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WO2008100558A1 - Système de construction utilisant une technologie intégrée avec des âmes en polystyrène expansé moulées - Google Patents

Système de construction utilisant une technologie intégrée avec des âmes en polystyrène expansé moulées Download PDF

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Publication number
WO2008100558A1
WO2008100558A1 PCT/US2008/001941 US2008001941W WO2008100558A1 WO 2008100558 A1 WO2008100558 A1 WO 2008100558A1 US 2008001941 W US2008001941 W US 2008001941W WO 2008100558 A1 WO2008100558 A1 WO 2008100558A1
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WIPO (PCT)
Prior art keywords
panel
panels
wall
sip
concrete
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Ceased
Application number
PCT/US2008/001941
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English (en)
Inventor
Dan Williams
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Individual
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Individual
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Anticipated expiration legal-status Critical
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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
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/165—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with elongated load-supporting parts, cast in situ

Definitions

  • the invention pertains to modular constructed building systems that employ green technology and little, if any, wood products.
  • the disclosure pertains to a plurality of wall panels fabricated of molded expanded polystyrene (MEPS) with an outer layer or "skin" of cement board, oriented strand board, metal or magnesium oxide.
  • MEPS molded expanded polystyrene
  • the panels can be 4 feet wide by 8 feet high and 3 V* inches to 11 !4 inches thick. Other dimensions are possible.
  • the vertical ends of the panels may be cut to form block and tongue lap joints with the next adjoining panel. The resulting lap joint allows for increased surface area for bonding the panels together.
  • Adhesives are used to "weld" the MEPS at the panel lap joint to create a "continuous like" structural wall.
  • the panels are secured with compression fasteners that traverse through the thickness of both panels at the block and tongue lap joint and anchor at the outer surface.
  • the structure can be anchored to a concrete pad.
  • the roof structure can be made of the panel material and attached to the walls with attachment connectors.
  • the panels may also contain preformed voids creating forms for pouring and shaping internal vertical concrete columns and horizontal concrete beams thereby combining structural insulated panel (SIP) technology with insulated concrete form (ICF) technology.
  • SIP structural insulated panel
  • ICF insulated concrete form
  • the horizontal ends of the panels may also be similarly cut and shaped to form block and tongue lap joints.
  • Figure 1 illustrates an example of a SIP panel illustrated to be 4 feet wide and 8 feet long. This is a side view. Also illustrated are the chamfer heads of the compression fasteners mounted vertically every 2 feet. Also illustrated in the tongue component of the lap joint.
  • Figures 2A and 2B illustrate opposing lap joint ends of two SIP panels.
  • Figure 2C illustrates the two panels joined together utilizing a compression fastener.
  • Figure 2D illustrates a two piece threaded compression fastener.
  • Figure 3 illustrates a block lap end cut of a SIP panel with an internal column forming void or annulus.
  • Figure 4 illustrates an end view of the SIP panel showing the void for a concrete horizontal beam.
  • Figure 5 illustrates an end view of another SIP panel showing an expanded installed top portion into which a concrete horizontal beam can be formed.
  • Figure 6 is a detail of the end view of Figure 5 with vertical and horizontal reinforcing bar and compression fasteners.
  • Figures 7 and 8 illustrate examples of a SIP I-beam attached to a vertical SIP panel with associated structural connectors and compression fasteners.
  • Figures 9A, 9B and 9C illustrate differing perspective views of connectors that can be used to connect I-beam to the SIP panel.
  • Figure 10 illustrates the positioning of an angle structural connecting plate on top of a vertical SIP panel and angle roof comprised of an I-Beam.
  • Figure 11 illustrates the attachment of a horizontal I beam on the top of a vertically oriented SIP panel.
  • Figure 12A, 12B and 12C illustrate 3 views of the angled structural connector plate illustrated in Figure 10.
  • FIGS 13 and Figure 14 illustrate alternative structural attachment connectors for attaching the vertical SIP panel to an angle I-beam.
  • Figure 15A, 15B and 15C illustrate a front, side and back view respectively of one connector device.
  • Figures 16 and 17 illustrate details of the lap joints joining the adjacent SIP panels for a roof structure.
  • Figure 18 illustrates a block and tongue lap joint reinforced by a preformed structural Z shaped member.
  • Figure 19 and Figure 20 illustrate the SIP vertical panel base attached to the floor concrete slab with a structural connector.
  • Figure 21 illustrates an isometric view of 3 SIP panels joined together into a wall and containing internal vertical concrete columns and horizontal beams.
  • Figure 22 illustrates an isometric view of the vertical edge of two panels forming a block and tongue lap joint and the placement of the compression fasteners.
  • Figure 23 illustrates an isometric view of a series of SIP panels joined into a wall and including the structural top and bottom base connectors joining two panels.
  • Figure 24 illustrates an isometric view of a block and tongue lap joint reinforced by the 2 shaped structural member illustrated in Figure 18 and the installation of compression fasteners with a top structural connector plate joining two panels.
  • Figures 25 and 26 illustrate a top view and side view respectively of a SIP panel production line.
  • Figures 27 and 28 illustrate front and side views respectively of a twin SIP laminating press.
  • the building structure and method described herein incorporates structural insulated panel technology (hereinafter “SIPs”) and may include a concrete pad or foundation, wall panels that are adhesive bonded and secured together with compression fasteners, optional internal concrete beams and a roofing system attached to the wall system.
  • SIPs structural insulated panel technology
  • the structure and the building method come in two versions, one that integrates concrete and one that does not.
  • the panel is a structural insulated wall or roof panel 11 which has a core made of molded expanded polystyrene (hereinafter "MEPS") of various thicknesses from 3 1 A" to 11 V 2 ".
  • the outer layers 110 are cement board (CB) or oriented strand board (OSB), metal or Magnesium Oxide (MgO) board which may be pressure adhered with a Type II, Class 2 structural adhesive or similar.
  • CB cement board
  • OSB oriented strand board
  • MgO Magnesium Oxide
  • SIP panel One embodiment of a SIP panel is illustrated in Figure 1.
  • the panel is 4 feet wide and 8 feet high. As discussed the thickness of the panel may be between 3 /4 inches and 11 ⁇ A inches.
  • the illustrated panel 1 is a side perspective. Also illustrated are the chamfer heads 3 of the compression fasteners as will be discussed later. The head of the compression fastener can also have square sides.
  • the compression fittings are illustrated as placed every two feet. Other configurations are possible.
  • the CB and MgO outer materials also have fire retardant properties.
  • components of the structure system e.g., fiberglass
  • the system utilizes a 3-4" block projecting tongue fabricated on the vertical edge, and in some cases the top horizontal edge, of each panel and which butt and lap together with the similar edge of a second panel.
  • a series of compression fasteners are placed vertically and horizontally along the butt joint forming the lap juncture.
  • the compression fasteners attach to each panel skin, whether cement board, OSB, metal or MgO of each panel.
  • the compression fastener therefore incorporates both skins of the SIP panels.
  • the compression fasteners are placed horizontally at gables and 2 story walls. This strengthens the bond between the panels.
  • concrete may be used in the structure.
  • the panel contains a vertically oriented void that forms the various shapes of the concrete column internal to the panel.
  • a panel is placed on the cement pad of the structure where a vertical concrete column is to be placed.
  • the reinforcing bar (rebar) placed in the column is tied to rebar extending from the concrete pad. Compression fasteners are utilized to stabilize the sides of the form (within the panel wall) when the concrete is poured.
  • the form for the concrete column is a void created in the interior MEPS and extends the length of the SIP panel.
  • a horizontal beam that sits on top of the vertical column can be created by a second void in the top of the SIP panel or by use of an installed or "detachable" beam form.
  • the rebar of the horizontal beam will be tied to the vertical rebar extending from and attached to the structure's concrete pad. (See information below).
  • Block projecting tongue lapping is used on all vertical panel joining and at gable ends and when structure side walls have a greater height than the standard SIP wall panels
  • Block projecting tongue lapping or lap juncture is illustrated in Figures 2A through 2C.
  • a two part compression fastener is also illustrated 1 , 2, 3.
  • the MPES panel 105 is shown to be between 6 and 8 inches in thickness with an outer surface (7/16 inch) 110 of cement board, OSB, metal or MgO.
  • the outer surface or skin is pressure adhered with a Type II, Class 2 structural adhesive.
  • Waterproof construction adhesive 5 may be applied to both sides of the lap joint.
  • a 1/8 inch air gap 130 is recommended between the joined SIP wall panels.
  • the horizontal off set 135 of the block projecting tongue combination may be approximately 4 inches.
  • Each roof panel comprises a series of individual SIP panels joined in the block projecting tongue lapping configuration.
  • the SIP panel 2OD, 2OE illustrated in Figure 17 may be various thicknesses, including the cement bonded particle board, OSB, metal or MgO layer. Also illustrated is the recommended 1/8 inch expansion joint 130 and the approximate 4 inch offset 135 of the lap joint. The placement of the adhesive 5 is also illustrated.
  • SIP panel lapping is used on all vertical (wall) panel joining and may be used horizontally at gable ends of the structure.
  • the system utilizes a unique compression fastener comprising a bolt that can be mounted flush to the SIP panel surface or "skin".
  • the compression fastener is illustrated in Figure 2D comprising a bolt component 1 and a nut component 2. The two part combination is designated 3.
  • the large chamfer or square sided head on both bolt and nut ends of the compression fastener and engage with the SIP panel skins facilitates compression of the SIP panel.
  • the head and nut components are threaded and can be tightened. This is a more secure connection that staples, nails or screws. This also enhances the stability of the structure, including stability in earth movement or high wind conditions.
  • the construction technique forms a box beam effect on the panel wall connection.
  • Composition of fasteners can be either non-metallic, e.g., fiberglass, or metallic, e.g., stainless steel.
  • the compression fasteners may be of any appropriate length consistent with the thickness of the SIP panel. In one embodiment, the fasteners are 7 inches to 10 inches in length.
  • the diameter of the rod portion of the fastener may, in one embodiment, be % inch.
  • the chamfer or square ends may have a 1 inch diameter. The chamfer ends may include hex slot for tightening.
  • the system described herein permits the installation of vertically oriented concrete columns within constructed SIP panels. See Figure 3.
  • the molded expanded polystyrene 105 can be molded or cut to create the form or annulus for the concrete.
  • the shape of the concrete column is formed using pre-formed voids or annulus within the SIP panels.
  • the double layers of outer skin 110 first skin on one side of the panel and a second skin on the opposite side of the panel.
  • the compression fastener 3 spanning across the form is also illustrated. These compression fasteners are utilized to stabilize and secure the sides of the form when the concrete is poured. These compression fasteners may be placed vertically every 2 feet although other configurations may be selected.
  • a rectangular or other shaped void 140 is placed vertically in a wall panel for the purpose of pouring a structural concrete column.
  • the void extends the entire length of the SIP panel. If a horizontal concrete beam is to be installed, the concrete column will not extend to the top of the panel.
  • the form or void may be 5 VA inches by 13 14 inches in a panel that is 7 % inch wide.
  • the rectangular shape is shown as an example only and is not a limitation.
  • compression fasteners and adhesive will be applied at each lap joint.
  • the compression fasteners may be placed vertically every two feet.
  • the series of joined wall panels, having fasteners traversing through the thickness of the lapped panels and the large chamfered ends engage the outer surface of each skin of the joined panels to pull them together which thereby becomes rigid and unified.
  • horizontal concrete beams may be constructed across the top of some or all panels. Two options are illustrated.
  • Figure 4 illustrates the top section of a vertically oriented SIP panel comprised of the interior molded expanded polystyrene 105 and exterior skins 110.
  • the panel includes a void 145 creating a form used for the purpose of pouring a horizontal concrete beam.
  • the form 145 may be 13 1 ⁇ inch deep. It is intended that the concrete be reinforced with rebar and that this rebar be tied into the rebar of adjacent vertical columns.
  • the detachable beam 125 form is clad with facings, 110 e.g., cement board, OSB, metal or MgO that project downward past the base 150 of the MEPS to create a securing mechanism for setting the beam form on a wall panel 220.
  • compression fasteners 3 are utilized to stabilize and secure the sides of the form 145 when concrete is poured as illustrated in Figure 6. Also illustrated in Figure 6 are the compression fasteners 3 extending through both layers of skin 110. Also shown is the horizontal rebar extending through the top beam 150 and the vertical rebar 155 extending through the vertical concrete column. Note that the form fits over the top of the SIP wall panel 215. This can be a method for raising the wall height as well as increasing the wall strength and wind resistance.
  • Figures 7 and 8 illustrate two examples of a structural connector plate 320, 321.
  • the plate extends across the top 215 of the SIP panel. It contains holes for tying the connector plate to the panel using at least one compression fastener 3.
  • the top of the panel also includes a cut out 316 for access to a bolt 310 extending through the horizontal roof I-beam 305 that includes a U shaped collar 311 for holding the beam to the connector.
  • Figures 9A, 9B and 9C illustrate alternate side views of the structural connector 320.
  • Figure 9C illustrates a cross section of a roof system I-beam and a U shaped collar holding the I-beam to the wall.
  • Figure 10 illustrates a structural connector plate 325 attached to the top of a horizontal concrete beam constructed as described above in conjunction with Figures 5 and 6.
  • the connecting plate is sloped or wedge shaped. Illustrated is the concrete 312 within the form 145, the MEP 105 and skin 110 creating the form and the top 215 of the SIP panel. Also illustrated is a sloped roof structure illustrated here to include an I-beam 305.
  • the structural connector is tied to the concrete bean by a bolt 311 vertically oriented within the concrete 312.
  • a U shaped collar 313 extends from the structural fastener over the I-beam.
  • the mechanism may include a flat plate bolted 310 over the I-beam.
  • Figures 12A, 12B, and 12C illustrates three views of the structural connector 325.
  • FIG 11 illustrates a flat roof system fastened over a horizontal concrete beam 312 placed on top of a SIP panel 215.
  • the form 145 comprises the MEPS 105 creating the concrete form and the outer skins 110.
  • the roof system is illustrated to include an I-beam 305 attached to the concrete beam with a bolt or similar attachment 310 embedded in the concrete.
  • Figure 13 also illustrates another embodiment of a sloped roof system attached to the top 215 of the SIP wall panel.
  • the illustrated roof system includes an I-beam 305.
  • the structural connector 326 is dimensioned to fit between the molded expanded polystyrene (MEP) 105 and the two layers of outer skin 110.
  • the structural connector includes holes for accommodating one or more compression fasteners 3 proximate to the top of the SIP wall panel.
  • the structural fastener is also sloped compatible with the roof system.
  • the I-beam can be held by a U shaped collar 313 spanning over the I-beam. It may also be held by a bolt traversing the I-beam.
  • a wedge shaped block of MEPS may be inserted into the void 331 of the sloped structural fastener.
  • Figure 14 illustrates a similar system with the structural connector 327 dimensioned to fit over the two skin layers 110.
  • Figure 15A, 15B, and 15C illustrate 3 views (front, side and back respectively) of the structural connector 326. The remaining components have been identified by the numbering sequence of Figure 13
  • Figure 16 illustrates SIP panels lapped together and used for a roofing system.
  • the lap joints are unified into a single piece using adhesive and compression fasteners.
  • Recall compression fasteners may be installed a various intervals depending upon the load factor. This load factor may be wind associated with storms.
  • the roof can be constructed for high wind resistance by the placement of compression fasteners, structural connector at the top and bottom of the walls and connected to horizontal beams and fastener connecting the wall to the concrete slab.
  • FIG 17 illustrates another detail of the lap joining method.
  • the SIP panel may be of various thicknesses. Illustrated is the compression fastener 3. The adhesive 5 is also illustrated. The offset for the lap structure is approximately 4 inches. The recommended expansion gap 130 of 1/8 inch is also illustrated.
  • Figure 18 illustrates another embodiment of a lap joint wherein a "Z" shaped component 8 is inserted between the two lapped panels 18-1 and 18-2.
  • the component may be fiberglass. This strengthens the bond between the joined panels.
  • This component 8 is also shown in Figure 24.
  • Figure 19 illustrates the preparation of the bottom 219 of the SIP wall panel and bottom plate 220 fabricated from MgO or similar water impervious material (See Figure 20). Illustrated is the molded expanded polystyrene 105 and the outer skin 110 of cement board, oriented strand board, metal or magnesium oxide.
  • the void 224 manufactured for placement of the structural connector (not shown) to be installed between the MEP and outer skin is also shown.
  • Figure 20 illustrates the SIP board bottom assembled on a concrete pad 175 and held in place with a bolt 170 embedded within the concrete.
  • the structural connector 225 is installed on top of the bottom plate 220 and held with a compression fastener 3 and adhesives 5.
  • Figure 21 is an isometric drawing of a SIP wall comprised of multiple SIP panels 11. Illustrated is the structural base connector 225 as part of the system that unifies or solidifies the multiple panels into a single structural wall. Also illustrated is the anchor bolt 170 fastened to the MgO base plate 220. Also illustrated are the multiple compression fasteners placed vertically at each lap joint. The Figure 21 shows by phantom lines the placement of vertical cement columns 141 and containing rebar. Also shown is the horizontal beam 312 also containing rebar 150. Illustrated is the MEP 105 and outer skin 110. A portion of the roof system is illustrated, particularly its connection to the wall. A threaded rod 313 is placed in the horizontal concrete beam with a hub nut 311 that holds down the roof. The structural connector is not, however, shown. See Figures 7, 8, 10, 11.
  • FIG 22 is a detail from 21 and illustrates the inter-joining lap joints of SIP wall panels.
  • Each SIP panel contains a block lap juncture or lap joint.
  • Panel 11 fits with the second panel 11 A.
  • the lap joint block 115 of each joint fits adjacent to the next adjoining panel.
  • the joint is structurally unified by a series of compression fasteners 3A, 3B, 3C. Adhesives may also be used (not shown).
  • the void 140 for the concrete form is illustrated along with the MEP 105 from which the void is formed. Also shown is a fascia board 325 with drip ledge.
  • FIG 23 is another isometric view of the SIP wall construction. Illustrated are the top structural connecting plates 320. These components can span each juncture between two SIP panels. Also illustrated are the bottom structural base connections 225 in Figures 20 and 21. These components can also span each juncture of two SIP panels. These top and bottom components, combined with the compression fasteners vertically oriented along each juncture and tying together of lap joints, the structural Z component 8 at each juncture, and further combined with adhesives at the juncture, form a structurally unified wall.
  • Figure 24 illustrates a detail of the lap juncture of two panels. Illustrated is the top structural fastening plate 320 that spans the panel juncture. The plate is held in place by two compression fasteners 3A, 3B, 3C. Also inserted between the lap blocks 115 is the Z component 8.
  • the same manufacturing techniques are used in creating the wind resistant roof system.
  • the result is a structurally unified roof system strongly connected to the wall system (optionally containing concrete columns and beams).
  • the complete structure is well adapted to area subject to earth movement and to storm prone areas where wind damage is experienced.
  • the manufacturing system also permits rapid construction of structures. Since components are factory manufacture, costs are minimized.
  • FIG 25 is an overhead view of the manufacturing equipment layout for fabricating SIP panels.
  • the process begins with in feed of mold expanded polystyrene (MEP) 426 to a gravity roller conveyor and then to an adhesive spreader 424 and water mister 423.
  • the skins are next fed 422 to the exterior of the panels to a pit mounted scissors lift with roller deck 420.
  • Included is an overhead truss vacuum lift 427.
  • Transfer carts on trolley rails 412 carry the combined panel (MEP panel with adhesive attached "skin” e.g., CB, MgO, etc.) to a press 400.
  • the area 410 in which additional presses can be added to increase production (due to the time required for the adhesive to cure under pressure of the press). With more presses, more panels can be curing simultaneously.
  • the equipment configuration forms a T-formation with the heated presses forming the top of the "T”.
  • Figure 26 provides a side view of the manufacturing layout. The same item numbers are used for the counter part equipment.
  • Figure 27 is a front view of the press unit 400 used to bond the skin to the MEPS component.
  • the press may be termed a "T-press" 406 since one vertical structure is used for two presses.
  • the press includes steel wide flange beams 401 and a base plate bolted to the slab floor 402. Included are two hold down rods 403.
  • Figure 29 illustrates the presses 400 and hold down rods.
  • the presses are operated by hydraulic cylinders 404 attached to a structural box channel 405. Other type or designed cold presses can be substituted for the "T- press" as long as they meet the standard and production requirements.
  • Figure 28 is a side view of the T-press assembly.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Joining Of Building Structures In Genera (AREA)

Abstract

La présente invention concerne un procédé de construction de structures et les structures résultantes avec la technologie SIP (panneaux structurels isolants), mais avec des composants de construction supplémentaires qui créent des bâtiments très résistants, capables de supporter des vents violents. L'invention comprend la possibilité de construire des colonnes de béton verticales et des poutres de béton horizontales dans les murs de façade joints. Cela entraîne la combinaison de la technologie des panneaux structurels isolants et de la technologie des coffrages isolants. L'invention concerne également des fixations par compression qui s'étendent à travers les deux couches du revêtement des panneaux pour donner une fixation mécanique aux revêtements de panneaux et ne se contente pas de la liaison adhésive que l'on rencontre avec la technologie SIP classique, créant ainsi un « vrai » effet de poutre caisson du panneau lui-même. Les fixations comportent de grands linteaux à chambre. Ces fixations peuvent être utilisées à la jonction de panneaux attenants. Les panneaux sont découpés pour former des joints à recouvrement et la fixation s'étend à travers les deux extensions du bloc.
PCT/US2008/001941 2007-02-17 2008-02-14 Système de construction utilisant une technologie intégrée avec des âmes en polystyrène expansé moulées Ceased WO2008100558A1 (fr)

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US90173807P 2007-02-17 2007-02-17
US60/901,738 2007-02-17

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WO2010144951A1 (fr) * 2009-06-15 2010-12-23 Stephen Tyralik Panneau mural thermique, système de construction et procédés d'utilisation et de construction associés
FR2950910A1 (fr) * 2009-10-01 2011-04-08 Const Composites Bois Panneau pour la realisation d'une construction et procede d'assemblage d'au moins deux panneaux
WO2011162708A1 (fr) * 2010-06-22 2011-12-29 Bbi Basic Board Industries Ab Élément de construction, et procédé pour fabriquer un tel élément de construction.
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