beams;
(b) Spaced apart transverse joists interconnecting the beams; and
(c) And the light heat insulation material layer is positioned below the joist.
In an embodiment of the invention, the beam comprises a structural channel configured to receive an end of the joist and an end of the insulation layer.
In an embodiment of the invention, in use, the beams of adjacent panels are secured together such that the cross-section of the beams of adjacent panels is generally in the form of an I-beam.
In an embodiment of the invention, the joists and/or beams comprise a service entrance opening.
In an embodiment of the invention, the panels are configured to form floor panels and/or roof panels of a building frame.
In an embodiment of the invention, the insulating layer comprises a layer of Expanded Polystyrene (EPS).
According to a second aspect of the present invention there is provided a wall panel for forming a wall structure of a building, the wall panel comprising:
(a) An outer wall layer;
(b) An interior wall layer; and
(c) A pair of spaced apart and opposed generally parallel and vertically extending beams sandwiched between wall layers and configured to be connected to the beams of adjacent wall panels so as to form a wall structure of a building.
In an embodiment of the invention, the wall layer comprises a layer of lightweight insulating material and the beam comprises a structural beam.
In an embodiment of the present invention, when viewed from above:
(a) One of the beams is offset inwardly from a first side edge of the wall layer such that a vertical slot is defined between the layer and the beam; and
(b) The other of the beams is offset outwardly from the second side edge of the wall layer, such that the beams protrude outwardly from between the wall layers,
wherein, in use, the protruding beam of a first wall panel is inserted into the slot of a second wall panel to connect the two panels.
In an embodiment of the invention, the wall panel further comprises one or more reinforcing strips between the wall panel beams, wherein the ends of each reinforcing strip comprise flanges for receiving and securing to the beams.
In an embodiment of the invention, the lateral flange of the at least one reinforcing strip protrudes into the slot, such that the lateral flange of the at least one reinforcing strip is configured to be fixed to the protruding beam of an adjacent wall panel.
In an embodiment of the invention:
(a) One of the opposing beams includes one or more outwardly extending tabs; and
(b) The other of the opposing beams includes one or more respective openings configured to releasably receive respective tabs of an adjacent wall panel.
In an embodiment of the invention, the insulating layer comprises an EPS layer.
According to a third aspect of the present invention there is provided a building structure, the floors and roofs of which comprise panels according to the first aspect of the present invention, and the walls of which comprise panels according to the second aspect of the present invention.
In an embodiment of the invention, a building structure is supported by an adjustable column comprising:
(a) A support head jack for supporting a floor;
(b) A base jack disposed on top of the footing at a ground reference surface (GBS) below the floor; and
(c) An adjustable threaded shaft between the base jack and the support head jack, the adjustable threaded shaft configured to operate as a turnbuckle.
In an embodiment of the invention, the support head jack and the base jack are aligned with a vertical axis to form a structural support to the floor that is always adjustable.
In an embodiment of the invention, the height of the support head jack above the GBS is adjustable.
In an embodiment of the invention, the shaft is threadedly engaged with the support head jack and the base jack to effect permanent (turnbuckle) height adjustment thereof.
In an embodiment of the invention, the building structure further comprises one or more freestanding kitchen and/or wet area activity centers supported by the adjustable columns.
In an embodiment of the invention, the or each activity centre creates at least one structural node to provide structural support to the floor, walls and/or roof of the building structure. For example, in one embodiment, the or each activity center creates at least one structural node to provide structural support for the roof of the building structure and lateral support for wind and seismic loads.
According to a fourth aspect of the present invention there is provided a method of constructing a building structure according to the third aspect of the present invention, wherein the kitchen and/or wet area activity center is spaced from the dry area of the building structure and is concentrated into an activity center prefabricated off site, the method comprising the steps of:
(a) Initiating installation of the structural support system by installing an adjustable column configured to support a kitchen and/or wet area activity center;
(b) Installing the or each activity centre so as to be supported by the installed adjustable column;
(c) The installation of the structural support system is accomplished by the remaining adjustable columns required to install the building structure;
(d) Constructing a floor structure using the panels according to the first aspect of the invention;
(e) Constructing a wall structure using the wall panel according to the second aspect of the invention; and
(d) The panels according to the first aspect of the invention are used to construct roof structures.
Drawings
In order that the invention may be more readily understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a top perspective view of a frame of an incomplete building structure and a freestanding activity center formed from building components embodying the present invention;
FIG. 2 is a partially transparent front perspective view of an incomplete building structure formed from building components embodying the present invention;
FIG. 3 is a partially transparent front view of an incomplete building structure formed by a building assembly embodying the present invention;
FIG. 4 is a perspective view of an external corner adjustable column (leg) building assembly according to an embodiment of the invention;
FIG. 5 is a perspective view of an internal adjustable post at the junction of 4 floor panels;
FIG. 6 is a partially transparent top perspective view of a floor structure of an incomplete building structure formed from building components embodying the present invention;
FIG. 7 is a front perspective view of a floor panel building assembly according to an embodiment of the present invention;
FIG. 8 is a close-up side view of the lower edge of a non-completed building structure showing the engagement between footing, floor panel and wall panel building assemblies embodying the present invention;
FIG. 9 is a close-up front view illustrating engagement between a footing and an adjacent floor panel building assembly in accordance with an embodiment of the present invention;
fig. 10 (a) is a side perspective view of an incomplete building structure having a series of wall panel building assemblies according to an embodiment of the present invention;
fig. 10 (b) is a cross-sectional front view of a series of different sized wall panel building assemblies according to an embodiment of the invention;
FIG. 11 (a) is a top perspective cross-sectional view of two wall panel building assemblies according to an embodiment of the present invention;
fig. 11 (b) is a top cross-sectional view of a wall panel building assembly according to an embodiment of the present invention;
fig. 12 is a partially transparent perspective view of two wall panel building components according to an embodiment of the present invention;
fig. 13 (a) is a close-up cross-sectional front view of two adjacent wall panel building components prior to being mounted together in accordance with an embodiment of the present invention;
FIG. 13 (b) is a close-up cross-sectional front view of the wall panel building assembly of FIG. 13 (a) mounted together;
fig. 14 (a) is an exploded front perspective view of a wall panel building assembly according to an embodiment of the present invention;
fig. 14 (b) is an exploded front perspective view of a wall panel building assembly according to an embodiment of the present invention;
FIG. 15 is a close-up front perspective view of a wall panel frame according to an embodiment of the invention;
fig. 16 (a) is a side perspective view of a roof panel building assembly according to an embodiment of the invention;
fig. 16 (b) is a cross-sectional end view of a roof panel building assembly according to an embodiment of the invention;
fig. 17 is a close-up side view illustrating engagement between a roof panel building assembly and a wall panel building assembly in accordance with an embodiment of the present invention; and
fig. 18 is a partially transparent interior perspective view illustrating the engagement between a roof panel and a wall panel building assembly according to an embodiment of the invention.
Detailed Description
Fig. 1-3 illustrate a partially completed residential building structure 2 formed from building components according to embodiments of the present invention. The building component comprises the following:
● An adjustable column (leg) 4 for supporting the above ground building structure 2;
● A freestanding kitchen and/or wet area activity center 6;
● A floor panel 8 forming a floor structure of the building structure 2;
● A wall panel 10 forming a wall structure of the building structure 2; and
● Roof panels 12 forming the roof structure of the building structure 2.
These relatively lightweight building components can be mass produced off-site and then transported and installed on-site with less effort and time without the need for cranes and other specialized machinery and equipment. The freestanding wet area and kitchen activity center 6 may be lifted and installed using a crane, but may optionally be forklift. The building component is described below with reference to the drawings.
Building support assembly
Fig. 4 and 5 show views of the adjustable column (leg) building assembly 4, which adjustable column (leg) building assembly 4 is configured to form a support system that is located below the above-ground building structure 2 and connects the above-ground building structure 2 to the footing. The support 4 comprises a head jack 16, a base jack 14 with a connecting threaded shaft 20 or "turnbuckle". The base jack 14 of the support 4 is fixed to the top of the footing in the ground at the GBL and the head jack 16 is fixed to the frame of the floor panel system 8.
The support 4 comprises a support head jack 16 and a base jack 14 for fixing to and supporting the floor structure of the building by being fixed to and bearing on top of the individual footings at the GBL. The support head jack 16 shown in figures 4 and 5 includes a "T" shaped bracket 17 for receiving an edge of a floor structure, as will be described with reference to figure 8. The support 4, which is configured to lie below and support the planar surface of the floor structure, is configured to have a planar support head 16 (e.g., not a "T" shaped bracket 17), as will be described with reference to fig. 9.
In the depicted embodiment, the support head jack 16 is supported by a central shaft 20 and the base jack 14, the central shaft 20 and the base jack 14 being connected by a threaded shaft 18 that is an adjustable turnbuckle. In the preferred embodiment of the support 4, the height of the support head 16 above the base jack 14 is adjustable to allow the height of the support head 16 to be finely adjusted to firmly rest against and receive the floor structure it is to support and to ensure floor levelling accuracy. To this end, and referring to fig. 5, the tube 18 is threaded such that an upper end thereof is configured to receive a lower end of the threaded shaft 20, and the support head jack 16 includes a downwardly extending and threaded tube 22, the threaded tube 22 being configured to receive an upper end of the threaded shaft 20. In this way, the central shaft 18 and the support head jack 16 are threadably engaged to effect a coarse or fine adjustment of the height of the support head jack 16 above the footing and base jack 14.
Independent wet area and kitchen building components (active center)
Fig. 1, 2, 3 and 10 illustrate an embodiment of a freestanding kitchen and/or wet area building assembly 6 (also referred to hereinafter as an activity center 6) according to an embodiment of the invention. The activity center 6 is prefabricated and contains wet areas of the house (e.g., kitchen, bathroom, cosmetic room, laundry, etc.). The activity centers (including their walls, insulation, liners, wet area amenities, cabinets and facings) may be constructed in a factory environment. Services and features such as plumbing, waterproofing, wall tiles, vanity, joinery products, kitchen and bathroom facilities may all be installed in the offsite activity center 6. The prefabricated activity center 6 may then be transported in the field and lifted or scooped into place to be supported by the adjustable columns (legs) 4 (see fig. 10). Standardized activity centers may be designed and built to fit the dimensions of the inner high cube container. This facilitates transport, lifting and protection from damage during transport.
Existing bathroom bays produced by local manufacturers do not form part of the complete construction process. In contrast, the present activity center 6, whether standardized or non-standardized, is built in a factory environment for shipping and installation as part of a complete construction method including the other building components disclosed herein.
For the installation procedure, the adjustable column (leg) 4 for supporting the activity center 6 should first be installed on the base. Next, the activity center 6 may be placed on those adjustable columns (legs) 4. The remaining adjustable uprights (legs) 4 of the whole house can then be installed.
Unlike existing modular wet areas that are simply installed within a building structure, it is contemplated that the present activity center 6 actually forms part of the building structure and creates structural nodes to provide both vertical and lateral support. For example, referring to fig. 1, it can be seen that the activity center 6 is not mounted behind the outer wall panels 10, but rather forms a very structural node of the overall building structure 2 itself. In this way, the activity center 6 also defines keys and fixed structural elements of the building structure 2 via which other elements can be fixed. In this way, the need for structural elements such as lateral support (e.g., via plywood panels) and associated labor may be significantly reduced or eliminated. The active center 6 may also serve an active center of a center through which service connections may be located. In essence, the functional and structural roles of the present activity center 6 may deviate from known modular wet areas, because the activity center 6 is not only a modular wet area installed in the building structure 2, but rather the activity center 2 defines the key structural nodes of the building structure 2.
Nevertheless, it is contemplated that the building structure 2 may include one or more such activity centers 6 (e.g., a house having multiple bathrooms), and that one or more activity centers 6 may form a critical portion of the building structure 2.
Floor panel building assembly
After the adjustable column (leg) system and activity center 6 have been installed, the floor structure of the building may be formed from a floor panel building assembly 8 embodying the present invention. Fig. 2, 3, 6, 8 and 9 show a floor panel building assembly 8 mounted in place and supported by an adjustable column (leg) system 4.
Referring to fig. 7-9, the floor panel 8 includes a pair of spaced apart and opposed structural beams or supports 36 having a Light Gauge Steel (LGS) C-shaped cross-section. The beams 36 are oriented such that their C-shaped channels 38 face each other. A series of longitudinally spaced apart transverse floor joists 40 are disposed between the C-shaped channels 38 and interconnect the beams 36. A layer 42 of Expanded Polystyrene (EPS) or other lightweight thermal insulation wrap is positioned below joists 40 and is similarly disposed between beams 36 and interconnected with beams 36. Because joists 40 and EPS42 are contained within the height of C-shaped channel 38, the overall floor thickness of the floor panel 8 of the present invention may be significantly less than conventional support and joist flooring systems.
As shown in fig. 8 and 9, the ends of joists 40 are adjacent (if not flush) to the upper flange surface 44 of C-shaped channel 36. Similarly, the EPS layer 42 is adjacent if not flush with the lower surface 46 of the C-shaped channel 38. Advantageously, EPS layer 42 acts as a thermal insulation and also provides a vapor barrier.
Referring to fig. 9, when installed, beams 36 of adjacent floor panels 8 are secured to one another to form an I-shaped cross-section beam in cross-section. The footing 4 in fig. 9 includes a flat support head 16 (a) or "T" support head 16 (b), which flat support head 16 (a) or "T" support head 16 (b) is configured to secure against and support the lower edges 46 of the I-shaped cross-sectional beams (i.e., the two lower edges 46 of the C-shaped channels 38 of adjacent floor panels 8).
Fig. 8 shows a close-up of the lower outer edge of the building structure 2 to illustrate how the adjustable stud 4, the floor panel 8, the square hollow section RHS steel or wood edge beam 48 and the wall panel 10 (to be discussed) are secured together. As shown, C-shaped cross-section beams 38 defining the outer edges of building structure 2 are screwed to RHS steel or wood edge beams 48. The RHS steel or wood edge beams 48 are in turn secured to the upstanding face 36 of the T-brackets 17 of the footing 4. Steel SHS or wood edge beams 48 are also screwed to the bottom of the wall panel 10 to achieve a complete structural "tie down". In this way, the outer edges of the floor are reinforced, thereby improving both load and deflection resistance, and eliminating the need for strapping or conventional tying. Fig. 8 also shows a floorboard 50 covering the floor panel 8, wherein protective steel Z-flashing screws 52 are fixed to the floorboard 50 and to the outer edge of the steel SHS or wood edge beam 48.
After installation of the floor panels 8, the services (mainly electrical and mechanical cabling) are installed within the depth of the cavity created by the panel frame before the floor panels 8 are covered with the floorboards 50. Advantageously, the floor joists 40 are provided with through holes 54 to facilitate service access and installation. It is contemplated that the support 38 may also be provided with such through holes for service access. Advantageously, the gap between the floor structure and the natural ground below it also provides a service portal.
The present standardized floor panels 8 can be manufactured off-site in bulk and transported and installed on site. The floor panel 8 is sized and configured to be of lightweight construction and can be handled and installed manually by two persons without lifting equipment.
It is conceivable to manufacture the floor panel 8 according to a limited size range; if different sizes of floor panels are required for the building structure 2, the mass produced floor panels 8 may be supplemented by a small number of filler floor panels 56, the filler floor panels 56 being custom made in the factory or being 'stuck-up' in the field by the relevant supplied material, as shown in fig. 6.
Wall panel building assembly
After the floor blocks 50 and bottom flashing 52 are installed around the outer edges of the floor, the wall panel building assembly 10 may then be installed to define the wall structure of the building 2. Fig. 10-15 illustrate a wall panel building assembly 10 according to an embodiment of the present invention.
Referring to fig. 11, 12 and 14, each wall panel 10 includes an opposing pair of structural beams 60 sandwiched between two layers of EPS 62. The first EPS layer 62 (a) defines the outside of the building structure 2 and is ready for painting or cladding. The second EPS layer 62 (b) may be lined with a beam-facing reflective foil and defines the inside of the building structure 2 and is ready to be finished with conventional plasterboard or other inner wall lining. The outer EPS layer 62 (a) is preferably thicker than the inner EPS layer 62 (b), and the configuration of the layer 62 and the LGS frame 78 provides thermal and acoustic insulation qualities and helps stabilize the wall panel 10 during handling and installation. The EPS layer 62 is bonded by structure, chemical glue and/or screws that are secured to the structural beams 60.
Referring to fig. 11 (a) and 11 (b), the wall panel 10 is configured to be secured together via a tongue and groove mechanism and a tab and slot mechanism. Looking downwardly at cross-sectional wall panel 10 in fig. 11 (b), left-hand side rail 60 extends leftwardly from between two EPS layers 62. This protruding beam defines the "tongue" of the tongue and groove mechanism. At the same time, right-hand side member 60 "plugs" to the left between two EPS layers 62. In this way, a space or groove 64 is defined between the two EPS layers 62 and the outer surface of the beam 60. This space 64 defines the "slot" of the tongue and groove mechanism. In other words, while the width of the EPS layer 62 is similar (if not the same) as the outer width between the beams 60, as viewed from above, the beams 60 are offset from the EPS layer 62. Thus, when adjacent wall panels 10 are assembled together, the protruding tongue beam 60 of the first wall panel 10 is inserted into the vertical space or groove 64 of the second wall panel 10, as shown in fig. 11 (a).
Referring to fig. 10 (a) and 10 (b), together with fig. 14 (a) and 14 (b), the wall panel 10 is manufactured according to a limited size and design range; if a small number of wall panels 10 of different sizes are required for the building structure 2, mass-produced wall panels 10 can be supplemented by a small number of manufactured filler wall panels or field 'stickers'. The filler panels provide cable and mechanical cable management.
Referring to fig. 10 (b) and 14 (b), the narrower leftmost three wall panels 10a include opposing beams 60 interconnected by transverse reinforcing bars 66a and diagonal reinforcing bars 66 b; the fourth wall panel 10b from the left side may be similarly constructed. The two wall panels 10c, which are wider and rightmost in fig. 10 (b) and 14 (a), include a third beam 68 and a center beam 68 located between the opposing end beams 60, the center beam 68 being interconnected with the end beams 60 via reinforcing strips 66.
Fig. 12 shows two wider wall panels 10 side by side. In addition to the tongue and groove mechanism described above, the beam 60 has complementary tab and slot engagement features to help facilitate installation of the wall panel 10. Referring also to fig. 11 (a), 13 (a) and 13 (b), one of the outer beams 60 in the channel of the wall panel 10 includes vertically spaced tabs 70 and the other outer beam 60 of the wall panel 10 includes corresponding vertically spaced slots or openings 72 for receiving the corresponding tabs 72. The tab 70 of one wall panel 10 clamps together with a corresponding tab 72 of an adjacent wall panel 10 in a "lifting" manner during installation and helps lock the wall panels 10 in place before additional structural fixtures can be implemented. The bottom of the attachment slot will be used to provide access to allow the bottom frame of the wall panel to be screwed into the underlying floor edge beam. For access this will be done before the following wall panels are installed.
Fig. 14 and 15 illustrate additional means for securing adjacent wall panels 10 together. Fig. 14 (a) shows an exploded view of the wall panel 10 c. The inner frame 78 includes a center beam 68, which center beam 68 is interconnected with a pair of opposed outer beams 60 via upper and lower joists 80 and a center reinforcement strip 66 a.
Fig. 14 (b) shows an exploded view of the wall panel 10 a. The inner frame 78 includes a pair of outer beams 60, upper and lower joists 80, horizontal reinforcing bars 66a and diagonal reinforcing bars 66b.
The wall panels 10a are used to support higher concentrated loads in place of outer wall structure studs and to resist horizontal loads (such as wind loads or seismic loads) in place of conventional lateral studs.
The LGS truss frame 78 without EPS layers may also be joined as an internal support wall or post.
Fig. 15 shows a close-up of reinforcing strip 66a that facilitates securing one wall panel 10 to another wall panel. In the depicted embodiment, the reinforcement strips 66a are formed of LGS channels similar to those forming the beams 60. At each end of the reinforcement strip 66a, its top and bottom surfaces 84 are cut away such that the top and bottom surfaces 84 abut the respective beams 60, 68. The sides of each end of the reinforcement bar 66a define flanges 86, and the flanges 86 may be secured to the respective vertical beams 60, 68 using a punch/press bonding method or conventional threaded fasteners. In fig. 15, the left-hand reinforcing strip is disposed toward the side of the wall panel 10 where the groove 64 is located (see fig. 11 (b)). Accordingly, the side flanges 86 of the reinforcement strip 66a protrude into the slots 64 and are configured to be secured to the vertical tongue beams 60 of an adjacent wall panel 10. For example, flanges 86 may be screwed to structurally connect wall panels 10 together.
Referring back to fig. 8, the wall panel 10 is also secured by tightening to the bottom flashing 52. The top flashing (not shown) is also screwed along the upper end of the wall panel 10. The flashing serves as a water barrier and an important part of the cinching mechanism while also helping to ensure that the wall panel 10 is installed in a straight and accurate alignment. The bottom flashing 52 also helps to distribute the load from the upper wall panel 10 and serves as a locating element to facilitate installation of the wall panel 10. In addition, a top wood wall panel 76 (see fig. 17 and 18) is secured between the roof panel 12 and the wall panel 10 by a hold down bracket 112 along the top of the installed wall panel 10.
Roof panel building assembly
After the wall panels 10, top flashing and top wood wall panels 76 are installed, the roof panel building assembly 12 may then be installed to define the roof structure of the building 2. Fig. 16-18 illustrate a roof panel building assembly 12 according to an embodiment of the invention.
It is envisaged that the roof panels 12 are manufactured according to a limited size range; if building structure 2 requires roof panels of different sizes, the filler panels may be custom made in the factory environment or constructed in the field from the relevant supplied materials.
Fig. 16 (a) and 16 (b) illustrate a roof panel building assembly 12 according to an embodiment of the invention. The composition and arrangement of roof panels 12 is similar to that of floor panels 8. The roof panel building assembly 12 is also made from a pair of opposed structural beams (i.e., cross beams) 100, the pair of opposed structural beams 100 having LGSC-shaped cross-sectional channels 102 with the transverse joists 104 and EPS layer 106 disposed between the LGSC-shaped cross-sectional channels 102. In the embodiment depicted in fig. 16 (b), the EPS layer 106 is thicker than the joists 104 and is preferably vertically spaced apart from the joists 104. The space 108 allows condensation and access to services such as cable management.
The roof panels 12 are adjacent to each other to form a roof structure and are not installed differently than the adjacent floor panels 8. In this regard, adjacent C-channel beams 100 of two roof panels 12 are screwed together to form an I-shaped cross-section beam. Referring to fig. 17, to install the roof panels 12, the lower flange 110 of each C-channel 102 is secured to an upper wood top wall panel 76 installed along the top of the wall panel 10. To this end, the C-shaped channel 102 is threadably secured to the upstanding portion 112a of the hold-down bracket 112 shown in FIGS. 17 and 18, thereby interconnecting the roof panel 12 and the wall panel 10.
The roof panels 12 of the present invention are relatively lightweight so that they can be handled and lifted into place by two or more persons without additional lifting assistance. Due to the simple linear configuration of roof panels 12, without the need for conventional trusses, roof spaces may be formed and used as attics, storage spaces, etc. A beveled, tall or church ceiling with skylights is accommodated by the roof panel 12 of the present invention. Joists 104 and/or opposing beams 100 of roof panel 12 are also provided with service access openings 114 for easy installation and access of cables and the like.
Due to the above-described building components 4, 6, 8, 10, 12, a substantial proportion of building structures 2 can be prefabricated off-site in batches under factory circumstances and conditions due to the repeated modular nature of the panel system. This allows many components of the building structure 2 to be tightly quality controlled and error protected. This in turn can reduce manufacturing and construction costs by repeating and reducing material wastage. The prefabricated assembly can then be transported and installed relatively quickly in the field without the need for specialized equipment and machinery in the field. Thus, after constructing the building structure 2 and installing the roof cladding, the remaining construction work can be mostly performed under indoor conditions. The reduced construction time also translates into reduced costs, OHS hazards during construction, and risk of vandalism and theft in the field.
Many modifications to the above embodiments will be apparent to those skilled in the art without departing from the scope of the invention. For example, other means for adjusting the height of the support head jack 16, wall panels on other footings or flooring systems, roof panels on other wall systems, any adaptable size of kitchen or wet areas are considered within the scope of the present description.
In an embodiment of the present invention, the frames (e.g., beams, joists, reinforcing strips, etc.) of the floor, wall, and roof panels are formed of Light Gauge Steel (LGS). Floor, wall and roof panels are formed from EPS with lining layers for insulation and condensation protection purposes. Of course, frames formed of other materials are also within the scope of this specification.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field relevant to the specification.

Claims (21)

1. A panel for forming part of a frame of a building structure, comprising:
(a) A pair of opposed longitudinally extending beams;
(b) Spaced apart transverse joists interconnecting said beams; and
(c) And a light heat insulation material layer below the joist.
2. The panel of claim 1, wherein the beam comprises a structural channel configured to receive an end of the joist and an end of the insulating layer.
3. A panel according to claim 1 or 2, wherein, in use, the beams of adjacent panels are secured together such that the beams of adjacent panels are generally in the form of I-beams in cross section.
4. The panel according to any one of the preceding claims, wherein the joists and/or beams comprise a service inlet opening.
5. A panel according to any one of the preceding claims, configured to form a floor panel and/or roof panel of a building frame.
6. The panel according to any one of the preceding claims, wherein the insulating layer comprises a layer of Expanded Polystyrene (EPS).
7. A wall panel for forming a wall structure of a building, comprising:
(a) An outer wall layer;
(b) An interior wall layer; and
(c) A pair of spaced apart and opposed generally parallel and vertically extending beams sandwiched between the wall layers, the beams being configured to be connected to the beams of adjacent wall panels to form the wall structure of the building.
8. A wall panel according to claim 7, wherein the wall layer comprises a layer of lightweight insulating material and the beam comprises a structural beam.
9. A wall panel according to claim 7 or 8, wherein, when viewed from above:
(a) One of the beams is inwardly offset from a first side edge of the wall layer such that a vertical slot is defined between the layer and the beam; and
(b) The other of the beams is offset outwardly from the second side edge of the wall layer such that the beam projects outwardly from between the wall layers,
wherein, in use, the protruding beam of a first wall panel is inserted into said slot of a second wall panel to connect said two panels.
10. A wall panel according to any one of claims 7 to 9, further comprising one or more reinforcing strips between the wall panel beams, wherein the ends of each reinforcing strip comprise flanges for receiving and securing to the beams.
11. A wall panel according to claim 10 when dependent on claim 9, wherein the lateral flange of at least one reinforcing strip protrudes into the slot such that the lateral flange of the at least one reinforcing strip is configured to be secured to the protruding beam of an adjacent wall panel.
12. A wall panel according to any one of claims 7 to 11, wherein:
(a) One of the opposing beams includes one or more outwardly extending tabs; and
(b) The other of the opposing beams includes one or more respective openings configured to releasably receive respective tabs of an adjacent wall panel.
13. A wall panel according to any one of claims 7 to 12, wherein the insulating layer comprises an EPS layer.
14. A building structure whose floors and roofs comprise the panels according to any one of claims 1 to 6, and whose walls comprise the panels according to any one of claims 7 to 13.
15. The building structure according to claim 14, supported by an adjustable column comprising:
(a) A support head jack for supporting the floor;
(b) A base jack disposed on top of a footing at a ground reference surface (GBS) below the floor; and
(c) An adjustable threaded shaft between the base jack and the support head jack, the adjustable threaded shaft configured to operate as a turnbuckle.
16. The building structure of claim 15, wherein the support head jack and the base jack are aligned with a vertical axis to form a consistently adjustable structural support for the floor.
17. The building structure of claim 15 or 16 wherein the height of the support head jack above the GBS is adjustable.
18. The building structure according to any one of claims 15 to 17, wherein the shaft is threadedly engaged with the support head jack and the base jack to enable permanent (turnbuckle) height adjustment of the support head jack and the base jack.
19. The building structure of any one of claims 15 to 18, further comprising one or more freestanding kitchen and/or wet area activity centers supported by the adjustable column.
20. A building structure according to claim 19 wherein the or each activity centre creates at least one structural node to provide structural support for a floor, wall and/or roof of the building structure.
21. A method of constructing a building structure according to claim 19 or 20, wherein the kitchen and/or wet area activity center is spaced apart from a dry area of the building structure and is concentrated into an off-site pre-manufactured service activity center, the method comprising the steps of:
(a) Initiating installation of a structural support system by installing the adjustable column configured to support a kitchen and/or wet area activity center;
(b) Installing the or each said activity centre so as to be supported by the installed adjustable column;
(c) The installation of the structural support system is accomplished by the remaining adjustable columns required to install the building structure;
(d) Constructing a floor structure using the panels according to any one of claims 1 to 6;
(e) Constructing a wall structure using the wall panel according to any one of claims 7 to 13; and
(d) Use of the panels according to any one of claims 1 to 6 for constructing a roof structure.
CN202180073166.4A 2020-10-29 2021-10-29 Building component, building structure formed by building component and construction method of building structure Pending CN116547432A (en)

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US20080263968A1 (en) * 2007-04-25 2008-10-30 Day Mark O Prefabricated rapid response accommodation structure
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