Method of building construction
A method of building construction wherein blocks and panels made from autoclaved aerated concrete are used as structural elements, and roof panels, including insulated panels having a rigid polyurethane/polyiscocyanurate foam core, are attached to structural elements via metal anchoring caps, ridge flashing, rake trim, beams, end plates, clips, and/or various fasteners. Preferably, anchoring caps are secured over external and internal bearing walls via large tube nails that engage inner reinforcement structures embedded within the walls during manufacture to provide enhanced uplift resistance, with the roof panels and anchoring caps secured together via clips and fasteners. Alternatively, large deck screws and rake trim can anchor roof panels to exterior walls. Roof panels not connected to anchoring caps are connected to beams attached between end plates secured to the opposing faces of external and interior bearing walls. Applications include, but are not limited to, residential, commercial, government, educational, and industrial construction.
This application is related to the subject matter of the provisional patent application filed on Sep. 7, 2005, which was given the Ser. No. of 60/741,613. Although the provisional patent application was filed in the names of Erwin J. Andersen and Christopher G. L. Welles-Pryor, the subject matter of the claims herein is attributable only to the first named inventor on the provisional patent application, Erwin J. Andersen. As a result, the applicant herein respectfully requests that any patent grant be in his name only and that he be given all appropriate benefit attributable to the prior U.S. provisional patent application.
BACKGROUND1. Field of the Invention
This invention relates to building construction and the use of building materials, specifically to a method of building construction that can be used to rapidly create low cost and affordable housing. The finished structures are thermally insulated, fire retardant, energy efficient, low maintenance, pest resistant, sound absorbent, and mildew resistant. They do not need the installation of independent moisture barriers and they are also sufficiently strong for use in areas subject to adverse forces of nature, such as but not limited to hurricanes and earthquakes. The method combines two energy efficient building materials. Structural blocks and panels are made from autoclaved aerated concrete, while insulated roof panels, including those having a sandwiched construction and a rigid polyurethane/polyiscocyanurate foam core, are connected to the structural blocks and structural panels via a variety of fasteners and attachment devices, with the fasteners and attachment devices used being selected according to whether the structural elements are load bearing. The shells of residential buildings can be formed quickly using the present invention, with structures used in affordable housing projects typically being formed in less than two working days. The attachment devices most often used in the present invention to connect metal roof panels to structural blocks and structural panels, and/or otherwise support or anchor metal roof panels in their usable position, include but are not limited to, anchoring caps, ridge flashing, rake trim, beams, end plates, clips, fasteners, large tube nails, large deck screws, and bolts. Panels containing an inner reinforcement structure are typically used in external and interior bearing wall applications. Metal anchoring caps secured with large tube nails over the top ends of the panels strengthen the connection between walls and applied roof panels. Since the large tube nails are arranged in a staggered pattern and positioned to engage the inner reinforcement structure within the wall panels, they provide enhanced uplift resistance. Also, clips and fasteners preferably anchor the metal roof panels to each anchoring cap used in the present invention. Flashing is typically secured over the ends of adjacent metal roof panels that form a ridge, such as the adjacent metal roof panels secured over an interior bearing wall. An alternative preferred means of anchoring metal roof panels to exterior walls in the present invention employs large deck screws and rake trim. To support the ends of metal roof panels situated between interior bearing walls and exterior walls, beams are extended via end plates between opposing wall panel faces, with clips and fasteners typically anchoring the metal roof panels to the beams. Applications include, but are not limited to, residential, commercial, government, educational, and industrial construction.
2. Description of the Related Art
Globally there is a need for affordable entry level housing that is resistant to earthquakes, windstorms, infestation, mold, and fire. It is also advantageous to the owners, and the communities in which they live, when such housing is well-built, cost efficient, energy efficiency, and less labor intensive to build. It is also desirable globally for commercial and industrial structures to have resistance to earthquakes, windstorms, infestation, mold, and fire. Although autoclaved aerated concrete is a structural building material that has been popular in Europe for nearly a century and insulating panels having a rigid polyurethane/polyiscocyanurate foam core have been previously used in cold storage constructions, they have never before been combined in building construction as in the present invention, whereby the needed structural elements of a building are created with blocks and panels made from autoclaved aerated concrete, and its roof structure is made at least in part from insulated sandwiched metal and non-metal panels having a rigid polyurethane/polyiscocyanurate foam core.
BRIEF SUMMARY OF THE INVENTIONIt is the primary object of this invention to provide a method of building construction that employs structural and roofing materials that are inherently sound absorbent, fire resistant, and thermally insulated, and result in cost efficient construction at least in part by avoiding the additional labor and material expense of on-site installation of independent materials capable of providing such characteristics in a finished structure. It is also an object of this invention to provide a method of building construction that uses materials that are lighter in weight than conventional construction materials and easy to install for fast construction. A further object of this invention is to provide a method of building construction that creates structures that are energy efficient, require reduced operating costs, permit reduced insurance premiums, and need little maintenance. It is also an object of this invention to provide a method of building construction that creates strong and durable structures better able to withstand hurricanes and earthquakes than structures made from conventional materials, as well as structures that are impervious to mold, rot, and infestation. It is a further object of this invention to provide a method of building construction that uses materials that are versatile and can be worked like wood without chipping or cracking. It is also an object of this invention to provide a method of building construction that uses materials that are recyclable, inert, and non-toxic. It is a further object of this invention to provide a method of building construction that uses materials made from raw materials that are in abundant supply and made without the creation of by-products.
The present invention method, when properly implemented, will provide residential, commercial, government, educational, and industrial buildings that are sound absorbent, fire resistant, moisture blocking, and thermally insulated without the cost of independent materials and on-site labor to provide such benefits, as the materials used for structural elements in the present invention, including the walls and roof, will already exhibit such characteristics. In addition, the materials used for structural elements and the roof are impervious to mold, rot, and infestation. The first material used as a part of the present invention to achieve the above-stated objectives and benefits is autoclaved aerated concrete, which is employed for structural elements. It is lighter in weight that conventional construction materials and easy to install, typically weighing between approximately one-half and one-fifth of the weight of conventional concrete. Further, autoclaved aerated concrete also yields readily and can be worked like wood, with conventional construction tools easily cutting and shaping the autoclaved aerated concrete without chipping or cracking it. Autoclaved aerated concrete is also desired as a building product in the present invention since it is inert, non-toxic, and needs little maintenance. Pictures can be easily hung on a finished wall of autoclaved aerated concrete. Since the autoclaved aerated concrete is aerated, it has a high porosity that provides excellent thermal resistance and sound absorption. Roofs made via the present invention method are constructed at least in part from sandwiched panels having a rigid polyurethane/polyiscocyanurate foam core, the second material used as a part of the present invention to achieve the above-stated objectives and benefits. Sandwiched roof panels are attached via elongated fasteners and caps to the top ends of vertically-extending autoclaved aerated concrete wall panels secured in load bearing applications, so as to engage the inner reinforcement structure within the autoclaved aerated concrete panels and provide enhanced uplift resistance. The elongated fasteners used are preferably, but not limited to, anchor screws and/or tube nails having a length dimension of approximately six inches. The roof panels of the present invention have a low thermal conductivity and are very energy efficient, they have a high mechanical strength and are very durable, and they also have an extremely high resistance to fire. Thus, the combined use of autoclaved aerated concrete panels and roof panels having a rigid polyurethane/polyiscocyanurate foam core leads to faster construction and an improved product for the consumer. It also creates strong and durable structures able to better withstand hurricanes and earthquakes than structures made from conventional materials, energy efficient structures that have reduced operating costs, and structures that are impervious to mold, rot, and infestation. In addition, due to the reduced risk of damage from hurricanes, earthquakes, fire, rot, mold, and infestation, insurance premiums in structures made via the present invention are reduced. Further, the materials used in the present invention method are recyclable, made from raw materials that are in abundant supply, and made without the creation of by-products.
The description herein provides preferred embodiments of the present invention but should not be construed as limiting its scope. Instead, the scope of the present invention should be determined by the appended claims and their legal equivalents, rather than being limited to the examples given.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention method, when properly implemented, provides residential, commercial, government, educational, and industrial buildings that are sound absorbent, fire resistant, and thermally insulated with reduced labor and material expense. Instead of the on-site addition of independent materials to provide thermal insulation, fire resistance, sound absorbency, pest resistance, mildew resistance, and the like, the two energy efficient materials used respectively for structural elements and the roof already provide such benefits. For example, the autoclaved aerated concrete used for structural elements in the present invention provides one hour of fire resistance per inch of thickness dimension. The resulting reduced labor and material expense helps to provide low cost residential construction for affordable and low income housing. The low cost of structures built using the present invention method is also due in part to the speed with which the structural elements can be installed in their usable positions. Thus, when small lifts (not shown) are used to orient and align wall and roof panels, such as panels 2 and 6 in the accompanying illustrations, the shell of a single-family residential building is typically finished in a time period of two working days or less. In addition, the materials primarily used for structural elements and the roof are also impervious to mold, rot, and infestation. First, autoclaved aerated concrete panels and block, as shown by the designation 2 in
For the support and securing of roof panels in the present invention to interior and exterior bearing walls made from autoclaved aerated concrete 2, including but not limited to the insulated sandwiched panels 6 with substantially vertically extending ribs 11 (as shown in
Thus, in summary, the most preferred embodiment of the present invention method of building construction combines two energy efficient building materials to produce low cost structures, including affordable housing. Blocks and panels made from autoclaved aerated concrete 2 are first connected together using conventional construction means of attachment (not shown), such as but not limited to tongue-and-groove connection, to form the vertically-extending walls, interior and exterior, and other structural elements needed for the building shell. It is preferred for added strength and enhanced uplift resistance in the connection of roof panels 6 to the autoclaved aerated concrete 2, that wall panels 2 having an inner reinforcement structure (not shown) be used for exterior and load bearing walls, instead of the exterior walls being constructed from block. Since the blocks and panels made from autoclaved aerated concrete 2 are lighter in weight and stronger than conventional concrete, and wall panels of autoclaved aerated concrete 2 can be worked like wood without chipping or cracking, they are easily handled on a construction jobsite for rapid assembly of a building shell. Roof panels 6 are then secured to the blocks and panels made from autoclaved aerated concrete 2 to complete the building shell, the interior of which can then be finished according to need. It is not unexpected for a building shell and roof combination made via the present invention to be completed in two days or less. Preferably, roof panels 6 are insulated and have a sandwiched construction with a rigid polyurethane/polyiscocyanurate foam core and are connected in the most preferred embodiment of the present invention to the autoclaved aerated concrete blocks and panels 2 in several ways, using varying combinations of anchoring caps 1, ridge flashing 10, rake trim 18, beams 4, end plates 5, clips 12, fasteners 13 and 17, large tube nails 3, long fasteners 17, and bolts 8. One preferred attachment is that of galvanized roof panels 6 to interior bearing walls made from autoclaved aerated concrete 2, wherein metal anchoring caps 1 having an upper cross-sectional configuration of an isosceles triangle are secured over the top of the wall with large tube nails 3 arranged in a staggered/offset pattern. The galvanized roof panels 6 are then anchored to each isosceles triangle shaped anchoring cap 1 with a minimum of two clips 12 per panel 2 and a minimum of two fasteners 13 per clip 12. Also, ridge flashing 10, is typically secured over the respective ends of adjacent roof panels 6 that are attached to an isosceles anchoring cap 1, and which together form a roof ridge. As an alternative, for attachment of the galvanized roof panels 6 to exterior walls of autoclaved aerated concrete 2, metal anchoring caps 1 having an upper cross-sectional configuration of a right triangle are secured over the tops of the wall panels 2 with large tube nails 3 arranged in a staggered pattern. The galvanized roof panels 6 are then anchored to each right triangle shaped anchoring cap 1 with a minimum of two clips 12 per panel and a minimum of two fasteners 13 per clip. In addition, in the most preferred embodiment of the present invention galvanized roof panels 6 can be anchored to exterior gable end/rake walls using anchoring cap 1 with a flat upper configuration, tube nails 3, large deck screws 17, and rake trim 18. Between interior bearing walls and exterior walls, beams 4 fixed in position by end plates 5 are preferably used to support the galvanized roof panels 6. The beams 4 can be hollow steel tubes, include cutouts for HVAC (such as the center hollow support beam 7 shown in
Further, the preferred embodiment of the present invention provides for the anchoring of autoclaved aerated concrete panels 2 to the foundation/footing 23 in both single and two story structures. In one story structures, the autoclaved aerated concrete panel 2 in exterior walls is preferably anchored to the foundation/footing 23 via a vertically extending steel strap 26 that is secured within aligned vertically extending recesses in both the foundation/footing 23 and autoclaved aerated concrete panel 2 positioned thereabove. Also, strap 26 is preferably secured to foundation/footing 23 via a coil bolt 28 fastened to a horizontally extending single loop coil insert 27, with reinforcing structure 25 embedded within the foundation/footing 23 engaging coil insert 27 and providing enhanced uplift resistance to any roof panels 6 secured to the top portion of autoclaved aerated concrete panels 2 supported by foundation/footing 23. Strap 26 is also preferably secured to the autoclaved aerated concrete panels 2 supported by foundation/footing 23 via multiple tube nails 3. Depending upon the application, interior walls of autoclaved aerated concrete panels 2 can be similarly constructed. In two story structures made according to the present invention, autoclaved aerated concrete panels 2 in exterior and interior bearing walls are preferably anchored to the foundation/footing 23 utilizing a vertically extending criss-cross loop coil insert 24 embedded in the foundation/footing 23 which receives a continuous vertically extending coil thread bolt 22 that passes upwardly through the autoclaved aerated concrete panel 2 positioned above foundation/footing 23 and ends within a continuous channel 19 extending longitudinally along the top of the center ridge wall and exterior walls and positioned within a recess or notch (not numbered in
One should recognize that all of the illustrations herein are not strictly to scale, and only generally represent the preferred structure, proportion, and placement of present invention components. Thus, the illustrations herein should not be relied upon for determining the relative size or configuration of such components, or any size and/or configuration limitations in the present invention.
Claims
1. A method of building construction that uses at least two energy efficient building materials to produce low cost structures, including affordable housing, that are rapidly assembled, thermally insulated, fire retardant, energy efficient, low maintenance, pest resistant, sound absorbent, mildew resistant, and sufficiently strong for use in areas subject to adverse forces of nature, including hurricanes and earthquakes, said method comprising the steps of:
- providing a plurality of structural members made from autoclaved aerated concrete, a plurality of insulated roof panels having a sandwiched construction and a rigid foam core made from polyurethane and polyiscocyanurate, and a plurality of attachment devices;
- using said structural members made from autoclaved aerated concrete to form interior and exterior walls and other needed structural elements; and
- using said attachment devices to connect said roof panels to said interior and exterior walls.
2. The method of claim 1 wherein said structural members are selected from a group consisting of panels and blocks, and said exterior walls are made from said panels.
3. The method of claim 1 wherein said attachment devices are selected from a group consisting of anchoring caps, anchoring caps having an isosceles triangle shaped upper portion, anchoring caps having a right triangle shaped upper portion, anchoring caps having a flat top end, ridge flashing, rake trim, support beams, end plates, clips, fasteners, large tube nails, large deck screws, and bolts.
4. The method of claim 1 wherein said attachment devices comprise anchoring caps and some of said interior walls are load bearing, and wherein said step of attaching said roof panels to said exterior walls and said load bearing interior walls further comprises the steps attaching at least one of said anchoring caps to each said exterior wall and each said load bearing interior wall and attaching of said roof panels to said anchoring caps.
5. The method of claim 4 wherein said anchoring caps are made from metal and said walls comprise vertically-extending interior bearing wall panels and vertically-extending exterior wall panels each having a top end, wherein said attachment devices comprise large tube nails, and wherein said step of attaching said anchoring caps to said interior bearing walls and said exterior walls further comprises the attaching of said anchoring caps to said top ends of said interior bearing walls and said exterior walls with said large tube nails arranged in a staggered pattern.
6. The method of claim 4 wherein said attachment devices comprise clips and fasteners, and wherein said step of attaching said roof panels to said anchoring caps further comprises the using of said clips and fasteners to attach said roof panels to said anchoring caps.
7. The method of claim 6 further comprising attachment devices selected from a group consisting of ridge flashing and eave trim.
8. The method of claim 1 wherein said walls comprise a vertically-extending exterior wall with a top end and said attachment devices comprise an anchoring cap having a flat top end, at least one large deck screw, at least one small fastener, and rake trim having an upper end and a lower end, and said step of attaching one of said roof panels to said vertically-extending exterior wall further comprises the steps of securing of said anchoring cap to said top end of said vertically-extending exterior wall, using said at least one large deck screw to secure said upper end of said rake trim to said roof panel, said anchoring cap, and said vertically-extending exterior wall, and using said at least one small fastener to secure said lower end of said rake trim to said vertically-extending exterior wall.
9. The method of claim 1 wherein said walls comprise interior bearing walls and exterior walls each having a panel face, and wherein said step of providing further comprises the providing of at least one support beam and at least two end plates, and further comprising a step of securing said end plates to opposing ones of said panel faces to create at least one opposing pair of end plates and a step of extending said at least one support beam between said at least one pair of end plates wherein said steps of securing said end plates and extending said at least one support beam between said at least one pair of end plates causes said at least one support beam to be positioned where said at least one support beam supports said ends of the one of said roof panels situated between said interior bearing walls and said exterior walls.
10. The method of claim 9 wherein said attachment devices comprise bolts, and wherein said step of securing said end plates to opposing ones of said panel faces further comprises the using of said bolts for attaching said end plates to said panel faces of said interior bearing walls.
11. The method of claim 9 wherein said attachment devices comprise large tube nails, and wherein said step of securing said end plates to opposing ones of said panel faces further comprises the using of said large tube nails for attaching said end plates to said panel faces of said exterior walls.
12. The method of claim 9 wherein said attachment devices comprise clips and fasteners, and further comprising a step of attaching said roof panels to said at least one support beam using said anchoring clips and fasteners.
13. The method of claim 1 wherein said insulated roof panels are selected from a group consisting of insulated metal panels having a rigid foam core made from polyurethane and polyiscocyanurate and insulated non-metal panels having a rigid foam core made from polyurethane and polyiscocyanurate, insulated roof panels having steel cores, and insulated roof panels having baked enamel finishes.
14. The method of claim 9 further comprising foundation attachment devices selected from a group consisting of embedded plates with at one elongated bar attached thereto, embedded reinforcement bars, shim plates, coil bolts, vertically extending criss-cross loop coil inserts, notches, channels, washers, coil nuts, tube nails, vertically-extending plates, tube nails, recesses, and single loop coils.
15. The method of claim 14 wherein said step of providing further comprises the providing of at least one structural member made from autoclaved aerated concrete having a notch and a metal plate with at least one elongated bar adjacent to said notch, at least one shim plate, and welding means, and further comprising the steps of positioning one of said support beams within said notch, adjusting the elevation of said support beam within said notch via said at least one shim plate, and using said welding means to weld said support beam and said at least one shim plate to said embedded metal plate.
16. The method of claim 14 wherein said step of providing further comprises the providing of a foundation with at least one vertically extending embedded criss-cross loop coil insert and at least one embedded reinforcement structure engaging said coil insert to provide enhanced uplift resistance, at least one structural member made from autoclaved aerated concrete having a notch in its top end, a coil bolt with an upper end and a lower end, a channel, a washer, and a coil nut, and further comprising the steps of inserting said coil bolt vertically through said structural member, supporting said structural member upon said foundation while aligning said lower end of said coil bolt with said insert, connecting said lower end of said coil bolt to said insert, inserting said channel into said structural member notch so that said upper end of said coil bolt extends upwardly beyond said channel, and securing said upper end of said coil bolt with said washer and said coil nut.
17. The method of claim 14 wherein said step of providing further comprises the providing of a foundation with at least one horizontally extending embedded loop coil and at least one embedded reinforcement structure engaging said loop coil to provide enhanced uplift resistance, said foundation also having a vertically extending recess, at least one structural member made from autoclaved aerated concrete having a vertically extending recess, a coil bolt, an elongated plate, and a plurality of tube nails, and further comprising the steps of supporting said structural member upon said foundation while aligning said vertical recess in said foundation with said vertical recess in said structural member, placing said elongated plate in said recesses against said foundation and said structural member, connecting said elongated plate to said foundation via connection of said coil bolt to said loop coil, and connecting said elongated plate to said structural member via connection of said tube nails to said structural member.
18. The method of claim 1 wherein said structural members comprise an inner reinforcing structure and said attachment devices comprise elongated fasteners, and further comprising a step of attaching said insulated roof panels to said structural members with said elongated fasteners so that said elongated fasteners engage said inner reinforcing structure and provide enhanced uplift resistance to said roof panels.
19. The method of claim 1 wherein said roof panels each have at least one vertical ridge and at least one tongue-in-groove structure, and connection of adjacent ones of said roof panels to one another is selected from a group consisting of crimping adjacent ones of said vertical ridges together and interconnecting adjacent ones of said tongue-in-groove structures.
20. The structure produced by the method of building construction in claim 1.
Type: Application
Filed: Sep 7, 2006
Publication Date: Jan 17, 2008
Inventor: Erwin Andersen (Bradenton, FL)
Application Number: 11/517,498
International Classification: E04C 5/08 (20060101); E04C 5/12 (20060101);