Modular Construction System and Method Utilizing Prefabricated Units for Load-Bearing Walls

The present invention relates generally to the field of construction, specifically to a system and method for erecting load-bearing walls. It involves the use of prefabricated hollow units and sheets designed for quick assembly and enhanced structural integrity.

The field of construction, particularly regarding the development and implementation of load-bearing walls, has long been a domain of continuous innovation and refinement. Traditional construction methods have laid the foundation for building practices, leveraging techniques such as bricklaying for block walls, stick build stud walls with timber or metal studs, panelized wall constructions, and concrete walls with false or permanent formwork. Each of these methodologies, while effective in their own right, carry inherent limitations and drawbacks that have spurred the search for more efficient, versatile, and cost-effective solutions.

Bricklaying, for instance, while a time-tested method, is labor-intensive and suffers from material inefficiency due to the extensive use of mortar joints. This traditional method also demands a significant degree of skilled labor, further escalating construction costs. Similarly, stick build stud walls, whether constructed with timber or metal studs, introduce challenges in terms of site installation speed, the requirement for skilled tradespeople, and difficulties in achieving airtight structures. Timber studs, in particular, face additional shortcomings related to fire resistance and susceptibility to moisture damage. Metal studs, while overcoming some of these issues, present their own challenges including higher thermal conductivity and the effective transmission of sound vibrations.

Panelized wall construction methods attempt to address some of these issues by preassembling wall sections in a controlled factory environment. However, this approach often necessitates custom-built panels for each specific project, limiting the scalability and flexibility of construction efforts. Moreover, both timber and metal stud-based solutions encounter complications in hanging objects from the walls and ensuring the airtight integrity of the structure.

The use of concrete walls with permanent formwork has emerged as a promising alternative, offering structural integrity and efficiency improvements. Proprietary systems such as the Logical Wall, Ritek Permanent Formwork Wall Systems, and the Fastform Wall System have demonstrated significant advancements. However, these systems often require custom-built formwork panels, intricate reinforcement works, and the handling of heavy materials, which complicates the construction process and limits flexibility.

In response to these challenges, the industry has been propelled towards the development of innovative construction methods that seek to harmonize efficiency, structural performance, and versatility. The quest for a solution has led to the exploration of lightweight, prefabricated units and sheets that can be readily assembled on-site, offering an alternative to traditional construction methods. This innovative approach aims to address the multifaceted limitations of existing systems by reducing labor requirements, streamlining the construction process, and providing enhanced thermal and acoustic performance. The pursuit of such advancements underscores a broader effort to enhance building practices, reflecting the industry's ongoing commitment to innovation and improvement.

EP1660734B1 outlines a building system using panels and studs tailored for constructing walls filled with concrete, where studs equipped with a head and flanges attach to panel facing sheets and secure spacer elements for assembly. The disclosure focuses on creating solid walls that necessitate a manual assembly of components to achieve the desired structural, thermal, and acoustic properties. It relies on concrete fill and a complex assembly of spacer elements and studs for wall construction, as opposed to minimizing construction complexity and potential material waste through a modular design.

WO2020098618A1 outlines a frame-type prefabricated wallboard system intended for the construction of prefabricated houses, particularly emphasizing the ease of manual transportation and assembly of wall panel and column modules in remote locations. This system consists of hollow, integrated frame constructions, including L-shaped, T-shaped, and ten-shaped columns, designed to be bolted together on-site. The method includes an option to fill frame voids with insulation materials. However, the lack of consideration of structural integrity and insulation properties within the prefabricated wall system is a disadvantage, leading to issues with load-bearing capacity and insulation performance.

It is within this context that the present invention is provided.

This invention relates to a construction system and method for assembling load-bearing walls, which includes prefabricated sheet studs, outer sheets, and a filler material. The sheet studs, comprising interlocked flange sheets and web sheets wrapped with alkali-resistant mesh, form a hollow rectangular profile. Pairs of outer sheets attached to these studs create a cavity between the studs, forming prefabricated hollow wall units that serve as permanent wall formwork. The introduction of a selected filler material into this cavity provides both insulation and structural integrity to the formwork, facilitating the construction of load-bearing walls with enhanced efficiency and durability.

In some embodiments, the flange sheets and web sheets are made from materials such as cement fiber boards, moisture-resistant plaster boards, and calcium silicate boards, offering improved durability and resistance to environmental factors.

Further embodiments include one or more steel sections disposed within the sheet studs, attached to the inner surface of the hollow profile, enhancing the structural integrity and load-bearing capacity of the wall units.

In certain embodiments, the outer sheets are affixed to the sheet studs using a bonding material selected from construction adhesive and polymer-modified mortar, ensuring a strong and durable bond between the components.

Some embodiments further comprise one or more aligning guide members, aiding in the precise assembly of multiple prefabricated hollow wall units into a cohesive and straight wall formwork.

In additional embodiments, the filler material comprises foam concrete, known for its insulation properties and structural integrity, contributing to the overall energy efficiency and strength of the constructed walls.

Certain embodiments are further characterized by specialized prefabricated hollow wall units designed for corner and T-junctions, incorporating extended flange sheets and end sheets, facilitating seamless integration of wall units at architectural junctures.

Other embodiments include prefabricated external wall units equipped for façade element support, incorporating insulation and outer sheets designed for façade attachment, thus enhancing the aesthetic and functional aspects of the exterior walls.

Further, some embodiments include jamb sheet studs configured for integration into the wall formwork at positions corresponding to openings for doors and/or windows, ensuring structural support and alignment for architectural openings.

Additionally, embodiments may include lintel units comprising sheet studs and outer sheets, reinforced with steel sections and equipped with fin plates for secure attachment over jamb sheet studs, providing robust support for overhead loads.

In some embodiments, the prefabricated hollow wall units are configured to incorporate back boxes for switches and outlets, facilitating the integration of electrical services within the wall structure.

Lastly, in certain embodiments, the alkali-resistant mesh wrapping the interlocks between the flange sheets and web sheets is made of fiberglass, offering enhanced durability and resistance to alkali-related degradation.

Common reference numerals are used throughout the figures and the detailed description to indicate like elements. One skilled in the art will readily recognize that the above figures are examples and that other architectures, modes of operation, orders of operation, and elements/functions can be provided and implemented without departing from the characteristics and features of the invention, as set forth in the claims.

The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.

Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

As used herein, the term “and/or” includes any combinations of one or more of the associated listed items.

As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise.

It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

When a feature or element is described as being “on” or “directly on” another feature or element, there may or may not be intervening features or elements present. Similarly, when a feature or element is described as being “connected,” “attached,” or “coupled” to another feature or element, there may or may not be intervening features or elements present. The features and elements described with respect to one embodiment can be applied to other embodiments.

The use of spatial terms, such as “under,” “below,” “lower,” “over,” “upper,” etc., is used for ease of explanation to describe the relationship between elements when the apparatus is in its proper orientation.

The terms “first,” “second,” and the like are used to distinguish different elements or features, but these elements or features should not be limited by these terms. A first element or feature described can be referred to as a second element or feature and vice versa without departing from the teachings of the present disclosure.

For the purposes of this patent, ‘prefabricated sheet studs’ are understood to encompass any assembly of interlocking flange sheets and web sheets, regardless of the specific locking mechanism employed. The term ‘interlocking’ should be broadly interpreted to include any form of engagement between flange sheets and web sheets that allows for the formation of a stable, hollow rectangular profile. Examples of materials suitable for the construction of these components include, but are not limited to, cement fiber boards, gypsum boards, and any composite material known to those skilled in the art to offer comparable structural properties.

The term ‘alkali-resistant mesh’ as used herein is intended to cover any mesh material capable of resisting degradation when exposed to alkaline conditions commonly found in construction environments. This includes fiberglass mesh, carbon fiber mesh, and any synthetic polymer mesh providing similar resistance.

When the term ‘attached’ or ‘affixed’ is used in relation to outer sheets and sheet studs, it encompasses a range of attachment mechanisms including, but not limited to, adhesive bonding, mechanical fastening (e.g., screws, nails, rivets), and interlocking mechanisms. The choice of bonding material for attaching outer sheets to the sheet studs includes construction adhesives, polymer-modified mortars, and any other adhesives known to those skilled in the art to be suitable for construction applications.

The ‘filler material’ described for insertion into the cavity of the wall units may include, but is not limited to, foam concrete, hempcrete, insulation foams, or any material that solidifies to provide structural integrity and insulation. Foam concrete, for instance, may be specified to have a density range suitable for the intended load-bearing requirements and insulation properties.

Furthermore, the construction system may include ‘guide members’ which are understood to be any structural element or tool designed to assist in the alignment and assembly of the prefabricated hollow wall units. This could include temporary bracing, alignment jigs, or laser-guiding systems.

The present invention relates generally to the field of construction, and more specifically, to a construction system and method for assembling load-bearing walls. This innovative approach utilizes prefabricated components, including sheet studs and outer sheets, which are designed to be easily assembled on-site to form the structural walls of a building. The system aims to streamline the construction process, offering a method that is not only efficient but also provides enhanced structural integrity and insulation properties to the resulting load-bearing walls.

The invention encompasses a set of prefabricated sheet studs, which are created by interlocking flange sheets and web sheets to form a hollow rectangular profile. These studs are then wrapped at their interlocking points with an alkali-resistant mesh to ensure durability and resistance to environmental factors commonly encountered in construction settings. Outer sheets are attached to these studs, forming prefabricated hollow wall units. These units, when assembled on-site, create a formwork into which a selected filler material is introduced. The filler material, chosen for its insulation properties and structural integrity, solidifies within the formwork, completing the construction of the load-bearing walls.

Referring now to the drawings, a set of example configurations of various aspects of the invention will be described.

provides an exploded view of the components that form a sheet stud. The sheet studis constructed from web sheetsand flange sheets, which are designed to interlock to form a hollow rectangular profile, along with a set of reinforcing steel gauge sectionsconnected via screws. This configuration not only facilitates ease of assembly but also contributes to the structural integrity of the wall system. The modular nature of the sheet studallows for customization in terms of size and shape to accommodate various architectural requirements.

shows a top-down view of an assembled sheet stud, where reinforcing gauge steel sectionshave been installed using screws. These steel sectionsare optional components that can be incorporated within the sheet studfor additional support, especially in applications requiring enhanced load-bearing capacity.

is an isometric view of the sheet studin an assembled state, with alkali-resistant fiberglass meshwrapping the junctions where the flange sheetsand web sheetsmeet. The meshserves a dual purpose: it secures the sheets together, reinforcing the structural integrity of the stud, and it provides resistance to environmental degradation, particularly in alkali-rich environments common in construction settings.

presents a top-down view of an assembled prefabricated wall unit, which includes a pair of outer sheetscoupling two standard sheet studstogether by attachment to their opposing parallel edges. Notably, the outer sheetscover only half of each edge of the sheet studs. This strategic design leaves room for additional outer sheets to attach to the exposed portions of the edges when multiple prefabricated wall unitsare assembled side-by-side, facilitating the creation of a continuous wall structure.

provides an isometric view of the prefabricated wall unitdepicted in. This perspective further illustrates the spatial relationship between the sheet studsand the outer sheets, as well as the cavityformed between the sheet studswithin the unit. The cavityis designed to be filled with a selected filler material, such as foam concrete, to provide insulation and additional structural support once the wall unitis installed.

depicts an exploded view of the components forming an alternative sheet stud, specifically designed for connecting corners and T Junctions within the wall formwork. This variant of the sheet stud includes extended flange sheetsand end sheets, alongside the standard web sheets.

offers an isometric view of the assembled connecting sheet studfrom. This view showcases how the extended flange sheetsand end sheetsinterlock with the web sheets, forming a robust and coherent structure. Alkali-resistant fiberglass meshwraps the assembled junctions, reinforcing the connections and providing environmental resilience. The connecting sheet studhelps in maintaining the structural coherence of the wall system at corners and T junctions.

illustrates an isometric view of a wall assembly, where a plurality of prefabricated wall unitsare being aligned and connected along one edge by a guide member. The guide memberensures the vertical and horizontal alignment of the wall units, facilitating a precise and straight construction of the wall formwork, achieving uniformity and structural integrity during the assembly process.

presents an isometric view showing a subsequent step in the wall construction, where outer sheetsare installed onto the aligned prefabricated wall unitsof. The outer sheetsare attached to the exposed edges of the sheet studswithin each wall unit, effectively enclosing the wall formwork and preparing the structure for the introduction of the filler material. This step helps in sealing the wall units and enhancing the overall stability and insulation of the wall system.

displays the constructed wall in its assembled state, following the installation of the outer sheetsand the introduction of filler materialinto the hollow portions of the wall formwork. The filler materialsolidifies within the cavities, providing both insulation and additional structural support to the wall.

presents a top-down view of an assembled external wall unit, incorporating façade supporting elements such as insulation. The unit is designed to facilitate the attachment of various façade elements, enhancing the thermal performance and aesthetic appeal of the exterior walls.