Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS AND METHODS FOR CONSTRUCTING A MULTI-STOREY BUILDING
Cross-Reference to Related Applications
[0001] This application claims priority from US Application No. 63/065373
filed 13 August
2020 and entitled SYSTEMS AND METHODS FOR CONSTRUCTING A MULTI-STOREY
BUILDING which is hereby incorporated herein by reference for all purposes.
For purposes
of the United States of America, this application claims the benefit under 35
U.S.C. 119 of
US application No. 63/065373 filed 13 August 2020 and entitled SYSTEMS AND
METHODS FOR CONSTRUCTING A MULTI-STOREY BUILDING.
Technical Field
[0002] The present invention relates generally to using prefabricated
insulated building
panels for constructing a multi-storey building.
Background
[0003] Constructing a multi-storey building (a building that includes one or
more sections
having two or more storeys) is typically an extensive project involving
significant amounts of
time and/or resources (labour, energy, materials, etc.). For example typical
conventional
construction techniques for residential or commercial buildings of multiple
storeys may
utilize cast-in-place concrete floors and pillars. The carbon footprint of a
building built using
such existing systems and methods can be large. Traditional building
construction methods
using cast-in-place concrete requires the use of expensive materials and
requires allocating
significant amounts of time for allowing concrete to cure, resulting in long
construction
times. Furthermore, concrete construction techniques are inflexible and offer
little
opportunity for modification after the buildings are completed.
[0004] Techniques of modular building construction using prefabricated
structural
components have been disclosed in the prior art. Such techniques comprise
prefabricating
panels and walls in a factory and then shipping them to a construction site
where they are
assembled into the final building. Modular building techniques have many
advantages such
as lower greenhouse gas emissions as compared to traditional cement building
techniques,
faster erection of buildings, and safer building practices.
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[0005] However, prior art modular building techniques using prefabricated
panels are
limited by the desire for modularity and universality, wherein the
prefabricated panels have
little to no variance in their material properties and are therefore not
optimized for their
specific applications. Due to the desire for uniformity in prior art
prefabricated panels, the
prior art building techniques fail to provide for the variable needs for
specific prefabricated
panels in different parts of multi-storey buildings, resulting in a decreased
flexibility for the
environments in which those buildings can exist. These variable needs include
weight,
structural strength, fire resistance, acoustic insulation, and temperature
insulation, for
example.
[0006] There remains a general need for systems and methods of constructing
multi-storey
buildings using prefabricated panels which are optimized for their specific
application and
which are cost effective and can be readily assembled.
[0007] The foregoing examples of the related art and limitations related
thereto are intended
to be illustrative and not exclusive. Other limitations of the related art
will become apparent
to those of skill in the art upon a reading of the specification and a study
of the drawings.
Summary
[0008] The following embodiments and aspects thereof are described and
illustrated in
conjunction with systems, tools and methods which are meant to be exemplary
and
illustrative, not limiting in scope. In various embodiments, one or more of
the above-
described problems have been reduced or eliminated, while other embodiments
are
directed to other improvements.
[0009] This invention has a number of aspects. These include, without
limitation:
= constructing a multi-storey building out of prefabricated wall panels and
floor panels,
where prefabricated panels of each storey span between a building foundation
and
roof panels;
= constructing a multi-storey building out of prefabricated panels in which
some of the
prefabricated panels comprise cross bracing embedded within an insulative core
of
the panel and/or comprise a frame disposed about a perimeter of the panel;
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= constructing a multi-storey building out of prefabricated panels with
cementitious
layers in which some of the different prefabricated panels comprise different
cementitious layers;
= constructing a multi-storey building using prefabricated wall panels
forming demising
walls, the panels comprising a cavity providing acoustic dampening;
= constructing a multi-storey building out of prefabricated panels in which
some floor
panels extend exteriorly and are cantilevered by one or more prefabricated
wall
panels; and
= constructing a multi-storey building using prefabricated roof panels,
which when
connected together, form a roof profile having a water drainage channel.
[0010] In addition to the exemplary aspects and embodiments described above,
further
aspects and embodiments will become apparent by reference to the drawings and
by study
of the following detailed descriptions.
Brief Description of the Drawings
[0011] Exemplary embodiments are illustrated in referenced figures of the
drawings. It is
intended that the embodiments and figures disclosed herein are to be
considered illustrative
rather than restrictive.
[0012] Figure 1 is a perspective view of a single storey of a multi-storey
building comprising
a plurality of different prefabricated panels.
[0013] Figure 2A is a perspective view of a multi-storey building comprising a
plurality of the
single storeys shown in Figure 1.
[0014] Figure 2B is an elevation view of the multi-storey building of Figure
2A.
[0015] Figure 2C is a cross-sectional elevation view of the multi-storey
building of Figure 2A
along lines C-C of Figure 2B. Figure 2D is a cross-sectional plan view of the
multi-storey
building of Figure 2A along lines D-D of Figure 2B.
[0016] Figure 3A is a perspective view of a partially complete exterior wall
panel according
to an example embodiment. Figure 3B is a perspective view of an exterior wall
panel
according to an example embodiment. Figure 3C is a schematic view of a
demising wall
according to an example embodiment.
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[0017] Figure 4 is a perspective view of a floor of a single storey comprising
a plurality of
prefabricated panels.
[0018] Figures 5A to 5E are schematic views illustrating a number of different
ways in which
floor panels may be positioned relative to corresponding wall panels.
[0019] Figure 6 is a perspective view, partially exploded, of a single storey
comprising a
plurality of prefabricated panels forming a floor and walls.
[0020] Figure 7 is a perspective view of a roof comprising a plurality of
prefabricated panels.
[0021] Figure 8 is a perspective view of a partially complete multi-storey
building showing
the positioning of roof panels, partially exploded, over the top storey of the
building.
[0022] Figure 9 is a block diagram illustrating an example method for
constructing a multi-
storey building.
Description
[0023] Throughout the following description specific details are set forth in
order to provide
a more thorough understanding to persons skilled in the art. However, well
known elements
may not have been shown or described in detail to avoid unnecessarily
obscuring the
disclosure. Accordingly, the description and drawings are to be regarded in an
illustrative,
rather than a restrictive, sense.
[0024] Figure 1 is a perspective view of a single storey 10 of a multi-storey
building
comprising walls formed from a plurality of different prefabricated panels. A
multi-storey
building 100, as illustrated in Figure 2C, is constructed by constructing a
first storey 10A on
a foundation 102, then constructing a second storey 10B on the first storey
10A, followed by
constructing a third storey 10C on the second storey and so on. Multi-storey
building 100
may be a residential apartment building, an institutional building, a
commercial office
building, or the like. In the illustrated Figure 1 embodiment, storey 10,
which may be a first
or any subsequent storey, comprises a plurality of exterior walls 12, demising
walls 14,
corridor walls 16, and core walls 18.
[0025] Different ones of walls 12, 14, 16 and 18 serve to form different
portions of a storey
10, which is best illustrated with reference to Figure 1. Exterior walls 12
are disposed about
and define an outer perimeter of storey 10. Demising walls 14 of storey 10 are
used for the
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purpose of separating individual residential or commercial units 20. Corridor
walls 16 of
storey 10 are used for the purpose of separating a building unit 20 from a
corridor 27,
corridor 27 leading to different building units 20. Core walls 18 of storey 10
are used for
defining the perimeter of stairwells, elevator shafts and service shafts. It
is not necessary
__ that instances of walls 14, 16 and 18 are present on every storey 10 or at
all in multi-storey
buildings described herein. The use of any combination of these walls is
possible in
practicing the present invention. Specific traits and desirable properties of
individual ones of
walls 12, 14, 16 and 18 are described in further detail below.
[0026] Multi-storey buildings built according to the present invention
generally rely on
prefabricated panels having an insulative core between two layers of a
structural element.
In some embodiments, the prefabricated panels used for walls 12, 14, 16 and 18
may be
structurally insulated panels (SIPs) comprising a foam core sandwiched between
two layers
of structural board.
[0027] According to a preferred embodiment of the invention, the prefabricated
panels used
herein may be similar to panels described in detail in Canadian Patent No.
2,994,868 filed
on Feb. 13, 2018 entitled PREFABRICATED INSULATED BUILDING PANEL WITH
CURED CEMENTITIOUS LAYER BONDED TO INSULATION, which is hereby
incorporated by reference in its entirety. Prefabricated panels described in
Canadian Patent
No. 2,994,868 comprise an insulative foam core covered on inner and outer
surfaces in a
composite cementitious layer.
[0028] Different constituent materials making up the cementitious layers may
have different
performance characteristics and material properties as disclosed in
corresponding United
States Provisional Application No. 63/000,942 filed on 27 March 2020 entitled
PREFABICATED PANEL WITH MULTI-LAYER CEMENTITIOUS COVERINGS, the
contents of which are incorporated herein by reference. For example, some
cementitious
materials used may feature higher fire protection and/or sound dampening,
while other
cementitious materials may have higher structural support characteristics.
These different
properties may advantageously be used for obtaining desirable characteristics
specific to
the function performed by each of walls 12, 14, 16 and 18 and by any other
prefabricated
panels described herein.
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[0029] Individual ones of prefabricated panels forming walls 12, 14, 16 and 18
or other
structural elements contained therein may be coupled to one another in a
number of
possible ways, as disclosed in corresponding United States Provisional
Application No.
63/003,401, filed 1 April 2020 entitled SYSTEMS AND METHODS FOR COUPLING
PREFABRICATED PANELS TOGETHER, the contents of which are incorporated herein
by
reference. The use of reinforcing frames having connectors with lifting points
as described
in United States Provisional Application No. 63/003,401 may advantageously be
used in
facilitating ease of transportation and assembly of prefabricated panels when
constructing
multi-storey buildings.
[0030] It is advantageous that certain ones of the prefabricated panels used
in the present
invention comprise a greater fire resistance construction than in other
prefabricated panels.
For example, prefabricated panels used for the construction of exterior walls
12 preferably
do not comprise any combustible materials or materials which may melt under
certain fire
conditions. Prefabricated panels fabricated from non-combustible materials may
be referred
to herein as "fire walls".
[0031] In some embodiments, prefabricated panels used for the construction of
fire walls
comprise a mineral wool insulative core. In some embodiments, one or both of
the
cementitious layers surrounding the insulative core of a fire wall comprise
perlite, which
provides stronger fire resistance properties. In this manner, different fire
ratings may be
selectively achieved for different surfaces of buildings described herein.
[0032] As an example, for exterior walls 12 situated on zero-lot-lines, it is
preferable that
walls 12 are fire walls having a high fire resistance rating in the range of 2
to 4 hours to
ensure that fires which may occur within building 100 are not spread to
adjacent properties.
In embodiments where building 100 is immediately adjacent other properties on
one or
more sides, but not on the remaining sides, exterior walls 12 adjacent the
other properties
may comprise fire walls while exterior walls 12 on the remaining sides
comprise
prefabricated panels not made with fire rated materials (e.g. having an
expanded
polystyrene insulative core).
[0033] Fire walls may be employed for other walls (including demising walls,
core walls and
corridor walls) of the present invention where it is important in the
circumstances to prevent
the spread of fire or to be in compliance with building regulations and codes,
such as for a
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fire-proof enclosure of a boiler room. In some embodiments, building 100 may
be sub-
divided into a number of discrete compartments, for example, where building
100 is large or
long. In such embodiments, walls separating different compartments may
advantageously
comprise fire walls, thereby restricting the spread of fire within a large
building 100.
[0034] Figures 2A-2D show a number of different views of an example multi-
storey building
100 comprising a plurality of storeys 10. Figure 2C is a cross-sectional
elevation view of
building 100 along lines C-C of Figure 2B. Figure 2D is a cross-sectional plan
view of
building 100 along lines D-D of Figure 2B.
[0035] Building 100 comprises foundation walls 19 extending into ground 11, as
best shown
in Figure 2C. A portion of foundation walls 19 is shown to extend slightly
above the surface
of ground 11, although this is not necessary. As illustrated, foundation walls
19 rest on top
of and are supported by a foundation 102. In some embodiments, foundation 102
is a
spread footing foundation wherein the foundation has a wider bottom portion
than the load-
bearing foundation walls it supports, the wider portion distributing the
weight of building 100
over a greater area. In some embodiments, foundation 102 comprises cast in
place
concrete. In other embodiments, foundation 102 comprises precast concrete
which is cured
in a plant and then transported to the construction site for installation.
[0036] In some embodiments, foundation 102 extends farther down beneath the
surface of
ground 11 to a deeper subsurface layer of earth. The use of a deep foundation
may be
desirable for a variety of reasons, such as for accommodating larger design
loads or where
the quality of soil is poor at shallower depths. Suitable prefabricated panels
for the
construction of foundation walls 19 are described in detail in United States
Provisional
Application No. 63/001,194 filed on 27 March 2020 entitled SYSTEMS AND METHODS
FOR CONSTRUCTING A SINGLE-STOREY BUILDING, which is hereby incorporated by
reference in its entirety. Prefabricated panels for use as foundation walls
described in
United States Provisional Application No. 63/001,194 comprise a variety of
features for
imparting higher axial load-bearing capacity, higher capacity for bearing
lateral forces due to
back fill tendencies of excavated soil, and higher capacity for bearing shear
forces
stemming from seismic events.
[0037] In embodiments where foundation 102 is located far beneath the surface
of ground
11, foundation walls 19 may comprise a plurality of adjoined tall
prefabricated panels. In
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such embodiments, individual panels forming foundation walls 19 may have a
height to
width ratio of around 2:1 to 6:1 or more. In other embodiments, foundation
walls 19
comprise a plurality of adjoined horizontal prefabricated panels. Individual
horizontal
prefabricated panels forming foundation walls 19 in this embodiment may have a
width to
height ratio of 2:1 to 6:1 or more. It is also possible that foundation walls
19 comprise both
horizontal and vertical prefabricated panels. In some embodiments, a plurality
of vertically
stacked prefabricated panels are used for forming foundation walls 19 having a
desirably
high height.
[0038] It will be appreciated that alternative means for providing suitable
structural
foundation elements are possible in constructing multi-storey buildings of the
present
invention. For example, a plurality of drilled vertical piles may be installed
within ground 11
to support building 100. The piles may be formed from any suitable materials
such as wood,
reinforced concrete, or a composite material. According to a specific
embodiment, the piles
are steel screw piles.
[0039] Referring to Figure 1, exterior walls 12 are disposed about and define
an outer
perimeter of storey 10. It is preferred that exterior walls 12 are load-
bearing. Therefore, it is
desirable for exterior walls 12 to be formed from prefabricated panels which
have a high
capacity for bearing compressive loads. Generally, the structural strength of
prefabricated
panels employed herein can be increased by strengthening interior/exterior
facing surfaces
of the panels and/or by embedding structural elements within the insulative
core of the
prefabricated panels. Such possible options described herein for imparting
structural
strength to prefabricated panels may be pursued individually or in combination
with one
another.
[0040] In some embodiments, prefabricated exterior wall panels 22 used for
forming
exterior walls 12 comprise one or more metal reinforcing bars embedded within
the
cementitious layer along the vertical length of the panel for providing
additional structural
strength. The metal reinforcing bars may be embedded in an inner layer of
cementitious
material facing the interior of building or in an outer layer of cementitious
material or both.
The reinforcing bars may be disposed and spaced apart along a horizontal
direction of walls
12 and may also be disposed and spaced apart along a thickness of the
cementitious
layer(s). Additionally or in the alternative, a reinforcing substrate spanning
both lateral and
longitudinal directions of the exterior panels 22 is provided within the
cementitious layer(s).
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The reinforcing substrate may be formed, for example, from fibreglass scrim or
carbon fiber
mesh.
[0041] In some embodiments, structural reinforcing members are embedded along
a
vertical length of the insulative core at opposite horizontal ends of exterior
panels 22. In
doing so, the resilience of panels 22 to withstand axial, shear and transverse
forces may be
improved. In some embodiments, corresponding vertical ends of the structural
members are
connected to one another through horizontally oriented structural members to
form a
rectangular-shaped reinforcing frame around the perimeter of exterior panel
22. In some
embodiments, the vertical reinforcing members and/or the reinforcing frame
(referred to
collectively as "reinforcing elements") are formed of a suitably rigid and
strong metal such
as steel or aluminum. These various reinforcing elements may comprise a wide
variety of
possible cross-sectional shapes, such as wide flange (I-beams), hollow
structural section
(HSS), U-channel, and angled bars, for example. Other suitable materials for
the reinforcing
element(s) include extruded fiberglass and composite cementitious materials.
In scenarios
where the load-bearing requirements of the panels 22 are lower, such as on
higher storeys
of building 100, the reinforcement elements may comprise reinforcing bars. In
some
embodiments, the reinforcing elements described herein are bonded to the
insulative core
by a cured cementitious casting.
[0042] Figures 3A and 3B illustrate an example exterior wall panel 122, which
may be used
as an exterior wall panel 22 in the Figure 1 embodiment. Figure 3A shows the
same exterior
wall panel 122 of Figure 3B with the omission of the cementitious layer on one
side to
display a structural frame 136. Exterior panel 122 comprises an insulative
core 132 having
layers of cementitious material 134 on opposing faces of panel 122. A
structural frame 136
is embedded within insulative core 132 around the perimeter of panel 122.
Structural frame
136 comprises vertical framing members 136-1, 136-2 and 136-3 at spaced apart
horizontal
locations of panel 122. The addition of framing members between the vertical
ends of frame
136 imparts structural rigidity and strength to panel 122. Advantageously,
such a design
permits panel 122 to feature a greater length to height ratio, allowing for
comparatively
larger panels to be used. Using such example framing methods, prefabricated
panels
described herein may comprise heights of 14 feet and lengths of 60 feet or
more.
[0043] Exterior wall panel 122 comprises a plurality of connectors 138, a
number of which
are shown in Figures 3A and 3B. In some embodiments, connectors 138 serve to
facilitate
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coupling distinct elements of frame 136 together. Connectors 138 may be
embedded into
the insulative core 132 of panel 122 such that connection of frame 136 to
connectors 138
additionally serves to rigidly couple frame 136 to panel 122. In some
embodiments,
connectors 138 are substantially similar to connectors disclosed in United
States
Provisional Application No. 63/003,401. In some embodiments, connectors 138
comprise an
HSS body formed from a suitably rigid material such as steel, extruded
aluminum, or
extruded fiberglass. In other embodiments, connectors 138 comprise a solid
block
connector formed from a suitably rigid material such as steel, aluminum, or
fiberglass.
Certain surfaces of connectors 138 may remain uncovered during and after
fabrication of
panel 122 so that an interior space of connectors 138 can be accessed to
install and/or
remove fasteners.
[0044] In the illustrated embodiment, the rectangular perimeter of frame 136
and
intermediate transverse framing members 136-1, 136-2 and 136-3 comprise a
monolithic
frame 136. In such embodiments, the components of structural frame 136 are
integrally
formed or the individual components are suitably joined to one another, such
as through
welding, bolting, or adhesive bonding. In some embodiments, the fabrication of
exterior wall
panel 122 comprising such a monolithic frame 136 comprises positioning frame
136 around
connectors 138 embedded within insulative core 132 and then subsequently
installing a
plurality of suitable fasteners to connect frame 136 to the connectors 138 to
thereby
securely install structural frame 136 onto panel 122.
[0045] According to another example embodiment, portions of frame 136
interposed
between each connector 138 (e.g. framing member 136-1) comprise distinct
structural
elements. These distinct elements may each be suitably fastened to connectors
138 to
thereby collectively form frame 136. Structural frame 136 of panel 122 may
comprise any
appropriate materials or cross-sectional shapes suitable for sustaining
expected loads
during operation. Structural frame 136 may comprise the design features and
considerations discussed above in relation to reinforcing elements of exterior
wall panel 22.
[0046] Preferably, exterior walls 12 are made to be resistant to shear forces
stemming from
seismic events and high winds. Shear forces from winds are generally in plane
and
transverse to the interior and exterior facing surfaces of walls 12. When the
exterior face of
walls 12 is engaged by direct wind pressure, the interaction between the
external
cementitious layer and the insulative core transfers the load to structural
elements disposed
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within the insulative core, which in turn transfers the load to the building
foundation. Shear
forces from seismic events may be in a transverse direction (similar to forces
from wind)
and/or in a horizontal direction co-planar to the interior and exterior facing
surfaces of walls
12.
.. [0047] In some embodiments, cross-bracing may be implemented within a
structural frame
disposed within the insulative core of exterior panels 22. Applying a system
of cross-bracing
to exterior panels 22 advantageously imparts high structural shear resilience
by allowing
panels 22 to support both tensile and compressive forces imposed by shear
loads resulting
from wind and seismic activity. Suitable methods for implementing cross-
bracing within
prefabricated panels are described in detail in United States Provisional
Application No.
63/001,194. In some embodiments, cross-bracing is applied only to
prefabricated panels 22
forming exterior walls 12 on lower storeys of a building 100 where the load-
bearing
requirements are generally higher. In other embodiments, exterior panels 22 of
all of the
storeys of building 100 comprise cross-bracing, which may be desirable in
environments
where there is increased risk of high winds and/or seismic activity. In some
embodiments, a
system of cross-bracing may be applied to exterior wall panels 122 of the
Figures 3A and
3B embodiment.
[0048] Some embodiments of the present invention provide for prefabricated
panels having
a greater height to length ratio, allowing for comparatively taller panels to
be used. Such tall
.. panels may advantageously employ techniques described herein for achieving
the desired
height to length ratio. For example, tall vertical prefabricated panels herein
may comprise a
number of intermediate vertical framing members (similar to vertical framing
members 136-
1, 136-2 and 136-3 shown in Figure 3A) spaced apart along a horizontal length
of the panel.
The tall vertical prefabricated panels may also advantageously employ a method
of cross-
bracing described above to better withstand shear loads. Tall prefabricated
panels may also
optionally feature intermediate horizontal framing members spaced apart along
a vertical
length of the panel. Different ones of adjoined tall vertical panels in a
multi-storey building
may comprise any combination of these or other appropriate reinforcing methods
depending
on the specific structural requirements at a panel's location in the building.
.. [0049] Using such example framing methods, prefabricated panels described
herein may
comprise lengths of 14 feet and heights of 60 feet or more. In some
embodiments, multi-
storey buildings comprising a lower number of storeys comprise a series of
adjoined tall
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prefabricated panels forming exterior wall panels 22 substantially spanning
the entire height
of the building above grade. For example, multi-storey buildings having 2, 3,
4 or 5 storeys
can be constructed from tall exterior wall panels 22 which span the entire
height of the
building. Advantageously, this reduces the need for different prefabricated
panels to be
coupled together. It is also possible for prefabricated panels forming
interior walls (such as
demising walls 14 and core walls 18) to span several storeys using the
described tall
prefabricated panels. In some embodiments, larger multi-storey buildings (such
as building
100), comprise tall prefabricated wall panels which can span 2, 3, 4 or 5
storeys.
[0050] In embodiments employing the use of tall vertical prefabricated panels,
appropriate
couplings should be located at intermediate vertical locations of the panels
to accommodate
the attachment of floor panels 32 at different storeys. Intermediate openings
may also be
defined in the tall prefabricated panels to interface with openings defined in
floor panels 32
for allowing ducts, pipes, wire bundles and such to pass. Methods for
constructing multi-
storey buildings, described later herein, may be suitably adapted to
accommodate the use
of tall wall panels spanning multiple storeys. For example, temporary bracing
may be
applied to support and level the installation of floor panels after a number
of, but not all, of
the tall wall panels have been installed.
[0051] In some embodiments, walls 12 on lower storeys of building 100 have a
greater
load-bearing capacity than walls 12 on higher storeys. In the illustrated
Figure 2C
embodiment, exterior walls 112A and 112B on first and second storeys 10A and
10B
comprise a greater thickness than exterior walls 112C on third storey 10C.
Exterior walls
112A and 112B may comprise prefabricated exterior panels 22 having thickened
composite
cementitious layers. A greater number or a greater thickness of metal
reinforcing bars or
other reinforcing materials may optionally be disposed within the thickened
cementitious
layer. In this manner, multi-storey building 100 is afforded higher structural
capacity while
reducing the weight of the building structures on the higher storeys.
[0052] As illustrated in the Figure 1 embodiment, exterior walls 12 may
comprise openings
which define windows 13 or doors 15, such as to an exterior fire escape
stairwell or to a
balcony. In some embodiments, window openings are cast into the cementitious
layers and
insulative core of panels 22 with an appropriate mold. In some embodiments,
the casting
process may be used to form drip edges and sloped window sills. To avoid
introducing any
thermal bridges, which may diminish the insulative capabilities of exterior
walls 12, it is
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preferable that inner and outer cementitious layers of exterior wall panels 22
do not come in
contact with one another, such as at the outer edges of panels 22 or at
interior edges
defined by any openings.
[0053] It is also desirable that an exterior facing surface of exterior walls
12, which may be
exposed to humidity and rain, has properties of reduced moisture permeability.
This may
be achieved by providing a cementitious layer in exterior wall panels 22
having a higher
density. Additionally, by providing internal channels at the interface of the
exterior-facing
cementitious layer and the insulative core of panels 22, exterior walls 12 are
able to
equalize pressure and to drain moisture which has penetrated the outer
cementitious layer.
As discussed below, a suitable cladding or finishing may be applied to an
exterior-facing
surface of panels 22 to provide waterproofing properties.
[0054] Multiple exterior wall panels 22 may be joined together in any
appropriate manner
and configuration to form the exterior of storey 10 (i.e. exterior wall 12).
As illustrated in
Figure 1 by adjacent exterior wall panels 22A and 22B, exterior wall panels 22
may be
joined perpendicularly to one another. As illustrated by adjacent exterior
wall panels 22C
and 22D, wall panels 22 of walls 12 may be joined co-planar to one another.
Other
configurations not illustrated are possible, such as where adjacent exterior
wall panels are
joined to one another at an oblique angle.
[0055] Demising walls 14 of storey 10 are used for the purpose of separating
individual
residential or commercial units 20. Building unit 20 may define distinct
private dwellings or
the offices of separate businesses operating in the same storey. Demising
walls 14 may
generally have a lower insulative capacity and weather proofing capacity
compared to that
of exterior walls 12. Demising walls 14 preferably provide strong acoustic
insulation so as to
prevent sound from travelling between adjacent building units 20. The levels
of desired
acoustic insulation may be guided by relevant building codes. As an
illustrative example,
under the National Building Code of Canada, partitions separating dwelling
units must meet
a minimum sound transmission class of 50, mitigating around 50 dBA of noise.
Furthermore, demising walls 14 preferably feature high fire resistance so that
fires which
start in a building unit 20 are not readily spread to other building units 20.
Preferably,
demising walls 14 are fire rated assemblies or are fire walls and have a fire
resistance rating
between 1 to 4 hours.
13
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[0056] Figure 3C is a schematic illustration of an example demising wall 114,
which may be
used as demising wall 14 in the Figure 1 embodiment. Demising wall 114
comprises two
individual prefabricated panels 150A and 150B (which may be collectively
referred to herein
as prefabricated panels 150). Each prefabricated panel 150 comprises an
insulative core
152 and a cementitious layer 154 bonded to the respective surfaces of each of
panels 150A
and 150B facing the interior of separate building units 20. This construction
of prefabricated
panels 150 differs from that of other prefabricated panels described herein
which generally
comprise structural layers of material disposed on both sides of an insulative
core.
[0057] Structural cementitious layers on the inner surfaces of insulative
cores 152 of panels
150A and 150B may be omitted where demising walls 14 have lower load-bearing
requirements, for example. This is advantageous in keeping the overall weight
of demising
walls 114, and therefore building 100, to a minimum. In some embodiments, both
interior
and exterior surfaces of panels 150A and 150B comprise a layer of cementitious
material
for providing additional structural rigidity. Metal reinforcing bars are
optionally disposed
within cementitious layers 154 for adding structural strength. In some
embodiments,
cementitious layers 154 comprise a lower density cementitious material
containing perlite,
which provides stronger fire resistance properties.
[0058] It is also possible to provide demising walls 114 which are able to
sustain structural
sheer and axial loads by embedding structural elements within the insulative
core of one or
both of panels 150A and 150B by employing methods described above in relation
to exterior
wall panels 22. Although this has the disadvantage of making demising walls
114 heavier,
such a design increases the versatility of demising walls 114 in permitting
walls 114 to
provide structural support to multi-storey buildings of the present invention.
[0059] Prefabricated panels 150A and 150B are spaced apart such that a cavity
156
comprising dead air space is defined in demising wall 114. Cavity 156
generally prevents
waves and vibrations from travelling therewithin, thereby allowing demising
wall 114 to
provide acoustic insulation between adjacent units 20. In some embodiments,
electrical
wires and cables are disposed in cavity 156. Panels 150 may comprise
appropriate
openings in the insulative core(s) 152 and in the cementitious layer(s) 154
for receiving
such components in building units 20.
14
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[0060] In other embodiments, demising walls 14 of the present invention do not
rely on
having a dead air space for achieving desired acoustic ratings. Demising walls
14 may
comprise prefabricated panels having a monolithic insulative core formed from
materials
having high acoustic performance. For example, demising walls 14 comprise an
insulative
core formed of rigid mineral fiber to achieve a desirably high acoustic
rating. In some
embodiments, one or more cementitious layers of demising walls 14 feature the
multi-layer
cementitious coverings disclosed in United States Provisional Application No.
63/000,942.
The multi-layer coverings may be advantageously used to provide increased fire
protection,
sound dampening, and structural support characteristics.
[0061] Individual prefabricated panels 150A and 150B may be rigidly connected
to one
another in any appropriate manner to form a demising wall 114. In some
embodiments,
structural shims having a thickness substantially spanning the thickness of
cavity 156 are
disposed at spaced apart locations within cavity 156. The shims may be
installed between
panels 150A and 150B using any appropriate means, such as through an
interference fit,
adhesives, bolted connectors, and the like. In other embodiments, panels 150A
and 150B
are not connected to one another and individually connect to floor/roof panels
on adjacent
storeys using suitable connectors.
[0062] Corridor walls 16 of storey 10 are used for the purpose of separating a
building unit
from a corridor 27, corridor 27 leading to different building units 20.
Corridor walls 16
20 generally have lower requirements for providing acoustic insulation than
that of demising
walls 14 such that the dual-panel configuration of Figure 3C is not necessary.
Corridor walls
16 comprise prefabricated corridor panels 26, wherein multiple ones of panels
26 may be
coupled to define a suitably shaped corridor 27. Corridor wall panels 26 may
optionally
feature reinforcing elements described herein for adding structural strength
to corridor wall
panels 26, such as through embedded metal reinforcing bars and structural
frames.
Corridor wall panels 26 may comprise openings for providing doors 29 which
facilitate
access between building units 20 and corridor 27. Corridors in multi-storey
buildings
generally form portions of fire exit routes and building codes commonly
require corridor
walls to be constructed with a 1 hour fire rating, which may be achieved using
the methods
described herein.
[0063] Core walls 18 of storey 10 are used for defining the perimeter of
stairwells, elevator
shafts and service shafts, as illustrated by prefabricated core wall panels
28A, 28B and
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28C, respectively, in Figure 1. Other applications of core walls 18 within
storey 10 are
possible. In the event of a fire, building occupants must evacuate, and first
responders must
enter, through the elevators and/or stairwells of building 100. It is
therefore of particular
importance that fires within building 100 present outside of elevators,
stairwells and the like
are unable to penetrate through core walls 18. As such, it is highly
preferable that walls 18
enclosing such building features feature a high fire resistance rating and are
non-
combustible "fire walls". As an illustrative example, under the ULC-S101 fire
resistance
testing standard employed in Canada, core walls 18 may have a fire resistance
rating of 2
hours. In some embodiments, core walls 18 have a fire resistance rating of up
to 4 hours.
[0064] As described previously herein, the use of lower density cementitious
materials
containing perlite can be advantageously employed in core wall panels 28 to
provide
stronger fire resistance properties. Core wall panels 28 may additionally
comprise thicker
cementitious layers for obtaining maximal fire protection. In some
embodiments, the
thickness of the cementitious layer is between the range of 1/4" to 2.5". In
some
embodiments, core wall panels 28 comprise an exterior cementitious layer (i.e.
opposite the
interior of the passageways) which is thicker than an interior cementitious
layer in order to
prevent fires from entering building escape routes.
[0065] Core wall panels 28 may optionally feature reinforcing elements
described herein for
adding structural strength to core walls 18. In some embodiments, the
cementitious layers
of core wall panels 28 feature the multi-layer cementitious coverings
disclosed in United
States Provisional Application No. 63/000,942. The multi-layer coverings may
be
advantageously used to provide increased fire protection and structural
support
characteristics.
[0066] Although only one or a few instances of each of walls 12, 14, 16 and 18
and their
corresponding prefabricated panels are labelled, it will be apparent from the
foregoing
description and figures that storey 10 and building 100 comprises a plurality
of each type of
wall and their corresponding prefabricated panels. Any interior facing or
exterior facing
surfaces of walls 12, 14, 16 and 18 may be coated with a cladding, siding or
finish to protect
the building materials and/or to achieve a desired aesthetic effect. Cladding
may be
achieved as disclosed in corresponding United States Provisional Application
No.
63/002,142 filed 30 March 2020 titled SYSTEMS AND METHODS FOR ADHERING
CLADDING, the contents of which are incorporated herein by reference.
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[0067] In some embodiments, it is desirable that certain faces of walls 12,
14, 16, 18 and
any other prefabricated panels described herein are water-resistant or
waterproof. Water-
resistance and waterproofing may be added to prefabricated panels through a
variety of
methods. For example, liquid waterproofing materials including paint, mineral
coating and
clear sealer may be applied to the surface of prefabricated panels. Rigid
cladding including
ceramics, metals, wood, elastomers, and glass may also be applied to surfaces
of
prefabricated panels to provide waterproofing. A combination of materials and
application
techniques may be utilized to provide a level of desired waterproofing and for
ensuring
impermeability between joints. As an illustrative example, metal flashing may
be applied
between joints of adjacent prefabricated panels whereupon a liquid or
reinforced metal
sheet/membrane is applied over the surface of the panels.
[0068] Preferably, surfaces of prefabricated panels exposed to the external
environment
(e.g. exterior panels 22, roof panels 34 and floor panels 32 forming a
balcony) comprise a
suitable means of providing waterproofing, such as through the application of
the
techniques described above. Prefabricated panels having water-resistant or
waterproof
properties may also be desirable for certain interior-facing surfaces of
prefabricated panels
described herein. For example, a waterproof cladding or finish may be applied
to the
surfaces of prefabricated panels defining the walls, floors, and ceilings of
high humidity
rooms such as indoor pools, bathrooms and the like.
[0069] Figure 4 illustrates a plurality of adjoining floor panels 32 which
collectively form a
storey floor 200. A plurality of storey floors 200 may be provided in a
building 100 and each
storey floor 200 may be positioned and be secured to the prefabricated walls
which
collectively form each storey 10 in any appropriate manner. Attachment of a
storey floor 200
to a storey 10 forms a ceiling of that storey 10 and serves as the floor of an
immediately
higher storey 10. This concept is illustrated in Figure 2C which shows storey
floor 200A
simultaneously serving as the ceiling of storey 10A and as the floor of storey
10B.
[0070] Figures 5A-5E illustrate a number of different ways in which floor
panels 32 may be
positioned (or framed) relative to corresponding wall panels of storey 10,
shown as generic
prefabricated wall panel 21. Figure 5A shows an example configuration wherein
a floor
panel 32 is positioned on top of and is supported by a wall panel 21A of a
lower storey.
Floor panel 32 in this configuration in turn supports a wall panel 21B of a
higher storey.
17
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[0071] Figure 5B shows an example configuration wherein multiple floor panels
32 are
positioned on top of and are supported by a single wall panel 21A. Floor
panels 32
correspondingly both support a wall panel 21B on a higher storey. In this
sense, the
configuration of 5B is similar to that of Figure 5A. However, it will be
understood that the
dual-sided configuration illustrated in Figure 5B is applicable to other floor-
wall panel
configurations described herein and may be appropriately employed depending on
the
circumstances. The dual-sided configuration of Figure 5B may be appropriate
where the
interface between floor panels 32 and wall panels 21 is within building 100,
such as where
wall panels 21 comprise demising walls 14. In contrast, the single-sided
configurations of
Figure 5A, 5C, 5D and 5E may be appropriate where the floor-wall interface is
at the
perimeter of the building, such as where panels 21 comprise exterior wall
panels 22.
[0072] Figure 5C shows an example configuration wherein a floor panel is
positioned on top
of and is supported by a lip 21A-1 of panel 21A. Wall panel 21B is accordingly
supported by
both floor panel 32 and wall panel 21A. Figure 5D shows an example
configuration wherein
Floor panel 32 is positioned and attached at the top and bottom side surfaces
of wall panels
21A and 21B, respectively, and wherein upper wall panel 21B rests directly on
top of lower
wall panel 21A. Figure 5E shows a configuration similar to that of Figure 5D,
except that
floor panel 32 is attached only to lower wall panel 21A. The opposite is
possible wherein
floor panel attaches only to a side surface of upper wall panel 21B.
[0073] The selection of the particular configuration may be informed by a
number of design
considerations and constraints, where each configuration has their own
advantages and
disadvantages. For example, floor panel 32 in the Figure 5A embodiment is a
simply
supported beam which does not transfer bending moments to wall panel 21A.
Panel 21A is
therefore only required to support an axial load. However, one disadvantage is
that there
are a greater number of distinct surfaces in the Figure 5A configuration. The
junctions
between these surfaces may require suitable sealing or cladding, for example,
to provide
adequate sound protection or weatherproofing.
[0074] The configurations of Figures 5D and 5E advantageously comprise a lower
number
of potential sealing surfaces compared to the Figure 5A configuration.
However, floor panel
32 in these configurations comprises a fixed beam which requires wall panels
21 to bear
bending moments. Such configurations further require connectors at the floor-
wall interface
to suitably transfer loads encountered on floor panels 32 to wall panels 21.
Any appropriate
18
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connectors, including those disclosed in United States Provisional Application
No.
63/003,401, may be suitable for this purpose.
[0075] The configuration of Figure 5C in providing a lip 21A-1 on which floor
panel 32 rests
remedies a number of above limitations of the Figure 5A, 5D and 5E
configurations by
reducing the number of surfaces requiring sealing and by requiring panel 21A
to bear only
axial loads. However, the design and manufacture of panel 21A is accordingly
more
complex. It will be appreciated that the foregoing example floor-wall
configurations and any
other possible configurations may be employed, individually or in combination
with one
another, within the same building 100 in practicing the present invention.
[0076] Figure 6 shows a storey floor 200 and a storey 10, comprising a
plurality of walls,
disposed thereon. In the illustrated Figure 6 embodiment, prefabricated floor
panels 32
interpose prefabricated wall panels of storey 10 according to the Figure 5A
floor-wall
configuration. However, it will be appreciated that other configurations are
possible, such as
those described by Figures 5C-5E.
[0077] Floor panels 32 comprise an insulative core covered on top and bottom
surfaces in a
composite cementitious layer. Floor panels 32 are designed such that the span
of floor
panels 32 between its supports is appropriate for bearing expected loads
experienced
thereon. As an illustrative example and with reference to Figures 1 and 4,
floor panel 32A
may be supported on the top edges of each of prefabricated wall panels 22A,
22B, 22E and
28A. As illustrated, floor panel 32A has a span S. Based on the measurement of
span S,
the maximum bending moment and deflection based on expected loads can be
measured,
which panel 32A must be designed to support whilst considering a relevant
safety factor. In
some embodiments, span S may be 24 feet. In other embodiments, span S may be
32 feet
or more. In some embodiments, floor panels 32 comprise a total thickness
between the
range of 8 to 28 inches. In some embodiments, the thickness of the
cementitious layers in
floor panels 32 is between the range of 1/4" to 2.5".
[0078] At larger values of span S, the vibration and deflection of floor
panels 32 becomes
an issue. Generally, weight may be added to floor panels 32 to dampen
vibration. This may
be achieved by making the cementitious layers thicker and/or by forming the
cementitious
layers from a higher density material. However, adding excessive weight to
floor panels 32
becomes a problem for shipping panels 32 to the construction site and for
adding to the
19
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overall weight of building 100. In some embodiments, pretensioned or
prestressed joists are
embedded within the insulative core of floor panels 32 to provide greater
resistance to shear
loads.
[0079] In some embodiments, water pipes are embedded at the factory within the
insulative
core of floor panels 32 wherein flowing water pumped through the pipes stiffen
and dampen
floor panels 32, allowing for a greater span S. A reservoir stored underneath
building 100
and a suitable plumbing system may supply the water to be circulated at
different storeys 10
in such an embodiment. Advantageously, in the summer, water contained in the
reservoir
and water pumped through building 100 is heated by the hot weather. This
heated water
may then be used in winter to provide heating through the pipes embedded in
floor panels
32. Methods for providing radiant heating to the interior of a building using
prefabricated
floor panels and for improving the load-bearing capacity of floor panels are
discussed in
detail in United States Provisional Application No. 63/001,194 and are
applicable in the
present circumstances.
[0080] In some embodiments, floor panels 32 can be made fire resistant using
the methods
described herein. In some embodiments, mechanical chases are defined in floor
panels 32
which allow ducts, pipes, wire bundles and such to pass from units 20 into the
interior of
floor panels 32. For example, electrical wiring may be run through the
insulative core of
panels 32 which connects to a ceiling lighting box and which interfaces with
wiring from a
unit 20. Example methods for providing electrical conduits along an interior
length of floor
panels 32 and for providing interfacing elements in adjoining prefabricated
panels are
discussed in detail in United States Provisional Application No. 63/001,194
and are
applicable in the present circumstances. Floors and ceilings separating units
on adjacent
floors must typically meet a minimum sound transmission class of 50. In some
embodiments, an acoustic underlayment is installed on prefabricated floor
panels 32 during
manufacturing or after installation into building 100.
[0081] As shown in Figures 2A, 2D and 6, a portion of floor panel 32B forms a
balcony. In
the illustrated embodiment, the balcony is cantilevered and projects from
exterior wall panel
22F. However, it is not necessary that balconies of the present invention are
cantilevered. In
other embodiments, the portion of floor panel 32 forming a balcony rests on
one or more
exterior wall panels 22 which protrude outward from the general envelope of
building 100.
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[0082] In some embodiments, there is a correspondence between floor panels 32
and the
various areas present in each storey 10. For example, with reference to
Figures 2A and 6,
floor panels 32A and 32B correspond to and are adapted for use with a building
unit 20A.
Floor panel 32A corresponds to the floor of an area disposed entirely within
the interior of
.. storey 10 and unit 20A. In contrast, floor panel 32B defines a portion
which serves as a
balcony, while remaining portions of panel 22B are disposed interiorly of
storey 10. With
reference to Figures 1 and 4, floor panel 32C corresponds to and is adapted
for use with a
corridor 27. The use of standard floor panel shapes which correspond to areas
of storey 10
defined by the prefabricated wall panels advantageously improves the ease and
efficiency
with which different building components are assembled together.
[0083] A possible disadvantage of the illustrated configuration of providing
balconies using
an externally protruding portion of floor panel 32B is that floor panel 32B
may act as a
thermal bridge. Cementitious materials used in prefabricated panels herein
(e.g. panel 32B)
may have a relatively high thermal conductivity such that the illustrated
configuration of
providing balconies may diminish the insulative strength of building 100. In
other
embodiments of the invention, thermally broken balconies are provided. For
example,
separate balcony panels may be coupled to floor panels 32 such that a thermal
break is
formed therebetween. In other embodiments, separate balcony panels are coupled
to
exterior wall panels 22, with exterior wall panels 22 or the interface between
respective
balcony panels and exterior wall panels 22 providing a thermal break.
[0084] Figure 7 illustrates a plurality of adjoining roof panels 34 which
collectively form a
roof 250. Figure 8 is an illustration of a partially complete building 100
showing the
placement of roof panels 34 overtop of the highest storey 10. Roof panels 34
and roof 250
may share some common features and design considerations with floor panels 32
and
storey floor 200. For example, roof panels 34A and 34B may correspond to floor
panels 32A
and 32B in being adapted for enclosing the same vertical area of the same
building unit
20A. As shown in Figure 2A, a portion of roof panel 34B may form a
cantilevered portion of
roof 250. Roof panels 34 may similarly provide conduits and appropriate
interfacing
elements for integrating various electrical components into a storey 10 and
building 100.
.. [0085] In contrast to floor panels 32, it is of relatively greater
importance that roof panels 34
and roof 250 feature strong thermal insulation properties and are impermeable
to moisture.
As previously discussed herein, strong thermal insulation properties may be
achieved by
21
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the use of a thicker insulative core and by avoiding the creation of thermal
bridges.
Additionally, as previously discussed herein in relation to exterior wall
panels 22,
impermeability to moisture may be provided by providing cementitious layers in
roof panels
34 that have a higher density and by additionally applying a finish, coating,
or membrane
which provides weather proofing properties to roof panels 34 and roof 250. In
some
embodiments, a membrane is applied to roof panels 34 as part of the
prefabrication process
at the plant, where only the joints between panels 34 are sealed with an
overlapping
membrane (e.g. a splice) during installation.
[0086] Figure 7 shows roof 250 having a roof panel 34C which defines a
drainage channel.
A drainage channel advantageously collects water present on the roof 250 and
diverts the
water to another location in order to mitigate water leakage through the roof.
In some
embodiments, roof panel 34C comprises a plurality of prefabricated panels
which, when
joined, slope inwards toward an internal drain on roof 250. Alternatively, the
plurality of
adjoined panels forming roof panel 34C slopes outwards toward an external
drain.
[0087] In some embodiments, panels 34 comprise flat prefabricated panels
positioned at an
angle over the uppermost storey 10 of building 100. In some embodiments panels
34 are
angled such that water present on roof 250 collects at an internal drainage
channel on roof
250 (e.g. roof panel 34C). In other embodiments, panels 34 are angled outwards
such that
water is directed toward an external drain (i.e. roof 250 is a pitched roof).
Alternatively, roof
panels 34 are positioned flat over the uppermost storey 10 of building 100 and
comprise a
non-uniform cross-section along both a height and width to create an internal
sloping profile
as described in United States Provisional Application No. 63/001,194. This
sloping profile
may be used and adapted for achieving any desired roof arrangement.
[0088] Figure 9 is a block diagram showing an example method for constructing
a multi-
storey building 100. Block 305 comprises establishing a building foundation in
an excavated
area of land. Block 305 may further comprise embedding receiving connectors in
the
foundation. At block 310, structural elements for supporting building 100 are
attached to the
foundation. This attachment may be facilitated using the receiving connectors.
In some
embodiments, the structural elements comprise drilled vertical piles. In other
embodiments,
the structural elements comprise prefabricated foundation wall panels.
22
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[0089] Method 300 proceeds to block 315 where prefabricated floor panels are
connected
to the structural elements to form a floor 200 of the first storey of building
100. At block 320,
wall panels are installed overtop of the below floor 200 to form a storey 10
of building 100.
In some embodiments, temporary bracing is applied to support and level the
wall panels
during the installation at block 320. Additionally, as part of the
installation of the wall panels
at block 320, joints between adjoining panels may be sealed to provide
weatherproofing,
acoustic insulation, or structural rigidity.
[0090] Method 300 proceeds to decision block 325 which evaluates whether the
storey 10
installed at block 320 is the top storey of building 100. If the evaluation at
block 325 is
negative, then method 300 proceeds to block 330. At block 330, floor panels
are installed
over the uppermost storey 10. Method 300 then returns to block 320 wherein
another storey
10 is installed. If the evaluation at block 325 is positive, then method 300
proceeds to block
335. At block 335, prefabricated roof panels are installed overtop of the
walls of the
uppermost storey 10 to form roof 250. A sealant or waterproof membrane may be
applied
overtop of the prefabricated panels of roof 250 at block 335 to provide
weatherproofing to
building 100.
[0091] Using the systems and methods described herein, multi-storey buildings
can be
assembled and disassembled in an expedient manner. Prefabricated panels may be
added
to or subtracted from a building throughout the building's lifecycle depending
on the tenant's
needs. As disclosed in corresponding United States Provisional Application No.
63/003,401,
connectors within reinforcing frames or in other parts of prefabricated
building panels can
be adapted to be easily accessible during the life of the building. This
advantageously
allows prefabricated panels within a completed building 100 to be disconnected
and re-
connected to facilitate the addition or subtraction of prefabricated panels.
[0092] In some embodiments, one or more storeys can be added to or subtracted
from
building 100. This may comprise first removing a roof 250 of building 100
before adding or
subtracting one or more storeys. Removal of a roof 250 may comprise first
removing a
waterproof membrane covering individual roof panels. Connectors of the roof
panels of roof
250 may then be exposed by appropriately removing a sealant or covering. This
permits the
subsequent disconnection and removal of the roof panels.
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[0093] Following the removal of roof 250, interior and exterior wall panels of
a storey 10
may be removed to subtract a storey from building 100. Similar to the removal
of roof
panels, removal of wall panels may comprise a step of exposing connectors by
appropriately removing a sealant or covering. In some embodiments, additional
storeys may
be added to building 100 by performing the steps outlined in blocks 320, 325,
and 330 of
method 300.
[0094] In some embodiments, the arrangement of interior and exterior walls of
a particular
storey 10 may be modified following the removal of roof 250. It is also
possible for the
arrangement of floor panels of a particular storey 10 to be modified. Such
modifications may
be performed by the appropriate disconnection of connectors of the
prefabricated panels
described herein and then subsequently re-connecting them in the desired
configuration.
[0095] In some embodiments, modular building components can be advantageously
employed in building scenarios where modifications to building 100 are
anticipated. For
example, moveable partition walls, the positions of which are easily modified,
may be
employed in defining certain interior spaces of storey 10. Bathroom and
kitchen pods which
are easily re-configurable may also be employed to add further modularity to
the design of
units 20 and storeys 10 within building 100.
[0096] Using the systems and methods described herein, multi-storey buildings
comprising
3 to 20 or more storeys may be constructed in a cost effective,
environmentally friendly and
efficient manner.
Interpretation of Terms
[0097] Unless the context clearly requires otherwise, throughout the
description and the
claims:
= "comprise", "comprising", and the like are to be construed in an inclusive
sense, as
opposed to an exclusive or exhaustive sense; that is to say, in the sense of
"including, but not limited to";
= "connected", "coupled", or any variant thereof, means any connection or
coupling,
either direct or indirect, between two or more elements; the coupling or
connection
between the elements can be physical, logical, or a combination thereof;
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= "herein", "above", "below", and words of similar import, when used to
describe this
specification, shall refer to this specification as a whole, and not to any
particular
portions of this specification;
= "or", in reference to a list of two or more items, covers all of the
following
interpretations of the word: any of the items in the list, all of the items in
the list, and
any combination of the items in the list;
= the singular forms "a", "an", and "the" also include the meaning of any
appropriate
plural forms.
[0098] This description employs a number of simplifying directional
conventions. Directions
are described in relation to a building having an existing vertical building
wall and an
existing horizontal roof. Directions may be referred to as: "external",
"exterior", "outward" or
the like if they tend away from the building; "internal", "interior", "inward"
or the like if they
tend toward the building; "upward" or the like if they tend toward the top of
the building;
"downward" or the like if they tend toward the bottom of the building;
"vertical" or the like if
they tend upwardly, or downwardly, or both upwardly and downwardly;
"horizontal",
"sideways" or the like if they tend in a direction orthogonal to the vertical
direction. Those
skilled in the art will appreciate that these directional conventions are used
for the purpose
of facilitating the description and should not be interpreted in the literal
sense. In particular,
the invention may be adapted for buildings which have walls that are not
strictly vertically
oriented and/or roofing structures that are inclined.
[0099] For example, while processes or blocks are presented in a given order,
alternative
examples may perform routines having steps, or employ systems having blocks,
in a
different order, and some processes or blocks may be deleted, moved, added,
subdivided,
combined, and/or modified to provide alternative or subcombinations. Each of
these
processes or blocks may be implemented in a variety of different ways. Also,
while
processes or blocks are at times shown as being performed in series, these
processes or
blocks may instead be performed in parallel, or may be performed at different
times.
[0100] In addition, while elements are at times shown as being performed
sequentially, they
may instead be performed simultaneously or in different sequences. It is
therefore intended
that the following claims are interpreted to include all such variations as
are within their
intended scope.
CA 03191465 2023-02-10
WO 2022/032390 PCT/CA2021/051113
[0101] Specific examples of systems, methods and apparatus have been described
herein
for purposes of illustration. These are only examples. The technology provided
herein can
be applied to systems other than the example systems described above. Many
alterations,
modifications, additions, omissions, and permutations are possible within the
practice of this
invention. This invention includes variations on described embodiments that
would be
apparent to the skilled addressee, including variations obtained by: replacing
features,
elements and/or acts with equivalent features, elements and/or acts; mixing
and matching
of features, elements and/or acts from different embodiments; combining
features, elements
and/or acts from embodiments as described herein with features, elements
and/or acts of
other technology; and/or omitting combining features, elements and/or acts
from described
embodiments.
[0102] Various features are described herein as being present in "some
embodiments".
Such features are not mandatory and may not be present in all embodiments.
Embodiments
of the invention may include zero, any one or any combination of two or more
of such
__ features. This is limited only to the extent that certain ones of such
features are
incompatible with other ones of such features in the sense that it would be
impossible for a
person of ordinary skill in the art to construct a practical embodiment that
combines such
incompatible features. Consequently, the description that "some embodiments"
possess
feature A and "some embodiments" possess feature B should be interpreted as an
express
indication that the inventors also contemplate embodiments which combine
features A and
B (unless the description states otherwise or features A and B are
fundamentally
incompatible).
[0103] It is therefore intended that the following appended claims and claims
hereafter
introduced are interpreted to include all such modifications, permutations,
additions,
omissions, and sub-combinations as may reasonably be inferred. The scope of
the claims
should not be limited by the preferred embodiments set forth in the examples,
but should be
given the broadest interpretation consistent with the description as a whole.
26
