US20050166533A1 - Residential construction method and apparatus - Google Patents
Residential construction method and apparatus Download PDFInfo
- Publication number
- US20050166533A1 US20050166533A1 US10/754,964 US75496404A US2005166533A1 US 20050166533 A1 US20050166533 A1 US 20050166533A1 US 75496404 A US75496404 A US 75496404A US 2005166533 A1 US2005166533 A1 US 2005166533A1
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- United States
- Prior art keywords
- panels
- roof
- recited
- floor
- residence
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
Home residential construction based on the use of panels made of metal cladding with expanded polystyrene therebebetween. The metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel is strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes. A pitched roof is formed of roof panels, supported by a bar joist at the peak. Walls are formed of wall panels joined using trays for their bottom ends and caps for their top ends and sides. A residence constructed using the present materials and methods is stronger than conventional “brick and stick” homes and can be constructed more quickly and cheaply, and is less expensive to heat and cool.
Description
- Generally, the present invention relates to residential construction. In particular, it relates to a material for use as wall material and methods for using that material.
- Historically, homes, some apartments and smaller offices are built on the jobsite using bricks and lumber, plus other materials such as shingles and insulation panels. These materials can be used to construct an endless variety of residences, from simple tract homes to elaborate custom-built homes.
- Although great strides have been made in pre-assembling some components, such as roof trusses and windows and doors, in factories where they can be made more quickly and cheaply, still most of residential construction is made at the jobsite, laying one brick and nailing one “2 by 4” at a time. As a result, a significant component of residential construction cost is for labor.
- Another disadvantage of residential construction that is related to the fact that homes are largely built on site is that the quality of construction is uneven. When foundations are made of bricks individually laid and walls are made of individual studs nailed together, there inevitably will be flaws. Most of these flaws are minor, but even minor ones, when sufficiently numerous, add up to a significantly higher heating and cooling bill.
- Thus there remains a need for better ways to build residences of better quality and lower cost of construction as well as heating and cooling.
- According to its major aspects and briefly recited, the present invention is a method and apparatus for constructing residences. The term “residences” will be used to refer to one and two-story structures with pitched roofs, including individual homes, duplexes, small office buildings and small apartment buildings, but not warehouses, large office buildings and other commercial buildings of more than two stories.
- In particular, the present invention is characterized by the use of panels made of metal cladding with expanded polystyrene between. The panels are adapted to meet the strength requirements and dimensional requirements of residential specifications. For example, the metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel will be strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes so that further modifications of construction techniques and materials (i.e., window units) will be unnecessary. When these panels are supported and joined as described herein, with their bottom ends set in trays and their top ends capped, they form strong, weather-tight, energy-efficient floors, walls, and roofs and result in homes that appear to be much like conventional “brick and stick” homes but can be constructed more quickly and cheaply and are less expensive to heat and cool. They are also quieter.
- A feature of the present invention is the use of insulated panels. These panels are known in warehouse construction as “freezer panels.” Some types of freezer panels, namely those with urethane between the cladding, are unsuitable for residential construction because of the gases given off by the urethane. However, those that are made of expanded polystyrene (EPS, known more commonly under the trademark STYROFOAM), preferably those made of EPS foamed with air, are unknown in residential construction. These panels, in addition to being sufficiently strong enough for making warehouse walls, are also energy efficient for refrigeration purposes. When applied to residential construction, their energy efficiency rating is much higher than conventional materials provide.
- Another feature of the present invention is the use of a bar joist to support the roof panels at the peak of the roof. A bar joist avoids the need for roof trusses. Bar joists are commonly found in supporting flat surfaces such as flat roofs and floors. They are not found as supports for pitched roofs. Roof trusses work well in traditional homes but make attic space largely unusable other than for storage of boxes because the existence of the trusses require those walking around in an attic to keep their heads low to avoid injury. By eliminating trusses, there is more usable space just under the roof. Furthermore, bar joists, in combination with the structural strength of the panels, provides a sufficiently strong roof.
- Another feature of the present invention is the use of trays and caps in combination with the panels to provide a rigid structure for a roof, a wall or a floor.
- A particular feature of the present invention is the use of EPS several inches thick. EPS has considerable thermal efficiency and makes the present method and materials especially attractive in very cold and very warm climates, particularly those that are subject to strong winds or heavy snows.
- Other features and their advantages will be apparent to those skilled in the art of lamp design from a careful reading of a Detailed Description Of Preferred Embodiment accompanied by the following drawings.
-
FIG. 1 illustrates a typical residence that can be made using the present construction methods or prior art methods; -
FIG. 2 illustrates a foundation and wall joint, according to a preferred embodiment of the present method; -
FIG. 3 illustrates a support for a wall, according to a preferred embodiment of the present invention; -
FIG. 4 illustrates a mid-floor support for a floor, according to a preferred embodiment of the present invention; -
FIG. 5 illustrates a detailed portion of the roof joint at the roof peak, made according to a preferred embodiment of the present invention; -
FIG. 6 illustrates a detailed portion of the roof and wall joint, made according to a preferred embodiment of the present invention; and -
FIG. 7 illustrates a partially cut away view of the end of a roof, made according to a preferred embodiment of the present invention. - The present invention is a construction method and apparatus for building residences. An important aspect of the present invention is the use of pre-fabricated panels made of a cladding, preferably a metal cladding and most preferably of a galvanized steel cladding with expanded polystyrene (EPS) therebetween. Also, the EPS is preferably made using air to expand it rather than some other gas. The EPS is preferably at least approximately four and most preferably approximately six inches thick or even thicker when thickness is important. The term “approximately” is used in the sense of a “two-by-four” is approximately two inches by four inches. If the cladding is galvanized steel, it is preferably 26-gauge, galvanized steel. The cladding may be pre-painted or primed prior to use.
- These panels are used as roof panels and also preferably as wall and floor panels. Although these panels in a form referred to as “freezer panels” are known in construction of warehouses for cold storage, freezer panels in residential construction using air-expanded polystyrene is unknown.
- In addition to the use of panels for the roof, walls and floor, there are particular techniques disclosed herein for joining the panels, particularly in the foundation and the pitched roof of the residence. These techniques will now be described
- Referring now to
FIG. 1 , there is shown a typicalresidential home 10 including aroof 12 withshingles 14,walls 16 withwindows 18, aporch 20 and afoundation 22.Home 10 could be made with prior art materials and techniques or with the present materials and techniques. However, the exterior and interior finish will look the same. To those living in a home made of the present materials constructed with the present techniques, there would be few differences in appearance and in operation, but these would be important differences. One of these differences would be the energy efficiency whenhome 10 is made according to the present invention. A monthly energy bill for heating and cooling the present home would be much smaller, perhaps one-half to one-third the amount of the bill for the same home made with conventional techniques and materials. Use of the present materials and techniques also results in a quieter home in that noise outside the home is attenuated to a greater degree by the walls. - Another difference apparent to those living in
home 10 when made with the present materials and techniques as opposed to prior art materials and techniques, is the absence of trusses in the attic, making the attic more usable for storage or living space. Less apparent to those who live inhome 10, constructed with present materials and techniques, is the strength ofhome 10 against strong winds. - Referring now to
FIGS. 2-4 , there are illustrated details offoundation 22 ofhome 10, according to a preferred embodiment of the present invention. As in a conventional home, a concrete footer (seeFIG. 3 and 4) is poured and a foundation is constructed on a footer. In the present invention, a foundation 32 (also laid on afooter 30, now shown inFIG. 2 ) may consist of ablock wall 34 with a brick facing 36, capped with awood board 38, as illustrated inFIG. 2 . Alternatively, and for support interior tofoundation 32,steel pipes 44 embedded infooter 30 may be used to hold a steel I-beam 42, as illustrated inFIGS. 3 and 4 . InFIG. 3 , afoundation board 40 is supported by an I-beam 42 on asteel pipe 44 using asteel bracket 46. InFIG. 4 , afoundation board 48 is secured to an I-beam 50, supported on asteel pipe 52 for a floor support interior tofoundation 32. -
Foundation boards Steel pipes Bracket 46 is preferably galvanized sheet steel formed so that it can be attached to the side of I-beam 42 and tofoundation board 40 extending laterally inward, thus providing support forfloor panels 56.Floor panels 56 can be placed in adjacent relationship, running from exterior wall to exterior wall, secured together to define a floor forhome 10. - A
metal tray 60, dimensioned to receivedwall panels 62 is attached tofoundation boards Wall panels 62 are secured totray 60 using long screws. The tops ofwall panels 62 are joined with a cap 64 (seeFIG. 6 ) using long screws.Trays 60 and caps 64 are preferably made of galvanized channel steel. Holes may be formed inwall panels 62 to accommodate standard windows and doorframes as desired. Windows and doors are framed and setwall panels 62, as in conventional construction.Caps 64 are preferably angled at the pitch of roof (seeFIG. 6 ).Floor panels 56 andwall panel 62 havecladding 66 on both sides withEPS 68 therebetween. - As shown in
FIGS. 5, 6 , and 7, the formation of a pitchedroof 70 requires support at thepeak 72 and at theeves 74.Roof panels 76 are strong enough if properly supported atpeak 72 andeves 74 to support the weight of, for example, workers onroof 70 installing shingles.Roof 70 will be finished on its upper side in a conventional manner usingplywood boards 78 secured toroof panels 76, then covered withfelt 80 and thenshingles 82 as shown inFIGS. 5, 6 , and 7.Roof panel 76 likefloor panel 56 havecladding 84 of galvanized steel on both sides andEPS 86 therebetween. - At
peak 72,roof panels 76 are brought together and sealed withliquid polystyrene 94 as a sealer and supported atpeak 72 with asupport system 96 that runs the length ofroof 70.Support system 96 includes abar joist 98 secured to the underside ofroof panels 76, atpeak 72 by a series of pitch forms 100 secured toroof panels 76, either directly or usingpeak support boards 102 running the length of the joint atpeak 72. Preferablyroof panels 76 havelong screws 104 driven entirely throughplywood boards 78,roof panels 76,peak support boards 102 and into pitch forms 100.Bar joist 98 is secured to pitch members using screws. -
Bar joist 98 is supported at the tops of opposing walls using aflanged end bracket 110 using screws.End bracket 110 may be a rectangular box only on the ends ofbar joist 98 or may run the length of bar joist enclosing it. The interior ofbracket 110 is preferably backfilled with foam insulation 112 to form an enclosed, insulated box running the length of roof peak. - At
eves 74,roof panel 76 has afacie cap 120 and asoffet piece 122 joined to wallpanel 62 with an “F”trim piece 124.Roof panel 76 is secured to wallpanel 62 with a long screw, preferably throughplywood 78,roof panel 76, andcap 64, and has anend cap 126 on the ends ofroof panels 76 not terminated at a peak 72 oreve 74, as shown inFIG. 7 . - All EPS is air-expanded rather than using another gas or rather than using urethane. EPS is strongly preferred as a core for floor, wall and
roof panels - It is intended that the scope of the present invention include all modifications that incorporate its principal design features, and that the scope and limitations of the present invention are to be determined by the scope of the appended claims and their equivalents. It also should be understood, therefore, that the inventive concepts herein described are interchangeable and/or they can be used together in still other permutations of the present invention, and that other modifications and substitutions will be apparent to those skilled in the art of lamp manufacture from the foregoing description of the preferred embodiments without departing from the spirit or scope of the present invention.
Claims (20)
1. A method for constructing a residence, said method comprising the steps of:
forming a foundation for a residence;
placing trays on said foundation;
setting wall panels into said trays, said wall panels each being made of cladding with expanded polystyrene therebetween;
placing caps onto said wall panels;
fastening said trays and said caps to said wall panels; and
installing a pitched roof onto said panels.
2. The method as recited in claim 1 , wherein said pitched roof further comprises roof panels made of cladding with expanded polystyrene therebetween.
3. The method as recited in claim 1 , further comprising the step of installing a floor on said foundation, said floor further comprising floor panels made of cladding with expanded polystyrene therebetween.
4. The method as recited in claim 1 , wherein said cladding is galvanized steel.
5. The method as recited in claim 1 , further comprising the step of positioning a bar joist between said wall panels near said cap to support said roof.
6. The method as recited in claim 1 , further comprising the step of providing I-beams interior to said foundation and installing a floor on said I-Beams and said foundation, said floor comprising floor panels made of cladding with expanded polystyrene therebetween.
7. The method as recited in claim 2 , further comprising the step of sealing adjacent roof panels using liquid polystyrene.
8. A residence, comprising:
a foundation;
trays attached to said foundation;
walls made of wall panels having a top and an opposing bottom, said bottom of said wall panels being inserted into and fastened to said trays, said wall panels made of cladding with expanded polystyrene therebetween;
caps fastened to said tops of said wall panels;
means carried by said walls for supporting a roof;
a pitched roof supported by said roof supporting means; and
a floor carried by and fastened to said foundation.
9. The residence as recited in claim 8 , wherein said pitched roof further comprises roof panels made of cladding with expanded polystyrene therebetween.
10. The residence as recited in claim 9 , wherein said roof supporting means is a bar joist.
11. The residence as recited in claim 9 , wherein said cladding of said wall panels and said roof panels is galvanized steel.
12. The residence as recited in claim 9 , wherein said polystyrene is expanded with air.
13. The residence as recited in claim 9 , further comprising:
plural supports; and
an I-beam attached to said supports for supporting said floor.
14. The residence as recited in claim 13 , wherein said floor further comprises floor panels attached to said I-Beam and said foundation, and wherein said floor panels are made of cladding and expanded polystyrene therebetween
15. A residence, comprising:
a foundation;
a floor carried by said foundation;
walls carried by said foundation; and
a pitched roof carried by said walls, said pitched roof made of plural roof panels, each roof panel of said plural roof panels made of cladding with expanded polystyrene therebetween.
16. The residence as recited in claim 15 , further comprising a bar joist carried by said walls, and wherein said roof is supported by said bar joist.
17. The residence as recited in claim 16 , wherein said roof has a peak, and wherein said bar joist supports said peak of said pitched roof.
18. The residence as recited in claim 17 , wherein said roof panels are joined at said peak using liquid polystyrene.
19. The residence as recited in claim 15 , wherein said walls and said floor further comprise wall panels and floor panels, respectively, said wall panels and said floor panels being made of cladding with expanded polystyrene therebetween.
20. The residence as recited in claim 19 , wherein said polystyrene of said roof panels, said wall panels and said floor panels are made of polystyrene expanded with air.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US10/754,964 US20050166533A1 (en) | 2004-01-09 | 2004-01-09 | Residential construction method and apparatus |
Applications Claiming Priority (1)
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US10/754,964 US20050166533A1 (en) | 2004-01-09 | 2004-01-09 | Residential construction method and apparatus |
Publications (1)
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US20050166533A1 true US20050166533A1 (en) | 2005-08-04 |
Family
ID=34807452
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US10/754,964 Abandoned US20050166533A1 (en) | 2004-01-09 | 2004-01-09 | Residential construction method and apparatus |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100088981A1 (en) * | 2008-10-09 | 2010-04-15 | Thermapan Structural Insulated Panels Inc. | Structural Insulated Panel for a Foundation Wall and Foundation Wall Incorporating Same |
US20100236173A1 (en) * | 2009-03-19 | 2010-09-23 | Sergiy Pacha | System of Wall Facings |
US7810296B1 (en) * | 2007-05-03 | 2010-10-12 | Blendi Turku | Sheathing assembly and method of sheathing a roofing structure |
US20120167504A1 (en) * | 2011-01-04 | 2012-07-05 | Mckinney John | Precast insulated concrete wall assembly |
US20120233950A1 (en) * | 2011-03-17 | 2012-09-20 | Cemwall Systems | Concrete wall systems and methods and spacers therefor |
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-
2004
- 2004-01-09 US US10/754,964 patent/US20050166533A1/en not_active Abandoned
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Publication number | Priority date | Publication date | Assignee | Title |
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US7810296B1 (en) * | 2007-05-03 | 2010-10-12 | Blendi Turku | Sheathing assembly and method of sheathing a roofing structure |
US20100088981A1 (en) * | 2008-10-09 | 2010-04-15 | Thermapan Structural Insulated Panels Inc. | Structural Insulated Panel for a Foundation Wall and Foundation Wall Incorporating Same |
US20100236173A1 (en) * | 2009-03-19 | 2010-09-23 | Sergiy Pacha | System of Wall Facings |
US20120167504A1 (en) * | 2011-01-04 | 2012-07-05 | Mckinney John | Precast insulated concrete wall assembly |
US20120233950A1 (en) * | 2011-03-17 | 2012-09-20 | Cemwall Systems | Concrete wall systems and methods and spacers therefor |
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Legal Events
Date | Code | Title | Description |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |