WO2008135758A2

WO2008135758A2 - Structural panel system

Info

Publication number: WO2008135758A2
Application number: PCT/GB2008/001562
Authority: WO
Inventors: Kevin Mcinerney; Paul Miarowski; David Charles Bishop
Original assignee: Kevin Mcinerney; Paul Miarowski; David Charles Bishop
Priority date: 2007-05-02
Filing date: 2008-05-02
Publication date: 2008-11-13
Also published as: GB0708468D0; EP2155984A2; AU2008247132A1; WO2008135758A3

Abstract

A structural panel system for constructing a wall or roof elevation of any desired length from two basic panel modules (1, 4). The panel modules are arranged alternately and the side edges of adjacent panels overlap. One of the panels can slide relative to the adjacent panel to adapt the overlap to provide an elevation of the required length.

Description

Structural Panel System

This invention relates to a structural panel system and to modular panels for use therein. The invention is especially, but not exclusively, suitable for timber frame buildings constructed using the system employing a ring beam structure as described in our International patent application No. WO 2006/109041.

According to one aspect of the invention, there is provided a structural panel system comprising a plurality of overlapping panel modules wherein adjacent panel modules are different.

Preferably alternate panels are the same.

According to another aspect of the invention, there is provided a structural panel system that can be constructed to any length from a combination of two different types of pre-assembled panel modules.

Providing an alternating/overlapping structural panel system from predominately two standard length and profiled panel modules, predominately incorporating standard component lengths, would make scale-able volume manufacturing for structural elevation of for example, walls/roofs easier. This benefit is achieved because the structural elevation is fabricated from two complimentary panel modules capable of accommodate off panel module grid lengths of structural elevations, because the one panel module can overlap its adjacent alternating panel module its full width, therefore closing the end space of the elevation run.

Providing the panel modules as standard type, light-weight, one man handling, pre- manufactured modules which is because of the overlap function predominately "Non Plot Specific" could be a great benefit to the building industry.

The ability to produce such standard panel modules with insulation on one side and clear service zones on the opposite side, could allow a number of practices to continue with improved efficiencies. One such practice/end user which may benefit is factory produced, open panel timber frame. The ability for them to cross over from elevations of non insulated panel fabrication to extended elevations of insulated panel construction, which falls more in line with what is recognised as MMC (Modern Methods of Construction) without a huge cost implication may be a desirable goal for them, by for example:

• Using a predetermined number of standard, pre-insulated modules, as outlined above, coupled to predetermined deep profiled ring-beam/header and specific profiled lower- plate means a longer off-grid panel elevation may be fabricated from one side without now having to turn over/rotate the newly fabricated panel elevation to accommodate insulation, vapour control layers, would remove the need for an expensive turning machine

• Utilising a ring-beam/header reduces design engineering and drawing bottlenecks by distributing load transfer from above throughout the wall panelled elevation fabrication

• Making use of a calibrated/pattern ring-beam/header showing type and positions of panel modules in wall panelled elevation fabrication

• Positioning within the ring-beam/header window/doorway spans and fixing blocks/stops for panel modules to be sited either side

• Predetermining the structural grid of the panelled elevation fabrication set within the ring-beam/header can outline the panels performance/calculation in terms of, for example, racking/wind resistance and the ring-beam/header in terms of load capacity

• Providing a ring-beam/header member which automatically form lintel section above window doorways and can be re-enforced by coupling to a further ring-beam above as described in our co-pending International patent referred to above

• Attaching re-enforcing components/structural sheet to ring-beam/header when they spans openings

• Draping a breather membrane from the ring-beam/header during construction

A further practice/end user that may find benefits using the off grid panel module system is current building sites with brick and block building programmes. The campaign for more greener/sustainable building products, may result in them switching to alternative building systems with alien building programmes to which they are not accustomed. The panel module system above, coupled to ring-beam/ header members may provide them with near identical building programmes, currently in use. Because the panel modules can be supplied to site as stocked packs, which are predominately not plot specific (similar to the current block supply model) may enable their current carpenters to assemble the panel modules coupled to specific ring-beam/header members into for example wall panelled elevations. The wall elevations may then support ring-beamed joist and roof stages independently, or in conjunction with external cladding, for example brickwork. This "ground up" construction method may be incorporated within current scaffold and bricklaying lifts/stages, for example, a two storey dwelling may be constructed as follows:

Stage 1 , Installation of - sole-plates - modules/ring-beam/headers into all ground floor panelled wall elevations - brace wall panelled elevations

Stage 2, brickwork layed to 1.5 m

Stage 3, scaffold 1^st lift

Stage 4, installation of safety bags

Stage 6, installation of ring-beamed joist set and weather deck floor board.

Stage 7,installation of - modules/ring-beam/headers into all 1^st floor panelled elevations - brace wall panelled elevations.

Stage 8, brickwork layed to 3m.

Stage 9 scaffold 2^nd lift.

Stage 10, brickwork layed to roof eaves level

Stage 11, scaffold 3^rd lift.

Stage 12, installation of safety bags

Stage 13, installation of roof trusses or panel modules forming roof elevations replacing the ring-beams and sole-plates with ridge and wall/head plate members.

Stage 14, felt and batten roof.

The ring-beam/header members may be supplied by current engineered joist/truss suppliers, because of their current assembly methods (long sections) and structural calculation service.

The "non plot specific "standard panel module fabrications may be mass produced and supplied to site or to factories to then be assembled into bespoke panelled elevations.

The supply of the one man handling, alternating/overlapping panel modules to be assembled in-situ, on/off site, may sanction a production facility for the ring- beam/header to be made plot specific, by applying to ring-beam/headers all panel module/window/doorway configurations and associated references/components to permit the systematically construction of specific elevations in the factory or on site.

The panel modules are generally available as either, a support/racking type module, or as an overlap/racking type module. The ring-beam/headers are generally available as lengths of boxed sections of which the spaced apart support/racking panel modules connects too, forming a multiple portal action utilising three fixings lines within the panel module height, two rows through the sheet/board material into the ring-beam/ header and one row into the upper soleplate, whilst the overlap type panel modules closes off/spans/overlaps the space between the spaced apart support/racking panel modules. The overlap/racking panel module utilises two fixing lines, both rows are through their sheet/board material, one into the head-plate and one row into the lower sole-plate, further fixings are made through the vertical rails into the alternating vertical rail behind belonging to the support module, increasing stiffness of panelled elevation. The overlap or sliding feature enables off grid elevations of panel modules to be assembled.

The panel modules may also for example be utilised as roof members to form a panelled roof elevation to support felt, batten and tiles. A number of spaced apart support/racking panel modules extend lengthwise spanning from a ridge member at their upper region down and over a wall/head-plate at their lower region -forming the eaves. The overlap panel modules have a seat cut at their lower region and extend lengthwise spanning between the lower region of the ridge at the overlap modules upper region down to and on top of the wall/head-plate at their lower region. The overlap or now more appropriately the under-lap panel module, again links/spans the spaced apart support panel modules together by fixing through their rail components into alternating rail components of the support panel module which is now position on top.

The seat cuts at the overlap/under-lap panel modules lower region acts as a multiple stop (anti slip) for the combined roof panelled elevation.

The overlap/under-lap panel module likewise has a overlap/sliding facility for off grid roof panelled elevations. Both modules again can incorporate multiple fixings through their sheet/board material but now into wall/head-plates/ridge members and purlin members if applicable. An additional seat cut can be incorporated within the smaller rail components within the support/racking panel module at the wall/head -plate position. The modules may also be position horizontally/parallel to the ridge/wall/head-plate members.

According to another aspect of the invention there is provided a structural panel system comprising a plurality of panel modules extending between upper and lower components, wherein adjacent panel modules overlap and the extent of the overlap is adjustable whereby the length of the panel system can be adjusted.

In this way a panel system of any desired length can be produced from standard panel modules.

The structural panel system described herein may be employed with the ring beam system described in our International patent application No. WO 2006/109041. The panel system may be formed off-sit or on site to form the walls and, optionally roof of a timber frame building constructed using the ring beam system.

Embodiments of the invention will now be described with reference to the accompanying drawings in which: -

Figure 1 shows the proposed external side of the supporting/racking panel module without insulation

Figure 2 shows an end view of the panel module in fig 1

Figure 3 shows a view from above of panel module in fig 1 and 2

Figure 4 shows the proposed internal side of the overlap panel module without insulation

Figure 5 shows an end view of the panel module in fig 4 Figure 6 shows a view from above of panel module in fig 4 and 5

Figure 7 shows an end view of panel module in fig 1 , end profile of ring-beam/header member, and end profile of sole-plate

Figure 8 shows a view of a partial fabrication of a panelled wall elevation utilising three spaced apart panel modules of fig 1 viewed from the opposite side, attached to a ring-beam/header member at their upper region and upper member of sole-plate at their lower region

Figure 9 shows an end view of fig 8 as well as end view of overlap panel module shown in fig 5 prior to attachment to partial wall panelled elevation of fig 8

Figure 10 shows attachment of three overlap modules of fig 4 fixed to the edge of head-plate at their upper region and edge of lower soleplate in their lower region and through their vertical rails into vertical rail component of support/racking panel module behind -this is the predominate assembly method of module build up in an external wall panelled elevation

Figure 11 shows from above a section through a standard assembly/build up of modules of fig 1 ,4 without head-plate and ring-beam/header member 4 forming wall panelled elevation of fig 10

Figure 12 shows from above and again without head-plate and ring-beam/header member, a panel module assembly into a wall panelled elevation showing an overlap module overlapping/sliding over a support/racking panel module

Figure 13 shows a view of the proposed internal side of a ring-beam/header member without head-plate with window/doorway block and incorporating spaced apart blocks of rigid insulation boards to position/locate the support/racking panel module on either side

Figure 14 shows a view of a proposed internal load bearing/party wall assembly utilising single skins of overlap board about to be coupled to a support/racking panel module of fig 1 which is about to be coupled to sole-plate and ring-beam/header member to allow a reduce wall depth

Figure 15 shows a view from above of module assembly in fig 14 without head-plate and ring-beam/header member and sole-plate

Figure 16 shows a view from above of a partition module and overlap board layout without head-plate and sole-plate

Figure 17 shows a view of a proposed internal partition assembly utilising partition module made from 16a, 16b, head 17b and sole-plates 17c, coupled to single skin overlap boards 17a

Figure 18 shows a compression gap 18a between head-plate 17b and top of stud members 16b of partition module 16a/ 16b to allow partition to be installed preloading of roof for with tiles for example

Figure 19 shows the module in figs 1, 2 and 3 as a roof member with a plumb cut at its upper and lower region

Figure 20 shows the overlapping panel module in figures 4, 5 and 6 as a roof member with a seat cut at its lower region, and

Figure 21 shows a roof panelled elevation utilising a number of roof members in fig 19 and roof members in fig 20

A support/racking panel module 1 shown in figs 1 , 2 and 3 is formed from a structural sheet material Ia of, for example 9mm OSB 600mm in width and 2327mm in length. The vertical rails Ic are, for example timber 38mm x 63mm CLS , 2327mm in length. The vertical rails Ib are, for example 38mm x 29mm timber, 2015mm in length. The vertical rails Ic may be faced fixed through sheet Ia into rails Ib.

An overlap/racking panel module 4 shown in figs 4, 5 and 6 is formed from a sheet material 4a of, for example 9mm OSB ,594mm in width and 2400mm in length. The sheet Ia is positioned and fixed into a rebated rail 4b along each side. The rebated rail 4b is, for example timber 38mm x 63mm CLS, 2400mm in length with a continuous rebate of, for example 22mm 9mm.

A panel system employing the panel modules l,4of figs 1-6 to construct a structural elevation, for example a wall is shown in Figures 7 to 12.

As shown in Figures 7,8, spaced apart support/racking panel modules 1 of fig 1 extend vertically and are connected to horizontally extending components at the upper and lower ends to form a multiple portal elevation. The upper component may be a ring beam/header 7 and the lower component may be a sole plate 8. Three fixings lines within the module height are used, two rows through the sheet/board material Ia into the ring-beam/header member 7a and one row into the upper soleplate member 8d.

A shown in Figures 9,10, overlap/racking panel modules 4 of fig 4 extend vertically ad are connected to the upper and lower components 7,8 between the support/racking panel modules 1 to close off the portals between the panel modules 1. Two fixing lines within the module height are used, both rows are through the sheet/board material 4a, one into the head-plate 7b and one row into the lower sole-plate member 8c. Further fixings are made through the vertical rails 4b into the alternating vertical rails Ic behind belonging to the adjacent support panel module 1 increasing stiffness of wall panelled elevation fig 10.

The spacing between the panel modules 1 may be uniform so that the edges of the panel modules 4 overlap and are secured to the edges of the panel modules 1 as shown in Figure 11. Alternatively, a reduced spacing may be provided between two panel members 1 as shown in Figure 12, and the overlapping panel module 4 can slide over the edges of the panel modules 1 to align with the side edge of one of the panel modules enabling an off grid panel module elevation to be assembled from standard support/racking and overlap/racking panel modules 1 ,4. The ring-beam/header member 7a is formed from, for example lengths of 18mm x 40mm plywood, doubled up to form top and bottom rails 7h and sandwiched between 18mm and 9mm plywood/OSB sheets/boards 7g,7j

The ring-beam/header member 7a fig 13 may incorporate window/doorway blocks 7e spaced apart blocks of rigid insulation boards 7f to position/locate the support/racking module of fig 1 on either side.

The ring-beam/header member 7a would now be plot specific, further configurations and associated references points/components may be added to permit the systematical construction of specific elevations in the factory or on site, for example blocks of rigid insulation boards 7f may position/locate the support/racking panel modules 1 on either side, as well as indicating overlap position of overlap panel modules 4

Predetermining the structural grid and in-turn structural performance of the fabricated panelled wall elevation, within the ring-beam/header member 7a, from testing data will provide software to approve the calculations of the fabricated panelled elevation fig 10 in terms of, for example, racking/wind resistance and reference the ring- beam/header 7a in terms of load capacity from take- off software tables.

The ring-beam/header member 7a will automatically form lintel section above window doorways and can be re-enforced by coupling to a further ring-beam above, attaching additional structural components to the side or inserted within.

The ring-beam/header member may also attach and drape a breather membrane from the proposed external side during construction to drop over the assembled panelled elevation below, providing protection.

Referring now to Figures 14 and 15, application of the structural panel system to an internal load bearing wall is shown. In this embodiment, the overlap panel module 4 is replaced an overlap panel module 17a comprising sheet material only that can overlap/slide relative to the other panel to accommodate different lengths of wall elevation. Referring now to Figures 16 to 18, application of the structural panel system to an internal partition assembly is shown in which a compression gap 18a is provided at the upper end by allow to allow the partition to be installed before loading a roof.

The panel modules of figs 1 -6 may also be adapted/utilised as roof members fig 19,20 to form a panelled roof elevation fig 21 to support felt, batten and tiles (not shown). A number of spaced apart support/racking roof panel modules fig 19 extend lengthwise spanning from a ridge member 21a at their upper region down and over a wall/head- plate 7b at their lower region -forming the eaves. The overlap roof panel modules fig 20 have a seat cut at their lower region and extend lengthwise spanning between the lower region of the ridge 21a at the overlap roof panel modules upper region down to and on top of the wall/head-plate 7b at their lower region.

The overlap or now more appropriately the under-lap roof panel module, fig 20 again links/spans the spaced apart support roof panel modules fig 19 together by fixing through their rails 4b into the predominately alternating rails Ic of the support roof panel module which is now position on top. The seat cuts at the overlap/under-lap roof panel modules fig 20 lower region acts as a multiple stop (anti slip) for the combined roof panelled elevations fig 21.

The overlap/under-lap roof panel module figs 19,20 likewise has an overlap/sliding facility for off grid roof panel module elevation construction. Both modules again can incorporate multiple fixings through their sheet/board Ia, 4a material into wall/head- plates 7b/ridge 21a members and purlin members if applicable. An additional seat cut can be incorporated within the smaller rail components Ic within the support/racking roof panel module fig 19 at the wall/head -plate 7b position. The modules may also be position horizontally/parallel to the ridge 21a/wall/head-plate 7b members.

Other features, benefits and advantages of the invention include

Pre-insulated panel modules, coupled to predetermined deep profiled ring- beam/header member and specific profiled lower sole-plate provides a longer off-grid panel elevation which may be fabricated from one side without now having to turn over/rotate the newly fabricated panel elevation Utilising a ring-beam/ header member reduces design engineering and drawing bottlenecks by distributing load transfer from above throughout the fabrication of the panelled elevation Making use of a calibrated/plot specific, ring-beam/header member showing type/positions of panel modules in panelled fabrication

Positioning within the ring-beam/header member window/doorway spans and fixing blocks/stops for panel modules to be sited either side

Predetermining the structural grid of the panelled elevation fabrication set within the ring- beam/header member can outline the structural elevations performance/calculations in terms of, for example, racking/wind resistance and the ring-beam/header in terms of load capacity Providing a ring-beam/header member which automatically form lintel section above window doorways and can be re-enforced by coupling to a further ring-beam above if applicable Attaching re-enforcing components/structural sheet to ring-beam/header member when they span openings

Draping a breather membrane from the ring-beam/header member during construction The structural elevations may then support ring-beamed joist and roof stages independently

The "non plot specific "standard panel module fabrications may be mass produced and supplied direct to site or to factories to then be pre-assembled into bespoke panelled structural elevations.

The supply of one man handling, supporting and overlapping panel modules to be assembled in-situ, on/off site, may sanction a production facility for ring-beam/header members to be made plot specific, by applying to the ring-beam/headers all panel module/window /doorway/hanger positions and configurations and associated references/components to permit the systematically construction of specific structural elevations in the factory or on site.

The panel modules are generally available as either, a support/racking type module, or as an overlap/racking type module. The ring-beam/headers are generally available as lengths of boxed sections of which the spaced apart support/racking panel modules connects too, forming a multiple portal action utilising three fixings lines within the panel module height , two rows through the sheet/board material into the ring- beam/header member and one row into the upper soleplate member

The overlap/racking type panel modules closes off /spans/slides/ overlaps the space between the spaced apart support/racking panel modules. The overlap/racking panel module utilises two fixing lines, both rows are through the sheet/board material, one into the head-plate and one row into the lower sole-plate member, further fixings are made through the vertical rails into the alternating vertical rails behind belonging to the support panel module, increasing stiffness of the panelled elevation.

The panel modules may be utilised as roof members to form a panelled roof elevation to support felt, batten and tiles.

A number of spaced apart support/racking panel modules extend lengthwise spanning from a ridge member at their upper region down and over a wall/head-plate at their lower region -forming the eaves.

The overlap panel modules have a seat cut at their lower region and extend lengthwise spanning between the lower region of the ridge at the overlap panel modules upper region down to and on top of the wall/head-plate at their lower region.

The overlap or now more appropriately the under-lap panel module, again links/spans the spaced apart support panel modules together by fixing through their rails into the alternating rails of the support panel module which is now position on top

The seat cuts at the overlap/under-lap panel modules lower region acts as a multiple stop (anti slip) for the combined roof panelled elevations.

The overlap/under-lap panel module likewise has a sliding facility for off grid roof panel module constructed elevations.

Both roof panel modules again can incorporate multiple fixings through their sheet/board material into wall/head-plates/ridge members and purlin members if applicable An additional seat cut can be incorporated within the smaller rail components within the support/racking panel module at the wall/head -plate position.

The panel modules may also be position horizontally/parallel to the ridge/wall/head- plate members

Internal load bearing/party wall assembly utilising support/racking panel modules, coupled to single skins of overlap board to reduce wall depth fixed to sole-plate and ring-beam/header member

Internal partition wall panel utilising head and sole-plates, coupled to partition panel modules and single skin overlap boards

A compression gap between head-plate and top of stud members of partition panel module allow for pre-fitting of partitioned wall elevations prior to loading of roof - compression gap is closed when roof is loaded

Two type panel module system constructing structural elevations of any length which can accommodate off grid dimensions by incorporating an overlap/sliding facility with a number of standard type, light weight, one man handling, pre-manufactured panel modules which can facilitate scale-able volume manufacturing which is predominately "Non Plot Specific"

Standard sized panel modules are provided with insulation on one side/both sides or insulation on one side and clear service zones on the opposite side

The factory assembled ring-beam/header section provides a "plot specific" hardware "blue print" giving precise locations for fixing connecting panel modules, other components and defining the key features, such as door and window positions etc.

Claims

1. A structural panel system comprising a plurality of overlapping panel modules wherein adjacent panel modules are different.

2. A structural panel system according to claim 1 wherein one panel module is utilised as a load and racking panel module, and the adjacent panel module is used as a binding and racking panel module.

3. A structural panel system according to claim 2 wherein the two panel modules are predominately installed in an alternating, overlapping sequence to each other .

4. A structural panel system according to claim 3 wherein the overlap sequence predominately allows for the panel modules to be face attached with vertical lines of fixings at the alternating overlap.

5. A structural panel system according to claim 2 or claim 3 wherein horizontal fixing of the panel modules is at different levels in their upper and lower regions to different components.

6. A structural panel system according to claim 5 wherein the two panel modules have complimentary profiles that enable them to overlap/slide over each other, but still fix to their components above and below to complete any structural elevation length using standard sized panel modules.

7. A structural panel system according to any preceding claim wherein the panel modules form a wall elevation.

8. A structural panel system according to any of claims 1 to 6 wherein the panel modules form a roof elevation.