Abstract:
A method of construction. A first step involves stabilizing prefabricated load bearing walls for an underlying vertical level of a multi-story building. The walls have opposed surfaces and a top peripheral edge. A second step involves securing floor joists for an overlying vertical level to at least one of the opposed surfaces of the walls of one of the underlying vertical level. A third step involves installing prefabricated load bearing walls for the overlying vertical level along the top peripheral edge of the underlying vertical level. The walls have opposed surfaces and a top peripheral edge. The steps set forth above are repeated until a desired number of vertical levels are installed.

Description:
FIELD 
       [0001]    The present invention relates to a method of building construction, which makes it easier to incorporate prefabricated components into the building. 
       BACKGROUND 
       [0002]    A building can be constructed more rapidly, if some portions of the building, such as load bearing walls, can be constructed off site and then incorporated on site into the building. However, problems have been experienced in incorporating such prefabricated components into the building with current building methods. 
       SUMMARY 
       [0003]    Accordingly, there is provided a method of construction. A first step involves stabilizing prefabricated load bearing walls for an underlying vertical level of a multi-story building. The walls have opposed surfaces and a top peripheral edge. A second step involves securing floor joists for an overlying vertical level to at least one of the opposed surfaces of the walls of one of the underlying vertical level. A third step involves installing prefabricated load bearing walls for the overlying vertical level along the top peripheral edge of the underlying vertical level. The walls have opposed surfaces and a top peripheral edge. The steps set forth above are repeated until a desired number of vertical levels are installed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to in any way limit the scope of the invention to the particular embodiment or embodiments shown, wherein: 
           [0005]      FIG. 1  is a detailed side elevation view, in section, of load bearing wall and floor joist detail in accordance with the present method of construction, using joist supports with upper attachment flanges. 
           [0006]      FIG. 2  is a detailed side elevation view, in section, of load bearing wall and floor joist detail in accordance with the present method of construction, using a joist support with an upper attachment hook. 
           [0007]      FIG. 3  is a detailed side elevation view, in section, of load bearing wall and floor joist detail in accordance with the present method of construction, using C channel joist supports. 
           [0008]      FIG. 4  is a detailed side elevation view, in section, of load bearing wall and floor joist detail in accordance with the present method of construction, using a combination of a joist support with an upper attachment flange and a C channel joist support. 
           [0009]      FIG. 5  is a detailed side elevation view, in section, of load bearing wall and floor joist detail in accordance with the present method of construction, using a combination of a joist support with an upper attachment hook and a C channel joist support. 
           [0010]      FIG. 6  is a perspective view of a joist support with an upper attachment flange. 
           [0011]      FIG. 7  is a perspective view of a joist support with an upper attachment hook. 
           [0012]      FIG. 8  is a perspective view of a C channel joist support. 
           [0013]      FIG. 9  is a side elevation view of a modular bathroom unit and exterior load-bearing wall. 
           [0014]      FIG. 10  is a detailed side elevation view, in section, of load bearing wall and floor joist detail of  FIG. 9 . 
           [0015]      FIG. 11  is a detailed side elevation view, in section, of an exterior load bearing wall. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    A method of construction will now be described with reference to  FIG. 1 through 11 . 
         [0017]    Load Bearing Wall Installation 
         [0018]    This method was developed for use in a light gauge steel construction project of twelve stories. In that project all exterior and interior bearing walls were prefabricated off site and then incorporated into the building. In that project all bathrooms were delivered to the site as prefabricated bathroom modules. There will now be provided an explanation as to how the prefabricated bearing walls were incorporated into the building and an explanation as to how the bathroom modules were similarly incorporated into the building. 
         [0019]    Referring to  FIG. 1 , an underlying wall  20  is stabilized as part of a multi-story building. Underlying wall  20  is a prefabricated load bearing wall, underlying wall  20  having opposed surfaces  22  and  24 , and a top peripheral edge  26 . Underlying wall  20  is part of an underlying vertical level  28  in the multi-story building. In order to complete underlying vertical level  28 , numerous underlying walls  20  may be needed. A floor joist  30  is secured to opposed surface  22  of underlying vertical level  28 . The purpose of floor joist  30  is to support an overlying vertical level  32 . Overlying vertical level  32  is defined by a floor  34 . Numerous floor joists  30  may be necessary to support floor  34  adequately. Floor  34  may consist of a concrete topping on metal docking. An overlying wall  36  is then installed along top peripheral edge  26 . Underlying and overlying walls  20  and  36 , respectively may contain studs  37  and bracing  39 . Studs  37  give multi-story building more structural support. Bracing  39  provides a suitable surface for securing floor joists  30  to. Overlying wall  36  is a prefabricated load bearing wall, overlying wall  36  having opposed surfaces  38  and  40 , and a top peripheral edge  41 . Overlying wall  36  and floor  34  make up overlying vertical level  32 . The process of stabilizing underlying walls  20 , securing floor joists  30 , and installing overlying walls  36  is repeated until a desired number of vertical levels are installed to complete the multi-story building. As each overlying vertical level  32  is secured on top of underlying vertical level  28 , overlying vertical level  32  becomes the next underlying vertical level  28 , and the process is repeated. This construction method may be used to quickly and efficiently put up the structure of a multi-story building using prefabricated load bearing walls. 
         [0020]    Floor joist  30  may be suspended from top peripheral edge  26  of underlying wall  20 . 
         [0021]    This may be accomplished by using a joist support  42  that extends along all or a portion of underlying wall  20 . Because joist support  42  extends along underlying wall  20 , it may not be necessary to have floor joist  30  align with the studs in underlying wall  20 . Joist support  42  has an upper attachment  44 , a lower attachment  46 , and a connecting web  48 . Connecting web  48  extends between upper attachment  44  and lower attachment  46 . There may be holes (not shown) on joist support  42 , holes being used to secure joist support  42  to various materials using conventional methods. Upper attachment  44  engages top peripheral edge  26  of underlying wall  20  and lower attachment  46  engages floor joist  30 . In this manner, floor joist  30  is secured to opposed surface  22  of underlying vertical level  28 . 
         [0022]    Referring to  FIG. 1 , upper attachment  44  of joist support  42  consists of a flange  49 . This embodiment of joist support  42  is shown in greater detail in  FIG. 6 . The dimensions of upper attachment  44 , lower attachment  46  and connecting web  48  may differ depending on the dimensions of both floor joist  30  and top peripheral edge  26 . Referring back to  FIG. 1 , floor joist  30  is secured to joist support  42 . This figure shows a side elevation view of adjacent interior rooms  50  and  52  in a multi-story building. Opposed surfaces  38  and  40  face interior rooms  50  and  52 , respectively. Interior room  52  contains a floor  54 , floor  54  having the same characteristics as floor  34 . Floor  54  is also part of overlying vertical level  32 . Supporting floor  54  is a floor joist  56  and a joist support  58 . Floor joist  56  and joist support  58  share the same basic elements described above for floor joist  30  and joist support  42 , respectively. Floor joist  56  may have a different depth than floor joist  30  as shown in  FIG. 1 . In the embodiment shown in  FIG. 1 , screws  60  are used to secure floor joists  30  and  56  to joist supports  42  and  58 , respectively. Screws  60  secure floor joist  30  and joist support  42  to opposed surface  22  of underlying wall  20  through holes (not shown) in connecting web  48 . Floor joist  30  is also secured to joist support  42  at lower attachment  46  using screws  60 . In addition, upper attachment  44  is secured to top peripheral edge  26  directly using screws  60 . Floor joist  56  and joist support  58  are secured in an identical fashion as described above for floor joist  30  and joist support  42 . In the embodiment shown in  FIG. 1 , joist supports  42  and  56  are secured over top of each other to top peripheral edge  26  using screws  60 . 
         [0023]    Another embodiment of a joist support  62  is shown in  FIG. 7 . Joist support  62  shares all the same elements as joist support  42  and is intended to extend along all or part of an underlying wall, with the addition of a hook  64  connected to upper attachment  44 . This embodiment of joist support  62  is used in  FIG. 2 .  FIG. 2  details a side elevation view of underlying and overlying vertical levels  28  and  32 , respectively. In this figure, opposed surfaces  24  and  40  face an exterior  66  of the building, while opposed surfaces  22  and  38  face an interior room  68 . Floor joist  30  is secured to joist support  62  as described above in the previous embodiment for joist support  42 . Joist support  62  is secured to underlying wall  20  as described above for the previous embodiment, with the addition that hook  64  is secured to opposed surface  24  of underlying wall  20 . By securing hook  64  to opposed surface  24 , joist support  62  is given extra stability. 
         [0024]    A further embodiment of a joist support  70  is shown in  FIG. 8 . Joist support  70  has an upper attachment  72 , a lower attachment  74 , a connecting web  75 , and is designed to extend along all or part of a wall. Upper attachment  72  consists of a C channel support  76  as shown. C channel support  76  defines a joist-receiving cavity  78 . Referring to  FIG. 3 , C channel support  76  is secured to opposed surface  24  of underlying wall  20 . In this figure, opposed surfaces  24  and  40  face an interior room  80  of the building, while opposed surfaces  22  and  38  face an exterior  82 . Joist receiving cavity  78  is used to secure floor joist  30  to opposed surface  24  of underlying wall  20  of underlying vertical level  28 . Floor joist  30  is secured to joist support  70  using screws  60 . Floor joist  30  and joist support  70  are also secured to opposed surface  24  through connecting web  75  using screws  60 . 
         [0025]      FIG. 4  details an embodiment of a method of construction using joist supports  42  and  70  in combination. Opposed surfaces  22  and  38  of underlying and overlying walls  20  and  36 , respectively, face a corridor  84  of the building. Opposed surfaces  24  and  40  of underlying and overlying walls  20  and  36 , respectively, face an interior  86  of the building. Opposed surface  22  of underlying wall  20  has secured to it C channel support  76  of joist support  70 . Opposed surface  24  of underlying wall  20  has secured to it joist support  42  with flange  49 . Joist support  42  is also secured to top peripheral edge  26 . C channel support  76  and joist support  42  support floor joists  88  and  90 , respectively. Floor joists  88  and  90  support floors  92  and  94 , respectively. Floor joist  88  and  90  may be of different sizes, as shown in  FIG. 4 , in order to properly support different sizes of floors  92  and  94 . 
         [0026]      FIG. 5  details an embodiment of a method for construction using joist supports  62  and  70  in combination. In this embodiment, there are two underlying walls  96  and  98 , and two overlying walls  100  and  102 . Underlying wall  96  has opposed surfaces  104  and  106 , and a top peripheral edge  108 . Underlying wall  98  has opposed surfaces  110  and  112 , and a top peripheral edge  114 . Overlying wall  100  has opposed surfaces  116  and  118 , while overlying wall  102  has opposed surfaces  120  and  122 . Underlying walls  96  and  98  are part of underlying vertical level  28 , and overlying walls  100  and  102  are part of overlying vertical level  32 . Underlying walls  96  and  98  are secured under overlying walls  100  and  102 , respectively. Opposed surfaces  104  and  116  of underlying and overlying walls  96  and  100 , respectively, face an interior room  124  of the building. Opposed surfaces  112  and  122  of underlying and overlying walls  98  and  102 , respectively, face an interior room  126  of the building. Opposed surface  104  of underlying wall  96  has joist support  70  secured to it. Opposed surface  112  of underlying wall  98  has secured to it joist support  62  with hook  64 . Joist support  62  is also secured to top peripheral edge  114 , and hook  64  is secured to opposed surface  110 . C channel support  76  and joist support  62  support a floor joist  127  and  128 , respectively. Floor joists  127  and  128  support floors  130  and  132 , respectively. Floor joists  127  and  128  may be of different sizes, as shown in  FIG. 5 , in order to properly support different sizes of floors  130  and  132 . The configuration shown in  FIG. 5  is called a “party room” configuration. By using double the number of walls, effective soundproofing is achieved between interior rooms  124  and  126 . Underlying walls  96  and  98  and overlying walls  100  and  102 , may contain studs  134  and bracing  136 . Opposed surfaces  106  and  110  of underlying walls  96  and  98 , respectively, face each other. Opposed surfaces  118  and  120  of overlying walls  100  and  102 , respectively, face each other. Top peripheral edge  108  is secured to top peripheral edge  114  using a centre support  133 . Centre support  133  is secured to top peripheral edges  108  and  114  using screws  60 . 
         [0027]    Referring to  FIG. 11 , exterior cladding panels  200  may be attached to walls  20  and  36  on an exterior face of the building to provide protection from the external environment. Exterior cladding panel  200  is mounted on exterior grade drywall sheathing  202  such as by using an adhesive as is common with EIFS panels. Drywall  202  is in turn mounted on opposed surfaces  24  and  40 . Drywall  202  may have an air vapour seal  203  applied to its surface. Cladding panel  200  may be, for example, 3″ insulation that includes sloped metal through-wall flashing  204  installed along the base of cladding panel  200 . Cladding panel  200  is installed by applying a bead of sealant  206  along the top edge of a lower panel  200 . Liquid applied envelope seal  208  is also applied along the top of the exterior drywall  202  on the lower panel  200  to seal the joint between the drywall  200 . Envelope seal is also applied along vertical joints between panels as well. Envelope seal  208  acts as an initial air barrier and a back-up water seal. A low expansion spray foam/air and vapour barrier type insulation  210  is applied to the horizontal and vertical joints to seal the joints and provide insulation at the joint locations. Caulking dams (not shown) should also installed at the ends of the through wall flashing to prevent moisture from flowing off the ends of the flashing. The joints may then be sealed using a high quality exterior sealant  212 . When properly installed, flashing  204  should overlap with any membrane flashing and air and vapour barrier. An exterior finish  214 , such as an acrylic stucco finish is then applied to the outer surface of cladding panel  200 . 
         [0028]    Modular Bathroom Installation 
         [0029]      FIG. 9  details a method of construction using modular structures. Overlying module  138  is stacked above underlying module  140 . Both overlying and underlying modules  138  and  140  are prefabricated load bearing modular structures. By stacking overlying module  138  on underlying module  140 , a column  142  of modular structures is formed, column  142  having a defining wall  144 . An underlying wall  146  is stabilized in spaced relation to column  142 . Underlying wall  146  is a prefabricated load bearing wall, underlying wall  146  having opposed surfaces  148  and  150 , and a top peripheral edge  152 . Underlying wall  146  is part of an underlying vertical level  154  of a multi-story building. In order to complete underlying vertical level  154 , numerous underlying walls  146  may be needed. A floor joist  30  is secured to opposed surface  150  of underlying vertical level  154 . Floor joist  30  is also secured to defining wall  144 . The purpose of floor joist  30  is to support an overlying vertical level  156 . Floor joist  30  may be secured to both defining wall  144  and opposed surface  150  using any of the above described embodiments of joist supports  42 ,  62  or  70 . In  FIG. 9 , floor joist  30  is secured to opposed surface  150  using joist support  42 . Overlying vertical level  156  is defined by a floor  158 . Numerous floor joists  30  may be necessary to support floor  158  adequately. Floor  158  may consist of a concrete topping on metal docking. An overlying wall  160  is then installed along top peripheral edge  152 . Overlying wall  160  is a prefabricated load bearing wall, overlying wall  160  having opposed surfaces  162  and  164 , and a top peripheral edge  165 . Overlying wall  160  and floor  158  make up overlying vertical level  156 . The process described above is then repeated until a desired number of vertical levels are installed to complete the multi-story building. As each overlying vertical level  156  is secured on top of underlying vertical level  154 , overlying vertical level  156  becomes the next underlying vertical level  154 , and the process is repeated. This construction method may be used to quickly and efficiently put up modular structures of a multi-story building using prefabricated load bearing walls. All of the embodiments of construction methods described above may be included in this embodiment. 
         [0030]    The modules  138  and  140  of  FIG. 9  may be bathroom modules. Within overlying module  138  is positioned a module floor  166 . Below module floor  166  is positioned an underlying roof  168 , so that there is a plumbing space  170  between module floor  166  and underlying roof  168 . Underlying roof  168  forms part of underlying vertical level  154 , and is lower than floor  158 . The purpose of plumbing space  170  is to make room for a drainage system  172  to be installed below overlying module  138 . Drainage system  172  may be any system of drainage or plumbing devices or pipes necessary for multi-story building. Underlying roof  168  may be supported by floor joists  30  (not shown). The embodiment of a method of building construction shown in  FIG. 9  is shown in more detail in  FIG. 10 . An opposed surface  174  is positioned on the side of column  142  opposite to defining wall  144 . Opposed surface  174  faces a bathroom  176 , while defining wall  144  faces an interior room  177 . Secured to opposed surface  174  and defining wall  144  are joist supports  178  and  180 , respectively. Joist supports  178  and  180  both share the same elements as joist support  70 , described above. Secured to joist supports  178  and  180  are floor joists  182  and  184 , respectively. Floor joists  182  and  184  support module floor  166  and floor  158 , respectively. Below module floor  166  is positioned underlying roof  168 . In the embodiment shown, underlying roof  168  is secured to underlying module  140 . Plumbing space  170  is positioned between underlying roof  166  and module floor  166  in order to provide room for the appropriate drainage piping and plumbing elements. 
         [0031]    In all embodiments of the disclosed method of building construction, screws  60  are used as a securing means, although other means of securing may be used. An example of an alternate means of securing may involve securing with nails or bolts. 
         [0032]    In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements. 
         [0033]    It will be apparent to one skilled in the art that modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention as hereinafter defined in the Claims.