NZ609969B2 - Building system - Google Patents
Building system Download PDFInfo
- Publication number
- NZ609969B2 NZ609969B2 NZ609969A NZ60996913A NZ609969B2 NZ 609969 B2 NZ609969 B2 NZ 609969B2 NZ 609969 A NZ609969 A NZ 609969A NZ 60996913 A NZ60996913 A NZ 60996913A NZ 609969 B2 NZ609969 B2 NZ 609969B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- wall
- panels
- building
- tensioner
- anchor
- Prior art date
Links
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Abstract
building with a foundation and a plurality of upstanding juxtaposed wall panels (31) is disclosed. The panels together define at least one wall section of the building seated on the foundation and tied together by orthogonal tensioners. At each end of the wall section, a vertical tensioner (27) is located parallel to an adjacent wall panel and is fixed by and extends between the foundation and a respective anchor (150) at or near the top of the adjacent wall panel. This binds the adjacent wall panel onto the seat of the foundation. A horizontal tensioner extends between the anchors at each end of the wall section to tension the wall section together. located parallel to an adjacent wall panel and is fixed by and extends between the foundation and a respective anchor (150) at or near the top of the adjacent wall panel. This binds the adjacent wall panel onto the seat of the foundation. A horizontal tensioner extends between the anchors at each end of the wall section to tension the wall section together.
Description
COMPLETE SPECIFICATION
“Building System”
FIELD OF THE INVENTION
The present invention relates to building and building systems and related methods. In
particular but not solely to systems for modular buildings that may be erected from
prefabricated panels and components and constructed on site.
BACKGROUND
There are many construction systems for low to mid-rise structures that commonly use
factory made component such as panels of concrete, wood or other framing materials. The
panels are located with a structural frame, securing one panel to the other such as by bolts or
nails to form part of a building or enclosure. These are commonly used in low cost housing
through to industrial buildings.
Such buildings are invariably built on a conventional concrete slab that has been
established using removable formwork, with anchors for anchoring the panels directly or
indirectly to the slab. The anchors are either cast in during the pour, or post pour drilled and
secured using epoxy.
One of the difficulties/expense in constructing of buildings is time and labour input.
Where walls are to be secured to the slab, alignment of any pre-defined anchor points on the
panels with the anchors presented at the slab can be difficult and requires skilled tradesmen.
Errors in the positioning of such components in the slab permit misalignment and the
advantages of factory ensured accuracies are lost. As a result correction and reinstatement can
be required and can be expensive and negate any advantages initially given by the modular
panels.
In addition, reinstatement may be done in a manner that creates deviation from the
plans. Inaccuracies at the foundation level can quickly translate into inaccuracies in many other
aspects of the building. Sometimes compounding inaccuracies occur that require the fit-out
work to be entirely custom rather than relying on kitset component to complete the building.
It is therefore an object of the present invention to provide a building, system and/or
structure that offers at least some solution to overcome the abovementioned issues and/or to
provide the industry with a useful choice.
SUMMARY OF THE INVENTION
In a first aspect the present invention may broadly be said to a building comprising a
foundation and a plurality of upstanding juxtaposed wall panels together defining at least one
wall section of said building seated on said foundation and tied together by orthogonal
tensioners comprising;
a. at each end of the wall section, a vertical tensioner located parallel an adjacent wall
panel and fixed by and extending between the foundation and a respective anchor
positioned to act at or near the top of the adjacent wall panel to allow a binding of
the adjacent wall panel by said vertical tensioner onto the seat of the foundation,
b. a horizontal tensioner extending between said anchors at each end of the wall
section to allow a horizontal binding of wall panels of the wall section together.
Preferably intermediate of and parallel with adjacent wall panels of said wall section is an
intermediate vertical tensioner that is fixed by and extends between the foundation and a
respective mid wall anchor positioned to act at or near the top of the two adjacent wall panels
to allow binding of the two adjacent wall panels by said vertical tensioner onto the seat of the
foundation.
Preferably said horizontal tensioner extends from and acts directly on the anchor at one
end of the wall section to the anchor at the other end of the wall section to bind all wall panels
in the wall section horizontally together.
Preferably the horizontal tensioner does not act on the intermediate vertical anchor..
Preferably the mid wall anchor is positioned on top of two adjacent wall panels..
Preferably each vertical tensioner extends from the foundation to a respective anchor..
Preferably the intermediate tensioner extends from the foundation to a respective
anchor..
Preferably each anchor is keyed or registered to the wall panel(s) at which it is located in
a manner to hold it in place against the force(s) applied to it by one of more tensioners..
Preferably a said anchor is integrally formed with a wall panel..
Preferably the vertical tensioner(s) is/are located in a slot (preferably along the entire of
and) at the side edge of an adjacent wall panel..
Preferably each tensioner is a variable operative length tensioner.
Preferably each tensioner comprises a rod having a threaded section at which the
tensioner can vary its operative length.
Preferably building is self shoring, the wall panels shoring themselves with each other
and with the foundation as a result of the tension established by the tensioners..
Preferably each anchor is located at or near the upper edge of the wall panels..
Preferably the tensioners at a wall section are coplanar the wall section..
Preferably tensioners extend adjacent all sides of each wall panel save for the side at
which each wall panel is seated to the foundation..
Preferably the horizontal tensioners act only on anchors at the ends of the wall section to
bind all wall panels of that section together..
Preferably the tensioners are adjustable tensioners..
Preferably a lateral wall section extends from said first mentioned wall section, said
lateral wall section comprising of a wall panel located contiguous the end wall panel of the first
mentioned wall section, the vertical tensioner at the end of the first mentioned wall section
located therebetween, its respective anchor located also at the wall panel or the lateral wall
section.
Preferably a lateral wall section horizontal tensioner extends from said respective anchor
to a further anchor, the lateral wall section horizontal tensioner and the first mentioned
horizontal tensioners able to cooperate together to bind the lateral wall section and the first
mentioned wall section together.
Preferably a ceiling or roof comprising of a row of contiguous cover panels is at least
partially supported by and at the top of the wall panels.
Preferably the mid wall anchor(s) anchor cover panel tensioners and extend between
adjacent cover panels.
Preferably cover panel tensioners extend between adjacent cover panels from a mid wall
anchor on one wall section to another anchor.
Preferably the other anchor is to a mid wall anchor on an opposed wall section.
Preferably the cover panels are quadrilateral in shape.
Preferably at least two opposed sides of each cover panel include a slot or rebate at
where the cover panel tensioner is located.
Preferably there are two contiguous rows of cover panels.
Preferably the cover panels slope to define a sloping roof of said building.
Preferably the cover panels are horizontal and define a sloping roof or ceiling/floor of
said building.
Preferably the cover panels are horizontal and a lateral tensioner extends between the
two rows of horizontal panels, that is anchored at a mid wall anchor located at the top of a wall
section aligned therewith.
Preferably the lateral tensioner extends at 90 degrees to the first mentioned cover
tensioner..
Preferably the cover panels tessellate together..
Preferably the cover panel tensioners are rods.. Preferably such are as herein described
with reference to the vertical tensioners..
Preferably the mid wall anchor is keyed to the wall panel to prevent it from moving
parallel to the normal of the wall panel..
Preferably at least two of the wall panels are identical..
Preferably the wall panels are prefabricated..
Preferably said building that has a second storey located above the wall panels, the
second storey comprising of a plurality of second storey wall panels supported above the first
mentioned wall panels.
Preferably said second storey comprises a plurality of upstanding juxtaposed second
storey wall panels together defining at least one second storey wall section of said building
wherein at each end of the second storey wall section, a second storey vertical tensioner is
located parallel an adjacent second storey wall panel and fixed by and extending between the
anchor of the and a respective second storey anchor positioned to act at or near the top of the
adjacent second storey wall panel.
Preferably a second storey horizontal tensioner extends between said second storey
anchors anchors at each end of the second storey wall section to allow a horizontal binding of
second storey wall panels of the second storey wall section together..
Preferably intermediate of and parallel with adjacent second storey wall panels of said
second storey wall section is an intermediate vertical tensioner that is fixed by and extends
between the anchor and a respective mid wall second storey anchor positioned to act at or near
the top of the two adjacent second storey wall panels.
Preferably a second storey horizontal tensioner extends from and acts directly on the
second storey anchor at one end of the second storey wall section to the anchor at the other
end of the second storey wall section to bind all second storey wall panels in the second storey
wall section horizontally together.
Preferably beams span between opposing wall sections of the building at or near the
upper edges of the walls..
Preferably tensioners extend along the top of the beams between said separated parts..
Preferably the wall sections are planar wall sections..
Preferably said foundation compromises footing at which said wall panels are seated.
Preferably said footing is assembled on site from a plurality of prefabricated footers
rigidly connected together and supported by ground below.
Preferably said footing defines a seat for said wall panels to register.
Preferably said footers are located at least at the perimeter of the footprint of the
building to be erected on the foundation..
Preferably the footers are located at least at the perimeter for supporting said wall
panels that define at least part of the envelope of the building..
Preferably said seat is elevated above the ground by which said foundation is supported..
Preferably said prefabricated footers are supported on the ground below..
Preferably said footers are connected together by connectors that create a rigid
connection between adjacent footers.
Preferably said footing comprises said connectors..
Preferably said connectors locate intermediate of said footers and each connect to at
least two said footers.
Preferably said connectors are adapted and configured to allow a sliding engagement
therewith by adjacent footers..
Preferably the connectors effect a dovetail connection between adjacent footers..
Preferably the footing includes adjustable ground engageable props..
Preferably the ground engageable props can be adjusted to help level and prop up the
footing from uneven ground below. The propping may be only until such time as poured
concrete has set and then assumes the propping function for the footing or part of the footing..
Preferably the props include feet connected to said footing..
Preferably said props are threadingly adjustable..
Preferably said connectors may form part of the footing of the foundation..
Preferably said connectors are carried by or integrally formed with the footers or a
combination of such..
Preferably the connectors effect a rigid connection between footers to create a footing
that is resistant to being deformed..
Preferably foundation comprises a filler.
Preferably the filler includes a cementitious material.
Preferably the filler is poured concrete.
Preferably the footing defines formwork for the pour and remains in place during and
after the pour.
Preferably the footing is amalgamated by and with the filler.
Preferably the poured concrete embeds some of the footing therein to amalgamate the
footing to the concrete once set..
Preferably the filler material is located between the seat of the footing and the ground
below..
Preferably the filler material is located against the footing to support wall loading on the
seat of the footing from the ground below..
Preferably the footers provide said seat at a location above the ground below, part of
said footer supported on said filler located between the seat and the ground below..
Preferably the footers have at least one undercut or rebate or ledge or aperture below
said seat, the filler material vertically supporting said footers thereat..
Preferably the undercut allows for weight being borne on the footing to be largely
transferred to the filler material..
Preferably the foundation may also comprise of a gap filler embedded in the filler..
Preferably the foundation may also comprise of a foam insert located in the filler.. This
may be supported on the ground below and under the filler.. The foam insert may increase
thermal insulation for the building..
Preferably the footers function as formwork during the pouring and setting of the poured
concrete.
Preferably the filler defines a floor pad.
Preferably the top of the footers are coplanar and the filler is level with the top of the
footers.
Preferably the top of the footers are coplanar and defines a screed guide for the poured
filler material to screed the filler material flush with the top of the footers..
Preferably the floor pad is the internal floor pad of the building..
Preferably the footing remains in-situe..
Preferably the foundation presents a plurality of fixtures at which the vertical tensioners
secure.
Preferably the footing presents a plurality of fixtures for securing said vertical tensioners.
Preferably the fixtures are spaced apart from each other at predefined locations.
Preferably the fixtures are spaced apart from each other at predefined locations by virtue
of the footers being pre fabricated..
Preferably the fixtures are spaced apart from each other at equispaced locations..
Preferably the fixtures are located at the seat of the footing..
Preferably each fixture allows a threaded engagement therewith by said tensioner..
Preferably the footing secures tensioners for binding the wall panels at the seat with the
footing..
Preferably a plurality of footers have such a tensioner located.. These may be pre-
located to the footer prior to their assembly on site or post located..
Preferably the fixtures are embedded at least partially in said filler..
Preferably the foundation defines the ground floor to the building..
Preferably the footers extend orthogonal to each other..
Preferably the footing allows a plurality of wall panels to be registered in a manner to
define an at least partial envelope to the building.
Preferably the footers are shaped and adapted to allow and interlocking together with a
plurality of wall panels..
Preferably the interface between the footers and wall panels is an at least partial nesting
of the panel with the formwork..
Preferably the interface is waterproof..
Preferably the interface is waterproof by the inclusion of a seal or foam filler..
Preferably the interface is waterproof by the inclusion of a lapped relationship between
the wall panel and the footing..
Preferably the foundation defines a seat, the seat includes a lip laterally against which a
wall panel can register and a lower surface on top of which a wall panel can register.
Preferably the lower surface is outward of the building more than the lip.
Preferably the footer defines the seat. Preferably the top edge of the footing is proximate
more the lip than the lower surface..
Preferably the lower surface includes a region that is downwardly sloping towards the
lip..
Preferably a wall panel can locate on top of the sloping region to be biased under its own
weigh and any clamping more down and laterally towards the lip..
Preferably the seat is in a channel formation..
Preferably the footing presents major forming faces facing each other to define a void to
receive a pourable settable filler material..
Preferably the footing defines a perimeter to contain the poured filler material..
Preferably the footing defines a perimeter that encases the poured filler material..
Preferably the foundation may sit above or be set in the ground on which the building is
to be located..
Preferably the footers are external footers to define the perimeter of the foundation and
are connected to internal footers connected extending across the foundation..
Preferably the internal footers brace the external footers..
Preferably the internal footers brace the external footers until the poured concrete has
set..
Preferably the internal footers include several aspects of the external footers as is herein
described..
Preferably the internal footers define a seat for wall panels to register..
Preferably the seat is defined at a channel of the internal footer..
Preferably the wall panel can register by way of an at least partial nesting at the
channel..
Preferably the interface between the wall and the internal footer may be such as to
define a channel there between..
Preferably the channel can allow for utilities to be run there through..
Preferably below the seat of the internal footer is a conduit to allow for utilities to be run
through..
Preferably the footers comprise of at least one elongate member to generally extend
horizontally.
Preferably said elongate member is taller than it is wide.
Preferably two said elongate members are provided each extending at an acute or
obtuse angle to the other.
Preferably the angle is 90 degrees..
Preferably two said elongate members are provided integrally formed with each other
and each extending at an acute or obtuse angle to the other.
Preferably said footer is provided at a corner of the foundation.
Preferably said two members are coplanar each other..
Preferably the footing is supported by ground below and wherein at least some footers
are so supported via at least one intermediate member.
Preferably said intermediate member includes a post.
Preferably said intermediate member includes a bearer..
Preferably the foundation is supported on un even ground..
Preferably the foundation is supported on sloping ground..
Preferably said foundation comprises of formwork that co-operates with the ground on
which it is supported to define a cavity for receiving a concrete pour, said formwork remaining
in-situ after said pour.
Preferably the formwork is footing adapted and configured to seat said wall panels.
Preferably the footing is as herein described..
Preferably the footing comprises of a plurality of interconnecting footers that can define
an enclosure for the concrete pour.
Preferably the footers include registration surfaces to allow the registration of a wall or
wall panels to be supported on said formwork..
Preferably the footers are of a kind as herein described..
Preferably the formwork includes fixtures to allow vertical tensioners to threadingly
engage..
In yet a further aspect the present invention may be said to be a modular building
structure comprising:
(a) a foundation comprising of footing assembled on site from prefabricated footers
each connected together,
(b) a plurality of abutting wall panels creating wall sections of the building, each wall
panel supported on the footing,
(c) a plurality of elongate vertical wall tensioners each located between and parallel
to two adjacent wall panels and secured at (a) one end by the footing (preferably by a footer)
and (b) at an anchoring location to the two adjacent panels, to allow each wall tensioner to
clamp two adjacent panels from above onto the footing,
(d) extending parallel to and at the top of at least two adjacent said panels of each
wall section, an elongate horizontal tensioner to bind the two adjacent panels together at where
they abut, a said vertical and horizontal tensioner connected (directly or indirectly) at said
anchoring location,
(e) a roof or ceiling connected secured above the plurality of panels.
Preferably the plurality of abutting wall panels create wall sections of the envelope of the
building..
Preferably the horizontal wall tensioner is anchored at each end thereof..
Preferably a wall section of abutting wall panels abuts with a lateral thereto like wall
sections of the building.
Preferably each wall section comprises of a linear array of abutting wall panels, there
being a said elongate vertical wall tensioner intermediate of the contiguous wall panels of
abutting wall sections.
Preferably each wall section comprises of a linear array of abutting wall panels, there
being a said elongate vertical tensioner between abutting wall panels of the array.
Preferably said elongate vertical wall tensioners are located between and parallel to two
adjacent wall panels of laterally disposed abutting wall sections and are each secured to an
anchor at a respective said anchoring location.
Preferably said anchor secured a said vertical tensioner.
Preferably the elongate horizontal tensioner at each wall section extends at the top of all
abutting wall panels of the wall section and is anchored at each end of the wall section.
Preferably the anchor is located atop of said adjacent panels..
Preferably said horizontal tensioner of each said abutting wall section is secured to a said
anchor.
Preferably a plurality of vertical tensioners are connected to the footing..
Preferably the plurality of vertical tensioners are fastened to the footing..
Preferably the plurality of vertical tensioners are each fastened to the footing at a
fixture..
Preferably the fixture is embedded in a footing..
Preferably the fixture presents a threaded portion to which a vertical tensioner can
threadingly engage..
Preferably the threaded portion of the fixture is a threaded stud or a threaded aperture
(blind or otherwise)..
Preferably the vertical and horizontal tensioners are connected together by an anchor..
Preferably the anchor can key with the wall panels at which it is to be located..
Preferably the anchor presents securing locations for the tensioners to present therefrom
at 90 or 180 degrees to each other..
Preferably each tensioner has a threaded section to locate through an aperture of the
anchor and a threaded members (eg a nut) can engage thereat, to change the operative length
of the tensioner..
Preferably each panel has two parallel vertical edges and a said vertical tensioner is
located at each said edge..
Preferably each panel has two parallel horizontal edges, and a horizontal tensioner is
located at the top edge of said two parallel horizontal edges..
Preferably the tensioners are able to be tensioned by reacting against the anchors as a
result of a changing of their operative length..
Preferably such tensioning is by use of threaded couplings or connections..
Preferably the roof or ceiling is secured to the vertical tensioners..
Preferably said prefabricated footers have been connected with like footers at the
building site for creating said foundation.
Preferably the footer is able to connect with like footers to create a rigid footing and
define formwork to receive a pour of settable material.
Preferably the footers are bound together by a settable material.
Preferably the settable material is located at least partially below at least part of the
footers and above ground there below.
Preferably the footer comprises a first elongate section and a second elongate section
extending from the first at an angle thereto..
Preferably the first and second sections are integrally formed..
Preferably a series of fixtures are located by said footing.
Preferably the adjacent fixtures of the series are regularly spaced (preferably
equispaced) from each other.
Preferably adjacent fixtures are positioned so as to be spaced from each other once the
footing is completed at wall panel width distances apart..
Preferably each wall panel bear onto said footing only..
Preferably the footing is made from interconnectable footers that are prefabricated..
In a further aspect the present invention may be said to be a method of forming a modular
building comprising:
(a) preparing a ground site for said building,
(b) establishing a foundation on said ground site, said foundation presenting a
plurality of fixtures for receiving tensioners,
(c) attaching a plurality of exterior wall panels to said foundation to form the walls of
said building,
(d) attaching a plurality of interior wall panels to said foundation to form rooms in
said building,
(e) providing tensioners to have one end of each tensioner attached to said
respective fixture,
(f) attaching the other end of each tensioner to a bracket at or near the end of each
wall panel distal the foundation, and
(g) securing a roof above.
Preferably step (b) comprises placing formwork (preferably of a kind as herein described
and preferably of a kind as herein described as footers) on the prepared ground site to define a
cavity to receive a concrete pour.
Preferably the method includes pouring concrete into said cavity allowing the concrete to
cure to thereby bind the formwork together.
Preferably horizontal tensioners are connected to the bracket at or near the end of each
wall panel..
Preferably the tensioners are tensioned once connected..
Preferably the tensioners are tensioned once connected to shore up the structure so
formed..
Other aspects of the invention may become apparent from the following description
which is given by way of example only and with reference to the accompanying drawings.
As used herein the term “and/or” means “and” or “or”, or both.
As used herein “(s)” following a noun means the plural and/or singular forms of the
noun.
The term “comprising” as used in this specification means “consisting at least in part of”.
When interpreting statements in this specification that include that term, the features, prefaced
by that term in each statement, all need to be present but other features can also be present.
Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.
This invention may also be said broadly to consist in the parts, elements and features
referred to or indicated in the specification of the application, individually or collectively, and
any or all combinations of any two or more of said parts, elements or features, and where
specific integers are mentioned herein which have known equivalents in the art to which this
invention relates, such known equivalents are deemed to be incorporated herein as if
individually set forth.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only and with reference to the
following drawings of a scale model designed and built to demonstrate the assembly process.
Figure 1 is an exterior corner footer of footing of a foundation of a modular building and
system.
Figure 2 is an internal footer of the footing.
Figure 3 is a double internal footer that may be used in creating the footing.
Figure 4a shows the exterior corner footer of Figure 1 and internal footer of Figure 2
connected.
Figure 4b shows two exterior corner footer of Figure 1 and internal footer of Figure 2
connected.
Figure 4c shows footing constructed from four exterior corner footers and two double
span internal footers.
Figure 5 is a close up view of the footing, showing reinforcement rods and spacing
members for insulation and reducing concrete requirements.
Figure 6 shows a perspective view of the footing of Figure 5 with one of the 4 cells filled
with concrete for illustrative purposes.
Figure 7 shows the foundation of Figure 6 with the addition of foundation fixture, where
vertical tensioners are attached to each of the fixtures.
Figure 8 shows a close up view of a corner footer showing a corner fixture and vertical
tensioner extending there from.
Figure 9 shows a close up view of a divider fixture on the footing with a vertical
tensioner extending there from.
Figure 10 shows an exterior wall panel.
Figure 11 shows a connecting beam for use to extend laterally between wall panels, to
provide structural support.
Figure 12 shows an exterior panel for defining a passage (e.g. a door or window).
Figure 13 shows an interior panel for room or area partitioning within the building.
Figure 14 shows an example of a partial building scale model built showing exterior wall
panels and an internal beam extending across the building.
Figure 15 shows a close up of the top of the panels of the building of Figure 14, showing
a tensioner protruding from the top of the panels.
Figure 16 shows a close up of the footing with a channel to receive the edges of each a
wall.
Figure 17 shows a close up of a top edge of a building with a corner anchor that receives
vertical and horizontal tensioners.
Figure 18 is an alternative view of the anchor of Figure 17.
Figure 19 shows a close up view of the internal beam and anchor, having received a
vertical tensioner, the top of the cable ready to receive a roof or floor for the next level of the
building, showing a groove in the beam that is capable of receiving a horizontal tensioner to
engage the anchor.
The following figures describe some variations to some of that shown in the figures
above and in which:
Figure 20 is a plan view of a foundation showing 4 cells adjacent each other.
Figure 21 is a sectional view of detail H of figure 20.
Figure 22 is a perspective view of a partially assembled footing.
Figure 23 is a perspective view of a partially assembled footing.
Figure 24a is a perspective view of an internal footer that may be used.
Figure 24b is an alternative perspective view of an internal footer that may be used.
Figure 25 is a perspective view of a partially assembled footing with foam pods located in
each cell.
Figure 26a is a perspective view of a partially assembled footing with a footer being
removed to help show the modularity and connectivity between components of the footing.
Figure 26b is a perspective view of a footing connector.
Figure 26c is a side cross section view of a showing the lower wall and footer interaction.
Figure 27 is a close up view at region H of figure 20 of a footing connector that may form
part of an internal footer.
Figure 28 is a sectional view of section DD of figure 20.
Figure 29 is a sectional view at part of section HH of figure 20 and with a wall panel in
part shown above.
Figure 30 is a plan view of a footing connector,
Figure 31 is a perspective view of a building prior to a concrete foundation pour and with
a ceiling/roof partially installed.
Figure 32 is an alternative perspective of the building with a roof partially installed.
Figure 33 is a view of a wall to roof anchor.
Figure 34 is a close up view of the interface between the wall and roof showing the wall
to roof anchor in place with tensioners connected.
Figure 35 is a close up view of a wall to roof anchor located at the top of a wall.
Figure 36 is a close up view of a wall to roof anchor located at the top of a wall and a
roof panel adjacent.
Figure 37 is a plan view of components at the roof to wall interface, including a gutter.
Figure 38 is a sectional view looking horizontally at the interface between the roof and
the wall and a gutter.
Figure 39 is a perspective cut away view of the interface between the roof and wall and
gutter.
Figure 40 is a section view looking horizontally at the interface between the roof and the
wall.
Figure 41 is a sectional view looking vertically at the interface between two walls at a
corner showing an external capping member to cap any gap between the two adjacent panels.
Figure 42 is a perspective cut away view of part of a two storey building.
Figure 43 is a perspective cut away of part of a two storey building.
Figure 44 is a perspective view of a multi-storey wall to floor anchor.
Figure 45 is a perspective cut away of part of a two storey building.
Figure 46 is a sectional view through of the walls and floor looking horizontally at the
interface between a lower and upper more storey.
Figure 47 is a sectional view through of the walls and floor looking vertically at the
interface of two adjacent wall panels at a corner.
Figure 48 is a sectional view through of the walls and floor looking vertically at the
interface of two adjacent wall panels forming part of a wall of a structure.
Figure 49 is a front perspective view of a multi-storey anchor and tensioners.
Figure 50 is a rear perspective view of figure 49.
Figure 51 is a perspective view of a two storey building with a beam.
Figure 52 is a front view of figure 51.
Figure 53 is an alternate side view of figure 51.
Figure 54 is cross section C-C of figure 53 showing the beam.
Figure 55 is a detail view of D in figure 54 showing the beam connector
Figure 56 is a detail view of E in figure 51 showing the beam and associated connector.
Figure 57 is a cross section of a one storey construction showing sloped ground
foundations.
Figure 58 shows a close up view of detail A of figure 57.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Here below is described a modular building, components and aspects therefore and
methods of their construction. The building can be formed using modular components including
panels. Many of the components are able to connect and cooperate such as by interlocking with
each to create a rigid building structure. The foundation of the building includes a footing. The
foundation may also include concrete preferably poured adjacent the footing. The footing is
formed by prefabricated footers that may be connected together to define the footing of the
foundation. A number of panels are used to form either outer walls of the building or internal
walls, forming rooms or partitions within the building envelope. The panels may include
apertures for window or doors or the like. Each of the panels is capable of being fitted to the
footing. A roof may be fitted on the top of the panels supported on the footing or alternatively
a roofed second storey may be supported.
Components are factory made with precision so as to ensure accurate assembly on site
right from the foundation up.
Foundation
With reference to figure 6, there is shown a foundation 1 for a simplified representation
of a building, namely one that has a square footprint.
The foundation 1 includes a footing 2. The footing 2 is created by the use of
prefabricated components that are able to be assembled on site.
The site may be prepared by levelling and compacting the ground sufficiently to be able
to place the footing thereon. The foundation may be set down below ground level or may sit at
ground level. No trenching is required as the foundation is capable of sitting on top of
compacted ground.
The prefabricated components of the footing may comprise of footers such as external
corner footers 10. These may be connected to like corner footers or other shaped footers.
Footing connectors 50 may be used to connect footers together so that they can be
assembled on site with each other to define the footing.
The foundation of the building preferably comprises such footing to support panels that
form the exterior walls of a building. Interior wall or partition panels may be supported on
internal footers that will herein after be described.
The external footers once placed on the ground, can create a formwork or cavity for a
concrete pour. This can be seen in figure 6 where the bottom left part of the foundation is
shown to have been filled with concrete to the top of the external corner footer 10. Filling may
be achieved by other composites or appropriate settable materials as are known in the art,
concrete being an easily accessible material.
Filling with concrete or the like amalgamates components of the footing together. It also
creates a load transfer path to the ground below as it can be seen that the concrete pour is at
least partially into the ground below and in particular onto the ground below, below and/or
adjacent where the footers will receive wall panel loading.
The poured concrete can settle onto the ground below, even if it is not perfectly smooth
or coplanar with the lower edge of the footing. The concrete can act as a gap-filler between the
ground and where building structure load transfer will occur from the footing. The foundation
may remain as a raft foundation with little or no ties to the ground below that may restrict its
lateral movement such as during an earth quake.
Figures 1 to 3 show various parts making up the footing 2 of the foundation 1. The
footing 2 may be individual footers that can be connected or joined together. They may create
an endless footing or a footing having two ends. Preferably the footing is created to define an
enclosure. Wall panels may be supported on top of the footers.
In the examples shown, the footers may include external corner footers 10. To ensure
accuracy of the foundation, the external corner footers 10 are prefabricated with their corner
angle predefined. This ensures that for example, 90 degree corner accuracy is maintained
when the components making up the footing are assembled on site. This helps keep the footing
true and square when assembled and during the concrete pour. In particular designs, the
external corner footers may not be 90 degrees. The flexibility of multiple angles allows more
design options. Acute or obtuse angles are also envisaged between the elongate sections of a
corner footer.
The footing 2 may also have internal footers 51 that support internal walls of the
building. The internal footers 51 may be of a single span as shown in figure 2 or a multi-span
crossing over other internal footer(s) as shown in figure 3. Also shown in Figure 3 is a connector
4 that incorporates a hold down bolt that slots into the internal junction of the divider pieces.
The connector supports the divider pieces intermediate of the frame of the footing.
The internal footers 51 and external footers may be connected to each other using footer
connectors 50. As shown in figure 2 and 3 the footer connectors may be integrally formed with
the internal footers 51. Alternatively, they may be integrally formed with the external footers or
both. Alternatively, separate components may be used to connect adjacent footers together.
Bolt through securing of the footers and the connectors may be achieved as seen in figure 4a.
Alternatively, locking or interlocking features and/or components may be provided such as dove
tail, mortise and tenon or dowel joint configurations to ensure a securing of the footing
components together.
In the example model foundation as shown in figure 6, four corner footers 10 are used to
form a square shaped foundation. However, other external footers such as straight external
footers, opposite acting corner footers and the like could be used to construct different shaped
foundation layouts for a building.
The footer pieces are preferably factory made to exact sizes, so that they can be easily
handled and fitted together. They may be made in a mould or they may be cast in a mould.
The interface of joining footers allows substantial resistance to out of horizontal plane
deformation of adjacent footers. This helps ensure that the footers remain fixed to each other
and coplanar and a flat concrete floor slab can be poured. This is important from a building
accuracy point of view. Additionally, the internal footers may also have a downwardly facing
surface or lip 19 as shown in figure 4c, defining an undercut for the filler material to sit under
the members. The filler, abutting the surface helps support the footer once the filler material is
insitue.
The interface between adjacent footers and their connection via intermediate footer
connectors to achieve resistance to deformation is achieved by having a sufficiently high I-
value. E.g. by having a high footer wall height and/or vertically spread connection points of two
connected footer components, to resist horizontal bending of two connected footers. Resistance
to bending of two connected external footers in a lateral direction can be achieved by there
being an internal footer extending from at or near the junction of the two external footers to as
to create support thereat.
Once the footing 2 is in place on supporting ground, such as is shown in Figure 4c,
spacers 20 may be placed in bay(s) or void(s) 21 created. In Figure 5, only one spacer is
shown in one bay. However, in the preferred embodiment of the present invention any
appropriate number of spacers may be used in any number of bays in the footing assembly.
Preferably all bays have at least one spacer in them. The spacers are preferably made from
foam, polystyrene or any other appropriate material that will provide insulative properties.
They also help reduce volume of the subsequent concrete pour.
Provision may be made for reinforcement or rebars. These may be supported by the
footers for support and positioning during the concrete pour to become embedded in the
concrete. Rebar hangers 13 may be carried by or from part of the footers. The hangers may
include apertures or slots that are of a size and shape to receive reinforcement rods or rebars
22. The rods or rebars may be made from any appropriate material, for example, steel or glass
fibre.
Once the footing is constructed, any spacers and reinforcement rods laid, a filler material
may be poured. The top edge 23 of the footers forms the screed guide for the filler poured.
The filler flows about the reinforcing rods, spacers and fills all the reaming spaces within the
footing. Once the filler has set, the footers, rods and spacers remain as an integral part of the
foundation 1.
In Figure 6, a foundation is shown with one bay filled up to illustrate the level of the filler
24. In the preferred form the filler fills all voids forming a single integral base. The filler
amalgamates the footing once it is set.
In the preferred form of the invention the filler is concrete, but other filler materials
known in the art may be used. Examples include but are not limited to UHPC, Taktl , GRFC, or
plastic or other resins.
In the resulting foundation, the external footers form the perimeter of the foundation
with the internal footers providing internal wall support and support to the external footers
during construction of the foundation.
The perimeter footers also provide an exterior finish for the foundation as the filler
material is fully enclosed and not visible to the outside.
The direct load from the walls and roofing that will be placed upon the foundation is
taken by the footers. However, some or most of the weight loading will be transferred to the
set filler material to the ground below. Preferably the footers are shaped and configured to have
a lip 17 or undercut or space or similar for the filler material to flow under at least part of the
footers. The undercut(s) allow for weight being borne on the footer to be at least partially
transferred to the filler material.
At least one of the footers (and when used the footer connectors) present a fixture 18
for use in creating the above foundation structure.
Each fixture 18 may be cast into or secured to the footer or footer connector at a
factory, precisely in location to accurate positioning such for subsequent alignment with wall
panels. Such positioning is to ensure they are accurately spaced from each other and to
correspond to the panels to be located on the footers.
The fixtures allow the connection thereto of a rod or cable 27 that is used in the
subsequent construction process that will later be described in detail. The rod or cable may be
directly connected to the fixture. Alternatively the connection may be indirect. Or alternatively,
the rod or cable is already located with the footer or footer connector with or without the use of
the fixture.
Each fixture in one form may be or include an anchoring bolt. The anchoring bolt may
be a threaded upstand or stud to which a vertical tensioning cable or rod can be attached.
Alternatively, the fixture may be barrel nut of the like having a threaded aperture, blind or
otherwise into which a swaged fitting at the end of a tensioning cable of tensioning rod may be
threaded.
Figure 7 shows the fixture being secured to the footer using brackets 25, 26. Shown are
brackets 25 that are L shaped at 90 degrees, attached to the corners of the footing 2, and
brackets 26 that are straight. Each of these brackets help secure the fixture to a footer in a
defined location. These brackets may also have a purpose of helping to locate the wall panels
that will be placed and fixed to the foundation and anchor tensioners that tension during
location of the wall panels. The brackets 25, 26 preferably include a lip that can locate with a
wall panel to position the wall panel.
A variation to what has been described to now with reference to Figure 1 to 9 will now be
described with reference to figures 20 to 29.
With reference to Figures 20 to 29 there is shown a variation of the foundation as
described above. The foundation illustrated is still in a simplified form, substantially of a square
plan.
With reference to Figure 22 the footing 2 comprises of external corner footers 10,
external straight footers 52 and internal footers 51. The footing 2 also includes footing
connectors 50 which connect the external corner footers 10 together and/or to the external
straight footers 52 as shown in Figure 22. Where the footer connectors 50 connect internal
footers 51 to external footers, the footing connector 50 may be integrally formed with the
internal footer as shown in Figure 24a. Where the footing connector 50 connects between, for
example, an external corner footer 10 and a straight footer 52, the footer connector 50 may
look like that shown in Figure 26b.
The connectors 50 and the external footers preferably include locators 60 and 61 to help
locate the footers with the connectors in a condition where they are desirably aligned.
The locators 60 and 61 may for example be a mortise and tenon like configuration or
may be of a dowel pin or dovetail configuration. The dovetail configuration can allow for a
vertical sliding between a connector and a footer to occur to locate the two together. The
locators 60 and 61 help ensure correct alignment and positioning of the components of the
footing. The use of a dovetail-like configuration may avoid the need for fasteners that have
previously been described as being useful for connecting the footers together.
A top plate 63 of a connector as seen in Figure 30 may have a dovetail-like zone 64 for
location with a complimentary zone of an adjacent footer 10 or the like. This can help establish
a connection between the adjacent components.
As can be seen with reference to Figure 26a and Figure 29, height adjustment feet 65
may be utilised for the purposes of levelling the footing during installation. The feet 65 may be
threadingly adjustable relative to the connector and/or footer from which they are disposed. In
the example shown in Figure 29 the foot 65 is disposed from a connector 50 and is supported
on the ground 66 on which the foundation is to be established. In situations where the ground
is uneven a foot can be adjusted to thereby support the connector 50 and/or the footer until
such time as the concrete pour has set whereupon the concrete will then assume the load
bearing responsibility of the foundation and the footer on which the wall panels will be erected.
With reference to Figure 29, the internal footer 51 preferably includes a service conduit
68 which allows for services such as power cables, data cables or the like and/or water and gas
conduits to pass therethrough. This allows for a retrospective fitting of such utilities into the
building. The conduit 68 through the internal footer may be set approximately 5 mm below the
top surface to permit easy access from the floor by drilling through the top.
The conduit 68 of the internal footer 51 may be aligned with a similar vertically aligned
conduit or passage in the walls once they are established. This can allow for data and power
cables to pass up through the walls from the conduit 68.
Presented by and preferably protruding from preferably each connector is the fixture 18.
The fixture 18 as shown with reference to Figure 28 includes a barrel nut 69 that has an internal
thread that may be threaded to L-shaped rod 70 that is supported by the connector 50. The L-
shaped rod 70 is presented in a manner so as to become embedded in the concrete pour of the
foundation. The leg 71 of the L-shaped member 70 is presented for becoming so embedded.
This provides strong anchoring of the fixture 18.
The barrel nut 69 can be threaded to the L-shaped member or may be integrally formed
therewith and is presented to allow for a cable or a rod 67 to be engaged therewith as for
example shown in Figure 29. It can be seen that the connector 50 and likewise the footers 10
and 52 have a profile that includes an undercut under which the concrete pour can run. This
ensures that some concrete is located beneath the connectors and/or the footers 10 and 52 so
that the concrete then provides some load bearing function for the structure to be built on a
foundation.
It can be seen with reference to for example Figure 26a that the footer seat region 75,
compared to that of the earlier described embodiment, has a wedge shape profile. A wall
placed on top of the seating region of the footers with a complimentary shaped bottom edge to
be seated by the seating region, will help locate the wall panels on the footers. In particular
once the wall panels are on and are being drawn against the footers by the tensioning cables or
rods will force the wall panels against the lip 76 of the footers thereby facilitating in the creation
of a close and proximate juxtaposition of the wall panels and the footers 10. An intermediate
seal may be provided for helping create an adequately sealed interface between the footers 10
and the wall panels above. This ensures that the sloping angle and the tensioning pressures
direct the wall components to fit snugly against the interior floor edge.
The footers are preferably made from an ultra high performance concrete (UHPC), such
. However, they may be formed from wood, glass fibre reinforced concrete (GFRC) or
as Taktl
other appropriate materials or may be made composite of various materials. The connectors
may likewise be made from such materials or other.
The foundation may be placed on a level site, a sloping site, or a site that is a
combination of sloping and level as shown in figure 58. Where the foundation is to be erected
on a non-level site, conventional piles or screw piles may be used to support the foundation.
Concrete may be poured or not. If not, floor panels 201 can be supported by the footers.
The footers on a non-level or sloping site may be supported by one or more of the
following; beams 202 supported by the footers or anchors, or bearers, joists or piles built into
the sloping site. The foundation may be stepped so that any water internal of the walls can
drain to the exterior of the building, rather than onto the floor. This is achieved by the top outer
edge of the footing, where the wall panels are mounted, comprising a rebate or ledge below the
floor level. In the unlikely event water penetrates the panel joint; it falls to the bottom of the
rebate to exit outside.
The foundation may be pre-fabricated in a factory, and then transported to the building
site. However in the preferred form the footing may only be pre-fabricated in a factory,
assembled onsite for the concrete or filler material to then be added on-site.
The footers once connected together are rigidly connected together and do not require
additional bracing or support for when the concrete pour is received. The connections between
external and internal footers creates a strong footing assembly that can resist, without
deformation the hydraulic pressures of the concrete pour whilst it is curing. Internal footers can
provide some bracing to the external footers. The footers can establish a gridded footing
creating a plurality of cells.
In the preferred form the following steps to construct the foundation may be followed.
1. Optionally excavate the building site.
2. Level the building site to the required levels.
3. As necessary add crushed rock basecourse and compact to the conventional
compaction standards.
4. Level the ground to the required heights.
. Lay out the footing components and fix together to the designed building
perimeter, and level using as necessary the optional screw footing height adjusters.
6. Optionally excavate around the footing for storm water drainage to the exterior of
the building.
7. Optionally excavate to the footing for soil pipe/s, potable water, gas , electricity,
communications cable to the exterior of the building.
8. Install waterproofing membrane within the building perimeter.
9. Add spacers in the center of each bay or void to provide insulation and minimize
the concrete volume.
. Place the reinforcing bar if needed.
11. Add a concrete pad reinforcing mesh if needed.
12. Pour the filler material (e.g. concrete), ensuring the filler is screeded flush with
the and level to the top of the footers.
For elevated footings – (for sloping sites)
1. Establish the high datum level of the floor/s.
2. Trench along the line of the upper footing, or if partially at ground level; follow
steps 1 – 11 to lay the first bay module as shown above
3. Locate and place piles as necessary to support the footing beams.
4. Connect and lock in the footing precast beams.
. Tie together with post tensioned rods/wires.
6. Lay the floor panels on top.
7. Post tension together from the edges.
Modular Building
At the exterior perimeter of the foundation 1 there is defined a seat 30 to receive
building wall panels. This is shown in one example in Figures 8 and 9.
The seat 30 may be defined by one or more of a protrusion, channel, slot, recess or relief
lip, surface by one of each of the footer connectors and/or footers. Intermediate members may
be located thereat, such as a seal strip or the like.
The lower edges of the exterior wall panels that are to be placed and fitted to the
perimeter of the foundation 1 are of a complimentary shape to become adequately located to
the seat at a respective seat. Such location is primarily by way of being clamped, as will herein
after be described.
The perimeter footers have a seat of a kind that may include a flat surface 29 bounded
to the building interior side thereof by a lip 28 as in figure 9. A wall panel can sit on top of the
seat and against the lip 28. As will be later described, the wall panel may be pressed against
such a lip during assembly of the building structure. The top of lip 28 is the finished floor level.
With the wall panel seated in the rebate below the flat surface 29, there can be no water
penetration to the floor or interior.
The internal footers may have a channel formation 35 formed in them to define the seat
for the inner wall panels. The lips 36, 37 to the channel 35 extend to the screed surface 15 of
the footing 2.
Figure 10 shows an exterior wall panel 31. Preferably each panel is similar in
configuration. Figure 12 shows a frame wall panel 31a for defining a passage (e.g. a door or
window).
A panel may have two parallel vertical edges 33 and two parallel horizontal edges. The
panel 31 may be formed of laminated panels, or may be formed of in a single moulded material.
A channel 32 may be formed around the perimeter of the panel. The external side 33b of the
panel perimeter (the side of the panel that will form the outer wall of the building) preferably
extends out further than the internal side 34 of the panel perimeter, forming a lip 33a, and at
the base 31, overlaps the footing outer edge providing further weather proofing.
In alternative forms of the wall panels, the panels may be integrally moulded with (or
without) a channel about their perimeter and having an external lip 33a.
When the panel is located on the footing seat, the lip 33b laps over the edge 3 of the
external footing and the internal surface edge 34 of the panel abuts the lip 28. This helps
provides weatherproofing and accurately locates the exterior walls in position. Additionally, an
elongate seal may be placed within the channel 32 in the panel, to provide additional
waterproofing.
With reference to figure 29,26a and 26c the footer seat may include a wedge 75 to help
drive the wall against the lip of the footer.
An interior wall panel is shown in Figure 13, similar to the exterior wall panel, about the
perimeter of the interior wall panels are formed two channels 41, 42. Preferably these extend
completely about the perimeter of the panel. Between each channel is a projecting part 43 that
fits into the channel 35 formed in the internal footers.
The channel 35 formed in the internal footer may in some forms be deep enough to take
electrical wires, water and waste pipes for the buildings power and plumbing supplies.
Alternatively or additionally, the channels 41, 42 formed in the interior wall panels 40 may take
electrical wires, water or waste pipes.
The internal footers are structural members that can support the roof or upper level floor
through the inner walls or partitions of the building.
It is preferred that all panels have identical edge detail and channels on all four sides,
allowing optional rotation and location of the panels and formwork. For some panels, this will
eliminate orientation errors. Additionally some of the channels may receive tensioners such as
tensioning cables or rods. The channels may also receive rubber seals for dust and
waterproofing.
The exterior edges of the panels may butt together as shown in figure 48 where two
external wall panels 85 and 86 abut together at interface 87. The internal edges of two adjacent
wall panels may be separated as seen in figure 48 and a cap or joiner or spaces 89 may be
provided to bridge the gap. It may be configured to provide a passage 90 for cables etc. The
cap 89 can be factory slotted, pre-cast or drilled or cut or similar to allow access to such cables
for placement of light switches, power outlets etc.
Additional cladding, coating or trim 91 may be provided over the interface between
adjacent panels on one level or between adjacent panels of two levels of the building structure.
At interfaces between corners located panels, the edges may be flush or also separated.
As seen in figure 47, two external panels 31 abut each other but a cap 93 may be used to
bridge the gap at their external faces.
The wall panels may include apertures for windows or doors. A panel may define an
opening frame that may or may not be closed or closable by a door or window.
Tensioners such as tensioning cables or rods are able to pass up between adjacent
panels to or towards the top edge of the walls. At the top edge, the tensioners are able to
secure to anchors such as anchor 150 that sit atop of the walls. Preferably the anchors sit in a
recess at the top of the walls as seen in figure 18. The top of the panel is the logical place for
the tensioners to be anchored given it's a free surface at which a compression of the panel onto
the seat at the footers can occur.
The anchors receive the vertical tensioners as seen in figure 15 and locate these in
manner so that they can be tensioned. This may be achieved by the tensioners passing through
an aperture of the anchor 150 and having a nut 162 in which a threaded portion of the
tensioner can locate to then be threadingly tightened up. Threaded connection may occur at
the bottom or the top of the panels or both. Hence a tightening of the tensioner may be
achieved at one or both of the top and bottom of the panel. Alternatively the tensioner may be
made of multiple parts split between the top and bottom of the panel and a turnbuckle style
adjustment of the tension may be achieved.
The tensioners are located intermediate of walls panels and where provided between
floor or ceiling panels. They are located intermediate of such and obscured from view when the
building is completed. This is may be by virtue of the panels having rebates at their edges that
house the tensioners. The anchors also provided in a manner so at to be obscured from view.
With the anchor 150 resting on top of the panels and the tensioner being anchored at
the fixture at the foundation, a compression force can be applied to the wall panels. This drives
the wall panels into their seats below and by virtue of the location lips and/or friction, the wall
panels become secured to the foundation. Lateral movement of a wall panel so secured relative
the footer is very hard to achieve. Even more so when contiguous coplanar panels are so
mounted and even more so when contiguous lateral wall panels are so mounted and even more
so when a ceiling/floor/roof diaphragm is located at the top of the wall panels.
Anchors 150, 151 (see Figures 17, 18 and 19) are preferably provided for each of the
corner junctions of wall panels, and intermediate of coplanar wall panels. The connectors
preferably bridge across two contiguous panels.
Additionally, it is preferred that horizontal tensioners extend across at least two adjacent
wall panels and are clamped preferably at the same anchors 150, 151, at adjacent joins or
edges. Preferably such horizontal tensioners run along the entire perimeter of the structure.
They may be secured to effect clamping at each adjacent panel interface or may be secured for
clamping at spaced apart panels, e.g. at the ends of a multi-panel wall section.
The tensioner anchor 150 as seen in figure 17 allows for the vertical and horizontal
tensioners to be connected thereto and together. Horizontal tensioners 154 and 155 locate to
the anchor 150 in a similar manner as the vertical tensioner 27. They may pass through an
aperture and be captured to the anchor by a nut that can be threadingly adjusted to cause the
tension in the horizontal tensioners to be increased. Other kinds of constructions enabling a
threaded adjustment to be made for tensioning the tensioners will be possible.
In the preferred form the anchor that receives the vertical tensioner may also receive a
or several horizontal tensioners as shown in figures 49 -50. However it is envisaged that
separate anchors may connect with the vertical tensioners compared to the horizontal
tensioners. However, for speed or assembly and for rigidity, it is the same anchor that connects
to both vertical and horizontal tensioners at each panel interface. Features to allow the
tensioners to extend at 90 or 180 degrees to each other are hence provided by the anchor.
In use, the vertical tensioning cables extend down each of vertical parallel edges of the
wall panels, preferably in the channels formed in the edges, and the horizontal tensioning
cables extending in, or adjacent similar channels in the horizontal edges of the wall panels.
If a support beam 100 is used between wall panels (as shown in Figures 16 and 19), a
anchor 151 may be used to allow a tensioner to run along the beam 100. The anchor 151 can
also support and locate the beam 100. The beam 100 may include a beam channel 158 (or
hole) for such a tensioner to locate in and extend to a tensioner anchors at the other end of the
tensioner.
In a preferred embodiment the anchor 151 can locate and support a beam 100 in multi-
storey constructions also, as shown in figures 51 – 56. The beam 100 can either support a roof,
or floor depending on the construction. In single and multi-storey constructions the anchor 151
integrates the support and location of the beam 100 along with multiple apertures and features
configured to integrate with the multiple tensioners (351 352 353 354 29).
It is preferred that the wall panels are formed from an ultra high performance concrete
(UHPC), such as Taktl . However, they may be formed from wood, glass fibre reinforced
concrete (GFRC) or other appropriate materials. Furthermore, it is preferred that a core portion
of the wall panels are polystyrene, or other similar materials, to provide for insulation, rigidity
and weight saving.
To build the walls of a building the following steps may be followed.
1. Erect two exterior wall panels forming a corner, and connect the panels using an
anchor 150 by dropping it the recess at the top of each panel to loosely hold the panels
in position.
2. Continue to assemble the external panels, making up the external wall, and
interior panels, making up the rooms inside the building, inserting connecting beams,
and connectors as assembly progresses, as necessary.
3. Install the vertical tensioning cable or rod and loosely tension.
4. Install horizontal tensioning cables in the channels at the tops of the wall panels
and loosely tension.
. From each corner square and plumb each of the panels, then tension.
6. Progressively tension all cables; the result being a locked together integrated wall
system and building.
The provision of the footers and their fixtures in a prefabricated manner and their ability
to connect to each other so as to space the fixtures accurately as part of the foundation,
provides for convenient subsequent erection of the wall panels. The accurate dimensioning of
the fixtures position and the wall panels, means that the fixtures are going be accurately
located so as to be able to extend between adjacent wall panels.
Along a multi-panelled wall section of the structure, a linear array of a plurality of
fixtures are going to presented ensuring the wall is straight.
The wall structure is frameless and hence requires no extra structural posts as all
compression and shear strength of a wall can be provided by the wall panels and associated
tensioners. With the footings, walls and roof all connected in this overall fashion, the result is an
integral structure of substantial strength and rigidity. The clamping forces exerted via the rods
compresses the panels. This ensures they become snug with each other and the foundation.
Any movement of the building (such as during a quake) causing the panels to move relative to
each other in a manner reducing their snugness, is resisted. Any movement that may occur will
result in the panels from becoming more snug with each other due to the bias that the clamping
force exerts on each panel and the structure as a whole.
The roof construction
With reference to Figures 31 to 40 there is shown some slight variations to the
construction of the walls and in addition how a roof may be established on the building
structure. With reference to Figure 36 there is shown horizontal tensioners 250 that extend
across the tops of the external wall panels and lateral horizontal tensioners 251 that extend
laterally from the external wall panels.
The lateral horizontal tensioners 251 may run across internal wall panels or may not run
across internal wall panels but preferably intermediate of roof panels 252. Wall to roof anchors
253 are provided that connect the vertical tensioners 29 with the horizontal tensioners 250 and
251. A close up view of such an anchor is shown in Figure 33.
Figure 33 shows the anchor 253 with multiple holes for a lateral horizontal tensioner 251
to connect or fasten at/through. The lateral horizontal tensioner 251 can run, locate or be
guided by a channel in the floor or roof panels.
In a preferred embodiment the top or bottom hole is used to connect a lateral horizontal
tensioner 251 that runs across to an opposite wall. Horizontal tensioners running at right angles
to theses horizontal tensioners do not interact with each other as the other of the top or bottom
hole is used to fasten the lateral horizontal tensioner 251 running at right angles.
In some embodiments, the lateral horizontal tensioners 251 run in their own individual
channel. In other embodiments the opposing (at right angles, or substantially thereto) lateral
horizontal tensioners 251 may run in a similar opposing channel, and are kept separate from
each other via use of the top and bottom fastening holes. In a less preferred embodiment,
lateral horizontal tensioners 251 that cross paths can both use the top (or bottom) holes (or
the anchor can only have one hole) and the lateral horizontal tensioners 251 are able to deflect
around each other. This method allows for flexibility in the building process.
The anchor can receive a lateral horizontal tensioner 251 and a vertical tensioner 29 in a
manner to allow for threaded adjustment of the tension as seen in Figure 33 by the use of a nut
that secures to a threaded portion of the tensioners. Turnbuckle style tensioning may be one of
other ways of creating compression or the panel.
The horizontal tensioner 250 may likewise be secured to the anchor 253 or may
alternatively pass therethrough for its tensioning to occur at another location remote from the
anchor 253. Preferably tensioning occurs at the terminal end of the tensioners commensurate
to the termination of the surface of the panel along which the tensioner runs.
The roof panels 252 locate preferably on top of the side walls as shown in Figure 38. The
tensioning of the tensioners forces the roof panel at the top of a wall panel against the wall
panel. Preferably the forcing is in a horizontal direction where the roof panel is drawn against a
vertical lip or other surface or surfaces of the wall panel or against such of the anchor as seen in
the drawings, the anchor having been anchored relative the wall panel by virtue of the vertical
tensioner acting on the anchor.
The roof panels may be pitched/sloped (not shown) for aesthetics and/or improved water
run-off or increased interior space. In these cases a similar anchor to that of anchor 253 is
used. However the sloped anchor will have a hole for a sloped roof panel tensioner to go
through and fasten to. The hole will be at a similar angle to the slope/pitch. The anchor can still
have horizontal holes for lateral horizontal tensioners of a level ceiling inside.
Extending from an upper surface or other surface of the roof 252 is a transitional cap or
bridge incorporating drainage for rain water or other precipitation that may be collected on the
roof for directing this to a gutter 270 as shown in figures 32, 38 - 40. The gutter 270 locates
over the top end 271 of the wall panel 31 so that rain water cannot penetrate between the roof
panel 252 and the wall panel 31. Preferably the guttering 270 will nest or interlock with the
roof panel 252 for ease of construction and waterproofness. Silicon sealer or other appropriate
sealers may be used to seal any edges or joins for optimum waterproof qualities.
As will be appreciated, the roof as herein described can be a ceiling/floor for a multi
storey construction instead of a roof. The roof panel, instead offering floor and/or ceiling
functionality between floors of the building.
Multi-storey construction
With reference to Figure 42 there is shown a multi-storey construction of a building
utilising aspects of the present invention. The construction on the top of the first level is similar
to that which has been described prior, including installation of a floor at the top of the first
level (rather than a roof as what has herein been previously described). One of the differences
however at the interface between levels is the use of a different anchor 350. The anchor 350
provided at the interface of the wall panels 31 of one level and of wall panels 331 of the next
level and floor/roof panel 252, allows a connection of tensioners for both levels.
As can be seen with reference to Figure 43, the anchor 350 locates and/or engages for
tensioning the,
- lower wall tensioners 351 (horizontal tensioners 250) located at the top of the lower
walls 31, and
- vertical tensioners 29 extending between the foundation and the top of the lower
level walls 31, and
- lateral horizontal tensioners 352 (251) that run coplanar and along edges of flooring
332, and
- vertical tensioners 354 that are provided for compressing the wall panels of the level
above.
Horizontal tensioners 353 may run along the lower edge of the wall panels of a level
above may pass through the anchor 350 or may also be anchored thereto. The anchor shown
in more detail in figures 49 - 50 preferably terminates the vertical tensioners 29 rather than
such passing through the anchor 350 to the next level.
Likewise the vertical tensioner 354 for the next level up is terminated at the anchor 350
to allow for independent tensioning of the vertical tensioner 29 below.
Preferably the horizontal tensioners 351 and 353 pass through the anchor 350 and are
terminated at the terminal ends which correspond to the terminal ends of the wall along which
such a tensioner runs.
The tensioners used to tension the building and hold the panels together are preferably
rod. Preferably it is a metal rod such as a stainless steel rod. But a stainless steel 1/19 wire
with swaged threaded fittings at each end may also be used. Other appropriate materials may
be used, such a rope, chain, or similar.
At the interface between a wall panel of the lower level such as the wall panel 31 and a
wall panel 331 of an upper more level as shown in Figure 46, a flashing 360 may be provided
for the purposes of draining any water on the interior side of the external face of the two-storey
wall to direct any such water flow outwardly of the building envelope.
It is preferred that the wall panels are first drawn onto to the foundation, while the roof
panels and/or other levels above can be locked down later as a separate operation.
The above described system and components can be factory made. This helps ensure
accuracy for the foundation through to the roof or upper level(s) for assembly of the complete
structure. The system includes the foundation and hence provides for accuracy and continuity
from start to finish of a building in accordance with that described above. Yet the system and
components of the present invention encourages design flexibility to enable creative
architecture.
A building constructed in accordance to that described above can be rapidly and
accurately assembled on site. Each component can be handled by two to four people,
eliminating the need for cranes or powered lifting devices for single level structures. As such
erection of a building according to the present invention can be by an un-skilled labourer, as no
drilling or cutting is required, only assembly of the parts.
Additionally, any size or proportion of a building can be readily accommodated. Thus,
this system can be utilized for many building types, for example, single residential, multi-
residential, schools, halls, etc.
The connection system is self supporting and the final structure/building is post
tensioned, ensuring all components are locked together. As such the building is seismic
tolerant.
The structure can also be rapidly broken down as panels and many other components
are not bonded together.
Finally, the system of the present invention provides for flexibility for electrical and
plumbing installation services.
The components are for the total build, including the footing, to ensure continuity and
accuracy is maintained throughout the build.
Floor, walls and roof are positioned and held in place with bracket connectors that once
the component parts are in place, take tensioners for post tensioning vertically and horizontally.
This ensures a “locked in” comprehensive and cohesive structure.
Claims (29)
1. A building comprising a foundation and a plurality of upstanding juxtaposed wall panels together defining at least one wall section of said building seated on said foundation and tied together by orthogonal tensioners comprising; a. at each end of the wall section, a vertical tensioner located parallel an adjacent wall panel and fixed by and extending between the foundation and a respective anchor positioned to act at or near the top of the adjacent wall panel to allow a binding of the adjacent wall panel by said vertical tensioner onto the seat of the foundation, b. a horizontal tensioner extending between said anchors at each end of the wall section to allow a horizontal binding of wall panels of the wall section together wherein a ceiling or roof comprising of a row of contiguous cover panels is at least partially supported by and on top of the at least one wall section.
2. A building as claimed in claim 1 wherein intermediate of and parallel with adjacent wall panels of said wall section is an intermediate vertical tensioner that is fixed by and extends between the foundation and a respective mid wall anchor positioned to act at or near the top of the two adjacent wall panels to allow binding of the two adjacent wall panels by said vertical tensioner onto the seat of the foundation.
3. A building as claimed in claim 1 or 2 wherein said horizontal tensioner extends from and acts directly on the anchor at one end of the wall section to the anchor at the other end of the wall section to bind all wall panels in the wall section horizontally together.
4. A building as claimed in anyone of claims 1 to 3 wherein each tensioner is a variable operative length tensioner.
5. A building as claimed in claim 4 wherein each tensioner comprises a rod having a threaded section at which the tensioner can vary its operative length.
6. A building as claimed in anyone of claims 1 to 5 wherein a lateral wall section extends from said first mentioned wall section, said lateral wall section comprising of a wall panel located contiguous the end wall panel of the first mentioned wall section, the vertical tensioner at the end of the first mentioned wall section located therebetween, its respective anchor located also at the wall panel or the lateral wall section.
7. A building as claimed in claim 6 wherein a lateral wall section horizontal tensioner extends from said respective anchor to a further anchor, the lateral wall section horizontal tensioner and the first mentioned horizontal tensioners able to cooperate together to bind the lateral wall section and the first mentioned wall section together.
8. A building as claimed in claim 2 wherein the mid wall anchor(s) anchor cover panel tensioners that extend between adjacent cover panels.
9. A building as claimed in claim 8 wherein cover panel tensioners extend between adjacent cover panels from a mid wall anchor on one wall section to another anchor.
10. A building as claimed in claim 9 wherein the other anchor is to a mid wall anchor on an opposed wall section.
11. A building as claimed in anyone of claims 1 to 10 wherein the cover panels are quadrilateral in shape.
12. A building as claimed in claim 9 wherein at least two opposed sides of each cover panel include a slot or rebate at where the cover panel tensioner is located.
13. A building as claimed in claim 8 to 12 wherein there are two contiguous rows of cover panels.
14. A building as claimed in claim 1 to 13 wherein the cover panels slope to define a sloping roof of said building.
15. A building as claimed in claim 1 to 13 wherein the cover panels are horizontal and define a sloping roof or ceiling/floor of said building.
16. A building as claimed in claim 13 wherein the cover panels are horizontal and a lateral tensioner extends between the two rows of horizontal panels, that is anchored at a mid wall anchor located at the top of a wall section aligned therewith.
17. A building as claimed in claim 1 that has a second storey located above the wall panels, the second storey comprising of a plurality of second storey wall panels supported above the first mentioned wall panels.
18. A building as claimed in claim 17 wherein said second storey comprises a plurality of upstanding juxtaposed second storey wall panels together defining at least one second storey wall section of said building wherein at each end of the second storey wall section, a second storey vertical tensioner is located parallel an adjacent second storey wall panel and fixed by and extending between the anchor of the and a respective second storey anchor positioned to act at or near the top of the adjacent second storey wall panel.
19. A building as claimed in claim 18 wherein intermediate of and parallel with adjacent second storey wall panels of said second storey wall section is an intermediate vertical tensioner that is fixed by and extends between the anchor and a respective mid wall second storey anchor positioned to act at or near the top of the two adjacent second storey wall panels.
20. A building as claimed in claim 18 or 19 wherein a second storey horizontal tensioner extends from and acts directly on the second storey anchor at one end of the second storey wall section to the anchor at the other end of the second storey wall section to bind all second storey wall panels in the second storey wall section horizontally together.
21. A modular building structure comprising: (a) a foundation comprising of footing assembled on site from prefabricated footers each connected together, (b) a plurality of abutting wall panels creating wall sections of the building, each wall panel supported on the footing, (c) a plurality of elongate vertical wall tensioners each located between and parallel to two adjacent wall panels and secured at (a) one end by the footing and (b) at an anchoring location to the two adjacent panels, to allow each wall tensioner to clamp two adjacent panels from above onto the footing, (d) extending parallel to and at the top of at least two adjacent said panels of each wall section, an elongate horizontal tensioner to bind the two adjacent panels together at where they abut, a said vertical and horizontal tensioner connected (directly or indirectly) at said anchoring location, (e) a roof or ceiling connected and secured to the vertical wall tensioners above the plurality of panels.
22. A modular building structure as claimed in claim 21 wherein a wall section of abutting wall panels abuts with a lateral thereto like wall sections of the building.
23. A modular building structure as claimed in claim 22 wherein each wall section comprises of a linear array of abutting wall panels, there being a said elongate vertical wall tensioner intermediate of the contiguous wall panels of abutting wall sections.
24. A modular building structure as claimed in anyone of claims 21 to 23 wherein each wall section comprises of a linear array of abutting wall panels, there being a said elongate vertical tensioner between abutting wall panels of the array.
25. A modular building structure as claimed in claim 21 wherein said elongate vertical wall tensioners are located between and parallel to two adjacent wall panels of laterally disposed abutting wall sections and are each secured to an anchor at a respective said anchoring location.
26. A modular building structure as claimed in claim 25 wherein said anchor secures a said vertical tensioner.
27. A modular building structure as claimed in anyone of claims 21 to 26 wherein the elongate horizontal tensioner at each wall section extends at the top of all abutting wall panels of the wall section and is anchored at each end of the wall section.
28. A modular building structure as claimed in claim 25 or 26 wherein said horizontal tensioner of each said abutting wall section is secured to a said anchor.
29. A method of forming a modular building comprising: (a) preparing a ground site for said building, (b) establishing a foundation on said ground site, said foundation presenting a plurality of fixtures for receiving tensioners, (c) attaching a plurality of exterior wall panels to said foundation to form the walls of said building, (d) attaching a plurality of interior wall panels to said foundation to form rooms in said building, (e) providing tensioners to have one end of each tensioner attached to said respective fixture, (f) attaching the other end of each tensioner to a bracket at or near the end of each wall panel distal the foundation, and (g) securing a roof above, utilising at least some of said brackets.
Publications (1)
Publication Number | Publication Date |
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NZ609969B2 true NZ609969B2 (en) | 2015-06-30 |
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