BUILDING SYSTEM

SYSTEME DE CONSTRUCTION

English Abstract

A building system and/or an erected building is based
on a kit of parts including portable, prefabricated wall
sections of a width of 4 feet and a height dependent on the
room height desired. The sections include a metal frame
having parallel members to be vertical in the erected
building. These members are provided with a thermal break
along their length. The thermal break may also serve as a
water resistant connector between sections. Sections are
aligned with abutting side edges to form walls of the
building. Parallel abutting vertical members of adjacent
sections form composite load bearing members for roof
trusses which may be spaced apart by the width of a wall
section. A hinged template for interior partitions may be
provided which can be folded for transport. Ceiling panels
may be connected to roof trusses through an adjustable
linkage so that compensation for movement of the roof
trusses is possible.

French Abstract

Un système de construction et/ou un bâtiment érigé est basé sur un ensemble de composantes comprenant des sections murales préfabriquées transportables d'une largeur de 4 pieds et d'une hauteur dépendant de la hauteur de pièce souhaitée. Les sections ont une ossature métallique comportant des éléments parallèles qui seront verticaux dans le bâtiment érigé. Ces éléments sont munis d'un isolant thermique sur leur longueur. L'isolant thermique peut aussi servir de connecteur hydrofuge entre les sections. Les sections sont alignées avec les bords latéraux en aboutement pour former les murs du bâtiment. Les éléments verticaux parallèles aboutés des sections adjacentes forment des éléments porteurs composites pour les fermes de toiture qui peuvent être espacées de la largeur d'une section murale. Un gabarit articulé pour les cloisons intérieures peut compléter le système et il est repliable pour fins de transport. Des panneaux de plafond peuvent être raccordés aux fermes de toiture au moyen d'éléments de liaison réglables de sorte que le mouvement des fermes de toiture peut être compensé.

Claims

EMBODIMENTS OF THE INVENTION IN WHICH EXCLUSIVE PROPERTY AND
PRIVILEGE IS CLAIMED ARE AS FOLLOWS:

1. A building system for a building having at least one
room therein, the system comprising:

a plurality of portable prefabricated wall sections
each of similar size to another to form an exterior
wall when aligned with a side edge of one section
abutting a side edge of an adjacent section, the height
of each section, when erected, generally corresponding
to the height of said room, and each wall section
including a rigid peripheral metal frame and a wall
panel coextensive with the frame and attached thereto;

the rigid peripheral frame comprising a pair of metal
frame members, one pair located to each side edge of
said panel member, the frame member of each pair having
a thermal break therebetween, the frame members, when
the section is erected, being vertical, the pair of
frame members of one of the wall sections being
connectable to the pair of frame members of an adjacent
wall section to form a composite load bearing member.

2. A building system as claimed in claim 1 in which each
wall section is four feet wide.

3. A building system for a building having at least one
room therein, the system comprising:

a plurality of portable prefabricated wall sections
each of similar size to another to form an exterior
wall when aligned with a side edge of one section
abutting a side edge of an adjacent section, the height
of each section, when erected, generally corresponding
to the height of said room, and each wall section


16


including a rigid peripheral metal frame and a wall
panel comprising a slab of foam plastics material
coextensive with the frame and attached thereto;

the rigid peripheral frame comprising a pair of
elongate metal C-sections, one pair located to each
side edge of said slab, the mouths of the metal
C-sections opening in the same direction directed
inwardly of the frame and accommodating parallel edge
portions of said slab, the steel C-sections, when the
section is erected, being vertical, the paid of metal
C-sections of one wall section being connectable to the
pair of metal C-sections of an adjacent wall section to
form a composite load bearing member.

4. A building system as claimed in claim 3 in which each
wall section is four feet wide.

5. A building system as claimed in claim 4 in which the
metal is steel.

6. A building system as claimed in claim 3 in which each
pair of metal C-sections are latched together and spaced
apart by an elongate plastic C-section latch, inturned
flanges of the metal C-sections and the plastic latch
C-section being interengagable, elongate spacing ribs being
provided on the plastic latch C-section to bias the metal
C-sections apart.

7. A building system as claimed in claim 6 in which the
spacing ribs of one of the plastic latches between metal
C-sections at one side edge of the slab are short to leave an
open channel between the metal C-sections, and the spacing
ribs of the other of the plastic latches between metal
C-sections at the other side edge of the slab are extended as

17


a spline outwardly of the metal C-sections at said other
side edge and to project into the channel between C-sections
of an abutting wall section.

8. A building system as claimed in claim 7 in which the
spline is hollow and is provided with a reinforcing rib to
be located generally on a line of abutment between wall
sections.

9. A building system as claimed in claim 8 in which the
spline, when uncompressed, has a bulge in its thickness to
form a firm water resistant seal between wall sections.

10. A building system as claimed in claim 1 including
connection means for connecting the wall section together.

11. A building system as claimed in claim 10 in which the
connection means includes means for progressively tightening
the wall sections together.

12. A building system as claimed in claim 11 in which the
connection means comprises a plate hinged to at least one
surface of a frame member to pivot in a plane flush with
said one surface, the plate having a slot open at one end to
engage a projections on an adjacent wall section, the slot
being angled to draw the wall sections together when the
plate is pivoted in one direction with the projection
engaged in the slot.

13. A building system as claimed in claim 1 in which a
cutout region is provided in at least one of the wall
sections for insertion of a member of the group consisting
of doors and windows.

18


14. A roof truss including purlins hinged to the roof truss
and movable between a transport position in which they lie
generally parallel to the plane of the truss and an in-use
position in which they lie at right-angles to the plane of
the roof truss.

15. A roof truss comprising a pair of symmetrical metal
frames each having the shape of a right angled triangle to
abut one another whereby the hypotenuse sides for roof
rafters, corresponding first sides form a vertical truss
tie, and corresponding second sides are aligned as a
composite truss chord for ceiling rafters; means to connect
the frames and purlins hinged to the roof rafters to move
between a folded position to the roof rafter for transport
and an open position flush with a roof plane.

16. A building system as claimed in claim 1 including a
roof truss including purlins hinged to the roof truss and
movable between a transport position in which they lie
generally parallel to the plane of the truss and an in-use
position in which they lie at right-angles to the plane of
the roof truss.

17. A building system as claimed in claim 20 including a
roof truss comprising a pair of symmetrical metal frames
each having the shape of a right angled triangle to abut one
another whereby the hypotenuse sides for roof rafters,
corresponding first sides form a vertical truss tie, and
corresponding second sides are aligned as a composite truss
chord for ceiling rafters; means to connect the frames and
purlins hinged to the roof rafters to move between a folded
position close to the roof rafter for transport and an
unfolded position for attachment of a roof.

19
18. A building system as claimed in claim 3 including at
least one roof truss; and support means to support the roof
truss between composite load bearing members of an opposed
pair of exterior walls, the support means comprising a lug
extending downwardly from each end region of the roof truss;
and a U-shaped bracket having a web and two legs, the web
being adapted to extend across the thickness of the wall
section and one of the pairs of metal C-sections and each
leg of the bracket being attachable to metal C-sections of
the composite load bearing member of adjacent wall sections;
and each of the lugs being supportable on and attachable to
the U-shaped bracket.

19. A building system as claimed in claim 18 in which the
web of the U-shaped bracket is provided with a pair of
downwardly directed prongs to locate the bracket with
respect to metal C-sections of one of the composite load
bearing members.

20. A building having at least one room therein,
comprising:

a plurality of portable prefabricated vertical wall
sections each of similar size to another forming an
exterior wall with a side edge of one section abutting
a side edge of an adjacent section, the height of each
section, generally corresponding to the height of said
room, and each wall section including a rigid
peripheral metal frame and a wall panel coextensive
with the frame and attached thereto;

the rigid peripheral frame comprising a pair of metal
frame members, one pair located to each side edge of
said panel member, the frame member of each pair having
a thermal break therebetween, the pair of frame members




of one of the wall sections being connectable to the
pair of frame members of an adjacent wall section to
form a composite load bearing member.

21. A building system as claimed in claim 24 in which each
wall section is eight feet high and four feet wide.

22. A building having at least one room therein,
comprising:

a plurality of portable prefabricated vertical wall
sections each of similar size to another forming an
exterior wall, a side edge of one section abutting a
side edge of an adjacent section, the height of each
section, generally corresponding to the height of said
room, and each wall section including a rigid
peripheral metal frame and a wall panel comprising a
slab of foam plastics material coextensive with the
frame and attached thereto;

the rigid peripheral frame comprising a pair of
elongate metal C-sections, one pair located to each
side edge of said slab, the mouths of the metal
C-sections opening in the same direction directed
inwardly of the frame and accommodating parallel edge
portions of said slab, the pair of metal C-sections of
one wall section being connectable to the pair of metal
C-sections of an adjacent wall section to form a
composite load bearing member.

23. A building as claimed in claim 20 in which each wall
section is four feet wide.

24. A building system as claimed in claim 23 in which the
metal is steel.

21


25. A building as claimed in claim 23 in which the metal
C-sections of the spacing ribs of one of the plastic latches
between metal C-sections at one side edge of the slab are
short to leave an open channel between the metal C-sections
and the spacing ribs of the other of the plastic latches
between metal C-sections at the other side edge of the slab
are extended as a spline outwardly of the metal C-sections
at said other side edge and to project into the channel
between C-sections of an abutting wall section.

26. A building as claimed in claim 25 in which the spline
is hollow and is provided with a reinforcing rib to be
located generally on a line of abutment between wall
sections.

27. A building as claimed in claim 26 in which the spline,
when uncompressed, has a bulge in its thickness to form a
firm water resistant seal between wall sections.

28. A building as claimed in claim 20 including connection
means progressively tightening the wall sections together
comprising a plate hinged to at least one surface of a frame
member to pivot in a plane flush with said one surface, the
plate having a slot open at one end to engage a projection
on an adjacent wall section, the slot being angled to draw
the wall sections together when the plate is pivoted in one
direction with the projection engaged in the slot.

29. A building as claimed in claim 20 including at least
one roof truss supported by support means between composite
load bearing members of opposed exterior walls.

30. A building as claimed in claim 29 in which the support
means comprises a lug extending downwardly from each end
region of the roof truss; and a U-shaped bracket having a

22

web and two legs, the web being adapted to extend across the
thickness of the wall section in the region of one of the
pairs of metal C-sections and each leg of the bracket being
attachable to a metal C-section of the composite load being
member of adjacent wall sections; and each of the lugs being
supportable on and attachable to the U-shaped bracket.

31. A building as claimed in claim 30 in which the web of
the U-shaped bracket is provided with a pair of downwardly
directed prongs to locate the bracket with respect to metal
C-sections of one of the composite load bearing members.

32. A building system for a building having at least one
room therein, the system comprising:

a plurality of portable prefabricated wall sections
each of similar size to another to form an exterior
wall, a side edge of one section abutting a side edge
of an adjacent section, the height of each section,
when erected, generally corresponding to the height of
said room, and each wall section including a rigid
peripheral metal frame and a wall panel coextensive
with the frame and attached thereto;

the rigid peripheral frame comprising a pair of metal
frame members, one pair located to each side edge of
said panel member, the frame member of each pair having
a thermal break therebetween, the frame members, when
the section is erected, being vertical, the pair of
frame members of one of the wall sections being
connectable to the pair of frame members of an adjacent
wall section to form a composite load bearing member;

roof truss supported by support means between composite
load bearing members of opposed exterior walls; and

23


a plurality of ceiling panels each one of which has a
width similar to the width of the wall sections.

33. A building system as claimed in claim 32 in which the
roof trusses are provided with a guide track along a lower
chord member thereof to support opposed edges of ceiling
panels located therein, means being provided to provide
compensatory adjustment of the track with respect to said
lower chord member on any vertical movement of said chord.

34. A building system as claimed in claim 33 in which the
track has a T-section, the vertical leg of the T lying to
the side of the cross member of one of the trusses and being
connectable to respective ceiling panels, and said T-member
being connectable to said lower chord member through a
linkage allowing limited movement therebetween.

35. A building having at least one room therein,
comprising:

a plurality of portable prefabricated vertical wall
sections each of similar size to another to forming an
exterior wall, a side edge of one section abutting a
side edge of an adjacent section, the height of each
section, when erected, generally corresponding to the
height of said room, and each wall section including a
rigid peripheral metal frame and a wall panel
coextensive with the frame and attached thereto;

the rigid peripheral frame comprising a pair of metal
frame members, one pair located to each side edge of
said panel member, the frame member of each pair having
a thermal break therebetween, the frame members, when
the section is erected, being vertical, the pair of
frame members of one of the wall sections being

24


connectable to the pair of frame members of an adjacent
wall section to form a composite load bearing member;

roof truss supported by support means between composite
load bearing members of opposed exterior walls; and

a plurality of ceiling panels each one of which has a
width similar to the width of the wall sections.

36. A building as claimed in claim 35 in which the roof
trusses are provided with a guide track along a lower chord
member thereof supporting opposed edges of ceiling panels
located therein, means being provided to provide
compensatory adjustment of the track with respect to said
lower chord member on any vertical movement of said chord.

37. A building as claimed in claim 36 in which the track
has a T-section, the vertical leg of the T lying to the side
of the cross member of one of the trusses and being
connectable to respective ceiling panels and said T-member
connected to said lower chord member through a linkage
allowing limited movement therebetween.

38. A building system for a building having at least one
room therein, the system comprising:

a plurality of portable prefabricated wall sections
each of similar size to another to form an exterior
wall when aligned with a side edge of one section
abutting a side edge of an adjacent section, the height
of each section, when erected, generally corresponding
to the height of said room, and each wall section
including a rigid peripheral metal frame and a wall
panel coextensive with the frame and attached thereto;




the rigid peripheral frame comprising a pair of metal
frame members, one pair located to each side edge of
said panel member, the frame member of each pair having
a thermal break therebetween, the frame members, when
the section is erected, being vertical, the pair of
frame members of one of the wall sections being
connectable to the pair of frame members of an adjacent
wall section to form a composite load bearing member;
and

a floor platform.

39. A building system as claimed in claim 38 in which
tracking is provided to define a pattern for interior
partitions, the tracking comprising track members being
connected one to another to be hingeable between a folded
position in which they lie closely together and an unfolded
position defining said pattern, the tracking being
attachable to the floor platform in the unfolded position.

40. A building system as claimed in claim 39 in which the
tracking includes a removable spacer at predetermined
doorway locations.

41. A building system as claimed in claim 39 including
interior partition units, lower edges of which are locatable
in said tracking in its unfolded position, the partition
units comprising gypsum cement board panels sandwiched about
a core panel of stiff foamed plastic or metal frame members.

42. A building having at least one room therein,
comprising:

a plurality of portable prefabricated wall sections
each of similar size to another to form an exterior

26


wall with a side edge of one section abutting a side
edge of an adjacent section, the height of each
section, when erected, generally corresponding to the
height of said room, and each wall section including a
rigid peripheral metal frame and a wall panel
coextensive with the frame and attached thereto;

the rigid peripheral frame comprising a pair of metal
frame members, one pair located to each side edge of
said panel member, the frame member of each pair having
a thermal break therebetween, the frame members, when
the section is erected, being vertical, the pair of
frame members of one of the wall sections being
connectable to the pair of frame members of an adjacent
wall section to form a composite load bearing member;
and

a floor platform.

43. A building as claimed in claim 42 in which tracking is
provided to define a pattern for interior partitions, the
tracking comprising track members being connected one to
another to be hingeable between a folded position in which
they lie closely together and an unfolded position defining
said pattern, the tracking being attachable to the floor
platform in the unfolded position.

44. A building as claimed in claim 43 in which the tracking
includes a removable spacer at predetermined doorway
locations.

45. A building as claimed in claim 43 including interior
partition units, lower edges of which are locatable in said
tracking in its open position, the partition units

27


comprising gypsum cement board panels sandwiched about a
core panel of stiff foamed plastic or metal spacers.

Description

CA 02204~9~ 1997-0~-0~


This invention relates to designs, materials, and
procedures to create high-quality low-cost buildings which
are quick and easy to erect. The buildings comprise
manufactured components which may be assembled rapidly by
unskilled labour, typically within three to five days,
yielding a building that is comparable in appearance and
superior in quality to a building produced by traditional
building methods.

There is a pressing world-wide need for housing. The
present demand is for 250 million units. Traditional
building methods will never address this need. A
construction method is required that is efficient and
economical, which produces housing that is acceptable and
durable.

Much of this housing is required in remote areas, with
extremes of climate, lack of skilled labour, and no
infrastructure. Typically, this would be much of the Third
World, and Indian communities in northern Canada. While
these communities are cut-off by vast distances, television
makes them aware of the standards of living in the rest of
the world, a standard to which they aspire.
Thus they will not be satisfied by an inferior product.

There is an attempt to address this market by
manufactured housing. Some of the present offerings are
technologically advanced but are extremely inflexible; they
cannot be adapted to individual wishes. Some of these
buildings also have a strange space-age appearance which is
not culturally acceptable. At a lower level of technology
more flexibility may be achieved, but at this level
efficiency and economy are reduced, so there is little
advantage over traditional construction methods.

CA 02204~9~ 1997-0~-0~



Traditional construction methods for the provision of
frame housing, whether utilizing wood or metal studs,
usually involves delivery of raw building materials to the
building site and subsequent building of open work frames
for each wall. The open work frames are then, before or
after erection, provided with cladding. Insulation is
usually provided after erection either in recesses between
studs and/or as foam panels applied flush onto the frame.
Vapour barrier is also applied independently after erection
of the frames. Electrical wiring runs to the exterior of
the vapour barrier into which cuts must be made for socket
access. In all the erection of a building from raw
materials is a skilled job for a craftsman.

Various prefabricated buildings have been proposed.
Where these are reasonably low cost they tend to be "fit-
together" units such as half houses which tend to be large
and require specialized transport. Often such units exceed
the sizes allowed on the roads and special provisions for
their transport must also be made.

The basic philosophy of this invention is to
manufacture building components which are so
technologically advanced they reduce to a minimum the tasks
that are needed to assemble them on-site. Thus all
electrical and plumbing work, all measuring and cutting,
fitting and testing, are done and checked in the factory.
Despite this, the system offers considerable flexibility of
lay out. Components may be taken apart and reused to create
new buildings of different size, form, and function.

The building has a higher insulation level (R-30) and
is lighter than any other building of similar size, so the
components are easy to transport. They may be assembled by
an unskilled staff, with no left-over waste to dispose of.

CA 02204~95 1997-0~-0~



According to the invention there is provided a building
system for a building having at least one room therein, the
system comprising: a plurality of prefabricated wall
sections each of similar size to another to form exterior
walls when aligned with a side edge of one section abutting
a side edge of an adjacent section, the height of each
section, when erected, generally corresponding to the height
of said room, and each wall unit including a rigid
peripheral metal frame and a wall panel coextensive with the
frame and attached thereto; the rigid peripheral frame
comprising a pair of metal frame members to each side edge
of said panel member the frame members of each pair having a
thermal break therebetween, the frame members, when the
section is erected, being vertical, the pair of frame
members of one of the wall sections being connectable to the
pair of frame members of an adjacent wall section to form a
composite load bearing member. Conveniently the height of
each wall unit depends on ceiling height desired. Usually
in Canada and the United States a standard ceiling is 8
feet. Allowing for some overlap of ceiling insulation this
would entail a panel having a height of just over 8 feet,
say 8 feet and three inches. If the ceiling insulation is
very thick the height of the wall panel is correspondingly
increased and when the room height is different, the panel
height is adjusted. The panels may be four feet wide and
cutout regions may be provided in at least one of the wall
sections for insertion of a member of the group consisting
of doors and windows.

The system may include at least one roof truss; and
support means to support the roof truss between a pair of
said composite load bearing members of an opposed pair of
adjacent wall sections. The support means may comprise a
U-shaped bracket having a web and two legs, the web being
adapted to extend across the thickness of the wall unit in

CA 02204~9~ 1997-0~-0~



the region of one of the frame members and each leg of the
bracket being attachable to both of the frame members
forming the composite load bearing member; and each of the
lugs being supportable on and attachable to the U-shaped
bracket. The web of the U-shaped bracket may be provided
with a pair of downwardly directed prongs to locate the
bracket with respect to the frame members of one of the
composite load bearing members.

The system may include at least one ceiling panel
having a width similar to the width of the wall sections.

Each roof truss may be provided with a guide track
along a bottom chord thereof to support edges of adjacent
ceiling panels located therein. The track may be of a
T-section, the vertical leg of the T lying to one side of
the cross member of one of the trusses and the arms of the
T projecting horizontally.

A platform may be included having a load-bearing
perimeter to support the wall sections.

The system may include tracking to define a pattern for
interior partitions, the tracking comprising track members
being connected one to another to be hingeable between a
closed position in which they lie closely together for
transportation and an open position defining said pattern,
the tracking being attachable to the floor platform in the
open position. The tracking may include a removable spacer
at predetermined doorway locations.

The system may also include interior partition units,
lower edges of which are locatable in said tracking in its
open position, the partition units comprising gypsum cement
board panels sandwiched about a core panel of stiff foamed

CA 02204~9~ 1997-0~-0



plastic or steel framing.

Each frame member of the wall sections may comprise a
pair of elongate steel C-sections located side by side
separated by a thermal break, the mouths of the C-sections
opening in the same direction and accommodating parallel
edge portions of a wall panel. The steel C-sections may be
latched together by a snap-on elongate plastic latch also of
C-section with projections to engage with the inturned
flanges of the steel C-sections. Spacing ribs are provided
on the plastic latch C to bias the steel C-section inturned
flanges towards the inturned flanges of the plastic latch.

An elongate plastic extrusion spline member may fit
into a space between the steel C-sections.

Embodiments of the invention are described below with
reference to the accompanying drawings, in which:
Figure 1 is a pictorial representation of a structure
according to the invention showing how roof trusses are
supported by panels the structure being formed from a system
according to the invention;
Figure 2 is an illustration of how roof loads are
transferred to the perimeter framing of panels;
Figure 3 is an illustration of a detail of Figure 2;
Figure 4 shows an enlarged view of a
connector/tightener member for wall sections of a building
as shown in Figure 1;
Figure 5 illustrates a typical roof truss with a device
to support ceilings without imposing a load on partitions;
Figure 6 is a view of an embodiment of a roof truss
according to the invention;
Figure 7 is a section illustrating how composite
ceiling panels are attached to the trusses;
Figure 8 shows a typical lay out for a partition floor

CA 02204~9~ 1997-0~-0



track;
Figure 9 shows the track of Figure 8 partially folded
and collapsed for delivery;
Figure 10 is a section of a typical partition;
Figure 11 shows a detail of the edges of a wall
section;
Figure 12 shows the joining of one wall panel to
another; and
Figure 13 shows a furring channel used as a wall brace.

Figure 1 shows a general structural lay out for a
building according to the invention. Roof trusses 10
fabricated from cold-rolled steel sections sitting on wall
unit 12 which rest on a floor platform 14. The wall
sections 12 have a panel portion 22 and at least vertical
frame units 18 formed of metal and having thermal breaks in
their thickness. The spacing of the roof trusses 10 is made
equal to the width of the wall panels, typically 48 inches.
Roof trusses 10 have a heel member 16 at each end in the
form of a downwardly depending lug. The heel 16 transfers
load of the roof trusses 10 to the shoe 30 and thence to
vertical frame members 18 of the wall sections 12 and thence
to perimeter members 20 of the floor panels 14. This
involves a spacing of structural members which is greater
than the industry standard 24 inches. Although the trusses
10 should be stronger, there are half as many of them,
reducing the labour required for their installation.

By setting the trusses 10 at the same spacing as the
width of the wall sections 12, vertical loads are confined
to the perimeter framing members 18 of the wall panels, as
shown in Figure 2, and no loads are transferred to the body
of panels. The upper chord 24 and lower chord 26 of the
trusses are connected together through a heel member 16
bearing on a bent metal shoe 30 in the form of a U-bracket

CA 02204~9~ 1997-0~-0~



which laps over the wall unit 12. This shoe 30 is stiff
enough to transfer loads equally to the adjacent vertical
perimeter members 18 which together form a composite
load-bearing member 32. No loads are transferred to upper
horizontal framing members of the wall panels 34. A
stamping 28 strip bent through 90~ along its vertical axis
attaches lower chord 26 to both framing members 18 of
adjacent panels. This means that the panel requires no
internal framing. Any sort of door or window or other
opening can be accommodated without lintels, double-headers,
or cripple studs.

An enlarged view of the shoe 30 is shown in Figure 3.
Holes 36 for screws are provided in the web of shoe 30
whereby the shoe may be attached to lower chord or cross
member 26 of truss 10 and to heel member 16. Two legs 40 of
shoe 30 locate the truss on the wall panel longitudinally.
Two tabs 42 are punched out of the central area of the shoe
and project downwards as prongs. The gap between these
prongs receives the central web of a wall panel connector
which is aligned with the joint between panels and which
will be described further hereafter. This serves to locate
the truss laterally, so the combined action of the four
downward projections (legs 40 and prongs 42) from the shoe
30 serves to align the truss precisely and automatically
over the centre of the joint between the vertical frame
members 18.

The punched opening 44 of the prongs 42 takes up most
of the width of the web of the shoe 30, leaving intact two
relatively narrow strips 46 which reduces the cross-
sectional area available for heat transfer, helping toretain the thermal integrity of the building envelope.

CA 02204~9~ 1997-0~-0~



The wall sections 12 may be easily erected on either a
wooden or concrete floor platform 14 simply by abutting one
edge of one panel to an edge of another panel. Thermal
breaks which will be described in more detail hereinafter,
are provided in the thickness of the frame members 18
comprise an insulating spline 94A projecting from one edge
of one panel to engage in a channel of the adjacent edge of
an abutting section. These thermal breaks may, due to this
engagement aid in assembly of the sections. It is, of
course, important that the sections be connected together
with a consistent degree of tightness so that the resultant
building will be built on the square. For this purpose
connector/tightener means 17 as shown in Figure 4 are
provided at intervals over the height of frame members 18 of
abutting panels. Each connector/tightener member comprising
a small plate 19 having an aperture 21 therethrough. A
pivot pin 23 through the aperture protrudes from wall
section surface of frame member 18 so that the plate 19 is
pivotable to overlap the join between wall sections 12.
Plate 19 has an angled slot 25 open at a downward direction.
Slot 25 engages a pin 27 projecting from a wall section
surface of the abutting wall section 12. The angle of the
slot 25 is such that, as the plate is moved downwardly
pivoting about pivot pin 23, the pin 27 is forced into
closer proximity to pivot pin 73, and the wall sections 12
are tightened against each other.

The wall sections 12 may conveniently be set in metal
sole plates 29 on floor platform 14.

As may be seen from Figures 4 and 5 ceilings are built
up of composite panels 48 comprising a gypsum cement board
50 adhered to a foamed plastic core 52. This provides the
stiffness necessary to span across the increased distance
between roof trusses. The roof trusses 10 span across the

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entire building space from exterior wall to exterior wall.
Such long spans may generate measurable deflections when the
trusses 10 are loaded. The trusses 10 may be conventional
trusses of either wood or metal but are preferably of metal.
The trusses may in particular be as illustrated in Figure 5
which shows part of such a truss.

Members needed to interconnect trusses one to another
to ensure stability are attached to the trusses during
manufacture, so the member of discrete pieces to be handled
on the construction site is reduced to a minimum. As shown
in Figure 6, sections of purlin 37 are hinged to the top
chord of the truss 39 so they may be folded in for transport
and folded out to engage with the top chord of the adjacent
truss during erection to ensure their correct spacing.
Similarly, diagonal braces 35 are attached to the top chord
of top truss 39 by pivots, so after the truss has been
installed they may be deployed to attach to adjacent
trusses, triangulating the orthogonal array of purlins and
creating a structure of great rigidity.

Similarly, spacing member 41 may be attached to the
sides of the central vertical truss member so that during
erection they may be rotated to engage with the next truss
to preserve the spacing of the bottom members of the
trusses. Corresponding central vertical members of gable
end walls have two such spacing members with separate
pivots. Attaching these to the ad~acent truss triangulates
the gable and maintains its vertical alignment.

If the trusses 10 support a ceiling which is rigidly
attached to partitions, roof loads could then be transferred
to partitions which are not designed to sustain them. One
way to avoid this difficulty is to provide nesting ceiling
tracks which can slide within one another at the top of the

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1 0
partition to give the ceiling the capability of independent
movement. This has the disadvantage that there is a
variable gap between wall and ceiling that needs an
additional trim member to cover it.

The present invention optionally provides a sliding
connection between truss and ceiling, so ceiling and wall
remain in fixed position with respect to each other. A T-
member 54 with projecting arms 56 is attached to the bottom
chord 26 of the truss 10 extending between opposing wall
sections 12. The T-member 54 is attached to the bottom
chord 26 by a series of screws 58 engaging in slots in the
leg 57 of the T-member 56. The T-member 56 (and therefore
the ceiling) is horizontal when the truss is unloaded. As
the truss becomes loaded and the bottom chord 26 moves
downwards the screw will slide in the slot and the ceiling
supported by partitions will remain stationary, and no load
will be imposed on the partitions.

Ceiling panels 50 are installed by fitting the ceiling
panel onto a projecting flange 56 of the T-section 54, which
then supports one edge of the ceiling panel 50. The other
edge of the panel 50 is then screwed to the next T-member.
Rigid insulation 66 is attached to the "upstream" side of
the T-member.

Figure 8 shows a system according to the invention
including interior partitions 70 which may be set in
position positively and accurately without taking site
measurements, and without marking out their positions on the
floor. Interior partitions 70 are located by tracking 72
screwed to the floor 14. Each track member 74 is pre-cut in
the factory for the partition it is to serve, and individual
pieces of track 74 are hinged together to form the tracking
72 which locates correctly the partition intersections. The

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tracking 72 may be joined by slotted connections which are
colour-coded to ensure their correct placement.

The hinged sub-assemblies of track may be folded into
compact bundles to simplify transportation. Figure 9 shows
such a bundle of tracking 72 partially unfolded.

At door openings a disposable removable spacer 76
maintains the spacing and alignment of the track members.
Coded graphic symbols along the tracking identify the panel
which the tracking is to serve, and the location for
electrical items such as receptacles and switches.

The installation procedure for partitions 70 is
illustrated in Figure 10. After deploying the floor track
72 on the floor 14 and screwing it in position using screws
78, the portions of a shallower, but otherwise similar,
ceiling tracking 80 are screwed to the ceiling exactly above
the floor tracking. A movable stud with ends fabricated to
engage with the floor and ceiling tracks and a built-in
level assures that these members are aligned.

The ceiling tracking has a built in electrical raceway
82, and pre-wired runs of cable with electrical boxes
attached are inserted into the raceway, the boxes for
switches and receptacles hanging down in their correct
positions.

Partitions 70 consist of sandwich panels with facings
of gypsum cement board 84 bonded to a foamed plastic core 86
or steel spacers. The core is recessed from the perimeter
of the panel to provide space for track and other
connectors. To erect the partition the bottom is first
introduced over the floor track. The partition is then
raised to a vertical position and lifted until it touches

CA 02204~9~ 1997-0~-0~



the ceiling with the legs of the ceiling tracking extending
into the space formed by the core. It is screwed into place
by screws 86 in this position, and the gap at the bottom is
covered by the baseboard 88.

Figure 11 shows an exterior wall section 12. The
vertical frame members 18 of the panels consist of pairs of
cold- rolled galvanized steel C-sections 90. A panel of
foamed plastic insulation 92 is located with edge portions
lodged in the mouths of the C-sections. The C-sections are
separated by vinyl plastic extrusions 94, 94A which provide
a thermal break between the steel members on the exterior
and interior of the building.

The plastic extrusion 94 comprises the form shown in
Figure 9 and is an elongate plastic C-section extrusion.
The toes of which hook into adjacent toes 95 of the steel
channels 90 to hold them together. The toe 95 of the steel
channel 90 snaps into the hook 97 of the plastic extrusion
94 and bears against a projecting rib 96 on the extrusion
which locks it into position.

The plastic extrusion 94A between the steel C-sections
of adjacent panel (see Figure 10) and the other edge of the
single panel shown in Figure 9 has a spline 98 instead of
ribs 96. Spline 98 slots between steel C-sections of the
frame member 18 of the adjacent wall unit to help align the
panels during erection and to form a firm abutment between
C-sections. The completed joint may be seen in Figure 10
which shows a section through a composite load-bearing
member 32 which itself comprises two frame members 18 each
comprising 2 steel C-sections.

An arrangement of vertical steel C-sections which may
be used at the corner of the building. Because wall

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sections 12 are to be set at right angles to each other,
additional framing members, comprising steel C-sections may
be set into the surface of one of the corner sections
adjacent the C-sections 18. The abutting section latches
between C-sections 18 and 18A of the corner section.

Furring channels 100 having top hat section are
connected to the inner face of the panel to support the
interior finish. The furring channel 100 closest to the
splined extrusion 94A is attached by keyhole shaped slots
195 so it is easily removable. End portions 197 of the web
199 of this furring channel extend beyond the legs. The
extensions are bent inwards, 75~ at the bottom and 15~ at
the top, and are pre-drilled for screws, so the removed
channel may be re-screwed to the panel and screwed to the
floor at an angle of approximately 75~. This attachment of
the furring channel forms a brace which preserves the
verticality of the walls while roof trusses are being
erected, and during strong winds, when the roof system is
installed and braced, the furring channels are detached and
re-installed on the wall panels to provide support for the
interior finishes. Thus the furring channels may do double
duty as vertical braces while the structure is being
erected. Furring channels may also be provided on the inner
face of the unit 12 for additional support of the drywall.
These furring channels may be located with the web flush
with the inner face of unit 12 or spaced from it (see Figure
13).

The conjunction between two wall sections 12 is shown
in Figure 10. Here the spline is shown inserted into the
groove between steel C-sections of the adjacent unit, and
the leading furring channel 100 is shown in its advanced
position with the interior finish 104 attached. The rotary
clip 102 has now advanced to overlap the frame member 18 of

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14
the next unit 12, and by screwing it to this frame member 18
the two units 12 are connected. A similar rotary clip
connects the outer faces of the panel frames.

The plastic extrusion 94A is illustrated in an enlarged
view in Figure 12. It has a web 106 across the projecting
portion which is aligned with the centre line of the joint
between units. This will transfer lateral loads from
between the inner and outer steel framing members. The web
acts as a short column, so it is thickened in the centre to
resist buckling due to compressive loads. At the ends 108
of the web 106 the thickness is reduced symmetrically. This
directs lateral forces through the centre of the web, and
reduces bending of the web due to eccentric loading.

The body of the extrusion 94A is dimensioned to be a
sliding fit between the flanges of the steel channels that
encase it. Nearer the end, the width of the spline is
increased to create an interference fit between the steel
channels of the next panel. This pressure causes the
central part of the sides of the projection to rotate, the
narrowed portion of the web acting as a hinge. The rotation
causes the sides of the root of the projection to press
against the flanges of the channels framing the first panel,
creating an air-tight seal between panels, and between the
interior and the exterior of the building.

The combination of plastic extrusion and steel channels
thus combines in one unit the functions of a thermal break,
a vapour barrier, an air barrier, a connector for steel
framing members, a load transfer device, and a locating
spline for aligning panels during erection.

Representative Drawing