Note: Descriptions are shown in the official language in which they were submitted.
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METHOD OF CONSTRUCTING A MULTI-STOREY BUILDING
USING PREFABRICATED MODULAR PANELS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is the first application filed for the present
technology.
TECHNICAL FIELD
[0002] The present technology relates generally to building
construction and, in particular, to the construction of
buildings using prefabricated components.
BACKGROUND
[0003] Cast-in-place concrete (CIPC) is commonly used to
construct both low-rise and high-rise buildings. This
technique requires concrete forms to be installed and then
removed after the concrete is poured and cured. This is both
time-consuming and expensive, thus increasing the overall
construction time and construction cost for a given building.
[0004] In addition, it is typical practice for the formwork,
steel reinforcement and the fabrication of concrete elements
to be done by one trade and the infilling between the columns
with steel studs and exterior sheathing, along with the
interior demising partition, done by another trade. The same
holds true for low-rise structural steel construction with
open web joists and concrete slabs, which are erected by one
trade, followed by infilling of exterior curtain and interior
demising partitions by another trade. Because both of these
methods involve using multiple trades, coordination can become
problematic, i.e. there is more room for error when more than
one trade is responsible for interrelated tasks. This in turn
can lead to construction delays and a higher overall
construction cost.
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[0005] Furthermore, in cold-weather climates, typical
construction techniques can be problematic. For example,
extensive tarping is often required to keep the interior of
the unfinished building warm and dry.
[0006] From the foregoing, it is apparent that the prior-art
construction techniques need to be improved. Accordingly,
there remains a need in the construction industry for a more
efficient technique for constructing a building.
SIIbIlKARY
[0007] In general, the present technology provides an
innovative method of constructing a multi-storey building by
using prefabricated modular wall panels and prefabricated
modular floor panels. The novel prefabricated wall panels
have a frame that includes studs and an upright channel into
which concrete is poured and cured to form a concrete column
(or a hybrid steel-and-concrete column). Similarly, the novel
prefabricated floor panels have a frame that includes joists,
sheathing and a trench-like track that forms a trough for
receiving concrete that cures in the trough to create a
concrete beam (or a hybrid steel-and-concrete beam).
[0008] Thus, a main aspect of the present technology is a
method of constructing a building, the method involving steps
of preparing a construction site by pouring a floor slab with
upright rebar positioned to align with load-bearing concrete
columns that are to be poured, erecting an assembly of modular
prefabricated wall panels by connecting the wall panels to
define one or more walls of the building, the wall panels
comprising a frame having a plurality of substantially
vertical members, a subset of the plurality of substantially
vertical members being closed channels, laying modular
prefabricated floor panels onto a top end of the assembly of
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modular prefabricated wall panels, the floor panels comprising
a frame having a plurality of horizontally arranged joists and
a sheathing mounted onto the frame, each of the floor panels
further comprising a trench-like track that acts as a trough
for receiving concrete, and pouring concrete into the troughs
in the floor panels for flowing into the channels, the
concrete curing in the troughs to form horizontal concrete
beams and curing in the channels to form concrete columns.
This completes the walls and load-bearing columns. A roof can
then be added for a simple one-storey building. However, the
main utility of this invention lies in building multi-storey
buildings. Thus, in the context of the construction a multi-
storey building, the method would further comprise steps of
erecting wall panels and laying modular prefabricated floor
panels onto a top end of the assembly of modular prefabricated
wall panels, the floor panels comprising a frame having a
plurality of horizontally arranged joists and a sheathing
mounted onto the frame, each of the floor panels further
comprising a trench-like track that acts as a trough for
receiving concrete. The method would also furthermore
comprise laying reinforcing rods horizontally over the floor
panels and then pouring concrete over the reinforcing rods and
into the troughs in the floor panels, the concrete curing to
form horizontal concrete beams that are aligned with and
supported from below by the load-bearing concrete columns.
[0009] For completion of the second floor, the method would
further comprise steps of erecting a third-storey assembly of
modular prefabricated wall panels on top of the floor panels,
the wall panels having closed channels and then pouring
concrete into the troughs which enable concrete to flow into
the closed channels through an open top end of each of the
closed channels. The concrete cures in the troughs and closed
channels to form second-storey load-bearing concrete beams and
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columns within the floor and wall panels of the second storey.
The second-storey horizontal concrete beams are aligned with
and supported from below by the concrete columns.
[0010] In like fashion, to complete yet a further floor, the
method would further involve installing another set of wall
and floor panels and then pouring concrete over the floor,
into the troughs and into the channels, the concrete curing in
the troughs and channels to form horizontal concrete beams and
vertical columns. The beams are aligned with and supported
from below by the load-bearing concrete columns.
[0011] To build further floors, this process can be repeated.
In other words, for building further floors, the method would
further involve steps of erecting wall panels, laying floor
panels, pouring concrete beams and columns within the troughs
and channels in the floor and walls panels.
[0012] Another main aspect of the present invention is a
modular prefabricated wall panel for use in constructing a
building. The wall panel has a frame having a plurality of
spaced-apart vertically arranged studs and a vertically
arranged closed channel within which concrete can be poured
and cured. This wall panel also has a sheet of exterior
cladding attached to one side of the frame.
[0013] Yet another main aspect of the present invention is a
modular prefabricated floor panel for use in constructing a
building. The floor panel has a pair of spaced-apart frames,
each frame comprising a plurality of spaced-apart horizontally
arranged joists and a sheathing attached to each frame. This
floor panel also has a trench-like track connected to each of
the pair of spaced-apart frames panels to thereby define a
trough between the frames for receiving concrete.
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[0014] By implementing the method outlined above and the wall
and floor panels introduced above, it is possible to construct
a novel multi-storey building, which thus represents another
main aspect of this invention. This novel multi-storey
building has a plurality of modular prefabricated wall panels
assembled together to form the walls of the building, the wall
panels comprising upright channels into which concrete is
poured and cured to form hybrid steel-and-concrete load-
bearing columns. This multi-storey building also has a
plurality of modular prefabricated floor panels assembled
together to form the floors of the building, the floor panels
comprising horizontal troughs into which concrete is poured
and cured to form hybrid steel-and-concrete horizontal beams.
[0015] In one main implementation of this technology, the
concrete columns are aligned with and supported by the
concrete beams of the storey immediately below while the
concrete beams are, in turn, aligned with and supported by the
concrete columns of the storey immediately below.
[0016] This innovative construction method is highly
efficient, thus reducing construction time and construction
cost when building multi-storey buildings.
[0017] The details and particulars of these aspects of the
technology will now be described below, by way of example,
with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further features and advantages of the present
technology will become apparent from the following detailed
description, taken in combination with the appended drawings,
in which:
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[0019] FIG. 1 is a flowchart depicting steps of constructing
a building in accordance with an aspect of the present
invention;
[0020] FIG. 2 is a flowchart depicting steps of constructing
a building in accordance with another aspect of the present
invention;
[0021] FIG. 3 is a flowchart depicting steps of constructing
a building in accordance with another aspect of the present
invention;
[0022] FIG. 4 is a flowchart depicting steps of constructing
a building in accordance with another aspect of the present
invention;
[0023] FIG. 5 is an isometric view of a wall panel in
accordance with an embodiment of the present invention;
[0024] FIG. 6 is an isometric view of a floor panel in
accordance with an embodiment of the present invention;
[0025] FIG. 7 is an isometric view of the floor panel of FIG.
6 overlaid with reinforcing rod;
[0026] FIG. 8 is an isometric view of the floor panel of FIG.
6 after concrete has been poured;
[0027] FIG. 9 is an isometric view of a floor slab at a
construction site;
[0028] FIG. 10 is an isometric view schematically depicting
the assembly of ground floor wall panels on the floor slab;
[0029] FIG. 11 is an isometric view schematically depicting
the assembly of floor panels on the wall panels;
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[0030] FIG. 12 is an isometric view schematically depicting
assembly of second-storey wall panels;
[0031] FIG. 13 is an isometric view schematically depicting
the laying of second-storey floor panels on top of the
assembly of wall panels;
[0032] FIG. 14 is an isometric view schematically depicting a
the concrete beams and columns poured and cured for the first
storey;
[0033] FIG. 15 is an isometric view schematically depicting
assembly of wall and floor panels on the third storey in
preparation for pouring concrete for the second storey;
[0034] FIG. 16 is an isometric view schematically depicting
the concrete columns and beams that have been poured and cured
for the second storey;
[0035] FIGS. 17 and 17A are elevation and cross-sectional
views of an example of a wall panel having a window;
[0036] FIGS. 18 and 18A are top plan and front views of an
example of a floor panel;
[0037] FIGS. 19A-19D are plan views of exemplary wall panel
assemblies for each of the various storeys of a multi-storey
building, presented by way of example;
[0038] FIG. 19E is an exemplary shoring plan, presented by
way of example;
[0039] FIGS. 20A-20E are plans views of exemplary floor panel
assemblies for each of the various storeys of the same multi-
storey building, again presented by way of example;
[0040] FIG. 20F is an example of a roof plan showing
exemplary panel layout;
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[0041] FIGS. 21A-21E are various elevation views of the
multi-storey building;
[0042] FIGS. 22A-22R are various cross-sectional views that
are referenced in FIGS. 20B and 20C;
[0043] FIG. 23 is an isometric view of the multi-storey
building framework, showing all of the wall panel frames and
floor panel frames; and
[0044] FIG. 24 is an isometric cutaway view of a portion of
the building framework shown in FIG. 23, showing how concrete
can flow through the upright channels and horizontal troughs
of the framework.
[0045] It will be noted that throughout the appended
drawings, like features are identified by like reference
numerals.
DETAILED DESCRIPTION
[0046] In general, the present technology provides an
innovative method of constructing a multi-storey building by
using prefabricated modular wall panels and prefabricated
modular floor panels. The novel prefabricated wall panels
have a frame that includes studs and an upright channel into
which concrete is poured and cured to form a concrete column
(or a hybrid steel-and-concrete column). Similarly, the novel
prefabricated floor panels have a frame that includes joists,
sheathing and a trench-like track that forms a trough for
receiving concrete that cures in the trough to create a
concrete beam (or a hybrid steel-and-concrete beam). These
panels are prefabricated before being delivered to the
construction site. They are assembled into walls (both
exterior and interior) and floors. Concrete is poured into
the channels of the wall panels to produce load-bearing
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concrete columns. Similarly, concrete is poured into troughs
in the floor panels to form concrete beams.
[0047] These load-bearing columns and beams are thus formed
only in the walls (either exterior walls or interior demising
partition walls) and in the floors, thus minimally interfering
with the architectural layout of the floor plans. Because all
columns are within the walls, there are no "orphaned" columns
inconveniently placed on the resulting floor plan. In
contrast, when constructing a building with prior-art formwork
methods (Cast in Place concrete and structural steel
construction with open joists), columns are placed
strategically throughout all floors which take up valuable
floor space. This present invention reduces column sizes and
places them within the 6" (or other size) stud wall cavity,
and thus eliminates all columns within the floor space. The
columns can be placed within the partitions, for example
roughly every 6%' and are reduced in size to, for example,
6"x 6" or 6" x 12" (or other appropriate sizes), thereby
maintaining the structural integrity of the building. There
are thus more columns that are spaced closer together than in
a typical (prior-art) building, thus allowing the building to
withstand just as much weight, if not more than a standard
building.
[0048] Furthermore, no removable concrete forms are required
using this novel construction method, which thereby greatly
reduces time, cost and complexity.
[0049] Moreover, since the troughs (which can be, for
example, steel tracks) remain with the cured concrete, the
result is a hybrid steel-and-concrete beam, which has
excellent load-bearing capability. Likewise, since the
channels (which can be, for example, steel box-beam channels)
also remain with the cured concrete, the resulting structure
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is a hybrid steel-and-concrete column, which also has
excellent load-bearing capability.
[0050] The present invention will now be described in greater
detail with reference to the embodiments illustrated in the
attached figures.
[0051] FIG. 1 is a flowchart showing steps of the novel
method of constructing a building in accordance with one
embodiment of the present invention. As shown in FIG. 1, an
initial step 10 involves preparing a construction site by
pouring a floor slab. Upright rebar can be positioned to
align with load-bearing concrete columns that are to be
poured. Once the floor is ready, the next step 12 entails
erecting an assembly of modular prefabricated wall panels by
connecting the wall panels to define one or more walls of the
building. As will be elaborated below, the wall panels
comprise a frame having a plurality of substantially vertical
members, a subset of the plurality of substantially vertical
members being closed channels that are aligned with the
upright rebar set in the floor slab. At step 14, modular
prefabricated floor panels are installed over the assembly of
wall panels. At step 16, second-storey wall panels are
assembled on top of the first-storey floor panels. At step
18, second-storey floor panels are assembled on top of the
second-storey wall panels. Accordingly, two storeys of wall
and floor panels are assembled before concrete is poured for
the first storey. At step 20, concrete is poured over the top
of the first-storey floor panels, to thus form the floor slab.
In the process, concrete flows into the troughs of the floor
panels and from the troughs flows into the channels in the
wall panels. Concrete thus cures in both the channels and the
troughs. As a result, concrete beams are formed in the
troughs in the floor panels and concrete columns are formed in
the channels of the wall panels.
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[0052] In one embodiment, the method involves (as depicted in
FIG. 2) a step 19 of installing rebar or reinforcing rod.
This can entail splicing additional upright rebar to the
upright rebar that is already set in the floor slab. Rebar is
laid (as will be elaborated below) over the floor panels prior
to pouring concrete, as well as in the channels and troughs.
[0053] In one embodiment, the method involves (as depicted in
FIG. 3), shoring the floor panels prior to pouring the
concrete. An example of a shoring plan is presented by way of
example only in FIG. 19E.
[0054] In one embodiment, the method involves (as depicted in
FIG. 4), cross-bracing the wall panels. In other words, the
wall panels are temporarily braced. Workers check that the
wall panels are plumb, and fasten the wall panels to the floor
slab.
[0055] Additional storeys of the multi-storey building can be
built by repeating the foregoing steps of erecting wall
panels, pouring concrete columns within the channels in the
walls panels, laying floor panels atop the wall panels, laying
reinforcing rods horizontally, and pouring concrete over the
reinforcing rods and into the horizontal troughs to form
concrete beams that are supported by the concrete columns
which in turn support the concrete beams of the floor above.
[0056] FIG. 5 is an isometric view of a wall panel 100 in
accordance with an embodiment of the present invention. As
depicted in FIG. 5, the wall panel 100 has top and bottom
tracks 102, 104 that form part of a frame. The frame of each
wall panel 100 can be prefabricated by fastening a plurality
of spaced-apart, vertically arranged studs 106 and a
vertically arranged box channel 108 to the top and bottom
tracks 102, 104. The top track 102 has a hole 112 in the
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track above the box channel 108 to thereby enable concrete 110
to flow through the hole in the top track into the box
channel. Cross-bracing and stiffeners can then be fastened to
the studs and box channel. During prefabrication, an exterior
wall cladding (e.g. DensGlass Gold Sheathing by Georgia-
Pacific or any other gypsum sheathing) can be attached to one
side of the frame. As will be appreciated by those of
ordinary skill in the art, other claddings can be added such
as insulation, wood, vinyl siding, etc. Although this figure
shows only a single channel 108, it should be understood that
two or more channels can be provided in the wall panel for
receiving concrete to form respective load-bearing columns.
The two channels can be spaced apart to permit an aperture for
a window to be disposed between the channels.
[0057] FIG. 6 is an isometric view of a floor panel 200 in
accordance with an embodiment of the present invention. This
modular prefabricated floor panel 200 can be used in
constructing a building. The floor panel 200 comprises a pair
of spaced-apart frames, each frame comprising a plurality of
spaced-apart horizontally arranged joists 202, 204 and a
sheathing 208 attached to each frame. The floor panel also
comprises a trench-like track connected to each of the pair of
spaced-apart frames panels to thereby define a trough 206
between the frames for receiving concrete. In one embodiment,
the frame comprises a plurality of joists connected back to
back with fasteners, top and bottom tracks connected to the
top and bottom sides of the joists and a sheathing mounted to
the top track. Optionally, stiffeners can be provided for
interconnecting adjacent joists.
[0058] In one embodiment, the frames of the floor panels are
spaced apart by a predetermined distance defining an elongated
gap into which is placed a trench-like track that acts as the
horizontal trough for receiving concrete which, when cured,
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forms each concrete beam. In one particular embodiment, the
predetermined distance defining the gap between the frames is
equal to a depth of the joists.
[0059] FIG. 7 is an isometric view of the floor panel of FIG.
6 overlaid with reinforcing rod 210. This figure is
intentionally simplified since normally a plurality of these
panels is assembled together before the reinforcing rods are
overlaid. Once the reinforcing rod is laid, concrete is
poured and cured. FIG. 8 shows how the concrete 212 fills in
the trough 208 and forms an upper level floor slab.
[0060] FIG. 9 is an isometric view of a floor slab 50 at a
construction site (prepared using techniques already known in
the art). FIG. 10 is an isometric view schematically
depicting the assembly of ground floor wall panels 100 on the
floor slab 50. Subsequently, as shown in FIG. 11, the floor
panels 200 are installed. FIG. 12 is an isometric view
schematically depicting the erecting of second-storey wall
panels. FIG. 13 is an isometric view schematically depicting
the laying of second-storey floor panels 200 on top of the
assembly of second-storey wall panels 100. As shown
schematically, the floor panels have troughs 206 for receiving
concrete. Concrete is then poured over the first storey
ceiling. The concrete flows into the troughs, and then flows
into the channels, thus forming columns in the channels and
beams in the troughs. The concrete is poured to also form an
upper level slab floor over the sheathing. In the process,
the bottoms of the next storey columns are set, thus locking
these into place. FIG. 14 is an isometric view schematically
these concrete beams and concrete columns after these have
been poured.
[0061] FIG. 15 is an isometric view schematically depicting
the addition of third-storey wall panels and floor panels.
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FIG. 16 is an isometric view schematically depicting the
building after concrete is poured for the second storey, i.e.
after pouring the second-storey slab, the troughs and channels
are filled with concrete to thereby form the concrete beams
and concrete columns. As mentioned above, the rest of the
multi-storey building is constructed by repeating these steps
of assembling the modular prefab wall and floor panels and by
pouring the concrete columns and beams.
[0062] FIGS. 17 and 17A are elevation and cross-sectional
views of an example of a wall panel 100 having a window
designated by label W10. The wall panel in this particular
example has five channels for pouring five columns. Any
number of columns can be created in a wall panel. However,
suitable spacing must be provided between adjacent columns for
windows and doors. Likewise, the number, spacing and type of
studs that are used in the wall panels may vary.
[0063] FIGS. 18 and 18A are top plan and front views of an
example of a floor panel 200. The number, spacing and type of
joists that are used in the floor panels may vary. The floor
panels, like the wall panels, can be constructed in various
different shapes with any number of troughs. The troughs can
be disposed at various orientations. However, as noted above,
it is preferable for load bearing, to ensure that the beams
and columns are aligned with one another so that building
loads are transferred through the columns and beams.
[0064] FIGS. 19A-19D are plan views of exemplary wall panel
assemblies for each of the various storeys of a multi-storey
building, presented by way of example. It should be
understood that these plans are presented merely by way of
example to illustrate one particular layout of wall and floor
panels (and one particular configuration of columns and
beams). The black squares represent the concrete columns.
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These panel, column and beam configurations will, of course,
vary for different buildings. FIG. 19E is an exemplary
shoring plan, presented by way of example, showing how the
shoring is to be done for this particular building.
[0065] FIGS. 20A-20E are plans views of exemplary floor panel
assemblies for each of the various storeys of the same multi-
storey building, again presented by way of example. Note how
the concrete beams and columns align with one another. FIG.
20F is an example of a roof plan showing exemplary panel
layout;
[0066] FIGS. 21A-21E are various elevation views of the
multi-storey building. These views show how windows are
placed in the building (in between the adjacent columns, as
described above).
[0067] FIGS. 22A-22R are various cross-sectional views that
are referenced in FIGS. 20B and 20C. These cross-sectional
views present myriad construction details for the sake of
completeness, but will not be further described herein.
[0068] FIG. 23 is an isometric view of the multi-storey
building framework, showing all of the wall panel frames and
floor panel frames.
[0069] FIG. 24 is an isometric cutaway view of a portion of
the building framework shown in FIG. 23, showing how concrete
can flow through the upright channels 108 and horizontal
troughs 106 of the framework. The resulting structure can be
referred to a hybrid structure since the load-bearing columns
are hybrid steel-and-concrete columns while the beams are
hybrid steel-and-concrete beams. In other words, the
surrounding steel channels share part of the load with the
concrete columns that are formed inside the channels.
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Likewise, the three-sided steel tracks (that form the troughs)
share part of the bending load with the concrete beams.
[0070] The frames of the wall and floor panels presented in
the foregoing disclosure can be constructed of steel or any
other suitable metal or composite material. Preferably, but
not necessarily, the studs and joists can be made using steel
tracks, e.g. commercially available 18 gauge (or 16 gauge)
galvanized C-channel or U-channel steel tracks. Similarly,
the troughs and box channels can also be made using steel
tracks, e.g. 18 gauge or 16 gauge galvanized steel tracks,
although other materials or steel of another gauge can be
substituted. For the sake of illustration only, an example
exterior wall panels can be constructed of 6"x 18 gauge C-
channel, 1 - 1 x 3" - 18ga L-angle, 1 - 1" x 1"- 18ga L-angle
which are used for the bottoms of the panels, one being
smaller to enable concrete to flow over it, 6"x 18 ga steel
studs with various flanges (1 1/4, 1 5/8 depending on load
design), 6" x 6" galvanized columns, 1%" stiffeners , 5 1/2"
bridging clips (18ga), wafer head -self drilling framing screw
fasteners 7/16, exterior DensGlass sheathing or equivalent
(1/2" or 5/8") , 8" by 16 gauge track. Once shop drawings for
each wall and floor panel assembly have been engineered,
materials are ordered for all the variously sized components
of both the wall and floor panels. Wall panel jigs are
constructed for the assembly of various panels. Firstly, both
top and bottom tracks are installed in the jig. Then, 6" studs
are placed at 16" on center (o.c.) or 24"o.c. Once the track
and studs are installed in the panel, columns are placed
within the wall cavity at various locations and are designed
to align with the floor assembly beams. Then, 1% " stiffeners
with bridging clips are added at the midpoints of the panels
with clips fastened at each stud to increase the rigidity of
the panel. Once the fastening of the upper and lower track is
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complete, the panel is turned over to fasten the track and
studs on both the top and bottom of the other side. Then, 6" x
6" column holes are cut into the 6" track at the column
locations. This allows the upper floor concrete to flow down
into the channels to form the concrete columns. An 8" C-
channel is installed perpendicular to the studs on a
horizontal plane fastened the top of the 6" track. This will
give support to the upper exterior wall panels and form for
the concrete on the perimeter beam. The DensGlass or gypsum
will then be installed on the exterior of the wall panel. The
exterior (perimeter) wall panel is thus complete. Windows and
door opening(s) should be framed within the wall panels
between the concrete column forms, as needed.
[0071] For interior demising wall panels, the following
methodology can be used: firstly, top track and bottom angles
are installed in the jig. Then, 6" studs are placed at 16"
o.c. or 24" o.c. inside the track and angles. Once that is
completed, 6" x 6" columns are placed at various locations
within wall assembly and are designed to align with floor
assembly beams. Then, 1 1/2" stiffeners are added at the
midpoint of the panels with clips fastened at each stud to
increase the rigidity of the panel. Once the fastening of the
upper and lower track is complete, the panel is then turned
over to fasten the track and stud on both the top and bottom
of the other side. 2"- 18 ga galvanized flat stock cross
bracing is fastened to the track / studs and columns. Then, 6"
by 6" column holes are cut out of the 6" track at the column
locations. This will allow upper floor concrete to flow down
into the channel and form the column.
[0072] For floor panels, the following materials can be used:
8" track- 18 ga galvanized, 6" joist - 18ga galvanized, 1
1/8" or 1 5/8 flange, 1M 18 ga galvanized U-channel, 'A " fire
treated plywood sheathing, 7/16 wafer head self-drilling
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galvanized screws. In terms of methodology, a jig is
assembled on a working table for the various sizes of panels
to be fabricated. The joists are fastened back to back
continuously with 7/16 screws. They are then placed within the
jig at a spacing of 16 o.c. or 18 o.c. and fastened with 8"
track on both ends. Then the two outer studs are turned
inwardly, thus creating a flat surface around the perimeter.
The surface will then be the form work for the concrete beam
of each panel on each side. The plywood is installed
perpendicular to studs, covering the complete panel.
Stiffeners are added at various locations as required. All
floor and walls panels are loaded on a flat bed in a
progressive manner and shipped to site. Site preparation
requires a floor slab in place with rebar for the columns and
plumbing to be installed. The floor slab has to be designed to
support the structure.
[0073] Installation and assembly of wall panels proceeds as
follows: The assembly of the wall panels for the first storey
walls and the floor panels for the first storey ceiling
(second-storey floor) are repeated in the same fashion for the
upper floors.
[0074] Exterior wall and interior wall panels are offloaded
and placed on the floor slab in their respective locations.
45-degree interior cross-bracing is added as temporary bracing
to support the panels. Wall plumbness is checked as walls are
secured with cross-bracing. Panels are then fastened to the
slab and levelled. Floor panels are then shipped on a flat
bed to the site and offloaded. Each floor panel is placed on
top of the wall panels in its respective location while
maintaining a gap between each panel that is approximately 6"
to 8". This gap can be filled with an 8" track which will then
be fastened on each side of the panel that will act as a form
once the concrete is poured. Each beam has been designed to
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line up with the columns in the wall panels. Floor panels are
then fastened with screws to the top of the wall panels. This
is only a temporary means to hold them together - once the
concrete is poured and cured the structure will hold together
by itself. Once the floor system has been secured, cross-
bracing is removed and shoring is placed at the underside of
the complete floor system, as engineered. See, for example,
the shoring plan depicted in FIG. 19E. Reinforcing rod is
placed on the floor and the rebar is placed in all columns
extending above floor deck for splicing to rebar for the next
floor. 2nd floor wall panels and/or floor panels are then
shipped to site and installed in the same manner as the first
floor. The reinforcing rod is placed inside the entire
interior and perimeter beams on the first floor along with
rebar and complete slab as engineered. Pea stone concrete of
the first floor is then pumped uniformly into all columns and
then floor throughout and finished according to engineered
specs. The following day, re-shoring of the 2nd floor proceeds
along with the removal of cross-bracing for the complete area.
The 3rd and 4th floor etc will be based on curing and re-
shoring as engineered. The complete system must be engineered
to comply with all applicable building codes. The foregoing
example is merely intended to be illustrative of the best mode
of implementing this technology as of the filing date, and is
not meant to limit the scope of the invention. It should be
expressly understood that the specific dimensions, material
types, fastener sizes, etc. are presented solely to illustrate
one way of implementing this technology. These dimensions,
sizes, fasteners, material types, etc. can be varied without
departing from the spirit and scope of the present invention.
[0075] For the purposes of this specification, the term
"prefabricated" means that the panel or other component in
question has been fabricated prior to being transported to the
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construction site. It should be understood that while it is
preferable to prefabricate the complete panels prior to
transporting them to the job site, it is not essential that
this be done, since it is also possible to assemble some of
the components of the panels in situ, i.e. at the job site.
[0076] For the purposes of this specification, "sheathing"
means a structural covering, usually boards, plywood, or other
sheet material that is placed over studding, rafters, etc. In
this case, the sheathing is placed on top of the assembly of
frames to support the rebar can be placed and the concrete
that is poured to form the floor of the next storey. The
sheathing can be plywood treated with a fire-resistant
preservative or any other suitable covering. It should be
understood that it is preferable to attach the sheathing
before transporting the panels to the job site, but this is
not necessary.
[0077] This novel technology can be applied to efficiently
construct multi-storey buildings. While this technology is
primarily intended for low-rise multi-storey buildings such
as, for example, buildings have six floors or less, the
technology can be applied in theory to the construction of a
high-rise building as well, provided that the structure is
engineered to withstands the loads involved.
[0078] This novel technology provides a number of substantial
advantages over the prior art. For example, this novel
technology reduces construction time and construction cost by
doing away with removable concrete forms and eliminating the
coordination problems associated with employing different
trades to complete the framing and cladding. Since the panels
are lightweight, mobile cranes can lift the panels from a
flatbed truck (without requiring a tower crane, which is far
more expensive and time-consuming). This novel construction
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method also eliminates the forming contractor and all the
structures are engineered in house, reducing on-site
engineering costs. Since only one trade is responsible for
the entire framework and all partitions, quality control is
improved (fewer mistakes are likely to be made by only a
single trade). Furthermore, this technique allows other
trades (e.g. electricians, plumbers) to proceed on the lower
levels while the construction on the upper levels may
continue, again reducing construction time substantially.
[0079] This technique furthermore is easy to implement. The
panels are quickly and easily attached to one another using
fasteners. A mobile crane can easily lift the panels from a
flatbed truck and with the guiding hand of a couple workers
easily position the panels at the right place on the building.
Due to the repetitive nature of the assembly process, workers
will quickly become adept at assembling the panels and pouring
the columns and beams, thus improving efficiency.
[0080] This novel technique furthermore reduces waste
(compared to prior-art construction techniques) and is thus
environmentally friendly.
[0081] Since the prefab panels already have exterior
cladding, there is no need to tarp the building (during bad
weather). Alternatively, a first (intermediate) cladding can
be pre-installed and a finished (final) cladding can be added
on site, which also is efficient. Moreover, the floor space
is optimized since the columns are intelligently located
within exterior and interior walls. Since the columns are
small, i.e. no thicker than a stud, they perfectly fit within
the wall space.
[0082] This new technology has been described in terms of
specific implementations and configurations which are intended
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to be exemplary only. The scope of the exclusive right sought
by the Applicant is therefore intended to be limited solely by
the appended claims.
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