Note: Descriptions are shown in the official language in which they were submitted.
CA 02310880 2000-06-06
1 "MODULAR CONSTRUCTION SYSTEM"
2
3 FIELD OF THE INVENTION
4 This invention relates to the modular construction of buildings and
more particularly to the use of a modular system of load-bearing concrete
panels
6 and connectors to build housing.
7
8 BACKGROUND OF THE INVENTION
9 It is known to construct buildings using rigid frameworks such as
wooden studs or steel girders, and providing external covering material such
as
11 wooden sheeting or concrete panels and internal coverings such as drywall.
12 The construction of such buildings is expensive and time
13 consuming and requires special materials, tools and expertise. This is
especially
14 true for the construction of buildings that are fire-resistant and capable
of
withstanding tornadoes, earthquakes, moisture related damage and insect
16 infestation.
17 It is also known to use modular systems, comprising prefabricated
18 load-bearing panels. If created from concrete, such panels are often very
heavy
19 and have little insulating value. Insulation does not adhere well to
concrete and
the resulting panels are not composite in nature. Further surface finishing
21 requires the use of craftsmen.
22 With an eventual shortage of natural building materials such as
23 lumber and the lack of skilled craftsmen in many areas of the world, the
current
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CA 02310880 2000-06-06
1 invention provides a modular, rapid, construction system that does not
require
2 conventional fasteners and is easily put together with minimal skill.
3
4 SUMMARY OF THE INVENTION
A modular construction system is provided for erecting buildings
6 with a minimum of tools or specialized knowledge. The resulting structure
and
7 its' material of manufacture ensure it is substantially impervious to
environmental
8 hazards, particularly relevant in more primitive locations.
9 High strength composite concrete panels utilize plasticized high
strength concrete. The panels can be precision factory produced for hand
11 assembly in the field and are provided in both corrugated and channel or
ribbed
12 forms. Panels can be pre-formed with openings such as window's and doors
and
13 have pre-finished surfaces. Light, hollow corrugated panels have a zigzag
high
14 strength concrete shape sandwiched and secured with adhesive between two
flat high strength concrete panels. For panels applied to the building
exterior,
16 low-weight, ultra low tensile aerated concrete can be added between ribs as
17 insulation and added rigidity.
18 The composite concrete panels integrate edge connection means
19 which interlock to each other and to primary concrete building components
such
as complimentary pilings, wall footings, crown beams and roof purlin
connectors.
21 These connectors are particularly amenable for installation by hand.
22 As a result, structures, such as housing, can be erected on-site,
23 with a minimum of equipment and without the requirement for craftsmen.
2
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1 In one embodiment, the edge connection means comprise C-
2 shaped FRP extrusion for forming a mortise about the periphery of the
panels.
3 For composite corrugated panels, the mortises are formed of extruded
plastic,
4 sandwiched between high strength concrete sheets. In channel panels and
building components, the mortise preferably take the form of dovetail grooves
6 formed directly in the panel's concrete. Each of the C-shaped or dovetail
7 mortises accepts one lateral half of a pultruded epoxy, fiber-reinforced
joiner or
8 tenon insert having an X-shaped cross-section. When mortises of components
9 and panels are facing or adjoining each other, they form a cavity into which
these X-connectors can be inserted as a tenon, locking the components and
11 panels, or panel to panel, together. Unlike concrete, the X-connector
tenons are
12 elastic and are forgiving of misalignment and movement.
13 Using the X-connector tenons, a floor channel panel having a
14 downward facing groove can be locked to a piling having an upward facing
and
complementary groove. The bottom of a wall panel can be locked to the floor
16 panel. A crown beam can be locked to the top of the wall panel and the
bottom
17 of a roof panel can be locked to the crown beam.
18 Preferably, the crown beam has a low profile by providing a greater
19 lateral dimension than height. This unconventional orientation also aids in
providing lateral strength to resist roof-spreading loads and transferring
them
21 vertically into the walls. Advantageously, the lateral extension also make
it
22 possible to secure exterior gutter and interior valences thereto,
preferably using
23 the same X-connector tenons.
3
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1 Further, adjoining roof panels can be connected using purlin
2 connectors having a deep depending rib portion for adding extra beam section
3 and strength to the roof structure.
4 In the broadest form of the invention, a method of modular
concrete construction comprises providing two or more lightweight composite
6 concrete building components having one or more linear peripheral edges
7 formed with linear dovetailed fitting mortises, providing one or more
flaring
8 tenons, aligning two adjacent building components with facing fitting
mortises,
9 and joining the aligned panels by inserting one or more of the flaring
tenons
along the peripheral edge and into the facing fitting mortises so that the
panels
11 cannot be separated.
12 Preferably this method is applied to the formation of walls panels
13 for forming a walled structure, all of which are joined using the mortises
and
14 tenons. This method of construction can be extended to form a plurality of
components for forming a wide crown beam which rests atop the walled
16 structure and supports a plurality of roof panels resting thereon.
17 More preferably, additional building components such as floor
18 panels can be similarly formed. Using the lightweight composite concrete,
19 corrugated panels can be formed of a profiled or corrugated sheet glued
sandwiched between two sheets. These corrugated panels, fitted with mortises,
21 can be used a beams as part of a suspension system, resting on piles, or
22 assembled as interior partitions.
23
4
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1 BRIEF DESCRIPTION OF THE DRAWINGS
2 Figure 1 is an exploded cross-sectional view of one half of a
3 modular building manufactured in accordance with a preferred form of the
4 present invention;
Figure 2 is an exploded view of the construction components of a
6 building manufactured in accordance with the invention;
7 Figure 3 is a perspective view of a building constructed using one
8 embodiment of the invention and illustrating the concrete culvert detail;
9 Figures 4a and 4b are side and exploded fastener views
respectively of the rock pile;
11 Figure 5 is a plan view of a nine-pile grid;
12 Figure 6 is a partial cross-sectional detailed view of the crown
13 beam and interlocking to the roof and wall panels;
14 Figure 7 is a partial cross-sectional detailed view of the crown
beam with interlocked exterior gutter and interior valance;
16 Figure 8 is a partial cross-sectional plan view of a 90 corner crown
17 beam;
18 Figure 9 is a partial cross-sectional view of part of the wall panels,
19 the crown beam and roof panels accordingly to Fig. 1;
Figures 10a - 10d illustrate the nature of the interior corrugated
21 partitions. Specifically,
22 Figure 10a is a overall arrangement illustrating a side view of a
23 partition butted up to and illustrating a cross-section of an exterior
wall;
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1 Figure 10b is a plan cross-sectional view detail showing the strip
2 connector between the partition and the a complementary slot at the joint
3 between two exterior wall panels;
4 Figure 10c is a plan cross-sectional view detail showing the
interlocking of adjacent partitions;
6 Figure 10d is a side cross-sectional view of the top and bottom
7 partitions illustrating capping and hook and loop fastener between the
partition
8 bottom and the floor;
9 Figure 11 is a partial cross-sectional view of a corrugated panel;
Figures 12a and 12b are an end cross-sectional view and a side
11 view of the X-connector;
12 Figure 13 is a plan cross-sectional view of a vertical tongue joint
13 illustrating a typical serpentine external wall panel joint; and
14 Figures 14a - 14g illustrate structural framing details:
a. is a plan view of the building of Fig. 3;
16 b. is a cross-sectional view according to lines A-A of Fig. 14a;
17 c. is a cross-sectional view according to lines B-B of Fig. 14a;
18 d. is a plan cross-sectional view of a wall corner of Fig. 14a;
19 e. is partial plan view of the hip and peaks of the building of
Fig. 14a;
21 f. is a cross-sectional view of the hip and peak sections of Fig.
22 14e along lines f-f;
23 g. is a cross-sectional view of the hip and peak sections of Fig.
24 14e along lines g-g; and
6
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1 h. is an elevation view of the hip and peak connector of Fig.
2 14e.
3
4 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Overall, and shown generally in Figs. 1,2, and 3, there is disclosed
6 a concrete building 10 and method of construction of same which comprises a
7 connecting a plurality of exterior walls 11, a support or suspension system
12, a
8 floor 13 and a roof 14, all of which are manufactured of composite concrete
9 components. Individual building components interlock with each other and
with
other building components with a consistent arrangement of dovetail-like
11 mortises 16 and tenon connectors 17.
12 It is instructive to first identify the building's major components and
13 then describe them in greater detail thereafter.
14 As shown in overall Figs. 1-1c, 4a,4b form of suspension system
12 is shown for use in soil footings. A pile 20 comprising an epoxy-resin
fiber-
16 reinforced (FRP) auger 21 and a square milled top 22.
17 Having reference also to Fig. 5, a rectangular suspension grid 30 is
18 formed for a total of nine piles 20 in a 3-by-3 arrangement. A grid shaped
19 pattern (not shown) can be employed to ensure accurate positioning of the
piles
20. Each pile 20 connects to and supports the ends of floor beams 31 spanning
21 between piles 20. Typically, six strong, three-ply floor beams 31 run end
to end,
22 in co-axially extending pairs, running parallel each other pair spaced by
three
23 pairs of transverse, single-ply, weaker floor beams 32. Floor panels 13,
having a
7
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1 channel profile, span the entire length of the 3 piles 20 aligned
perpendicular to
2 the strong beams 31.
3 Exterior walls 11 stand vertically from and interlock with the
4 periphery of the floor panels 13.
As shown in detailed Figs. 6 and 7, a header or crown beam 40
6 interlocks with and extends about the top of the walls 11. Exterior rain
gutters 41
7 and interior valence and utility tray 42 are interlocked to and are
supported from
8 the crown beam 40.
9 At wall corners, a 90 curved section 43 of crown beam 40, seen in
Fig. 8, is used to connect linear sections 40. Interlocking, vertically
tapered
11 fingers 44 provide a connection to resist lateral separating forces.
Internal
12 reinforcement is provided using epoxy/fiberglass (FRP) pultruded
reinforcing
13 rods 45.
14 Sectional roof panels 14 interlock with and are supported atop the
crown beam 40 as seen in Figs. 1 and 9. A cottage-style roof 14 is shown which
16 extends vertically upwardly and then deviates laterally to approach the
peak and
17 a peak connector 46 at an angle. Best shown in Fig. 9, compound curved
18 panels 47 provide the section of the roof 14 adjacent the crown beam 40.
Flat
19 panels 48 constitute the balance of the roof panels 14. Dependent upon the
span of the roof 14, flat roof panels 48 are occasionally interlocked to one
21 another using a purlin connector 49, providing a locally increased and
strong
22 beam section.
8
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1 Interior partitions 50 shown in Figs. 10a - 10d, interlock at
2 interfaces 51 between adjacent wall panels 11 and are attached to the floor
3 panels 13.
4 More specifically, three basic panel types are pre-formed using
high strength concrete: a corrugated structural panel 60 for forming beams
31,32
6 and interior partitions 50; a channel form 61 for floor panels13; and an
insulated
7 channel 62 for forming exterior wall 11 and roof panels 14.
8
9 Corrugated Panels - Beams and Partitions
Having reference to Figs. 8 and 10a - 10d, panels 60 for partitions
11 50 and beams 31,32 are planer composite corrugated panels entirely
12 constructed of a matrix of high-density, high strength, plastic and fiber-
reinforced
13 concrete (hereinafter "HS concrete").
14 Concrete having strength of 5,000 psi or greater is preferred. As
shown, each panel 60 can be readily factory mass-produced by forming of first
16 and second planer sheets 70,70 of HS concrete with a third corrugated sheet
71
17 sandwiched therebetween. The corrugated sheet 71 is molded in a zigzag
18 pattern, having alternating angular sections 71a and short planer sections
71b
19 for spacing the planer sheets 70,70 apart. The first and second planer
sheets
70,70 are secured at the third corrugated sheet's short planer sections 71 b
with
21 an adhesive mortar. The result is a lightweight concrete panel 60 which is
22 strong, without the requirement for reinforcing tensile bar and which is
23 substantially invulnerable to natural degradation. Optionally, the
corrugations
24 can be filled with insulation.
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1 Opposing linear peripheral edges 72 of each substantially
2 rectangular corrugated panel 60 is fitted with a structural plastic C-shaped
3 extrusion 73. The C-shaped extrusion 73 has an open side 74 which is
oriented
4 outwardly from the panel 60. The C-shaped extrusion 73 has inward-facing
flanges 75 at the open side 74 for constricting the opening and forming a
mortise
6 16. It is understood that the term mortise 16, used herein, refers to any
7 peripheral edge connector which has a larger internal dimension that outer
8 dimension, such as a dovetail, thus being capable of retaining a tenon 17.
9 Having reference to Fig. 12a and 12b, linear tenons 17 are formed
from epoxy resin over a matrix of fiberglass strands (FRP) pultruded through X-
11 shaped dies. As a result, tenons in the form of X-connectors are formed
having
12 an X cross-section of 4 symmetrical radially extending wings 19. As
described
13 below, the resultant X-connector tenons 17 are used to connect adjacent and
14 facing mortises of corrugated panels 60, both to each other and to other
building
components.
16 In the case of adjacent panels 60,60, when the C-shaped mortises
17 16 of the peripheral edges 72 of the adjacent panels are placed facing each
18 other, the X-connector tenons 17 can be slid along the facing mortises 16
19 wherein two wings 19 engage one mortise 16 while the remaining two wings 19
engage the other opposing mortise 16. Thus, as shown in Fig. 10c, the X-
21 connector tenon joins two panels 60,60 together.
22 The constricted opening of the C-shaped mortise prevents lateral
23 release of the two engaged wings 19 and prevents separation of the panels
60.
CA 02310880 2000-06-06
1 Accordingly, the only permitted displacement of the X-connector tenon 17 is
2 linearly along the mortise 16.
3
4 Walls, Floor and Roof Panels
The second type of composite panel 61 and 62, as seen in Figs. 1
6 and 9, is constructed of a HS concrete outer sheet 80 and has perpendicular
7 stiffeners or flanges 81 for forming a channel section. An example of use of
8 such a panel 61 is the floor panels 13. Utilities and the like can be run
between
9 the flanges 81. Mortises 16 are formed at the peripheral edges 72, both top
and
bottom, for connection to walls 11 and piles 20 respectively.
11 An insulated panel 62 is used for prefabricated and insulating
12 exterior panels, such as wall 11 and roof panels 14. A low-density, ultra-
low
13 tensile strength, highly-aerated concrete filler 82 (hereinafter referred
to as
14 "aerated concrete") is placed in between the flanges 81 of the channel
section.
The filler 82 acts as an insulation which also increases the panel's diagonal
16 rigidity. Again, mortises 16 are formed at the peripheral edges 72, on each
of
17 the two sides, top and bottom, for connection to adjacent walls 11, crown
beam
18 40 and floor panels 13 respectively.
19
11
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1 Suspension- Beam and spacers
2 Support beams for the suspension system 12, best seen in Fig. 1,
3 can be formed using a plurality of corrugated panels 60 such as those used
to
4 form the triple-ply beam 31.
Triple-ply strong beams 31 and single ply weaker spacer beams
6 32, are supported at the piles 20. The beams 31,32 can be positioned using
7 tongue 24 and groove 25 connectors for positioning on the piles 20 using a
8 mortise 16 and tenon 17 connection.
9
12
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1 Suspension System - Pilings
2 Two types of supports are provided to accommodate local
3 conditions; particularly to facilitate construction on either a shifting or
on a more
4 consolidated base.
Referring to Figs. 1,1 b, 4a and 4b a piling 20 is used construction
6 on soft soil. The piling is an FPR pultruded rod with an auger tip 21 on the
7 bottom for screwing into soil, and a square milled top 22. The beams 31,32
of
8 the suspension system 12 are supported on the milled top 22 of the piles 20.
In
9 soft-soil conditions, this type of pile is easily relocatable should the
ground shift.
In consolidated terrain, a mere pad 23 can be substituted for the
11 piles.
12
13 Floors
14 Floor panels 13 are secured to the suspension system 12, as
shown in Figs. 1-1 c, being anchored to the beams at the outside perimeter of
16 the grid 30. These panels 13 are formed first with a tongue 24 or groove 25
to
17 mesh with a groove or tongue on the pile's milled top 22 to act as a
locator and
18 secondly with a continuous dovetail mortise 16 in the floor 13 to
facilitate joining
19 to a mortise 16 in the pile using the X-connector tenons 17. The floor
panels 13
are amenable to installation of heat transfer tubes and installation of other
21 utilities between their flanges 81. The panels 13 can be profiled at their
ends to
22 match the wall profile, such as if the wall was curved.
23
13
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1 Exterior Walls
2 Exterior walls 11, seen in Figs. 1,9 and 10a, are formed having an
3 exterior concrete shell 80, a foamed concrete fill 82 and a skreeded
interior
4 concrete surface (not detailed). Exterior walls 11 are joined to the floor
channels
by a series of continuous dovetail mortises in the top of the floor panel 13
which
6 corresponds to dovetail mortises 16 formed on the bottom of the exterior
walls
7 11. Connections are secured using X-connector tenons 17. Tongue or grooves
8 on the tops and bottoms of the walls correspond to grooves or tongues
9 respectively on the floor panels 13 and crown beam 40 to act as locators for
positioning of walls 11.
11 Exterior walls 11 are joined to one another side by side using a
12 serpentine tongue joint 85, as shown in Fig.13, sealed with a sealant
adhesive
13 86 which prevents air, frost and contaminants from entering the building
10.
14 Positioning of the walls 11 typically begins at a designated wall
corner and continues about the circumference of the floor panels, ending at a
16 recessed setting point pre-molded into selected floor panels 13. The last
wall
17 panel 11, having a similar setting point moulded into the wall panel's
sides, is
18 levered into position to interlock with the first floor panel 13, thus
providing a
19 completely interlocked exterior finish to the building 10.
21 Interior Walls
22 Lightweight wall panels, shown in Figs 1 and 9, having similar
23 corrugated construction to the panels used for the beams and spacers 31,32,
24 only thinner, are provided for use as interior partitions 50. The panels 60
are
14
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1 joined together to form partitions 50 as shown in Fig. 10a using C-shaped
2 extrusion mortises 16 and X-connector tenons 17, best seen in Fig. 10c. The
3 partitions 50 are removeably secured to the exterior walls 11 utilizing a
female
4 socket 90 between the joints of two exterior wall panels 11, a male
elongated
strip connector 91 and the C-shaped mortise 16 at the panel 60. The strip
6 connector 91 has a barb 92, which fits securely and into the complimentary
7 socket 90, and two wings 19 of a tenon for fitting with the adjacent panel's
8 mortise 16. The partitions 50 are readily connected to the floor panels 13
using
9 conventional hook and loop fasteners 94 (VelcroTM ) as seen in Fig. 10d.
As shown in Fig. 10d, where the partitions 50 are open to the roof
11 14, they are capped using an extruded cap 95. The partitions 50 are also
able to
12 support the optional addition of ceilings (not shown). In cases where
enhanced
13 circulation is necessary, ceilings are omitted. In cases where ceilings are
useful,
14 the same partitions 50 can be used as ceiling material and are constructed
to
join to the partitions' mortises using suitable right angle connector tenons.
16
17 Crown beam and roof construction
18 A crown beam 40, seen in Figs. 6 and 7, is formed from HS
19 concrete, having lightening holes 100 along its horizontal axis, to reduce
the
weight of the beam 40. It is used similarly as it would be in a conventional
21 construction for roofs built without trussing or rafters. In such cases, it
is
22 normally placed vertically with respect to the exterior walls. The addition
of a
23 crown beam 40 provides means, at the point of juncture between the wall
panels
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1 11 and the roof 14, to accept the spreading load therefrom. This load would
2 otherwise be dependent upon the walls 11 and could result in wall deviation.
3 Rather than being placed in the conventional vertical position which
4 would result in extra wall height, the crown beam 40 is placed horizontally
on top
of the walls 11. Due to its width, the crown beam 40 creates a protuberance on
6 the outside and on the inside of the walls 11, which further allows it to be
used
7 as a building component suitable for the addition of external and internal
8 structural and architectural attachments.
9 As seen in Fig. 7, externally the crown beam 40 is used as an
anchor for a concrete rain gutter 41 capable of controlling large volumes of
water
11 flow such as might be found in a monsoon. The exposed face of the gutter 41
12 provides one form of a substitute for the soffit and fascia found in
conventional
13 construction and minimizes the wind loading, and associated destruction,
caused
14 by high winds.
As seen in Fig. 7, internally the crown beam 40 is used as a
16 connection for a continuous lighting valance 42. The lighting valance 42
provides
17 a suitable location for the installation of electrical, plumbing and
communication
18 harnesses used to provide services to the building 10.
19 Installation of the crown beam 40, between the wall panels 11
below and the roof panels 14 above, provides continuous horizontal strength
21 with overall wall rigidity and relies on special joining conditions to
maintain the
22 final wall positioning. The system employs a finger joining technique, as
seen in
23 Fig. 8, designed to improve tensile strength in a lateral direction, while
24 maintaining the required horizontal positioning or "bedding" by the casting
of the
16
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1 finger joints 44 using a draw-casting method. This method of forming the
finger
2 joints 44 results in a downward diminishing taper for locking against
movement.
3 The finger joints 44 are further reinforced by the insertion of epoxy
4 fiberglass reinforcing rods 45 which extend axially into the crown beam and
vertically through holes formed in the fingers of the finger joints 44.
6 Roof panels 14 are moulded with overlapping extensions 33 along
7 a bottom and a first vertical side edge. Formed In this fashion, roof panels
14
8 can be installed by sliding the non-overlapping vertical edge of a panel
under the
9 overlapping edge of the previously installed adjacent panel, while at the
same
time ensuring the bottom edge overlaps panels installed below. Roof panels are
11 connected to one another using X-connectors 17 fitted into the facing
dovetail
12 mortises 16 of the adjacent roof panels 14. The final roof panels 14 must
be
13 levered into position as they cannot be slid into position.
14 A peak connector 46 is installed at the apex of the roof 14 to
connect the top edges of the opposing roof panels 14 where they meet. The
16 peak connector 46, shown in Fig 1, acts to connect and to cap the top of
the roof
17 14.
18 The overlapping connection of the roof panels 14 provides a
19 continuous, sealed structure relatively impervious to wind and rain.
21 Lighting Valance
22 The continuous lighting valance 42, as seen in Figs. 1, 9 and 7, is
23 connected to the interior edge of the crown beam 40 using an X-connector
tenon
24 17 fit into dovetail mortise 16 on the crown beam 16 and the valance 42.
17
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1 Reflectors 96 are placed on the adjacent curved roof panel 47 to reflect
light
2 from over the valance 42 and into the spaces below.
3 Trays 59 are fitted into the enclosure created by the lighting
4 valance 42 and are joined to dovetail mortise 16 in the top of the crown
beam 40
using X-connector tenons as seen in Fig. 1, 9 and 7. These trays 59 are used
to
6 carry all service lines, in harness form, that can be installed or moulded
into the
7 walls 11. This includes electrical, plumbing and communication services.
8
9 Heating and Cooling System
As shown in Fig. 1, a heating and cooling system is provided
11 having a compressed-air, constant-pressure hot air heating system and a
series
12 of floor plenums and heat transfer tubes underneath the floor panels 13.
13
14 Assemblv
As shown in Figs. 14a - 14g, the panels 13,11,14 are all
16 assembled and held rigidly together as a unit using corner wall panels 110,
and
17 hip and peak connectors 111. These connectors 110 and 111 are preferably
18 held together using mortise and tenon connections.
18
