GB2597473A - A wall assembly - Google Patents
A wall assembly Download PDFInfo
- Publication number
- GB2597473A GB2597473A GB2011338.7A GB202011338A GB2597473A GB 2597473 A GB2597473 A GB 2597473A GB 202011338 A GB202011338 A GB 202011338A GB 2597473 A GB2597473 A GB 2597473A
- Authority
- GB
- United Kingdom
- Prior art keywords
- frame assembly
- infill
- opening
- stud
- wall
- 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.)
- Granted
Links
- 238000000034 method Methods 0.000 claims abstract description 15
- 230000000712 assembly Effects 0.000 claims description 28
- 238000000429 assembly Methods 0.000 claims description 28
- 238000004519 manufacturing process Methods 0.000 description 7
- 238000010276 construction Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000009435 building construction Methods 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000010079 rubber tapping Methods 0.000 description 1
Classifications
-
- 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
- E04B2/70—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood
- E04B2/706—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function
- E04B2/707—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function obturation by means of panels
-
- 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
- E04C2/386—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 frame of unreconstituted or laminated wood
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Load-Bearing And Curtain Walls (AREA)
Abstract
The wall assembly comprises a wall frame assembly 100 comprising a plurality of spaced apart elongate stud members 102 extending between a first elongate track member 104 and a second elongate track member 106. The assembly also includes a plurality of spaced apart elongate cross members114, 116 extending between adjacent ones of the stud members. At least one infill frame assembly 200 is located in an opening defined by a pair of the stud members and upper and lower ones of the cross members to thereby at least partially reduce the opening. A method of assembling a wall of a building using such a system is also claimed
Description
A WALL ASSEMBLY
The present invention relates to a wall assembly for a steel-framed building and in particular, but not exclusively, to a system and method for assembling a wall structure of a modular building construction.
The use of prefabricated sections or modules for assembling an overall building structure is now commonplace, particularly in the modular building industry. Modular buildings have many different single or multi-storey applications, including domestic dwellings, commercial offices, school, hospitals, military housing, and the like. The buildings are around 60-90% completed off-site in a factory-controlled environment, and transported and assembled at the final building site. This can comprise the entire building or be components or subassemblies of larger structures to be assembled on-site. In many cases, modular contractors work with traditional general contractors to exploit the resources and advantages of each type of construction.
Completed modules are transported to the building site and assembled by crane.
A typical construction of a modular section includes a number of vertically oriented outer wall frame assemblies attached to both a horizontally oriented base or floor frame assembly and a horizontally oriented ceiling frame assembly. Vertically oriented inner wall frame assemblies are also attached to the base and ceiling frame assemblies to define a desired internal room layout of the modular structure. The frame assemblies typically comprise steel C-sections and the wall frame assemblies are typically bolted and screwed to the base and ceiling frame assemblies.
Apertures are defined in the frame assemblies for the installation of correspondingly sized and shaped windows and doors.
To enable the full benefits of mass production, such as the use of production lines and automation, without requiring significant complexity of machines, standardisation 30 of components is required. As such, common structural frame assemblies are typically used for modular building fabrication and construction.
However, modular buildings with identical structural frames results in a fixed aesthetic which is often not suitable for a local area or architectural style. Common frame assemblies also lead to other challenges during manufacturing of the overall building structure, such as safely accessing upper floor module structures which may have no full height access openings.
It is an aim of certain embodiments of the present invention to provide a universal wall frame assembly for a modular building wherein the wall frame assembly can be adapted to selectively provide different sized and shaped apertures for mounting windows and doors therein according to particular local planning and/or design requirements or preferences.
It is an aim of certain embodiments of the present invention to provide a universal wall frame assembly for a modular building wherein the wall frame assembly can be adapted to selectively provide suitable access through said wall frame assembly into an upper storey module section during manufacturing of the overall building structure.
It is an aim of certain embodiments of the present invention to provide a method of assembling a modular building structure wherein the size and shape of apertures defined by a wall frame assembly of the structure can be selectively determined on site in accordance with particular local planning and/or design requirements or preferences.
According to a first aspect of the present invention there is provided a system for assembling a wall of a building, comprising: a wall frame assembly comprising a plurality of spaced apart elongate stud members extending between a first elongate track member and a second elongate track member, and including a plurality of spaced apart elongate cross members extending between adjacent ones of the stud members; and at least one infill frame assembly locatable in an opening defined by a pair of 30 the stud members and upper and lower ones of the cross members to thereby at least partially reduce the opening.
Optionally, the at least one infill frame assembly is selectable from a plurality of differently sized infill frame assemblies.
Optionally, the or each infill frame assembly comprises upper and lower cross members and a plurality of spaced apart stud members extending therebetween including an intermediate stud member locatable in axial alignment with a stud 5 member of the wall frame assembly which terminates at the opening.
Optionally, an axis of the intermediate stud member is spaced from axes of side stud members of the infill frame assembly by around 400 to 600mm.
Optionally, opposed surfaces of the pair of stud members of the wall frame assembly to which the infill frame assembly is attachable each comprise a plurality of longitudinally spaced holes for securing the infill frame assembly to the stud members at a longitudinal location corresponding to selected ones of the plurality of holes.
Optionally, the infill frame assembly is configured to extend fully across a height and/or width of the opening.
Optionally, the infill frame assemblies are configured to attach to each other in a 20 side-by-side arrangement and/or a stacked arrangement.
Optionally, each cross member of the wall frame assembly and infill frame assembly is substantially parallel to the track members.
According to a second aspect of the present invention there is provided a building comprising a system according to the first aspect of the present invention.
According to a third aspect of the present invention there is provided a method of assembling a wall of a building, comprising: providing a wall frame assembly comprising a plurality of spaced apart elongate stud members extending between a first elongate track member and a second elongate track member, and including a plurality of spaced apart elongate cross members extending between adjacent ones of the stud members; and locating at least one infill frame assembly in an opening defined by a pair of the stud members and upper and lower ones of the cross members to thereby at least partially reduce the opening.
Optionally, the method comprises selecting the at least one infill frame assembly from a plurality of differently sized infill frame assemblies.
Optionally, the method comprises locating an intermediate stud member of the infill frame assembly in axial alignment with a stud member of the wall frame assembly 10 which terminates at the opening.
Optionally, the method comprises locating the at least one infill frame assembly fully across a height and/or width of the opening.
Optionally, the method comprises attaching a plurality of said infill frame assemblies together in a side-by-side arrangement and/or a stacked arrangement.
Optionally, the method comprises accessing the building via the opening.
Description of the Drawings
Certain embodiments of the present invention will now be described with reference to the accompanying drawings in which: Figure 1 illustrates a wall frame assembly according to certain embodiments of the present invention; Figure 2 illustrates a front elevation of a modular structure defining a pair of semidetached houses each comprising a plurality of wall frame assemblies according to certain embodiments of the present invention; and Figure 3 illustrates a wall frame assembly according to certain embodiments of the present invention including an infill frame assembly to close an access opening of the wall frame assembly usable during assembly of the building structure.
Detailed Description
Figure 1 illustrates an upper wall frame assembly 100 of an upper storey of a modular structure located on a lower wall frame assembly 101 of a lower storey of the module structure.
As illustrated in Figure 1, a wall frame assembly 100 according to certain embodiments of the present invention includes a plurality of spaced apart and parallel elongate stud members 102 extending between first and second elongate track members 104,106 which respectively define a top track member and a base track member of the wall frame assembly when in situ. The stud members 102 are typically spaced apart by around 400 to 600mm. A plurality of axially spaced apart and substantially horizontal elongate cross members 108 are provided between adjacent ones of the stud members 102 to add strength and stiffness to the wall frame assembly. A plurality of angled elongate brace members 110 are also provided between adjacent ones of the stud members 102 to add further strength and stiffness to the wall frame assembly.
A portion of at least one stud member 112 is omitted and first and second cross members 114,116 extend between the adjacent stud members 118,120 to each side of the central stud member 112 to thereby define at least one elongate opening 122 in the wall frame assembly for receiving a window or door.
The entire opening 122 may be used to accommodate a window or door.
Alternatively, an infill frame assembly 200 according to certain embodiments of the present invention may be located in a portion of the opening 122 to selectively change the size and shape of the opening for accommodating a window, for example, of a desired size and shape, as illustrated in Figure 2a.
As illustrated in Figure 1, the infill frame assembly 200 includes a plurality of spaced apart and parallel vertical elongate stud members 202 extending between first and second elongate beam members 204,206. In accordance with the wall frame assembly 100, the stud members are oriented substantially perpendicularly to the beam members. The stud members 202 are also spaced apart such that a central stud member 212 of the infill frame assembly 200 axially aligns with the central stud member 112 of the wall frame assembly 100 to provide a continuous load path between the wall frame assembly and the infill frame assembly and also enables outer and inner boards attached to the frame to be fixed at the required locations.
As illustrated, the stud members 202 of the infill frame assembly 200 may be substantially equally spaced apart or not such that the central stud member aligns with its corresponding wall frame stud member. A further infill stud member may be required proximal one of the end infill stud members, as illustrated in the right-hand infill frame assembly, to thereby ensure the infill frame assembly is provided with one or more stud members located between the side stud members to be in alignment with the or each corresponding stud member of the wall frame assembly. The stud members 118,120 of the wall frame assembly and the stud members 202 of the infill frame assembly are aptly C-section steel members. Aptly, the stud members of the wall frame assembly are oriented such that their open sides face outwardly with respect to the opening and the stud members of the infill frame assembly are oriented such that their open sides face inwardly with respect to the opening thereby to provide substantially smooth outer engagement surfaces for sliding the infill frame assembly into the opening defined by the wall frame assembly. Aptly, an outer board is attached to the outer surface of the infill frame assembly prior to mounting the infill frame assembly in the opening. The outer board is aptly sized larger than the perimeter of the infill frame assembly such that its edges extend beyond the edges of the infill frame assembly. The overhang provides an abutment surface for engaging the wall frame assembly when the infill frame assembly is mounted in the opening from the outer side of the wall frame assembly and prevents the same falling through the opening before being securely attached therein. The outermost stud members of the infill frame assembly 200 are attached to the stud members of the wall frame assembly which define the opposed vertical sides of the opening 122 by suitable mechanical fasteners, such as bolts or self-tapping screws. Likewise, the lower beam member 206 of the infill frame assembly 200 is attached to the second cross member 116 which otherwise defines the lower horizontal side of the original opening 122. The upper beam member 204 thereby defines the lower side of a new and smaller opening 222 for receiving a window of desired size and shape. The stud members 118,120 of the wall frame assembly may each comprise a double-stud arrangement including a pair of back-to-back C-section studs resulting in the opening of the wall frame assembly being defined by opposed open sides of the inner C-section studs. In this case, the open sides of the C-section studs are closed by one or more suitable infill sections to provide a substantially smooth surface for slidably engaging with the outer surfaces of the infill frame assembly.
The height of the infill frame assembly 200 may be any desired height to create a new and relatively shorter opening 222 of a corresponding desired height for receiving a window of desired size and shape. Additionally, the infill frame assembly 200 may be any suitable width, e.g. it may extend fully across the original opening 122 or it may extend partially across the original opening, such as halfway across, to create a new and relatively narrow opening. As such, a predetermined size and shape of infill frame assembly can be installed in the original opening 122 to thereby raise the window sill height and in turn reduce the window height and/or narrow the opening to reduce the window width.
As illustrated in Figure 2, a modular structure according to certain embodiments of the present invention defines a pair of mirror-imaged semi-detached dwellings 250,260. !nthl panel assemblies have been used to reduce one of two identical openings in each of the ground and first floor wall assemblies to thereby provide a relatively small window opening and a relatively large door opening in the ground floor wall assembly for installing a small window 252 and a door 254 therein respectively, and also a relatively small window opening and a relatively window opening in the first floor wall assembly for installing a small window 256 and a large window arrangement 258 therein respectively. The large window arrangement may comprise a single window unit or two or more window units. The infill panel assembly below a window unit may be boarded to provide a flush finish with the side of the house or alternatively the infill panel assembly may be used to provide a recessed and/or differently coloured/textured surface below the window to add an aesthetic feature/surface decoration to the assembled building.
Further alternatively, infill panel assemblies may be mounted in both first floor openings to allow both windows on the first floor to be relatively small. As illustrated, the relatively small windows in the ground floor wall assembly are shorter than the small windows in the first floor wall assembly. This is achieved by using a taller infill panel assembly in the corresponding opening of the ground floor wall assembly. By not using an infill panel assembly, a relatively large opening may be provided in a wall frame assembly which may be fully utilised to receive a large window or set of windows, such as a set of patio doors or doors behind a Juliet balcony, for example.
A plurality of differently conformed infill frame assemblies may be selected and installed in the original opening of a wall frame assembly to create two new openings of different size and shape for receiving a relatively narrow set of patio doors, or the like, and a window, for example.
A relatively large array of different arrangements and configurations of window/s and/or door/s can therefore be created in the original opening defined in the wall frame assembly by selecting and installing differently conformed infill frame assemblies according to certain embodiments of the present invention. Furthermore, the infill frame assemblies are reversible to allow them to be installed either way round in the original opening of the wall frame assembly to in turn allow them to be used on a 'handed' or 'mirror image' structure, such as for a pair of adjoined semidetached houses.
As illustrated in Figure 3, an opening 322 defined by a wall frame assembly 300 according to certain embodiments of the present invention can be used by authorised personnel to gain full height access into an upper storey of a modular structure being built, wherein typically the only access to an upper storey is internally via a ladder or the like in view of stairs generally not being in place during the module construction stage. This allows greater efficiency and safety in terms of accessing the upper storey/s of a modular building for personnel and materials during the manufacturing stages. The access opening/s can then be efficiently closed with a correspondingly sized and shaped infill frame assembly 400 according to certain embodiments of the present invention. Aptly, the access infill frame assembly 400 provides a central stud member 332 which axially aligns with the corresponding stud member 312 of the wall frame assembly 300 to provide a continuous load path between the wall frame assembly and the infill frame assembly and also enables outer and inner boards attached to the frame to be fixed at the required locations.
Aptly, the elongate members of the/each infill frame assembly according to certain embodiments of the present invention are manufactured from the same high strength, cold-rolled and galvanised steel box section as the elongate members of the wall frame assembly. Alternatively, each wall frame assembly and infill frame assembly may be a different material, such as aluminium, plastic, timber, or the like, to structurally suit a particular application. Aptly, the stud members to which the infill frame assembly attach may include a plurality of longitudinally spaced apart holes to allow the infill frame assembly to quickly secured in place at any desired height in the opening corresponding to the horizontally aligned holes chosen by the installer. As such, a single infill frame assembly may also be used to efficiently create upper and lower window openings within the original larger opening.
Certain embodiments of the present invention therefore provide a universal wall frame assembly for a modular building wherein the wall frame assembly can be adapted to selectively provide different sized and shaped apertures for mounting one or more doors and/or windows therein according to particular local planning and/or design requirements or preferences. The wall frame assembly is adapted to selectively provide suitable access into an upper storey module section during construction of the overall building structure, wherein the access opening can be efficiently closed to provide aligned and spaced apart stud members for efficient load transfer through the structure and for fixing wall panels etc. A system is provided including one or more wall frame assemblies and a plurality of infill frame assemblies, wherein the infill frame assemblies may be differently sized and shaped to allow different sizes and shapes of opening to be created in the original opening defined by the wall frame assembly. The present invention reduces the time and energy and associated material usage and wastage to manufacture wall frame assemblies for modular building construction in an off-site, mass produced and automated manner. The wall frame assembly according to certain embodiments of the present invention is not limited to substantially vertical walls of a building and may be utilised for sloping wall structures and roofs including dormer and VeluxTmstyle windows therein.
Claims (15)
- Claims 1. A system for assembling a wall of a building, comprising: a wall frame assembly comprising a plurality of spaced apart elongate stud members extending between a first elongate track member and a second elongate track member, and including a plurality of spaced apart elongate cross members extending between adjacent ones of the stud members; and at least one infill frame assembly locatable in an opening defined by a pair of the stud members and upper and lower ones of the cross members to thereby at least partially reduce the opening.
- 2. The system according to claim 1, wherein the at least one infill frame assembly is selectable from a plurality of differently sized infill frame assemblies.
- 3. The system according to claim 1 or 2, wherein the or each infill frame assembly comprises upper and lower cross members and a plurality of spaced apart stud members extending therebetween including an intermediate stud member locatable in axial alignment with a stud member of the wall frame assembly which terminates at the opening.
- 4. The system according to claim 3, wherein an axis of the intermediate stud member is spaced from axes of side stud members of the infill frame assembly by around 400 to 600mm.
- 5. The system according to any preceding claim, wherein opposed surfaces of the pair of stud members of the wall frame assembly to which the infill frame assembly is attachable each comprise a plurality of longitudinally spaced holes for securing the infill frame assembly to the stud members at a longitudinal location corresponding to selected ones of the plurality of holes.
- 6. The system according to any preceding claim, wherein the infill frame assembly is configured to extend fully across a height and/or width of the opening.
- 7. The system according to claim 2, wherein the infill frame assemblies are configured to attach to each other in a side-by-side arrangement and/or a stacked arrangement.
- 8. The system according to any preceding claim, wherein each cross member of the wall frame assembly and infill frame assembly is substantially parallel to the track members.
- 9. A building comprising a system according to any preceding claim. 10
- 10. A method of assembling a wall of a building, comprising: providing a wall frame assembly comprising a plurality of spaced apart elongate stud members extending between a first elongate track member and a second elongate track member, and including a plurality of spaced apart elongate cross members extending between adjacent ones of the stud members; and locating at least one infill frame assembly in an opening defined by a pair of the stud members and upper and lower ones of the cross members to thereby at least partially reduce the opening.
- 11. The method according to claim 10, comprising selecting the at least one infill frame assembly from a plurality of differently sized infill frame assemblies.
- 12. The method according to claim 10 or 11, comprising locating an intermediate stud member of the infill frame assembly in axial alignment with a stud member of the wall frame assembly which terminates at the opening.
- 13. The method according to any of claims 10 to 12, comprising locating the at least one infill frame assembly fully across a height and/or width of the opening. 30
- 14. The method according to any of claims 10 to 13, comprising attaching a plurality of said infill frame assemblies together in a side-by-side arrangement and/or a stacked arrangement.
- 15. The method according to any of claims 10 to 14, comprising accessing the building via the opening.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2011338.7A GB2597473B (en) | 2020-07-22 | 2020-07-22 | A wall assembly |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2011338.7A GB2597473B (en) | 2020-07-22 | 2020-07-22 | A wall assembly |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB202011338D0 GB202011338D0 (en) | 2020-09-02 |
| GB2597473A true GB2597473A (en) | 2022-02-02 |
| GB2597473B GB2597473B (en) | 2024-05-08 |
Family
ID=72339019
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2011338.7A Active GB2597473B (en) | 2020-07-22 | 2020-07-22 | A wall assembly |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2597473B (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT386236B (en) * | 1985-03-08 | 1988-07-25 | Schaufler Christoph | Wall element for framework-construction walls |
| GB2339809A (en) * | 1998-06-19 | 2000-02-09 | John Hinton | Timber frame construction |
| US20110247286A1 (en) * | 2010-04-09 | 2011-10-13 | Houle Andre | Insulating wall panel assembly and method for manufacturing same |
-
2020
- 2020-07-22 GB GB2011338.7A patent/GB2597473B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT386236B (en) * | 1985-03-08 | 1988-07-25 | Schaufler Christoph | Wall element for framework-construction walls |
| GB2339809A (en) * | 1998-06-19 | 2000-02-09 | John Hinton | Timber frame construction |
| US20110247286A1 (en) * | 2010-04-09 | 2011-10-13 | Houle Andre | Insulating wall panel assembly and method for manufacturing same |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2597473B (en) | 2024-05-08 |
| GB202011338D0 (en) | 2020-09-02 |
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| Date | Code | Title | Description |
|---|---|---|---|
| 732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) |
Free format text: REGISTERED BETWEEN 20240418 AND 20240424 |