US20250327296A1

US20250327296A1 - Modular Construction System and Method Utilizing Prefabricated Units for Load-Bearing Walls

Info

Publication number: US20250327296A1
Application number: US19/097,479
Authority: US
Inventors: Kumarasamy Ganeshananth
Original assignee: Sonmill Ltd
Priority date: 2024-04-23
Filing date: 2025-04-01
Publication date: 2025-10-23
Also published as: GB202405726D0; GB2640544A

Abstract

This invention presents a construction system and method for assembling load-bearing walls that integrate prefabricated components for enhanced efficiency and structural integrity. The system comprises prefabricated sheet studs, created by interlocking flange sheets and web sheets into a hollow rectangular profile, which are wrapped at their interlocks with alkali-resistant mesh. Outer sheets are attached to these studs, forming prefabricated hollow wall units with defined cavities, serving as permanent wall formwork when assembled on-site. A filler material, selected for its insulation properties and structural strength, is introduced into these cavities, completing the construction of the load-bearing walls. This approach simplifies the construction process, offering a modular, efficient method for building durable, insulated walls capable of bearing structural loads, suitable for a wide range of architectural applications.

Description

FIELD OF INVENTION

The present invention relates generally to the field of construction, specifically to a system and method for erecting load-bearing walls. It involves the use of prefabricated hollow units and sheets designed for quick assembly and enhanced structural integrity.

BACKGROUND

The field of construction, particularly regarding the development and implementation of load-bearing walls, has long been a domain of continuous innovation and refinement. Traditional construction methods have laid the foundation for building practices, leveraging techniques such as bricklaying for block walls, stick build stud walls with timber or metal studs, panelized wall constructions, and concrete walls with false or permanent formwork. Each of these methodologies, while effective in their own right, carry inherent limitations and drawbacks that have spurred the search for more efficient, versatile, and cost-effective solutions.
Bricklaying, for instance, while a time-tested method, is labor-intensive and suffers from material inefficiency due to the extensive use of mortar joints. This traditional method also demands a significant degree of skilled labor, further escalating construction costs. Similarly, stick build stud walls, whether constructed with timber or metal studs, introduce challenges in terms of site installation speed, the requirement for skilled tradespeople, and difficulties in achieving airtight structures. Timber studs, in particular, face additional shortcomings related to fire resistance and susceptibility to moisture damage. Metal studs, while overcoming some of these issues, present their own challenges including higher thermal conductivity and the effective transmission of sound vibrations.
Panelized wall construction methods attempt to address some of these issues by preassembling wall sections in a controlled factory environment. However, this approach often necessitates custom-built panels for each specific project, limiting the scalability and flexibility of construction efforts. Moreover, both timber and metal stud-based solutions encounter complications in hanging objects from the walls and ensuring the airtight integrity of the structure.
The use of concrete walls with permanent formwork has emerged as a promising alternative, offering structural integrity and efficiency improvements. Proprietary systems such as the Logical Wall, Ritek Permanent Formwork Wall Systems, and the Fastform Wall System have demonstrated significant advancements. However, these systems often require custom-built formwork panels, intricate reinforcement works, and the handling of heavy materials, which complicates the construction process and limits flexibility.
In response to these challenges, the industry has been propelled towards the development of innovative construction methods that seek to harmonize efficiency, structural performance, and versatility. The quest for a solution has led to the exploration of lightweight, prefabricated units and sheets that can be readily assembled on-site, offering an alternative to traditional construction methods. This innovative approach aims to address the multifaceted limitations of existing systems by reducing labor requirements, streamlining the construction process, and providing enhanced thermal and acoustic performance. The pursuit of such advancements underscores a broader effort to enhance building practices, reflecting the industry's ongoing commitment to innovation and improvement.
EP1660734B1 outlines a building system using panels and studs tailored for constructing walls filled with concrete, where studs equipped with a head and flanges attach to panel facing sheets and secure spacer elements for assembly. The disclosure focuses on creating solid walls that necessitate a manual assembly of components to achieve the desired structural, thermal, and acoustic properties. It relies on concrete fill and a complex assembly of spacer elements and studs for wall construction, as opposed to minimizing construction complexity and potential material waste through a modular design.
WO2020098618A1 outlines a frame-type prefabricated wallboard system intended for the construction of prefabricated houses, particularly emphasizing the ease of manual transportation and assembly of wall panel and column modules in remote locations. This system consists of hollow, integrated frame constructions, including L-shaped, T-shaped, and ten-shaped columns, designed to be bolted together on-site. The method includes an option to fill frame voids with insulation materials. However, the lack of consideration of structural integrity and insulation properties within the prefabricated wall system is a disadvantage, leading to issues with load-bearing capacity and insulation performance.
It is within this context that the present invention is provided.

SUMMARY

This invention relates to a construction system and method for assembling load-bearing walls, which includes prefabricated sheet studs, outer sheets, and a filler material. The sheet studs, comprising interlocked flange sheets and web sheets wrapped with alkali-resistant mesh, form a hollow rectangular profile. Pairs of outer sheets attached to these studs create a cavity between the studs, forming prefabricated hollow wall units that serve as permanent wall formwork. The introduction of a selected filler material into this cavity provides both insulation and structural integrity to the formwork, facilitating the construction of load-bearing walls with enhanced efficiency and durability.
In some embodiments, the flange sheets and web sheets are made from materials such as cement fiber boards, moisture-resistant plaster boards, and calcium silicate boards, offering improved durability and resistance to environmental factors.
Further embodiments include one or more steel sections disposed within the sheet studs, attached to the inner surface of the hollow profile, enhancing the structural integrity and load-bearing capacity of the wall units.
In certain embodiments, the outer sheets are affixed to the sheet studs using a bonding material selected from construction adhesive and polymer-modified mortar, ensuring a strong and durable bond between the components.
Some embodiments further comprise one or more aligning guide members, aiding in the precise assembly of multiple prefabricated hollow wall units into a cohesive and straight wall formwork.
In additional embodiments, the filler material comprises foam concrete, known for its insulation properties and structural integrity, contributing to the overall energy efficiency and strength of the constructed walls.
Certain embodiments are further characterized by specialized prefabricated hollow wall units designed for corner and T-junctions, incorporating extended flange sheets and end sheets, facilitating seamless integration of wall units at architectural junctures.
Other embodiments include prefabricated external wall units equipped for façade element support, incorporating insulation and outer sheets designed for façade attachment, thus enhancing the aesthetic and functional aspects of the exterior walls.
Further, some embodiments include jamb sheet studs configured for integration into the wall formwork at positions corresponding to openings for doors and/or windows, ensuring structural support and alignment for architectural openings.
Additionally, embodiments may include lintel units comprising sheet studs and outer sheets, reinforced with steel sections and equipped with fin plates for secure attachment over jamb sheet studs, providing robust support for overhead loads.
In some embodiments, the prefabricated hollow wall units are configured to incorporate back boxes for switches and outlets, facilitating the integration of electrical services within the wall structure.
Lastly, in certain embodiments, the alkali-resistant mesh wrapping the interlocks between the flange sheets and web sheets is made of fiberglass, offering enhanced durability and resistance to alkali-related degradation.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention are disclosed in the following detailed description and accompanying drawings.

FIG. 1 illustrates an example exploded view of the components of a sheet stud with web and flange sheets separated.

FIG. 2 illustrates an example top-down view of an assembled sheet stud with reinforcing gauges installed with screws.

FIG. 3 illustrates an example isometric view of the sheet stud in an assembled state with mesh wraps securing the flange and web sheets together.

FIG. 4 illustrates an example top-down view of an assembled prefabricated wall unit comprising a pair of outer sheets coupling two standard sheet studs together by attachment to their opposing parallel edges.

FIG. 5 illustrates an example isometric view of the prefabricated wall unit showing the cavity between the coupled sheet studs.

FIG. 6 illustrates an example exploded view of components of a sheet stud designed for connecting corners and T Junctions in the formwork.

FIG. 7 illustrates an example isometric view of the connecting sheet stud designed for corners and T Junctions.

FIG. 8 illustrates an example isometric view of a wall showing the assembly of multiple prefabricated wall units being aligned along one edge by a guide member.

FIG. 9 illustrates an example isometric view of a subsequent step in construction of the wall, showing the installation of outer sheets onto the prefabricated wall units.

FIG. 10 illustrates an example isometric view of the constructed wall in an assembled state with filler material sealing the hollow portions.

FIG. 11 illustrates an example top-down view of an assembled external wall unit with facade supporting elements such as insulation filler.

FIG. 12 illustrates an example isometric view of the external wall unit with façade supporting elements.

FIG. 13 illustrates an example front view of an external wall jamb stud with a Fin plate installed and outer sheets that reach a desired height for doors/windows.

FIG. 14 illustrates an example top-down view of the external wall jamb stud.

FIG. 15 illustrates an example isometric view of the external wall jamb stud with a Fin plate installed and outer sheets that reach a desired height for doors/windows.

FIG. 16 illustrates an example top-down view of a prefabricated external wall lintel unit with horizontal steel sections and outer sheets comprising lintels.

FIG. 17 illustrates an example side view of the prefabricated external wall lintel unit.

FIG. 18 illustrates an example isometric view of the external wall lintel being assembled together with a pair of external wall jamb studs to form a doorway.

FIG. 19 illustrates an example cutaway view of the assembled doorway, revealing the connections between the steel sections and the Fin plate.

Common reference numerals are used throughout the figures and the detailed description to indicate like elements. One skilled in the art will readily recognize that the above figures are examples and that other architectures, modes of operation, orders of operation, and elements/functions can be provided and implemented without departing from the characteristics and features of the invention, as set forth in the claims.

DETAILED DESCRIPTION AND PREFERRED EMBODIMENT

The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.
Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

Definitions

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
As used herein, the term “and/or” includes any combinations of one or more of the associated listed items.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise.
It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.
When a feature or element is described as being “on” or “directly on” another feature or element, there may or may not be intervening features or elements present. Similarly, when a feature or element is described as being “connected,” “attached,” or “coupled” to another feature or element, there may or may not be intervening features or elements present. The features and elements described with respect to one embodiment can be applied to other embodiments.
The use of spatial terms, such as “under,” “below,” “lower,” “over,” “upper,” etc., is used for ease of explanation to describe the relationship between elements when the apparatus is in its proper orientation.
The terms “first,” “second,” and the like are used to distinguish different elements or features, but these elements or features should not be limited by these terms. A first element or feature described can be referred to as a second element or feature and vice versa without departing from the teachings of the present disclosure.
For the purposes of this patent, ‘prefabricated sheet studs’ are understood to encompass any assembly of interlocking flange sheets and web sheets, regardless of the specific locking mechanism employed. The term ‘interlocking’ should be broadly interpreted to include any form of engagement between flange sheets and web sheets that allows for the formation of a stable, hollow rectangular profile. Examples of materials suitable for the construction of these components include, but are not limited to, cement fiber boards, gypsum boards, and any composite material known to those skilled in the art to offer comparable structural properties.
The term ‘alkali-resistant mesh’ as used herein is intended to cover any mesh material capable of resisting degradation when exposed to alkaline conditions commonly found in construction environments. This includes fiberglass mesh, carbon fiber mesh, and any synthetic polymer mesh providing similar resistance.
When the term ‘attached’ or ‘affixed’ is used in relation to outer sheets and sheet studs, it encompasses a range of attachment mechanisms including, but not limited to, adhesive bonding, mechanical fastening (e.g., screws, nails, rivets), and interlocking mechanisms. The choice of bonding material for attaching outer sheets to the sheet studs includes construction adhesives, polymer-modified mortars, and any other adhesives known to those skilled in the art to be suitable for construction applications.
The ‘filler material’ described for insertion into the cavity of the wall units may include, but is not limited to, foam concrete, hempcrete, insulation foams, or any material that solidifies to provide structural integrity and insulation. Foam concrete, for instance, may be specified to have a density range suitable for the intended load-bearing requirements and insulation properties.
Furthermore, the construction system may include ‘guide members’ which are understood to be any structural element or tool designed to assist in the alignment and assembly of the prefabricated hollow wall units. This could include temporary bracing, alignment jigs, or laser-guiding systems.

DESCRIPTION OF DRAWINGS

The present invention relates generally to the field of construction, and more specifically, to a construction system and method for assembling load-bearing walls. This innovative approach utilizes prefabricated components, including sheet studs and outer sheets, which are designed to be easily assembled on-site to form the structural walls of a building. The system aims to streamline the construction process, offering a method that is not only efficient but also provides enhanced structural integrity and insulation properties to the resulting load-bearing walls.
The invention encompasses a set of prefabricated sheet studs, which are created by interlocking flange sheets and web sheets to form a hollow rectangular profile. These studs are then wrapped at their interlocking points with an alkali-resistant mesh to ensure durability and resistance to environmental factors commonly encountered in construction settings. Outer sheets are attached to these studs, forming prefabricated hollow wall units. These units, when assembled on-site, create a formwork into which a selected filler material is introduced. The filler material, chosen for its insulation properties and structural integrity, solidifies within the formwork, completing the construction of the load-bearing walls.
Referring now to the drawings, a set of example configurations of various aspects of the invention will be described.
FIG. 1 provides an exploded view of the components that form a sheet stud 100. The sheet stud 100 is constructed from web sheets 104 and flange sheets 102, which are designed to interlock to form a hollow rectangular profile, along with a set of reinforcing steel gauge sections 106 connected via screws 107. This configuration not only facilitates ease of assembly but also contributes to the structural integrity of the wall system. The modular nature of the sheet stud 100 allows for customization in terms of size and shape to accommodate various architectural requirements.
FIG. 2 shows a top-down view of an assembled sheet stud 100, where reinforcing gauge steel sections 106 have been installed using screws. These steel sections 106 are optional components that can be incorporated within the sheet stud 100 for additional support, especially in applications requiring enhanced load-bearing capacity.
FIG. 3 is an isometric view of the sheet stud 100 in an assembled state, with alkali-resistant fiberglass mesh 108 wrapping the junctions where the flange sheets 102 and web sheets 104 meet. The mesh 108 serves a dual purpose: it secures the sheets together, reinforcing the structural integrity of the stud, and it provides resistance to environmental degradation, particularly in alkali-rich environments common in construction settings.
FIG. 4 presents a top-down view of an assembled prefabricated wall unit 110, which includes a pair of outer sheets 112 coupling two standard sheet studs 100 together by attachment to their opposing parallel edges. Notably, the outer sheets 112 cover only half of each edge of the sheet studs 100. This strategic design leaves room for additional outer sheets to attach to the exposed portions of the edges when multiple prefabricated wall units 110 are assembled side-by-side, facilitating the creation of a continuous wall structure.
FIG. 5 provides an isometric view of the prefabricated wall unit 110 depicted in FIG. 4 . This perspective further illustrates the spatial relationship between the sheet studs 100 and the outer sheets 112, as well as the cavity 114 formed between the sheet studs 100 within the unit. The cavity 114 is designed to be filled with a selected filler material, such as foam concrete, to provide insulation and additional structural support once the wall unit 110 is installed.
FIG. 6 depicts an exploded view of the components forming an alternative sheet stud 150, specifically designed for connecting corners and T Junctions within the wall formwork. This variant of the sheet stud includes extended flange sheets 152 and end sheets 154, alongside the standard web sheets 104.
FIG. 7 offers an isometric view of the assembled connecting sheet stud 150 from FIG. 6 . This view showcases how the extended flange sheets 152 and end sheets 154 interlock with the web sheets 104, forming a robust and coherent structure. Alkali-resistant fiberglass mesh 108 wraps the assembled junctions, reinforcing the connections and providing environmental resilience. The connecting sheet stud 150 helps in maintaining the structural coherence of the wall system at corners and T junctions.
FIG. 8 illustrates an isometric view of a wall assembly, where a plurality of prefabricated wall units 110 are being aligned and connected along one edge by a guide member 160. The guide member 160 ensures the vertical and horizontal alignment of the wall units 110, facilitating a precise and straight construction of the wall formwork, achieving uniformity and structural integrity during the assembly process.
FIG. 9 presents an isometric view showing a subsequent step in the wall construction, where outer sheets 162 are installed onto the aligned prefabricated wall units 110 of FIG. 8 . The outer sheets 162 are attached to the exposed edges of the sheet studs 100 within each wall unit 110, effectively enclosing the wall formwork and preparing the structure for the introduction of the filler material. This step helps in sealing the wall units and enhancing the overall stability and insulation of the wall system.
FIG. 10 displays the constructed wall in its assembled state, following the installation of the outer sheets 162 and the introduction of filler material 164 into the hollow portions of the wall formwork. The filler material 164 solidifies within the cavities, providing both insulation and additional structural support to the wall.
FIG. 11 presents a top-down view of an assembled external wall unit 170, incorporating façade supporting elements such as insulation 172. The unit is designed to facilitate the attachment of various façade elements, enhancing the thermal performance and aesthetic appeal of the exterior walls.
FIG. 12 offers an isometric view of the external wall unit 170 shown in FIG. 11 , further detailing the arrangement of façade supporting elements, including the placement of insulation 172.
FIG. 13 displays a front view of an external wall jamb stud 174 equipped with a fin plate 176. Outer sheets 178 extend to a predetermined height suitable for accommodating door or window openings.
FIG. 14 provides a top-down view of the external wall jamb stud 174 depicted in FIG. 13 . This view shows the configuration of the fin plate 176 in relation to the outer sheets 178, demonstrating how the jamb stud assembly supports the structural integrity around openings.
FIG. 15 is an isometric view of the external wall jamb stud 174, further illustrating the assembly with a fin plate 176 and outer sheets 178 reaching the desired height for doors or windows. This perspective offers a comprehensive view of how the jamb stud integrates into the wall formwork, supporting openings and enhancing the wall's structural framework.
FIG. 16 features a top-down view of a prefabricated external wall lintel unit 180, showcasing horizontal steel sections 182 and inner 183 and outer sheets 184 that comprise lintels. This assembly provides robust support over openings, ensuring the load is adequately transferred and distributed.
FIG. 17 provides a side view of the prefabricated external wall lintel unit 180 introduced in FIG. 16 , now with both vertical steel section 186 and horizontal steel sections 182 visible along with the outer sheets 184. The side of the lintel opposite the steel sections is for the façade.
FIG. 18 illustrates an isometric view of the assembly process for an external wall lintel unit 180 with a pair of external wall jamb studs 174, forming the framework for a doorway.
FIG. 19 provides a cutaway view of the assembled doorway structure, with the outer sheet 184 and inner sheet 183 of the lintel partially removed to reveal the connections between steel sections 186 and 182 and the fin plate 176, as well as the internal sheet studs.

CONCLUSION

Unless otherwise defined, all terms (including technical terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The disclosed embodiments are illustrative, not restrictive. While specific configurations of the system and method of the invention have been described in a specific manner referring to the illustrated embodiments, it is understood that the present invention can be applied to a wide variety of solutions which fit within the scope and spirit of the claims. There are many alternative ways of implementing the invention.
It is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.

Claims

What is claimed is:

1. A construction system for assembling load-bearing walls, comprising:

a plurality of prefabricated sheet studs configured to form a hollow rectangular profile, each sheet stud comprising interlocked flange sheets and web sheets, where the interlocks between the flange sheets and web sheets are wrapped with alkali-resistant mesh;

a plurality of outer sheets configured for attachment to the prefabricated sheet studs, wherein pairs of outer sheets are attached to parallel edges of corresponding pairs of prefabricated sheet studs, defining a cavity between the pair of sheet studs, to form one or more prefabricated hollow wall units that serve as a permanent wall formwork of a building structure; and

a filler material for insertion into the defined cavity of the one or more wall units to create the load-bearing walls, the filler material being selected to provide insulation and structural integrity to the wall.

2. The construction system of claim 1, wherein the flange sheets and web sheets are selected from the group consisting of cement fiber boards, cement particle boards, and calcium silicate boards.

3. The construction system of claim 1, further comprising one or more steel sections disposed within the plurality of sheet studs, attached to an inner surface of the hollow rectangular profile.

4. The construction system of claim 1, wherein the outer sheets are affixed to the sheet studs by a bonding material selected from the group consisting of construction adhesive and polymer-modified mortar.

5. The construction system of claim 1, further comprising one or more aligning guide members configured to facilitate the assembly of multiple prefabricated hollow wall units into formwork.

6. The construction system of claim 1, wherein the filler material selected from the group consisting of foam concrete and hempcrete.

7. The construction system of claim 1, further including one or more prefabricated hollow wall units specifically designed for corner and T-junctions, said specialised hollow wall units incorporating extended flange sheets and end sheets to alter their rectangular profiles.

8. The construction system of claim 1, further including one or more prefabricated external wall units equipped for façade element support, incorporating insulation and outer sheets for façade attachment.

9. The construction system of claim 1, further including one or more jamb sheet studs configured for integration into the wall formwork at positions corresponding to openings for doors and/or windows.

10. The construction system of claim 1, further including one or more lintel units comprising sheet studs and outer sheets, and reinforced with steel sections, the lintel units being adapted for positioning over jamb sheet studs with the inclusion of fin plates for attachment.

11. The construction system of claim 1, wherein one or more of the prefabricated hollow wall units are configured to incorporate back boxes for switches and outlets.

12. The construction system of claim 1, wherein the alkali-resistant mesh is a fibreglass mesh.

13. A method for constructing load-bearing walls, comprising the steps of:

providing a plurality of sheet studs, wherein each sheet stud is formed by interlocking flange sheets and web sheets to create a hollow rectangular profile, and wrapping the interlocks between the flange sheets and web sheets with alkali-resistant mesh;

attaching pairs of outer sheets to the edges of corresponding pairs of sheet studs to form prefabricated hollow wall units, each unit defining a cavity between the pair of sheet studs;

assembling the prefabricated hollow wall units on-site to construct wall formwork; and

introducing a filler material into the cavities of the assembled wall formwork.

14. The method of claim 13, further comprising the step of utilizing guide members to facilitate the vertical alignment and positioning of the prefabricated hollow wall units during assembly.

15. The method of claim 13, further comprising the steps of assembling specialized prefabricated hollow wall units for corner and T-junctions by incorporating extended flange sheets and end sheets.

16. The method of claim 13, further comprising the steps of preparing prefabricated external wall units equipped for façade support by incorporating insulation and attaching outer sheets for façade elements.

17. The method of claim 13, further comprising the step of positioning jamb sheet studs within the wall formwork at locations corresponding to openings for doors and windows.

18. The method of claim 13, further comprising the steps of fabricating and integrating lintel units into the wall formwork, wherein the lintel units are reinforced with steel sections, and securing the lintel units over jamb sheet studs using fin plates for attachment.

19. The method of claim 13, further comprising the step of cutting the sheet studs and outer sheets to predetermined lengths to accommodate specific architectural requirements.

20. The method of claim 13, further including the step of pre-installing back boxes for switches and outlets within the prefabricated hollow wall units prior to the introduction of the filler material.