Patent Publication Number: US-2004040255-A1

Title: Building method and structure

Description:
BACKGROUND OF THE DESCRIPTION  
       [0001] 1. Field of the Invention  
       [0002] This invention relates to building. More particularly, this invention relates to a method of building a structure and to a structure erected by the method.  
       [0003] 1. Discussion of the Background Art  
       [0004] Many conventional building techniques require the use of panel structures. However, in many cases, such panel structures perform load-bearing functions and this places limitations on their design. An example of such a limitation is the necessity for cladding which serves to seal the panels and to provide insulation.  
       SUMMARY OF THE INVENTION  
       [0005] The applicant has found that it is possible to provide a means whereby suitable panels can be used in such a way that cladding is unnecessary. The applicant has found that this can be achieved by providing suitable building components, apart from the panels, to perform load-bearing functions. This allows the panels to be provided in a suitable configuration to perform their conventional role and the role of cladding.  
       DISCLOSURE OF THE INVENTION  
       [0006] According to a first aspect of the invention, there is provided a method of building a structure, said method including the steps of:  
       [0007] mounting a number of support posts on a substrate in a spaced apart, substantially upright orientation, so that at least one floor area is bounded by the support posts;  
       [0008] mounting an upper support means on operatively upper end portions of the support posts;  
       [0009] positioning at least one panel between consecutive support posts; and  
       [0010] fixing the panels in position between the support posts, the method including the step of arranging the support posts and the upper support means so that substantially all load bearing functions are performed by the support posts and upper support means.  
       [0011] The method may include the steps of forming a footing corresponding with each support post and mounting an operatively lower end portion of each support post in the footing. The support posts are preferably vertical.  
       [0012] A slab may be formed within the floor area defined by the support posts. The slab may be formed to be positioned on each footing. A rebate may be formed in a periphery of the slab.  
       [0013] In one embodiment, the method may include the step of forming the slab so that each support post extends through the slab and into its respective footing. In particular, the method may include the step of forming the slab so that each support post extends through the slab at the rebate.  
       [0014] In another embodiment, the method may include the steps of mounting a stub member in the footing, forming the slab so that the stub member extends through the slab, and mounting the support post on the stub member. In particular, the method may include the step of forming the slab so that each stub member extends through the slab at the rebate.  
       [0015] A lower edge of each panel may be positioned in the rebate, between consecutive support posts. A base element may be positioned in the rebate and each panel may be fastened to the base element.  
       [0016] The method may include the step of sealing a region defined between each side of each support post and an edge of a panel adjacent the support post.  
       [0017] At least two panels may be positioned between each support post. Adjacent edges of the at least two panels may be sealingly fastened together.  
       [0018] Floor support beams may be fastened to the support posts at a position intermediate the upper and lower end portions of the support posts. The method may include supporting a floor structure on the floor support beams.  
       [0019] According to a second aspect of the invention, there is provided a structure erected in accordance with the method described above.  
       [0020] Each support post may be of steel. Each support post may be of any suitable cross sectional shape. In one embodiment, each support post may be tubular and may have a substantially rectangular cross section.  
       [0021] Each panel may be of a cementitious, primary building material. Each panel may instead, or in addition, be of an expanded primary building material.  
       [0022] The upper support means may be in the form of a number of Z-beams, which are positioned on the upper portions of the support posts to span the support posts. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0023] A method of building a structure and a structure in accordance with the invention may manifest themselves in a number of different forms. It will be convenient hereinafter to describe, in detail, preferred embodiments of the invention with reference to the accompanying drawings. The purpose of this specific description is to instruct persons having an interest in the subject matter of the invention how to carry the invention into practical effect. It is to be clearly understood, however, that the specific nature of this description does not supersede the generality of the preceding broad disclosure. In the accompanying drawings:  
     [0024]FIG. 1 shows a schematic, three dimensional view of a support post arrangement of a first embodiment of a structure, in accordance with the invention.  
     [0025]FIG. 2 shows a schematic, three-dimensional view of a support post arrangement of a second embodiment of the structure.  
     [0026]FIG. 3 shows a side view of a footing of the structure.  
     [0027]FIG. 4 shows a front view of a footing of the structure.  
     [0028]FIG. 5 shows a three dimensional view of a corner of the structure.  
     [0029]FIG. 6 shows a three dimensional view of an inner wall of the structure.  
     [0030]FIG. 7 shows a schematic side view of a wall of the structure.  
     [0031]FIG. 8 shows a schematic front view of a wall of the structure shown built on a sloping substrate.  
     [0032]FIG. 9 shows a schematic view of the structure at an opening in an outer wall of the structure.  
     [0033]FIG. 10 shows a schematic view of an under eaves bulkout of the structure.  
     [0034]FIG. 11 shows a schematic view of standard eaves of the structure.  
     [0035]FIG. 12 shows a cross sectioned plan view of a support post between a pair of adjacent panels of the structure.  
     [0036]FIG. 13 shows a schematic three-dimensional exploded view of a wall of the structure.  
     [0037]FIG. 14 shows a series of alternative sections of roof beams of the structure.  
     [0038]FIG. 15 shows a series of alternative sections of support posts of the structure.  
     [0039]FIG. 16 shows one embodiment of a fastening arrangement for fastening the panels to a slab of the structure.  
     [0040]FIG. 17 shows another embodiment of a fastening arrangement for fastening the panels to a slab of the structure. 
    
    
     DESCRIPTION OF EMBODIMENT OF THE INVENTION  
     [0041] A structure, in accordance with a preferred embodiment of the invention and built according to a preferred method of the invention includes a number of support posts  10 .  
     [0042] Each support post  10  is of steel. It is to be appreciated that the applicant envisages that the support post may be of any suitably strong material, such as aluminium or, possibly, some other high strength composite. In this particular example, each support post  10  has a substantially rectangular cross section. However, it is to be appreciated that each support post  10  can have a number of different cross sections, some of which are indicated in FIG. 15.  
     [0043] In use, the support posts  10  are mounted on a substrate in a spaced apart, substantially upright orientation so that the support posts  10  bound a floor area  12 . In the embodiment the support posts are vertical.  
     [0044] An upper support means in the form of a number of roof support beams  14  are mounted on upper portions  16  of the support posts  10 . In this particular example, the beams  14  are in the form of Z-beams. However, as shown in FIG. 14, the beams  14  can take a number of different forms, depending on their particular application and the requirements and preferences of a builder.  
     [0045] A concrete slab  18  is formed in the floor area  12 . The concrete slab  18  defines a rebate  20  in a periphery  22  of the slab  18 . A base element  24  in the form of a length of angle iron is positioned in each rebate.  
     [0046] A lower end portion  26  of each support post  10  is fastened to the base element  24 . This can occur in a number of different ways.  
     [0047]FIGS. 3 and 4 show an example of a footing  28  used with this particular example. Prior to the slab  18  being formed, the footing  28  is constructed for each support post  10 . A screw pier  30  is initially positioned in the ground. A concrete block  32  is formed about each pier  30 . The concrete block  32  can be of any suitable shape. A starter post  34  is positioned in each concrete block  32 , to extend upwardly from the concrete block  32 .  
     [0048] The slab  18  is then formed above the footings  28 , about the starter posts  34 .  
     [0049]FIG. 1 shows a schematic diagram of one manner in which each support post  10  can be arranged on the slab  18 . In this embodiment, the lower end portion  29  of each support post  10  extends through the slab  18  to engage a respective starter post  34 . The footing  28  shown in FIGS. 3 and 4 is suited for this embodiment. As can be seen in these drawings, the starter post  34  and the lower portion  26  of the respective support post  10  have corresponding openings  36  to permit the lower portion  26  to be fastened to the starter post  34  with screw fasteners.  
     [0050] A C channel  38  is fastened to the support post  10  and the starter post  34 . A lower flange  40  bears against the concrete block  32 , while an upper flange  42  is aligned with the rebate  20 . A web  44  of the C channel  38  is fastened to both the support post  10  and the starter post  34 .  
     [0051] In the embodiment shown in FIG. 2, each starter post  34  extends through the slab  18  to engage a respective support post  10 . In this embodiment, the lower end portion  26  and the starter post  34  have corresponding openings  46  to permit the lower end portion  26  and the starter post  34  to be fastened together with suitable screw fasteners.  
     [0052] The structure includes a plurality of panels  48 . Each panel  48  is of a lightweight material. In this particular example, each panel is of a lightweight cementitious material. For example, each panel  48  can be in the form of autoclaved, aerated concrete. It is to be appreciated, however, that each panel  48  can be of any other suitable primary material such as an expanded plastics material. An example of such a material is polystyrene.  
     [0053] A lower edge  50  of each panel  48  is positioned on the base element  24 . The lower edge  50  of each panel  48  can be fastened to the base element  24  in a number of different ways, two of which are shown in FIGS. 16 and 17. FIG. 5 shows the panels  48  as defining outer walls  52  of the structure. On the other hand, FIG. 6 shows the panels  48  defining inner walls  54  of the structure. Each panel  48  is rectangular in the embodiment.  
     [0054] In addition to being fastened to the base element  24 , the panels  48  are fastened to each other as shown in FIG. 13. Corresponding holes  56  are formed in adjacent edges  58  of the panels  48 , so that adjacent holes  56  are aligned. A dowel member  60  extends into each pair of corresponding holes  56 . Suitable sealing material is positioned between the adjacent edges  58 .  
     [0055]FIG. 12 shows a region  60  of the structure where a pair of panels  48  is positioned on each side of a support post  10 . A pair of backing rods  62  are positioned between each side  64  of a panel  48  and the support post  10 . The backing rods  62  provide a desired spacing between the support post  10  and the panels  48  on each side of the support post  10 . A resultant gap between the support post  10  and each side  62  of the panels  48  is filled with polyurethane filler  66 .  
     [0056] A thermal shield coating  72  is provided on each support post  10 . Further, a layer of heavy-duty woven fibreglass mesh  74  is positioned on inner and outer sides  68 ,  70  of the region  60 . Thin bed adhesive filler  76  is positioned on the fibreglass mesh  74 . An architectural coating  78  is positioned on the adhesive filler  76 .  
     [0057] It follows that a high strength connection is defined between the panels  48  at each support post  10 .  
     [0058]FIGS. 7 and 8 show part of the structure in a multi-storey configuration. A length of C-section  80  is mounted on the support posts  10 , intermediate the upper and lower end portions  16 ,  26  of the support posts  10 . The C-section  80  is dimensioned so that an intermediate floor structure (not shown) can be received between flanges  82  of the C-section  80 .  
     [0059] In this case, upper edges  84  of lower panels  48 . 1  are fastened to a web  86  of the C-section  80 . Fastening elements used for this purpose are indicated at  88  in FIG. 8.  
     [0060] The Z-beams  14  are positioned on the outer walls  52  of the structure. The Z-beams  14  are positioned so that a lower flange  90  of each Z-beam  14  is directed outwardly, and an upper flange  92  is directed inwardly. An upper portion  94  of each upper panel  48 . 2  is fastened to an inner side of a web  96  of each Z-beam. This is achieved by bugle head batten screws  98  internally fixed through the panels  48 . 2  to the web  96 . Further, the upper portions  16  of the support posts  10  are fixed to the web  96  with fasteners indicated at  99 .  
     [0061] It will, of course, be appreciated that it is necessary to have openings in the outer walls  52  for windows, doors etc. An example of a configuration suitable for a door or a window is shown in FIG. 9. Here, a length of C-section  100  is positioned over the Z-beam  14  to span an opening indicated at  102 . Suitable fasteners  104  are provided for fastening the C-section  100  to the Z-beam  14 .  
     [0062] One of the inner walls  54  is shown in FIG. 6. Instead of the Z-beams, the panels  48  defining such inner walls  54  have a length of channel steel  106  positioned on upper edges  108  of those panels  48 . The channel steel  106  is positioned to extend between the Z-beams  14 . An example of this is shown in FIG. 13.  
     [0063] Lower edges  110  of these panels  48  are fastened within base channel members  112  positioned on the slab  18 .  
     [0064]FIGS. 10 and 11 show two different embodiments of eaves of the structure.  
     [0065]FIG. 10 shows an under eaves bulkout  114 . In this embodiment further panels  116  are provided and are spaced outwardly from the panel  48 . The further panels  116  are substantially the same as the panels  48 .  
     [0066] Lower ends  118  of roof trusses  120  are connected to an upper edge  122  of each panel  116 . Angle brackets  124  are fixed to the lower ends  118  of the roof trusses. A Z-beam  126  is connected to the upper edge  122  of each panel  116 . The angle brackets  124  are connected to the Z-beams  126 . FIG. 11 shows standard eaves  128 .  
     [0067] It will be appreciated that the structure described above discloses a point loading system for the structure. The reason for this is that substantially all load bearing functions are performed by the support posts  10  and the Z-beams  14 . This allows the panels  48  to perform substantially only insulation functions. The panels  48  also perform some cross-bracing functions.  
     [0068] The fact that the structure uses a point loading system facilitates the erection of the structure on a slope as shown in FIG. 8. As a result of the fact that the panels do not carry any load, uneven stresses on the panels  48  as a result of the structure being built on the slope is avoided.  
     [0069] The point loading arrangement defined by the structure described above also allows a roof structure to be erected prior to the panels  48  being positioned.  
     [0070] An advantage of the invention is that there are substantially less components used with the erection of the structure than are presently used with the erection of similar structures. This facilitates off-site fabrication of the various components and delivery to the site where they are erected to form the structure. Thus, ordering of components for building projects via a medium such as the World Wide Web is facilitated.  
     [0071] A particular advantage of the invention is the fact that the panels  48  can be configured to perform insulating functions. The reason for this is that the panels do not have to be configured to perform load-bearing functions. This obviates the need for cladding and therefore increases the speed of building and lowers the cost of building.  
     [0072] It is to be understood that the above embodiments have been provided only by way of exemplification of this invention, and that further modifications and improvements thereto, as would be apparent to persons skilled in the relevant art, are deemed to fall within the broad scope and ambit of the present invention as set out in the claims which follow.