WO2001014657A2 - Systeme de construction a charpente minimale et procede de construction - Google Patents

Systeme de construction a charpente minimale et procede de construction Download PDF

Info

Publication number
WO2001014657A2
WO2001014657A2 PCT/US2000/022872 US0022872W WO0114657A2 WO 2001014657 A2 WO2001014657 A2 WO 2001014657A2 US 0022872 W US0022872 W US 0022872W WO 0114657 A2 WO0114657 A2 WO 0114657A2
Authority
WO
WIPO (PCT)
Prior art keywords
walls
roof
panels
foundation
foam
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/022872
Other languages
English (en)
Other versions
WO2001014657A3 (fr
Inventor
F. Peter Zoch, Iii
J. Victor Neuhaus, Iii
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Microstone Building Systems LLC
Original Assignee
Microstone Building Systems LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Microstone Building Systems LLC filed Critical Microstone Building Systems LLC
Priority to AU67918/00A priority Critical patent/AU6791800A/en
Priority to MXPA02001794A priority patent/MXPA02001794A/es
Publication of WO2001014657A2 publication Critical patent/WO2001014657A2/fr
Publication of WO2001014657A3 publication Critical patent/WO2001014657A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/022—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of a plurality of parallel similar trusses or portal frames
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/04—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs supported by horizontal beams or the equivalent resting on the walls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
    • E04B7/22—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material

Definitions

  • This invention relates to a building system using a minimal amount of framing comprising foam panels that are bonded together using a sprayed-on cementitious coating that forms a load-bearing shell around the entire structure.
  • the sprayed-on coating provides structural support, and the framing allows construction of large or
  • the minimal framework structure disclosed herein has significantly fewer parts
  • the present invention comprises a minimum framework building system
  • a method for constructing a minimum framing building comprises constructing a concrete foundation and one or more columns supporting a plurality of foam walls and a foam panel roof, wherein the walls and the roof comprise a load- bearing shell around them which comprises a spray on cementitious coating.
  • spray-on coating provides fire rated protection.
  • Fig. 1 is a plan view of an expository embodiment of the building system showing the position of walls and a foundation.
  • Fig. 2 is an expository elevation view showing the wall panels.
  • Fig. 3 is a detail of wall section A, showing the location of the steel tubing, the notch in the foam panels, the "C" channel track and the groove in the bottom of the foam panels.
  • Fig. 4 is a cut away detail of wall section B-B.
  • Fig. 5 is a detail view of an eave where the steel tubing meets the joist.
  • Fig. 6 is a detail view of the connection between two joists at the peak of the
  • Fig. 7 is a detail of the corner of the roof.
  • Fig. 8 is a perspective view of a partially assembled frame skeleton.
  • Fig. 9 is a roof plan view showing multiple foam panels positioned side by side and joined together to form the roof.
  • Fig. 10 is a plan view of the foundation showing the location of trenches under
  • Fig. 11 is a cross-sectional view of the foundation at a cross section showing the trench at the edge of the foundation beneath the exterior wall.
  • Fig. 12 is a cross-sectional view of the foundation at a cross-section showing the
  • Fig. 1 is a plan view of a minimal framework building system 2.
  • the building may be constructed on any type of conventional foundation 4.
  • Fig. 3 is connected to the foundation, running along the top of the foundation where the walls 6 will be. Exterior walls 7 are typically placed over the perimeter of foundation 8.
  • the "C” channel track 14, shown in Fig. 3, is an elongated metal channel approximately 4 inches wide with two side walls extending up approximately 2 inches, on either side of the channel to form the "C”.
  • Fig. 1 also shows a thin coating 54 of cementitious material 50 sprayed-on the outside of the structure 2 to form a load- bearing shell 52.
  • Figs. 3 and 4 show in detail the connection between the steel tubing 10 or
  • the steel tubing 10 may be unitary in structure and no supporting filling within the hollow central portion of the
  • the steel tubing 10 is needed.
  • the steel tubing 10 is spaced 4' [four feet] apart and extends
  • the steel tubing 10 can be connected to the "C" channel track 14 by any conventional means, including gluing.
  • Figs. 3 and 4 show the
  • Fig. 4 is an elevation of a wall showing foam panels 20 aligned side by
  • the foam panels may comprise expanded polystyrene foam (EPS), polyurethane, or foamed plastic.
  • EPS expanded polystyrene foam
  • a system of joists 34 support a roof 40 structure.
  • the joists 34 can be angled to support a pitched roof, the pitch dependent upon taste and architectural design.
  • Fig. 2 is an elevation view of a side of the structure 2, showing the foam panels 20 positioned vertically side by side.
  • the foam panels 20 will preferably have a width 22 of four feet. A uniform or standardized width allows for ease of construction.
  • steel tubing 10 is placed along the"C" channel track 14 every four
  • FIG. 2 also shows that the height 24 of foam panels 20 can vary, if required, to meet the roof joists 34. In other embodiments
  • vertical joints 26 can be formed by gluing the side walls 21 of the foam panels 20 to each other or to the steel tubing 10.
  • Fig. 3 is a detail of the wall section showing the connection between the steel tubing 10 and the "C" channel track 14. Fig. 3 also shows the notch 12 cut into the side
  • Fig. 3 also shows the groove 16 in the bottom 30 of the foam panels 20.
  • the groove 16 is cut to receive the two side walls 15 of the "C" channel track 14.
  • the steel tubing 10 is attached to the "C" channel track 14
  • angle bracket 18 is bolted to the "C" channel track 14 and welded to the steel tubing 10 so as to present a flat surface that is flush with the base of
  • Fig. 4 is a cut away detail of wall section B-B showing the 6 inch foam panel 20, and the 2 inch x 4 inch [2"x4 M ] steel tubing 10. This view also shows the correspondence between the "C" channel track side wall 15 and the groove 16 in the bottom of the foam panel 20. With the groove 16 cut into the bottom of the foam panel 20 receiving the "C" channel track side wall 15, and the notch 12 in the side wall 21 of
  • Fig. 5 is a detail of the connection between the steel tubing 10 and the joist 34
  • the roof 40 is constructed of foam panels 20 sprayed with cementitious material 50. In another embodiment, the roof 40 is
  • the roof foam panels 20 may be 10 inches thick with grooves 16 located
  • the steel tubing 10 may pass through a hole or notch in an angled C-channel 37 for attachment to and support of the roof joists 34.
  • the tubing 10 may be secured or fastened to the angled C-channel 37 and to the roof joist 34 by
  • the angled C-channel 37 may have its central portion angled to conform to the pitch of the roof.
  • the two end portions of the angled C-channel 37 may be vertically disposed for fitting into grooves 16 at the top of the wall foam panels 20.
  • the top of the vertical wall foam panels 20 may be cut at an angle to conform to the pitch of the roof.
  • Fig. 6 is a detail of the peak of the roof 40 showing the connection between the joists 34 with a steel plate 36. Also shown is the roof beam 42, which runs underneath and supports the joists 34 at the peak of the roof 40.
  • the roof beam 42 is supported on either end by steel tubing 10 in the exterior walls 7 of the building structure 2, and intermittently in the interior of the structure by steeling tubing 10 in the interior walls 5.
  • the roof beam 42 is preferably wrapped by foam material and sprayed with cementitious coating 50.
  • the roof beam 42 may comprise two "C" shaped channels
  • each C-channel is bent to the pitch of the roof, so that the top of the I- beam is angled or bent to conform to the pitch or apex of the roof.
  • Fig. 7 shows a detail of the roof corner showing a foam panel 20 used for the
  • a series of hat channels 44 may be placed on top of the roof
  • the hat channel 44 is a galvanized steel channel approximately 2 inches by 4 inches running substantially the
  • the hat channel 44 may be secured or fastened to the joist 34
  • FIG. 8 shows a partially assembled skeletal framework for the building structure
  • the structure 2 is constructed by placing the "C" channel track 14 on the perimeter 8 of the foundation 4.
  • the "C" channel track 14 can be attached by
  • the steel tubing 10 may include gluing or bolting.
  • the steel tubing 10 is then attached to the "C" channel track 14.
  • the steel tubing is generally spaced 4 feet apart.
  • a multi - storied structure may be constructed by the addition of a beam 32, and a second series of steel tubing 10 added above the beam 32. A roof beam 42 is then placed with each
  • Fig. 9 is a plan view of the roof 40 showing foam panels 20 placed over the joists 34. While Fig. 9 shows an overhang in this embodiment, there is no requirement for one, and its presence or absence is dictated by the architectural and structural needs
  • the foam panels 20 may be attached to the joists 34 by a wide variety
  • Such architectural foam pieces may be
  • foam trim panels may be placed at the corners of the structure 2 and around doors and windows to provide architectural contours.
  • Architectural features of a great variety may be achieved.
  • wood frames constructed preferably of 2' x 4's are installed around the openings for the doors and windows. Openings for windows and other items are then covered with plastic, and then a cementitious material 50 that sticks directly to the foam panels 20 is sprayed- onto the structure 2. Once the structure 2 is assembled, it is sprayed with a cementitious coating
  • cementitious material 50 is sprayed directly on the structure 2 without the need for wire or other meshing to hold the material.
  • the cementitious material 50 is prepared by mixing together water, sand, lime, marble particles, Portland cement, fibers, and an
  • the cementitious coating comprises about 5% by weight of the adhesive additive.
  • Other additives may be mixed in to improve the cement properties, such as a retarder. Further, up to about two more gallons of water may be mixed into the cement, depending on the heat, humidity and viscosity of the cement mix.
  • the sand used in the process is preferably a blend of number three and four sands (about 50% of each) which
  • the lime and marble particles are available from suppliers such as General Terrazo in Houston, Texas.
  • the marble is preferably in particles similar in size to number one size sand.
  • Type one Portland cement is preferably used and can be obtained from concrete companies or hardware stores such as Home Depot.
  • the fibers used are preferably
  • the fibers may be made of many materials including fiberglass, or other plastics, or metal.
  • This cement mixture is preferably mixed in the mixer of the machine that sprays
  • the spraying machine is a mixer/pump such as the Putzmeister PUS Vario Worm Pump (Germany).
  • Other machines that may be used to mix and spray the cementitious coating include the Spray
  • the spraying machine has a rubber hydraulic hose (available from Putzmeister) attached to its output that is preferably about 75 feet long. The first approximately 25 feet of the hose has an
  • an adjustable nozzle such as the type used for stucco or gunnite, is attached to the end of the hose. In the preferred embodiment, it has a 3/16 inch to a 3/4 inch variable tip diameter.
  • an air hose is attached from the spray machine to the nozzle to provide air entrainment into the cement mix as it blows from the nozzle, as is well-
  • the air pressure and the nozzle tip size are adjusted.
  • a 3/8 inch nozzle tip is used with about 50 psi
  • the primer is comprised of about 60 lbs. of lime and about 4
  • a single coating in the range of about 1/4 inch to about 3/4 inch is preferably applied. In the most preferred embodiment, two thin coatings are applied.
  • the first coating is applied to a thickness of about 1/4 inch and allowed to cure for
  • cement coating is applied by troweling or other non- spray methods.
  • the coating Before the coating dries, it may be decorated by etching patterns into it; by pressing rocks or other appliques into it; by troweling the surface smooth, and by many other decorative techniques.
  • appliques may be screwed into the cement.
  • the structure After the structure has cured for about five days, it may be painted or further water sealed.
  • An elastomeric paint such as Hydrostop® accomplishes both water sealing and provides color to the structure.
  • the paint or sealant is preferably applied by rolling, airless paint gun, or paint brush.
  • powdered dyes are added to the cementitious
  • the structure may be built on any type of conventional foundation. Figs. 10, 11
  • a welded wire mesh 104 as shown in Figs. 11 and 12, is used to reinforce
  • the concrete such as No. 6 mesh (the wires run perpendicularly to each other at about 6 inch intervals).
  • the wire fabric 104 is laid in a grid work pattern and is bent on the ends into a trench 102 that is excavated around the perimeter 8 of the concrete foundation 4, as further shown in Figs. 11 and 12.
  • the foundation 4, in another preferred embodiment, may be constructed with a system of I-beams place under the
  • the dimensions of the concrete foundation 4 should match the dimensions of
  • the structure 2 at ground level, plus any porches, patios, loading docks, etc. affixed to the structure 2.
  • the dimensions of the foundation 4 may be any size.
  • the foundation 4 is preferably in the range of approximately 2 to 6 inches in thickness, but can be greater depending on need, for example, one foot or more for cold climates.
  • the concrete foundation 4 is about 2 inches thick across the entire foundation 4, except where trenches 102 are formed around the perimeter 8 of the structure 2 and under any walls 6 of the structure 2.
  • the trenches 102 are about 4 inches deep and about 6 inches wide and create additional support under the walls 6 of the structure 2.
  • Fig. 1 1 shows a cross-section of the trench
  • Fig. 12 shows a cross-section of the trench 102 under an interior wall 5 of the structure 2 across the line S-S in Fig. 10.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne un système de construction à charpente minimale, comprenant des fondations en béton et une ou plusieurs colonnes soutenant plusieurs parois en mousse et un toit en panneaux de mousse, les parois et le toit étant entourés d'une coque porteuse comportant un revêtement cémenteux vaporisé. L'invention porte également sur un procédé de construction d'un bâtiment à charpente minimale, qui consiste à construire des fondations en béton, à accoupler des panneaux en mousse, de manière que des parois de bâtiment soient construites, à accoupler les panneaux de mousse juxtaposés, de sorte qu'une toiture soit formée, à renforcer les parois et la toiture à l'aide d'un ou plusieurs supports, et à pulvériser un revêtement cémenteux sur les parois et la toiture, de sorte qu'une coque porteuse soit formée autour du bâtiment. Dans le système et le procédé de construction de l'invention, les panneaux de paroi en mousse (fig. 4) sont soutenus par des tubes en acier (10) disposés verticalement entre chaque panneau (20) de paroi. Les parois renforcées par un tube en acier (10) sont accouplées aux fondations par une voie de guidage en forme de C (14), s'étendant le long du sommet de la fondation (4), et s'adaptant dans des rainures (16) de parois latérales, découpées dans le bas de chaque panneau en mousse (20). Par ailleurs, des support d'angle en acier (18) vissés à la voie en C (14) sont soudés à chaque pièce du tube en acier (10).
PCT/US2000/022872 1999-08-20 2000-08-18 Systeme de construction a charpente minimale et procede de construction Ceased WO2001014657A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU67918/00A AU6791800A (en) 1999-08-20 2000-08-18 Minimal framework building system and method of construction
MXPA02001794A MXPA02001794A (es) 1999-08-20 2000-08-18 Sistema y metodo de construccion de edificios con armazon minima.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15010499P 1999-08-20 1999-08-20
US60/150,104 1999-08-20

Publications (2)

Publication Number Publication Date
WO2001014657A2 true WO2001014657A2 (fr) 2001-03-01
WO2001014657A3 WO2001014657A3 (fr) 2001-06-14

Family

ID=22533136

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/022872 Ceased WO2001014657A2 (fr) 1999-08-20 2000-08-18 Systeme de construction a charpente minimale et procede de construction

Country Status (3)

Country Link
AU (1) AU6791800A (fr)
MX (1) MXPA02001794A (fr)
WO (1) WO2001014657A2 (fr)

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2193030A1 (fr) * 1996-12-16 1998-06-16 Gerald Robinson Systeme de construction
US5966885A (en) * 1997-12-01 1999-10-19 Chatelain; Paul J. Foam panels for wall construction

Also Published As

Publication number Publication date
WO2001014657A3 (fr) 2001-06-14
MXPA02001794A (es) 2003-09-25
AU6791800A (en) 2001-03-19

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