Static structures (e.g. – buildings) – Processes – Barrier construction
Reexamination Certificate
2000-05-15
2003-07-01
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Processes
Barrier construction
C052S223700, C052S565000, C052S749100, C052S749100
Reexamination Certificate
active
06584750
ABSTRACT:
This application claims the priority of PCT/AU98/00652, filed Aug. 19, 1998, which in turn claims the priority of Australian patent application numbers PO8647 filed Aug. 19, 1997, PP1067 filed Dec. 19, 1997, and PP3966 filed Jun. 9, 1998, all of which are incorporated herein by reference.
1. Field of the Invention
This invention relates to a system or method for the modular construction of walls of the type used in the building industry generally and in the housing industry in particular. The system or method is suitable for construction of both load and non-load bearing walls. The system is called the STRONGWALL™ construction system.
2. Background to the Invention
Structural walls, as generally used in the building and housing industries, fall into one of the following categories, being blockwork construction; in situ concrete, or similar curing material; prefabricated panels, requiring a secondary process, such as post-tensioning, or on site bolting.
Brickwork or blockwork wall construction requires the slow, labour intensive process of mortaring each joint, maintaining strict discipline to, horizontal and vertical alignments and requires scaffolding for lifts greater than 1.8 metres, increasing cost and slowing construction. This category is greatly affected by the weather.
Clad framework is also labour intensive whether the framework is fabricated from steel, timber or other material. Modern construction tools, fasteners and equipment needs to be employed. It is also greatly affected by weather conditions.
In situ concrete wall construction is similarly labour intensive, requiring teams to construct formwork, place reinforcement erect scaffolding, propping and shoring; and then pour the concrete. The forming, placing and curing time create extra costs and lengthy construction time. Any errors in the process necessitate expensive remedies and long delays and, again, the process is greatly affected by weather conditions.
Prefabricated panels relieve many of the problems associated with the previous methods, by substantially reducing time on site, and confining much of the labor intensive work of fabrication to an efficient factory environment. However, to make such a system cost effective, the panels need to be of such a scale that cranes are required in the factory and on site to move and place the panels, and methods of connection and alignment become secondary processes that add to the cost of construction.
In each of the prior art methods of construction, a high degree of direct supervision and/or a highly skilled work force is required to efficiently and safely construct a wall of acceptable quality and standard.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a fast and economical system or method of construction of a wall that reduces the dependency on. skilled labour; cranes; modern construction tools and fasteners; and scaffolding for the construction of load bearing and non-load bearing walls.
With this object in view, the present invention provides, in a first aspect, a method of construction of a wall from first, second and end modules each having a portion forming part of the wall including:
aligning a first or end module and one of: a first and an end module in a desired alignment;
connecting the two modules together with at least one connection means, having a tie portion generally extending in the direction of the alignment, to form a supporting structure for at least one second module;
connecting a second module to the supporting structure by cooperation of a connection portion of the second module with a corresponding connection portion of said supporting structure to form at least a portion of the wall.
In this form of the invention, first and end modules may be called supporting modules.
In a preferred embodiment of the invention, the connection portion of the second module cooperatively engages with a corresponding portion of the tie portion of the connection means. Such engagement allows connection of the second module to the supporting structure forming part of the wall and may allow, during construction, the second module to be temporarily hung from the supporting structure, which may be called a hanger unit.
The connection means may be provided with one or a number of guide means for locating the second module in a desired space relation to the supporting structure. The guide means are positioned appropriately relative to the tie portion to achieve this objective. The guide means may form part of the tie portions with the corresponding tie portions extending between them.
The first, end or first and end modules may be connected together by a plurality of connection means spaced along vertical lengths of the adjoining modules providing a plurality of corresponding different tie portions for engaging cooperation with plural connection portions of the second module allowing connection to the supporting structure. The connection means may be the same or different, for example connection means connecting first modules may be different in length than those connecting end modules; or first and end modules. Length may be dictated by flange length of adjoining modules. At least two such connection means may be used to connect adjoining modules therefore providing at least two corresponding tie portions for engagement with two second module connection portions. A greater number than two may be used as necessary.
The second modules may have a T-section with a flange portion and a vertically extending web portion provided with at least two connection portions. In this case, the corresponding tie portions may have length substantially equal the width of the web of the second module. First modules may also have a T-section with a flange portion and a web portion and may be assembled from L-shaped or other sub-first modules, for example half modules, where desired. On connection, the vertically extending web portions of second modules extend between the guide means of the connection means.
In a particularly preferred aspect of the invention, bevelled slots or cuts may be employed as second module connection portions which, during construction, engage with rods forming at least two corresponding tie portions of said connection means for connection of second modules to the supporting structure. This should enable secure connection between the second module and the supporting structure but use of further fastening is not precluded.
The wall may include a number of end modules defining the start and end of the wall. End modules may have an L-section rather than a T-section preferred for the first and second modules and may be similar to a half section. The same wall may also have one or more starts and ends along its length. At each start and end an end module may be connected with connection means, as described above, to a first module. End modules may be connected together to form supporting structures for second modules, notably at piers in a piered wall construction.
End modules may also define openings in a wall such as doors and windows. For these cases and also in the case of the same wall abutting another wall (for example, at right angle to it) the end modules may be connected by connection means to a door or window frame or similar fitting or to another wall. Connection means may be hook bracket assemblies with co-operating portions fixed to the door or window frame and end modules at each side of the door or window frame and fixed to the end module and the abutting wall. Hook bracket assemblies on either side of the door or window frame are advantageously in inverted relation to each other to facilitate construction.
In analogous manner, internal walls or partitions may be connected to other walls or partitions of the structure with hook bracket assemblies. Thus a first wall or partition may be connected to a second wall or partition by hook bracket assemblies having first cooperating portions connected to the first wall or partition along a line of desired connection and second cooperating portions connected along a vertical l
Dorsey & Whitney LLP
Friedman Carl D.
Slack Naoko
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