Note: Descriptions are shown in the official language in which they were submitted.
CA 02615154 2007-11-20
1
TITLE:
Method of building construction
FIELD
The present invention relates to a method of building construction, which
makes it
easier to incorporate prefabricated components into the building.
BACKGROUND
A building can be constructed more rapidly, if some portions of the building,
such as
load bearing walls, can be constructed off site and then incorporated on site
into the building.
However, problems have been experienced in incorporating such prefabricated
components
into the building with current building methods.
SUMMARY
Accordingly, there is provided a method of construction. A first step involves
stabilizing prefabricated load bearing walls for an underlying vertical level
of a multi-
story building. The walls have opposed surfaces and a top peripheral edge. A
second step
involves securing floor joists for an overlying vertical level to at least one
of the opposed
surfaces of the walls of one of the underlying vertical level. A third step
involves
installing prefabricated load bearing walls for the overlying vertical level
along the top
peripheral edge of the underlying vertical level. The walls have opposed
surfaces and a
top peripheral edge. The steps set forth above are repeated until a desired
number of
vertical levels are installed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent from the
following description in which reference is made to the appended drawings, the
drawings are
for the purpose of illustration only and are not intended to in any way limit
the scope of the
invention to the particular embodiment or embodiments shown, wherein:
FIG. 1 is a detailed side elevation view, in section, of load bearing wall and
floor joist
detail in accordance with the present method of construction, using joist
supports with upper
attachment flanges.
CA 02615154 2007-11-20
2
FIG. 2 is a detailed side elevation view, in section, of load bearing wall and
floor joist
detail in accordance with the present method of construction, using a joist
support with an
upper attachment hook.
FIG. 3 is a detailed side elevation view, in section, of load bearing wall and
floorjoist
detail in accordance with the present method of construction, using C channel
joist supports.
FIG. 4 is a detailed side elevation view, in section, of load bearing wall and
floor joist
detail in accordance with the present method of construction, using a
combination of a joist
support with an upper attachment flange and a C channel joist support.
FIG. 5 is a detailed side elevation view, in section, of load bearing wall and
floor joist
detail in accordance with the present method of construction, using a
combination of a joist
support with an upper attachment hook and a C channel joist support.
FIG. 6 is a perspective view of a joist support with an upper attachment
flange.
FIG. 7 is a perspective view of a joist support with an upper attachment hook.
FIG. 8 is a perspective view of a C channel joist support.
FIG. 9 is a side elevation view of a modular bathroom unit and exterior load-
bearing
wall.
FIG. 10 is a detailed side elevation view, in section, of load bearing wall
and floor
joist detail of FIG. 9.
FIG. 11 is a detailed side elevation view, in section, of an exterior load
bearing wall.
DETAILED DESCRIPTION
A method of construction will now be described with reference to FIG. 1
through 11.
Load Bearing Wall Installation
This method was developed for use in a light gauge steel construction project
of
twelve stories. In that project all exterior and interior bearing walls were
prefabricated off site
and then incorporated into the building. In that project all bathrooms were
delivered to the
site as prefa.bricated bathroom modules. There will now be provided an
explanation as to
how the prefabricated bearing walls were incorporated into the building and an
explanation as
to how the bathroom modules were similarly incorporated into the building.
Referring to FIG. 1, an underlying wall 20 is stabilized as part of a multi-
story
CA 02615154 2007-11-20
3
building. Underlying wall 20 is a prefabricated load bearing wall, underlying
wall 20 having
opposed surfaces 22 and 24, and a top peripheral edge 26. Underlying wall 20
is part of an
underlying vertical level 28 in the multi-story building. In order to complete
underlying
vertical level 28, numerous underlying walls 20 may be needed. A floor joist
30 is secured to
opposed surface 22 of underlying vertical level 28. The purpose of floor joist
30 is to support
an overlying vertical level 32. Overlying vertical level 32 is defined by a
floor 34. Numerous
floor joists 30 may be necessary to support floor 34 adequately. Floor 34 may
consist of a
concrete topping on metal docking. An overlying wall 36 is then installed
along top
peripheral edge 26. Underlying and overlying walls 20 and 36, respectively may
contain
studs 37 and bracing 39. Studs 37 give multi-story building more structural
support.
Bracing 39 provides a suitable surface for securing floor joists 30 to.
Overlying wall 36 is a
prefabricated load bearing wall, overlying wall 36 having opposed surfaces 38
and 40, and a
top peripheral edge 41. Overlying wall 36 and floor 34 make up overlying
vertical level 32.
The process of stabilizing underlying walls 20, securing floor joists 30, and
installing
overlying walls 36 is repeated until a desired number of vertical levels are
installed to
complete the multi-story building. As each overlying vertical level 32 is
secured on top of
underlying vertical level 28, overlying vertical level 32 becomes the next
underlying vertical
level 28, and the process is repeated. This construction method may be used to
quickly and
efficiently put up the structure of a multi-story building using prefabricated
load bearing
walls.
Floor joist 30 may be suspended from top peripheral edge 26 of underlying wall
20.
This may be accomplished by using a joist support 42 that extends along all or
a portion of
underlying wall 20. Because joist support 42 extends along underlying wall 20,
it may not be
necessary to have floor joist 30 align with the studs in underlying wall 20.
Joist support 42
has an upper attachment 44, a lower attachment 46, and a connecting web 48.
Connecting
web 48 extends between upper attachment 44 and lower attachment 46. There may
be holes
(not shown) on joist support 42, holes being used to secure joist support 42
to various
materials using conventional methods. Upper attachment 44 engages top
peripheral edge 26
of underlying wall 20 and lower attachment 46 engages floor joist 30. In this
manner, floor
joist 30 is secured to opposed surface 22 of underlying vertical level 28.
CA 02615154 2007-11-20
4
Referring to FIG. 1, upper attachment 44 of joist support 42 consists of a
flange 49.
This embodiment of joist support 42 is shown in greater detail in FIG. 6. The
dimensions of
upper attachment 44, lower attachment 46 and connecting web 48 may differ
depending on
the dimensions of both floor joist 30 and top peripheral edge 26. Referring
back to FIG. 1,
floor joist 30 is secured to joist support 42. This figure shows a side
elevation view of
adjacent interior rooms 50 and 52 in a multi-story building. Opposed surfaces
38 and 40 face
interior rooms 50 and 52, respectively. Interior room 52 contains a floor 54,
floor 54 having
the same characteristics as floor 34. Floor 54 is also part of overlying
vertical level 32.
Supporting floor 54 is a floor joist 56 and a joist support 58. Floor joist 56
and joist support 58
share the same basic elements described above for floor joist 30 and joist
support 42,
respectively. Floor joist 56 may have a different depth than floor joist 30 as
shown in FIG. 1.
In the embodiment shown in FIG. 1, screws 60 are used to secure floor joists
30 and 56 to
joist supports 42 and 58, respectively. Screws 60 secure floor joist 30 and
joist support 42 to
opposed surface 22 of underlying wall 20 through holes (not shown) in
connecting web 48.
Floor joist 30 is also secured to joist support 42 at lower attachment 46
using screws 60. In
addition, upper attachment 44 is secured to top peripheral edge 26 directly
using screws 60.
Floor joist 56 and joist support 58 are secured in an identical fashion as
described above for
floor joist 30 and joist support 42. In the embodiment shown in FIG. 1, joist
supports 42 and
56 are secured over top of each other to top peripheral edge 26 using screws
60.
Another embodiment of a joist support 62 is shown in FIG. 7. Joist support 62
shares
all the same elements as joist support 42 and is intended to extend along all
or part of an
underlying wall, with the addition of a hook 64 connected to upper attachment
44. This
embodiment of joist support 62 is used in FIG. 2. FIG. 2 details a side
elevation view of
underlying and overlying vertical levels 28 and 32, respectively. In this
figure, opposed
surfaces 24 and 40 face an exterior 66 of the building, while opposed surfaces
22 and 38 face
an interior room 68. Floor joist 30 is secured to joist support 62 as
described above in the
previous embodiment for joist support 42. Joist support 62 is secured to
underlying wall 20 as
described above for the previous embodiment, with the addition that hook 64 is
secured to
opposed surface 24 of underlying wall 20. By securing hook 64 to opposed
surface 24, joist
support 62 is given extra stability.
CA 02615154 2007-11-20
A further embodiment of a joist support 70 is shown in FIG. 8. Joist support
70 has an
upper attachment 72, a lower attachment 74, a connecting web 75, and is
designed to extend
along all or part of a wall. Upper attachment 72 consists of a C channel
support 76 as shown.
C channel support 76 defines a joist-receiving cavity 78. Referring to FIG. 3,
C channel
5 support 76 is secured to opposed surface 24 of underlying wall 20. In this
figure, opposed
surfaces 24 and 40 face an interior room 80 of the building, while opposed
surfaces 22 and 38
face an exterior 82. Joist receiving cavity 78 is used to secure floor joist
30 to opposed surface
24 of underlying wall 20 of underlying vertical level 28. Floor joist 30 is
secured to joist
support 70 using screws 60. Floor joist 30 and joist support 70 are also
secured to opposed
surface 24 through connecting web 75 using screws 60.
FIG. 4 details an embodiment of a method of construction using joist supports
42 and
70 in combination. Opposed surfaces 22 and 38 of underlying and overlying
walls 20 and 36,
respectively, face a corridor 84 of the building. Opposed surfaces 24 and 40
of underlying and
overlying walls 20 and 36, respectively, face an interior 86 of the building.
Opposed surface
22 of underlying wall 20 has secured to it C channel support 76 of joist
support 70. Opposed
surface 24 of underlying wall 20 has secured to it joist support 42 with
flange 49. Joist
support 42 is also secured to top peripheral edge 26. C channel support 76 and
joist support 42
support floor joists 88 and 90, respectively. Floor joists 88 and 90 support
floors 92 and 94,
respectively. Floor joist 88 and 90 may be of different sizes, as shown in
FIG. 4, in order to
properly support different sizes of floors 92 and 94.
FIG. 5 details an embodiment of a method for construction using joist supports
62
and 70 in combination. In this embodiment, there are two underlying walls 96
and 98, and
two overlying walls 100 and 102. Underlying wall 96 has opposed surfaces 104
and 106, and
a top peripheral edge 108. Underlying wa1198 has opposed surfaces 110 and 112,
and a top
peripheral edge 114. Overlying wall 100 has opposed surfaces 116 and 118,
while overlying
wall 102 has opposed surfaces 120 and 122. Underlying walls 96 and 98 are part
of
underlying vertical level 28, and overlying walls 100 and 102 are part of
overlying vertical
level 32. Underlying walls 96 and 98 are secured under overlying walls 100 and
102,
respectively. Opposed surfaces 104 and 116 of underlying and overlying walls
96 and 100,
respectively, face an interior room 124 of the building. Opposed surfaces 112
and 122 of
CA 02615154 2007-11-20
6
underlying and overlying walls 98 and 102, respectively, face an interior room
126 of the
building. Opposed surface 104 of underlying wall 96 has joist support 70
secured to it.
Opposed surface 112 of underlying wall 98 has secured to it joist support 62
with hook 64.
Joist support 62 is also secured to top peripheral edge 114, and hook 64 is
secured to opposed
surface 110. C channel support 76 and joist support 62 support a floor joist
127 and 128,
respectively. Floor joists 127 and 128 support floors 130 and 132,
respectively. Floor joists
127 and 128 may be of different sizes, as shown in FIG. 5, in order to
properly support
different sizes of floors 130 and 132. The configuration shown in FIG. 5 is
called a `party
room" configuration. By using double the number of walls, effective
soundproofng is
achieved between interior rooms 124 and 126. Underlying walls 96 and 98 and
overlying
walls 100 and 102, may contain studs 134 and bracing 136. Opposed surfaces 106
and 110 of
underlying wa.lls 96 and 98, respectively, face each other. Opposed surfaces
118 and 120 of
overlying walls 100 and 102, respectively, face each other. Top peripheral
edge 108 is
secured to top peripheral edge 114 using a centre support 133. Centre support
133 is secured
to top peripheral edges 108 and 114 using screws 60.
Referring to FIG. 11, exterior cladding panels 200 may be attached to walls 20
and 36
on an exterior face of the building to provide protection from the external
environment.
Exterior cladding panel 200 is mounted on exterior grade drywall sheathing 202
such as by
using an adhesive as is common with EIFS panels. Drywall 202 is in turn
mounted on
opposed surfaces 24 and 40. Drywall 202 may have an air vapour seal 203
applied to its
surface. Cladding panel 200 may be, for example, 3" insulation that includes
sloped metal
through-wall flashing 204 installed along the base of cladding panel 200.
Cladding panel 200
is installed by applying a bead of sealant 206 along the top edge of a lower
panel 200. Liquid
applied envelope seal 208 is also applied along the top of the exterior
drywall 202 on the
lower panel 200 to seal the joint between the drywall 200. Envelope seal is
also applied
along vertical joints between panels as well. Envelope sea1208 acts as an
initial air barrier
and a back-up water seal. A low expansion spray foam/air and vapour barrier
type insulation
210 is applied to the horizontal and vertical joints to seal the joints and
provide insulation at
the joint locations. Caulking dams (not shown) should also installed at the
ends of the
through wall flashing to prevent moisture from flowing off the ends of the
flashing. The
joints may then be sealed using a high quality exterior sealant 212. When
properly installed,
CA 02615154 2007-11-20
7
flashing 204 should overlap with any membrane flashing and air and vapour
barrier. An
exterior finish 214, such as an acrylic stucco finish is then applied to the
outer surface of
cladding panel 200.
Modular Bathroom Installation
FIG. 9 details a method of construction using modular structures. Overlying
module
138 is stacked above underlying module 140. Both overlying and underlying
modules 138
and 140 are prefabricated load bearing modular structures. By stacking
overlying module 138
on underlying module 140, a column 142 of modular structures is formed, column
142 having
a defining wall 144. An underlying wall 146 is stabilized in spaced relation
to column 142.
Underlying wall 146 is a prefabricated load bearing wall, underlying wa11146
having opposed
surfaces 148 and 150, and a top peripheral edge 152. Underlying wall 146 is
part of an
underlying vertical level 154 of a multi-story building. In order to complete
underlying
vertical level 154, numerous underlying walls 146 may be needed. A floor joist
30 is secured
to opposed surface 150 of underlying vertical level 154. Floor joist 30 is
also secured to
defining wall 144. The purpose of floor joist 30 is to support an overlying
vertical level 156.
Floor joist 30 may be secured to both defining wall 144 and opposed surface
150 using any of
the above described embodiments of joist supports 42, 62 or 70. In FIG. 9,
floor joist 30 is
secured to opposed surface 150 using joist support 42. Overlying vertical
level 156 is defined
by a floor 158. Numerous floor joists 30 may be necessary to support floor 158
adequately.
Floor 158 may consist of a concrete topping on metal docking. An overlying
wall 160 is then
installed along top peripheral edge 152. Overlying wall 160 is a prefabricated
load bearing
wall, overlying wall 160 having opposed surfaces 162 and 164, and a top
peripheral edge 165.
Overlying wal1160 and floor 158 make up overlying vertical level 156. The
process described
above is then repeated until a desired number of vertical levels are installed
to complete the
multi-story building. As each overlying vertical level 156 is secured on top
of underlying
vertical leve1154, overlying vertical leve1156 becomes the next underlying
vertical leve1154,
and the process is repeated. This construction method may be used to quickly
and efficiently
put up modular structures of a multi-story building using prefabricated load
bearing walls. All
of the embodiments of construction methods described above may be included in
this
embodiment.
CA 02615154 2007-11-20
8
The modules 138 and 140 of FIG. 9 may be bathroom modules. Within overlying
module 138 is positioned a module floor 166. Below module floor 166 is
positioned an
underlying roof 168, so that there is a plumbing space 170 between module
floor 166 and
underlying roof 168. Underlying roof 168 forms part of underlying vertical
level 154, and is
lower than floor 158. The purpose of plumbing space 170 is to make room for a
drainage
system 172 to be installed below overlying module 138. Drainage system 172 may
be any
system of drainage or plumbing devices or pipes necessary for multi-story
building.
Underlying roof 168 may be supported by floor joists 30 (not shown). The
embodiment of a
method of building construction shown in FIG. 9 is shown in more detail in
FIG. 10. An
opposed surface 174 is positioned on the side of column 142 opposite to
defining wall 144.
Opposed surface 174 faces a bathroom 176, while defining wall 144 faces an
interior room
177. Secured to opposed surface 174 and defming wall 144 are joist supports
178 and 180,
respectively. Joist supports 178 and 180 both share the same elements as joist
support 70,
described above. Secured to joist supports 178 and 180 are floor joists 182
and 184,
respectively. Floor joists 182 and 184 support module floor 166 and floor 158,
respectively.
Below module floor 166 is positioned underlying roof 168. In the embodiment
shown,
underlying roof 168 is secured to underlying module 140. Plumbing space 170 is
positioned
between underlying roof 166 and module floor 166 in order to provide room for
the
appropriate drainage piping and plumbing elements.
In all embodiments of the disclosed method of building construction, screws 60
are
used as a securing means, although other means of securing may be used. An
example of an
alternate means of securing may involve securing with nails or bolts.
In this patent document, the word "comprising" is used in its non-limiting
sense to
mean that items following the word are included, but items not specifically
mentioned are not
excluded. A reference to an element by the indefinite article "a" does not
exclude the
possibility that more than one of the element is present, unless the context
clearly requires that
there be one and only one of the elements.
It will be apparent to one skilled in the art that modifications may be made
to the
illustrated embodiment without departing from the spirit and scope of the
invention as
CA 02615154 2007-11-20
9
hereinafter defmed in the Claims.
