US20220049502A1

US20220049502A1 - Systems and methods for retrofitting an existing building

Info

Publication number: US20220049502A1
Application number: US17/402,380
Authority: US
Inventors: Michael Anthony Dombowsky; Benedict John Dombowsky; Mark Benedict DOMBOWSKY; Braden Louis DOMBOWSKY
Original assignee: Nexii Building Solutions Inc
Current assignee: Nexii Building Solutions Inc
Priority date: 2020-08-13
Filing date: 2021-08-13
Publication date: 2022-02-17
Also published as: EP4196649A1; CA3191467A1; WO2022032391A1

Abstract

Example embodiments of the described technology provide a building wrap useful for retrofitting a building. The building wrap may comprise a plurality of different types of pre-fabricated panels such as roof panels, wall panels and foundation panels. Wall panels may be coupled to mounting rails which are attached to an exterior wall of the building. The foundation panels may carry the weight of the wall panels. At least some portions of some of the foundation panels may be below a grade level of the building.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119 of U.S. application No. 63/065,380 filed 13 Aug. 2020 and entitled SYSTEMS AND METHODS FOR RETROFITTING AN EXISTING BUILDING which is hereby incorporated herein by reference for all purposes.

TECHNICAL FIELD

This invention relates to building wraps for buildings. The invention has example applications for retrofitting an existing building.

BACKGROUND

The carbon footprint of a building built using existing systems and methods can be large. There is a general desire to replace energy inefficient buildings with energy efficient buildings. This can be done by demolishing an existing energy inefficient building and constructing a brand new energy efficient building. However, demolishing and rebuilding involves significant amounts of time and/or resources (e.g. labour, energy, materials, etc.).
Retrofitting existing buildings offers a cost-effective solution for reducing energy consumption and carbon emissions. One way to retrofit an existing building is to install building panels which improve the insulating and/or weatherproofing characteristics of the building. Existing retrofit building panels are known to be expensive in terms of material and/or labor. Existing retrofit building panels are also known to be difficult to install.
There remains a need to provide building wraps which can efficiently and effectively improve the insulating and/or weatherproofing characteristics of a building.
There remains a need for practical and cost effective ways to retrofit an existing building using systems and methods that improve on existing technologies.

SUMMARY

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
Aspects of the invention include without limitation:

- systems and methods for retrofitting an existing building with a building wrap; and
- building wraps which improve desired performance characteristics of a building.

In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.

FIG. 1A is a schematic front view of a building wrap wrapped around a building according to an example embodiment of the invention. FIG. 1B is a schematic perspective view of various components of the building wrap shown in FIG. 1A. FIG. 1C is a schematic top view of the FIG. 1A building wrap wrapped around a building. FIG. 1D is a perspective view of various components of the building wrap shown in FIG. 1A wrapped around an exemplary building.

FIG. 2A is a perspective partially cut-away view of a wall panel according to an example embodiment of the invention. FIG. 2B is a side sectional view of a connection joint between two adjacent wall panels. FIG. 2C is a plan view of a section of two adjacent wall panels. FIG. 2D is a perspective view of a connector which may be used to secure the FIG. 2A wall panel against a building. FIG. 2E is a side sectional view of the FIG. 2D connector securing a wall panel against a building.

FIG. 3 is a side sectional view of a foundation panel secured against the foundation of a building according to an example embodiment of the invention.

FIG. 4A is a perspective view of a roof panel according to an example embodiment of the invention. FIG. 4B is a top view of the roof panel shown in FIG. 4A. FIG. 4C is a side view of the roof panel shown in FIG. 4A. FIG. 4D is a side sectional view of the roof panel shown in FIG. 4A.

FIG. 5 is a side sectional view of a parapet panel secured against a parapet of a building according to an example embodiment of the invention.

FIG. 6 is a block diagram illustrating a method of retrofitting a building according to an example embodiment of the invention.

DETAILED DESCRIPTION

Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
This description employs a number of simplifying directional conventions. Directions are described in relation to a building having an existing vertically extending building wall and an existing horizontally extending roof. Directions may be referred to as: “external”, “outward” or the like if they tend away from the building; “internal”, “inward” or the like if they tend toward the building; “upward” or the like if they tend toward the top of the building; “downward” or the like if they tend toward the bottom of the building; “vertical” or the like if they tend upwardly, or downwardly, or both upwardly and downwardly; “horizontal” or the like if they tend in a direction orthogonal to the vertical direction. Those skilled in the art will appreciate that these directional conventions are used for the purpose of facilitating the description and should not be interpreted in the literal sense. In particular, the invention may be adapted for buildings which have walls that are not strictly vertically oriented and/or roofing structures that are inclined.
FIG. 1A is a schematic front view of a building wrap 10 according to an example embodiment of the invention. Building wrap 10 is designed to be attached to the exterior of a building 12, such as a residential apartment building, a single story house, an institutional building, etc. Building wrap 10 is formed by joining multiple pre-fabricated building panels (e.g. wall panels 30, foundation panels 40, roof panels 50, etc.) together as described in more detail below. The size and/or shape of the pre-fabricated building panels described in this application may be customized during manufacturing based on the topography of building 12. In some embodiments, some of the pre-fabricated building panels are joined together (e.g. mechanically fastened together) before they are attached to building 12. When secured against the exterior of building 12, building wrap 10 provides advantages such as improved thermal insulation and/or improved weatherproofing for building 12.
As depicted in FIG. 1A, building wrap 10 comprises a plurality of wall panels 30 and a plurality of roof panels 50. Building wrap 10 may also comprise foundation panels 40 and/or parapet panels 70.
Wall panels 30 refer to panels which are secured against the outside of the exterior wall of building 12. Wall panels 30 have a width which is typically in the range of about 10′ to about 14′, a length which is typically in the range of about 20′ to about 60′, and a thickness which is typically in the range of about 3″ to 24″. Two or more adjacent wall panels 30 are mechanically fastened and/or sealed together as described elsewhere herein to form a wall 300. Wall 300 may completely enclose the existing exterior walls of building 12 (e.g. see FIG. 1C) although this is not necessary. Wall 300 is preferably shaped to conform to the exterior contours of building 12. In the example embodiment shown in FIGS. 1B and 1C, wall 300 forms a rectangular enclosure shaped to conform to the rectangular shape of building 12.
FIG. 2A is a perspective partially cut-away view of a wall panel 30 according to an example embodiment of the invention. Wall panel 30 comprises a structural frame 31 framed around a panel body 32. Frame 31 provides structural support for panel body 32. Panel body 32 is made of one or more layers of construction materials suitable for providing structural robustness and/or thermal insulation. For example, panel body 32 may comprise one or more layers of cementitious materials, thermally insulating foams (e.g. expanded polystyrene insulation), surface finishes, etc. In the example embodiment shown in FIG. 2A, panel body 32 comprises an interior layer 32A made of cementitious material, an insulating layer 32B, an exterior layer 32C made of cementitious material, and an exterior finish 32D. Panel body 32 may have a composition similar to that described in Canadian Patent No. 2,994,868 entitled PREFABRICATED INSULATED BUILDING PANEL WITH CURED CEMENTITIOUS LAYER BONDED TO INSULATION, which is hereby incorporated by reference herein in its entirety.
Wall panel 30 may optionally comprise one or more cut-out regions 38 as shown in FIG. 1D. Wall panels 30A which are secured against an area of building 12 having existing windows, doors and/or the like may have one or more cut-out regions 38 which can allow the existing windows and/or doors of building 12 to open through cut-out region 38. The shape of cut-out region 38 may be designed based on the shape of the existing windows or doors of building 12. In some embodiments, wall panel 30 comprises mechanical connectors provided to receive retrofit windows and/or retrofit doors which cover cut-out region 38. In these embodiments, the existing windows and/or doors of building 12 may be removed and replaced with more energy efficient retrofit windows and/or retrofit doors. These retrofit windows and/or retrofit doors may be installed on wall panel 30 directly to cover cut-out region 38.
Frame 31 is typically made of a rigid material. For example, frame 31 may be made of hollow structural section (HSS) steel, stainless steel, aluminum, fiberglass (FRP) and/or cementitious materials. Frame 31 may be embedded in a middle layer of panel body 32 such as insulating layer 32B as shown in FIG. 2A. Frame 31 typically comprises horizontal frame members and vertical frame members. The horizontal frame members and the vertical frame members may be mutually orthogonal. Frame 31 may comprise frame members which have the shape of an angle beam, a channel beam, a flat beam, an I-Beam, etc.
In some embodiments, frame 31 and/or members of frame 31 are galvanized.
In some embodiments, frame 31 comprises slotted holes 31A or the like (e.g. see FIG. 2C) spaced longitudinally along the horizontal frame members and/or the vertical frame members of frame 31. In some embodiments, frame 31 comprises one or more clips 33 attached at spaced locations on the horizontal frame members and/or the vertical members of frame 31. For example, frame 31 may be shaped and/or structured to receive clips 33 spaced along the horizontal frame members of frame 31. Clips 33 are typically coupled to frame 31 at locations adjacent to slotted holes 31A. In some embodiments, clips 33 are provided as an integral component of frame 31 (i.e. clips 33 are integrally formed with frame 31). In other embodiments, clips 33 are provided as standalone components (i.e. clips 33 are detachable from frame 31).
In some embodiments, the ratio between the number of clips 33 and the number of slotted holes 31A on a horizontal frame member of frame 31 may be 1:1. In some embodiments, a clip 33 and its corresponding slotted hole 31 are separated by a distance of no more than 1″. In some embodiments, adjacent clips 33 are coupled to frame 31 at different sides of adjacent slotted holes 31A. For example, a first clip 33 may be coupled to frame 31 at a right side of a first slotted hole 31A while a second adjacent clip 33 may be coupled to frame 31 at a left side of a second adjacent slotted hole 31A.
Clips 33 engage mounting rails 36 which are attached to the exterior of building 12 to secure wall panel 30 against building 12 (e.g. see FIGS. 2B and 2C). Rails 36 are attached to the exterior of building 12 through attachment mechanism 36A. Rails 36 extend in a generally vertical direction (i.e. along the height of building 12). In some embodiments, rails 36 extend continuously between an upper edge 300A and a lower edge 300B of wall 300. In some embodiments, adjacent rails 36 are spaced apart in a generally horizontal direction. Each wall panel 30 preferably engages at least two rails 36 to stably secure wall panel 30 against building 12.
In the example embodiment shown in FIG. 2C, rail 36 comprises slots 36B spaced apart along its longitudinal axis (which is along the general vertical direction). Slots 36B are shaped to receive clips 33 (e.g. hanger clips) to secure wall panel 30 against the exterior of building 12. In some embodiments, the distance between adjacent slots 36B correspond to the width of wall panel 30. In some embodiments, clips 33 comprise an inwardly spring-biased end which engages slot 36B in rail 36.
In the example embodiment shown in FIGS. 2B-2C, attachment mechanism 36A comprises bolts (e.g. a ½″×6″ Gr. 8 Bolts Hilti Epoxy Set) which are fastened to the exterior wall of building 12. As discussed in more detail below, rail 36 may in some cases be provided as a guide for securing wall panel 30 against building 12 at a suitable location and does not need to carry the weight of wall panel 30.
FIG. 2B is a side sectional view of an interface between two vertically adjacent wall panels 30-1, 30-2 (i.e. wall panel 30-2 is stacked on top of wall panel 30-1) which form part of building wrap 10 according to an example embodiment of the invention. As shown in FIG. 2B, clips 33 are sandwiched between lower wall panel 30-1 and upper wall panel 30-2.
In some embodiments, building wrap 10 comprises means for securing the upper horizontal frame member of a lower wall panel 30-1 to the lower horizontal frame member of an upper wall panel 30-2. For example, the slotted holes 31A of an upper horizontal frame member of frame 31-1 of lower wall panel 30-1 and the slotted holes 31A of a lower horizontal frame member of frame 31-2 of upper wall panel 30-2 may be aligned with each other to receive pin 34 which secures the lower wall panel 30-1 to the upper wall panel 30-2 (e.g. see FIG. 2B). In some embodiments, pin 34 is a ¾″ tapered bolt. Pin 34 may be threaded in or welded on slotted holes 31A depending on the construction of pin 34. Pin 34 fastens lower wall panel 30-1 and upper wall panel 30-2 together to prevent unwanted slippage and/or provide ease of installation.
In some embodiments, building wrap 10 comprises sealing means 37 provided between vertically and horizontally adjacent wall panels 30. Sealing means 37 may advantageously shield pin 34 from exposure to the ambient environment. Sealing means 37 may be provided between horizontally extending edges of vertically adjacent wall panels 30-1, 30-2 and/or vertically extending edges of horizontally adjacent wall panels 30-1, 30-3 to prevent water and/or air from penetrating building wrap 10 through gaps located at the interface of adjacent wall panels 30. In some embodiments, building wrap 10 comprises sealing means 37 provided between wall panels 30 and building 12 (i.e. sealing means 37 may be provided at air gap 35).
Examples of sealing means 37 include, but are not limited to, one or a combination of: backer rods, foam sealants, caulking, liquid applied membranes, mineral wool insulation, etc. In some embodiments, sealing means 37 comprises suitable fire rated caulking such as intumescent fire stop caulking or the like. In some embodiments, a fireproof seal is provided between wall panels 30 and building 12.
FIG. 2C is a plan view of an interface between two horizontally adjacent wall panels 30-1, 30-3 (i.e. wall panel 30-3 is to the left of wall panel 30-1) which form part of building wrap 10 according to an example embodiment of the invention. As discussed above, clip 33 engages slot 36B of rail 36 to secure wall panel 30 against building 12. In some embodiments, clip 33 is integrally formed with frame 31 (e.g. a hanger clip may be directly welded onto frame 31). In other embodiments clip 33 is coupled to frame 31 via a threaded connection, a nut and washer connection, etc.
In the example embodiment shown in FIG. 2C, rail 36 is kinked to provide an air gap 35 between wall panel 30 and building 12. Proving air gap 35 between wall panel 30 and building 12 can advantageously help prevent variances in the façade of building 12 from affecting the uniformity of building wrap 10 (i.e. adjacent wall panels 30 will be flush despite variances in the façade of building 12). Preferably air gap 35 is relatively small (e.g. not exceeding about 2″). For example, the size of air gap 35 may be in the range of about ½″ to about 1½″ or about ¾″ to about 1″. Air gap 35 is preferably smaller than the width of frame 31. A relatively small air gap 35 may be preferred because larger air gaps may require stronger attachment mechanisms 36A to secure mounting rails 36 against building 12.
FIG. 2D is a perspective view of a connector 39 which may be provided in addition or in alternative to rails 36 to secure wall panels 30 against building 12. Connector 39 comprises a first portion 39A secured against building 12 through attachment mechanisms 39B and a second portion 39C designed and/or shaped to receive wall panel 30. First portion 39A and second portion 39C are removably coupled to each other. In some embodiments, first portion 39A and second portion 39C are designed to allow for adjustment of the size of the air gap 35 between wall panels 30 and building 12 when wall panels 30 are secured against building 12.
In some embodiments, second portion 39C is coupled to a horizontal frame member of frame 31 of wall panel 30. In some embodiments, second portion 39C is coupled to a top horizontal frame member of frame 31. In some embodiments, second portion 39C is integrally formed as part of frame 31. As discussed elsewhere herein, connector 39 may be provided as a guide for securing wall panel 30 against building 12 in some cases and does not need to carry the weight of wall panel 30.
In some embodiments, adjacent wall panels 30 are mechanically secured to each other via suitable threads and/or connectors provided on frame 31 of panels 30.
Referring back to FIG. 1B, wall 300, formed by joining multiple wall panels 30 together, has an upper edge 300A and an opposing lower edge 300B located near the base of building 12. In some embodiments, wall 300 or sections of wall 300 extend downwards until it abuts ground 11 (i.e. lower edge 300B extends downwards to the grade elevation of building 12). In other embodiments, lower edge 300B of wall 300 does not abut ground 11. Instead, lower edge 300B is located at an elevation of about 3″ to 36″ above the grade elevation of building 12.
In embodiments where lower edge 300B of wall 300 does not abut ground 11 (i.e. ground 11 does not carry the weight of wall 300), building wrap 10 preferably comprises foundation panels 40 which help support the weight of wall panels 30. Like wall panels 30, multiple foundation panels 40 may be joined together to form a retrofit foundation 400. In some embodiments, retrofit foundation 400 completely encloses the existing foundation 13 of building 12.
In some embodiments, building wrap 10 comprises foundation panels 40A which extend downwards to the elevation level of footing 13A of foundation 13. In these embodiments, foundation panels 40A may stand on footing 13A so that footing 13A carries at least part of the weight of foundation panels 40A and may also carry at least part of the weight of wall panels 30 supported by foundation panels 40A.
In some embodiments, building wrap 10 comprises foundation panels 40B which extend below grade, but not to the level of footing 13A of foundation 13 (e.g. see FIG. 1A). This may be the case in situations where excavation is prohibited (e.g. by government by-laws, etc.) and/or costly. In these embodiments, foundations panels 40B may be supported by a ledger 46 which is secured to the existing foundation 13 of building 12.
FIG. 3 is a side sectional view of a foundation panel 40B which extends below the grade level 11A of ground 11, but not all the way down to the level of footing 13A of foundation 13. Foundation panels 40B may extend below the grade level 11A of ground 11 by about 4′ to about 12′. The depth of extension of foundation panels 40B can vary depending on the environment and/or height of building 12. For example, deeper insulated foundations are suitable for cold climates where the frost line is usually much deeper.
In the example embodiment shown in FIG. 3, foundation panel 40B is supported by a ledger 46 which is secured to the foundation 13 of building 12. Preferably ledger 46 is sufficiently robust to withstand the weight of foundation panels 40B and/or wall panels 30. Ledger 46 may be secured to foundation 13 with concrete anchors 46A. Examples of concrete anchors 46A include, but are not limited to: wedge anchors, screw anchors, epoxy set anchors, sleeve anchors, etc.
In some embodiments, foundation panels 40 share the same general composition as wall panels 30. For example, foundation panel 40 may comprise a structural frame 41 framed around a panel body 42 comprising an interior layer 42A made of cementitious material, a middle insulating layer 42B, and an exterior layer 42C made of cementitious material. Like wall panels 30, foundation panels 40 have a width which is typically in the range of about 10′ to about 14′, a length which is typically in the range of about 20′ to about 60′, and a thickness which is typically in the range of about 3″ to 24″.
Foundation panels 40 may optionally comprise additional structures which help carry the load of the panels located above them (e.g. wall panels 30). For example, foundation panels 40 may comprise one or more stiffening members coupled to frame 41. Foundation panels 40 may also comprise structures which are suitable for reinforcing and/or thickening the face of interior layer 42A. Foundation panels 40 may also comprise a water barrier membrane coated around one or more surfaces of foundation panel 40.
In some embodiments, building wrap 10 comprises a combination of foundation panels 40A which extend to footing 13A and foundation panels 40B which do not extend to footing 13B (e.g. see FIG. 1A).
Building wrap 10 comprises one or more roof panels 50 mounted on top of the existing roof of building 12. FIG. 4A is a perspective view of a roof panel 50 according to an example embodiment of the invention. Roof panels 50 have a width which is typically in the range of about 8′ to about 14′, a length which is typically in the range of about 20′ to about 60′, and a thickness which is typically in the range of about 8″ to about 36″. Roof panels 50 are typically thicker than wall panels 30. In some embodiments, roof panels 50 are about two to three times as thick as wall panels 30. For example, a building wrap 10 comprising wall panels 30 which have a thickness of about 8″ typically comprises roof panels 50 which have a thickness of about 18″.
In some embodiments, roof panels 50 share the same general composition as wall panels 30. For example, roof panel 50 may comprise a structural frame 51 framed around a panel body 52 comprising an interior layer 52A made of cementitious material, a middle insulating layer 52B, and an exterior layer 52C made of cementitious material. Like frame 31 of wall panel 30, frame 51 may be made of hollow structural section (HSS) steel, stainless steel, aluminum, fiberglass (FRP) and/or cementitious materials. Like frame 31 of wall panel 30, frame 51 may comprise frame members which have the shape of an angle beam, a channel beam, a flat beam, an I-Beam, etc.
In some embodiments, roof panels 50 share the same composition as wall panels 30 except that panel body 52 comprises additional layers which may partially or fully enclose frame 51 as shown in FIGS. 4C and 4D. In the example embodiment shown in FIG. 4A, roof panel 50 comprises a frame 51 framed around a panel body 52 comprising an interior layer 52A made of cementitious material, a first insulating layer 52B, a first exterior layer 52C made of cementitious material, a second insulating layer 52D, and a second exterior layer 52E made of cementitious material. As shown in the FIG. 4A example embodiment, interior cementitious layer 52A is sandwiched between first insulating layer 52B and second insulating layer 52D.
Second insulating layer 52D has a thickness which is typically in the range of about ⅛″ to about ¼″. Second insulating layer 52D may be provided or shaped to form an angle relative to the surface of first insulating layer 52B (i.e. second insulating layer 52D may comprise a sloped surface facing towards the sky). For example, second insulating layer 52D may be angled towards the edges of building 12 to encourage water to drain towards the edges of building 12.
Roof panels 50 may optionally comprise slots 55 which face upwards (i.e. towards the sky) when roof panels 50 are mounted on top of the existing roof of building 12. As shown in FIG. 4A, slots 55 may be provided to receive suitable mechanical fasteners 56 (e.g. see FIGS. 4C and 4D). Mechanical fasteners 56 may be inserted in slots 55 to bolt roof panel 50 together with wall panel 30 or to bolt adjacent roof panels 50 together. In some embodiments, slots 55 are filled with suitable plastic materials such as expanded polystyrene (EPS) and/or coated with a membrane after mechanical fasteners 56 are inserted in slots 51 and bolted to wall panel 30 or an adjacent roof panel 50.
Roof panels 50 may comprise one or more exposed sides 50A and one or more enclosed sides 50B as shown in FIG. 4A. For the purposes of facilitating the description, an exposed side 50A refers to a side which has not been sealed or coated with a surface finish (i.e. a side where the insulating layers 52B, 52D are exposed). For the purposes of facilitating the description, an enclosed side 50B refers to a side which has been sealed or coated with a surface finish (e.g. exterior cementitious layer 52E).
Adjacent roof panels 50 may be joined together by suitable seals and/or mechanical fasteners to form a roof 500 having edges 501 which extend around the perimeter of roof 500 (e.g. see FIG. 1B). In some embodiments, adjacent roof panels 50 are joined together at their respective exposed sides 50A (i.e. the exposed sides 50A of the adjacent roof panels 50 face each other).
Edges 501 or segments of edges 501 are adjacent to an upper edge 300A of wall 30 when building wrap 10 is installed on building 12. Wall panels 50 which form edges 501 typically comprise slots 55 which receive mechanical fasteners 56 to couple roof 500 to wall 300.
Roof 500 is depicted in FIG. 1B to cover the entirety of the existing roof of building 12 but this is not necessary. In some embodiments, roof 500 is provided to cover only portions of the existing roof of building 12. In some embodiments, it may be desirable to cover the entirety of the existing roof of building 12 with roof panels 50 to provide uniform insulation and/or avoid thermal bridges.
Building wrap 10 may optionally comprise parapet panels 70 which cover parapet 14 of building 12. Parapet panels 70 typically have a width in the range of 1′ to 14′, a length in the range of 20′ to 60′, and a thickness in the range of 3″ to 18″. FIG. 5 is a side sectional view of a parapet panel 70 secured against parapet 14 of building 12. In the example embodiment shown in FIG. 5, parapet panel 70 has the same general structure as wall panel 30 except that that it is shorter in the vertical direction (e.g. see FIG. 1D).
Building wrap 10 may in some cases be embodied as a “kit”, that is, as a collection of components that can be delivered to and/or assembled at the location of building 12 or any other suitable location to form all or parts of building wrap 10. Such a kit typically comprises one or a combination of components which form building wrap 10 as described elsewhere herein, which includes but is not limited to: wall panels 30, foundation panels 40, roof panels 50, parapet panels 70, clips 33, mounting rails 36, sealing means 37, etc.
Another aspect of the invention provides a method for retrofitting an existing building 12 with pre-fabricated panels (e.g. wall panels 30, foundation panels 40, roof panels 50, parapet panels 70, etc.).
FIG. 6 is a block diagram showing an example method 1000 for retrofitting a building 12.
At block 1001, building 12 is scanned using suitable 3-dimensional (3D) scanning technologies such as laser scanning to determine an exterior topography of building 12.
At block 1002, panels 30, 40, 50, 70 are designed based on the exterior topography determined in block 1001. Panels 30, 40, 50, 70 may be designed using suitable computer-aided design software and/or techniques such as 3D Building Information Modelling (BIM). Example design parameters include, but are not limited to: size, shape, material composition, thermal conductivity, and air permeability. Where the exterior topography of building 12 is similar to those of a known topography, panels 30, 40, 50, 70 may be designed based on the known topography.
At block 1003, panels 30, 40, 50, 70 are fabricated based on the design. Block 1003 preferably involves digital fabrication techniques such as Computer Numerical Control (CNC) machining. In some embodiments, block 1003 comprises providing casting beds which may be sized based on the desired dimensions of panels 30, 40, 50, 70. The casting beds may optionally comprise one or more block-outs to create opening(s) (e.g. windows, doors, etc.) on panels 30, 40, 50, 70. In some embodiments, block 1003 comprises providing suitable formworks and/or other structural reinforcements before the cementitious material is poured into the casting bed.
At block 1004, mounting rails 36 are attached to building 12. In some embodiments, mounting rails 36 are customized based on the exterior topography of building 12 and/or the design of panels 30, 40, 50, 70. In some embodiments, mounting rails 36 comprise standardized commercially available tracks (e.g. 0.188″ thick steel channel tracks).
At block 1005, wall panels 30 are secured against mounting rails 36. In some embodiments, roof panels 50 are mounted on top of building 12. In some embodiments, foundation panels 40 are installed below grade 11A to support the weight of wall panels 30.

INTERPRETATION OF TERMS

Unless the context clearly requires otherwise, throughout the description and the claims:

- “comprise”, “comprising”, and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”;
- “connected”, “coupled”, or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof;
- “herein”, “above”, “below”, and words of similar import, when used to describe this specification, shall refer to this specification as a whole, and not to any particular portions of this specification;
- “or”, in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list;
- the singular forms “a”, “an”, and “the” also include the meaning of any appropriate plural forms.

While processes or blocks are presented in a given order, alternative examples may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, or may be performed at different times.
Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.
Various features are described herein as being present in “some embodiments”. Such features are not mandatory and may not be present in all embodiments. Embodiments of the invention may include zero, any one or any combination of two or more of such features. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible).
It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
permutations, additions and sub-combinations as are consistent with the broadest interpretation of the specification as a whole.

Claims

1. A building wrap for retrofitting a building, the building wrap comprising:

a plurality of pre-fabricated roof panels joined together to form a roof;

a plurality of vertically extending mounting rails attachable to an exterior wall of the building at horizontally spaced locations;

a plurality of pre-fabricated wall panels, each of the plurality of wall panels coupled to at least one of the plurality of mounting rails, the wall panels joined together to form a wall abutting the roof at an upper edge of the wall;

a plurality of pre-fabricated foundation panels supporting the weight of the wall panels at a lower edge of the wall;

wherein each said pre-fabricated wall panel comprises a rigid frame having horizontal and vertical frame members and clips attached at spaced locations on said horizontal frame members for engaging said mounting rails and securely holding each said panel against said mounting rails;

means for securing the lower horizontal frame member of one wall panel to the upper horizontal frame member of a vertically adjacent wall panel; and

water and air sealing means between vertically and horizontally adjacent wall panels.

2. The building wrap of claim 1 wherein at least some portions of some of the foundation panels extend below a grade level of the building.

3. The building wrap of claim 2 wherein at least some of the foundation panels extend to a footing of the building.

4. The building wrap of claim 2 wherein at least some of the foundation panels are supported by a ledger, the ledger mounted to the foundation of the building at a location below the grade level and above the footing of the building.

5. The building wrap of claim 1 wherein each of said clips comprises an inwardly spring-biased end for engaging a slot in a corresponding mounting rail.

6. The building wrap of claim 1 wherein the pre-fabricated wall panels comprise an insulating layer sandwiched between an exterior cementitious layer and an interior cementitious layer.

7. The building wrap of claim 6 wherein said frame is framed around the insulating layer of the pre-fabricated wall panels.

8. The building wrap of claim 1 wherein said frame is made of hollow structure section steel, an angle beam, a channel beam, a flat beam, or an I-beam.

9. The building wrap of claim 1 wherein said frame is made of a cementitious material.

10. The building wrap of claim 1 wherein at least one of the pre-fabricated wall panels comprises a cut-out region.

11. The building wrap of claim 1 wherein the plurality of pre-fabricated wall panels are joined together to form a perimeter wall enclosing the building.

12. The building wrap of claim 1 wherein each of the mounting rails receives at least two wall panels.

13. The building wrap of claim 1 wherein the thickness of each of the plurality of roof panels is greater than the thickness of each of the plurality of wall panels.

14. A kit comprising the pre-fabricated roof panels, the pre-fabricated wall panels, the pre-fabricated foundation panels, the mounting rails and the clips for use in assembling the building wrap claimed in claim 1.

15. A method of retrofitting a building, the method comprising:

scanning the building to determine an exterior topography of the building;

designing a plurality of prefabricated building panels which conform to the exterior topography of the building;

fabricating the plurality of building panels based on the design;

installing a plurality of mounting rails on the building;

securing at least some of the plurality of prefabricated building panels against at least some of the mounting rails; and

securing at least some of the plurality of prefabricated building panels against each other.