Patent Publication Number: US-2004040234-A1

Title: Constructional element, building system and method of construction

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates to constructional elements, construction systems and methods of construction.  
       DESCRIPTION OF THE PRIOR ART  
       [0002] Building systems in the form of prefabricated modular building systems have a tendency to rely upon heavy machinery for their construction, are generally labour intensive requiring may different trades persons and although being modular require the separate construction and application of external and internal finishes. An example of components of a prefabricated modular building systems is aluminium cladding. Such cladding is typically positioned and fixedly located on the exterior of a fibre panel or wood panel building structure.  
       [0003] Another example of modular elements for building systems includes a system comprising end posts and concrete slabs attached therebetween. These slabs may then be rendered or coated as necessary once the building is constructed.  
       SUMMARY OF THE INVENTION  
       [0004] According to one aspect of the invention there is provided a constructional element including:  
       [0005] a structural member;  
       [0006] cladding formed about at least part of the structural member; and  
       [0007] abutment means formed in at least part of the cladding&#39;s perimeter for mutual abutment and alignment with abutment means on an adjacent constructional element.  
       [0008] Advantageously, the configuration of the invention allows for a constructional element which includes pre-finished cladding such that once, for example, a wall is constructed from several constructional elements there is no need to further clad, render, etc the constructed wall. This applies whether the wall is a sidewall, floor, roof, ceiling, etc.  
       [0009] Preferably, the constructional element may act as a load-bearing member.  
       [0010] Preferably the element is elongate, and the structural member includes an end which protrudes from the cladding. Preferably the structural member is hollow.  
       [0011] Preferably the end is adapted to seat in a channel of a C-section support element. If the constructional element is configured such that it includes an end and an opposite end protruding from the cladding, the constructional element may be secured between two C-section support elements.  
       [0012] Alternatively, the end is adapted to seat and is fixable in an internal corner of an L-section support element.  
       [0013] Preferably the connection means are formed in opposing sides of the cladding. The connection means may include a tongue formed in one said side of the cladding and a groove formed in an opposing said side. Alternatively, the connection means may include complementary step formations. The connection means aid in seating one constructional element immediately adjacent another.  
       [0014] Preferably, the core is rectangular in lateral cross section. Preferably the core is metallic, fibreglass, or carbon fibre.  
       [0015] Preferably the cladding includes cement, concrete, fibre cement, fibreglass, or cellulose. The cellulose may be derived from recycled paper.  
       [0016] According to a second aspect of the invention there is provided a method of construction including forming a wall by placing two or more constructional elements according to the first aspect of the invention in parallel relationship whereby the connections means on adjacent constructional elements mutually abut and align with one another.  
       [0017] Advantageously, the configuration of the constructional elements allows for improved construction of a panel or wall for use as a sidewall, floor, retaining wall, etc.  
       [0018] Preferably the constructional elements are held in parallel relationship by two support elements at respective ends of the constructional elements. Preferably the ends of the constructional elements are secured to the support elements once the constructional elements are in a predetermined position.  
       [0019] Preferably the support elements are elongate and C-shaped in lateral cross section.  
       [0020] Preferably the support elements are fixed to one another by intermediate brace elements.  
       [0021] According to another aspect of the present invention there is provided a building system including:  
       [0022] at least two spaced apart end supports; and  
       [0023] two or more constructional elements according to the first aspect of the invention,  
       [0024] wherein the first and second ends of the constructional elements are engageable with respective end supports, and arrangeable in a vertical relationship to each other to form a wall portion.  
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0025] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:  
     [0026]FIGS. 1 a - c  are perspective side and end views of a preferred embodiment of a constructional element according to the present invention;  
     [0027]FIGS. 2 a - c  and  3   a - c  illustrate alternative arrangements of the abutment means of the structural element illustrated in FIGS. 1 a - c;    
     [0028]FIGS. 4, 5 and  6  are perspective views of the element illustrated in FIG. 1 a,  showing variations in the cladding;  
     [0029]FIGS. 7, 8,  10 ,  12 ,  15 ,  16 ,  19  to  21 ,  23  to  26 ,  35  and  36  illustrate complete and partial views of various constructional elements and components of a building system according to an embodiment of the present invention, in use;  
     [0030]FIG. 9 is a perspective view of several components of the building system, illustrating the constructional element with a portion of the cladding cut away;  
     [0031]FIGS. 13 a - k  illustrate components of a building system according to the present invention;  
     [0032]FIGS. 14 a - h  illustrate several of the components of FIGS. 13 a - k  in use;  
     [0033]FIGS. 17 a - b  are an alternative embodiment of the constructional element including two cores;  
     [0034]FIG. 18 a  is an alternative embodiment of the embodiment illustrated in FIGS. 17 a - b,  where the ends do not protrude from the cladding;  
     [0035]FIG. 18 b  illustrates the embodiment of the constructional element illustrated in FIG. 18 a  showing the cores filled with insulating material;  
     [0036]FIG. 22 is a perspective view of the constructional element illustrated in FIG. 1 a,  with a power point connected thereto;  
     [0037] FIGS.  27  to  34  are perspective views of various embodiments of quoins and post covers for use with the building system according to the present invention; and  
     [0038]FIGS. 37 and 38 are perspective views of alternative embodiments of a method of construction according to the present invention. 
    
    
     [0039] In the Figures, like reference numerals denote like parts.  
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0040] Referring to the Figures, a preferred embodiment of the invention is a constructional element in the form of an elongate board  100 . The board can be made in any desired length, depending on the desired function or end use of the board  100 . However, the board is usually manufactured in several lengths up to a preferred length of 3.6 m. The board  100  includes a structural member in the form of a hollow closed sectioned core  102 . The core  102  is typically manufactured from steel though alternatively may be manufactured from alluminium, carbon fibre, fibre glass, or any other suitable structural material.  
     [0041] Cladding  104  is formed about at least part of the core  102 . The cladding  104  is usually a cement based material such as fibre cement, though alternatively may be constructed from fibre glass; ceramics; foamed polymeric materials such as polystyrene; or cellulose based material, such as recycled paper or wood pulp; etc. The type of material used to form the cladding  104  will depend on the desired look of the finished product. For example, if a sandstone look is desired, the cladding may be formed from glass reinforced modified cement.  
     [0042] Abutment means in the form of corresponding tongue  105  and groove  106  formations are formed in respective first and second opposing longitudinal edge portions  107  and  108  of the board  100 . Two variations of the tongue  105  and groove  106  formations are illustrated in FIGS. 1 a - 1   c  and FIGS. 2 a - 2   c,  for example. The tongue  105  and groove and  106  formations allow for mutual abutment and alignment on and with adjacent boards  100 . An example of this alignment and abutment is illustrated in FIGS. 1 c  &amp;  2   c.    
     [0043] The height of the tongue  105  is smaller than the depth of the groove  106 , defining a gap  109  between the tongue  105  and groove  106  when adjacent boards  100  are mutually abutted and aligned. This serves two purposes. Firstly, the gap  109  allows for accommodation of a control joint between the tongue  105  and groove  106 . The control joint is usually a rubber strip, or silicon tube, for example. Secondly, in practice the gap  109  allows for seating of tongue shoulders  110  directly on groove shoulders  112 , to ensure there is no gap between the respective abutted shoulders  110  &amp;  112 . This improves reduction of acoustic, heat and water transfer through the join between adjacent mutually abutted and aligned boards  100 .  
     [0044] Alternative embodiments of the abutment means are illustrated in FIGS. 3 a - 3   c  where the abutment means are in the form of corresponding step, or shiplap formations  114  and  116 .  
     [0045] First and second opposing faces  117  and  118  are also formed in the cladding  104 , typically in a flat arrangement. In alternative embodiments, one or both of the faces  117  and  118  are formed in different aesthetic shapes. Examples of such alternative embodiments are illustrated in FIGS.  4  to  6 , where face  118  is shaped for aesthetic purposes. The thickness of the faces  117  and  118  of the cladding  104  about the core  102  is usually about 10 mm, though may be about 3 mm in some applications. The depth of the faces  117  and  118  is usually 300 mm.  
     [0046] The first and second ends  120  and  122  of the core  102  extend beyond the cladding  104 . This is to allow the ends  120  and  122  of the board  100  to seat in a channel  124  of a C-section support element  126 . This arrangement allows for a plurality of boards to be held in mutual abutment and alignment, as illustrated in FIG. 7 for example.  
     [0047] In an alternative embodiment of the board  100 , the first and second ends  120  and  122  of the board are flush with the first and second respective ends  128  and  130  of the cladding  104 .  
     [0048] The board  100  can be used in a building system including any one of retaining walls, multi walled buildings, etc. The board  100  in such a system can be used for construction of walls in the form of sidewalls  131 , or portions thereof, internal partitions, floors  132 , ceilings  133 , roofs  134  etc.  
     [0049] In one embodiment, to build a wall using a plurality of boards  100 , two C-sectional support elements  126  are fixed in an upright position relative to the ground in concrete pillars  135  which are set into the ground. The C-section support elements  126  are arranged such that their respective channels  124  face towards each other. The C-section support elements  126  are spaced apart at a predetermined distance, being approximately the width of the required wall. A standard wall width is 3.6 m, for example. With the width of the wall determined and C-section support elements  126  in position, appropriate boards  100  are selected to build the desired wall, where the distance between the first and second cladding ends  128  and  130  of the plurality of boards  100  to the fitted between the elements  126  is approximately the distance between the C-section support elements  126 .  
     [0050] As illustrated in FIG. 8, a board  100  is then placed between the C-section support elements wherein the first and second ends  120  and  122  of the core  102  are fitted and fixed within respective channels  124 . FIG. 9 illustrates in detail how an end  120  fits within the channel  124  of a C-section support element  126 . More boards  100  are then fitted and fixed between the C-section support elements  126  on top of one another wherein immediately adjacent first and second sides  107  and  108  of immediately adjacent boards  100  mutually abut. This described arrangement can be used for building a single sidewall, such as a retaining wall.  
     [0051] In a method for construction of, for example, a building, a plurality of side walls  131 , floors  132 , ceilings  132  and roof  134 , and so on are erected. In this embodiment, either concrete pillars  135  or a concrete slab  136  is typically laid, upon which support posts  137  are vertically erected, as illustrated in FIG. 8 or  10 , for example. Main horizontal beams  138  are then attached between two support posts  137 , and subsidiary horizontal beams  139  are attached between main horizontal beams  138 .  
     [0052] As illustrated in FIG. 11, for example, main and subsidiary beams  138  and  139  used for supporting a roof structure  134  are typically trapezoidal in cross section to allow for a pitched roof. FIG. 12 illustrates in detail one way in which the main horizontal beam  138  is connected to a support post  137 . FIGS. 13 a  to  13   k  illustrate various connection means  140  for connecting main horizontal beams  138  to support posts  137  and support posts  137  to concrete slabs  136 . FIGS. 14 a  to  14   h  illustrate several of the connection means  140  in use in supporting main horizontal beams  138  on support posts  137  and support posts on concrete slabs  136  or pillars  135 .  
     [0053] Once the support posts  137 , main and subsidiary horizontal beams  138  and  139  are in place, C-section support elements  126  are then attached in desired locations on the support posts, completing a framework super structure suitable for receiving boards  100 . In an alternative embodiment, the elements  126  are attached to the support posts  137  prior to the support posts being erected on the concrete slab  136 .  
     [0054] Where a slab  136  is used, and is therefore in direct contact with the ground, damp course, or weatherproof flashing is placed between the slab  136  and the boards  100  which directly abut the slab.  
     [0055] As illustrated in FIG. 15, once the first end  120  of a given board  100  is in a predetermined position in a channel  124 , the end  120  of the board  100  may be secured to the C-section support element  126  by crimping a portion  142  of the C-section support element inwardly to at the same time crimp a portion of the first end  120  of the board  100 . This secures the board  100  in position on the support element  126 . Alternatively, a hole and thread forming screw such as a TECHSCREW is employed to screw directly through a wall of the C-section support element  126 , and the first or second end,  120  or  122  engaged within the C-section support element  126 , to secure the first or second end on the C-section support element.  
     [0056] In an alternative embodiment, holes  144  may be preformed within the first and second ends  120  and  122 , and a securing means such as a screw, bolt, nail, etc placed through corresponding holes  144  in the first or second end and  122  of the board and preformed holes  146  in the C-section support element  126 .  
     [0057] Also, as illustrated in FIGS. 8 and 16, a plurality of boards  100  may be used to form a floor  132  within the building system. In one embodiment, the boards  100  used to form the floor  132  include one core  102 , for example as illustrated in FIGS. 1 a  to  1   f,  or alternatively, for added load bearing support, boards  100  used for the floor  132  may include twin cores  102 , as illustrated in FIGS. 17 a,    17   b,    18   a  and  18   b.  FIG. 19, for example, illustrates the boards of FIGS. 18 a  and  18   b  in a floor  132  configuration. In the preferred embodiment of the invention, the ends  120  and  122  of the cores  102  of the boards  100  used to construct floors  132  do not protrude from the respective ends  128  and  130  of the cladding  104 . This is illustrated in FIGS.  19  to  21 , for example. This is so the ends  120  and  122  of the cladding  104  are flush with an adjacent wall  131 . Also, as illustrated in FIG. 20, individual boards  100  when part of a floor  132 , are typically secured to a respective main horizontal beam  138  by a mounting bracket  156 . A lining strip in the form of a control/expansion joint  158 , typically formed from rubber or polymer, is placed between the floor  132  or roof  134  and main horizontal beam  138 . A ceiling  133  or roof  134  is constructed in an identical manner as described in relation to construction of floor  132 . If the length of board  100  used to construct a floor  132  or ceiling  133  is a standard length of  3 . 6 m or less, subsidiary beams  139  are not required.  
     [0058] Aside from load bearing properties of the hollow core  102 , the hollow nature of the core  102  allows for running of electrical services  152  through resultant walls  131 , floors  132 , etc, as illustrated in FIG. 20. The hollow support posts  137  and main and subsidiary horizontal beams  138  and  139  also allow for running of electrical services, which may be continued through the walls, floors, etc or connected to electrical services therein. The electrical services can then be connected to powerpoints  154  connected to a board  100  in a desired location, as illustrated in FIG. 22. It will be clear to a person skilled in the art that the cores  102 , posts  137 , etc, also allow for running through of water, telephone and gas services, and ducting for air conditioning. In the case of air conditioning, this could be used to either heat or cool side walls  131 , floors  132 , or ceiling  133 , or to direct hot or cold air to an outlet to blow the air into a predetermined room, for example.  
     [0059] The hollow nature of the cores  102  also allows for insulating material  160  to be placed therein, as illustrated in FIG. 18 a.  The insulating material  160  is typically foam, though alternatively may be paper based, wool based, or made from any other suitable insulating material.  
     [0060] Once floors  132 , side walls  131 , roofs  134  and ceilings  133  have been constructed, quoins  164  and post covers  166  are positioned on the building, for example as illustrated in FIGS.  23  to  26 . Both quoins  164  and covers  166  are typically connected to their respective support posts  137  by bolting attachment plates  168  to the posts  137 . In the embodiments of the quoins  164  and post covers  166  where the attachment plates are flat (FIGS.  27  to  31 ), a second quoin  164  or cover  166 , as appropriate, is positioned above the first attached quoin  164  or cover  166  such that the exposed portion  170  of the plate  168  of the attached quoin or cover is covered by a recess  172  in the next quoin  164  or cover  166 .  
     [0061] In alternative embodiments of the quoins  164  and post covers  166  illustrated in FIGS.  32  to  34 , the attachment plates include a step portion  174 , and bottom extending portion  176 . In these embodiments, when a second quoin  164  or cover  166 , as appropriate, is positioned above the first attached quoin  164  or cover  166 , the step portion  174  is located in the recess  172  between the bottom extending portion  176  and main body  178  of the quoin  164  or cover  166 .  
     [0062] In another alternative embodiment illustrated in FIG. 35, a corner  178  is formed directly on to the corner of the building, typically from a cement based material. In another alternative embodiment, illustrated in FIG. 36, an end  180  of the boards  100  are cut or formed at a  45  angle to form a building corner with another like board positioned end to end to that board  100 .  
     [0063]FIG. 36 illustrate how C-section elements  126  are used in part to form window  181  and door  182  vertical frame portions. Also, an alternative embodiment of the board  100  illustrated in FIGS. 6 and 36 is used directly above windows  181  and doors  182 , which includes a thickened cladding portion  183  and a drip groove  184 . The thickened cladding portion  183  is both aesthetic and bears the drip groove  184 . If water, such as from rain, runs down this board  100 , the thickened cladding portion  183  aids in directing the water away from the window  181  or door  182 , and the drip groove  184  aids in preventing water from running transversely along the underside  185  of the board  100  and into the building. Weatherproof flashing  187  is also placed between the window or door frame and the board  100  directly above the window or door frame and between the board  100  directly below the window frame.  
     [0064] The embodiment of the board  100  illustrated in FIG. 5 is usually used as the uppermost board  100  in a side wall  131 , being the board  100  directly under the roof  134 .  
     [0065]FIG. 37 illustrates another alternative embodiment for forming a side wall  131 , where the side wall  131  is pre-assembled by placing C-section support elements  126  directly onto respective ends  120  and  122  of exposed core  102 . The preformed wall  131  is then placed in position on a building frame structure, which includes L-section support elements  186 . The C-section support elements  126  are then abutted against their respective L-section support elements  186 , and secured in place.  
     [0066] In an alternative embodiment of the embodiment illustrated in FIG. 37, the boards  100  are assembled and secured directly onto L-section support elements  186 . This is achieved by securing respective ends  120  and  122  of individual boards  100  directly into internal corners of the L-section support elements  186 .  
     [0067]FIG. 38 illustrates another alternative embodiment for forming a side wall  131 , where a recess  188  is formed in the cladding  102  of one face  118  of the boards  100  to accommodate the adjacent support posts  137 . The board  100  is then attached to the support post  137  by a screw or the like, which couples between the support post  137  and the core  102 . In this embodiment, post covers  166  are not required. Also in this embodiment, quoins  164  are also not required.  
     [0068] Now that preferred embodiments of the invention have been described, it will be apparent to those skilled in the art that the constructional element, method of construction and building system has at least the following advantages:  
     [0069] 1 they offer a cheaper alternative to standard building methods;  
     [0070] 2 the hollow nature of the constructional element acts as an acoustic dampener, and insulator;  
     [0071] 3 the resultant building structure has high structural integrity, since each constructional element is connected to the superstructure;  
     [0072] 4 they allow for a relatively inexpensive kit building system which allows for building of an aesthetic building; and  
     [0073] 5 the resultant building, retaining wall, etc, is relatively easy to install, being able to be assembled without the use of heavy machinery, and with reduced tradespeople activity.  
     [0074] Although the invention has been described with reference to particular examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.