Structure and method of construction

Abstract

The core wall structure is assembled by attaching together elements made of lightweight thermally insulating material (16) and elements made of mineral plates (20) positioned at spaced-apart intervals between the elements made of lightweight thermally insulating material to serve as webs (20). Opposite edges (22) of the web (20) are exposed on outer surfaces (26, 28) of the core wall structure with recesses (24) around the opposite edges. A cementitious mortar skin layer (18) is applied to the outer surfaces (26, 28) to at least partially cover the core wall structure and the exposed edge (22) of the web (20) is at least partially embedded in the cementitious mortar.

Description

Technical Field

[0001] The present invention relates to the construction of buildings, including buildings used for human habitation as well as for other purposes, and including single-storey or multi-storey buildings. Background Art

[0002] Conventional construction techniques such as brick and mortar are often supplemented with thermal insulation. Thermal insulation is applied in addition to other functional elements of the building, such as structural walls. This increases costs, construction time, and requires additional space. Particularly in buildings with space, cost, or weight constraints, such as affordable housing or high-rise buildings, this approach of adding different functional layers can cause problems and, in some cases, hinder the economic or technical feasibility of the building.

[0003] Attempts have been made to combine structural and thermal elements, for example by providing prefabricated building modules, but construction methods developed to date have been deficient in at least one of: material cost; labor cost; structural integrity; thermal performance; durability (e.g., weather resistance); practicality (e.g., mounting an object to a wall by driving fasteners into the wall or by drilling holes in the wall); scalability using conventional tools and skills; or design freedom (e.g., rooms exceeding certain dimensions dictated by the logistical limitations of prefabricated building modules).

[0004] Horizontal spanning building elements are typically made of reinforced concrete, with the rebar located in the tension zone at the lower portion of the building element. However, while steel is stronger than concrete in tension, it is also susceptible to corrosion. To protect the reinforcing steel in horizontal spanning concrete structures from moisture and corrosion, the steel is typically spaced from the lower side of the structure, leaving the steel covered with minimal concrete coverage. The concrete beneath the rebar is not strong in tension and adds little to the strength of the structure, but significantly increases its weight and cost. Furthermore, the concrete beneath the rebar is prone to cracking under tension, shortening the lifespan of these structures.

[0005] The present invention seeks to provide a construction of a building which at least partially addresses these deficiencies. Summary of the Invention

[0006] According to one aspect of the present invention, there is provided a structure comprising:

[0007] a core wall structure comprising elements made of a lightweight thermally insulating material and a web made of a mineral board, the core wall structure having two opposing outer surfaces, and the web being positioned between the elements made of the lightweight material at spaced intervals to extend through the core wall structure, wherein opposing edges of the web are exposed on opposing outer surfaces of the core wall structure; and

[0008] a cement-based mortar skin layer extending over opposing exterior surfaces of the core-wall structure to at least partially cover opposing sides of the core-wall structure;

[0009] Therein, the exposed edges of the webs are at least partially embedded in a surface layer of cement-based mortar on opposing sides of the core-wall structure.

[0010] The word "wall" is used herein to refer to a generally thin structure having generally parallel opposing surfaces, which may be vertical (such as the interior and exterior walls of a building), but may also be horizontal (such as a roof and floor) or have any other orientation, and may be curved or straight in one or more dimensions.

[0011] The cement-based mortar skin may be reinforced around the exposed edges of the web, wherein these exposed edges are embedded in the cement-based mortar skin. Preferably, the edges of the elements made of lightweight thermal insulation material are recessed (e.g., chamfered or rounded) adjacent the exposed edges of the web to provide space for the cement-based mortar skin to be reinforced.

[0012] According to another aspect of the present invention, there is provided a construction method, the method comprising:

[0013] assembling a core-wall structure by positioning elements made of a lightweight thermally insulating material and webs made of a mineral plate, the core-wall structure having two opposing outer surfaces, and the mineral plate webs being positioned at spaced intervals between the elements made of the lightweight material to serve as connectors, the webs extending through the core-wall structure, wherein opposing edges of the webs are exposed on opposing outer surfaces of the core-wall structure;

[0014] providing recesses around exposed edges of the web at opposing outer surfaces of the core wall structure;

[0015] A surface layer of cement-based mortar is applied to opposing exterior surfaces of the core-wall structure to at least partially cover the core-wall structure, and the exposed edges of the web are at least partially embedded in the cement-based mortar.

[0016] The step of providing a recess around the exposed edge of the web may comprise recessing the edge of the element made of lightweight thermal insulation material adjacent the exposed edge of the web, for example by chamfering or rounding the edge of the lightweight thermal insulation material.

[0017] The lightweight thermal insulation material may be expanded polystyrene, the mineral board may be magnesium oxide board, and the cement-based mortar surface layer may include embedded reinforcements such as wire mesh or fibers.

[0018] The reinforcement embedded in the cementitious mortar surface layer may include an elongated tensile element, such as a steel rod or a basalt fiber reinforcement, embedded in one or both of the cementitious mortar surface layers, and the tensile element may be aligned with the web, for example, the tensile element may extend in one of the cementitious mortar surface layers adjacent to one of the embedded edges of one of the webs. The cementitious mortar surface layer may be reinforced around the tensile element.

[0019] The method may include attaching a plurality of core wall structures together before applying a surface layer of cement-based mortar to opposing exterior surfaces of the core wall structures, and may include attaching webs of adjacent core wall structures to one another. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] For a better understanding of the invention and in order to show how it may be implemented, the invention will now be described by way of non-limiting example with reference to the accompanying drawings, in which:

[0021] Figure 1 shows a three-dimensional view, partially in perspective, of a first embodiment of a structure according to the invention in the form of a dwelling;

[0022] Figure 2 shows a cross-sectional view of a portion of a second embodiment of a structure according to the invention;

[0023] Figure 3 shows a cross-sectional view of a portion of a third embodiment of a structure according to the invention; and

[0024] Figure 4 A cross-sectional view of a portion of a fourth embodiment of a structure according to the invention is shown. DETAILED DESCRIPTION

[0025] Reference Figure 1 and Figure 2 A first embodiment of a structure according to the present invention in the form of a dwelling is generally designated by reference numeral 10, and a second embodiment of a structure according to the present invention in the form of a wall is generally designated by reference numeral 12. Wall 12 can have any orientation or shape and can serve the purpose of an exterior or interior wall, whether structural or non-structural, and can be part of a roof. Dwelling 10 is constructed from a plurality of walls, such as wall 12, some of which are angled and curved to form a roof 14 of the dwelling.

[0026] Reference Figure 2In the present invention, thermal insulation material 16 is provided at the core of the wall 12, and the main structural elements of the wall are two structural skins 18 located on opposite sides of the wall - the two structural skins 18 may be, for example, the outer and inner sides of the wall. The two skins 18 are structurally connected at regular intervals by webs 20 having exposed edges 22 embedded in the skins. The term "exposed" is used in this case to refer to the fact that the opposite edges of the webs 20 are exposed from the thermal insulation material 16, and the term "exposed" does not necessarily mean that the edges protrude beyond the outer surface of the thermal insulation material. In fact, in some cases, the edges of the webs 20 are exposed from the adjacent thermal insulation material 16 within a recess formed along the edge of the thermal insulation material, but the edges of the webs are set back relative to the outer surface of the thermal insulation material. (This is in Figure 3 This is clearly shown in the .)

[0027] The thermal insulation material 16 may be any suitable lightweight thermal insulation material, and one highly suitable and cost-effective example is expanded polystyrene (EPS).

[0028] The structural surface layer 18 is made of a cement-based high-strength mortar that is preferably reinforced with mesh or fibers and the mortar may be applied in multiple layers.

[0029] The web 20 is made of a mineral plate having suitable mechanical properties that are preferably similar to those of the skin 18, and one example of a highly suitable and cost-effective mineral plate is a magnesium oxide (MgO) plate.

[0030] The connection between the exposed edge 22 of the web 20 and the structural skin 18 is preferably strengthened by a localized thickening of the structural skin around the exposed edge. This is preferably achieved by a diagonal bevel 24 along the edge of the EPS 16 adjacent to the web 20. The diagonal bevel 24 is simple and cost-effective to form or cut (in a process described below), but in other embodiments, the shape of the thickening of the structural skin 18 around the exposed edge 22 can take a different form—for example, the thickening can be rounded or can take the form of a rectangular recess.

[0031] Wall 12 derives its structural strength primarily from skin 18 and web 20. Web 20 transfers loads (including compression, tension, bending, and / or shear loads) between the structural skins. In addition to transferring loads between skins 18, web 20 also increases the bending strength of wall 12 by increasing the space between the skins, similar to how the web of an I-beam increases the beam's section moment of inertia.

[0032] When constructing the dwelling 10 or any other structure according to the invention, the core wall structure or core panels are first assembled from elements in the form of EPS 16 blocks and elements in the form of strips of MgO sheet for forming the webs 20 .

[0033] The EPS 16 is typically cut from blocks using a hot wire CNC cutter, and the webs 20 are typically cut from MgO sheets using a router CNC cutter. The EPS elements 16 and MgO webs 20 are then assembled into a core-wall structure in the form of wall and roof panels of varying sizes. The EPS elements 16 and webs 20 are preferably attached together using a suitable adhesive, such as polyurethane foam, but other attachment methods may be used instead. In order to best fulfil the structural function of the webs 20, each of the webs 20 extends continuously through the core panels. The cutting and assembly of the core panels can be carried out off-site, for example in a factory or warehouse that does not need to be close to the construction site - or can be carried out on-site where preferred.

[0034] Once assembled, each panel of the core wall structure has two opposing exterior surfaces, and for purposes of illustration these surfaces are identified as top surface 26 and bottom surface 28, as shown. Figure 2 shown.

[0035] The webs 20 are spaced apart at intervals along the panel between the blocks of the EPS 16, and each web extends through the panel so that opposite edges 22 of each web are exposed from the EPS 16 on opposite exterior surfaces 26, 28. The spacing and orientation of the webs 20 may vary from panel to panel and is dictated by structural requirements and manufacturing constraints to provide appropriate load transfer for the structural strength required for a particular wall 12.

[0036] A recess is provided around the exposed edge 22 of the web 20, and in the illustrated embodiment this is achieved by recessing the edge of the EPS 16 block adjacent to the exposed edge with a diagonal bevel 24, but in other embodiments the edges of the EPS block may be rounded or may be rectangular recesses and / or the exposed edge 22 may protrude beyond the outer surfaces 26, 28.

[0037] Once the core wall panels have been assembled, they are transported to the site and erected to form the thermal core of the wall 12, with the webs 20 preferably oriented to follow the direction of load transfer. The webs 20 of adjacent panels are preferably aligned and can be connected together to achieve load transfer between them. For example, the webs of adjacent core panels can be connected by tongue and groove joints, but can also be attached by steel straps or the like. In some embodiments of the present invention, the webs 20 of adjacent core panels can be attached together, for example, using clamps or rods. At this stage, the erected structure is preferably temporarily supported (for example, with brackets, straps, and struts) to maintain the panels in their precise position during the application of the structural skin 18. The panels can be connected using adhesives such as polyurethane foam, fasteners, interlocking connections (such as tongue and groove joints), etc. to provide additional stability in high strain areas, such as the panels of the roof 14.

[0038] Once the core wall panels are in place, the structural skin 18 is applied in layers to the outer surfaces 26, 28 of the panels, typically working from the top of the structure downwards and from the outside of the structure inwards. The structural skin 18 can be applied by hand or spray application with both the hot core forming substrate and the lost shutter.

[0039] The webs 20 provide structural strength to the core panels while they are erected and assembled, so that the required support and bracing is primarily to ensure accurate positioning of the core panels. Furthermore, the webs 20 provide sufficient structural strength to the core panels so that they can bear the weight of the structural skin 18 while it is being applied—even for non-vertical walls such as roofs—thus avoiding the need for extensive temporary load-bearing structures such as scaffolding, shoring, and the like.

[0040] When the structural skin 18 is applied, it covers the outer surfaces 26, 28, but also covers and embeds the exposed edge 22 of the web. The connection between the exposed edge 22 and the skin 18 is strengthened by the local thickening of the skin adjacent the exposed edge, and the bevel 24 provides a space for the cement-based mortar of the skin to fill and forms a reinforcement of the skin around the exposed edge.

[0041] Reference Figure 3 A third embodiment of a structure according to the invention in the form of a wall is generally designated by reference numeral 13. The wall 13 is Figure 2 The walls 12 shown have much in common including EPS thermal insulation elements 16, a structural skin 18 made of a cement-based high strength mortar, a web 20 made of a mineral board such as magnesium oxide (MgO) board with the exposed edge 22 of the web embedded in the structural skin.

[0042] Web 20 embedded Figure 3The top surface 26 of the wall 13 is applied with a structural skin 18 in a manner similar to that embedded in the Figure 2 The top surface 26 of the wall 12 is applied in the same manner as the structural skin 18, but the web is embedded in the structural skin applied on the bottom surface 28 in a different manner. Figure 2 The method shown.

[0043] Figure 3 Two embodiments of recesses are shown formed along the bottom corners of the EPS element 16. These embodiments of recesses would not necessarily be used in combination in practice (although they could be used in combination), but are shown in a single figure for simplicity.

[0044] Figure 3 The recess 30 shown on the left is triangular and is Figure 3 The cut shown is deeper in the EPS element 16, and Figure 3 The recess 24 shown on the right is identical to the recess at the top of the web 20. In both recesses 30, 24, the exposed edge 22 of the web 20 protrudes beyond the EPS element 16 on either side of the EPS element 16, but the exposed edge 22 of the web 20 on either side of the EPS element 16 is not exposed. Figure 3 The exposed edge on the left side is recessed relative to the entire core panel. As a result, the recess 30 is smaller than Figure 2 The recess 24 shown is larger and has tensile elements such as reinforcing rods 34 embedded in the substructure skin 18. The reinforcing rods 34 may be made of steel, basalt fiber, high molecular weight polyethylene, carbon, or other alkali resistant material with high tensile strength.

[0045] The reinforcing rods 34 are positioned and each aligned with one of the webs 20 prior to application of the structural skin 18. Figure 3 In the example of the web 20 and stiffener 34 shown on the left, the stiffener is immediately adjacent to the exposed edge 22 of the web. Figure 3 In the example of the web 20 and stiffener 34 shown on the right, the stiffener is in contact with the exposed edge 22 of the web.

[0046] Once the structural skin 18 is applied, both the stiffeners 34 and the exposed edges 22 of the webs 20 are embedded in the thickened portions of the skin 18 formed in the recesses 30, 24, so that both the stiffeners and the webs can increase the strength of the structure 13 by transferring loads to and from the skin 18. The structural function of the webs 20 has been described above, and this function, in conjunction with the tensile load-bearing ability of the stiffeners 34, provides the structure 13 with significant bending strength while being lightweight, allowing it to be used in large structures such as floors or roofs, with far fewer supports, such as columns, than are required with current building methods.

[0047] Reference Figure 4 A fourth embodiment of a structure according to the invention in the form of a wall is generally designated by reference numeral 15. The wall 15 is Figure 3 The walls 13 shown have many features in common, including EPS thermal insulation elements 16, a structural skin 18 made of cement-based high-strength mortar, a web 20 made of mineral board, exposed edges 22 of the web, and reinforcing rods 34 embedded in the structural skin.

[0048] The web 20 and the reinforcing rod 34 are embedded Figure 4 The structure of the wall 15 in the surface layer 18 is embedded in the manner Figure 3 The structure of the wall 13 is very similar to that of the skin 18, but the reinforcing rods 34 are made of basalt steel, but can also be made of fiberglass rebar or other non-corrosive high tensile material.

[0049] like Figure 4 As shown, when the wall 15 is in a horizontal orientation, basalt reinforcement rods 34 are located below the lower edge 22 of the web 20 and in a tension zone below the neutral axis 36 of the wall. The reinforcement rods 34 are covered on their undersides with the cementitious material of the structural skin 18 on the underside of the wall 15. However, because the reinforcement rods are made of basalt, they do not need to be embedded as deeply in the cementitious material as steel reinforcement to protect the reinforcement from moisture. In the preferred embodiment shown, the bottom edges of the reinforcement rods 34 are aligned with the bottom surface of the thermal insulation element 16 on a common axis 38.

[0050] The wall 15 may be used in any orientation, but is particularly advantageous when used in a horizontal or partially horizontal orientation, such as for roofs, interior floors, foundations, or connections between building elements requiring high tensile strength.

[0051] Wall 15 overall reference Figure 1 and Figure 2 The construction is carried out as described above. Basalt reinforcement bars 34 are placed in the tension zone at the edges 22 of the web 20 after the panels have been erected, either at the factory or on site. If the wall 15 is used in a horizontal manner, temporary support for the bars 34 is required while a cement-based mortar is applied to form the bottom skin 18. The mortar is preferably applied in two coats: on the side of the panel with the greatest tensile design strength, i.e. Figure 4 On the lower side shown, a first base coating layer of cement-based mortar of about 2 mm to 5 mm thickness is applied. On the opposite side of the panel (top, as shown Figure 4 A second base coating layer of about 2 mm to 5 mm thickness is applied on the side of the panel with lower tensile design strength (top, as shown). Figure 4Thereafter, the temporary support is removed and the side with greater tensile design strength (bottom, as shown) is covered with a first main coating of cement-based material. Figure 4 The cementitious material is allowed to fully cure before applying the second primary coating layer on the surface of the cementitious material (as shown).

[0052] The wall 15 could also be constructed using rebar, but then more surface layer 18 of cement-based material would be required to cover the rebar, and this would result in greater weight and reduced span width.

Claims

1. A structure comprising: a core wall structure comprising elements made of a lightweight thermally insulating material and a web made of a mineral board, the core wall structure having two opposing outer surfaces, and the web being positioned at spaced intervals between the elements made of the lightweight material to extend through the core wall structure, wherein opposing edges of the web are exposed on the opposing outer surfaces of the core wall structure; and a cement-based mortar skin layer extending over the opposing outer surfaces of the core wall structure to at least partially cover opposing sides of the core wall structure; Wherein, the exposed edges of the web are at least partially embedded in the cement-based mortar surface layer on the opposite sides of the core wall structure.

2. The structure according to claim 1, wherein The cement-based mortar skin is reinforced around the exposed edge of the web, wherein the exposed edge is embedded in the cement-based mortar skin.

3. The structure according to claim 2, wherein: The edges of the element made of lightweight thermal insulation material are recessed adjacent the exposed edge of the web to provide space for reinforcement of the cement-based mortar surface layer.

4. The structure of claim 1 , comprising reinforcement members embedded in the cement-based mortar surface layer.

5. The structure of claim 4, comprising fiber reinforcement embedded in the cement-based mortar surface layer.

6. The structure of claim 4 including an elongated tensile element embedded in at least one of the cementitious mortar skins, the tensile element being aligned with the web.

7. The structure according to claim 6, wherein At least some of the tensile elements extend within one of the cement-based mortar skin layers proximate to one of the embedded edges of one of the webs.

8. The structure according to claim 6, wherein The cement-based mortar surface layer is reinforced around the tensile elements.

9. The structure according to claim 6, wherein The tensile elements are made of basalt.

10. The structure according to claim 1, wherein The lightweight thermal insulation material is expanded polystyrene.

11. The structure according to claim 1, wherein The mineral board is a magnesium oxide board.

12. A construction method comprising: assembling a core wall structure by attaching together elements made of a lightweight thermally insulating material and elements made of a mineral plate, the core wall structure having two opposing outer surfaces, and the elements made of the mineral plate being positioned at spaced intervals between the elements made of the lightweight material to serve as webs, the webs extending through the core wall structure, wherein opposing edges of the webs are exposed on the opposing outer surfaces of the core wall structure; providing recesses around exposed edges of the web at the opposing outer surfaces of the core wall structure; A surface layer of cement-based mortar is applied to the opposing exterior surfaces of the core wall structure to at least partially cover the core wall structure, and the exposed edges of the web are at least partially embedded in the cement-based mortar.

13. The method of claim 12, comprising reinforcing at least one of the cement-based mortar surfaces.

14. The method of claim 13 , comprising providing an elongated tensile element adjacent one of the opposing outer surfaces of the core-wall structure, the tensile element being aligned with the web, and embedding the elongated tensile element in a surface layer of the cement-based mortar when the cement-based mortar is applied to the outer surface of the core-wall structure.

15. The method of claim 14, comprising positioning at least some of the tensile elements to extend proximate one of the embedded edges of one of the webs prior to applying the cement-based mortar to the outer surface of the core wall structure.

16. The method according to claim 14, wherein The tensile elements are made of basalt.

17. The method according to claim 12, wherein: The step of providing a recess around the exposed edge of the web comprises recessing an edge of the element of lightweight thermally insulating material adjacent the exposed edge of the web.

18. The method according to claim 12, wherein: The lightweight thermal insulation material is expanded polystyrene.

19. The method according to claim 12, wherein: The mineral board is a magnesium oxide board.

20. The method of claim 12, comprising attaching a plurality of the core wall structures together before applying the cement-based mortar skins to the opposing exterior surfaces of the core wall structures.

21. A method according to claim 20, comprising attaching the webs of adjacent core wall structures to each other.

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