A building construction method and device

Abstract

A method of constructing a portion of a building includes building a wall using bricks or panels 12 and locating a lintel 20 on top of the wall. The lintel 20 is formed from an elongate sheet of meta

Description

The present invention relates to a method of constructing a portion of a building and to a device therefor. It relates particularly, but not exclusively, to a method of panel construction a building having more than one floor. The speed at which buildings can be constructed and the number of skilled tradespeople needed is an important aspect of the cost of construction and therefore reducing the time and number of people required is important in reducing construction costs particularly for affordable housing. Similarly, the cost of construction of commercial and industrial buildings is sensitive due to the size of the building and are particularly suited to construction from panels. An example of the panels used in such construction is disclosed in UK Patent Application published under then number GB2280916. The use of these panels enables rapid construction of walls compared to using traditional bricks and blocks. However, managing the junctions between vertically and horizontally adjacent panels remains a time consuming aspect of the construction process. Preferred embodiments of the present invention seek to overcome or alleviate the above described disadvantages of the prior art. According to an aspect of the present invention there is provided a method of constructing a portion of a building including a wall and a floor attached to the wall, comprising: building a wall using bricks or panels; locating a lintel on top of the wall, the lintel formed from an elongate sheet of metal bent with at least three bends substantially parallel to a long edge of the sheet thereby forming at least four faces including, a first face orthogonal to a first vertical surface of the wall, a second face for engaging an upper portion of the first vertical surface, a third face for engaging an upper surface of the wall, and a fourth face for engaging an upper portion of a second vertical surface of the wall; fixing the lintel to the wall; and locating floor joists on the first face and fixing thereto. By locating a lintel, of the type described above, on top of a wall, the advantage is provided that the lintel can be used to support the joists of a floor. Furthermore, the lintel helps to keep the structure of the wall rigid, particularly where panels are used, and ensures that there are multiple locations for joists to be attached. In a preferred example of the method the lintel includes a fifth face formed therein, the fifth face extending from a lower edge of the fourth face orthogonal to the second vertical surface of the wall. By including the fifth face, the lintel can support joists on both sides of a wall allowing the structural or loadbearing panels to be used as internal as well as external walls. In another preferred example of the method the second and forth surfaces are substantially the same size. In an additional preferred example of the method adjacent faces are orthogonal to each other. In a further preferred example of the method the wall comprises panels including opposing Magnesium oxide or Cement Particle boards having a thermally insulating material and a structural stud therebetween. The use of these panels in combination with the lintels described above allows for very rapid construction of buildings on site. The method may further comprise installing a U-shaped floor channel comprising an elongate sheet of metal having two orthogonal bends formed therein parallel to a long edge and locating the panels in the channel. The use of the channel on the floor ensures that the layout of the walls of the building can be set before the panels are introduced and it ensures that, once in position, the panels do not move. In a preferred example of the method the installing of the channel comprises fixing the channel to the floor. In another preferred example of the method a length of a lintel is more than two but less than three times a horizontal width of a panel. By having the length of the lintels more than two but less than three times a horizontal width of a panel then gaps between lintels can be easily arranged so that the junctions between the lintels never coincide with the junctions between the panels. According to another aspect of the present invention there is provided a lintel for use on top of a wall forming part of a building, the lintel comprising an elongate sheet of metal bent with at least three bends substantially parallel to a long edge of the sheet thereby forming at least four faces, the faces comprising: a first face orthogonal to a first vertical surface of the wall, a second face for engaging an upper portion of the first vertical surface, a third face for engaging an upper surface of the wall, and a fourth face for engaging an upper portion of a second vertical surface of the wall. The lintel may further comprise a fifth face extending from a lower edge of the fourth face orthogonal to the second vertical surface of the wall. In a preferred embodiment the second and forth surfaces are substantially the same size. In another preferred embodiment the adjacent faces are orthogonal to each other. According to a further aspect of the present invention there is provided a panel for use in the construction of an internal wall of a building, the panel comprising: a frame having upper and lower elongate metal horizontal frame sections and a plurality of elongate metal vertical frame sections joining the horizontal frame sections; a pair of magnesium oxide or cement particle boards fixed on opposing sides of the frame; and acoustic fibre between the sheets. The panel may further comprise at least one pin extending from a first vertical edge of the panel and at least one respective tube located in an opposing vertical edge of the panel in use for receiving a pin of an adjacent board. The panel may preferably further comprise a metal channel attached to an inner surface of one of the sheets and at least one pipe contained within the channel. In a preferred embodiment the upper and lower elongate metal horizontal frame sections have a substantially U-shaped cross-section. In another preferred embodiment the elongate metal vertical frame sections have a substantially C-shaped cross-section. According to another aspect of the present invention there is provided a method of constructing internal walls within a building comprising: forming a frame by connecting an upper and a lower elongate metal horizontal frame section to a plurality of elongate metal vertical frame sections; attaching a pair of magnesium oxide or cement particle boards on opposing sides of the frame; and locating acoustic fibre between the sheets. According to a further aspect of the present invention there is provided a building comprising: a plurality of walls including, a plurality of panels according to any of claims 14 to 18; a plurality of lintels according to any of claims 10 to 13, wherein at least one said lintel is joined to an upper edge of a plurality of said panels; and a plurality of joists connected to first surfaces of said lintels . The building may further comprise at least one floor comprising panels as set out above. The building may also further comprise at least one roof comprising panels as set out above. Preferred embodiments of the present invention will now be described, by way of example only, and not in any limitative sense with reference to the accompanying drawings in which:- Figure 1 is a perspective view of a portion of a building being constructed according to the method of the present invention; Figure 2 is a perspective view of a lintel of the present invention; Figure 3 is a plan view of a template used in the construction of the lintel of figure 2; Figure 4 is a perspective view, an end view and a side view of a channel used in the construction method illustrated in Figure 1; Figure 5 is a front, side and plan view of a panel used in the construction method illustrated in Figure 1; Figure 6 is a perspective view of a portion of A-frame used in the panel of figure 5; Figure 7 is a perspective view of an alternative lintel to that shown in figure 2; Figure 8 is a perspective view of a panel for an internal wall used in the construction of a building; and Figure 9 is a perspective view of an alternative panel to that illustrated in figure 8. Referring initially to figures 1 to 3, a portion 10 of a building is shown in figure 1. The building, not shown in full, is a domestic or commercial building and is not particularly limited in size. The portion 10 of the building is a wall which is formed from a series of panels 12 which are located next to each other with the long edges of the panels engaging an adjacent panel. The panels 12 sit with their bottom edges in a channel 14 which is formed from sheet metal and fixed to a floor surface 16. One of the panels has a window 18 formed therein. A series of lintels 18 run along an upper edge of the panels spanning more than one of the panels. The lintel is shown in more detail in figures 2 and 3 and is formed from an elongate sheet 22 of metal. Typically, the metal is steel but any suitable metal can be used that can provide the structural rigidity described below. The sheet used is ideally 3m long and 571mm wide. The image in figure 3 is a template which shows how the lintel 20 is formed from the sheet 22. Three folds 24, 26 and 28 are formed in the sheet 22. The first fold 24, is parallel to one long edge 30 and is 60mm from that edge thereby creating a first face 32. The second fold 26 is parallel to and ideally 304mm from the first fold 24 thereby defining a second face 34. The third fold 28 is parallel to and ideally 107mm from the second fold 26 thereby defining a third face 36. Between the third fold 28 and a second long edge 38 is a fourth face 40. Each of the first to fourth faces extend orthogonally from the adjacent face meaning that each of the folds is a right angle. The second face 34 has a series of holes 42 in it for fixing the lintel 20 to the panel 12. In this example, vertically arranged series of three 7mm diameter holes arranged in rows with 60mm between each hole and the rows are separated by 200mm. This multiplicity of holes 42 allows screws (not shown) to be fixed through the lintels 20 into the panels 12 at any convenient location. Turning to figure 4, the channel 14, like the lintel 12, is formed from a sheet of metal with just two folds 44 and 46 which are both ideally 80mm from the respective edges 48 and 50 of the sheet that forms the channel thereby forming a pair of side faces 52 and 54. The folds are right-angular and therefore define a bottom face 56 onto which the panel 12 sits. A series of holes 58 are positioned 200mm apart on the side faces 52 and 54. A further hole 60 positioned in line with the holes 58 is in the bottom face 56 and is used to fix the channel 14 to the floor 16. The panel 12 is shown in more detail in figure 5. The panel formed from pair of fire resistant magnesium oxide or cement particle boards 62 and 64 with a thermally insulating material 66 sandwiched between. The boards are held in place by a pair of galvanised steel reinforcing steel elements 68 which have a 2 (sigma) shaped cross-section shown in figure 6. Ideally the thermally insulating material 66 is a CFG free polyurethane foam material which is injected between the boards 62 and 64 during manufacture of the panels 12. Respective male and female connectors 70 and 72 are provided on the long edges 74 and 76 of the panels 12 to connect the panels together. Turning to figure 7, an alternative version of the lintel 20 is shown and labelled 20a. This lintel is for use on internal structural walls which have joists extending from both sides of the wall. The lintel 20a has the same three folds 24, 26 and 28 creating the three faces 32, 34 and 36. However, the fourth face 40a is longer and does not terminate in the second long edge. Instead, a fourth bend 80 defines the end of the fourth face 40a which is much longer than 40 and matches the second face 34. Between the fourth bend 80 and the second long edge 38a is a fifth face 82 which can support a joist in the same way that the first face 32 can. The process of constructing a portion 10 of a building using the panels and lintels set out above, will now be described. The wall being built is supported on a foundation to which the channel 14 is attached. The channels are laid out in the shape of the structural, joist supporting, walls that are required and are fixed to that foundation surface by drilling holes into the foundation and using suitable fixings such as bolts or screws. Panels 12 are then placed into the channel 14 and the first panel that is erected is supported by a supporting rod, known as a prop, 84. The panels 12 have mutually engaging recesses and protrusions formed into the long edges 74 and 76 which help to maintain the engagement of the panels. Once a few panels (most typically three) have been erected into the channel 14 a lintel 20 is placed over the upper edges of these panels. The length of the lintels 20 and widths of the panels 12 are such that the junctions between adjacent lintels and panels are not aligned. Where a doorway is required in the wall, a panel can simply be not included leaving a gap over which the lintel 20 extends. If the doorway is not as high as the bottom of the lintel 20 than a small section of non-structural infill can be included to bring the wall down to the height of the door. Once the construction of a wall has been completed and all of the lintels 20 are in place, the joists 86 can be attached to the lintels 20. This is achieved by engaging the end surface of a joist 86 with the second face 34 of the lintel 20 and as a result a portion of the bottom surface of the joist engages the first face 32 of the lintel 20. The joists 86 are attached to the lintel 20 using an L-shaped bracket (not shown) which attaches to the second 34 and / or fourth face 40a of the lintel and to a vertical face of the joist. The bracket is screwed to the joist and through the lintel into the panel 12 to secure. Although this is the ideal form of attachment, other fixing methods could be used including, but not limited to, screwing through the first 32 and / or fifth 82 faces of the lintel straight into the bottom face of the lintel 20. Once the joists are connecting the lintels, and therefore panels, together the structure is self-supporting and the props 84 can be removed. Turning to figure 8, a panel 100 for use on internal, and therefore typically non-loadbearing, walls of a building will now be described. The panel 100 has an internal frame formed from upper and lower elongate metal horizontal frame sections 102 and 104. These frame sections are connected together by a pair of elongate metal vertical frame sections 106 and 108 joining the horizontal frame sections 102 and 104. There could be more vertical frame sections but two is generally enough to create a stable frame structure. The vertical frame sections 106 and 108 and located inward of the ends of the horizontal frame sections 102 and 104. The horizontal frame sections 102 and 104 have a squared substantially U-shaped cross-section meaning that there is a base and two sides extending perpendicular to the base. On the bottom of the panel the base forms the bottom surface of the panel and the two side extend vertically upwards from the base. On the top of the panel the base forms the top surface of the panel and the two side extend vertically downward from the base. The vertical frame sections 106 and 108 have a squared substantially C-shaped cross-section meaning that there is a base and two sides extending perpendicular to the base as well as two short flanges extending inwards from the ends of the two sides. In the embodiment shown in figure 8 it can be seen the two vertical frame sections 106 and 108 are oriented in the same direction. Which direction or whether they are in the same direction is not significant to the function of the frame. The two vertical frame sections 106 and 108 sit inside the two horizontal frame sections 102 and 104. A pair of fire resistant magnesium oxide or cement particle boards 110 and 112 are attached to either side of the frame 102, 104, 106 and 108. Between the boards a fire resistant or noncombustible acoustic insulating material is provided. The long edges of the panels 100 are provided with two pairs of pin and socket connectors 114 and 116. The pin 114 is in the form of a short metal rod 118 which extends from one long edge of the panel 100 and is supported by a mounting plate 120. In use the rod 118 extends into a tube 122 which is recessed into the opposing long edge of the panel. In use, when pairs of panels are brought together, the rod 118 extends into the tube 122 and prevents the long edges from sliding over each other . A channel 124 is formed in the middle of one of the large surfaces of the panel 100 behind the board 110. The channel is formed as an elongate recess in the insulating material and extends from the top to the bottom parallel with the vertical frame sections 106 and 108. The channel is defined by a metal strip which is shaped to create a recess with a trapezium shaped cross-section. This is achieved with a first face which is fixed (adhered) to an internal face of the board 110, a second face which extends at an angle of approximately 30° to the first face and the board. A third face extends from the second face parallel to the board surface. A fourth face extends from the third face back towards the board and the fifth face engages and is fixed (adhered) to the board surface. The space defined by the second to fourth faces and the board is an opening that receives a pipe through which cables are fed. Apertures are cut into the horizontal frame sections 102 and 104 to approximately match the cross-section of the channel 124 to allow cables to pass therethrough. This is achieved by predrilling suitable holes (not shown) into the third face 136 (top) of the lintel. The position of the holes is determined as part of the design process and the holes are preferably formed before delivery for onsite construction. Referring to figure 9, in which parts in common with figure 8 have been labelled with like reference numerals increased by 100, a panel 200 has a frame formed with horizontal frame sections 202 and 204. However, in addition to the vertical frame sections 206 and 208, there are two further vertical frame sections 226 and 228 which are located at the ends of the horizontal frame sections 202 and 204. Indicated schematically at 230 are a pair of male striker (cam) locks which cooperated with corresponding female strikers 232. The male and female strikers are in the long edges of the panel and therefore attached to the outermost vertical frame sections 226 and 228. The cable channel 224 is also provided. It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the protection which is defined by the appended claims. In particular, where various embodiments and aspects of the invention have been described above, features and steps of the apparatus and method are interchangeable between the embodiments and aspects of the invention. For example, where dimensions are indicated in the examples set out above these are examples of ideal measurements but should not be taken as being indicative of being essential to the performance of the invention. The panels 12, 100 and 200 have been described as being used in the construction of the walls, particularly internal walls, of the building. However, the same, or substantially the same, panels can be used as the floor and / or ceiling between adjacent floors of the building. Joists are added between the lintels and panels to create a floor surface. By using the panels less joists are required and the width of the panels adds rigidity to the structure. Furthermore, the panels also can be used as roofing panels or external wall panels. In both cases the panels can be used as manufactured or covered or coated. For roofing panels, a lightweight tile or other cladding can be applied to give an external appearance in common with traditional roofing materials. Panels used as external walls can be clad with a brick slip cladding or other materials used for external cladding or recreating a traditional external building surface. For both external walls and roofs, the panels can be simply painted with a protective and aesthetic coating. The example set out above primarily uses panels 12 in the construction of the wall. However, the lintels 20 can be used in conjunction with any structural wall which is capable of supporting the weight of a joist, such walls being constructed from materials including, but not limited to, brick and block work.

Images