WO1998048124A1

WO1998048124A1 - Building system and components of this system for modular do-it yourself houses

Info

Publication number: WO1998048124A1
Application number: PCT/DK1998/000151
Authority: WO
Inventors: Mogens Danborg
Original assignee: Mogens Danborg
Priority date: 1997-04-10
Filing date: 1998-04-08
Publication date: 1998-10-29
Also published as: AU6821198A; DK70997A

Abstract

Building system of steel and components of this system, for complete do-it-yourself houses composed of a load bearing thin steel skeleton frame made of profiled vertical H-columns (211) with profiled horizontal over- and underrails (411) where a system of holes for bolts secure horizontal and vertical lines and also secure against sliding and longitudinal influence of traction force. A thin steel rafter in H-profile consisting of a skirting (511) with matching pieces of top rafters (511) and pressure beams (611), connected together with bolts to form the whole rafter. The roof construction is battened with thin steel battens with holes and fastened with bolts. The wall plates (1011) are fixed to the profiled vertical H-columns (211) with bolts (1014) from the inside which secures the house from weather penetration. Windows and doors are fixed to the holders for windows (811) on the vertical H-columns (211). The roof covering and internal coverings are fixed with bolts to thin steel battens with holes, made of uniprofile (711).

Description

BUILDING SYSTEM AND COMPONENTS OF THIS SYSTEM FOR MODULSR DO-IT YOURSELF HOUSES.

THE INVENTION

The invention concerns a standardized, readymade, prelocked, nut-and-bolted, modular designed, light-weight-element building system, that can be assembled by the end-user with practically no professional assistance by the do-it-yourself principle to the stage of turnkey homes.

The technique with plate-covered steel-skeletons is known in high-rise and in industrial-buildings performed with heavy cast-iron-profiles. Prefab constructions in wooden-elements gives inaccurate fixing-points and are vulnerable to insects.

DE 35 32 846 and DE 37 12 249 do not employ H-profiles and do therefore not have static for hard climatic circumstances. They are assembled in factories and need welding on the erection site and cannot be compared to the concept in this application since they cannot be assembled without use of lift or crane. Never before has a building kit been produced for small dwellings where precision is a product of industrial manufacturing and where stability in the construction is designed to withstand the hardest climatic conditions.

The special effect that is achieved by construction with this building-system is that a home is produced by means of no other tools than a spanner, since the superstructure as well as the roof, rafters, trusses and sidings are bolted together easily and therefore can be mounted by non-professionals. No single parts of the superstructure weighs more than app. 30 kg and can in a short time be assembled by very few people without use of lifting equipment.

Due to its "Lego/Ikea" principle combined with the readypacked delivery system this building-concept will be adaptable in areas that so far have been unreachable because of transportation difficulties as well as for price-reasons. Due to modular design and to pre-perforation, the homes cannot be erected wrongly, crooked, uneven or aslope and they can be built in any optional size without use of architect, engineer or contractor. The construction is calculated to withstand the hardest climatic- conditions for snow-load, wind-load and earthquakes.

The means to achieve this objective is a genuinely engineered, logic, well-proportioned, easy comprehended and easy practicable lightweights-profile-system, that due to its free span of app. 10 meter in the width can be utilized for many building-purposes from small cabins to a variety of larger houses, schools, common buildings and institutions, stores and light industry.

The houses are produced in modular bays in a new developed, rolled soft-steel- coil-skeletons consisting of a number of vertical H-profiled columns, V-profiled corner columns, horizontal U-shaped steering-rails which altogether produces a load-carrying wall that externally are clad with special produced sidings in suitable sizes made e.g. from concrete, claybricks, wooden, fibers or any other locally suitable material according to customers wishes, while the walls inside the homes internally are fitted preferable with Gypsum or FRC plates.

Due to the great accuracy that modern mass-produced, rolled, perforated soft- steel profiles are delivered in, together with the great precision of well-developed FRC-sheets and other standard sheets and sidings there is no problem with jointing and assembling of the covering materials.

The rafters consists of triangles of l-profiles with built-in trusses for support and all profiles in walls and in roofing makes space for necessary insulation that is kept in position by the flanges of the profiles which also makes space for hidden installations of electricity, water, telecommunication, ventilation and heating-pipes. Windows and doors are likewise kept in position and fastened to the vertical H-columns by means of window-fittings bolted to the H-profiles and all fixing and fastening is done from inside due to safety considerations.

The effect of the supporting system is attained by the shape of the profiles in that the double C-shape used in the vertical columns and in the supporting rafters provides a supporting power equal to that of pipes known for great strength in compression as tension in both planes. The C-profiles are identical in both ends and in both sides in the shape and in the perforation so if you take two pieces and turn the one upside down, fix them back to back you will conse- qently have profiled column that is identical in both ends and on both sides. In this way you have achieved a practical, useful and easy handled supporting unit for any kind and size of building construction and the units, vertical as well as horizontal are so light that any adult can easily handle them on his own.

By means of a further u-shaped single profile a steering rail is provided which is identical for the bottom as well as for the top and that due to its shape has great strength in lengthwise control of the superstructure. When the vertical columns and the horizontal rails are bolted together as shown in fig. 1c, one will get a completely stable construction and the finished superstructure will be secured with anchors that are casted into the foundation. To secure against wind-load, the last modules at the corners have to be provided with windload struts by metal-strings and the angles at the top bottom level will also be controlled by likewise metal-straps.

When the walling part of the superstructure is in place the trusses can be added. If more than one person is involved the rafters can be assembled on the ground and lifted up on the wall-construction since they will have a weight of approximately 50 kg a truss. When the rafters are raised to its position they must be supported by a temporary lath until the permanent lath or purlins are in place and fixed.

When the steel-superstructure is assembled and the rafters are in place, laths are fitted and bolted to the rafters, and then windows and doors should be fitted by means of the windowholders and finally all bolts and nuts must be fastened, with a spanner, throughout the superstructure.

The superstructure is now ready to be covered with cladding-materials inside and outside. At first the house should be covered with chosen roofing materials such as metal-sheets bolted to the laths on top of the rafters. Then the outside siding-board materials must be fitted from below and upwards. Inside the wall the insulation materials should be inserted between the vertical columns and then finally the inside walls are covered with gypsum-sheets or other chosen boarding-material fitted to the laths that are bolted to the vertical columns.

LIST OF FIGURES:

Fig. 1a,b,c,d,e and f are general views showing examples of a finished house (1a) how it looks partly un-covered (1 b) in order to understand the individual components, the superstructure (1 c) showing the horizontal and vertical steel-profiles and the rafters-construction, also shown is the supporting structure in an exploded form (1 d) and finally the external cover (1e) and the internal sheets (1f).

All drawings are shown in perspective.

Fig. 2 shows the supporting H-columns design and construction as standard-columns consisting of two tight-fixed C-forms back to back.

Fig. 3 shows the V-formed corner-columns consisting of an inner and an outer angel.

Fig. 4a, b, c, and d shows the design of the steering rails (4a) as U-formed rails for sides and corners and the rails placed in position (4b) before the vertical columns are placed and fixed as shown (4c) along sides and (4d) as corners.

Fig. 5a and b shows the design of the rafters (5a) consisting of 2 C-shaped profiles fixed together to form H-beams which cut to measure can be assembled in a triangle with supporting bars inserted and (5b) the rafters placed in position.

Fig. 6a, b and c shows the special shape and form and the way of inserting the supporting bars with bolt and nut in the holes premade in truss-beams in top (6a) and in bottom (6b) and (6c) the supporting bars are shown in cut outs shaped form and profile.

Fig. 7 shows the unique standard "Uniprofile" (7) formed with rolled-in flange to strengthen the purlin-lath-bar lengthwise as well as cross-wise and for recessing the head of the screws and finally to fasten clip and clamp fittings sideways. The Uniprofile purlins are also used for supporting bars or rods mentioned under fig. 6.

Fig. 8a and b shows the window-holders (8a) which are mounted in all places where windows or doors are to be inserted. The holders are mounted 1 to 5 in a row all according to the size of the window or door (8b).

Fig. 9a and b. shows the windowframes (9b) preformed in soft-steel and also how they are assembled in corners and (9a) shows in section how the frame has the same shape as the opening frame section.

Fig. 10a and b shows a part of the construction of the wall seen in section (10a) and a close-up of a corner (10b) that shows the shape and design of the siding cover with weather protecting groove and rabbet form for a water drip.

REFERENCES:

Reference to claim 1. (fig. 1a,b,c and d.)

Building-system 111 composes a total-concept for erection of buildings of desired but modularly stipulated sizes formed by a set of integrated galvanized, profiled rolled, softsteel-skeletton composed by the vertical H-columns 211 who on their part consist of two back-to-back fixed C-profiles and which further including the vertical V-shaped corner-columns 311 which again on their part consists of an outer and an inner V-profile with bent flanges thus the H- and the V- profiles all in all are used as supporters of the horizontally fixed U-shaped rolled steering rails 411 as well as all other part-components and covers on the specially developed laths 711 as well on the outer (fig. 1e) as on the inner side (fig. 1f) of the superstructure all furthermore for anchoring (fig. 1 b) to the foundation and finally as supporter of the roof-construction 511 which is likewise formed into supporting truss-beams by composed by two back-to-back fixed C-profiles 512 and the inserted C-formed supporting-bars 611 . The super-structure H- V- and I profiles act as channels for installations and frame for the insulation which is placed between the vertical H-columns.

Reference to claim 4, (fig. 4a,b,c and d).

The above mentioned H-columns 211 and V-corner-columns 311 are fixed in position by means of lengthwise U-shaped steering rails 411 grasping up respectively down over the H-columns and they are controlling the mutual distance of these, the horizontal as well as the vertical flush by the fact that the steering-rails 411 are provided with a double set of fixing and fastening bolt-holes 412 in the vertical part of the rails matching the holes in the H-columns 213 and V-columns 316 (fig.4c and d) and due to their shape they provide great strength and stiffness in the total construction. The steering rails have further larger round holes 413 in the horizontal level for ventilation, drain and fixing the internal cables and wires. The steering rail are naturally fixed lengthwise one after the other in the top as well in the in bottom of the h- and V-columns. In corners the Rails are mitred to fit the angle of the walls 416.

Reference to claim 5, (fig. 5a and b).

The rafter 511 is in itself a set of integrated profiles formed by two c-shaped rolled softsteel-profiles 512 that fixed back to back form the carrying H-profiles 513, where three parts of mentioned H-profiles formed into a triangle creates the rafter-sets 515. Before assembling the triangles, the supporting bars 611 , are inserted and fixed with bolt and nuts 518. The rafter-profiles are supplied with holes in the horizontal flanges 516 for fixing both roofing- and ceiling-lathes, and in the ends 517 they are supplied with holes for fixing the rafters to the wall-structure and for assembling the three parts in the triangle to each other into a complete firm set of roof-trusses. The H-profiles are provided with a curved bending in the flanges for stiffness and stability.

Reference to claim 6, (fig. 6a and b).

The supporting bars in the rafters are formed by the uni-profile 611 after being cut and shaped in both ends 612 in such a way that four supporting bars and three rafter-profiles 515 fits together and immediately are assembled into the rafters 511 with no other tools but a spanner. The supporting bars 611 are formed in such a way that they can be inserted no matter if they are right or left turned and the procedure is first to bolt the two outer ends when the top ends 519 meet it can all be bolted and then the whole rafter-set is ready to be positioned on the supporting wall-structure. A rafter-construction like this has never been made before and is a unique invention that can be used in many other types of housing construction because they are so incredibly easy to assemble.

Reference to claim 7, (fig. 7a and b)

The lathe 711 (purlins) is used for both supporting the roofing sheets and for carrying the Inner walling sheets, the ceiling sheets and if necessary also the outer siding sheets. The profile is also used for the supporting bars 611 mentioned above under fig. 6. The square profile (uni-profile) that is made of soft-steel has in the rolling process been supplied with recessed curves 713 on the three sides for strengthening the profile load-ability and for fixing clamps and clips to the sides and finally for hiding the head of screws and bolts 713.

Reference to claim 8, (fig. 8a and b).

For fixing windows and doors to the vertical H-columns 211 special window-holders 811 have been created and they are provided with holes on the outer face of the holder 812 and on the inner face of the holder 813 designed for fixing the holder to the vertical H-columns 211 in the corresponding holes. The holders are designed to fit exactly around the H-columns in the inner flanges 214 and the outer flanges 213 and into the holes that otherwise would have been used for fixing the inner and the outer sheeting cover. The window-holders 811 are furthermore provided with holes 814 for fixing the windows and doors all along the edges 816 from one to five levels 818 and finally they are provided with holes 817 in order to get a hand in for fastening the bolts and nuts with a spanner.

Reference to claim 9, (fig. 9a and b)

Windows and doors 911 are formed and rolled in soft-steel and are the profiles that are used For the main-frame part 913 and for the opening part 912 of the windows. They are created with a square pipe-like body with a curb-flange 914 for tightening. Windows in soft-steel are a new invention and it has a great twist stability achieved by means of two half C-forms fixed together over a corner-shaped fitting 914. The profiles are tightened with foam-strips 917 and the glass single or double is fastened by means of clips 915. The profiles are pre holed to fit the window-holders 911. Reference to claim 10, (fig. 10a and b)

Sheeting-cover or sidings 1011 for the outer cladding of the superstructure are manufactured In standardized sizes in such a way that each single plate can be fitted and fixed exactly in the position where it is supposed to be by means of precisely potitined fixing-devi- ces on the back of the plates. The siding-plates are designed with grooves 1012 and rabbets 1013 for water-protection. The siding-plates are preferably made in fiber-concrete, concrete or other

FRC materials and they are mounted from inside directly on the vertical H-profiles 211 and V-profiles 311 with mastic-strips as water-proofing between the plates both vertically and horizontally. The siding plates or cladding panels can be made in all colors and surfaces and in such a way as to allow other materials to fit local and national materials and architectural practices.

Claims

PATENT CLAIMS:

1. Building-system for erection of buildings of desired but modularly fixed sizes formed by a set of integrating profiles consisting of supporting vertical H-shaped columns, supporting V-shaped corner columns, horizontal steering top and bottom rails, supporting H-shaped rafter beams, supporting insert uni-profiled bars, laths for fixing wall and ceiling cover plates, roofing cover plates and externally cover plates, planks or sheets, window and doors holder profiles, windows and door-frames profiles and finally external siding cover plates.

Characterized by:

Supporting vertical H-shaped columns 211 consisting of two C-shaped profiles fixed back-to-back and provided with bolting holes 213 an 214 with prefixed distance along the flanges, and; supporting V-shaped columns 311 formed by two separate angles, a larger outer angel 321 and a smaller inner angel 322 which together forms a stable corner provided with bolting holes 314 with prefix distance, and; steering U-shaped horizontal top- and bottom rails 411 provided with prefixed holes for fixing the rails to the vertical H-columns 211 and V-columns 311, and; supporting H-shaped rafter-beam profiles 511 formed by two C-shaped profiles fixed back-to-back and cut in such a way that they directly can be assembled and bolted into triangular sets of readymade rafters ready to be positioned and bolted to the wall superstructure, and;

C-formed rolled supporting bars 611 for immediate insertion in the triangle by the holes 613 as well as in the flanges of the rafter-beams and in the supporting bars itself 612 and with holes 614 for fixing them together with the rafters, and; C-formed rolled laths in uni-profiles 711 for fixing covers on the outside and on the inner sides (see fig 1e and f), and;

U-formed profiles 811 as fixing-fitting for windows and doors 911 when mounted on the H-profiles 211 , and; square-pipe shaped window and door profiles 911 used as the fixed frames as well as the opening-frames, and; external siding-plates 1011 which are "bulletproof" and constructed in such a way that the over-plate is hanging down over the under-plate and provided with groove and rabbet and furthermore provided with nut-bushing on the back to be fixed from inside on the vertical columns.

2. Part of building system consisting of vertical rolled supporting H-shaped profiles 211 according to claim 1 characterized by the fact that they consist of two C-shaped profiles fixed back-to-back 219 into a single column and provided with bolting-holes with a prefix distance along the outer-flanges 214 and along the inner flanges 213 for fastening the inner and outer cover sidings and sheets 1011 and furthermore provided with holes 212 and 312 in the top and bottom of the outer flanges of the H- and V-columns 211 and 311 for fastening of the horizontal steering rails 411 in top and Bottom and the vertical H-column is also provided with lengthwise perforations 216 In the middle-flange of the H-profile 211 for reduction of heat conduction and it has Furthermore bolting-holes 218 in top and bottom of the middle flange for anchoring the superstructure to the foundation (fig 1b) and to the roofing construction and finally a square cut in top and bottom 220 and round cut holes in the inner-flanges for installation of water-pipes and electricity-lines and other installations.

3. Part of building-system consisting of two vertical supporting angle-shaped corner- columns 311 according to claim 1 and characterized by the two angle-shaped 321 and 322 in soft-steel rolled profiles respectively an inner and smaller inner-profile 322 and a larger outer profile 321 and furthermore provided with bolting holes as mentioned under claim 2, 313, 314, 326.

4. Part of building-system according to claim 1 characterized by the fact that the top- and bottom U-shaped steering rail 411 is rolled in the same soft-steel coil-material in such a way that they grip respectively up and down over the end of the 211 vertical H- and 311 V-columns ends 415 and since they are provided with bolting holes 412 in both sides and in both ends of the H- and V- columns and when fastened with the bolts and nuts they are fixed flush in the vertical as well as in the horizontal direction and the rails are provided with left-open holes 413 for ventilation and fixing devices and the steering rails 411 also shapep for fixing lengthwise also in corners and finally the steering rail are provided with two set of holes for fixing the rafter-structure to the wall structure.

5. Part of building system according to claim 1 characterized by the rafter-set 511 is consisting of two rolled soft-steel C-profiles fixed together back-to-back and thus forming an H-profiles 513 which cut in the ends can be assembled 519 into a triangle of variable 15 to 60 angle-grades roofing and the rafter-beam H-profiles 512 is provided with holes in the upper-beam upper-flanges and in the lower beam under-flanges with a prefix distance for fixing laths 611 and the rafter-beam 513 is furthermore provided with left-open parts for inserting the supporting bars 611 and the bolting thereof in the holes 514 and the lower rafter beam is also provided with holes 517 for fastening the rafter-set to the horizontal steering rails 411 which are again fixed to the vertical columns 211 and 311 and thus giving the total superstructure stability structure.

6. Part of building system according to claim 1 characterized by the C-shaped and curved profile 611 , which is cut in the ends 612 so it can immediately be inserted in the rafter-beams 511 during the assembling of these and be bolted in the holes provided 613 . Due to the curved-in design in the three flanges 614 the supporting bar has an extraordinary strength and stability.

7. Part.of building system according to claim 1 characterized by the fact that the lath 711 has the same profile 713 as the supporting bars mentioned under claim 6 and that the lath-profile called "uni-profile" is provided with a recess on three sides - on top for hiding the bolting heads 713 when mounted to the columns so as not to interfere with the cover-sheets and on the sides for clip-fitting the lath (purlins).

The recess furthermore gives strengths sidewise and the laths are all cut length-wise to fit the modules and pre-holed so they can be mounted to the superstructure without any other tools other than a spanner.

8. Part of the building system according to claim 1 characterized by the fact that the window-holder 811 for mounting the windows and doors 911 is designed in a U-shape so it exactly fits over the vertical H-column 211 and the window-holder 811 is provided with holes with the same distance as the holes in the H-column 211 and in the siding plates 1011 for substituting these 812, 813 where windows and doors are situated, and the window-frame-holder are furthermore provided with larger holes 817 making it possible to get access to the inner parts of the H-columns and the window-frame-holder is finally provided with holes for fixing the windows and doors to the system.

9. Part of building-system according to claim 1 characterized by the profiles for windows and doors 911 are flexible to be used for the fixed-frames 913 as well as for the moving frames 912 since the profile has the same design namely a square body and flange 914 in one side so that whatever way you turn it you will have a moulding that forms a tightening part 915 and the back of the square profile supports the mounting of a window against the window-holder 811 or against the glass 915 supported by clips for fastening the glass. The window-frame profile is assembled into the actual window by square corner pipe fitting 918 that are inserted before fixing and the profiles are finally provided with holes for mounting the window to the window-holder 811.

10. Part of building-system according to claim 1 characterized by the external sidings 1011 of the superstructure is constructed to fit the modular distance between the vertical H- and V- columns 211 and 311 and the distance in the height divided by preferably 6 plates as a standard and the siding-plates 1011 are designed with a groove on the top 1012 and a rabbet in the bottom 1013 to shed rain water and protect against climatic effects and the plates are provided with fixing-devices 1014 and 1015 on the back of the plates so that they can be mounted directly on the vertical H- 211 and V-

311 columns from inside for protection and the plates and in the corners the plates are formed and designed in angles to fit around the corner 1015.