Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS, METHODS, AND ARTICLES OF MANUFACTURE FOR USE IN
PANELIZED CONSTRUCTION
Field of the Invention
This invention relates to the field of panelized construction for use in
residential,
commercial, industrial, and other buildings.
Background of the Invention
On-site building construction, including additions to and renovations of
existing
buildings, presents numerous inefficiencies and disadvantages. On-site
construction is
typically slow and labor intensive. Quality control is frequently difficult to
maintain
during on-site construction. On-site construction may require expertise in
numerous
construction techniques and building subsystems (e.g., electrical, plumbing,
communication systems, heating and cooling, etc.). In most regions, on-site
construction
may also be limited by variable weather conditions, limited building seasons,
and other
scheduling difficulties.
In most cases, it is impractical or impossible to build an entire building off
site.
Transportation logistics and costs are debilitating. Various techniques for
pre-fabricating
some or all of a building have been attempted and have been successful to
varying
degrees. Pre-fabrication provides the labor, material, and time efficiencies
of mass
production. Pre-fabrication provides the manufacturer with the ability to
monitor quality
control under production line conditions. Pre-fabrication may radically
decrease the
amount of construction time required on-site.
Numerous technical difficulties have been encountered in providing pre-
fabricated
buildings. Prior techniques may include pre-fabricated building portions that
are large
and difficult to transport and install. Prior techniques are inflexible and do
not allow for
individual customization or integration with existing building structures.
Prior techniques
may not include pre-installation of various building subsystems and do not
provide pre-
installed subsystems that are fast and easy to complete on site. Prior
techniques may be
inappropriate for use in commercial and industrial construction.
These and other drawbacks of prior art systems are overcome by the various
embodiments of the invention.
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Summary of the Invention
The invention may include systems, methods, and articles of manufacture for
use
in panelized construction of residential, commercial, industrial, and other
buildings.
Some aspects of the invention may include prefabricated construction panels,
methods of
using prefabricated construction panels, panelized construction systems with
integrated
wire-based subsystems, methods of installing panelized construction systems
with
integrated wire-based subsystems, panelized construction systems with
integrated
mechanical subsystems, methods of installing panelized construction systems
with
integrated mechanical subsystems, panelized construction systems for a
commercial or
industrial building module, and methods for constructing a commercial or
industrial
building module.
One aspect of the invention may be a construction panel for use in building
construction, including building additions and renovations. The construction
panel may
include a plurality of peripheral frame members that define a rectangular
frame. A
plurality of stud members within the rectangular frame may extend from a first
portion of
the frame to an opposite second portion of the frame and may be parallel to at
least one
edge of the frame. These stud members may define spaces within the rectangular
frame
between adjacent stud members and between stud members and adjacent peripheral
members of the frame. Iri some embodiments, the spaces may accommodate
insulation,
portions of one or more building subsystems, or other internal structures. The
frame may
also define a first and second rectangular surface along first and second
opposite faces of
the peripheral frame members and stud members. First and second surface
covering
layers, such as dry wall or exterior sheathing, may be disposed on the first
and second
rectangular surfaces. The frame may accommodate fasteners for connecting the
frame to
an adjacent structure, such as another construction panel or a pre-existing
portion of a
building.
Another aspect of the invention may be a method of using prefabricated
construction panels. The method may include preparing a pre-existing building
to
accommodate one or more prefabricated construction panels. At least one
construction
panel may be placed adjacent to a building structure defining a portion of the
pre-existing
building. The construction panel may be attached to the adjacent building
structure.
Attachment of the construction panel to the adjacent building structure may
define one or
more seams between a surface covering layer of the construction panel and one
or more
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surface covering layers of the building structure. At least one seam between
the
construction panel and the building structure may be covered to integrate the
prefabricated construction panel into the pre-existing building.
Still another aspect of the invention may be a panelized construction system
with
integrated wire-based subsystems, such as electrical, communication, and
security
systems. The panelized construction system may include a construction panel
with a
built-in surface device, such as an outlet, switch, fixture, or other device,
for a wire-based
subsystem. The surface device may be electrically connected by wires internal
to the
construction panel to a junction box that can be accessed from outside the
panel. The
construction panel may define a guide conduit extending from an edge of the
construction
panel to the junction box, allowing a connecting wire to be inserted into the
guide conduit
and electrically connected to the surface device through the junction box.
An additional aspect of the invention may be a method of installing a
panelized
construction system with integrated wire-based systems. A construction panel
including a
surface device for a wire-based subsystem may be positioned for installation.
The
construction panel may be fixed in place, such as by attaching it to an
adjacent
construction panel or building structure. A connecting wire may be run to the
construction panel and electrically connected to the surface device through a
junction box
in the construction panel. The connecting wire may be electrically connected
to a source
for the wire-based subsystem.
A further aspect of the invention may be a panelized construction system with
an
integrated mechanical subsystem. The system may include one or more
construction
panels. At least one construction panel may have a conduit for the mechanical
subsystem
built into the construction panel and extending to an edge of the construction
panel. The
conduit may be functionally connected to a surface device, such as a vent, for
the
mechanical subsystem, also built into the first construction panel. The
conduit may also
be functionally connected at the edge of the construction panel to a source
for the
mechanical subsystem.
A still further aspect of the invention may by a method of installing a
panelized
construction system with an integrated mechanical subsystem. The method may
include
the positioning of a construction panel with a built in surface device for a
mechanical
subsystem and a built in first conduit extending from the surface device to an
edge of the
construction panel. The construction panel may be fixed in place. A second
conduit,
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functionally connected to a source for the mechanical subsystem, may be
engaged to the
first conduit such that the first conduit if functionally cormected to the
second conduit and
the source. In some embodiments, additional construction panels with conduits
may be
positioned, the conduits may be engaged to the conduit of an adjacent
construction panel,
and the construction panels may be fixed in place.
Yet another aspect of the invention may be a panelized construction system for
commercial or industrial buildings. The panelized construction system may
include a
plurality of prefabricated wall panels and prefabricated roof panels. The
prefabricated
wall panels and prefabricated roof panels may be attached to adjacent panels
using a
plurality of fasteners. Placement and attachment of the prefabricated wall
panels and
prefabricated roof panels may be defined by a building module configuration.
Still another aspect of the invention may be a method of constructing a
commercial or industrial building module. The method may include preparing a
base
structure according to a building module configuration. A plurality of wall
panels may be
positioned above the base structure. The plurality of wall panels may be
attached to the
base structure and each adjacent wall panel. A plurality of roof panels may be
positioned
above the plurality of wall panels. The plurality of roof panels may be
attached to at least
some of the wall panels and to each adj acent roof panel.
The accompanying drawings, which are incorporated in and constitute a part of
this specification, illustrate an embodiment of the invention and, together
with the
description, serve to explain the principles of the invention.
Brief Description of the Drawings
Figure 1 is a front view of an example vertical panel for use in panelized
construction.
Figure 2 is a front view of a second example vertical panel.
Figure 3 is a front view of a third example vertical panel.
Figure 4 is a front view of a fourth example vertical panel.
Figure 5 is a front view of a frame for an example vertical panel, such as the
example vertical panel of Figure 1.
Figure 6 is a side view of an example vertical panel, such as the example
vertical
panel of Figure 1.
Figure 7 is a side cross-sectional view of an alternate configuration for an
example
vertical panel, such as the example vertical panel of Figure 1.
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Figure 8 is a top view of an example pitched panel for use in panelized
construction.
Figure 9 is a top view of a second example pitched panel.
Figure 10 is a side cross-sectional view of an example pitched panel, such as
the
example pitched panel of Figure 8.
Figure 11 is a cross-sectional view of a frame for an example pitched panel,
such
as the example pitched panel of Figure 8.
Figure 12 is a top view of an example horizontal panel for use in panelized
construction.
Figure 13 is a bottom view of an example horizontal panel, such as the
horizontal
panel of Figure 12.
Figure 14 is a side cross-sectional view of an example horizontal panel, such
as
the horizontal panel of Figure 12.
Figure 15 is a side cross-sectional view of an alternate example horizontal
panel,
such as the horizontal panel of Figure 12.
Figure 16 is a top view of a frame of an example horizontal panel, such as the
horizontal panel of Figure 12.
Figure 17 is a schematic top cross-sectional view of an example building for
renovation.
Figure 18 is a schematic top cross-sectional view of the example building for
renovation of Figure 17 after removal of various pre-existing building
structures.
Figure 19 is a schematic top cross-sectional view of the example building for
renovation of Figure 17 after placement of sills.
Figure 20 is a schematic top cross-sectional view of the example building for
renovation of Figure 17 after placement of a plurality of vertical panels
Figure 21 is front view of an example attachment mechanism for attaching
construction panels to adjacent structures, including other construction
panels.
Figure 22 is a top view of an example attachment mechanism for attaching
construction panels to adjacent structures, including adjacent construction
panels.
Figure 23 is ~a side cross-sectional view of an example attachment mechanism
for
attaching vertical panels to a base structure.
Figure 24 is a front view of an example attachment mechanism attaching
adjacent
vertical panels to each other and a base structure.
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Figure 25 is a front view of a plurality of vertical frames and a wire-based
subsystem of an example panelized construction system.
Figure 26 is a side view of a base portion of an example panelized
construction
system with a wire-based subsystem.
Figure 27 is a flow chart of an example method of installing a panelized
construction system with a wire-based subsystem.
Figure 28 is a top view of a portion of horizontal panel frames and a
mechanical
subsystem of an example panelized construction system.
Figure 29 is a front view of a vertical panel frame and mechanical subsystem
of an
example panelized construction system.
Figure 30 is an example connection between the conduits of adjacent
construction
panels for an example panelized construction system with a mechanical
subsystem.
Figure 31 is a an example connection between the conduits of adjacent
construction panels for an example panelized construction system with a
mechanical
subsystem.
Figure 32 is a an example method for installing a panelized construction
system
with a mechanical subsystem.
Figure 33 is a front view of a frame for an example vertical panel for use in
panelized construction of commercial or industrial buildings.
Figure 34 is a front view of a frame for a second example vertical panel for
use in
panelized construction of commercial or industrial buildings.
Figure 35 is a side cross-sectional view of a third example vertical panel for
use in
panelized construction of commercial or industrial buildings.
Figure 36 is a cross-sectional view of an example commercial or industrial
building using panelized construction.
Figure 37 is an example attachment mechanism for attaching adjacent panels.
Figure 38 is an example attachment mechanism between a vertical panel with a
bearing ledger and a horizontal panel.
Figure 39 is an alternate example attachment mechanism between a vertical
panel
with a bearing ledger and a horizontal panel.
Figure 40 is an example attachment mechanism between vertical panels defining
a
pocket and a horizontal panel.
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Figure 41 is an example attachment mechanism between a vertical panel and a
base structure.
Figure 42 is a top view of an example building configuration for use in
panelized
construction of commercial and industrial buildings.
Figure 43 is a top view of a second example building configuration for use in
panelized construction of commercial and industrial buildings.
Figure 44 is a flow chart of an example method of constructing a commercial or
industrial building using panelized construction.
Detailed Description of the Preferred Embodiments
With reference to the drawing figures generally, and particularly to Figures 1-
16, a
variety of example construction panels for use in panelized construction are
shown.
Figures 1-7 show a variety of horizontal panel configurations, such as those
used for
walls. Figures 8-11 show a variety of pitched panel configurations, such as
those used for
pitched roofs and ceilings. Figures 12-16 show a variety of horizontal panels,
such as
those used for floors, ceilings, and flat roofs. Figures 17-20 show an example
use of
construction panels to renovate a building. Figures 21-24 show a variety of
example
attachment mechanisms for attaching construction panels to adjacent
structures. Figures
25-27 relate to an example of a wire-based subsystem for use in panelized
construction
systems. Figures 28-32 relate to an example of a mechanical subsystem for use
in
panelized construction systems. Figures 33-44 relate to panelized construction
of
commercial or industrial buildings.
Construction Panels
Figures 1-16 show a variety of example construction panels. These construction
panels may generally be grouped by function. Figures 1-7 show vertical panels.
Vertical
panels are generally rectangular and intended to be installed in an upright
position to
define at least a portion of a building wall or other vertical structure. Wall
panels are
generally vertical panels. Figures 8-11 show pitched panels. The pitched
panels shown
are for defining at least a portion of a pitched roof and are installed at an
angle between
support structures at either end of the panel, such as a wall and a ridge
beam, support
ledger, post, or other support. In some building, such as those with cathedral
ceilings,
finished attics, etc., pitched panels may also act as pitched ceiling panels.
Some roof
panels, ceiling panels, and combined roof/ceiling panels are pitched panels.
Figures 12-
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16 show horizontal panels. The horizontal panels shown are designed to be
installed in a
horizontal position to define at least a portion of a floor, ceiling, flat
roof, or some
combination thereof. Some roof, ceiling, and combined roof/ceiling panels are
horizontal
panels. Most floor, ceiling, and combined floor/ceiling panels are horizontal
panels.
The horizontal panels of Figures 1-7 are wall panels and may be designed with
various dimensions, materials, purposes, features, and subsystems. For
example, Figure 1
shows a wall panel 100 with several surface devices. As shown, panel 100
includes a
vent 110 for a mechanical subsystem, as well as a switch 120 and outlet 130
for one or
more wire-based subsystems. Figure 2 shows a wall panel 200 with a door 210.
Figure 3 .
shows a wall panel 300 with a window 310 and an outlet 320. Figure 4 shows a
wall
panel 400 with a built in support truss 410 and an outlet 420.
The dimensions of any given wall panel may vary depending on the purpose of
the
wall panel. A number of wall panels may be positioned next to one another such
that the
widths of the adjacent wall panels define the length of a full wall or portion
of a wall.
Because wall lengths vary depending on, among other things, the size of the
room the
walls are defining, widths of the individual wall panels may be variable. In
one
embodiment, most wall panels are fabricated to a standard width and a smaller
number of
wall panels of variant widths are used to adjust for length increments that
are not divisible
by the standard panel width. In a preferred embodiment for use in domestic
residential
construction, standard wall panels are fabricated in 4' widths and non-
standard wall
panels are fabricated in smaller widths. Four foot widths assist in ease of
productions as
many sheet building materials, such as drywall and exterior sheathing, are
sold in 4'
widths. Four foot wall panels are also small and light enough to be maneuvered
with
minimal equipment and manpower, making such wall panels accessible to
contractors and
do-it-yourselfers. Heights of the wall panels may also vary. In a preferred
embodiment
for domestic residential construction, wall panels may be fabricated with 8'
heights.
Eight foot high wall panels also assist in ease of production, since many
sheet building
materials are sold in 8' lengths. However, wall panels may also be fabricated
for half
walls (3-4' high), 9-10' luxury ceilings, basements with lower ceilings, or
other
dimensions as appropriate to the building. Commercial, industrial, and other
non-
residential building may have variant wall heights much larger than those for
residential
buildings. Wall panel thickness may also vary. Thickness may be dependant on
the
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structural requirements of the wall panel, the number and type of surface
covering layers,
and the thickness of the frame members.
The materials used for fabrication of a wall panel may vary according to the
structural requirements, available materials, preferences, and applicable
building
regulations for any given purpose. Any given project may include a variety of
wall
panels with varying materials and material configurations based upon the
purpose of the
particular wall panel. Each wall panel may generally include a frame and one
or more
surface covering layers. For example, Figure 5 shows an example wall panel
frame 500.
Frame 500 includes a rectangular outer frame 510. Outer frame 510 is comprised
of two
members defining each side of the rectangle and an edge of the wall panel. Top
members
511 and 512 define the top side of the outer frame 510 and the top side of top
member
511 may define the top edge of the wall panel. Bottom members 513 and 514
define the
bottom side of the outer frame 510 and the bottom side of bottom member 514
may
define the bottom edge of the wall panel. Lateral frame members 515 and 516
define a
first lateral side of the outer frame 510 and the outer side of lateral frame
member 515
may define a first lateral edge of the wall panel. Lateral frame members 517
and 518
define a second lateral side of the outer frame 510 and the outer side of
lateral frame
member 518 may define a second lateral edge of the wall panel. The frame 500
may also
include a number of stud members 520 and 521 extending from top member 512 to
bottom member 513, parallel to lateral frame members 515, 516, 517, and 518.
Lateral
frame members 51 S, 516, 517, and 518 may also be considered stud members. The
stud
members define spaces 530, 531, and 532 between lateral frame members 561 and
517,
and adjacent stud members 520 and 521. The spaces may accommodate internal
layers,
such as insulation, or portions of various building subsystems. In a preferred
embodiment
for use in domestic residential construction, the various members of the frame
are
comprised of 2x4 building grade lumber and the stud members are placed no
greater than
16" apart. For other types of construction, different materials and
configurations may be
employed for the frame, such as larger lumber members (e.g., 2x6, 2x10, etc.),
light gage
structural metal members, pre-cast concrete, extruded or cast structural
polymers and
composites, recycled materials, and other materials. Stud distances may vary
in
accordance with the structural requirements of the frame materials and
relevant building
codes. Other material variations include the surface covering materials
disposed on one
or more surfaces defined by the frame. For example, frame 500 defines two
surfaces
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parallel to the front and back edges of the frame members which may
accommodate
surface covering layers. Figures 6 and 7 show side views of two example
configurations
of surface covering layers for wall panels. Wall panel 600 includes a frame
610, a first
surface covering layer 620 disposed on a first surface of frame 610, and a
second surface
covering layer 621 disposed on an opposite second surface of frame 610. Wall
panel 700
includes a frame 710, a second surface covering layer 720 disposed on a first
surface of
frame 610, a second surface covering layer 721 disposed on an opposite second
surface of
frame 610, and a third surface covering layer 722 disposed on the second
surface
covering layer 721. Surface covering layers may include a variety of materials
for
covering a building surface, such as sheathing, drywall, paneling, siding, ~or
other building
materials. A surface covering layer need not cover the entire surface of a
wall panel.
Surface covering layers may be attached to the frame during fabrication by any
method
appropriate, such as fasteners, adhesives, mated connections, or other
attachment
methods.
Frame size, spacing, and material and surface covering layer number and
materials may be determined by the purpose of a particular wall panel.
Different building
types, such as residential, commercial, and industrial building, may have
different design
considerations. Similarly, within a particular type, there may be variations
in building
style depending on climate, expected use, costs, and other factors. Even
within a specific
building, wall panel's purpose may vary such that there may be substantial
variations in
the wall panels. For example, building may have different configurations for
internal and
external walls. Internal walls may have surface covering layers, such as dry
wall, on both
sides, while external walls may have a double surface covering layers on the
exterior
including sheathing and siding. A wall panel that backs up to a foundation
wall or is
otherwise accessible from only one side may not have surface covering layers
on both
sides. The number and type of surface covering layers may vary widely.
Additionally,
the structural considerations of a building may determine variations in the
walls. For
example, some walls may be load bearing, while others are non-load bearing.
Some
building designs may include some wall panels that have more stringent
structural
requirements to act as shear walls. Wall panels may be provided with core
layers, such as
insulation, of varying type and rating. For example, core layer 730, shown in
Figure 7,
may include Rl9 insulation.
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Built in features of wall panels may vary greatly. Doors and windows of
varying
sizes and configurations may be built into wall panels. The frames of these
wall panels
may have different configurations of studs and horizontal members to
accommodate and
support such features. In some embodiments, a single feature may be embodied
in
multiple wall panels or a larger than standard wall panels may be provided to
accommodate larger features. For example, a 6' sliding glass door may be
provided in a
single 8' wide wall panel. Other built in features may include shelves,
cabinets, fixtures,
fireplaces, and other structures.
Built in subsystems in wall panels may also vary greatly. Subsystems may
include electrical, communication, security, mechanical, plumbing, gas, and
other
building subsystems. Portions of one or more subsystems may be installed in a
wall
panel. In some cases, portions in one panel may be connected directly to
portions in an
adjacent panel. In some cases, additional components may be used to connect
portions of
the system in different wall panels. Portions of multiple subsystems may be
installed in a
single wall panel. Preinstalled portions of subsystems may include surface
devices, such
as vents, thermostats, outlets, switches, electrical boxes, hubs, sensors,
fixtures,
appliances, and other subsystem components. Preinstalled portions of
subsystems may
include connective components as well, such as wires, conduits, junctions,
wireless
connections, and other connective components. Further description of example
electrical
and mechanical systems are described below with reference to Figures 25-27
with
reference to wire-based subsystems and 28-35 with reference to mechanical
subsystems.
The pitched panels of Figures 8-I 1 are roof panels, which may have ceiling
surface covering layers and also be referred to as roof/ceiling panels. Roof
panels may
vary in dimensions, materials, purpose, features, and subsystems in a manner
similar to
wall panels. The comments provided above with regard to wall panels apply to
roof
panels as well. Figure 8 shows an example roof panel 800. Figure 9 shows an
example
roof panel 900 with a built in skylight 910. Figure 10 shows a side cross-
sectional view
of a roof panel 1000 showing surface covering layers 1020, 1021, and 1022 and
core
layer 1030. Figure 11 shows the frame 1110 of a roof panel 1100.
Dimensions of roof panels may be determined by the dimensions of the building
the roof panels are for and take into consideration ease of manufacture and
handling,
much as with wall panels. In a preferred embodiment, roof panels may be a
standard
width of 4'. The length of the roof panels may be determined by width of the
building
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and the pitch of the roof. Thickness of the roof panels may be determined by
the material
selections for the frame and surface covering layers.
A variety of materials may be used for fabricating roof panels. As shown in
Figure 10, a roof panel 1000 includes a frame 1010, a first surface covering
layer 1030, a
second surface covering layer 1031, a third surface covering layer 1032, and a
core layer
1040. Frame 1010, surface covering layers 1020, 1021, and 1022, and core layer
1030
may each be made from a variety of materials. In a preferred embodiment, Frame
1010
includes wooden members of varying dimensions, such as 2x4, 2x6, 2x8, 2x10,
2x12, etc.
depending on the position and purpose of the member. The position of various
members
in the frame are shown in Figure 11. Frame 1110 includes upper end members
1111,
1112 1113, and 1114, side members 1122, 1123, 1125, and 1126 and lower end
member
1121, which define a rectangular frame and an upper surface. Frame 1110 may
also
include a stud member 1124, cross members 1115, 1116, 1117 and 1118, and lower
support engaging members 1119 and 1120. Upper end members 1111 and 1112, side
members 1122, 1123, 1125, and 1126, and cross members 1115, 1116, 1117, and
1118
may define a lower surface. Upper end members 111 l, 1112, 1113, and 1114 side
members 1122, 1123, 1125, and 1126, and stud member 1124 may use a large
member to
provide the structural integrity of the roof panel. Lower end member 1121 and
lower
support engaging members 1019 and 1020 may use mid-sized members to compensate
for
the angle of the lower end, engage a lower support structure, such as a wall
panel, and
provide structural integrity to the roof panel. Cross members 1120 and 1121
may use the
smallest members to assist in defining the lower surface, supporting any
surface covering
layer applied to the lower surface, and providing structural integrity to the
roof panel.
Lilce wall panels, roof panels may employ a variety of surface covering
layers. For
example, roof panel 1000 includes surface covering layers 1020, 1021, and
1022. In a
preferred embodiment, surface covering layer 1020 may be an external roofing
material,
such as shingles. Surface covering layer 1021 may be an under layer, such as
sheathing
material. Surface covering layer 1022 may be an interior covering layer, such
as drywall.
Some roof panels may not employ a lower surface covering layer where the area
immediately under the roof is unfinished, such as in an attic or other design
with separate
ceiling panels. In some buildings, particularly non-residential buildings,
exterior
sheathing may include sheet metal, corrugated polymers, or similar sheet
roofing
materials. A single exterior surface covering layer may be used. As with wall
panels, the
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number of interior and exterior layers may vary widely and include any number
of
intermediate layers between exterior surface layers and any under layer.
The variety of purposes for roof panels is similar to that for wall panels in
that it
can vary greatly according to building type and style, as well as the
particular
configuration of any roof portion on any given building. Material and size
variation, load
requirements, support structure, features and subsystems, and other factors
may determine
frame structure and other details of a roof panel. A single building may have
multiple
roof portions with varying spans, pitches, support structures, and internal
and external
surface covering materials. For example, a single residence may include a
large, steeply
pitched main peak, a smaller lower pitched garage peak, a pitched porch roof;
and several
dormers. The structural requirements of a dormer or a porch roof may be much
different
than the requirements of the main roof.
The features incorporated into roof panels may also vary. Skylights of
different
sizes and configurations may be incorporated into roof panels. For example,
roof panel
900 incozporates skylight 910. Some roof panels may include translucent or
transparent
surface covering materials such that the panel is functionally a skylight.
Trap doors,
chimneys, and other features may also be included in a roof panel design.
A variety of subsystems may also be incorporated into roof panels. Portions of
any subsystem may be included in a roof panel. For example, vents for
mechanical and
plumbing systems, solar panels, mounting systems for roof mounted HVAC units
and
other appliances, and other external surface devices may be incorporated in a
roof panel.
Similarly, roof panels may include vents, fixtures, appliances, and other
internal surface
devices. Wires, conduits, and other connective portions of subsystem may also
be
incorporated in the roof panels. Multiple subsystems may be incorporated into
a single
roof panel and portions of a subsystem may be distributed across multiple
panels. Further
description of example wire-based and mechanical subsystems are described
below.
Like vertical panels and pitched panels, there may be a wide variety in
dimensions, materials, purposes, features, and subsystems installed in
horizontal panels.
Figure 12 shows the top of a horizontal panel 1200. Figure 13 shows the bottom
of a
ceiling panel 1300, including surface devices 1310 and 1311. Figure 14 is a
side cross-
sectional of a horizontal panel 1400 with surface covering layers 1420, 1421,
and 1422.
Figure 15 is a side cross-sectional view of a horizontal panel 1500 with
surface covering
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layers 1520, 1521, 1522, and 1523. Figure 16 is a top view of a frame 1600 for
a
horizontal panel.
Dimensions of horizontal panels may be determined by the dimensions of the
building the panels are for and take into consideration ease of manufacture
and handling,
much as with wall and roof panels. In a preferred embodiment, floor, ceiling,
and roof
panels may be a standard width of 4'. The length of the horizontal panels may
be
determined by the span between support structures for the particular panel.
Thickness of
the horizontal panels may be determined by the material selections for the
frame and
surface covering layers.
A variety of materials may be used for fabricating horizontal panels. As shown
in
Figure 14, a horizontal panel 1400 includes a frame 1410, a first surface
covering layer
1420, a second surface covering layer 1421, a third surface covering layer
1422, and a
core layers 1430 and 1431. Figure 15 shows an alternate example where
horizontal panel
1500 includes a frame 1 S 10, a first surface covering layer 1520, a second
surface
covering layer 1521, a third surface covering layer 1522, a fourth surface
covering layer
1523, and a core layers 1530 and 1531. Frames 1410 and 1510, surface covering
layers
1420, 1421, 1422, 1520, 1521, 1522, and 1523 and core layers 1430, 1431, 1530,
and
1531 may each be made from a variety of materials. In a preferred embodiment,
frames
1410 and 1510 include wooden members of varying dimensions, such as 2x4, 2x6,
2x8,
2x10, 2x12, etc. depending on the position and purpose of the member. The
wooden
members may by composite floor joists. The position of various members in an
example
frame 1600 are shown in Figure 16. Frame 1600 includes lateral side members
1610,
1611, 1612, and 1613 and end members 1614 and 1615 defining a rectangular
frame.
Joist members 1616 and 1617 extend from end member 1614 to end member 1615
parallel to side members 1610, 1611, 1612, and 1613. Cross members 1620, 1621,
1622,
1623, 1624, 1625, 1626, 1627, and 1628 extend between adjacent joist members
1616 and
1617 and adjacent side members 1611 and 1612. Like wall panels and roof
panels,
horizontal panels may employ a variety of surface covering layers. In a
preferred
embodiment, surface covering layers 1420, 1421, 1422, 1520, 1521, 1522, and
1523 may
be any combination of sheathing or under flooring, drywall, ceiling paneling,
external
roofing material, padding, flooring, or other materials. For example, a
combination
roof/ceiling panel may include sheathing and tar sealant on the top side and
drywall on
the bottom side. A floor/ceiling panel may include under flooring and flooring
material
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on the top side and ceiling panels on the bottom side. Some horizontal panels
may not
employ a lower surface covering layer or an upper surface covering layer where
the area
immediately under the roof or floor is unfinished or the area above the
ceiling is
unfinished. As with other construction panels, the number of interior and
exterior layers
S may vary widely and include any number of intermediate layers between
exterior surface
layers and any under layer.
The variety of purposes for horizontal panels is large and can vary greatly
according to building type and style, as well as the particular configuration
of any roof
portion on any given building. Material and size variation, load requirements,
support
structure, features and subsystems, and other factors may determine frame
structure and
other details of a horizontal panel. A single building may have multiple
purposes for
horizontal panels, including roofs, floors, and ceilings. Spans, support
structures, load
requirements, and internal and external surface covering materials may differ
even on a
single level, as well as across multiple horizontal levels of a building.
1 S The features incorporated into horizontal panels may also vary. Horizontal
panels
may incorporate features of both wall panels and roof panels as described
above.
A variety of subsystems may also be incorporated into horizontal panels.
Portions
of any subsystem may be included in a horizontal panel. Horizontal panels may
incorporate features of both wall panels and roof panels as described above.
For example,
horizontal panel 1300 incorporates surface devices 1310 and 1311.
In a preferred embodiment, construction panels are prefabricated according to
standards meeting the building codes of one or more jurisdictions. The
construction
panels may also be designed and manufactured to conform with other verified
safety
standards, such as those administered by Underwriters Laboratories, Inc. For
example,
2S residential building panels may be designed to conform to minimum material
standards,
stud spacing, height of windows, location of electrical outlets and switches,
and other
requirements. Construction panels may be insulated to meet minimum
requirements.
Combinations of surface layer materials, frame materials, and core materials
may also be
used for construction panels meeting specific fire rating requirements or
other special
purpose requirements.
Construction panels may be used for a variety of purposes. For example, a
number of construction panels, including wall, roof, and possibly floor and
ceiling panels,
may be used to build a new building according to a building module
configuration.
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Similarly, construction panels may be used to build an addition to an existing
building or
a portion of a building site built or built using other techniques.
Construction panels may
also be used independently or in small groups to accent other construction
techniques,
make minor additions to an existing building, or assist in renovation of an
existing
building. Figures 17-20 show four stages of construction on building 1700
using
construction panels. In the example shown, only vertical panels are employed,
but
pitched, horizontal, or other panels could be used in substantially the same
way.
Figure 17 shows a pre-existing building 1700. Building 1700 includes a floor
1710 and exterior walls 1720, 1721, 1722, and 1723. Building 1700 also
includes an
exterior door 1724 in exterior wall 1721, an internal wall 1725 with a door
1726, and a
stairway 1728. For example, building 1700 could be the unfinished basement of
an
existing residence divided into two utility rooms by an unfinished stick-built
wall
(internal wall 1725). having a sliding glass door (exterior door 1724) to the
back yard,
and a concrete floor (floor 1710). The owner might desire to renovate the
basement and
finish it for use as a family room.
In Figure 18, building 1700 has been prepared for renovation by stripping pre-
existing structures incompatible with the owner's desired building
configuration.
Preparation may include demolishing and removing pre-existing walls, floors,
ceilings,
and doors and other features. Preparation may include stripping pre-existing
structures to
underlying structures, such as removing finishing and drywall to expose wall
frames, or
ripping out old flooring to expose the sub-floor. Preparation may include
minor site-built
construction or modification of existing structures in order to define one or
more spaces
compatible with a particular construction panel size or configuration. In the
present
example, exterior wall 1721, including exterior door 1724, has been removed. A
portion
of internal wall 1725, including internal door 1726, has been removed and
internal wall
portion 1827 remains.
In Figure 19, sills 1930, 1931, 1932, 1933, 1934, and 1935 have been attached
to
floor 1710. Sills 1930, 1931, 1932, 1933, 1934, and 1935 may provide a portion
of an
attachment mechanism for one or more construction panels and may assist in
positioning
those construction panels. Sills 1930 and 1931 have been placed between
internal wall
portion 1827 and a wall of stairway 1728 in order to define a location for
positioning a
wall panel with a door. Sill 1932 has been placed parallel to exterior wall
1720 in order
to define a location for positioning one or more interior wall panels. Sills
1933 and 1934
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have been placed parallel to the opening created by the removal of exterior
wall 1721.
Sills 1933 and 1934 define a location for positioning one or more exterior
wall panels,
include a wall panel with a door. Sill 1935 has been placed parallel to
exterior wall 1722
in order to define a location for one or more interior wall panels. Sills
1930, 1931, 1932,
1933, 1934, and 1935 may be attached to floor 1710 using a variety of
attachment
mechanisms, depending on the materials of floor 1710 and sills 1930, 1931,
1932, 1933,
1934, and 1935. For example, floor 1710 may be a concrete floor and sills
1930, 1931,
1932, 1933, 1934, and 1935 may be attached using anchors drilled into the
concrete.
Alternatively, floor 1710 may be wood and fasteners such as bolts, screws, or
nails could
be used to attach sills 1930, 1931, 1932, 1933, 1934, and 1935.
In Figure 20, a plurality of wall panels 2040, 2041, 2042, 2043, 2044, 2045,
2046,
2047, 2048, and 2049 are positioned over sills 1930, 1931, 1932, 1933, 1934,
and 1935.
Wall panels 2040, 2041, 2042, 2043, 2044, 2045, 2046, 2047, 2048, 2049, and
2050 may
be attached to each other, sills 1930, 1931, 1932, 1933, 1934, and 1935,
andlor pre-
existing building structures, such as floor 1710, exterior walls 1720 and
1722, stairway
1728, and interior wall portion 1827. Wall panel 2040 is a vertical panel with
a pre-
installed door. Wall panel 2040 is positioned over and attached to sills 1930
and 1931.
Wall panel 2040 may be attached to the wall of stairway 1728, interior wall
portion 1827,
and/or floor 1710 or a portion of the ceiling (not shown). Wall panel 2040 may
separate a
newly formed closet 2060 from a family room 2061. Wall panels 2042, 2042, and
2043
may be interior vertical construction panels fox providing a finished wall in
family room
2061. Wall panels 2041, 2042, and 2043 are positioned over and attached to
sill 1932.
Wall panel 2041 may be attached to interior wall portion 1827 and wall panel
2042. Wall
panel 2042 may be attached to wall panels 2041 and 2043. Wall panel 2043 may
be
attached to wall panels 2042 and 2044. Wall panels 2041, 2042, and 2043 may
each be
attached to floor 1710, a portion of the ceiling (not shown), and/or exterior
wall 1720.
Wall panels 2044, 2045, and 2046 may be exterior vertical construction panels
for
providing a finished and exterior wall for family room 2061. Wall panel 2045
may
include a pre-installed door, such as a set of French doors, for providing
access from
family room 2061 to a backyard (not shown). Wall panels 2044, 2045, and 2046
are
positioned over and attached to sills 1933 and 1934. Wall panel 2044 may be
attached to
exterior wall 1720, wall panel 2043, and wall panel 2045. Wall panel 2045 may
be
attached to wall panels 2044 and 2046. Wall panel 2046 may be attached to wall
panels
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2045 and 2047 and exterior wall 1722. Wall panels 2044, 2045, and 2046 may be
attached to floor 1710 or a portion of the ceiling (not shown). Wall panels
2047, 2048,
2049, and 2050 may be interior vertical construction panels for providing a
finished wall
for family room 2061. Wall panels 2047, 2048, 2049, and 2050 may be positioned
over
and attached to sill 1935. Wall panel 2047 may be attached to wall panels 2046
and
2048. Wall panel 2048 may be attached to wall panels 2047 and 2049. Wall panel
2049
may be attached to wall panels 2048 and 2050. Wall panel 2050 may be attached
to wall
panel 2049 and a wall portion of stairway 1728. Wall panels 2047, 2048, 2049
,and 2050
may be attached to floor 1710, a portion of the ceiling (not shown), andlor
exterior wall
1722. After the construction panels are positioned and attached, the seams
created
between each construction panel and adjacent structures (both pre-existing
building
structures and other construction panels) may be covered. Covering seams may
include
placing seam covering materials, such as adhesive tape, putty, joint compound,
cover
plates, or other materials, over the seams. After seams are covered,
additional finishing
may be done, such as painting, wall papering, adding molding, or other
finishing.
Construction panels may be attached to one another and adjacent structures
using
a variety of attachment mechanisms. Nuts and bolts, screws, nails, latches,
clips, and
other mechanical fasteners are all possible. Adhesives, welds, mating
surfaces, and other
attachment mechanisms may also be possible. In a preferred embodiment,
mechanical
fasteners are used to attach construction panels to adjacent structures.
Attachment
mechanisms for attaching construction panels to adjacent structures are shown
in Figures
21-24. Figures 21 and 22 show a fastener and strap attachment mechanism for
attaching
adjacent building structures. Figures 23 and 25 show a combination of
attachment
mechanisms used for attaching adjacent vertical construction panels to one
another and to
a floor using a sill, as described above with regard to Figures 17-20.
Figure 21 shows a side view of a fastener and strap attachment mechanism for
attaching adjacent structures, such as a construction panel to another
construction panel or
a construction panel to an adjacent building.structure. Figure 21 shows a
first building
structure 2110 and a second building structure 2111 positioned adjacent each
other and
defining a seam 2112. Seam 2112 is shown as a gap between first building
structure 2110
and second building structure 2111. However, in a preferred embodiment, the
adjacent
building structures are placed snuggly in contact with one another and seam
2112 does
not include a gap. A strap 2120 is located in contact with first building
structure 2110
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and second building structure 2111, spanning seam 2112. A number of fasteners
2130,
2131, 2132, and 2133 extend through strap 2120 and into first building
structure 2110 and
second building structure 2111. Strap 2120 may be made of metal, plastic, or
another
material. Strap 2120 may define a plurality of holes for accommodating a shaft
portion of
the fasteners, but not allowing a head portion to pass though. Straps may be
configured in
alternate shapes, such as L's, T's, and other shapes for conforming to the
attachment
surfaces and orientations of adjacent structures.
Figure 22 shows a top view of a plurality of fastener and strap attachment
mechanisms used to attach adjacent building structures. A first construction
panel 2210
and a second construction panel 2220 are positioned adjacent one another
defining a seam
2230. First construction panel 2210 includes a frame 2211 and Second
construction panel
2220 includes a frame 2221. A first strap 2240 and a second strap 2250 are
positioned in
contact with frame 2211 and frame 2221 spanning seam 2230. Fasteners 2241 and
2242
attach first strap 2240 to frame 2211 and fasteners 2243 and 2244 attach first
strap 2240
to frame 2221. Fasteners 2251 and 2252 attach second strap 2250 to frame 2211
and
fasteners 2253 and 2254 attach second strap 2250 to frame 2221.
Figure 23 shows an attachment mechanism for attaching a vertical construction
panel 2310 to a base structure 2320, such as a floor, by mating the bottom of
construction
panel 2310 with a complementary sill 2330. Construction panel 2310 includes a
frame
2311. Frame 2311 includes a base member 2312 extending approximately the width
of
frame 2311. Frame 2311 also includes a sill compliment member 2313 extending
only a
portion of the width of frame 2311. Base member 2312 and frame compliment
member
2313 are integral to frame 2311. A bottom side of sill compliment member 2313
engages
base structure 2320. Sill member 2330 engages base member 2312 and sill
compliment
member 2313. The combined width of sill member 2330 and sill compliment member
2313 may be approximately equal to the width of base member 2312. Many
alternate
configurations for complementary arrangement between the bottom of a
construction
panel frame and one or more sills are also possible, such as various tongue
and groove
combinations, multiple sills and complementary members, and other
configurations. Sill
member 2330 may be attached to base structure 2320 using a variety of
attachment
mechanisms. As shown, sill member 2330 is attached to base structure 2320
using an
anchor 2321. Construction panel 2310 is attached to sill member 2330 using a
variety of
attachment mechanisms. As shown, construction panel 2310 is attached to sill
member
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2330 using a strap and fastener attachment mechanism 2314, as described above
with
regard to Figures 2I and 22. Attachment mechanism 2314 attaches to a portion
of base
member 2312 and a portion of sill member 2330 and extends across the seam
between
them. A plurality of attachment mechanisms may be arranged along the length of
a
construction panel, as shown in Figure 24. Construction panel 2310 may also be
attached
to base structure 2320. Construction panel 2310 may be attached to base
structure 2320
using a variety of attachment mechanisms. As shown, construction panel 2310 is
attached to base structure 2320 using a strap and fastener attachment
mechanism 2315.
Attachment mechanism 231 S attaches to a portion of sill compliment member
2312 and a
portion of base structure 2320 and extends across a seam between them. A
plurality of
attachment mechanisms may be arranged along the length of a construction
panel.
Attachment mechanisms for attaching construction panel 2310 to base structure
2320 and
sill member 2330 may engage a portion of frame 2311 that is not covered by any
surface
covering layers. The attachment mechanisms may not be aesthetically desirable
in the
1 S finished state. One or more base plates 2340 and 2341 may be installed to
cover the
exposed portion of frame 231 l, sill member 2330, and various fastening
mechanisms.
Base plates 2340 and 2341 may include metal base plates, base board molding,
hard
rubber base plates, or other covers. Base plates 2340 and 2341 may be attached
to
construction panel 2310 and/or base structure 2320 using a variety of
attachment
mechanisms, such as fasteners, adhesives, or other attachment mechanisms.
Figure 24 shows a front view of adjacent construction panels 2410 and 2420
attached to a sill 2430. Construction panels 2410 and 2420 are attached to one
another
and sill 2430 using a plurality of strap and fastener attachment mechanisms
2430, 2431,
2432, 2433, and 2434.
2S Wire-based Subsystems
Any construction panel may have a portion of one or more building subsystems
pre-installed within it. Pre-installed subsystems generally include one or
more surface
devices, one or more internal devices, and one or more connective devices.
Surface
devices include any device that extends through one or more surface covering
layers of
the construction panel. Surface devices are usually visible, though not
necessarily
obvious, on the surface of the finished construction panel. Internal devices
include
devices that are installed within the interior space of the construction panel
and are
generally not visible on the surface of a finished construction panel.
Connective devices
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are devices used to interconnect other devices for the subsystem. Connective
devices are
installed within the interior space of the construction panel and may extend
to an edge of
the construction panel for interconnection with other portions of the
subsystem. Some
connective devices may by site-installed to interconnect portions of the
subsystem in
adjacent construction panels or building structures. In many cases, a
connective device
may be used to interconnect the pre-installed portions with a subsystem source
of some
kind.
Figure 25 shows an example wire-based subsystem 2500 with portions pre-
installed in a number of adjacent construction panels. The construction panels
are shown
as frames only, without surface covering layers, in order to expose the
internal devices
and connective devices. The construction panels may include one or more
surface
covering layers. First construction panel 2510, second construction panel
2520, and third
construction panel 2530 each include a frame comprised of a plurality of
members. First
construction panel 2510 may be attached to second construction panel 2520.
Second
construction panel 2520 may be attached to first construction panel 2510 and
third
construction panel 2530. Third construction panel 2530 may be attached to
second
construction panel 2520. Each of construction panels 2510, 2520, and 2530 may
be
attached to a sill 2540. Each of construction panels 2510, 2520, and 2530 may
be
attached to adjacent building structures (not shown), such as a base
structure, adjacent
walls or supports, or a ceiling. In each of construction panels 2510, 2520,
and 2530,
portions of the wire-based subsystem may be attached to the members of the
frames.
Attachment to the frame members may be accomplished in any number of ways, as
appropriate to the subsystem and frame material. For example, a wire-based
system
installed in a construction panel with a wooden frame may employ fasteners to
attach
internal and surface devices and wire guides or staples for attaching
connective wires to
the frame. Portions of the subsystem, specifically the wires, may pass through
one or
more members of the frames. The frame members may define holes for
accommodating
the wires. In some embodiment, holes in the frame members, such as members at
the
edge of the frame, may define guide conduits for site wiring portions of the
subsystem.
Frames may also be modified to accommodate or provide additional support for
devices
or portions of subsystems. For example, construction panel 2520 includes an
additional
member 2521 for securing a device. Other modifications are possible and may
include
adding members, removing members, moving members, using alternate materials,
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providing mounting devices and assemblies, or otherwise providing structure to
secure
portions of a subsystem. During fabrication of the construction panels and
installation of
the construction panels on-site, portions of the wire-based subsystem may be
electrically
connected. Being electrically connected includes providing conducting contact
between
portions of the subsystem. Conducting contact may not be direct contact.
Conducting
contact may include conduction through a series of intermediate devices or sub-
portions
of the subsystem. For example, in a completed circuit, all components may be
regarded
as electrically connected to each other component, including a circuit source.
Within the
context of wire-based subsystems within a building, each device in an
electrical,
communication, thermostat, security system, and other subsystems may be
regarded as
electrically connected if a conducting connection is provided between each
adjacent
component. The interruption in actual conductivity provided by switches, hubs,
and
similar components does not impact the concept of electrical connection in the
fabrication
and installation of a wire-based subsystem.
Construction panel 2510 includes a first portion 2560 of wire-based subsystem
2500. First portion 2560 may include one or more devices for centralized
directing,
switching, and/or controlling other portions of wire-based subsystem 2500. For
example,
first portion 2560 may include an electrical box, a communications hub,
central control
for an alarm system, a master computer for a smart house, a network server, a
central
receiver or router for an audio/video/broadcast system, central control for an
intercom, or
another central control system for a building subsystem. First portion 2560
may include
surface devices, internal devices, and connective wires for achieving its
controlling
function. For example, surface device 2561 may be a central control appliance,
such as a
switch, router, hub, computer, or other device. Surface device 2561 may
include
mechanical or electronic access to control functions. In a preferred
embodiment, surface
device 2561 is an electrical box for an electrical subsystem. In another
preferred
embodiment, surface device is a computer system and associated hardware for
controlling
the functions of multiple building functions. The computer system may direct
communications and broadcast signals and control security systems, HVAC,
networked
appliances, and other house subsystems. Though only a single surface device
2561 is
shown, a system of interconnected surface and internal devices may be employed
for the
control system. Other surface devices unrelated to central control may also be
included in
subsystem portion 2560, such as outlets, fixtures, or appliances. First
portion 2560 also
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includes junction boxes 2562 and 2563. Junction boxes 2562 and 2563 allow
first portion
2560 to be electrically connected to subsystem portion outside construction
panel 2510.
Junction boxes 2562 and 2563 may be any type of device for housing a
connection
between two or more wires. In one embodiment, junction boxes 2562 and 2563 may
include open boxes with access points for threading wires into the box, where
they may
be manually connected to other wires. In an alternate embodiment, junction
boxes 2562
and 2563 may include interconnected hardware receptors accommodating
connectors
attached to the ends of the wires to be connected. Junction boxes 2562 and
2563 may not
connect wires in a one-to-one ratio from the construction panel to wires
outside the
construction panel. For example, a junction box may accommodate a single input
wire
and electrically connect it to multiple wires internal to the construction
panel. In a
preferred embodiment, junction boxes 2562 and 2563 are accessible during
installation of
construction panel 2510 such that wires from other portions of subsystem 2500
may be
connected to first portion 2560 and those connection may be inspected. Surface
device
2561 is connected to junction boxes 2562 and 2563 by internal wires 2564,
2565, 2566,
2567, and 2568. In one embodiment, surface device 2561 is a control system for
multiple
wire-based subsystems and wires 2564, 2565, 2566, 2567, and 2568 may include
different
types of wire, such as electrical wire, telephone wire, coaxial cable, speaker
wire, etc., for
the different subsystems. In a preferred embodiment, where subsystem 2500 is
an
electrical system, wire 2564 may be a source wire and each of wires 2565,
2566, 2567,
and 2568 may be a different circuit for the building. Multiple wires may
electrically
connect first portion 2560 to the portions in other construction panels and/or
in other
building structures. In a preferred embodiment, these other wires are
installed on-site.
Source wire 2550 leads from junction box 2562 to a source 2551 for the wire-
based
system. Source 2551 may include an originating portion of subsystem 2500, such
as a
generator or other energy source. Source 2551 may include a connection to
private or
public distribution network, such as a power distribution line, telephone or
other data line,
satellite or terrestrial broadcast system,' or other network. Wires 2552,
2553, 2554, and
2555 may connect to other portions of subsystem 2500. For example, wire 2552
may
electrically connect wire 2565 to a portion of subsystem 2500 on the next
floor up (not
shown) in the building. Wire 2553 may electrically connect wire 2566 to
portions of
subsystem 2500 adjacent to construction panel 2510 opposite construction panel
2520 or
elsewhere in the building. Wire 2554 may electrically connect wire 2567 to a
second
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portion 2570 in construction panel 2520. Wire 2555 may electrically connect
wire 2567
to portions of subsystem 2500 adjacent to construction panel 2530 opposite
construction
panel 2520 or elsewhere in the building. First portion 2560 may support any
number of
subsystem types and any number of connections with other subsystem portions.
Construction panel 2520 includes second portion 2570 of wire-based subsystem
2500. Second portion 2570 includes multiple surface devices for providing
functional
interactivity with subsystem 2500. Surface devices 2571 and 2572 may be any
surface
device appropriate to the subsystem type. For example, in an electrical
system, surface
device 2571 may be a switch and surface device 2572 may be an outlet. Other
surface
devices may include other types of outlets and switches, control panels,
thermostats,
intercoms, network devices, speakers, appliances, sensors, and other devices.
Second
portion 2570 may also include junction boxes 2573 and 2574. Junction boxes
2573 and
2574 may function similarly to junction boxes 2562 and 2563 described above.
Wire
2575 may electrically connect surface device 2571 to junction box 2573. In one
embodiment, where surface device 2571 is a switch, wire 2575 and any subsystem
portion electrically connected to it through junction box 2573 may be switched
by surface
device 2571. Wire 2576 may electrically connect surface device 2571 to surface
device
2572. Wire 2577 may electrically connect surface device 2572 to junction box
2574.
Junction box 1573 may receive a wire 2555 for electrically connecting to an
additional
portion (not shown) of subsystem 2500. In one embodiment, the additional
portion may
be a light fixture, ceiling fan, or other surface device built into an
adjacent horizontal
construction panel (not shown). Where surface device 2571 is a switch, the
light fixture,
ceiling fan, or other surface device may be switched by surface device 2571.
Junction
box 2574 may receive wire 2554,to electrically connect second portion 2570 to
first
portion 2560. Junction box 2574 may also receive a wire 2556 electrically
connected to a
third portion 2580 in construction panel 2530. This is a second example of a
junction box
that does not receive an equal number of interior and external wires or an
equal number of
input and output wires.
Construction panel 2530 includes third portion 2580 of wire-based subsystem
2500. Third portion 2580 includes multiple surface devices for providing
functional
interactivity with subsystem 2500. Surface devices 2581, 2582, 2583, and 2584
may be
any surface devices appropriate to the subsystem type. For example, in an
electrical
system, surface device 2581 may be a light fixture, surface device 2582 may be
a switch,
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surface devices 2583 and 2584 may be outlets. Surface device 2584 may be a
combined
surface device and junction box, such as an outlet with space to receive a
wire and be
inspected. Third portion 2580 may further incorporate a guide conduit 2585 for
guiding a
wire from the edge of construction panel 2530 to surface device 2584. Wire
2586 may
electrically connect surface device 2581 to surface device 2582. In one
embodiment,
where surface device 2582 is a switch, surface device 2581 may be switched by
surface
device 2582. Wire 2587 may electrically connect surface device 2582 to surface
device
2583. Wire 2588 may electrically connect surface device 2583 to surface device
2584.
Surface device 2584 may receive wire 2556 to electrically connect third
portion 2580 to
second portion 2570.
Figure 26 shows a detailed view of system for site-wiring a construction panel
2610. Construction panel 2610 may by attached to a base structure 2630 using a
sill
2640. Construction panel 2610 may be electrically connected to other portions
of a
subsystem by a connecting wire 2650. Construction panel 2610 includes a frame
2611
and surface covering layers 2612 and 2613. Frame 2611 includes a base member
2614
and a sill complimentary member 2615. Base member 2614 defines a hole 2616 for
accommodating connecting wire 2650 from outside construction panel 2610. Frame
2611
also includes an additional member 2617 for securing a junction box 2620.
Additional
member 2617 defines a hole 2618 for accommodating an internal wire 2621.
Junction
box 2620 is electrically connected to internal wire 2621 that may be
electrically
connected to one or more surface devices or internal devices within
construction panel
2610. Construction panel 2610 may be attached to sill 2640. Base member 2614
and sill
complimentary member 2615 may mate with sill 2640 and one or more attachment
mechanisms may be used to attach construction panel 2610 to sill 2640, as
described
above. Sill 2640 may define an opening 2641 for accommodating connecting wire
2650.
A second connecting wire 2651 may run parallel to connecting wire 2650 and
electrically
connect other portions of a wire-based subsystem. Connecting wires 2650 and
2651 may
be accommodated within a space defined by base member 2614, sill 2640, and the
width
of surface covering layer 2612. A first base plate 2660 may be installed to
cover access
to junction box 2620 and the space accommodating connecting wires 2650 and
2651.
When installed, first base plate 2660 may extend vertically from base
structure 2630 and
overlap a portion of surface covering layer 2612. A second base plate 2661 may
be
installed on the opposite side of construction panel 2610.
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Figure 27 shows a method of installing a panelized construction system with at
least one wire-based subsystem preinstalled in the panels. In step 2710, a
construction
panel including a portion of a wire-based subsystem, such as one of
construction panels
2510, 2520, or 2530 from Figure 25, is positioned. The portion of the wire-
based
subsystem may include surface devices, internal devices, and/or connective
devices. The
construction panel may include one or more receptors for attaching one or more
connecting wires. For example, the construction panel may include one or more
junction
boxes, with or without guide conduits, accessible from an edge of the
construction panel.
The construction panel may be positioned in accordance with predetermined
building
configuration. For example, a vertical construction panel may be positioned
along a sill
attached to a base structure in a particular configuration. Horizontal or
pitched
construction panels may be positioned between two support structures, such as
vertical
panels, ridge beams, or bearing ledgers. In step 2720, the positioned
construction panel is
fixed in place. The construction panel may be attached to adjacent
construction panels or
building structures using a variety of attachment mechanisms. The construction
panel
may be attached to a sill and/or a base structure, or another support. Steps
2710 and 2720
may be repeated for a plurality of construction panels. In step 2730, a
connecting wire is
run to the positioned construction panel or panels. The connecting wire may be
run
through a space adjacent the construction panel frame. The connecting wire may
be
inserted into a guide conduit leading to a junction box or other receptor for
the connecting
wire. Alternatively, where there is access to a surface device or an internal
device, such
as when the construction panel has a side without a surface covering layer,
the connecting
wire may be run adjacent the construction panel directly to a receptor for the
surface or
internal device. In step 2740, the connecting wire is electrically connected
to the
subsystem portion in one or more construction panels. The connecting wire may
be
attached directly to connective devices, such as internal wires for the
construction panel,
within a receptor, such as a junction box. Alternatively, the receptor may
accept the
connecting wire and provide a hardware connection to the subsystem portion
within the
construction panel. In some cases, both ends of the connecting wire may be
connected to
subsystem portions within the construction panel. Alternatively, one end may
have been
previously connected or be part of a pre-existing building subsystem. Steps
2730 and
2740 may be repeated for multiple connecting wire. In step 2750, the subsystem
portion
is electrically connected to a source for the subsystem. Electrically
connecting to the
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source may include connecting a connecting wire to pre-existing portion of the
subsystem, connecting to a newly installed source, or connecting to a source
wire for a
public or private distribution system. In some cases, connecting to the source
may be
accomplished through steps 2730 and 2740 where one of the connecting wires run
and
connected is already electrically connected to the source. In step 2760, any
exposed
connecting wires and receptors are covered. Covering the connecting wires and
receptors
may include installing covers over open junction boxes, such as surface device
face
plates. Covering the connecting wires and receptors may include installing
base plates or
other covering panels over the spaces in which the connecting wires were run.
Where the
connecting wires run along the base of the construction panels and the
receptors are
immediately adjacent the construction panel base, a single base plate may be
installed to
cover both. Installing the base plate may include positioning and attaching
the base plate
to the construction panels. In some embodiments, construction panels may have
operable
covers preinstalled adjacent the receptors and/or the spaces for the
connecting wires.
Covering the connecting wires and receptors may include closing the
preinstalled covers.
In step 2770, the connections between the connecting wires and the subsystem
portions
pre-installed in the construction panels may be inspected by an individual of
relevant
experience or authority. In this way, quality and safety of subsystem
connections may be
evaluated and controlled. In some jurisdictions, inspections may be mandated
by building
code or other regulatory action. The method promotes for pre-installation of
the majority
of the subsystem in the construction panel to minimize on-site labor, while
allowing for
appropriate on-site inspection of the subsystem.
Mechanical Sub-systems
Many of the same principals from pre-installation of wire-based subsystems
apply
to the fabrication and installation of construction panels with mechanical
subsystems.
However, mechanical systems, such as heating, ventilation, and air
conditioning systems,
gas and vacuum systems, and other mechanical systems, utilize piping,
ductwork, or other
conduits. Generally, these conduits occupy more space than wires, are more
time
consuming to site install, and require greater mechanical precision to
interconnect.
Portions of a mechanical subsystem may be functionally connected. Functional
connection is determined by the function of the particular subsystem. In many
cases,
functional connection includes mating compatible conduits or mating conduits
to surface
devices or internal devices. Functional connection may also include bonding
and
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ensuring a seal between the mated devices. In some cases, mating of compatible
devices
may be approximate and additional material may be used to provide the seal,
producing a
functional connection. Functional connection may also be used to refer to the
connection
between two components where the two components are separated by one or more
intermediate components, yet the two components may exchange material or
otherwise
function according to their intended purpose. For example a surface device,
such as a
vent, and a source, such as a furnace, may be separated by a considerable
number of
conduits (such as duct sections). However, they may still be regarded as
functionally
connected to one another.
Figure 28 shows an example of a portion of a mechanical subsystem 2800
preinstalled in adjacent construction panels. Construction panel 2810 and
construction
panel 2820 are adjacent horizontal construction panels. Construction panels
2810 and
2820 include frames 2811 and 2821. Only a relevant portion of frames 2811 and
2821
are depicted in Figure 28. Construction panels 2810 and 2820 are not shown
with surface
covering layers in order to better show the portion of the mechanical
subsystem
preinstalled within them. Construction panels 2810 and 2820 may include one or
more
surface covering layers on one or both sides as described above with reference
to Figures
1-16. Frame 2811 of construction panel 2810 and frame 2821 of construction
panel 2820
define a seam 2830 along their adjacent edges. Conduits within construction
panels 2810
and 2820 may be shomz intersecting frames 2811 and 2821. Openings in the
members of
frames 2811 and 2821 accommodate such conduits and allow them to pass
uninterrupted
through the frame members.
Construction panel 2810 includes a first portion 2840 of mechanical subsystem
2800. First portion 2840 provides for functional connection to a source 2850.
First
portion 2840 includes a first conduit 2841 for connecting to source 2801 and a
second
conduit 2851 for connecting to source 2801. Connecting devices 2841 and 2851
may
include multiple sections of interconnected conduit. Conduit 2841 includes a
surface
device 2842 for mating with a conduit (not shown) from source 2801. Conduit
2841
includes a first redirecting joint (not shown) connected to surface device
2842. The first
redirecting joint alters the direction of conduit 2841 from perpendicular to
the surface of
construction panel 2810 to parallel to the surface of construction panel 2810
and seam
2830. The first redirecting joint connects to a first shaft portion 2843
parallel to seam
2830. First shaft portion 2843 extends to a second redirecting joint 2844 for
altering the
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direction of conduit 2841 from parallel to seam 2830 to perpendicular seam
2830.
Second redirecting joint 2844 connects to a second shaft portion 2845
perpendicular to
seam 2830. Second shaft portion 2845 extends to seam 2830 where it mates with
a
a
second portion 2860 of mechanical subsystem 2800. Conduit 2851 includes a
surface
device 2852 for mating with a conduit (not shown) from source 2801. Conduit
2851
includes a first redirecting joint (not shown) connected to surface device
2852. The first
redirecting joint alters the direction of conduit 2851 from perpendicular to
the surface of
construction panel 2810 to parallel to the surface of construction panel 2810
and seam
2830. The first redirecting joint connects to a first shaft portion 2853
parallel to seam
2830. First shaft portion 2853 extends to a second redirecting joint 2854 for
altering the
direction of conduit 2851 from parallel to seam 2830 to perpendicular seam
2830.
Second redirecting joint 2854 connects to a second shaft portion 2855
perpendicular to
seam 2830. Second shaft portion 2855 extends to seam 2830 where it mates with
a
second portion 2860 of mechanical subsystem 2800. In a preferred embodiment,
source
2801 may be HVAC unit with output conduit and a return conduit. Conduit 2841
may be
ductwork functionally connected to the return conduit. Conduit 2851 may be
ductwork
functionally connected to the output conduit.
Construction panel 2820 includes second portion 2860 of mechanical subsystem
2800. Second portion 2860 provides functional connection between a plurality
of other
portions, including first portion 2840. Second portion 2860 includes a first
conduit 2861
and a second conduit 2871. Conduit 2861 may interconnect conduit 2851 from
construction panel 2810, additional portions in adjacent horizontal panels
(not shown),
and additional portions in adjacent vertical panels (such as shown in Figure
29 below).
Conduit 2871 may interconnect conduit 2841 from construction panel 2810 and
additional portions in adjacent horizontal panels (not shown). Conduit 2861
includes a
first shaft portion 2862 extending from an edge of construction panel 2820 at
seam 2830
to a junction portion 2863. First shaft portion 2862 functionally connects to
conduit 2851
at seam 2830. For an example of a connection between conduit 2851 and 2861,
see
description below regarding Figure 30. First shaft portion 2862 extends
perpendicular to
seam 2830. Junction portion 2863 may connect first shaft portion 2862 to
second shaft
portion 2864 and third shaft portion 2865. Second shaft portion 2864 extends
perpendicular to first seam 2830, continuing first shaft portion 2862. Second
shaft
portion 2864 extends to an edge 2822 of construction panel 2820 opposite seam
2830.
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Second shaft portion 2864 may mate with additional portions of subsystem 2800
(not
shown) at edge 2822. Third shaft portion 2865 extends parallel to seam 2830
from
junction portion 2863 to a first redirecting joint 2866. First redirecting
joint 2866
redirects conduit 2861 from a direction parallel to a surface of construction
panel 2820 to
perpendicular to a surface of construction panel. First redirecting joint (not
shown)
functionally connects third shaft portion 2865 to a surface device 2866.
Surface device
2866 may define an opening in a surface of construction panel 2820 for mating
with a
conduit. The opening defined by surface device 2866 may mate with an opening
in a top
edge of a vertical construction panel, such as construction panel 2910 in
Figure 29 and
conduit 2921. For an example of a connection between surface device 2866 and
conduit
2921, see the description of Figure 3I below. In an alternate embodiment,
surface device
2866 may be a vent, register, or other surface device for mechanical system
2800.
Conduit 2871 extends from seam 2830 to edge 2822, perpendicular to both seam
2830
and edge 2822. Conduit 2871 mates with conduit 2841 at seam 2830 and may mate
with
additional portions of subsystem 2800 at edge 2822.
Figure 29 shows a vertical construction panel 2910 with a portion 2920 of a
mechanical subsystem, such as subsystem 2800 in Figure 28. Construction panel
2910
includes ~a frame 2811. Construction panel 2811 may include one or more
surface
covering layers (not shown). For further description of construction panels,
see the
description for Figures I-16 above. Construction panel 2910 includes a portion
2920 of a
mechanical subsystem. Portion 2920 includes a conduit 2921. Conduit 2921
extends
from a top edge 2912 of construction panel 2910 to a surface device 2925.
Arrow 2022
indicated a direction of connection to an adjacent construction panel or other
conduit.
Conduit 2921 defines an opening at top edge 2912 that may mate with a conduit
or a
surface device from an adjacent horizontal panel, such as construction panel
2820 and
surface device 2866 shown in Figure 28. Further description of an example
connection
between conduit 2921 and a surface device, such as surface device 2866, is
provided
. below with regard to Figure 31. Conduit 2921 includes a shaft portion 2923
that extends
from top edge 2912 parallel to a surface of construction panel 2910. Shaft
portion 2923
connects to a redirecting joint (not shown). The redirecting joint changes the
direction of
conduit 2921 from parallel to the surface of construction panel 2910 to
perpendicular to
the surface of construction panel 2910. Conduit 2921 connects to surface
device 2925
adjacent the redirecting joint. Surface device 2925 may include any surface
device for a
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mechanical system. In a preferred embodiment, conduit 2921 is duct work for an
HVAC
system and surface device 2925 is a vent.
Figure 30 shows a connection between conduits 3040 and 3050 in adjacent
construction panels 3010 and 3020. For example, the connection shown in Figure
30 may
be a connection between the subsystem portions 2840 and 2860 in horizontal
construction
panels 2810 and 2820 in Figure 28. Only a small portion of construction panels
3010 and
3020 are shown. Construction panel 3010 includes a frame 3011. Frame 3011
includes
an opening 3012 in members 3013 and 3014. Opening 3012 accommodates conduit
3040
where it extends to an edge 3015 of construction panel 3010. Construction
panel 3020
includes a frame 3021. Frame 3021 includes an opening 3022 in members 3023 and
3024. Opening 3022 accommodates conduit 3050 where it extends to an edge 3025
of
construction panel 3020. Where frame 3011 of construction panel 3010 and frame
3021
of construction panel 3020 are adjacent, a seam 3030 is defined. Conduit 3040
of
construction panel 3010 may be ductwork with a rectangular cross-section.
Conduit 3040
may include a first wall 3041, a second wall 3042, a third wall 3043, and a
fourth wall
(not shown). Each wall may define a lip, such as lip 3044 of first wall 3041
and lip 3045
of second wall 3042, extending beyond edge 3015. In some embodiments, lips
3044 and
3045 may be attached to member 3014 using fasteners or other attachment
mechanisms.
Conduit 3050 of construction panel 3020 may also be ductwork with a
rectangular cross-
section. Conduit 3050 may include a first wall 3051, a second wall 3052, a
third wall
3053, and a fourth wall (not shown). Each wall may define a lip, such as lip
3054 of first
wall 3051 and lip 3055 of second wall 3052, extending beyond edge 3025. In
some
embodiments, lips 3054 and 3055 may be attached to member 3024 using fasteners
or
other attachment mechanisms. Attachment mechanisms may be provided for
attaching
conduit 3040 to conduit 3050. In some embodiments, the attachment mechanism
may
include a seal 3031, such as an adhesive sealing ring. In some embodiments,
once
conduits 3040 and 3050 are mated to each other attachment of adjacent
construction
panels 3010 and 3020 may be sufficient to provide functional connection of
conduits
3040 and 3050. In other embodiments, one or both of conduits 3040 and 3050 may
include a collar or other portion for extending from one conduit, across seam
3030, and
into the other conduit. A collar or other extensions may or may not be
attached to the
opposite conduit.
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Figure 31 shows a connection between a surface device 3140 and a conduit 3150
in adjacent construction panels 3110 and 3120. For example, the connection
shown in
Figure 31 may be a connection between subsystem portion 2860 in horizontal
construction panels 2820 in Figure 28 and subsystem portion 2920 in vertical
construction
panel 2910 in Figure 29. Only a small portion of construction panels 3110 and
3120 are
shown. Construction panel 3110 includes a frame 3111 and a surface covering
layer
3112. Surface covering layer 3112 defines an opening 3113. Opening 3113
accommodates surface device 3140 where it extends through a surface 3115 of
construction panel 3110. Construction panel 3120 includes a frame 3121. Frame
3121
includes an opening 3122 in members 3123 and 3124. Opening 3122 accommodates
conduit 3150 where it extends to an edge 3125 of construction panel 3120.
Where
surface covering layer 3112 of construction panel 3110 and frame 3121 of
construction
panel 3120 are adjacent, a seam 3130 is defined. Surface device 3140 of
construction
panel 3110 may be ductwork with a rectangular cross-section for connecting to
adjacent
ductwork. Surface device 3140 may be continuous with a conduit 3145. Conduit
3145
may be ductwork with a rectangular cross-section extending parallel to surface
covering
layer 3112. Conduit 3145 may include a redirecting joint 3146 for connecting
to Surface
device 3140, which is perpendicular to surface covering layer 3112. Surface
device 3140
may include a first wall 3141, a second wall 3142, a third wall 3043, and a
fourth wall
(not shown). Each wall may define a lip, such as lip 3144 of first wall 3141
and lip 3145
of second wall 3142, extending beyond surface 3115. In some embodiments, lips
3144
and 3145 may be attached to surface covering layer 3112 using fasteners or
other
attachment mechanisms. Conduit 3150 of construction panel 3120 may also be
ductwork
with a rectangular cross-section. Conduit 3150 may include a first wall 3151,
a second
wall 3152, a third wall 3153, and a fourth wall (not shown). Each wall may
define a lip,
such as lip 3154 of first wall 3151 and lip 3155 of second wall 3152,
extending beyond
edge 3125. In some embodiments, lips 3154 and 3155 may be attached to member
3124
using fasteners or other attachment mechanisms. Attachment mechanisms may be
provided for attaching surface device 3140 to conduit 3150. In some
embodiments, the
attachment mechanism may include a seal 3131, such as an adhesive sealing
ring. In
some embodiments, once surface devices 3140 is mated to conduit 3150,
attachment of
adjacent construction panels 3110 and 3120 may be sufficient to provide
functional
connection of conduits 3140 and 3150. In other embodiments, one or both of
surface
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devices 3140 and conduit 3150 may include a collar or other portion for
extending from
one conduit, across seam 3130, and into the other device. A collar or other
extensions
may or may not be attached to the opposite conduit.
Figure 32 is a flow chart describing an example method if installing a
panelized
construction system with built-in mechanical subsystems. In step 3210, a
construction
panel with built-in internal conduits is positioned. The construction panel
includes a
portion of a mechanical subsystem. The portion of the mechanical subsystem
includes a
conduit extending to an edge or a surface of the construction panel such that
the conduit is
accessible from outside the construction panel. In some embodiments, the
construction
panel may be positioned according to a pre-determined building configuration.
Positioning the construction panel may include positioning a vertical
construction panel
on a base structure. For example, a wall panel may be positioned according to
the
location of a previously installed sill. Positioning the construction panel
may include
positioning a horizontal or pitched construction panel on two or more support
structures.
For example a horizontal construction panel may be positioned atop two wall
panels or
between two support ledgers. As another example, a pitched construction panel
may be
positioned between a the top of a wall panel and a ridge beam or support
ledger. The
construction panel may be positioned adjacent a source for the mechanical
subsystem,
such as a furnace, HVAC unit, or other source. The construction panel may be
positioned
adjacent a conduit to a pre-existing or pre-installed portion of the
mechanical subsystem
that includes a source for the mechanical subsystem. In step 3220, the
positioned
construction panel is fixed in place. The construction panel may be attached
to adjacent
construction panels or building structures using a variety of attachment
mechanisms. In
step 3230, a conduit external to the construction panel is engaged to the
internal conduit
built-into the construction panel. Engaging the external conduit may include
mating
compatible openings in the external conduit and internal conduit to form a
functional
connection. Engaging the external conduit may include providing a seal between
the
external conduit and the internal conduit. The external conduit may be a
conduit
functionally connected to a source for the mechanical system. The external
conduit may
be a portion of a pre-existing mechanical system. The external conduit may be
a portion
of a mechanical system built-into an adjacent building structure, such as a
pre-existing
wall or an adjacent construction panel. The external conduit may be engaged to
the
internal conduit by virtue of the positioning and attachment of the
construction panel. For
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example, the external conduit may be built-into an adjacent building structure
and
positioning the construction panel may include mating the external conduit to
the internal
conduit. In step 3240, an additional construction panel with an internal
conduits is placed
adjacent a previously placed construction panel, such as the construction
panel positioned
in step 3210. In step 3250, the internal conduit of the adjacent construction
panels are
engaged. In step 3260, the newly placed construction panel is attached to the
previously
placed construction panel and other adjacent building structures. Steps 3240
though 3260
may be repeated for as many additional construction panels as are to be
placed. The order
in which multiple construction panels are positioned and attached may be
determined by a
number of factors. For example, where some of the construction panels provide
the base
structure or support structure for other panels, the supporting panels may be
placed first.
Placement of a construction panel attached to the source may be made at any
point during
the sequence of placing the multiple construction panels. Further, all or a
sub-set of the
construction panels may be positioned and attached prior to connecting the
subsystem
portion built into the construction panels to other portions of the subsystem,
such as the
subsystem portion including the source. Connection of the subsystem portion
built-into
the construction panels to another subsystem portion may be a later step where
the
connection point for the internal conduit remains accessible in spite of
placement of the
other construction panels.
Industrial and Commercial Systems
Figures 33-44 relate to systems and methods of adapting panelized construction
techniques to commercial, industrial, and other buildings with different
structural,
organizational, and installation considerations. Largely, panelized
construction for
commercial and industrial buildings follows the same systems and methods as
residential
buildings. The description above for Figures 1-24, regarding construction
panels,
attachment mechanisms, and systems and methods for their use applies to use in
commercial and industrial buildings as well. Commercial and industrial
building may
have some different considerations with regard to material and structural
considerations.
For example, many commercial and industrial structures may need to meet
greater load
bearing requirements. Some commercial and industrial building configurations
may
reflect different priorities regarding the selection of both frame materials
and surface
layer materials. For example, commercial and industrial frames may be more
likely to be
constructed of larger wood members, light gage structural metal members, pre-
cast
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concrete, etc. Commercial and industrial building panels are more likely to be
fabricated
with heavier surface covering materials, such as 5/8" gypsum board, metal
roofing and
siding, and other materials. Commercial and industrial buildings may also be
more
amenable to prefabrication as larger panels. Builders of commercial and
industrial
building are more likely to have access to the equipment and manpower required
for
maneuvering and installing larger construction panels. Greater economy may be
achieved
through the prefabrication of larger construction panels, as long as they do
not exceed
sizes that may b reasonably transported and installed. Construction panels for
commercial and industrial building modules may include any number of pre-
installed
building subsystems, such as electrical and mechanical subsystems. The systems
and
methods described above with regard to Figures 25-32 apply to such subsystems
in
commercial and industrial building panels as well. In addition to portions of
building
subsystems, the interior spaces of commercial and industrial construction
panels may
include core materials.
~ Figures 33-35 show several example vertical panel configurations for use in
commercial and industrial buildings. Figure 36 shows a cross-section of a
commercial or
industrial building module showing how a variety of building panels may be
used in
constructing a commercial or industrial building. Figures 37-41 shows a
variety of
example attachment mechanisms for application in commercial and industrial
buildings.
Note that these attachment mechanisms may also be used in many building
configurations, including residential buildings. Figures 42 and 43 show two
building
configurations depicting the versatility of commercial and industrial building
layouts.
Figure 44 is a flowchart describing an example method of installing a
commercial or
industrial building using panelized construction systems and methods.
Figures 33-35 show three different construction panel configurations for use
in
commercial and industrial buildings. Figures 33 and 34 show front views of
vertical
construction panel frames, such as for use as wall panels in a commercial or
industrial
building. Figure 35 shows a side view of a vertical construction panels for
use in a
commercial or industrial building.
Figure 33 depicts a construction panel 3300. Construction panel 3300 includes
a
frame 3310 and two bearing ledgers 3320 and 3330. Frame 3310 includes a
rectangular
outer frame 3311. Outer frame 3311 includes top members 3312 and 3313 and base
members 3314 and 3315. Outer frame 3311 also includes side members 3316 and
3317.
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Outer frame 3311 defines a plurality of edges for attaching construction panel
3300 to
adjacent structures, Frame 3310 also includes stud members 3318 and 3319.
Frame 3310
defines a front surface and a back surface for supporting surface covering
layers. The
dimensions of frame 3310 are determined by the building configuration in which
construction panel 3300 is to be used. In one embodiment, frame 3310 is up to
20' high
and up to 4' wide. The spacing between stud members 3318 and 3319 and side
members
3316 and 3317 may be determined by the structural requirements of the building
and
applicable building codes. Construction panel 3300 may be configured to be a
bearing
wall, shear wall, fire-rated wall, exterior wall, interior wall, or any other
configuration. In
one embodiment, the vertical members are spaced less than 16" apart.
Construction panel
3300 includes two bearing ledgers 3320 and 3330. In a preferred embodiment,
bearing
ledger 3320 would support a horizontal roof construction panel. Bearing ledger
3330
would support a horizontal ceiling construction panel. In this building
configuration, the
area below bearing ledger 3330 would define an interior usable space of the
building, the
area between the bearing ledger 3320 and bearing ledger 3330 would define an
interior
attic crawlspace for housing storage or building subsystems, and the area
above bearing
ledger 3320 would define a flat roof with parapet walls. Bearing ledgers 3320
and 3300
may be made of a single lateral member or a composite lateral member. Bearing
ledgers
3320 and 3330 may be made of any of the materials that frames may be made of,
such as
wood, steel, or other materials. Bearing ledgers and the frames to which they
are attached
need not be composed of the same materials. Bearing ledgers 3320 and 3330 may
define
a space (not shown) for accommodating a complementary portion of a horizontal
or
pitched construction panel or an attachment mechanism for connecting to a
horizontal or
pitched construction panel. Bearing ledgers 3320 and 3330 may be attached to
frame
3310 using any attachment mechanism, such as fasteners, welds, and other
attachment
mechanisms. Further examples of bearing ledgers and their use are described
below with
regard to Figures 38 and 39.
Figure 34 shows an alternate construction panel configuration include a
prefabricated truss support for pitched construction panels. Construction
panel 3400
includes a frame 3410 and a bearing ledger 3450. Frame 3410 includes a
rectangular
outer frame 34I 1 and a truss frame 3430. Rectangular outer frame 3411 is
defined by top
members 3412 and 3413, bottom members 3414 and 3415, and side members 3416 and
3417. Truss frame 3430 includes pitched members 3431 and 3432 and truss plates
3433,
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3434, and 3435. Frame 3410 includes stud members 3418, 3419, 3420, 3421, 3422,
3423, 3424, and 3425 extending from base member 3414 to top member 3413 and
truss
stud members 3436, 3437, 3438, 3439, 3440, 3441, 3442, and 3443. In one
embodiment,
frame 3410 may be up to 25' wide, rectangular frame 3411 may be up to 20'
high, and the
total frame height may be up to 25'. Truss frame 3430 may support a pitched
roof, such
as a rood comprised of a plurality of pitched construction panels.
Construction panel
3400 includes a single bearing ledger 3450. In one embodiment, the area below
bearing
ledger 3450 defines an internal building space and the area between bearing
ledger 3450
and the top of frame 3410 may be a finished or unfinished attic area.
Construction panel
3400 may be fabricated out of a variety of the materials, as described above.
Figure 35 shows a side cross-sectional view of a construction panel 3500.
Construction panel 3500 includes a frame 3510, a first surface covering layer
3520, a
second surface covering layer 3521, a third surface covering layer 3522, a
core layer
3530, and a bearing ledger 3540. Frame 3510 includes a plurality of horizontal
members,
including top members 3511 and 3512 and base members 3513 and 3514. Frame 3510
may also include a plurality vertical members, such as side members (not
shown) and
stud members (not shown). Frame 3510 defines a first surface 3515 and a second
surface
3516 on opposite sides. Frame 3510 supports surface covering layers 3520,
3521, and
3522. Variations in the number of surface covering layers are possible. The
surface
above bearing ledger 3540 and below bearing ledger 3540 may include different
numbers
andlor materials for the surface covering layers. Surface covering layers
3520, 3521, and
3522 may include a variety of materials as described above. For example,
surface
covering layers 3520, 3521, and 3522 may all be 1/z" drywall of first surface
covering
layer 3520 may be metal siding, second surface covering layer 3521 may be
exterior
sheathing, and surface covering layer 3522 may be 3/4" gypsum board. As shown,
base
members 3513 and 3514 define a space for accommodating a sill for attaching
construction panel 3500 to a base structure. The vertical members define
spaces for
accommodating core layer 3530. Core layer 3530 may include a variety of
materials. For
example, core layer 3530 may be insulation.
Figure 36 is a cross-section of an example building 3600 constructed using a
plurality of pre-fabricated construction panels. Building 3600 may be a
commercial,
industrial, or other type of building. Building 3600 includes a base structure
3610, a first
wall panel 3620, a second wall panel, 3630, a floor panel 3640, a ceiling
panel 3650, a
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roof panel 3660, a wire-based subsystem 3670, and a mechanical subsystem 3680.
Base
structure 3610 may define at least a portion of a basement for building 3600.
First wall
panel 3620 may define at least a portion of a front wall of building 3600.
Additional
construction panels (not shown) positioned adjacent to first wall panel 3620
may further
define the front wall of building 3600. Second wall panel 3630 may define at
least a
portion of a rear wall of building 3600. Additional construction panels (not
shown)
positioned adjacent to second wall panel 3630 may further define the rear wall
of
building. Building 3600 may also include side walls (not shown) comprised of
one or
more construction panels. First wall panel 3620, second wall panel 3630, and
one or
more side walls may define a bay of predetermined size. Building 3600 may
include a
plurality of bays. Figures 42 and 43 below provide some example layouts of
panelized
buildings including multiple bays. Floor panel 3640 may define at least a
portion of a
floor of building 3600 and a ceiling for the basement of building 3600.
Additional
construction panels (not shown) adjacent to floor panel 3640 may further
define the floor
of building 3600. Ceiling panel 3650 may define at least a portion of a
ceiling of building
3600 and a floor for an attic space of building 3600. Additional construction
panels (not
shown) adjacent to ceiling panel 3650 may further define the ceiling of
building 3600.
Roof panel 3660 may define at least a portion of a roof for building 3600 and
a ceiling for
an attic space of building 3600. Additional construction panels (not shown)
adjacent
ceiling panel 3650 may further define the roof of building 3600.
Base structure 3610 may provide a foundation for supporting building 3600. For
example, base structure 3610 may be a site poured cement foundation. Base
structure
3610 may support one or more walls or floors. As shown, base structure 3610
supports
first wall panel 3620, second wall panel 3630, and floor panel 3640. Base
structure 3610
may include a foundation floor 3611, a first foundation wall 3612, and a
second
foundation wall 3613. Base structure 3610 may also include additional
foundation walls
(not shown) to further define a configuration for building 3600. Base
structure 3610 may
further include a variety of supports and attachment mechanisms for supporting
and
attaching to additional structures. For example, base structure 3610 includes
a first
bearing ledger 3614, a second bearing ledger 3615, and a support beam 3616 for
supporting floor panel 3640. Base structure 3610 may include attachment
mechanisms,
including fasteners, sills, and other attachment mechanism components within
the base
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structure material. Base structure 3610 may also define spaces for
accommodating
portions of one or more building subsystems.
First wall panel 3620 is a vertical construction panel. First wall panel 3620
is
supported by and attached to base structure 3610 adjacent first foundation
wall 3612. An
example attachment mechanism is shown in Figure 41. First wall panel 3620
includes a
frame 3621, a first surface covering layer 3622, a second surface covering
layer 3623, a
third surface covering layer 3624, a first interior bearing ledger 3625, and a
second
interior bearing ledger 3626. First wall panel 3620 may also include one or
more built-in
features (not shown). For example, first wall panel 3620 may include a door
and several
windows. Frame 3621 may include a plurality of members (not shown). Frame 3621
may provide support for surface covering layers 3622, 3623, and 3624 and
bearing
ledgers 3625 and 3626. First wall panel 3620 supports an end portion of
ceiling panel
3650 and roof panel 3660. Ceiling panel 3650 is supported by and attached to
bearing
ledger 3625. Roof panel 3660 is supported by and attached to bearing ledger
3626.
Example attachment mechanisms are shown in Figures 38 and 39. Frame 3621 and
third
surface covering layer 3624 define spaces for accommodating a portion of one
or more
building subsystems. First wall panel 3620 may also include an exterior
bearing ledger
3627 and exterior feature 3628. For example, exterior feature 3628 may be a
panelized
canopy, soffit, sign or sign mounting, marquee, or other feature. Exterior
feature 3628
may be supported by and attached to exterior bearing ledger 3627 using any
attachment
mechanism.
Second wall panel 3630 is a vertical construction panel. Second wall panel
3630
is supported by and attached to base structure 3610 adjacent second foundation
wall 3613.
An example attachment mechanism is shown in Figure 41. Second wall panel 3630
includes a frame 3631, a first surface covering layer 3632, a second surface
covering
layer 3633, a third surface covering layer 3634, a first interior bearing
ledger 3635, and a
second interior bearing ledger 3636. Second wall panel 3630 may also include
one or
more built-in features (not shown). For example, second wall panel 3630 may
include a
pair of rear utility doors. Frame 3631 may include a plurality of members (not
shown).
Frame 3631 may provide support for surface covering layers 3632, 3633, and
3634 and
interior bearing ledgers 3635 and 3636. Second wall panel 3630 supports an end
portion
of ceiling panel 3650 and roof panel 3660, opposite the end portions supported
by first
wall panel 3620. Ceiling panel 3650 is supported by and attached to bearing
ledger 3635.
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Roof panel 3660 is supported by and attached to bearing ledger 3636. Example
attachment mechanisms are shown in Figures 38 and 39. Frame 3631 and third
surface
covering layer 3634 define spaces for accommodating a portion of one or more
building
subsystems.
Floor panel 3640 is a horizontal construction panel. Floor panel 3640 is
supported
by bearing ledgers 3614 and 3615 and support beam 3616 of base structure 3610.
Floor
panel 3640 includes a frame 3641, a first surface covering layer 3642, and a
second
surface covering layer 3643. Frame 3641 may include a plurality of members
(not
shown). Frame 3641 may include any of a variety of materials, as described
above. For
example, frame 3641 may comprise a plurality of 2x12 wood joists, steel bar
joists,
prefabricated I joists, or a structural steel shape. Surface covering layers
3642 and 3643
may include any of a variety of materials, as described above. For example,
first surface
covering layer 3642 may include sheets of under flooring and second surface
covering
layer 3643 may include steel deck sheathing or concrete topping. In an
alternate
embodiment, floor panel 3640 may include a third surface covering layer
disposed on the
lower surface of frame 3641, such as dry wall or gypsum board. Frame 3641 may
define
spaces for accommodating portions of one or more building subsystems.
Ceiling panel 3650 is a horizontal construction panel. Ceiling panel 3650 is
supported by bearing ledgers 3625 of first wall panel 3620 and bearing ledger
3635 of
second wall panel 3630. Ceiling panel 3650 includes a frame 3651 and a surface
covering layer 3652. Frame 3651 may include a plurality of members (not
shown).
Frame 3651 may include any of a variety of materials, as described above.
Surface
covering layer 3652 may also include any of a variety of materials, as
described above.
For example, first surface covering layer 3652 may include drywall or gypsum
board. In
an alternate embodiment, ceiling panel 3650 may include another surface
covering layer
disposed on the upper surface of frame 3651. Frame 3651 and surface covering
layer
3652 may define spaces for accommodating portions of one or more building
subsystems.
Roof panel 3660 is a horizontal construction panel. Roof panel 3660 is
supported
by bearing ledgers 3626 of first wall panel 3620 and bearing ledger 3636 of
second wall
panel 3630. Roof panel 3660 includes a frame 3661 and a surface covering layer
3662.
Frame 3661 may include a plurality of members (not shown). Frame 3661 may
include
any of a variety of materials, as described above. Surface covering layer 3662
may also
include any of a variety of materials, as described above. For example, first
surface
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covering layer 3662 may include exterior sheathing for supporting an
appropriate roofing
material. The roofing material may be preinstalled on first surface covering
layer 3662.
In an alternate embodiment, roof panel 3660 may include another surface
covering layer
disposed on the lower surface of frame 3661, such as dry wall or gypsum board.
Frame
3661 may define spaces for accommodating portions of one or more building
subsystems.
Wire-based subsystem 3670 may be substantially as the wire-based subsystems
described above. Wire-subsystem 3670 may include a source wire 3671
electrically
connecting an outside source to a first portion 3672 in floor panel 3640. A
first
connecting wire 3673 may connect first portion 3672 to a second portion 3674
in first
wall panel 3620. A second connecting wire 3675 may electrically connect a
third portion
3676 in second wall panel 3630 to a source. Second connecting wire 3675 may
connect
through other portions (not shown) to first portion 3672 or second portion
3674. A third
connecting wire 3677 may connect to a fourth portion 3678 in ceiling panel
3650. Each
portion may include one or more surface devices providing subsystem access
within
building 3600.
Mechanical subsystem 3680 may be substantially as the mechanical subsystems
described above. Mechanical subsystem 3680 may include a source 3681. For
example,
source 3681 may be a roof mounted HVAC unit. Source 3681 is functionally
connected
to a first portion 3682 in roof panel 3660. First portion 3682 may be
functionally
connected to a second portion 3684 in ceiling panel 3650 by an external
conduit 3683.
Second portion 3684 may include one or more surface devices for providing
subsystem
access within building 3600. A plurality of additional portions (not shown)
may further
distribute mechanical subsystem 3680 throughout building 3600.
Figure 37 shows an example attachment mechanism 3700 for attaching a first
construction panel 3710 to an adjacent second construction panel 3720. First
construction
panel 3710 and second construction panel 3720 are positioned adjacent each
other such
that an edge 3711 of first construction panel 3710 and an edge 3721 of second
construction panel 3720 form a seam 3730. A seal 3731 may be provided along
seam
3730. A strap 3740 may be positioned across seam 3730 on adjacent surface 3712
of first
construction panel 3710 and surface 3722 of second construction panel 3720.
Strap 7340
is attached to first construction panel 3710 using fastener 7341. Strap 7340
is attached to
second construction panel 3720 using fastener 7342. Additionally, an angled
fastener
7343 may be directed through second construction panel 3720 into first
construction
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panel 3710 across seam 3730. Such strap and fastener and angled fastener
attachment
mechanisms may be repeated along the length of the seam (not shown). While
this
attachment mechanism is described in conjunction with commercial and
industrial
buildings, it may be used for any panelized construction system.
Figure 38 shows an example system for supporting and attaching a horizontal
construction panel 3810 to a vertical construction panel 3820 with a bearing
ledger 3830.
Bearing ledger 3830 includes a block member 3831 and a side plate 3832.
Vertical
construction.panel 3820, block member 3831, and side plate 3832 may be
attached to one
another using a variety of attachment mechanisms. For example, block member
3831
may be attached to vertical construction panel 3820 by a plurality of
fasteners 3833 and
3834 and side plate 3832 may in turn be attached to block member 3831 by a
plurality of
fasteners 3835, 3836, and 3837. In an alternate preferred embodiment, vertical
construction panel 3820, block member 3831, and side plate 3832 may be
attached to one
another by welds (not shown). Vertical construction panel 3820 and bearing
ledger 3830
may define a space 3838 for accommodating a complimentary portion 3811 of
horizontal
construction panel 3810. When horizontal construction panel 3810 is positioned
adjacent
to vertical construction panel 3820, complimentary portion 3811 may be mated
in space
3838 to support horizontal construction panel 3810. A seam 3840 may be defined
between horizontal construction panel 3810 and vertical construction panel
3820. A strap
and fastener assembly 3841 may be used to attach horizontal construction panel
3810 to
vertical construction panel 3820 across seam 3840. A plurality of strap and
fastener
assemblies (not shown) may be attached across the length of seam 3840 in order
to hold
horizontal construction panel 3810 in position relative to vertical
construction panel 3820.
Other attachment mechanisms are also possible. While this system for attaching
a
horizontal construction panel to a vertical construction panel is described in
conjunction
with commercial and industrial buildings, it may be used for any panelized
construction
system.
Figure 39 shows another example system for supporting and attaching a
horizontal
construction panel 3910 to a vertical construction panel 3920 with a bearing
ledger 3930.
Bearing ledger 3930 is steel member with U shaped cross-section. Alternate
materials
and configurations for bearing ledger 3930 are also possible. Bearing ledger
3930 may be
pre-installed on vertical construction panel 3920 using a plurality of
fasteners 3931 and
3932. Bearing ledger 3930 defines a shelf 3933. Horizontal construction panel
3910 may
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include a portion 3911 for engaging shelf 3933. Portion 3911 may mate with
shelf 3933
and a surface 3921 of vertical construction panel 3920. Portion 3911 and shelf
3933 may
define a seam 3940 where they are adjacent one another. A weld 3941 may attach
horizontal construction panel 3910 to vertical construction panel 3920. Other
attachment
mechanisms are also possible. While this system for attaching a horizontal
construction
panel to a vertical construction panel is described in conjunction with
commercial and
industrial buildings, it may be used for any panelized construction system.
Figure 40 shows an example system for supporting and attaching a horizontal
construction panel 4010 to adjacent vertical construction panels 4020 and 4030
without a
bearing ledger. First vertical construction panel 4020 and second vertical
construction
panel 4030 define a pocket 4040 for accommodating a portion 4011 of horizontal
construction panel 4010. First vertical construction panel 4020 includes a top
member
4021 defining the bottom 4041 of pocket 4040. Second vertical construction
panel 4030
includes base complimentary member 4031 of a width substantially less than the
width of
top member 4021 and defining the side 4042 of pocket 4040. First vertical
construction
panel 2020 may be positioned to support horizontal construction panel 4010.
Portion
4011 may be mated with top member 4021 of vertical construction panel 4020. A
fastener 4043 may attach portion 4011 to top member 4021 to attach horizontal
construction panel 4010 to first vertical construction panel 4020. Second
vertical
construction panel 4030 may then be positioned above first vertical
construction panel
4020 and portion 4011 of horizontal construction panel 4010. Any of a variety
of
attachment mechanisms (not shown) may by used for attaching second vertical
construction panel 4030 to first vertical construction panel 4020 and
horizontal
construction panel 4010. A seam 4050 may be defined between second vertical
construction panel 4030 and horizontal construction panel 4010. A seal 4051
may be
placed over seam 4050. In one embodiment, horizontal construction panel 4010
is a roof
panel and second vertical construction panel 4030 is a parapet wall panel.
Seal 4051 may
prevent leaking along seam 4050. While this system for attaching a horizontal
construction panel to one or more vertical construction panels is described in
conjunction
with commercial and industrial buildings, it may be used for any panelized
construction
system.
Figure 41 shows an example system for supporting and attaching a vertical
construction panel 4110 on a base structure 4120. A track 4130 is positioned
on and
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attached to base structure 4120. Track 5130 may be made of any of a variety of
materials, similar to construction panel frames and bearing ledgers. In a
preferred
embodiment, track 4130 is a steel member with a U cross-section. Track 4130
may be
attached to base structure 4120 may any of a variety of attachment mechanisms.
As
shown, fastener 4131 passes through track 4130 and into base structure 4120.
In an
alternate embodiment, anchors are embedded in base structure 4120 for
receiving and
attaching track 4130 to base structure 4120. Vertical construction panel 4110
may
include a base member 4111 and a track complimentary member 4112. Track
complimentary member 4112 mates with the internal dimensions of track 4130 to
support
vertical construction panel 4110. Any of a variety of attachment mechanisms
may be
used to attach vertical construction panel 4110 to track 4130. As shown, a
plurality of
fasteners 4132 and 4133 are inserted through track 4130 and into track
complimentary
member 4112 of vertical construction panel 4110. While this system for
attaching a
vertical construction panel to a base structure is described in conjunction
with commercial
and industrial buildings, it may be used for any panelized construction
system.
Figures 42 and 43 show two example building configurations for a commercial,
industrial, or other building using the construction panels, systems, and
methods
described above. Building configuration 4200 of Figure 42 and building
configuration
4300 of Figure 43 include a plurality of rectangular bays. Each bay is defined
by one or
more vertical construction panels, as well as other construction panels (not
shown). In
one embodiment, each bay includes one or more horizontal or pitched
construction panels
defining a floor, a ceiling, and a roof corresponding in dimensions to the
length and width
of the bay. Building configurations 4200 and 4300 include a mixture of
exterior vertical
construction panels and interior vertical construction panels. Building
configuration 4300
also includes a plurality of vertical supports. The construction panels of
building
configurations 4200 and 4300 may include any combination of features and
building
subsystems (not shown). The construction panels of building configurations
4200 and
4300 may include an materials, dimensions, and purposes appropriate to the
function and
type of building being constructed.
Building configuration 4200 includes four bays 4210, 4211, 4212, and 4213. Bay
4213 is divided into two sub-bays 4214 and 4215 by an interior wall 4233.
Building
configuration 4200 includes a plurality of exterior vertical construction
panels 4220,
4221, 4222, 4223, 4224, 4225, 4226, 4227, 422, 4229, and 4230. =Building
configuration
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4200 includes a plurality of interior vertical construction panels 4231, 4232,
and 4233.
Bay 4210 is defined by exterior walls 4220, 4221, and 4230 and interior wall
4231. Bay
4211 is defined by exterior walls 4222, 4228, and 4229, and interior wall
4231. Bay 4212
is defined by exterior walls 4223, 4224, and a portion of 4227 and interior
wall 4232.
Bay 4213 is defined by exterior walls 4225, 4226, and a portion of 4227 and
interior wall
4232. Bays may be designed as structurally autonomous units such that they may
be
arranged according to the desires of a particular builder and the conditions
of a particular
project. Building configuration 4200 may be an L-shaped strip mall intended to
house a
plurality of merchants. A first merchant may be assigned to bay 4210, a second
merchant
may be assigned to bays 4211 and 4212, a third merchant may be assigned to sub-
bay
4214, and a fourth merchant may be assigned to sub-bay 4215.
Building configuration 4300 includes eight bays 4310, 4311, 4312, 4313, 4314,
4315, 4316, and 4317. Building configuration 4300 includes a plurality of
exterior
vertical construction panels 4320, 4321, 4322, 4323, 4324, 4325, 4326, 4327,
4328, 4329,
4330, and 4331. Building configuration 4300 includes a plurality of interior
vertical
construction panels 4332, 4333, and 4334. Building configuration 4300 includes
a
plurality of vertical supports 4340 and 4341. Vertical supports 4340 and 4341
may
include any variety of wood, metal, or concrete support beams, such as a pipe
support.
Bay 4310 is defined by exterior vertical construction panels 4320 and 4321 and
vertical
support 4340. Bay 4311 is defined by exterior vertical construction panel 4322
and
vertical supports 4340 and 4341. Bay 4312 is defined by exterior vertical
construction
panel 4323, interior vertical construction panel 4332, and vertical support
4341. Bay
4313 is defined by exterior vertical construction panels 4324 and 4325 and
interior
vertical construction panels 4332 and 4334.. Bay 4314 is defined by exterior
vertical
construction panels 4326 and 4327 and interior vertical construction panels
4334 and
4334. Bay 4315 is defined by exterior vertical construction panel 4328,
interior vertical
construction panel 4333, and vertical support 4341. Bay 4316 is defined by
exterior
vertical construction panel 4329 and vertical supports 4340 and 4341. Bay 4317
is
defined by exterior vertical construction panels 4330 and 4331 and vertical
support 4340.
Building configuration 4300 may be an industrial building with a manufacturing
floor in
bays 4310 ,4311, 4312, 4315, 4316, and 4317, office space in bay 4313, and
storage space
in bay 4314.
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Figure 44 shows a flow chart of a method of installing a commercial,
industrial, or
other building using panelized construction. The method may be followed using
the
construction panels, systems, and building configurations described above. In
step 4410,
a base structure for a building module may be prepared. Preparation of a base
structure
may include identifying a building configuration to be used for the building
module.
Preparation of a base structure may include site-building a foundation for the
building
module according to the identified building configuration. Preparation of a
base structure
may include modifying an existing base structure to be compatible with the
identified
building configuration. Preparation of a base structure may include providing
attachment
mechanisms or structures for accommodating attachment mechanisms in the base
structure. For example, preparation of a base structure may include attaching
sills or
tracks to a base structure using fasteners or another attachment mechanism. In
step 4420,
a wall panel or other vertical construction panel may be positioned upon the
base
structure. Position of the wall panel may depend upon the building
configuration. In
some embodiments, sills, rails, or other portions of attachment mechanisms may
guide the
positioning of the wall panel. For example, a wall panel with an complementary
base
member may mate with an appropriately located sill or rail. In step 4430, the
positioned
wall panel is attached to the base structure. Attaching the wall panel to the
base structure
may utilize any of a variety of attachment mechanisms, as described above. For
example,
the wall panel that has mated with a compatible sill or rail may accept one or
more
fasteners for attaching the wall panel to the sill or rail. In step 4440, the
positioned wall
panel may be attached to an adjacent structure. The adjacent structure may
include a pre-
existing portion of a building structure or a previously placed construction
panel. Where
the positioned construction panel is the first vertical construction panel in
a free standing
building without pre-existing building structures, there may not be any
adjacent
structures, other than the base structure, to attach it to. Steps 4410 through
4440 may be
repeated for a plurality of wall panels. Each additional construction panel
may be
attached to a previously positioned and attached construction panel. In step
4450, a roof
panel is positioned over one or more wall panels. The roof panel may be a
horizontal or
pitched construction panel. Positioning the roof panel over one or more wall
panels may
include engaging the roof panel to one or more bearing ledgers. The bearing
ledgers may
be attached to the one or more roof panels or may be attached to a pre-
existing structure.
Alternatively or in combination, the roof panel may be placed on a top edge of
one or
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more wall panels. Placement of the roof panel may include engaging another
horizontal
or vertical support, such as a ridge beam or pipe support. In step 4460, the
positioned
roof panel is attached to adjacent structures. The adjacent structures may
include one or
more wall panels, pre-existing building structures, support structures, and/or
one or more
adjacent roof panels. Attachment to adjacent structures may be accomplished
using any
of a variety of attachment mechanisms. Attachment to adjacent structures may
also
include providing seals between the newly placed roof panel and one or more
adjacent
structures. Steps 4450 and 4460 may be repeated for a plurality of roof
panels. The
method may also include the steps of placing one or more floor or ceiling
panels,
interconnecting one or more building subsystems, adding additional exterior
surface
covering layers, such as roofing material or siding, and other additional
steps as described
above with regard to the various construction panels, systems, and attachment
mechanisms.
This invention has been described in connection with the preferred
embodiments.
These embodiments are intended to be illustrative only. It will be readily
appreciated by
those skilled in the art that modifications may be made to these preferred
embodiments
without departing from the scope of the invention as defined by the appended
claims.
