US20130192161A1 - Modular Post and Beam Building Envelope - Google Patents

Modular Post and Beam Building Envelope Download PDF

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US20130192161A1
US20130192161A1 US13751585 US201313751585A US2013192161A1 US 20130192161 A1 US20130192161 A1 US 20130192161A1 US 13751585 US13751585 US 13751585 US 201313751585 A US201313751585 A US 201313751585A US 2013192161 A1 US2013192161 A1 US 2013192161A1
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hollow post
ceiling
post form
panel
wall panel
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US13751585
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Mark W. Barker
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Mark W. Barker
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR OTHER BUILDING AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14Conveying or assembling building elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/165Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with elongated load-supporting parts, cast in situ
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/17Floor structures partly formed in situ
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/22Connection of slabs, panels, sheets or the like to the supporting construction
    • E04B9/24Connection of slabs, panels, sheets or the like to the supporting construction with the slabs, panels, sheets or the like positioned on the upperside of, or held against the underside of the horizontal flanges of the supporting construction or accessory means connected thereto
    • E04B9/245Connection of slabs, panels, sheets or the like to the supporting construction with the slabs, panels, sheets or the like positioned on the upperside of, or held against the underside of the horizontal flanges of the supporting construction or accessory means connected thereto by means of screws, bolts or clamping strips held against the underside of the supporting construction

Abstract

A method of constructing a building includes erecting a wall panel extending vertically. A hollow post form attaches to one side of the wall panel, and an insulation panel is placed adjacent to the inner wall panel. The method includes attaching an outer wall panel to the hollow post form on a side opposite the inner wall. The panels are sandwiched together by connecting the panels with a fastener that extends through all of the panels. The hollow post form is filled with a structural binder such as concrete. A ceiling structure is attached to the wall structure and includes layered panels. The ceiling structure defines a floor beam void and, along with the wall structure, defines a tie beam void. The hollow posts and the beam voids are filled with a structural binder such as concrete after the walls and ceiling are constructed.

Description

    CROSS REFERENCE TO RELATED APPLICATIONS
  • This patent application claims priority to and incorporates by reference U.S. Provisional Patent Application Ser. No. 61/590,866 filed on Jan. 26, 2012 naming the same inventor.
  • FIELD OF INVENTION
  • The invention relates to the field of building construction and presents a new method and associated apparatuses for achieving post and beam construction in which the forms for the posts and beams are integral to the final building.
  • BACKGROUND OF THE INVENTION
  • Since the dawn of civilization, humanity has sought to find better ways to construct shelter to best meet human needs. The present invention relates generally to building structure envelopes and more particularly to a novel, advanced and more comprehensive building system and method of making same to provide significant economic, environmental, and quality advantages over conventional building systems heretofore obtainable. It is desirable to provide better shelter to benefit all people and their environment utilizing the current age of information access and digital design process, virtual assembly, and communication to achieve an advanced shelter and method of making the same
  • It is desirable to advance the construction process to increase structural strength, elevate thermal performance, improve fire resistance, simplify production, reduce costs of construction and ownership, give water resistance, enhance safety against natural disasters, produce a healthier environment and provide sustainability.
  • A building envelope which significantly increases the level of these afore described attributes and uniquely delivers a comprehensive combination of all of the same would provide a substantial advance to the art of building.
  • BRIEF DESCRIPTION OF THE INVENTION
  • In a first embodiment, a method of constructing a building on graded ground includes connecting a hollow post form to at least one wall panel, wherein both the at least one wall panel and the hollow post form are substantially vertical relative to the ground, and after connecting the hollow post form and the at least one wall panel, filling the hollow post form with a structural binder.
  • In a different embodiment, a method of constructing a building on graded ground includes erecting at least one wall panel extending substantially vertical in relation to the graded ground, attaching a hollow post form to the at least one wall panel and leaving an interior of the hollow post form accessible for filling the hollow post form, and assembling a ceiling extending perpendicularly from the at least one wall panel attached to the hollow post form. The ceiling defines a floor beam void extending across the ceiling perpendicularly to the hollow post form, and the ceiling, along with at least one wall panel, defines a tie beam void extending around a perimeter of the ceiling. The method includes filling the hollow post form, the floor beam void, and tie beam void with a structural binder.
  • In yet another embodiment, a method of constructing a building on graded ground includes erecting at least one wall panel extending substantially vertical in relation to the ground, attaching a hollow post form to one side of the at least one wall panel, placing an insulation panel adjacent to the inner wall panel to at least partially encompass the hollow post form, and attaching an outer wall panel to the hollow post form on a side opposite the inner wall panel. The panels are attached so that the hollow post form is accessible for filling with a structural binder. A fastener connects all of the panels by extending through all of the panels. Finally, the method incorporates filling the hollow post form with a structural binder.
  • DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is an open perspective view of a wall and floor revealing the components of the building structure in accordance with the disclosure herein.
  • FIG. 2 is a top plan view of a post and represents a section of a wall with an outer panel according to the disclosure herein.
  • FIG. 3 is a top plan view of a post and wall section with a concrete outer layer according to the disclosure herein.
  • FIG. 4 is a cutaway mid-section to an insulated wall revealing the concrete posts and bond beam with an optional second floor according to the disclosure.
  • FIG. 5 is a sectional view of a wall and bond beam perpendicular to the floor beams between the wall posts according to the disclosure herein.
  • FIG. 6 is a section of the wall and floor/roof centered in parallel to a beam on a post in a wall according to the disclosure herein.
  • FIG. 7 is a cutaway section of a typical wall/footing/slab on grade according to the disclosure herein.
  • FIG. 8 is a section of an insulated form for the perimeter of a slab on grade.
  • FIG. 9 is a perspective view of a bracket for use in attaching a floor beam channel section to a hollow post form as described herein.
  • DETAILED DESCRIPTION OF THE INVENTION
  • The invention combines current technologies to merge components of advanced efficiency and intrinsic durability in the product system compared to prior envelope art.
  • The structure of such system is a reinforced, cast in place frame. One aspect is to place structural material in forms that stay in place and have a finish attached to deliver a finished product, not by removing forms and then going back to apply the finish, but to thereby simultaneously provide increased economy and durability. The system blends construction logic with current material and product manufacturing techniques to achieve a revolutionary building system.
  • In attributes, this system attains the benefits of an insulated concrete form (ICF) component system and includes like materials, but includes additional features, uses larger component modules, provides a post and beam structure, and incorporates other trades by design and is therefore more comprehensive than present ICF's. It embodies a great advance to an ICF.
  • While the configuration of this envelope remotely resembles some prior art precast wall systems, it is not a wall system. It is a post and beam system. Some current precast wall systems have vertical and lateral cast members as well as a monolithic diaphragm, but is only an unfinished wall system component and must be hauled and set with heavy equipment and connected as independent parts. Current tilt-up systems also fall in this category of configuration and erection.
  • Vertical cast in place wall systems have also been developed to attain increased efficiencies. Some examples are: The Laminar wall system, Hobbs, and TF Concrete Forming Systems. These wall systems illustrate some progress in vertical stay in place form efficiencies in the component market.
  • In isometric perspective, the cast in place structural frame of the invention uses the post and beam method of structural delivery, but the sequence is reversed. Finishes, insulation, utilities, and envelope first; poured in place, load bearing frame second. Traditionally, the frame has always come first, is normally constructed of wood or steel, and uses multiple steel lags, bolts, or wooden pegs, mortises and tenens for connections. The frame of the invention is cast monolithically after finishes are in place and minimizes mechanical connections and assembly, which also eliminates all hinge points which are typically the weak links in a structure.
  • To increase construction efficiency the product assembly incorporates structural insulated panels (SIPs) as the largest component by volume. These panels are placed in vertical layers to allow practical wiring and plumbing installments and then “sandwich” the core and structural frame plane with the starter panel and the final panel to complete the form. Prior art SIPs systems are only one layer of panels. Prior art ICFs have not previously used SIPs.
  • Inert setting material and binder, like concrete and cement have been in use for centuries. The intrinsic dynamic nature of these materials are used herein to connect a continuous and simultaneous post, beam, and panel composite envelope of high compressive strength with ductility cast in a standardized incremental configuration of panels, which is a novel use of these materials.
  • Steel has been used to reinforce concrete for decades, but not by cold forming light gauge into perforated forms to connect panels and engage the material to deliver the necessary tensile reinforcement as in the present invention. Traditional steel rebar can also be engineered as the reinforcement, but additional shoring for the wet pour would be required. These steel forms deliver inherent bearing capacity independent of the concrete, while rebar does not, so the resulting structural composite delivers an increased multiple of strength and placement advantages that avoid possible blow-outs and deflections. Other structural materials can be substituted for these forms such as fiber reinforced plastic (FRP).
  • The concept of modular production techniques and incremental design to gain efficiency and control quality is not new to the construction industry. Modular components are the key to industrializing construction. This new system of incremental design standards and sequence is based but not limited to industry product modules of forty-eight and ninety-six inches for width. It incorporates digital design, controlled environment, schedule independent manufacturing, and no waste production to optimize the benefit. The depth (thickness) of the modular panels and structural forms can vary to accommodate any engineering requirements for loads or spans, and also any designs for other finishes, chases and insulations. Panel and frame form configurations are not limited in scope of dimensions or materials, therefore there are no limitations to the scope of architectural designs or the benefit of virtual assembly line philosophy.
  • Foam is the insulator most used in thermally and energy efficient, tight air envelopes. ICFs, SIPs and many conventional prior art methods incorporate foam in their systems. There are many types of foam which can be used in an envelope. Expanded polystyrene (EPS) is the highest value foam and is the primary choice for the envelope system of the invention, but other insulation board types could be used.
  • The third or final layer of the system floor or roof is concrete. Concrete is also an option for the final layer on the walls. The floor is poured and the wall is sprayed concrete, also known as shotcrete or gunite, or the wall can be another panel. Sprayed concrete has been around for decades and used for retaining walls, swimming pools, tunnels and structural building walls. One aspect of the invention calls for the use of sprayed concrete as a monolithic box frame to a cast post and beam structure simultaneously delivering a finish.
  • The monolithic, panelized, site cast, inert envelope, of molded, perfectly fitted by casting, solidly connected structure delivers a rigid, resistant, strong, stable, impervious, durable building shell of substantially increased performance using a practical method. Most conventional envelope systems use numerous, nails, hangers, ledgers, lags, screws, nuts, bolts, braces, wraps, wood and other organic materials. The conventional systems do not have ideal characteristics, e.g., they can crack, hinge and disassemble, collapse, burn, rot and mold due to natural forces and elements.
  • Thus, the novel combination described which encompass materials, products, techniques, new technologies and experiences will deliver an advanced and substantial improvement for the envelope in the age old need for buildings and shelter.
  • A general object of the present invention is to provide a novel structural building envelope and method for making same to enable a substantial improvement in sustainability by increasing durability, affordability, availability and efficiency, with the aforementioned envelope.
  • A more particular object of the present invention is to provide a more efficient, insulated, concrete structure to achieve great strength and durability for buildings and a method of making same that employs a novel sequence of layered panel construction, beginning with a “starter” wall panel for the vertical and “starter” ceiling panels for the lateral with optional interior finish attached. This layer can be panelized unfinished, panelized with finish attached or sprayed with mechanical apparatus.
  • The second layer, or “core” panel, designates the plane for the structural frame. A foam core panel fills the space between the post and beam frame members and provides a place for the mechanicals, wiring, and plumbing and also in line support for the concrete forms.
  • The third and final panel layer blankets the core and frame layer to mechanically sandwich the entire assembly and complete the form to cast the concrete. A third layer option is to spray concrete (shotcrete) as the third layer and create a monolithic box frame. This method can be more economical and the resulting concrete box frame delivers extreme strength and rigidity, but requires specialized equipment and labor.
  • The frame form uses custom steel channels to connect the panels, form the posts and beams and engage the concrete to provide necessary tensile reinforcement and structural load capacity for the wet live load pour. These channels are manufactured from light gauge sheet metal pre-punched or laser cut, and shaped of specified gauge, using a mechanical brake or custom die roll form to shape a “W” channel with an inverted mid channel “hat.” The holes fall in the hat to engage the concrete. Both the gauge (weight), dimensions, and configurations of these form/channels can vary or rebar can be added to deliver any engineered requirements for loads and spans. There are no limitations to this product and system.
  • The frame form can also include fiber reinforced plastics or carbon fibers to provide these just mentioned components. The FRP advantages are no need to produce single line contiguous shapes thereby reducing the number of component items and labor. FRP is lighter and easier to cut and drill. Shapes are custom designed to accomplish desired requirements. The material cost of steel is lower. The labor, convenience and safety of FRP is advantageous.
  • The resulting frame is configured on an X, Y, and Z axis and is preferably designed in modules of forty-eight inches or ninety-six inches (other dimensions are optional) to maximize the production efficiency and avoid waste. The X, Y, and Z beam corners are connected at the form intersections with original light gauge steel clips and screws, designed for said purpose, to tie the forms together and deliver permanent tensile and ductile strength.
  • The product can be ordered and delivered as a package to simplify the process for the consumer and maximize efficiency by eliminating takeoffs, cutting and waste.
  • The only required fasteners for the assembly of all the aforementioned parts and pieces are merely small diameter, self tapping screws, to connect the stay-in-place forms, bracing and shoring, to pour the easily placed, high strength, continuous, reinforced, cast concrete, binder and connector.
  • This accomplishes a convenient, simple, easy, economical, advanced and streamlined building envelope. Such an unprecedented compendium of construction art is heretofore not used in prior and present building art systems.
  • The purpose of the description of the invention herein described is detailed and exact as to the specifications of an exemplary embodiment of the present invention to enable those skilled in construction art to practice the invention. However, it is to be understood that the invention may assume alternate variations and step sequences, components, processes and dimensions. The embodiments herein described are not to be considered as limiting the invention.
  • Referring to FIG. 1, a general perspective view, illustrates the invention isometrically to reveal the comprehensive scope of the invention as it relates to the assembly of a building structure envelope including the walls and the floors and the component relations to the same. Each component is described and labeled individually in the explanation of the figures that follows.
  • FIG. 2 illustrates a plan view of a wall arrangement which connects an inner wall panel (1) and an outer wall panel (3) to encompass a steel hollow post form (14) made of a first channel section half (5) and a second channel section half (15) for a concrete post (12) to engage the concrete with perforations (11) in the steel hollow post form (14). The first channel section half (5) of the post assembly (14) is attached with a plurality of self-tapping screws (8) to connect to an inner wall panel (1) and to place the first layer of the building structure which more commonly is set to the inside of the structure with a middle wall panel (2), or insulation panel (2), between an inner wall panel (1) and an outer wall panel (3). However, the sequence of construction may be reversed to progress from the outside in when site circumstances deem reverse sequence more preferable. This inner wall panel (1) may embody the final finish (13) for final building envelope. The inner wall panel is laminated with suitable adhesive prior to erection with interior finish (13). This finish can be magnesium oxide, phenolic resin fiberglass or other. The opposing side of this first panel receives a plurality of kerfs in preparation to accept a plurality of “C” channels (17), also called wall reinforcement channels (17), of light gauge steel or other suitable material to be embedded and laminated with suitable adhesive in the opposing side of the inner wall panel (1). The edge channels (7) are also positioned in the inner wall panel (1) and outer wall panel (3) to receive short fasteners (8) for the attachment of the respective channel section halves (5, 15) of the column form (14). The channels are placed in vertical position at set increments including each vertical edge of the panel. The panels are then connected to one another with short fasteners through a specially configured “w” channel which also forms the first half (5) of the hollow post form (14). The second half channel section (15) of the hollow post form (14) is attached to the first half (5) with screws (9) to create the hollow post form (14) for the structural column or post. The screws also engage the concrete when it sets to provide tensile reinforcement along with the perforations. The configuration of the two channel section halves (5, 15) and the resulting column or post configuration can be variously shaped and dimensioned to any specified requirements. The steel may also be substituted with other approved materials. A second wall panel (2) of foam insulation or an equivalent material, corresponding to the void between the hollow post forms (14) is then placed between the hollow post forms (14) to complete the middle plane of the building envelope. A third and final wall panel (3) is then placed over the aforementioned assembly. This wall panel (3) has embedded channels (16) which correspond to the incremental location of the prior channels (17). This panel (3) is attached to the assembly first using short fasteners (18) to secure the panels to the column and simultaneously complete the column form. Appropriate length fasteners (10) penetrate panel (2) with channel (16) towards the interior as in FIG. 2 for synthetic stucco (19) or reversed to the outside for visible attachment of rigid siding products. The column forms (5) and (15) combine to accept the concrete (12) or other appropriate structural binder (12) to create the complete structural post (14).
  • FIG. 3 illustrates an alternative process to apply the third layer (4) as a continuous concrete box frame monolithic to the post and beam structure by shooting the concrete onto a wire lathe (6) attached to the hollow post forms (14) and the channels (20) embedded in the second wall panel, also referred to as the insulation panel (2).
  • FIG. 4 illustrates a sectional mid-wall cut in parallel to the previously illustrated wall, perpendicular to the floor/roof beams (24) and slicing parallel through the tie beam (21) revealing any specified reinforcement structures (22) in the wall. The fasteners (10) sandwich and connect the middle wall panel (2) between the inner wall panel (1) and the outer wall panel (3). The reinforcement connection (23) is shown at the intersection of the lower posts (12), the tie beam (21), the floor beam (24), and a second floor concrete filled post (12).
  • FIG. 5 illustrates a cross-sectional view of a floor and wall with section of a beam (24) revealing the inner ceiling panel (25) with a side view of the embedded “c” channels (26) which are embedded perpendicular to the length of the inner ceiling panel (25) and thus perpendicular to the hollow post forms (14) which result from the presently described process. The inner ceiling panel (25) provides a ceiling and also a base to secure the sequentially progressive layers of the middle ceiling panel (28) and the final floor panel (29) with screws (27), as well as providing the space to lay a third “w” channel section (30) that forms the bottom of the lateral floor beams (24) to carry the floor (31) spanning between the beams along with a plurality of “c” channels (32). The c-channels (26) are carried by the floor beam (24). The c-channel (26) extends into the floor beam (24) via the channel “ears” (33) embedded in the concrete beams by placing the c-channels along the inner ceiling panel (25) with a length that extends into the floor beam void. These ears (33) of the c-channel engage the concrete after the concrete is set. In other words, the channel ears (33) are extensions of reinforcing c-channel structures (26) that engage the structural binder filling the floor beam void and forming the floor beam (24). Temporary shoring and bracing may be required for the concrete pour. The “w” channel section (30) is attached to the ceiling panels (25) with fasteners (34) to connect the panels and initially contributes to carrying the wet, live load pour. The c-channel (34) also provides the required tensile reinforcement for the floor beam (24). A steel angle (36) is screwed to the ceiling panel (25) and the inner wall panel (1) to connect the panels and encase the void to provide the wiring chase (37).
  • FIG. 6 illustrates a sectional side view cut through the center of a concrete filled post (14) and a floor beam (24). A cut view of the “w” channel (30) forming a bottom section of the floor beam (24) reveals the perforations (35) in the channel section (30) which engage the concrete. A plurality of fasteners (34) secure the “w” channels (30) to the perpendicular “c” channels (26) and connect the ceiling panels. A cut view of the wall post (14) reveals the pair of “w” channel section halves (5) and (15). A plurality of pairs of fasteners (8) connect channel section half (5) to the “c” channels embedded in the inner wall panels (1) to connect the wall panels to each other. The final panels (3) are connected through embedded “c” channels (16) with a plurality of fasteners (18) to the second half (15) of the concrete form (14). A steel angle (36) connects ceiling panel (25) to wall panel (1) with a plurality of fasteners and creates utility chase (37). A steel angle (43) connects the inner wall panel to the prior floor slab. A steel dowel or bar (23) reinforces the intersection and connects the upper pour to the prior pour. The steel angle (43) may provide a connection between a ceiling panel (25) and one of the wall posts as well.
  • FIG. 7 illustrates a sectional side view cut at the lower portion of a wall at a slab on grade at a post. A foam form (38) (shaded area) is secured to the footing (39) and gauges the gravel depth and provides a ledge (40) to place the sub slab insulation board (41) to place the concrete (42). The foam form (38) remains in place between the posts as perimeter insulation and is removed at the post locations to allow the loaded post to continue and bear directly to the footing. The inner wall panel (1) is secured to the slab (42) using a steel angle (43). The angle (43) is secured to the slab (42) using a plurality of concrete fasteners (44). The inner wall panel (1) is secured to the angle (43) using a fastener at each “c” channel (26) embedded in the panel. The middle wall panel (2), also referred herein as an insulation panel (2) rests in plane on concrete form (38). The outer wall panel (3) extends downward to the footing and also contains and insulates the structural post (14). A steel anchor (45) is set in the footing (39) to engage the cast post (14) and tie it to the footing (39). Required gravel (46) is located under the insulated slab (41) and (42).
  • FIG. 8 details a sectional view of the stay in place slab form (38) and the slab (42) also showing the sub slab insulation board (41) and the gravel (46). The offset ledge (40) provides a convenient gauge to accurately place the gravel, insulation, and concrete.
  • FIG. 9 illustrates an angled bracket (60) that can be used to secure a floor beam channel section (30) to an adjacent hollow form post (14) to result in the cross section shown in the inset of FIG. 6. The angled bracket (60) may be made of a single piece body with slits (61A-61 D) that form respective tongues (62, 67) that are bendable away from the body (60). The space formed by bending the tongue on each end of the angled bracket allows the angled bracket to slide under a floor beam channel section (30) with a first tongue (62) under the channel section (30) and with the sides of the body engaging the channel section (30) over an upper region of the w-shaped channel section (30). A similar engagement is established with a first channel half (5) of the associated hollow post form (14) such that the second tongue (67) slides to an underside of a hollow wall post form channel section half. The angled bracket adds more stability to the resulting engagement of the wall post and the floor beam.
  • The system of constructing a building according to the disclosure herein includes connecting a hollow post form (14) to at least one wall panel (1), wherein both the at least one wall panel (1) and the hollow post form (14) are substantially vertical relative to the ground, and after connecting the hollow post form and the at least one wall panel, filling the hollow post form (14) with a structural binder such as concrete (12). The step of connecting a hollow post form to at least one wall panel includes connecting the hollow post form to an inner wall panel (1) for facing inside the building prior to filling the hollow post form. After connecting the inner wall panel, the next step may include placing an insulation panel (2) adjacent to the inner wall panel (1) and the hollow post form (14) prior to filling the hollow post form. The insulation panel may be assembled from component portions of the insulation panel (i.e., the middle, or insulation, panel (2) may be formed in pre-shaped sections or as one single piece). The step of connecting at least one wall panel may further include connecting an outer wall panel (3) for facing outside the building, to the hollow post form (14) prior to filling the hollow post form (14). The step of connecting a hollow post form to the at least one wall panel may include connecting a first channel section half (5) to the inner wall panel (1) and connecting a second channel section half (15) to the first channel section half (5). In other words, the hollow post form may be made of separable portions, namely two channel section halves (5, 15) that fit together and are held by fastening screws. In one non-limiting embodiment, prior to filling the hollow post form, the method further encompasses connecting an inner ceiling panel (25) to the at least one wall panel (1) connected to the hollow post form (14), wherein the inner ceiling panel (25) extends substantially horizontal relative to the graded ground.
  • Next, the ceiling is prepared for pouring a floor beam (24) by placing a channel section (30) onto the inner ceiling panel (25) such that the floor beam channel section (30) is substantially perpendicular to the hollow post form (14). Embedding reinforcement c-channel structures (26) into the inner ceiling panel (25) prior to positioning the floor beam channel section (30) adds structural integrity to the overall ceiling. Afterwards, the method includes placing a middle ceiling panel (28) onto the reinforcement channels (26) and the inner ceiling panel (25) and placing a final ceiling panel (29) onto the middle ceiling panel (28). The floor beam channel section (30), the middle ceiling panel (28), and the final ceiling panel (29) are so dimensioned as to define a floor beam void running through the ceiling structure. Finally, the method includes filling the hollow post form (14) and the floor beam void with a structural binder such as, but not limited to concrete (12).
  • In another non-limiting embodiment, the method of building a structure includes erecting at least one wall panel (1) extending substantially vertical in relation to the graded ground, attaching a hollow post form (14) to the at least one wall panel (1) and leaving an interior of the hollow post form accessible for filling the hollow post form. Next, the method includes assembling a ceiling extending perpendicularly from the at least one wall panel attached to the hollow post form, wherein the ceiling defines a floor beam void extending across the ceiling perpendicularly to the hollow post form. Furthermore, the ceiling along with at least one wall panel defines a tie beam void extending around a perimeter of the ceiling. Typically, but not exclusively, the floor beam void is formed by a bottom ceiling channel (30) surrounded vertically by a middle ceiling panel (28) and a final ceiling panel (29) defining the boundaries of the floor beam void. Without limiting the invention to any one embodiment, the tie beam void surrounding the perimeter of the ceiling is formed by the ceiling structure in conjunction with an outer wall panel (3). After placing all of the panels, hollow post forms, and beam voids in place, the last step includes filling the hollow post form, the floor beam void, and tie beam void with a structural binder. The structural binder may be concrete or equivalent.
  • The method disclosed herein includes the step of inserting screws (50) into an upper surface of the ceiling structure such that the screw heads remain elevated relative to the ceiling even after installation. FIG. 5 illustrates the screws (50) installed in a final ceiling panel (29) such that the screw heads engage a floor layer (31) poured over the final ceiling panel to form a second story floor. These screw heads engage the poured floor on a second floor of the building and strengthen the poured concrete floor shown in the figures herein. Finally, a method of building a structure includes the step of constructing a floor layer (31) as noted above atop the ceiling, wherein the step of constructing the floor layer comprises pouring a structural binder over a surface of the ceiling and covering the screw heads. Again, the structural binder may be concrete or equivalent. In fact, each embodiment of the methods disclosed herein may utilize concrete as the structural binder.
  • From the foregoing description of the embodiments of the invention, it will be apparent that many modifications may be made therein. It will be understood that these embodiments of the invention are an exemplification of the invention only and that the invention is not limited thereto.

Claims (20)

  1. 1. A method of constructing a building on graded ground comprising:
    connecting a hollow post form to at least one wall panel, wherein both the at least one wall panel and the hollow post form are substantially vertical relative to the ground; and
    after connecting the hollow post form and the at least one wall panel, filling the hollow post form with a structural binder.
  2. 2. A method according to claim 1, wherein the step of connecting a hollow post form to at least one wall panel comprises connecting the hollow post form to an inner wall panel for facing inside the building prior to filling the hollow post form.
  3. 3. A method according to claim 2, further comprising placing an insulation panel adjacent to the inner wall panel and the hollow post prior to filling the hollow post form.
  4. 4. A method according to claim 3, wherein the step of connecting the insulation panel comprises assembling the insulation panel from component portions of the insulation panel.
  5. 5. A method according to claim 1, wherein the step of connecting at least one wall panel comprises connecting an outer wall panel, for facing outside the building, to the hollow post form prior to filling the hollow post form.
  6. 6. A method according to claim 1, wherein the step of connecting a hollow post form to the at least one wall panel comprises connecting a first channel section to the inner wall panel and connecting a second channel section to the first channel section.
  7. 7. A method according to claim 1, wherein prior to filling the hollow post form, the method comprises connecting an inner ceiling panel to said at least one wall panel connected to the hollow post, wherein the inner ceiling panel extends substantially horizontal relative to the graded ground.
  8. 8. A method according to claim 7, further comprising positioning a floor beam channel section onto the inner ceiling panel such that the floor beam channel section is substantially perpendicular to the hollow post form.
  9. 9. A method according to claim 8, further comprising embedding reinforcement channels into the inner ceiling panel prior to positioning the floor beam channel section.
  10. 10. A method according to claim 8, further comprising the steps of placing a middle ceiling panel onto the reinforcement channels and the inner ceiling panel and connecting placing a final ceiling panel onto the middle ceiling panel, wherein floor beam channel section, the middle ceiling panel, and the final ceiling panel are so dimensioned as to define a floor beam void.
  11. 11. A method according to claim 10, further comprising the step of filling the hollow post form and the floor beam void with a structural binder.
  12. 12. A method of constructing a building on graded ground, comprising:
    erecting at least one wall panel extending substantially vertical in relation to the graded ground;
    attaching a hollow post form to the at least one wall panel and leaving an interior of the hollow post form accessible for filling the hollow post form;
    assembling a ceiling extending perpendicularly from the at least one wall panel attached to the hollow post form, wherein the ceiling defines a floor beam void extending across the ceiling perpendicularly to the hollow post form, and the ceiling along with at least one wall panel defines a tie beam void extending around a perimeter of the ceiling; and
    filling the hollow post form, the floor beam void, and tie beam void with a structural binder.
  13. 13. A method of constructing a building according to claim 12, wherein the step of erecting the hollow post form comprises assembling the hollow post form from at least two channel sections.
  14. 14. A method of constructing a building according to claim 12, further comprising placing a floor beam channel section on an inner ceiling panel to form a base for the floor beam void.
  15. 15. A method of constructing a building according to claim 12, further comprising the step of inserting screws into the ceiling such that the screw heads remain elevated relative to the ceiling.
  16. 16. A method of constructing a building according to claim 15, further comprising the step of constructing a floor layer atop the ceiling, wherein the step of constructing the floor layer comprises pouring a structural binder over a surface of the ceiling and covering the screw heads.
  17. 17. A method of constructing a building according to claim 16, wherein pouring the structural binder comprises filling the floor beam void, the tie beam void, and constructing the floor.
  18. 18. A method of constructing a building on graded ground, the method comprising:
    erecting at least one wall panel extending substantially vertical in relation to the ground;
    attaching a hollow post form to one side of the at least one wall panel;
    placing an insulation panel adjacent to the inner wall panel to at least partially encompass the hollow post form;
    attaching an outer wall panel to the hollow post form on a side opposite the inner wall panel, wherein the panels are attached so that the hollow post form is accessible for filling with a structural binder;
    connecting the panels with a fastener that extends through all of the panels; and
    filling the hollow post form with a structural binder.
  19. 19. A method of constructing a building according to claim 18, further comprising assembling a ceiling extending perpendicularly from the panels attached to the hollow post form, wherein the ceiling defines a floor beam void extending across the ceiling perpendicularly to the hollow post form, and the ceiling along with an outer wall panel define a tie beam void extending around a perimeter of the ceiling; and
    filling the hollow post form, the floor beam void, and tie beam void with a structural binder.
  20. 20. A method of constructing a building according to claim 19, further comprising utilizing concrete as the structural binder.
US13751585 2012-01-26 2013-01-28 Modular Post and Beam Building Envelope Abandoned US20130192161A1 (en)

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2113875A (en) * 1937-02-04 1938-04-12 Clark Rankin Hollow wall
US4338759A (en) * 1980-07-28 1982-07-13 Universal Component Systems, Inc. Method of building construction using concrete reinforced wall modules
US4357783A (en) * 1980-08-04 1982-11-09 Universal Component Systems, Inc. Concrete reinforced wall modules for use in building construction
US6519904B1 (en) * 2000-12-01 2003-02-18 Charles N. Phillips Method of forming concrete walls for buildings
US20070044392A1 (en) * 2004-11-12 2007-03-01 Leblang Dennis W Modular building construction employing concrete mold assembly
US7882672B2 (en) * 2003-08-25 2011-02-08 Building Solutions Pty Ltd. Building panels
US8176696B2 (en) * 2007-10-24 2012-05-15 Leblang Dennis William Building construction for forming columns and beams within a wall mold

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2113875A (en) * 1937-02-04 1938-04-12 Clark Rankin Hollow wall
US4338759A (en) * 1980-07-28 1982-07-13 Universal Component Systems, Inc. Method of building construction using concrete reinforced wall modules
US4357783A (en) * 1980-08-04 1982-11-09 Universal Component Systems, Inc. Concrete reinforced wall modules for use in building construction
US6519904B1 (en) * 2000-12-01 2003-02-18 Charles N. Phillips Method of forming concrete walls for buildings
US7882672B2 (en) * 2003-08-25 2011-02-08 Building Solutions Pty Ltd. Building panels
US20070044392A1 (en) * 2004-11-12 2007-03-01 Leblang Dennis W Modular building construction employing concrete mold assembly
US8176696B2 (en) * 2007-10-24 2012-05-15 Leblang Dennis William Building construction for forming columns and beams within a wall mold

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