US20040103601A1 - Building structure and modular construction method - Google Patents

Building structure and modular construction method Download PDF

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Publication number
US20040103601A1
US20040103601A1 US10/473,913 US47391303A US2004103601A1 US 20040103601 A1 US20040103601 A1 US 20040103601A1 US 47391303 A US47391303 A US 47391303A US 2004103601 A1 US2004103601 A1 US 2004103601A1
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United States
Prior art keywords
panels
modular
building structure
longitudinal
modular panels
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Abandoned
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US10/473,913
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English (en)
Inventor
Tonny Bergqvist
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Euretech International Pty Ltd
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Individual
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Filing date
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Assigned to EURETECH INTERNATIONAL PTY LTD reassignment EURETECH INTERNATIONAL PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BERGQVIST, TONNY
Assigned to EURETECH INTERNATIONAL PTY LTD reassignment EURETECH INTERNATIONAL PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BERGQVIST, TONNY
Publication of US20040103601A1 publication Critical patent/US20040103601A1/en
Priority to US11/739,585 priority Critical patent/US20070245640A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/10—Deep foundations
    • E02D27/12—Pile foundations
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D5/00—Bulkheads, piles, or other structural elements specially adapted to foundation engineering
    • E02D5/74—Means for anchoring structural elements or bulkheads
    • E02D5/80—Ground anchors
    • E02D5/801—Ground anchors driven by screwing
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E04D3/352—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E04D3/355—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material the insulating layers of adjacent slabs having cooperating edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/36—Connecting; Fastening
    • E04D3/361—Connecting; Fastening by specially-profiled marginal portions of the slabs or sheets
    • E04D3/363—Connecting; Fastening by specially-profiled marginal portions of the slabs or sheets with snap action
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/36—Connecting; Fastening
    • E04D3/366—Connecting; Fastening by closing the space between the slabs or sheets by gutters, bulges, or bridging elements, e.g. strips
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/35—Extraordinary methods of construction, e.g. lift-slab, jack-block
    • E04B2001/3583—Extraordinary methods of construction, e.g. lift-slab, jack-block using permanent tensioning means, e.g. cables or rods, to assemble or rigidify structures (not pre- or poststressing concrete), e.g. by tying them around the structure

Definitions

  • THIS INVENTION relates to building structures employing modular structural panels and also to an improved construction method for assembling such modular panels to form such a building.
  • Ricchini discloses a structure using proportionally sized panels secured together by turn-lock fasteners inserted through aligned openings in adjacent sides of panels.
  • a further exemplary prior art construction arrangement is that disclosed in French Patent Document Number 2389724 in the name of Batimpro S A.
  • This document discloses a modular building using panels having adjacent vertical sides of complementary shapes. The panels are joined together by screws and are reinforced with metal plates at the location of the joints.
  • a yet further object of the invention is to provide a laminated modular panel adapted for use with the building structure and/or construction method which may also be expediently fabricated.
  • the invention resides in a building structure comprising:
  • a wall locating member positioned between a base and the one or more modular panels
  • the plurality of tie rods extend through said longitudinal cavities and secure said top member, walls and wall locating member to the base.
  • the modular panels comprise recesses on opposing longitudinal sides (herein after referred to as the longitudinal recess) of the adjoining panels, thereby defining, in use, the longitudinal cavity between the adjoining modular panels.
  • the top member provides a capping and/or compression feature to the walls of the building structure.
  • the top member may comprise a capping member and/or a compression member.
  • the wall locating member and the top member when it is a capping member, are both C section channelling.
  • the C channelling is placed so as to form a U and for the capping member the C channelling is placed so as to form an inverted U over the top of the modular panels.
  • an upright channel member may be fixed to one face of a modular panel for locating modular panels to form a corner or internal wall.
  • tie rods possess high tensile strength.
  • the tie rods may be releasably engageable with mounts provided at predetermined positions along the base.
  • the modular panels are of a laminated construction.
  • the modular panels are suitably formed from foamed plastics laminated panels having at least one outer skin member.
  • the modular panels may comprise an additional longitudinal aperture for accommodating a tie rod, located some distance in from the longitudinal recess, for the formation of a corner or join.
  • the base includes a floor structure, which may optionally be of modular construction, also employing laminated panels.
  • the laminated panels for the floor comprise a ribbed outer steel skin, a foamed plastic core and a ribbed inner skin.
  • the laminated floor panels made of a ribbed construction are preferably lined with composite flooring, waterproof ply or timber floor.
  • the building structure may also include a roof structure supported by the walls, which roof may also be of modular construction, employing further laminated panels.
  • the laminated panels for the roof may comprise a ribbed outer steel skin, a foamed plastic core and a ribbed inner skin.
  • the ribbed roof panel construction is preferably lined with fiber-cement board, plasterboard, random grooved ply or timber.
  • the step of placing the top member on the upper edge of the modular panels may comprise the steps of;
  • [0037] is placing a compression member on top of the capping member.
  • the invention resides in a modular panel for use in the abovementioned building structure or method of construction, wherein said modular panel comprises:
  • the modular panels may have an additional longitudinal cavity, sized so as to receive a tie rod, wherein the longitudinal cavity is located toward an end of the modular panel but inwardly from the longitudinal recess.
  • FIG. 1A is a front elevation of an exemplary building structure
  • FIG. 1B is an end elevation of the building structure
  • FIG. 1C is a schematic plan view of the building structure showing the arrangement of modular panels comprising the walls;
  • FIG. 2A is an enlarged partial sectional view of the structure's base showing the junction of the floor structure with an outer wall;
  • FIG. 2B is an enlarged sectional view of the portion of FIG. 2A in the circle.
  • FIG. 3A is an exploded isometric view illustrating the erection of modular panels to form a wall, wherein the top member is a capping member;
  • FIG. 3B is an exploded isometric view illustrating the erection of modular panels to form a wall, wherein the top member comprises a capping member and a compression member;
  • FIG. 3C is an enlarged detail view of an optional arrangement for locating the bottom side of the modular panels
  • FIG. 4 are enlarged sectional plan views of the aligned laminated panels showing the configuration of the positive positioning profiles on the laminated panels;
  • FIG. 5 is an enlarged partial sectional view of the roof area showing an arrangement of the fascia
  • FIG. 6A is an end elevation of a modular roof panel
  • FIG. 6B is an enlarged detailed view of the showing the positioning profiles on the roof panels
  • FIG. 7 is an exploded isometric view showing the arrangement of corner junctions and tee-junctions of the walls.
  • FIG. 1 shows a building structure 1 in the nature of a small dwelling which may be constructed in accordance with the invention.
  • the structure includes a base 2 , a number of walls 3 and a roof 4 .
  • the walls whether external or entirely internal, are composed of modular panels 5 .
  • the modular panels are fabricated to a typical module size of 900 mm wide by 3.0 m high. In some situations larger panels may be used, particularly to accommodate the pitch of a roof.
  • the modular panels are secured to the base by tie rods (described later) which are disposed along the walls at 900 mm centres 6 . Additional tie rods are disposed at the sides of openings in the walls 7 and at the comers 8 of the building structure.
  • the wall panels may be erected on a concrete or timber floor or, as illustrated in FIG. 2A, on a floor comprised of further laminated panels attached to screw-in foundations.
  • the base 2 comprises floor panels 9 supported by an inverted T member 10 mounted on screw-in foundations 11 .
  • FIG. 2A also shows floor panels 9 are mounted to the other half of the inverted T member 10 (the inner most horizontal face). The floor panels 9 are generally attached via screws 17 A.
  • FIG. 2B shows a wall locating member 12 , in the form of a C section channel, mounted on the outermost half of the inverted T member 10 .
  • the modular wall panels 5 are located in the wall locating member 12 .
  • Threaded studs 13 for securing respective tie rods 14 , are fastened to the horizontal face of the outer most half of the inverted T member 10 by welding, screwing or the like and protrude through the wall locating member 12 and into longitudinal cavity 16 for engagement with a nut 15 fastened to the end of each tie rod 14 .
  • the tie rods 14 extend through respective longitudinal cavities 16 provided in the upright wall panels 5 .
  • the studs project through the wall locating member 12 , via an aperture 17 .
  • wall panels 5 are erected and aligned such that the longitudinal cavities 16 , which are defined when the panels adjoin one another, correspond to the studs 13 and cooperating apertures 18 in the wall locating member 12 .
  • Each tie rod 14 is inserted into a respective longitudinal cavity 16 and engaged with a stud 13 disposed at the lower extremity of the cavity 16 .
  • the top member 19 is then placed so as to form an inverted U over the top side of the wall panels.
  • Apertures 22 in the top member 19 are sized to accommodate the shaft of the tie rods 14 and are spaced so as to correspond to the studs 13 .
  • the upper ends of the rods protrude through said apertures 22 in the top member 19 when they are positioned on the modular wall panels.
  • the upper end of the tie rods 14 may be screw threaded and engageable with a nut 23 to facilitate the tensioning thereof.
  • the nuts 23 are engaged with the rods and tightened against the top member 19 .
  • FIG. 3B illustrates the partial completion of a wall, similar to that of FIG. 3A, but wherein the top member 19 comprises a capping member 20 and a compression member 21 .
  • the compression member 21 is placed on top of the capping member 20 .
  • Apertures 22 and 22 A in both the capping member 20 and compression members 21 respectively, are sized to accommodate the shaft of the tie rods 14 and are spaced so as to correspond to the studs 13 .
  • the upper ends of the rods protrude through said apertures 22 and 22 A in the capping member 20 and the compression member 21 when they are positioned on the modular wall panels.
  • the upper end of the tie rods may be screw threaded and engageable with a nut 23 to facilitate the tensioning thereof.
  • the nuts 23 are engaged with the rods and tightened against the compression member 21 .
  • FIG. 3C illustrates in detail the locating the modular panels 5 placed in the wall locating member 12 , so that the cavity 16 is aligned with the cooperating aperture 18 in the wall locating member 12 , to allow the tie rods 14 to engage with the base 2 .
  • top member comprising a capping member and a compression member. It will be appreciated by the person skilled in the are that the exact nature of the top plate may vary depending on the building type under construction and the exact location of the top plate(s) within the building construction.
  • the rods are externally screw threaded at both lower and upper ends thereof.
  • the lower end engages with an internally screw threaded stud adapted, for example, for friction fitting in holes drilled into a concrete floor.
  • Further alternatives for securing the tie rods will be apparent to the skilled addressee.
  • the use of tie rods, preferably of high tensile strength, in accordance with the invention overcomes problems with fasteners, such as screws or the like, being pulled out of the modular panels in high wind load conditions.
  • the invention also overcomes any requirement for local reinforcement of the modular panels which might otherwise add to the cost and complexity of panel fabrication.
  • FIG. 4 shows in plan a schematic of one form of the longitudinal recesses formed on the upright sides of the wall panels.
  • the lightweight panels 5 comprise a core 25 of foamed plastics, such as polyurethane and outer skins, such as fiber-cement sheeting 26 .
  • the core is typically 66 mm thick whilst the skins are between 4.5 and 7.5 mm.
  • the modular panels may be made of a thinner inner skin and a thicker outer skin.
  • the thinner inner skin is typically 4.5 mm while the thicker outer skin is typically 7.5 mm.
  • the thicker outer skins may suitably be stucco fiber, whilst the inner skins may suitably be a plasterboard or timber finish.
  • the longitudinal cavity 16 is formed from the two recesses 27 and 27 A on the facing edges of the panels, as shown on the panels which are aligned with one another in FIG. 4A.
  • a longitudinal cavity 16 is formed between the recesses 27 and 27 A.
  • the cavity is sized for accommodating a tie rod 14 .
  • Further subsidiary cavities 29 may be provided immediately under the panel skins for accommodating building services such as electrical wiring (not shown).
  • FIG. 5 A first embodiment of a roof for the building structure is illustrated in FIG. 5.
  • the roof 4 has a minimum pitch, typically of from 3 to 10 degrees, and is supported directly by the external walls 30 and by the internal walls 31 .
  • the roof may also be comprised of modular panels as discussed in more detail below in relation to FIG. 6A.
  • the roof panels 33 are secured at one end to the external walls 30 by screws 34 which pass through the roof panels 33 , compression member 21 and capping member 20 before engaging with the modular wall panel 5 .
  • the screws 34 securing the roof panels engage with supporting internal walls 31 in the same manner as with the external walls 30 .
  • the peak portion of the roof panels is covered by ridge capping 36 which extends over the roof panel securing screws 34 , which capping is secured to the roof by further screws 36 A.
  • the modular roof panels 33 in this embodiment include a 25 mm ribbed steel outer skin 37 and an injected polyurethane foam core 38 which has a 25 mm ribbed steel inner skin 39 , the panel is typically 100 mm thick.
  • the underside of the roof panel is lined ( 39 A).
  • the roof lining ( 39 A) may be 4.5 mm fiber-cement board, 10 mm plasterboard, random grooved ply or a timber ceiling screwed directly onto the ribbed steel inner skin.
  • the roofing panel is hi-tensile spandeck steel sheeting. Wooden support blocks 40 are embedded in the core at spaced locations along one side of the roof panel to provide mounting points for the fascia panel 41 , shown in FIG. 5.
  • the floor panels described in FIG. 2 may also be made of a similar panel construction as the roof panels described above and in reference with FIG. 6. More preferably the floor panels are also formed from hi-tensile spandeck steel sheeting. When formed by the hi-tensile spandeck steel sheeting, the floor panels are lined with either composite flooring, waterproof ply or a timber floor applied directly onto the sheeting by screws or glueing.
  • hi-tensile spandeck sheeting for roof and floor panels has the advantage of having high strength, light weight, and being able to span up to 7 metres, thereby providing easy of construction whilst reinforcing the building strength.
  • the enlarged detail view of the roof panel joint in FIG. 6B shows the arrangement of a projection 42 and cooperating recess 43 formed in the sides of the foam core 38 of a roof panel 33 .
  • the enlargement shows a ridge 37 A of the outer roof skin extending laterally past the core such that, when two cooperating roof panels are engaged, the extended ridge 37 A clips over the ridge nearest the side of an abutting roof panel.
  • the core may also be undercut in the vicinity of the projection so as to produce a longitudinal cavity 44 when the roof panels are clipped together. This cavity may accommodate building services in the same manner as the subsidiary cavities provided in the wall panels.
  • the outer roof skin is turned-up 45 at the peak end edge thereof to minimise any leakage.
  • the roof skin also extends past the foam core 38 and coplanar embedded wooden blocks 40 , so as to overhang the guttering 46 at the fascia end 47 .
  • the wood or metal fascia panel 41 is suspended under the valleys of the overhung roof skin by screws 48 and attached to the embedded support blocks 40 by a further series of screws 49 .
  • the screws which are sunk into the fascia support blocks also pass through gutter brackets 50 which brackets in turn support the guttering 46 .
  • FIG. 7 show the arrangement of the corners and tee-junctions of walls, in particular, the alternative arrangements of the capping and compression members at these junctions.
  • a completed outer wall 30 is shown in place upon the base 2 , with a capping member 20 and compression member 21 on the top side thereof engaged by tie rod nuts 22 .
  • the wall junctions commonly include positioning profile members 51 which are attached upright to the completed wall 30 at selected positions by screws 52 .
  • Wall locating members 12 are fixed upon the floor surface or base 2 to locate the modular panels making up the walls.
  • An outer wall panel 53 is shown ready to be positioned at the corner of the structure, whereby the recess 53 A in the upright side of the outer wall panel cooperates with the nose 51 A of the positioning profile member.
  • the capping member 20 to be placed on one of the walls will have about 75 mm removed from the inner side of the C channelling. The remaining horizontal and outer side faces of the C channelling capping member then run to the outer edge of the corner.
  • the capping member 20 on the joining wall simply adjoins or overlaps the capping member with a side partially removed.
  • the compression members 21 at the comer joint are machined to half thickness for the length of the comer joint, thus forming half thickness tongues. These half thickness tongues are arranged so that the compression members interlace or overlap, resulting in an even thickness of the compression members at the comer.
  • One of the modular panels forming the comer join has an additional longitudinal cavity, capable of receiving a tie rod 14 . This additional longitudinal cavity is located so as to be at the centre of the corner join.
  • Apertures 55 and 55 A are provided on the capping members 20 and compression members 21 to facilitate fixing the members together and corresponding to the additional longitudinal cavity of the modular panel, thereby contributing to the structural integrity of the building.
  • FIG. 7 also shows the tee-junction arrangement of an internal wall where a tie rod in an intersecting wall is not in immediate proximity, but is provided at the intersecting end of the internal wall.
  • the internal wall panel 57 (shown in fragmentary form) engages with the respective positioning profile member 51 , in a similar fashion as two engaging panels (recall FIG. 4B), thereby defining a longitudinal cavity.
  • the capping member 58 and compression member 59 include apertures 60 & 60 A at their extremities.
  • the capping member 58 and compression member 59 are then disposed on the top side of the internal wall comprised of like panels 57 .
  • the tie rod 14 provided for the end of the internal wall, may then be inserted through the apertures 60 and 60 A and down into the cavity for securing the internal wall 57 .

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Architecture (AREA)
  • Mining & Mineral Resources (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Paleontology (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Joining Of Building Structures In Genera (AREA)
  • Floor Finish (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
US10/473,913 2001-04-05 2001-05-30 Building structure and modular construction method Abandoned US20040103601A1 (en)

Priority Applications (1)

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US11/739,585 US20070245640A1 (en) 2003-10-03 2007-04-24 Building Structure and Modular Construction

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AUPR4229A AUPR422901A0 (en) 2001-04-05 2001-04-05 Modular building structure
AUPR4229 2001-04-05
PCT/AU2001/000642 WO2002081835A1 (en) 2001-04-05 2001-05-30 Building structure and modular construction method

Related Child Applications (1)

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US11/739,585 Continuation US20070245640A1 (en) 2003-10-03 2007-04-24 Building Structure and Modular Construction

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US (1) US20040103601A1 (zh)
CN (1) CN1243168C (zh)
AU (1) AUPR422901A0 (zh)
CA (1) CA2443387A1 (zh)
NZ (1) NZ529283A (zh)
WO (1) WO2002081835A1 (zh)

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AUPR422901A0 (en) 2001-05-17
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WO2002081835A1 (en) 2002-10-17
CN1243168C (zh) 2006-02-22
CA2443387A1 (en) 2002-10-17

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