Structure and construction method

Abstract

The core wall structure is assembled by attaching together lightweight insulation material elements 16 with mineral board elements 20 spaced therebetween to act as webs 20. Two opposing edges 22 of web 20 are exposed at outer faces 26, 28 of the core wall structure, with recesses 24 thereabout. A cement-based stucco skin 18 is applied to outer faces 26, 28 to at least partially cover the core wall structure and at least partially embed the exposed edges 22 of web 20 within the cement-based stucco.

Description

[Technical Field]

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

[0002] Traditional building techniques, such as brick and mortar, are often supplemented with insulation. The insulation is applied in addition to other functional elements of the building, such as structural walls. This increases cost, 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 layers of different functionality can be problematic and, in some cases, prevents the building from being economically or technically feasible.

[0003] Attempts have been made to combine structural and thermal elements, for example, by providing pre-manufactured 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., being weatherproof), practicality (e.g., attaching an object to a wall by fasteners driven into the wall or by drilling holes in the wall), scalability with conventional tools and skills, or design freedom (e.g., rooms that exceed certain dimensions dictated by the logistical constraints of the pre-manufactured building module).

[0004] Horizontally spanning building elements are often constructed from steel-reinforced concrete, with steel reinforcement present in the tension zones below the building elements. However, while steel is stronger in tension than concrete, it is also more susceptible to corrosion. To protect the reinforcing steel from moisture and corrosion in horizontally spanning concrete structures, the steel is typically spaced from the underside of the structure, resulting in the steel being covered by a minimal concrete covering on the underside of the structure. The concrete below the steel reinforcement is not strong in tension and adds little to the strength of the structure, but significantly to its weight and cost. Furthermore, the concrete below the steel reinforcement is prone to cracking under tension, which shortens the lifespan of the structure. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention seeks to provide a building construction that at least partially addresses these shortcomings. [Means for solving the problem]

[0006] According to one aspect of the present invention, a structure is provided, comprising: a core wall structure comprising lightweight insulation material elements and mineral board web elements, the core wall structure having two opposite outer surfaces, the webs spaced apart between the lightweight material elements so as to extend across the core wall structure, and two opposite edges of the webs exposed at the opposite outer surfaces of the core wall structure; a cement-based stucco skin extending over two opposing outer surfaces of the core wall structure so as to at least partially cover two opposing sides of the core wall structure; Equipped with The exposed edges of the web are at least partially embedded in a cement-based stucco skin on two opposite sides of the core wall structure.

[0007] As used herein, the term "wall" is used to refer to a generally thin-walled structure having two generally parallel, opposite faces, which may be upright (such as the interior and exterior walls of a building), horizontal (such as the roof and floor), or of any other orientation, and which may be curved or straight in one or more dimensions.

[0008] The cement-based stucco skin can be reinforced around the exposed edges of the webs, which are embedded in the cement-based stucco skin. Preferably, the edges of the lightweight insulation material elements are recessed (e.g., chamfered or rounded) adjacent the exposed edges of the webs to provide space for the reinforcement of the cement-based stucco skin.

[0009] According to another aspect of the present invention there is provided a method of construction, said method comprising: assembling a core wall structure by arranging lightweight insulation material elements and mineral board webs, said core wall structure having two opposite outer faces, said mineral board webs spaced apart between the lightweight material elements to act as connectors, said webs extending across the core wall structure with two opposite edges of the web exposed at the two opposite outer faces of the core wall structure; providing recesses around exposed edges of the web on two opposite outer faces of the core wall structure; applying a cement-based stucco skin to two opposing exterior surfaces of the core wall structure so as to at least partially cover the core wall structure and at least partially embed the exposed edges of the webs in the cement-based stucco; Equipped with.

[0010] Providing a recess around the exposed edge of the web may comprise recessing an edge of the lightweight insulating material element adjacent to the exposed edge of the web, for example, by chamfering or rounding the edge of the lightweight insulating material.

[0011] The lightweight insulating material may be expanded polystyrene, the mineral board may be magnesium oxide board, and the cement-based stucco skin may include embedded reinforcement such as wire mesh or fiber.

[0012] The reinforcement embedded in the cement-based stucco skins can include elongated tension elements, such as steel rods or basalt fiber reinforcement, embedded in one or both of the cement-based stucco skins, and the tension elements can be aligned with the webs, e.g., the tension elements can extend into one of the cement-based stucco skins in close proximity to one of the embedded edges of one of the webs. The cement-based stucco skins can be reinforced around the tension elements.

[0013] The method may include attaching a plurality of core wall structures together and may include attaching webs of adjacent core wall structures to each other prior to applying a cement-based stucco skin to two opposing exterior faces of the core wall structures.

[0014] For a better understanding of the invention and to show how it may be carried into effect, the invention will now be described by way of non-limiting example with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a partially transparent three-dimensional view of a first embodiment of a structure in the form of a house according to the invention; [Figure 2] FIG. 4 is a cross-sectional view of a portion of a second embodiment of a structure according to the invention. [Figure 3] FIG. 10 is a cross-sectional view of a portion of a third embodiment of a structure according to the invention. [Figure 4] FIG. 10 is a cross-sectional view of a portion of a fourth embodiment of a structure according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0016] 1 and 2, a first embodiment of a structure in the form of a house according to the present invention is generally identified by the reference character 10, and a second embodiment of a structure in the form of a wall according to the present invention is generally identified by the reference character 12. Wall 12 may have any orientation or shape and may serve the purpose of an exterior or interior wall of a structural or non-structural nature, or may be part of a roof. House 10 is constructed from a plurality of walls, such as wall 12, some of which are angled or curved to form roof 14 of the house.

[0017] Referring to FIG. 2, in the present invention, insulation material 16 is provided in the core of a wall 12, and the primary structural elements of the wall are two structural skins 18 on two opposite sides of the wall, which may be, for example, the exterior and interior 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. In this context, the term "exposed" refers to the fact that the two opposite edges of the webs 20 are exposed from the insulation material 16, but does not necessarily mean that the edges protrude beyond the exterior surface of the insulation material. Indeed, in some cases, the edges of the webs 20 are exposed from the adjacent insulation material 16 within recesses formed along the edges of the insulation, but the edges of the webs are recessed from the exterior surface of the insulation material (this is particularly clearly illustrated in FIG. 3).

[0018] The insulating material 16 may be any suitable lightweight insulating material, one very suitable and cost effective example being expanded polystyrene (EPS).

[0019] The structural skin 18 is preferably made of a cement-based high-strength stucco reinforced with mesh or fiber, which may be applied in multiple layers.

[0020] The web 20 is preferably made of a mineral board having suitable mechanical properties similar to those of the skin 18; one example of a very suitable and cost-effective mineral board is magnesium oxide (MgO) board.

[0021] The connection between the exposed edge 22 of the web 20 and the structural skin 18 is preferably strengthened by locally thickening the structural skin around the exposed edge. This is preferably accomplished by a beveled chamfer 24 along the edge of the EPS 16 adjacent to the web 20. While the beveled chamfer 24 is easy and cost-effective to form or cut (in a process described below), in other embodiments, the shape of the thickened portion of the structural skin 18 around the exposed edge 22 may take a different form, such as being rounded or in the form of a rectangular recess.

[0022] Wall 12 derives its structural strength primarily from skins 18 and webs 20, which transfer loads (such as compression, tension, bending, and / or shear loads) between the structural skins. In addition to transferring loads between skins 18, webs 20 also increase the bending strength of wall 12 by increasing the spacing between skins, similar to the webs in an I-beam, which increase the beam's moment of inertia.

[0023] When a home 10 or any other structure is constructed in accordance with the present invention, a core wall structure or panel is first assembled from elements in the form of blocks of EPS 16 and strips of MgO board which form the webs 20.

[0024] The EPS 16 is typically cut from blocks with a hot-wire CNC cutter, and the webs 20 are typically cut from MgO boards with a router CNC cutter. The EPS elements 16 and MgO webs 20 are then assembled into core wall structures in the form of different sized wall and roof panels. The EPS elements 16 and webs 20 are preferably attached together using a suitable adhesive, such as polyurethane foam, although other attachment methods may alternatively be used. To best fulfill their structural function, each of the webs 20 extends continuously across the core panel. Cutting and assembly of the core panels may occur off-site, e.g., in a factory or warehouse that need not be near the building site, or may occur on-site if preferred.

[0025] Once assembled, each panel of the core wall structure has two opposing exterior faces, which for illustrative purposes are identified as a top face 26 and a bottom face 28, as shown in FIG.

[0026] The webs 20 are spaced apart along the panel between blocks of EPS 16, with each web extending across the panel such that two opposed edges 22 of each web are exposed from the EPS 16 at two opposed outer surfaces 26, 28. The spacing and orientation of the webs 20 may vary for different panels and is dictated by structural requirements and manufacturing constraints to provide adequate load transfer for the structural strength required for a particular wall 12.

[0027] A recess is provided around the exposed edge 22 of the web 20; in the embodiment shown, this is done by recessing the edge of the block of EPS 16 adjacent to the exposed edge with a beveled chamfer 24, but in other embodiments, the edge of the block of EPS may be rounded or may be a rectangular recess, and / or the exposed edge 22 may protrude beyond the outer surfaces 26, 28.

[0028] Once the core wall panels are 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 connected together to provide load transfer between them; for example, the webs of adjacent core panels may be connected by tongue-and-groove connections, but may also be attached by steel straps or the like. In some embodiments of the present invention, the webs 20 of adjacent core panels may be attached together by, for example, clamps or rods. The erected structure is preferably temporarily supported at this stage (e.g., by braces, straps, and braces) to hold the panels in their correct position during application of the structural skin 18. The panels may be connected by adhesives such as polyurethane foam, fasteners, interconnects (e.g., tongue-and-groove connections), etc. to provide additional stability in high-stress areas, such as the panels of the roof section 14.

[0029] Once the core wall panels are secured in place, the structural skin 18 is applied in layers to the outer surfaces 26, 28 of the panels, generally working from the top of the structure downward and from the outside of the structure to the inside. The structural skin 18 may be applied by hand or by spray application, and the thermal core forms both the foundation and the lost shutter.

[0030] The webs 20 provide structural strength to the core panels while they are being erected and assembled, and the required supports and bracing primarily ensure the correct placement of the core panels. Furthermore, the webs 20 provide sufficient strength to the core panels so that they can withstand the weight of the structural skin 18, even in non-vertical wall sections such as roof sections, while the structural skin 18 is being applied, thereby avoiding the need for large-scale temporary weight-bearing supports such as scaffolding, stanchions, etc.

[0031] When the structural skins 18 are applied, they cover the outer surfaces 26, 28, but also cover and embed the exposed edges 22 of the webs. The connections between the exposed edges 22 and the skins 18 are reinforced by locally thickening the skin adjacent to the exposed edges, and the chamfers 24 provide spaces that are filled by the cement-based plaster of the skin, forming reinforcement for the skin around the exposed edges.

[0032] Referring to Figure 3, a third embodiment of a structure in the form of a wall according to the present invention is generally identified by the reference character 13. Wall 13 may share many similarities with wall 12 illustrated in Figure 2, such as EPS insulation elements 16, a structural skin 18 of cement-based high-strength plaster, and a web 20 of mineral board, such as magnesium oxide board (MgO), with exposed edges 22 of the web embedded in the structural skin.

[0033] The manner in which the web 20 is embedded in the structural skin 18 applied to the top surface 26 in the wall 13 of FIG. 3 is the same as in the wall 12 of FIG. 2, but the manner in which the web is embedded in the structural skin applied to the bottom surface 28 is different from that illustrated in FIG. 2.

[0034] 3 illustrates two embodiments of recesses formed along the bottom corners of EPS element 16. These embodiments of recesses are not necessarily used in combination in practice (although they could be used in combination), but they are shown in a single drawing for simplicity.

[0035] The recess 30 illustrated on the left side of Figure 3 is triangular and cut deeper into the EPS element 16 than the one illustrated in Figure 3, while the recess 24 illustrated on the right side of Figure 3 is identical to the recess in the top of the web 20. In both recesses 30, 24, the exposed edge 22 of the web 20 extends beyond the EPS element 16 on either side, but the exposed edge of the web 20 on the left side of Figure 3 is recessed entirely from the core panel. As a result, the recess 30 is larger than the recess 24 illustrated in Figure 2, and tensile elements, such as reinforcing rods 34, are embedded in the bottom structural skin 18. The reinforcing rods 34 may be made of steel, basalt fiber, high molecular weight polyethylene, carbon, or other alkali-resistant materials with high tensile strength.

[0036] The reinforcing rods 34 are positioned before the structural skin 18 is applied, each aligned with one of the webs 20. In the example of the web 20 and reinforcing rods 34 illustrated on the left side of Figure 3, the reinforcing rods are in close proximity to the exposed edge 22 of the web. However, in the example of the web 20 and reinforcing rods 34 illustrated on the right side of Figure 3, the reinforcing rods are in contact with the exposed edge 22 of the web.

[0037] Once the structural skin 18 is applied, both the reinforcing rods 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, and both the reinforcing rods and the webs can contribute to the strength of the structure 13 by transferring loads to / from the skin 18. The structural function of the webs 20 has been described above, and this is synergistically complemented by the ability of the reinforcing rods 34 to withstand tensile loads; therefore, the structure 13 has excellent flexural strength and is lightweight, and therefore can be used in large structures such as floors or roofs, with fewer supports such as columns than are required in current building methods.

[0038] Referring to Figure 4, a fourth embodiment of a structure in the form of a wall according to the present invention is identified generally by the reference character 15. Wall 15 shares many similarities with wall 13 illustrated in Figure 3, including EPS insulation elements 16, a cement-based high-strength plaster structural skin 18, mineral board webs 20, and exposed edges 22 of the webs and reinforcing rods 34 embedded in the structural skin.

[0039] The manner in which the webs 20 and reinforcing rods 34 are embedded in the structural skin 18 in the wall 15 of Figure 4 is very similar to that in the wall 13 of Figure 3, except that the reinforcing rods 34 are made of basalt rebar. However, the reinforcing rods 34 may alternatively be made of fiberglass rebar or other non-corrosive, high-strength material.

[0040] When wall 15 is used in a horizontal orientation, as shown in Figure 4, basalt rebar rods 34 are below lower edge 22 of web 20, below neutral axis 36 of the wall, and in the tension zone. On the underside of wall 15, rebar rods 34 are covered on their underside by the cementitious material of structural envelope 18, but because they are made of basalt, they do not need to be embedded as deeply into the cementitious material as is necessary to protect the steel rebar from moisture. In the preferred embodiment shown, the bottom edges of rebar rods 34 are aligned with the bottom surfaces of insulation elements 16 on common axis 38.

[0041] The wall 15 can be used in any orientation, but is particularly advantageous when used horizontally or partially horizontally, for example for roofs, interior floor slabs, foundations, or in connections between building elements where high tensile strength is required.

[0042] The wall 15 is generally constructed as described above with reference to Figures 1 and 2. Basalt rebar reinforcing rods 34 are installed in the tension zones at the edges 22 of the webs 20, either at the factory or after the panels are erected on-site. If the wall 15 is used horizontally, the rebar rods 34 need to be temporarily supported while the cement plaster is applied to form the bottom skin 18. The plaster is preferably applied in two coats. A first base coat of cement plaster approximately 2 mm to 5 mm thick is applied to the side of the panel with the greatest tensile design strength, which is the bottom side, as shown in Figure 4. A second base coat approximately 2 mm to 5 mm thick is applied to the opposite side of the panel (top, as shown in Figure 4). A first main coat of cement material is applied to the side of the panel with the lower tensile design strength (top, as shown in Figure 4). The cement material is then allowed to fully cure before removing the temporary support and applying the second primary coating to the side with the greater tensile design strength (the bottom, as shown in FIG. 4).

[0043] The wall 15 could also be constructed using steel rebar, but then more skin 18 of cement material would be required to cover the rebar, which would lead to greater weight and shorter spans.

Claims

1. a core wall structure comprising lightweight insulating material elements and webs of hard mineral board, said core wall structure having two opposite outer surfaces, said webs spaced apart between said lightweight material elements so as to extend across said core wall structure, said two opposite edges of said webs being exposed at said two opposite outer surfaces of said core wall structure; a cement-based stucco skin extending over two opposing outer surfaces of the core wall structure so as to at least partially cover two opposing sides of the core wall structure; Equipped with A structure wherein the exposed edges of the webs are at least partially embedded in the cement-based stucco skin on the two opposing sides of the core wall structure.

2. 10. The structure of claim 1, wherein the cement-based stucco skin is reinforced around the exposed edges of the webs, the exposed edges being embedded in the cement-based stucco skin.

3. 3. The structure of claim 2, wherein edges of the lightweight insulation material elements are recessed adjacent the exposed edges of the web to provide space for reinforcement of the cement-based stucco skin.

4. 10. The structure of claim 1, including reinforcement embedded in said cement-based stucco skin.

5. 5. The structure of claim 4 including fiber reinforcement embedded in said cement-based stucco skin.

6. 5. The structure of claim 4, including elongated tension elements embedded within at least one of said cement-based stucco skins, said tension elements aligned with said webs.

7. 7. The structure of claim 6, wherein at least a portion of the tension elements extend into one of the cement-based stucco skins in close proximity to one of the embedded edges of one of the webs.

8. 7. The structure of claim 6, wherein the cement-based stucco skin is reinforced around the tension elements.

9. 7. The structure of claim 6, wherein the tension elements are made of basalt.

10. 10. The structure of claim 1, wherein said lightweight insulating material is expanded polystyrene.

11. 10. The structure of claim 1, wherein the mineral board comprises magnesium oxide board.

12. 1. A method of construction, said method comprising: assembling a core wall structure by attaching together lightweight insulation material elements and mineral board elements, said core wall structure having two opposite outer faces, said mineral board elements spaced apart to act as webs between said lightweight material elements, said webs extending across said core wall structure and having two opposite edges of said webs exposed at said opposite outer faces of said core wall structure; providing recesses around the exposed edges of the webs on the two opposing outer surfaces of the core wall structure; applying a cement-based stucco skin to the two opposing exterior surfaces of the core wall structure so as to at least partially cover the core wall structure and at least partially embed the exposed edges of the webs in the cement-based stucco; A method comprising:

13. 13. The method of claim 12, including reinforcing at least one of the cement-based stucco skins.

14. 14. The method of claim 13, including the steps of providing an elongated tension element adjacent one of the two opposing outer surfaces of the core wall structure, the tension element being aligned with the web, and embedding the elongated tension element in the cement-based stucco skin when applying the cement-based stucco to the outer surface of the core wall structure.

15. 15. The method of claim 14, including the step of positioning at least a portion of the tension elements to extend in close proximity to one of the embedded edges of one of the webs prior to the step of applying the cement-based stucco to the exterior surface of the core wall structure.

16. The method of claim 14 , wherein the tension element is made of basalt.

17. 13. The method of claim 12, wherein the step of providing a recess around the exposed edge of the web comprises the step of recessing an edge of the lightweight insulation material element adjacent the exposed edge of the web.

18. 13. The method of claim 12, wherein the lightweight insulating material is expanded polystyrene.

19. The method of claim 12, wherein the web is a magnesium oxide board.

20. 13. The method of claim 12, including attaching a plurality of said core wall structures together prior to said step of applying said cement-based stucco skins to said two opposing exterior faces of said core wall structures.

21. 21. The method of claim 20, including attaching the webs of adjacent core wall structures to each other.

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