WO1998041705A1

WO1998041705A1 - Construction of multi-storey buildings

Info

Publication number: WO1998041705A1
Application number: PCT/GB1998/000771
Authority: WO
Inventors: Frank Layzell
Original assignee: Avenue Research & Development Limited
Priority date: 1997-03-18
Filing date: 1998-03-16
Publication date: 1998-09-24
Also published as: GB2323404B; GB9705529D0; GB2323404A; AU6411998A

Abstract

The invention provides a method of constructing a building having at least two storeys using building panels each comprising a low density core contained within a surrounding support cage. The method comprises the following steps: i) preparing a foundation; ii) erecting vertical first storey columns at spaced apart locations around the foundation; iii) constructing vertical walls from building panels located between said vertical columns and a horizontal ceiling from building panels extending from adjacent top edges of the vertical walls; iv) rendering the wall panels and ceiling panels to form a rigid structure; v) fitting vertical second storey columns to the tops of said first storey columns; and vi) repeating steps (iii) and (iv) to complete the second storey.

Description

Construction of Multi-Storey Buildings

The present invention relates to the construction of multi-storey buildings. In particular, the invention provides a method for the construction of multi-storey buildings from factory fabricated building panels comprising a wire mesh reinforcing cage structure enclosing a low density core.

The construction of buildings from building panels comprising a low density core of a foamed plastics material supported in a wire mesh reinforcing cage is known. For instance, such a building construction system is provided by SpeedWall Building Systems (of Mobility Avenue Sdn Bhd, No 17 Section 92A Jalan Dua. off Jalan Chan Sow Lin. 55200 Kuala Lumpur. Malaysia). The factory fabricated building panels consist of a cage of welded wire trusses supporting a core of strips of a foamed plastics material (typically phenolic foam is used for its fire resistance properties) to which cement/plaster produced at site is applied to each side. The cage comprises "zig-zag^" warren trusses (positioned between each foam strip) which are held together by horizontal strapping wires. The width of the cage is typically of the order of 75mm whereas the width of the foam core is typically of the order of 50mm so that the cage extends approximately 9mm or so on either side of the foam core. The finished thickness of the wall, subsequent to the application of the cement/plaster layer, is typically of the order 95mm. The panels, which are typically manufactured in 1.2m widths and lengths of 2.4m. are light and easily handled. The panels may be used to construct both walls (internal and external) and roofs and may be cut if necessary to any desired shape.

In essence, buildings are constructed by arranging the building panels adjacent one another on a foundation to which the panels are anchored to form walls. Roof panels are simply supported on wall panels. Adjacent panels may be tied to one another by clipping to each panel a strip of reinforcing mesh. Once wall and roof panels have been erected, internal and outer surfaces of the panels are spray rendered with a Portland cement mixture. For instance, the external render may typically comprise Portland cement and sharp sand mixed with a plastisiser. As an alternative to Portland cement based render, gypsum plaster might typically be used for rendering ^" internal surfaces of panels. The layer of cement plaster encases the wire mesh cage on either side of the foam core producing a rigid structure when dry. If desired, various waterproofing, anti-fungal and fibre reinforcing agents may be applied to the cement mixture or the dried surface.

The result is a building which is rapidly constructed without requiring highly skilled labour.

It will be appreciated that only very basic aspects of the construction method have been outlined above. Other aspects of the building system will become apparent from the description of the invention set out hereinafter.

Whilst construction of a single-storey building is very straight forward, some difficulties are encountered in constructing multi-storey buildings. For instance, one conventional method of multi-storey construction requires the provision of a concrete load bearing support frame (particularly for buildings of three or more storeys) within which wall and roof panels etc. are assembled.

It is an object of the present invention to provide an improved method of constructing multi-storey buildings from building panels such as those described above.

According to the present invention there is provided a method of constructing a building having at least two storeys using building panels each comprising a low density core contained within a surrounding support cage, the method comprising: i) preparing a foundation; ii) erecting vertical first storey columns at spaced apart locations around the foundation; iii) constructing vertical walls from building panels located between said vertical columns and a horizontal ceiling from building panels extending from adjacent top edges of the vertical walls; iv) rendering the wall panels and ceiling panels to form a rigid structure; v) fitting vertical second storey columns to the tops of said first storey columns; and vi) repeating steps (iii) and (iv) to complete the second storey.

Thus, with the construction method according to the present invention each storey is essentially completed as a rigid load bearing structure prior to construction of the next storey. Accordingly, the building does not require an overall support frame since each completed storey provides support for the next. The vertical columns provide support, one storey at a time, for locating wall panels etc. but need not themselves be load bearing.

Horizontal members are preferably mounted between adjacent vertical columns of each storey subsequent to erection of respective columns to provide a support for ceiling panels and to provide a location for the top edges of wall panels.

For instance the horizontal members may be U sectioned channel members and so that top edges of wall panels may be received between arms of the U section (the U sectioned channel members may have unequal length sides to facilitate insertion of wall panels).

Vertical props may be used to support the horizontal members at locations between the vertical columns prior to location of wall panels to prevent the horizontal members from sagging.

Subsequent to erection of the wall panels, but prior to the rendering of the panels, locating members are preferably fitted to the wall panels such that they extend upwardly therefrom and above the level of the respective ceiling panels, to provide an aid in the positioning of wall panels of the next storey. For instance, the members may be elongate members (e.g. pins) which may be fixed to wall panels by inserting one end thereof into the low density cores of said panels and wherein wall panels of the next storey are positioned by locating their bottom edges onto the exposed top ends of the locating members which are received within the low density cores of said upper wall panels.

Preferably the vertical columns of one storey extend above the ceiling, and subsequent to completion of the storey a temporary support structure is secured to upper portions of said columns to provide a platform to facilitate construction of the next storey. The temporary support structure is preferably mounted on cantilevered brackets secured to upper portions of respective vertical columns.

The low density core of the building panels is preferably a foamed plastics material such as phenolic foam.

Specific embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings,

Fig. 1 illustrates a portion of a conventional building panel suitable for use in the present invention;

Fig. 2 illustrates a manner of anchoring a building panel to a foundation suitable for use in the present invention;

Fig. 3 illustrates a modification of the anchor system illustrated in Fig. 2;

Fig. 4 illustrates how adjacent wall panels may be tied together in construction of a building in accordance with the present invention;

Figs. 5a to 5d illustrate further examples of tying adjacent panels together;

Fig. 6 illustrates the manner in which a vertical column is secured to a foundation in a construction method in accordance with the present invention;

Fig. 7 is a plan view of Fig. 6;

Fig. 8 is a schematic drawing illustrating construction of a simple rectangular building in accordance with the present invention;

Fig. 9 is a plan view of Fig. 10;

Fig. 10 illustrates the manner of connection of horizontal restraint members to supporting vertical columns in accordance with the present invention:

Fig. 1 1 illustrates the manner in which horizontal restraint members may be propped in accordance with the present invention.

Fig. 12 to 14 illustrate the manner in which floor panels are supported on horizontal restraint members in accordance with the present invention; and

Fig. 15 illustrates a first stage of construction of an upper storey in accordance with the present invention.

The present invention relates to the construction of multi-storey buildings and thus only features directly relevant to the invention will be described in detail. However, conventional aspects of the basic construction system applicable to both^" single and multi-storey buildings will first be briefly described in relation to a simple single storey building.

Fig. 1 is a perspective illustration of a portion of a building panel of a type suitable for use in the present invention. The panel, which is generally indicated by the reference 1 , comprises a core of phenolic foam blocks 2 supported within a wire mesh cage 3. The cage 3 comprises an array of "zig-zag" trusses 4 which are strapped together by horizontal strapping wires 5 which provide tension which holds the foam blocks 2 in position centrally between opposing "faces^"' of the cage 3. The panels are essentially factory fabricated but may advantageously be fabricated in a mobile factory which can be conveniently located on site.

As mentioned in the introduction to this specification, in a completed building the panels are spray coated with a cement mixture (or any suitable render) which dries to form a rigid layer on each side of each panel. Portions 6 of such an exterior coating are shown in Fig. 1. It will be seen that each cement layer 6 encases part of the wire cage 3 which effectively reinforces the layer 6 to provide a very rigid structure capable of bearing substantial loads.

Fig. 2 illustrates one manner in which a panel 1 may be secured to a foundation 7. Anchor bolts 8 with hooked lower ends (not shown) are set into the foundation so that the shafts of each bolt extends upwardly from the foundation 7. A base plate 9. which has holes punched therein to receive the anchor bolts 8. is laid onto the foundation 7 on top of a mastic sealant 10. Anchor brackets 1 1 are bolted to the anchor bolts 8. Building panels 1 are then stood on the base plate 9 so that their bottom edges are received by the anchor brackets 1 1. The brackets 1 1 are then clipped to the wire mesh cage 3 of the respective panels 1 (using for instance, CL-15G STANLEY-HARTCO clips - manufactured from 20 gauge flat cold rolled steel by Hartco Manufacturing Company) to hold the panels 1 in position.

As an alternative to the use of anchor bolts/brackets, wall panels, particularly external wall panels, could themselves be set into a concrete foundation to provide them with a firm footing. Other arrangements could similarly be employed. Where a greater restraining force is required, for instance at door openings, a wire loop 12 may be fixed to each side of each anchor bracket 1 1 and clipped to the cage 3 at a plurality of positions, as is illustrated in Fig. 3.

In a typical construction adjacent wall panels are arranged immediately next to one another and may be tied to each other using a strip of wire mesh 4 (for instance a "zig-zag" truss) clipped to each panel (see Fig. 4).

Similarly, panels which meet to form a corner may be fixed together with strips of mesh bent to form an angled piece to fit in the angle of the corner. For instance Figs. 5a and 5b are plan views illustrating bent wire mesh strips 13 used to fix together panels at typical corner connections. Fig. 5c illustrates the same method used to fix a roof panel la to a wall panels 1 on which it is supported and Fig. 5d illustrates the method used to join together two roof panels la which meet at a ridge. Similar mesh reinforcement may be used at door and window openings.

As mentioned above, once wall and roof panels have been erected electrical/plumbing supplies may be put in place and the complete structure is then spray coated internally and externally with a suitable cement based render. The cement coating effectively forms a continuous layer covering all panels, and extending across joints between adjacent wall panels and roof panels, to form an extremely rigid structure. It is then a relatively simple matter to install necessary pluming and electrical fittings and other trimmings necessary to complete a building.

The system according to the present invention for constructing multi-storey buildings will now be described with particular reference to Figs. 6 to 15, Fig. 8 is a schematic drawing to help illustrate the positioning of the various components (shown in detail in the other Figures) for the construction of a simple rectangular building.

Referring firstly to Figs. 6 and 7. following laying of the foundation, steel "I" section columns 14 are erected at spaced apart locations around the foundation. Each column 14 stands on a base plate 15 which is bolted to angled anchor plates 16 set into the foundation. The height of each column 14 is such that it extends a short way above the level at which the first storey floor will be laid. Unequal sided "U" sectioned restraint channels 17 are then fitted horizontally between adjacent pairs of columns 15 at the height of the first storey floor level at the site of both external and internal walls. The restraint channels may. for instance, be fabricated as a hot rolled steel section but are preferably brake pressed from steel mesh as illustrated in Fig 9a. The latter structure allows easier access for the subsequently applied render (see below). Referring to Fig. 9, the restraint channels 17 are secured to the columns 15 by cleats 18 which are bolted or otherwise secured to the columns 15. In many cases the span of the restraint channels 17 will be such that the channel will tend to sag (it may be uneconomical to construct the channels to be sufficiently rigid so as not to sag) and in this case angle section steel props 1 1 (shown in detail in Figs. 1 1) are used to support the restraint channels 17. The props 19 are positioned at a spacing corresponding to two wall panels width. The props 19 may be positioned prior to erection of the restraint channels 17 and temporarily maintained in position by simple timber props (not shown).

Once the restraint channels 17 are erected, and propped if necessary, external and internal wall panels are erected by locating the top edges of the panels within the U-sectioned restraint channels (the shorter of the unequal length sides facilitate this) and anchoring their bottom edges to the foundation (which may be achieved in a conventional manner as described above). Adjacent wall panels can be tied to one another using the methods described above and it will be appreciated that the presence of the props 19 will not interfere with the tying together of panels on either side thereof. Exposed portions of columns 14 are "boxed off using sections of wall panel cut appropriately.

The wall panels 1 are also tied to the restraint channels, for instance using mesh sections 13 (see Fig. 12) tacked to the restraint channels 17 and clipped to the panels. Locating pins 20 (see Fig. 12) are then fitted into holes 17a provided in the restraint channels 17 so that their lower ends extend into the foam cores 2 of the wall panels 1 and their upper ends extend above the restraint channels 17. These will help locate the wall panels of the second storey as is described in more detail below. Referring now to Figs 12 to 14 floor panels la (which have the same structure as the wall panels 1) are then laid across the restraint channels 17 and temporarily propped up if necessary. Neighbouring floor panels la are separated by rectangular sectioned spacer beams 21 which are fitted to angle brackets 22 secured to the restraint channels 17. The floor panels la are tied to the restraint channels 17 and spacer beams 21, again using mesh portions 13.

It will be appreciated that door ways, window openings, and other features can be incorporated in the structure in a conventional manner.

Once all walls and floor panels etc. have been erected (and if necessary fittings such as electricity supply installed) the first storey is spray coated with a suitable render (e.g. a Portland cement mixture as mentioned above) both internally and externally (internal walls could alternatively be plastered). That is. the first storey is completed before construction of the second storey is initiated. It will be appreciated that once the first storey panels have been cement coated the resulting structure is rigid and capable of bearing loads.

Referring now to Fig. 15. the first step in construction of the second storey is to secure temporary cantilever brackets 23 to the exposed upper portions of columns 14 (which extend above the first storey, indicated generally by reference 24) to support a scaffold platform (not shown) around the building. The scaffold platform provides a temporary platform from which to construct the second storey.

Second storey columns 14a are then fitted to the top of the first storey columns 14 using splice plates 25 secured to both columns 14/14a. The tops of the second storey columns 14a extend above the intended level of the third storey floor. Once the second storey columns 14a are in place, restraint channels (not shown), with any necessary props etc., are erected in the same manner as for the construction of the first storey (in this case the restraint channels will be positioned at the height of the third storey floor).

Second storey wall panels (not shown) are then fitted in essentially the same way as the first storey floor panels except that the bottom edges of the panels are located by seating them upon the exposed ends of the locating pins 20. The pins 20 thus provide means for ensuring the panels are correctly positioned and also for temporarily holding the panels in place.

Once the wall panels are in place floor panels (not shown) are laid onto the second storey restraint channels and the third storey floor constructed in the same way as the first storey floor was constructed. The second storey is then completed by fitting any electrical fittings etc. and then cement coating, internally and externally, the wall and floor panels. Temporary cantilevered scaffolding can then be fitted around the top of the second storey to enable construction on a third storey if desired, or alternatively a roof if the building is to have only two storeys.

Subsequent storeys, if desired, are erected in exactly the same way as the second storey, temporary cantilevered scaffolding being erected after completion of each storey to provide a platform for construction of the next storey.

It should be understood that the columns X, restraint channels X, and props X, are essentially non-load bearing in the completed building. Rather, all load is born by the rigid structure formed from the cement coated wall and floor panels.

We appreciated that many modifications could be made to the above construction system. For instance, the exact design of the vertical columns, restraint members, props etc. could be varied. Similarly, details of the building panels could also vary. For instance, thicker panels might be used for buildings having a relatively large number of storeys to provide greater load bearing capacity. Similarly, detailed design of the panels, e.g. design of the support cage and material used for the foam core, could be varied.

Many other modifications to the details of how individual panels are secured in position and to one another could also be varied. Modifications suitable for different sites and building specifications may readily be made by an appropriately skilled person.

Claims

1. A method of constructing a building having at least two storeys using building panels each comprising a low density core contained within a surrounding support cage, the method comprising: i) preparing a foundation; ii) erecting vertical first storey columns at spaced apart locations around the foundation; iii) constructing vertical walls from building panels located between said vertical columns and a horizontal ceiling from building panels extending from adjacent top edges of the vertical walls; iv) rendering the wall panels and ceiling panels to form a rigid structure; v) fitting vertical second storey columns to the tops of said first storey columns; and vi) repeating steps (iii) and (iv) to complete the second storey.

2. A method according to claim 1. wherein horizontal members are mounted between adjacent vertical columns of each storey subsequent to erection of respective columns to provide a support for ceiling panels.

3. A method according to claim 2. wherein said horizontal members provide a location for the top edges of wall panels.

4. A method according to claim 3, wherein said horizontal members are inverted U sectioned channel members and top edges of wall panels are received between arms of the U section.

5. A method according to claim 4, wherein said U sectioned channel members have unequal length sides to facilitate insertion of wall panels.

6. A method according to claim 4 or claim 5, wherein said horizontal members are mounted at a height sufficient to provide clearance between the top edges of wall panels and the horizontal members to facilitate accurate positioning of wall panels.

7. A method according to any one of claims 2 to 6. wherein vertical props are used to support said horizontal members at locations between said vertical columns prior to location of wall panels.

8. A method according to any one of claims 2 to 7. wherein said horizontal members are fabricated from a metal mesh.

9. A method according to any preceding claim, wherein subsequent to erection of the wall panels but prior to the rendering of the panels, locating members are fitted to the wall panels such that they extend upwardly therefrom and above the level of the respective ceiling panels, to provide an aid in the positioning of wall panels of the next storey.

10. A method according to claim 9. wherein said locating members are elongate members and are fixed to wall panels by inserting one end thereof into the low density cores of said panels and wherein wall panels of the next storey are positioned by locating their bottom edges onto the exposed top ends of the locating members which are received within the low density cores of said upper wall panels.

1 1. A method according to any preceding claim, wherein the vertical columns of one storey extend above the ceiling, and subsequent to completion of the storey a temporary support structure is secured to upper portions of said columns to provide a platform to facilitate construction of the next storey.

12. A method according to claim 1 1 , wherein said temporary support structure is^" mounted on cantilevered brackets secured to upper portions of respective vertical columns.

13. A method of constructing a building, substantially as hereinbefore described, with reference to the accompanying drawings.