| Claims 1 . An open lattice pre-fabricated frame structure of hollow section beams, configured for selective local demountable panel infill, with conduit pathways for services between and/or within frame sections for selective connection to panels. 2. A structure of Claim 1 , with laminated or sandwich layered panel construction, allowing a diversity of outer cladding with inner lining. 3. A structure of either preceding claim, with through-fasteners between frames and/or panels and local capture or spreader plates for mutual entrainment, capture and retention with sealing intervention. 4. A structure of any preceding claim, with a vapour or moisture barrier sheet layer or membrane between opposite internal and external panel faces. 5. A structure of any preceding claim, with a protruding peripheral edge strip seal as a marginal overhang or overlap for a juxtaposed frame and/or panel. 6. A structure of any preceding claim, with demountable roof canopy frame modules. 7. A structure of any preceding claim, with a frame set to a rectangular grid array, with contiguous straight and/or curved frame members to achieve a desired outer frame profile. 8. A structure of any preceding claim, with a roof module frame assembly housing conduit or ducting in a loft space for heating and ventilation ready for installation and commissioning. 9. A structure of any preceding claim, with a flue or chimney stack, such as for a boiler, fitted within an ancillary adjunct module with ventilated, say mesh, external bounding wall isolated from the remaining structure. 10. A structure of any preceding claim, with optional cross-bracing or stiffening, set within frame bounds or confines, and compatible with or alongside other panel infill. 11 . A structure of any preceding claim in a mixed format building construction, with a core conduit frame support for conventional infill and/or cladding elements, under a roof canopy set upon the frame. 12. A structure of any preceding claim, with the frame faces juxtaposed with panel edges and/or faces. |
This invention relates to prefabricated assemblies, and is particularly, but not exclusively, concerned with prefabricated building structures. Core support, infill and cladding elements have certain roles. A mixture of prefabrication and conventional build is admitted. Steel frames are well-rehearsed, as are panel structures, per se, but the combination or seamless integration of such elements poses challenges. Metal, specifically steel, frame buildings are known, but the frame section profile needs careful consideration of the interface with infill and cladding. Conventional steel frame construction, using standard cross-sections, has a role in bespoke build, but can prove inflexible or limited in scope. IStructure categories includes stacked or tiered (wall) elements, such as bricks or blocks, which may be load-bearing, and structural frames for cladding; with transverse bridging beams and/or load-bearing panels spanning between walls or piers.
Generally, the more that is pre-built off-site, the more critical the conformity to a design plan, to ensure ready installation fit on-site, without laborious adjustment or infill. This may require a certain dimensional tolerance and stable temperature coefficient of expansion. A predominantly metal, say steel, frame can undergo significant dimensional change, as compared with say more inert elements such as brick or block work or timber.
One approach envisaged by the Applicant according to the invention is a support structure of common material with rigid joints and couplings, but allowing an intervening infill cladding or internal partition of different mixed materials, with intervening compliant mounting bearer elements and gasket seals for a weather-resistant outer shell or skin. In one aspect of the invention, a closed hollow frame section is adopted for flush-face fit with infill panels to create an outer wall.
In a traditional build the roof is typically a separate structure supported by external walls or frame upstaged and constructed incrementally on site. The Applicant envisages prefabricated tile-clad roof modules which can be mounted directly upon a frame upright directly erected and from which underlying floors can be suspended. Aside from the structure, the accommodation and routing of services, and again their adaptation for off-site pre-fitting has a bearing upon build time and simplicity. The former differentiation between traditional so-called first and second fixes would become blurred, or evaporate altogether.
On-site construction is subject to the vagaries of weather. Internal elements are vulnerable unless and until protected within a weatherproof shell. This favors emphasis upon the exterior at the outset of construction. However, this may not reflect optimum juxtaposition of exterior and interior elements, which might better justify a shared structure. On-site assembly from sub-assemblies built remotely and in more comfortable and controllable environment simplifies and streamlines the on-site task.
Prefabrication implies some parts made in advance and to a sufficient accuracy to ensure universality of matching fit with other components made separately at different times. Flexibility of outcome using a large proportion of sub-assemblies selected from a common library range; sub-assemblies themselves can also use a proportion of common component stock.
The Applicant envisages a modular lattice frame and intervening panel infix for on-site mutual assembly and mounting. Ready panel installation and a facility for change or interchange is desirable. Another challenge is to establish and preserve a dimensional rigor, which preserves conformity of intermit with other elements and overall structural integrity. This in turn allows a modular build, such as with 'mix and match' discrete individual modules. Individual frame elements individually and collectively in a derivative frame assembly have an inherent integrity; similarly with individual panel elements individually and collectively either directly interconnected or through the intermediary of a frame assembly.
Diverse prefabricated building systems have been devised, but not all lend themselves to an economic range of building sizes and formats meeting prevailing stringent regulation codes, such as those on environmental material consumption and low energy running. The provision, installation and routing of services conduit and the outer and internal cladding and 'leak and draft proof peripheral edge sealing of infill panels to a lattice frame are other considerations. It would be advantageous from a production (fabrication and assembly) standpoint to adopt a common frame section for a diversity of structural forms and sizes. A similar consideration applies to infix panel shape and size, at least within a given structure, to allow a standardized stock holding regime. The manner of frame jointing and panel mounting attachment should conveniently allow variable, interchangeable and/or adjustable configurations. Insulation at joints and seams and avoidance of leakage through gaps and exposed contact services by so-called 'thermal bridging' and attendant heat loss is desirable. A simple peripheral edge capture and mounting with minimal local fastening would help site installation.
Metal, in particular steel, framing is a common (lattice) spine or 'core' element, especially for taller buildings, and in clear-span portal framing for large (wide) span sheds, but historically traditionally less so for smaller domestic structures, although individual bespoke builds have employed structural steel local beams and on occasion framing, such as for roof, floor or stairway support and bracing; but usually in combination with traditional (block and brick) building techniques. Formative steel industry (Corus, per http://www.corusconstruction.com/en/) sponsored experimental attempts at low cost local authority housing have encountered condensation issues and have not been widely adopted. Later work has pursued the flexibility, light weight, strength, recyclability and durability of steel for house building particularly in conjunction with glass infill or cladding panels. Steel has not only been used in frames, but for infill walls. Multiple housing units, such as apartments also lend themselves to steel usage and offsite construction techniques. Wet trades can be reduced or obviated with less on-site wastage, [http://www.channel4.com/4homes/div-self-build/self-build-ad vice/a-z-of- self-build-guides/steel-frame-houses-09-01 -26 p 1 .html : also http://www.greendaieconstruction.com/: Another contemporary example of pre-fabricated steel braced or reinforced panel and boxed panel construction is Envirohouse(TM). Previous modest scale prefabricated panel and frame systems, some with embedded pitched roof trusses, include US 5,657,606 Ressel et al, US 4,559,748 Ressel, US 5,950, 374 Gromat. These have not integrated frame conduit, of services nor compact umbilical plumbing and routing. (Cast) concrete metal bar-reinforced panel structures have also been devised, but some have had problems of weather-proof sealing against moisture penetration and ingress with consequential internal damp. Timber frame prefabrications principally for individual domestic housing, but latterly for commercial use such as restaurants have also established a market niche by German suppliers triggered by post war housing and military occupancy dictates. Precast concrete panel structures have also been promoted, but with mixed success on sealing and ventilation against dampness and fungal growth. Consumer appeal of an aesthetic which appears system built against tradition is a bar to popularity and widespread adoption to achieve economies of scale. To counter this, flexibility in configuration from a common stock with a factory environment offers attractively short site build assembly times. One issue in justifying prefabrication is the ready repeatability of elements with overall design diversity, the investment in factory facilities, stocking and the availability of skills. The economics of transporting prefabricated elements long distances from factory of origin to remote sites is also a factor.
Statement(s) of Invention
A matrix, lattice or grid of spine frame members configured as a structural support matrix core of hollow frame members, with internal routing to accommodate services conduit. A hollow closed frame cross-section is a convenient format. Thus, a closed-section hollow rectangular box section frame provides convenient external mutually orthogonal flat surfaces for abutment and location with infill panels, along with a secure internal conduit for services routing and containment. An otherwise closed box section can be cut open locally, such as on one side face, to achieve, say, a local 'C or 'U' section frame, with an open-sided slot to allow access to the interior; and to an opposite frame side for through-fastener insertion. A panel assembly for mounting on the frame assembly comprising an inner core bounded by demountable (exterior and interior) cladding, with an edge interface with the frame through or alongside a peripheral edge seal strip element. A modular, otherwise open-sided, space supportive frame and selective intervening local panel infill assembly, with local infill by a plurality of panels bounded by a peripheral edge seal or face abutment joint. Thus a panel edge could sit in the throat, embrace, or juxtaposed to one side of, an otherwise open-sided frame member. An internal or face lining membrane, say with protruding edge strip or flap for overlay with that of another panel at overlapping or abutting edge joints, could be employed as a moisture barrier. A panel could be solid infill, wholly or partially glazed as fenestration, with doorway access and appropriate overall thermal insulation qualities. Separation of the frame from intervening infill allows a flexible
construction, to a modular grid layout. Thus, frame openings can be selectively filled or populated with discrete panel elements, which themselves could be self-contained with finished outer and inner faces, or of partial completion, say with only inner finished surfaces. An overlying roof structure can be used to help support and underlying suspended floor frame. A separate prefabricated roof truss assembly could be assembled in modules before wall mounting, for easier fitment of a water-proof surface layer and peripheral margin or edge sealing strips or facia plates. This also allows installation of facilities within the roof or attic void, such as (water) tanks, venting and ducting for heating and/or ventilation. To help distribute loads throughout the structure and retain a modest frame section size, it would be convenient to contrive an otherwise open lattice, grid or matrix for selective local panel infill. The panel outer cladding or coverage options include rendered finish facings or coatings, such as plaster or cement (stucco style) with smooth or roughcast surface finish. Paints or stains with polymer binders could be applied for additional weather resistance. Sprayed-on plastics polymer coatings, such as used on vehicle load beds, might also be considered where a tough, robust wearing 'under or top seal' layer is desirable. These might also have a role in load support or walkway surfaces. Whilst the frame and infill panel approach lends itself to contemporary designs, and is consistent with established institutional or commercial structure designs, it might not suit all domestic tastes. The outward appearance, ie overall style, form and surface, of a conventional build could be contrived around a contemporary core frame. Thus the frame could be concealed from outside and to some extent inside. Alternatively, a blend of traditional, 'retro' or past revisited and contemporary styles could be struck. To help support a rendered outer skin, a preparatory wire mesh 'containment' barrier layer could be fitted over the frame and infill panels. Such mesh could be malleable to follow underlying contours or tensioned or stretched to bridge or span underlying surface unevenness or discontinuities. A certain surface layer resilience or flex could be admitted to accommodate 'natural' material movement. This might also help shrug off moisture. An adjustable surface tensioner, such as cylindrical roller follower, could be employed to bolster surface 'skin' stretch and recovery. Earth shock or quake resistance could be imparted by reliance upon a semi-rigid or compliant core with frame stilts set upon cushion bearing pads and flexible frame mountings for infill panels. Differential thermal expansion coefficients and moisture absorbency of component elements could be accommodated by allowing certain relative movement, along with passive or force venting or purging, such as through service conduit channels. Air recirculation through the frame and panel conduits could be used for a 'healthier' environment, say to counter so-called 'sick building' syndrome. An ability to flex and recover, or 'pulse' sympathetically, would also be useful under high wind loadings such as in exposed settings. The frame and infill is primarily a rigid structure, but the frame could be used to support a deformable skin, such as a fabric canopy, as might feature in canopies for stadia. Similarly, modestly flexible frame elements might be used for such canopies - in the manner of sail and mast - better to accommodate wind loading.
A pre-fabricated, factory-built core can be combined with an otherwise conventional exterior shell, such as of brick or block work, if necessary with mutual locating and bracing ties, struts or stays. The core could be constructed first, as a self-contained operational unit, for separate subsequent build of an outer shell. Alternatively, such as with a barn conversion, the core assembly, sub-assembly or core elements could be lowered as an entity or piecemeal into an existing shell. An outer sheath or wrap, such as a tensioned plastics, metal fabric skin could be fitted around a perimeter frame, in the manner of a tent, marquee or wind-break. This as an outer finish, or a temporary protective film wrap or shroud. Frame stanchion outer profiles could be rounded and/or fitted with roller or slide elements, for low friction, load spreading fabric contact. Local fabric skin portions could be selectively reeled back to expose the inner core for access in an 'alfresco' summer climate, sun lounge or orangery, operational mode. In hotter climes greater use could be made of 'breathable', but moisture repellent coated, fabric cloaking or infill in one or more layers, in an umbrella, tent or marquee format. Fabric walls could be suspended from a cantilever roof eaves perimeter overhang in an adjustable roller blind action. Other blind styles, such as vertical panels upon a carrier rail, or shutters and/or louvered panels could also feature in infill panels or an outer layer.
Frame elements could be mutually entrained or tied, say with cable stays with opposite end mountings, orientated as transversely or diagonally when deployed or unravelled, to allow bundled delivery to site, then unbundling and mutual separation until intervening ties tensioned as a spacing limiter. Once perimeter frame upright stanchions are set in place upon respective foundation pads, cable tension could be adjusted, so the cables serve as restraint and counterpoised bracing stays. One or more levels and/or layers of circumferential cable rings could be used around or through the perimeter frame stanchions. Cables, chains or link plates, rather than say rigid tie rods, could also be used for floor suspension. A frame could be re-configured to a different, say, sub-divided or polygonal segmented footprint or floor plan, by mounting frame upright stanchions upon spreader pads, mobile legs or stilts, with ground running wheels or skids resting upon foundation bearer slabs. Similarly, telescopic tiers could be contrived to allow adjustment of between tier spacing or indeed wholesale conjoining or merger of tiers by raising underlying tiers and/or lowering overlying tiers using internal runners upon a perimeter frame. This would be useful for theatrical, cinematographic or event staging such as indoor or outdoor show ground, arena, displays or exhibition stands. Different tiered floor shapes and sizes could be carried by a common perimeter frame and/or suspension ties from a common overlying truss-braced roof. The roof could be a unitary canopy with perimeter eaves and drainage guttering overhang or itself fragmented or locally apportioned, say tiered to reflect respective underlying floor tiers.
Floor and/or wall and/or roof frames could feature (re-)movable or changeable infill. Multi-layer or juxtaposed multiple peripheral walls could create internal passages, such as for layered security shells (such as for bio-security in medical, laboratory or manufacturing) or corridors for access. A diversity of solid, resilient or flexible fabric exterior infill cladding and interior partition walls could be fitted, allowing variable appearance and sub-division. A frame could be mobile and re-configurable for transition between internal, say exhibition hall or studio environment and outside use where weather proofing is required. To facilitate such conversion, a protective security roller shutter infill between or over the peripheral or circumferential frame could span from, say, roof eaves to ground, with shutter slats solid or perforated for local effect. Floor beams are conveniently fabricated from standard rectangular hollow closed or open-sided sections with rounded corners and longitudinal face cut-out slots and residual transverse bridging strips or lands to form externally accessible internal conduit channels within the beam cross-section. Round tubes, pillars or columns could be contemplated for aesthetic effect, with flanges for jointing.
Demountable and interchangeable (partial or wholesale) room modules could be carried by and within the embrace of an otherwise open lattice support or carrier frame. A frame could extend beyond, ie above, below or to one or more sides of a panel or roof infill envelope, to allow for later expansion with more infill. This on the basis that it is cost-effective to settle a common structure upon an initial foundation justified by the immediate infill, but allowing further infill without fresh foundation. That said, the frame itself could be extendible, say by upward extension or lateral cantilever, upon a fixed foundation designed from the outset for that. A multi-layered panel or inter-nesting sleeve infill could be used for internal volume capacity change. A 'stock and swap' regime could be applied to ongoing panel change. For an open-plan interior, a perimeter or circumferential frame format is adopted. This along with suspended floor tier support from an overlying roof truss canopy. Twin parallel (horizontal) floor beams or joists could accommodate services routing, duct or conduit and also serve for wall and floor panel mounting and access. The invention variously embraces the following features:
A pre-fabricated frame building or structure, comprising an outer perimeter (circumferential shell) frame, of successive laterally interconnected 'H' profile upstanding frames, each with transverse beams set between spaced upright stanchions, with depending stilt legs to sit upon respective local foundation bearer pads to support an overlying roof structure, of a plurality of juxtaposed braced trusses, one or more floor beam lattice or matrix arrays, spanning intermediate levels between the perimeter frame, and secured thereto by (capture) mounting plates. Infill panels could fit between and/or upon perimeter frame members with an outer weather face cladding and internal facing. Outwardly projecting stubs could be distributed over the outer H frame faces for infill panel clamp plate mounting. A structure as preceding with perimeter frame outer cladding strips. Perimeter frame outer retention plates could be with overlaid insulated cladding. Service conduit channels could be defined within floor beam profiles or between juxtaposed beams. Service conduit level transition channels could lie between floors communicating with channels within floors or floor beams. Local foundation piers could lie at the foot of the perimeter frame in 'H' sections with transverse ties between spaced upright stanchions. A plurality of discrete foundation pads could each comprising a cluster, say four in a rectangular or square array, of tapering legs or pins set in a common overlying mounting plate with upstanding spigot bolts from respective legs for frame leg base plate location, coupling and mounting. Joint plates could fit between stanchions and transverse beams as locating abutment for ends of floor beams. A profiled landing gallery could rely upon a perimeter beam for cantilever support. A structure as preceding with floor beams of hollow rectangular section with one (upper) face largely cut out except for longitudinal opposite side lands with residual intervening lands. A structure as preceding with a clear-span (internal truss braced) roof canopy overlying a generally corresponding footprint clear span floor carried by an upstanding perimeter frame with intermediate suspension tension tie interventions at floor beam intersections between roof trusses and/or successive overlying floors. A structure as preceding with inter-fitting or inter nesting respective roof truss and perimeter wall frames, for lateral location, capture or restraint and underpinning support. A structure as preceding with mutual bracing and/or stiffening of roof and wall frames against lateral or sideways racking or lozenging, by relative mutual (inter-)location or (inter-)disposition. A structure as preceding with deep section truss frame roof canopy and deep inward penetration by perimeter frame upper end contiguous up stands. A structure as preceding with floor beams of rectangular tube originally closed section and a longitudinal face cut-out on one side except for residual lands between opposed edge flanges. A structure as preceding with rounded profile longitudinal edge beam section. A structure as preceding with a rectangular closed section at opposite ends and at spaced locations at intermediate span and an intervening largely open-sided C or U section. A structure as preceding with an upright elevator shaft column frame, set within perimeter frame confines and configured to support an outboard helical or spiral stair flight with stair treads cantilevered from outward from the elevator frame. A structure as preceding with perimeter frame upright stanchions extended into roof truss depth to support a perimeter roof frame. A structure as preceding with transverse roof truss under-frame bearer beam carried by perimeter frame stanchions. A structure as preceding with floor beam (upright) end faces, webs or flanges secured, by say threaded bolt fasteners, to upstanding side flanges or webs of a right angle section used as a joint member, leaving clear for access a throughway along and between beam or joist sections an an open intersection bounded by beams along with section end closure plate with bolts to perimeter frame stanchion inner face and access aperture in beam underside face. A structure as preceding with a service conduit duct, such as an elongate tube, located within a hollow floor beam section. A structure as preceding with prefabricated floor panel perimeter edge resting upon and supported by and between upper in-turned longitudinal side edge flanges of floor beams. A structure as preceding with clear span roof trusses, set upon upper ends of frame columns and carrying depending tension ties for supporting underlying floor beams. A structure as preceding with conduit face infill panels to rest upon opposite beam top face flanges and sit snug between respective floor panel edges. A structure as preceding with joint or junction (spreader) plates at intersections of upright and transverse, horizontal perimeter frame members also serving as face abutment mountings for horizontal floor beam ends. A structure as preceding with beam profile serving as an elongate housing for through passage of self-contained conduit. A structure as preceding configured as an insulated hollow outer shell of polygonal perimeter planform with lattice spine circumferential frame and local intervening infill panels, bounding a generally open core with clear-span interior, over one or more floor levels, tiers or storeys, each defined by matrix of intersecting open-top hollow beams utilised as conduits for service pathways. A structure as preceding configured for demountable and replaceable outer cladding and/or changeable internal partition wall sub-division layout and/or disposition within overall structure confines. A multistorey or tiered derivative of the structure as preceding with suspended internal floors carried by an overlying roof structure itself set upon a perimeter wall frame of upright stanchions spaced by transverse beams and straddled at one or more levels by transverse floor beam lattice or matrix arrays the stanchions serving as spaced piers standing upon respective local foundation pads. A structure as preceding configured as a frame stilt-supported, portable self-contained, free-standing, insulated shell, supported upon depending legs, struts or piers, of adjustable depth or span, in turn set on local foundation bearer pads. A structure as preceding with a ground floor beam lattice or matrix array set upon a plurality of intermediate stub piers at beam intersections or matrix interstices within a perimeter wall frame. A structure as preceding configured as a self-contained rigid, internally braced, rigid envelope or shell set upon selectively deployable underpinning flotation pontoons to allow overall elevation to a set height and/or buoyancy to a height variable with underlying water level. A structure as preceding with a demountable lifting crane gantry
fitted to the upper ends of upright frame stanchions, such as those forming an outer perimeter wall, deployable to carry frames or infill panels from the outside to within the perimeter. A structure as preceding with a demountable transfer transfer carriage configured to engage, capture and traverse an upright stanchion of a perimeter frame and fitted with carrier arms to allow lift of frame or infill panel elements on the outside of the structure. A structure as preceding with a side edge hinged frame outer infill or cladding panel movable to allow greater side access to the structure interior. A structure as preceding with a swivel-mounted outer infill or cladding panel to the outer perimeter wall, movable about an intermediate lateral span pivot for greater side access to the structure interior. A structure as preceding with pop-out outer infill or cladding panel operable to reveal an emergency access portal. Out folding, bottom edge pivot, outer infill or cladding panel could be operable to serve as an emergency access ledge, ramp or escape chute. Juxtaposed, say paired, frames and intervening spacing slot could allow through passage, with working clearance, of frame members or infill panels for insertion or removal in relation to an erected frame, linfill panels could have protruding edge locating pins for co-operative intermit with floor beam face slots or intervening beam spacing. A structure could be configured for stacking successive floor tiers one upon another, using outer perimeter frame upright stanchions as extendible pillars, along a with removable roof canopy option, to allow retrofit of an additional floor tier or removal of a floor tier. A roof truss could be cantilevered outward from an upright perimeter frame to support an overlying canopy overhang. A plurality of discrete frame members or frame assemblies could be set upon respective foundations and supporting intervening bridging beams. Movable frames could be carried upon static frames.
Attendant features are a frame structure erection sequence including steps of erection of freestanding outer perimeter frame leg piers or struts upon multiple local foundation bearer pads. Steps could include pre-assembly of 'H' frame modules, with upright stanchions bridge at intermediate heights by transverse beams, with a face mounting plate used for junctions and a mounting interface for ends of floor beams in later assembly stages. Crane lift of H frames in succession could achieve free-standing elements set upon respective foundation pads and secured by fastenings, such as embedded bolts or studs, in-situ thereto. Preparatory steps could include individual setting and mounting of H frame up stands, with intervening spacing, collectively to define the circumferential boundary of a perimeter frame assembly. Frame stubs could be set to project outward as location index, mounting and clamping points for frame infill panels. Progressive installation of local infill panels into outer frame could preface lowering of roof trusses upon upstanding perimeter frame stanchions. Prefabricated roof trusses could be settled upon and between upper end extensions of frame stanchions securing truss frames to stanchions with mountings and/or fasteners. Capture plates could be fitted on to frame stubs to overlie inserted infill panels securing with fastener bolts and tightening fasteners to clamp panels in situ. An upper perimeter roof truss rim frame could be sited to bear upon and between frame stanchion upper ends. Corner junction angle brackets could be fittted to floor beam intersections and securing angle bracket flanges to outer side walls of floor beams leaving clear internal conduit passage there between. Pre-fabricated floor panels could be laid to bear upon upper flanges of floor beams leaving clear exposed intervening beam conduit passages. Edge sealing gasket strips could be located and fitted between infill panel inside faces and perimeter frame outer faces and clamping panels in situ to compress the gaskets for seal action. Outer and/or inner faces could be pre-clad before mounting. A pre-fabricated columnar frame lift shaft could be installed to preface fitting a spiral stair case around a lift frame with cantilever support therefrom. An external drying tower could be fitted to the frame outer walls and installing a flue and through-wall interconnection to an internal boiler. Roof truss sections could be set initially upon temporary staging, fitting ceiling cladding panels to underside. Services could be installed in roof attic or loft void in between and around roof frame trusses. Transverse tie beams could be fitted between upstanding H frames at levels corresponding to the H frame transverse members and using H frame intersection joint plates. Infill panels could be installed in succession between stub tube frame projections fitting clamping strips or plates to stub tubes using threaded bolt into stub stem or a locking collar.
Further aspects include a frame element or assembly with a primary floor beam lattice or grid of open-top 'C' or 'U' section channel, with opposed upright side walls with respective mutually in-turned top flanges as bearers for floor panel cassette inserts followed by demountable infill cover plates. A frame element or assembly with an open-sided beam with multiple juxtaposed and/or mutually conjoined an orientated elements; thus mutually facing open-sided beams could be spaced to create a conduit of adequate span to accommodate service runs and/or intervening through-passage of elements, such as infill panels or other frame members; displaceable bridging members could be fitted between beams for mutual bracing, but movable to create an access pathway. A frame element or assembly with a local bridging strips brace and stabilise the top flanges to preserve separation and for mutual brace to help withstand in-turn. A frame element or assembly with an open-top fabricated plate box junction between beam ends; over and/or underlying plates used as mountings for depending suspension tie rods from overlying roof trusses. A frame element or assembly with a spreader collar or boss upstaged fitted between a tie end and beam carrier or spreader plate to distribute the load transfer. A frame element or assembly with a (depending) web flange hangar plate welded to roof truss to carry capture yoke for tension tie rod or cable. A frame element or assembly with an Ή' profile main (outer peripheral) frames; with spaced upright stanchions and transverse / horizontal bridging spars. A frame element or assembly with a junction or joint between floor beams and upright stanchions could be a closure face plate at beam ends and stanchion side and/or flange faces. A frame element or assembly with a beam section configured as a fabrication of conjoined complementary elements, such as with seam welds, or a bespoke extrusion. A frame element or assembly with a beam configured for weight reduction, without unduly undermining (section) bending stiffness, 'relief apertures could be cut out of beam side or flange faces and/or a pre-fabricated lattice brace strut frame web adopted. A frame element or assembly with stub tubes, posts or trunnions (with cylindrical circumferential bearing contact faces) projecting from outer faces as location and mounting points for frame infill panels (swivel) clamping plates secured by bolts into trunnions. A frame element or assembly with intermediate corner bar post stands with trunnions for corner transitions. A frame element or assembly with modular roof truss panels, with outer and inner cladding installed in factory build. A frame element or assembly with curtain wall glazed infill frames pre-assembled offs-site and fitted on site to primary frames. A frame element or assembly with floor beam matrix or grid array supported on stub pillars at beam junctions in turn bearing upon local foundation pads with under pins set in cast foundation pile. A frame element or assembly with internal wall margins fitted with stainless steel projecting pins to locate in floor and ceiling beam channels. A preferred option is building a complete weather-tight shell of the house to a more or less complete state (with external rain screens complete through to FERMACELL™ internal wall faces) but no services installed, all conduit covers left loose, all services fitted to suit end use of the building (eg house). When covered internal walls then build from standard components. A total prefabrication option would be required for
containerisation of shelter housing, MoD advanced units and the like. A frame element or assembly with a single or double-ended (swivel) capture and retention strip or plate for panels on one or both sides of frame. A frame element or assembly with individual or joint panel capture and retention to primary frame upstaged. A frame element or assembly with panel installation sequence of lower panel fitted / inserted into frame opening, captured and retained first. A frame element or assembly with upper panel installed later and secured with its own capture plate on respective trunnion stud. A frame element or assembly with toggle or spider profile retainer element for panel mounting abutment. A frame element or assembly variously with any or all of the following elements: infill panel edge strips, fastened, say bolted, to Ή' configuration frames, of stanchions spaced by transverse beams, with waisted or stepped end profile with local clamping strip plates; moulded foam fill over edge strips, pinned to panel outer boards; adjustable top and/or bottom spigot mounting to internal partition panels; mastic sealant to abutting edges of panel retention plates; infill at perimeter of base recess; treated weatherboard strip cladding; distinct external appearance of panel infill between bounding strip matrix; spiral stair flight bear upon elevator shaft or self-supporting from side rails, with top end bearing to upper floor landing beam; through-fastening of stairway inner rail to elevator shaft upright finish strips; infill cover to conduit slots permeating floors, ceilings and walls; perimeter infill skirting to floors and ceiling; fastening of landing baluster to floor uncertain; stepped inner peripheral marginal edges of outer panels creates perimeter trunking, both horizontally and vertically; stepped / recessed edge profile of floor panels, allowing upper edge lip to rest upon upper side flanges of floor beams; depending ceiling to bounding sides of floor beams; outer panel inboard upright edges sit somewhat inboard of H frame stanchion inner face to create vertical channel for services; inner core structure of floor panels; open slot around landing wall; cruciform brace at floor beam intersection to suspension yoke tapered web plate upstand.
Embodiments
There now follows a description of some particular embodiments of building structures of the invention, by way of example only, with reference to and as shown in the accompanying
diagrammatic and schematic drawings, in which:
Figure 1 A shows a 3D perspective view of an otherwise open lattice or matrix core of structural perimeter frame and intervening floor frames, with a variety of juxtaposed outer cladding infill panels and internal partition walls, overlaid by a braced truss roof canopy; an open lattice floor beam construction is also employed for floor beam infill panels (not shown);
Figure 1 B through 1 E show outer infill panel or skin cover or cladding variants;
Figure 1 F shows local detail of an outer perimeter Ή' frame junction between upright stanchions and transverse panel support rails; outer frame faces carry protruding mounting studs for panel clamp plates or strips shown in Figure 1 G ; infill panels can be inserted from outside and feature a stepped edge profile for outer layer for frame interfit and frame face abutment, with an inner layer insertion and protrusion inwardly to sit between frame inward faces;
Figure 1 G shows local detail of infill panel to perimeter frame inset mounting with edge clamping of a protruding panel edge lip, spreader plate and insulated cover strip; Figure 1 H shows local detail of a criss-cross or crossing floor beam intersection with tension tie suspension, such as from an overhead roof truss (per Figure 2 sequence) ;
Figure 11 shows a local detail of floor beam intersection with upright angle brackets fitted between beam faces;
Figure 1 G2 shows infill panel edge clamping with an intervening edge capture strip plate;
Figures 1 G2a-e show local enlargement detail of different infill panel outer coatings or finishes;
Figure 1 G3 shows cover strip mounting over the capture strips of Figure 1 G2; an insulating material would be used to obviate thermal bridging;
Figure 1 G3a shows local enlargement detail of Figure 1 G3, with inside face skirting over a trunking channel between panel and floor;
Figure 11 shows local detail of a floor beam intersection with boxed spacer plates;
Figure 1 J shows local enlargement detail of a perimeter frame stanchion with floor and tie beam mounting to an inner face plate;
Figure 1 K shows local enlargement detail of a the frame mounting and jointing plate of Figure 1 J with transverse beam of an Ή' configuration perimeter frame; in a variation from that illustrated, the steel frame could feature outer flush faces;
Figure 1 L shows local enlargement detail of Figure 1 K with floor beam mounted; a closed inner end face of a floor beam is bolted to the frame mounting plate;
Figure 1 M shows local enlargement detail of a floor beam intersection with angle plate joints in the included angles, with indicative conduit routing and service cable through-threading;
Figure 1 N shows a sectional view of successive overlaid floor tiers carried by intervening suspension cables;
Figure 10 shows a 3D perspective view of internal partition wall juxtaposed with an underlying floor ready for mounting just to one side of a floor conduit or trunking channel;
Figure 1 P shows a local enlarged section of floor panel cover strip support upon a hollow floor beam with an upper face slot for access;
Figure 1 Q shows a local enlargement detail floor internal partition wall mounting on adjustable stilts bearing upon opposed floor and ceiling panel faces; alternatively, such stilts could bear directly upon floor panel faces;
Figure 1 R shows a local enlargement detail of internal partition floor mounting upon a floor panel with opposed skirting trim plates;
Figures 2A through 2C shows modular canopy roof truss sections for the frame of Figure 1 ; the module size is for convenience of road trailer installation turned upon a long edge with support stillages (not shown) ; in fabrication the modules can be clad and fitted out before shipment; module size reflects the feasibility of transport from factory to site and local crane lift capacity; much of the canopy covering and services infill can be pre-fitted to the modules;
Figures 3A through 3D show elevations of the frame of Figure 1 with example panel infill and solid or glazed external cladding; an external drying tower, internal stairway and elevator shaft provision along with access doors and perimeter roof safety rail are featured;
Figures 4A and 4B show respectively upper and ground floor level plans of the clad structure of Figures 1 through 3D, with example room layouts and internal fitting out and furnishings; Figures 4C and 4D show local 3D perspective views respectively of the frame core and clad frame with internal boiler flue fitted of an external add-on drying tower side extension pod for the footprints of Figures 4A and 4B; a movable suspended clothes drying rack, with access through external walls; an access ladder allows personnel transit to roof level fitted with a cable stay walkway (not shown); Figures 5A and 5B show floor frame construction and local detail, with a rectangular matrix or grid array of paired juxtaposed opens-sided 'U' or 'C section beams or joists set with end and intermediate spacer plates to create an intervening services conduit;
Figure 5A shows a floor beam matrix or lattice with extremities spanning between perimeter frame;
Figure 5B shows a section from above of floor beam end mounting to a perimeter frame stanchion surrounded on each side by an infill panel;
Figure 6 shows a scrap section, from front to back wall, of an assembled frame core and clad panel infill structure of Figures 1 through 5B with selective local enlargement detail of insulation, mounting and measures against thermal bridging; outer infill panels are bounded by a timber batten rim held in place by bolts; opposed ring beams sit astride protruding spigots from outer floor ring beam and are held captive by a clamping plate with a series of bolt fasteners into the spigot stems, in turn overlaid by a cover plate; the stepped panel edge profile creates a mounting ledge allowing partial insertion from outside with an inner panel section protruding inwardly beyond the frame; a generous overall cumulative depth of insulation is thus achieved; expanding closed cell neoprene gaskets are fitted behind the clamping and location fitments for a weather and air tight seal; a 100x100 aluminium soffit angle strip screwed to roof battens captures compressed gaskets up to a zinc cladding;
Figures 7A and 7B show simplified local detail of floor beam outboard end and outer perimeter frame interconnection and intervening infill panel insertion and mounting inter fit for the structure of Figures 1 through 6;
Figure 7A shows panels juxtaposed for insertion;
Figure 7B shows panels after insertion;
Figures 7C and 7D show equivalent views to Figures 7A and 7B for a curtain wall infill between uppermost and lowest levels;
Figure 7E shows local junction mounting detail of floor beam to perimeter frame stanchion;
Figures 8A and 8B show local detail of floor frame, wall stanchion, outer panel solid and glazed curtain wall infill;
Figure 8A shows a sectional view of insulated wall panel infill and outer cladding set upon a lattice frame support;
Figure 8B shows a corresponding section to Figure 8A for curtain wall glazing;
Figures 9A through 9G show local sectional detail of frame and infill panel mutual juxtaposition and interconnection, interposed weather sealing, moisture barrier membrane and panel insulation; frame corners may be right angles, obtuse or acute, using a common securing principle of panel edge batten rim nesting alongside frame stanchions with protruding mounting stubs with outer threaded bosses and optional resilient bushes for fastening clamp strips or plates, with final finish overlay trim panels;
Figure 9A shows a sectional view of an insulated wall infill panel and perimeter frame interfit and capture, with local curtain wall glazing intervention;
Figure 9B shows local sectional detail of wall infill panel side edge abutment with an intervening perimeter frame upright and outer capture plate clamping to a framing mounting lug upstand; Figure 9C shows a sectional view of a frame and infill wall panel corner junction through an obtuse included angle;
Figure 9D shows a section of a right-angle corner;
Figure 9E shows simplified detail of temporary wall panel clamping to frame spigots;
Figure 9F shows clamp strips fitted;
Figure 9G shows a 3D corner edge perspective view of a permanent corner plate clamp mounting;
Figure 9H shows a transverse section of the corner plate mounting of Figure 9G ; breather membranes and neoprene gaskets (not shown) are interposed;
Figures 10A and 10B show scrap sections through a perimeter glazed access doorway;
Figure 10A shows a part cut-away, part-sectioned view of perimeter frame an infill triple glazed door panel installation;
Figure 10B shows a local view of a triple panel glazed access door frame and door closure in a perimeter frame;
Figures 11 A through 11 E show a ladder or Ή' configuration perimeter frame assembly with side limbs for lateral joining in a corner transition;
Figure 11 A shows an end view of Figure 11 B with angled edge jointing tails;
Figure 11 B shows a plan view or face elevation of a primary Ή' frame assembly with face mounting plates at frame member intersections;
Figure 11 C shows a plan view or face elevation of a secondary infill frame for intervention between primary frames such as of Figure 11 Bl
Figure 11 D shows a side view of Figure 11 B;
Figure 11 E shows a side view of Figure 11 C;
Figures 12A through 12F show further Ή' profile perimeter frame assembly with edge fittings for a straight side run; floor beam end carrier or mounting plates are shown at certain frame intersections, pre-drilled for threaded bolt fastener reception;
Figure 12A shows an end elevation Figure 12B;
Figure 12B shows a plan view of face elevation from one inward side of an Ή' frame assembly for use as a modular perimeter frame upright; floor beam bearer plates are fitted at the frame member intersections;
Figure 12C shows a side elevation of Figure 12B;
Figure 12D shows an end view of Figure 12E;
Figure 12E shows a plan view or face elevation of a secondary infill Ή' frame fro disposition between primary Ή' frames such as of Figure 12B;
Figure 12F shows a side view of Figure 12E;
Figures 13A through 13D show a roof canopy with surface cladding and insulation infill;
Figure 13A shows a side section through a roof canopy with cladding upon space frame to span between side wall frames (not shown) ; Figure 13B shows a local enlargement detail section of infill insulation of Figure 13A;
Figure 13C shows a plan view of canopy cladding panel of Figure 13A;
Figure 13D shows a side section of canopy and underlying insulation of Figure 13A;
Figures 14A through 14E show multiple plinth, pier or pile foundation detail for frame stanchions; Figure 14A shows a side elevation of frame feet setting in local ground bearing pad foundations;
Figure 14B shows a plan view of a grid array of frame foundation bearing pads;
Figure 14C shows a side elevation of frame feet in local and distributed slab footings;
Figure 14D shows a frame foundation bolt cage encast anchor bolts for inset into a ground cast foundation pad;
Figure 14E shows an upper view of the bearer of Figure 14D set in situ;
After installation of the anchor bolts in their conical tolerance tubes and after curing of the concrete foundations the anchor bolts are adjusted, using a steel positioning jig (not shown) some 12 metres by 12 meters, to precise centers and upper galvanised steel target plates are adjusted to precise level then all backfilled with non-shrink grout. All prior to delivery of the steel frame to site. No further leveling or alignment adjustment of the steel frame is therefore required during installation of the building, such as a house.
Figures 15A through 15E show wall panel infill and integrated services construction, with optional demountable or retractable lifting straps or eyes; the stepped bounding edge profile transition outer to inner face is apparent;
Figure 15A shows a rear view of a wall panel with internal support frame and services conduit routing with overlay cladding;
Figure 15B shows a clad wall panel;
Figure 15C shows a panel with inset frame to provide an edge recess for support frame interface;
Figure 15D shows a panel with internal services conduit routing before surface cladding;
Figure 15E shows the panel of Figure 15D after surface cladding with local cut-outs for services access;
Figure 15F shows a panel edge carry loop or sling;
Figure 15G shows a panel edge lift eye or ring;
Figures 16A through 16E show various movable external and/or internal wall panel, extendible, displaceable, removable or insertable room module 'plug', roof platform deck features; in a free-form construction, panels and even room modules could be interchanged between locations;
Figure 16A shows a 3D corner perspective view of a space frame with local wall panel infill;
Figure 16B shows an extendible room module carried between frame members;
Figure 16C shows roof canopy infill with load bearing wall ways or decks;
Figure 16D shows a movable internal partition wall between frame uprights;
Figure 16E shows a local detail of frame split around a movable internal partition wall; Figures 17A through 17D show movable infill panel, partition and local frame element options;
including pop-out, hinged balcony conversions, sliding, rotatable or swivel panels;
generally, a skeletal or spine frame can be supplemented or substituted locally with monocoque stressed skin panels (not shown) to share or distribute load or stress; the frame allows great flexility in configuration and usage and can be altered or extended locally without undermining local integrity, with local infill altered accordingly by panel removal and replacement;
Figure 17A shows a 3D corner perspective view of a portion of lattice frame assembly with frame upright spacing to allow internal partition wall insertion or removal;
Figure 17B shows a swivel mounted infill or cladding panel to the outer perimeter wall boundary, movable about an intermediate lateral span pivot to afford greater local access to the structure interior;
Figure 17C shows out folding of a bottom edge pivot outer infill or cladding panel operable to serve as an emergency access ledge, ramp, or escape chute or balcony; with optional pop-out infill or cladding panel operable to reveal emergency access portals;
Figure 17D shows local enlargement detail of frame upright spacing with intervening panel access;
Figures 18A through 181 show variant floor beam and/or perimeter frame sections and services conduit pathways; a hollow internal core and/or surface channel could serve;
Figure 18A shows a 3D corner perspective view of an open lattice space frame assembly;
Figure 18B shows a section of open-sided rectangular frame used for services conduit routing;
Figure 18C shows another upright section of open-sided frame for services conduit routing;
Figure 18D shows a 3D perspective view of an open-sided floor beam with access cut-outs for services conduit routing;
Figure 18E shows a local floor beam end mounting profile, with provision of fastening to a frame upright (not shown) ;
Figure 18F shows a closed end section with a blanking plate as a mounting plate for frame upright mounting;
Figure 18G shows a rear view of a wall infill panel 12 before surface cladding with access for services conduit installation;
Figure 18H shows a section of skirting frame with inset services conduit;
Figure 181 shows a section of frame 13 with internal services conduit;
Figures 19A and 19B show production line staging, stillages and movable support trestles or trolleys for panel assembly and storage; this format could also be used for warehouse stock for panel storage and return ready for call-off;
Figure 19A shows an array of stands or jigs for production line frame build;
Figure 19B shows an individual wall or partition infill panel on a mobile trestle with service conduits pre-installed;
Figures 20A through 20E show an erection and assembly sequence perimeter frame, floor frame and roof canopy erection with drop-in spiral stairway local infill;
a modular Ή' configuration frame (ie parallel upright legs with horizontal transverse spacing beams at intervals, such as at floor levels) sub-assembly with floor beam joint and mounting plate is convenient for ease of transportation from factory to site whilst preserving critical alignment jig geometry and the welded junctions provide structural stability; the close tolerance steel frame components are hoisted into position on the the previously aligned and leveled anchor bolt clusters; once the frame is fully assembled with precision, the subsequent panel infill is more readily accomplished, with due tolerance allowance in the design and fabrication, between the edges of external wall panels and floor panels and the sides of the apertures in the steel frame
internal jigs and fixtures (not shown) can be employed for factory build and on site the frames and foundations themselves serve as exposed external site jigs and fixtures for further frame inter connection, roof canopy installation and cladding infill panel insertion; overall, once fastened in situ the panels help frame bracing and stiffening of the assembly;
Figure 20A shows discrete floor stand frame assemblies in a juxtaposed array;
Figure 20B shows perimeter tie of the stands of Figure 20A to create a continuous perimeter frame;
Figure 20C shows crane jib mounting from the frame of Figure 20B to add other subsidiary frame of infill elements;
Figure 20D shows lowering of a spiral stairway and lift column assembly from above;
Figure 20E shows a roof canopy assembly installed and crane lift of side panel or cladding infill;
Figures 21 A through 21 D show variant floor plans, such as for a reconfigurable interlinking 'L' shaped footprint, convenient for a flexible classroom role, with the options of module separation or integration; Figure 21 A shows discrete footprint modules;
Figure 21 B shows conjoined modules of Figure 21 A;
Figure 21 C shows further merged modules of Figures 21 A and 21 B;
Figure 21 D shows an overall enlarged module embracing the original discrete floor areas as a single contiguous unit;
Figures 22A through 22E show an rise and fall structure mounted upon a jacking platform; the structure can rise or fall by stilt jacking to above an outside water level, such as in flood conditions;
Figure 22A shows a side elevation of a single storey structure in a lowered condition upon a sunken basement ground frame;
Figure 22B shows a plan view of a basement sub-frame of Figure 22A;
Figure 22C shows a sectional view of the structure of Figure 22A, revealing adjustable stand upon an intermediate sub-floor frame, itself carried upon perimeter stilts in a basement well;
Figure 22D shows local detail of basement stilts;
Figure 22E shows a local detail of jacking lift post;
Figures 23A through 23C show 3D perspective views of the jacking platform and pontoon of Figures 22A through 22E;
Figure 23A shows a part cut-away 3D perspective view from one corner, showing a single storey structure set upon a jacking frame in a base plinth; a twin tiered elevation is achievable by jacking an upper storey upon an intermediate platform itself carried upon stilts;
Figure 23B shows local corner jacking post enlargement detail; Figure 23C shows a local enlargement detail of a floor beam jointing plate;
Figures 24A and 24B show sectional views of elevation and pontoon flotation chamber variant for the construction of Figures 22A through 23C; a building is set upon a flotation pontoon confined within a basement flood chamber for immersion upon surrounding flood conditions; an internal core frame provides sufficient rigidity to preserve building integrity, without the building itself needing to be waterproof;
Figure 24A reflects a lowered condition with main internal floor plane generally consistent with surrounding ground level;
Figure 24B depicts an jacked up elevated condition, with internal floor re-disposed well above surrounding flood water level;
Figures 25A through 25C show 3D perspective views of a self-contained internal frame infill of a barn; the internal and external structures could be independent, such as carried upon respective footings or foundations, or tied locally for mutual bracing stability; with a weather-proof lined core module, the outer skin openings need not be filled, but if this is done an extra weather barrier is achievable;
Figure 25A depicts the start of an installation sequence by part assembled frame module lowering through a top opening, having removed an original roof structure, to be replaced by a new roof canopy supported by the new internal core perimeter frame;
Figure 25B shows elevated canopy roof support from an internal lattice frame, with peripheral eaves fenestration reveal;
Figure 25C shows a cut-away end view of conventional build shell retained but fitted with a closed self-supporting shell, with the option of locally tying the structures for mutual stability;
Figure 26 shows an indicative simplified conventional construction outer shell or skin, such as of block or brick, with outer render options, around an inner core support frame; an alternative would be a weather resistant plastic coating with a stippled rendered appearance; overall these conventional infills could give a more conventional outward appearance to a structure, but in a contemporary interpretation; the outer skin could be supportive or non-structural;
Figure 27 shows a modular multi-element frame used to construct an extended building footprint, in this case a series of piers with intervening porches, with potential for further infill or extension;
although this approach could feature individual frame members, it is convenient to use factory jig pre- assembled sub-frames for more precise rectilinear fit in a final construction;
Figure 28 shows a smaller scale modest shed or garage frame format for infill and overlay; the principles of the larger structure are employed on a smaller scale and without some of the infill detail; open frame is shown initially preparatory to canopy roof fitment and wall infill cladding;
Figures 29A and 29B show an opens-sided, central spine, canopy shelter over a (concertina) collapsible-extendible folding frame;
Figure 29A shows a concertina frame array overlaid by open lattice frame canopy;
Figure 29B shows a variant or later stage of Figure 29A with solid canopy infill;
Figures 30A through 30E show a fold-out frame with flexible strap, wire or cable conjoining link option; the cable restraint limits the frame spacing when fully stretched and can be wrapped around a rolled bundle of stacked frame elements for compact packaged storage and transport to site, preparatory to roll unfurl into a fully-deployed spaced frame set, with the cables fully stretched to define frame successive adjacent spacing intervals; the cable could be configured as a closed perimeter or boundary loop with opposite tied ends, say with a fastener ties and ratchet tensioner;
Figure 30A shows an initial unfold erection stage which is largely self-supporting; Figure 30B shows a closed peripheral frame assembly with mutual bracing of side walls;
Figure 30C shows a mixed format frame of rigid and initially slack flexible ties to allow flexibility in positioning with some mutual restraint and bracing;
Figure 30D shows the frame array of Figure 30C with ties stretched;
Figure 30E shows an enclosed frame array form the sequence of Figures 30A through 30D with a demountable rigid frame member to substitute or supplement for flexible ties and to allow through- wall access when removed;
Figures 31 A through 31 C show a fabric envelope frame wrap or cover; the fabric can be stretched taut locally by tie tension over the frame and peripheral lateral bracing cable stays (not shown), to create a tent or marquee with a rigid core; fabric and solid infill panels can be intermixed ; for aesthetics and additional weather proofing a solid panel can have a fabric covering; the fabric could be a breathable, but water-repellent or proofed, flexible membrane;
Figure 31 A is a three-quarter external 3D perspective view from one corner.
Figure 31 B is a side wall scrap section of Figure 31 A with fabric drawn over rounded edge frame section.
Figure 31 C is a side wall scrap section of Figure 3A1 A with fabric drawn a roller inset within a corner edge frame section.
Figures 32A and 32B show a multiple segmented slat roller shutter blind frame infill for adjustable security opening.
Figure 32A is a three-quarter external 3D perspective view from one corner.
Figure 32B is a side wall scrap section of Figure 32A.
Figures 33A-33D depict various section slices through a 3D model of a generic core frame with infill outer wall panels and internal partitions set within a conventional skin.
Description
The drawings should be generally self-explanatory, so not all features will be described in detail in words. Considerable variation in detail is tenable within a common agenda.
Essentially, an otherwise open lattice spine or matrix core perimeter framework is configured for flexible frame inter couple and selective infill with external cladding panels and internal partition subdivision to achieve a desired building format. This allows a diversity of outer form, internal layout and end-use, including domestic, institutional, infill and flotation. An entire structure can be supported upon framework stanchions set upon local foundation pads or piers, without continuous trench infill footings. A fastener secured demountable frame allows change, repositioning and weight distribution.
Routing of services throughout the building can use conduit pathways within the frame section itself, with side access gained through a continuous slot in an open-sided (internal) floor and/or wall. By panel reception and location within the 'embrace' of juxtaposed frame members, concealed internal connection can be made to a panel interior from within the conduit. Service access is thus preserved , enshrouded, even encapsulated, and so protected. Infill panels can be secured to the frame by through-fasteners, such as bolts, studs or screws, in the frame, accessible through the open-sided sectional profile and with clamping or spreader capture plates. Subject to prevailing building regulations, disparate services from electricity and gas to water supply or drainage, can share a common (generous section) frame conduit used as encased trunking. Even after final assembly, the conduit pathway remains accessible for maintenance, repair, or modification. Where feasible, to preserve a free or uncluttered conduit pathway, frame fasteners are minimally inward-intrusive and/or largely confined to outer wall section faces. An external ventilated side tower appendage for a boiler stack could be contained within a mesh screen to create a warm air void for use as a re-circulatory airing and drying tower. A suspension cable loop could be used to raise and lower hung items.
The shape, size and designation or allocation of internal room areas could be changed by repositioning dividing partition walls within the overall frame structure. Thus an open plan floor format between outer bounding walls admits flexible variable sub-division. Internal partition wall location is flexible and not tied to floor beam location, rather partition walls can sit upon floor infill panels, say, with adjustable support legs, ceiling braces and bearer pads and infill floor skirting or ceiling coving. Partition construction could meet local building regulation standards on thermal and acoustic insulation and fire break, screen or barrier. Self-finish surfaces requiring no plaster can be used. Additional fire protection could be incorporated, such as around stairway voids or between contiguous independent dwelling areas designated for separate habitation. Sprinkler fire protection systems could use supply feeds and spill drainage conduit, trunking or routing housed in the frame section.
Although a rectangular frame and panel infill grid format is convenient, internal sub-division could employ curved intermediate partition or screening walls. Local profile curvature could also be incorporated into the overall structure outer form by local curved spine frame profile. A local pier or pad foundation system can take primary frame weight download transfer through upright frame posts, pillars or stanchions.
Diagonal or cross-bracing can be fitted to certain frame openings. A stairway void spanning multiple floors, storeys or tiers could be admitted without undermining overall integrity or stability. Lateral stiffening against bending deflection, deformation, or lozenging can be provided by stringers, longerons, or bracing, such as in the manner of aircraft fuselage or wing construction. Panel infill members could also provide stiffness when installed, with panel depth and cladding or lining profile, such as corrugated skins, used to contribute enhanced local rigidity and for more distributed load transfer. For an even more flexible format, some or all of the framework and/or infill panels could be supplemented or substituted by stressed skin modules, in a form of local monocoque construction. A frame could be installed, piecemeal on site, possibly with a prefacing test assembly in a factory confines, or as a series of sub-assemblies of overall scale feasible for road transportation.
Frame jointing and fastening could be by direct abutment of frame member ends with frame sides, with pre-drilled holes aligned and through-fasteners inserted and tightened, or with intermediate mounting or capture plates, which could be of larger area for load spread and profiled to achieve a required frame member relative disposition and orientation when fitted, over a sharp or progressive segmented corner (re-)turn, at outer corners, such as a pronounced chamfer or curve. A frame member section could be locally re-profiled, such as folded, twisted and/or constricted, for visual architectural sculptural effect or to re-orientate an interconnection with another juxtaposed frame member and/or infill panel. Supplementary add-on structures, such as a flue or chimney stack or elevator shaft could be added externally or internally without disturbing the frame core.
In a floor support frame grid, an open-sided frame section could be orientated, in particular turned sideways, upward or downward, for infill panel reception, capture and location and 'outward' presentation for conduit access. Members could be paired and set to lie back to back, to present respective open-sided slots to opposite sides, mutually secured with fastener ties. A panel end could feature an outboard mounting block or bolster to abut alongside or astride frame members. A capture plate or yoke could be used to secure panels nested to inset frame members.
For installation on sloping or undulating sites, depending frame member legs and/or upstanding foundation piers, could be locally extended or foreshortened to complement site contours and so preserve an upright frame stance, with level intervening floor tiers. An adjustable jacking intervention could be adopted. Structure loads could be distributed evenly between frame uprights or differentially with frame section shape and size chosen accordingly. For uniformity of materials production sourcing and stocking, similar or uniform frame members could be grouped together as combination struts for greater collective strength and rigidity.
A library or repertoire of frame sections could be used for selective pick'n mix. An alignment jig or fixture could be used for internal factory build and on-site installation. An entire finished frame assembly or intermediate sub assembly could sit upon a peripheral foundation rim, of perimeter framing, supported on localised pier or elongate trench infill foundation. A suspension or cushion buffer interposition, with optional damper, could be employed to allow frame positioning settlement. A fluid, say pneumatic or hydraulic, strut intervention could be used, such as one chargeable to elevate a frame leg, such as to raise the frame in emergency local ground flooding situations. A base support platform, raft or pontoon could be elevated by flotation and/or jacking, either as a unitary module or in portions, as fragmented or sub-divided elements.
Some frame elements or sub-assemblies could be hung or suspended from others, so some frame members would be loaded in tension, rather than simply compression as with stacked frame loads. A cantilevered frame support, such as a braced truss, could also be used, with frame members in bending or shear loading.
A self-contained frame can be used in conjunction with conventional building elements. Thus, say, a barn conversion could use a frame as an inner core, with or without ties with a traditional outer shell. The core could have an integral roof, extended to overlie the shell. A characteristic footprint, stance, posture, attitude, bearing, carriage, comportment or gait can be adopted for the frame and support. Thus, say, a modest lean or cant could be adopted for a front glazed curtain wall under a cantilevered roof canopy eaves overhang, to provide a degree of rain shadow or shelter and glare reduction effect. The core can be factory or off-site pre-fabricated to tight tolerances in a sheltered environment and to a higher standard than feasible on-site. Similarly, with individual panel pre-fabrication at least to some intermediate level of finish.
Partial local dismantling in situ could be effected without undermining the integrity of the overall structure. Panels can be unfastened from the surrounding support framework and orientated for clearance and removal, either outward or inward with any necessary orientation. Split panel construction could facilitate this. A hinged or articulated corner frame would allow an adjustable wall angle to be set before final assembly or after as a lead to an extension. A stepped or staggered floor level, with step or incremental transitions at frame boundaries, could be adopted to allow a frame structure to follow site contours, such as a slope, whilst preserving intervening level floor platforms.
Floor and/or ceiling panels, along with dividing or partition walls such as those bounding stairways, could incorporate fire retardant materials. Tension ties could be united with the frame externally and/or internally for additional wind bracing such as on exposed or elevated sites and used for aesthetic effect. In one convenient structural format, no internal structural or load bearing walls are used, in favour of movable non-supporting partitions. Multiple panel glazed walls can be adopted to achieve external insulation.
Prime exponents of prefabricated build include Huf Haus, with dramatic chalet style roof pitches, floor to ceiling glazed external walls, balconies and open-plan interiors, in a pronounced timber frame post and beam architectural format. Whilst well executed to a refined formula, this is not a flexible approach best suited to more modest scale or restrained surface clad presentational forms. Relevant building codes for energy efficient and materials considerate construction include the Code for Sustainable Homes and the so-called 'Passiv Haus' standard.
A structural 'trough' or 'channel' beam can be achieved by orientating opposed pairs of open-sided beams set face to face to create a mutual internal recess or well as a potential mounting slot for internal partition wall panels and a useful commodious primary conduit or pathway for services. The otherwise open trough sides can be covered with removable plates to preserve future access.
Joint or bridging plates at beam ends can preserve the relative disposition whilst allowing conduit through passage to conjoined beams. A rectangular grid format could be employed for a stiff floor 'platform' requiring support only at opposite side walls. That said, upper floor intermediate span support could be gained through suspension hangers or drop ties or tendons, taken from an overlying internally-braced roof truss assembly.
In one example, external elevations feature sealed timber-framed, fully serviced timber clad panels, with rendered of metal faced options and neoprene gasket end seals to but with juxtaposed frames or panels. Clamping through-fasteners and capture elements can be used to secure walls in place, along with intervening edge and face seals, such as closed cell neoprene gaskets. Local floor beam suspension by tension tie from a roof truss overhang relieves the loads upon, or even need for, local upright stanchions, to allow a freer or clearer internal layout, particularly useful around stairways.
Conduit or services pathway provision distributed across floors and up (or down) through outer walls or internal divider partition panels is achieved within the floor beam sections or juxtaposed end- coupled sections, but can be supplemented between floor levels by upright transition or transfer trunking, such as within a services column; one example being an external flue housing or chamber. Higher rated capacity distribution manifolds can be located within between-beam cavities or conduit, with local interconnection for lower rated local services fed through the panel body or core.
In one configuration, the outer perimeter is bounded by a series of peripheral columns, pillars, piers or stanchions set upon local plinth foundations and carrying intermediate floor levels and supporting an overlying roof canopy. A clear-span floor assembly can be carried between the outer columns and supported at intermediate floor beam junctions by tension ties from an overlying roof truss. Overall, a clear span interior under a clear span roof can be achieved. A perimeter roof safety cable rail can be fitted to the upper frame.
Outer wall panels sit between uprights secured by outer clamping plates at the transverse and upright panel margins. A thermal buffer or cushion barrier beam can sit between floor edges and outer panels and carry or inter fit with an outer clamping flange assembly. For outer curtain walling, sealed glazed modules can similarly be captured to a frame core. A steel mounting boss or protruding spigot or trunnion could be secured to a floor boundary rim frame as an intervention between upper and lower outer wall panel timber side edge caps, and secured by a threaded fastener and nylon bush and internal inset capture plate in turn covered by an insulated cover profile.
Ladder floor trusses of corrugated folded section could be incorporated in the floor depth under floor surface panels for stiffness and light weight with capacity for service pathways and in or under floor heating channels along with in-floor insulation. An edge overlap between truss and floor beam carries and transfers floor loading for upper elevated floors. For ground floors, a bearer plate with projecting edges set under an open top face or slotted conduit beam provides floor panel edge support. A 'U' or 'C section frame could be used for uprights between floors and to provide a services transition pathway with a buffer plate for floor beam attachment. Frame on-site installation can be upon largely pre-prepared or finished ground works, even hard landscaping of ground contours, as minimal local disruption is entailed.
Plumbed-in serviced panels incorporate high and low voltage electrical supply, data cables, power outlet sockets, light fittings and switches, heating outlet and recovery ducts or channels, water supply and waste outlet pipes, fire sprinkler feed, fire or burglar alarm sensors and/or feed, wireless network, radio or tv panel antenna. For a commercial, institutional, educational, medical, laboratory or industrial unit, built-in service provision could include pneumatic, hydraulic and suction exhaust for dust extraction, filtered, temperature and humidity conditioned air, etc. Finished panels can be shrink- wrapped for protection and can be held in stock read for shipment to site in bespoke frames or stillages. Part-finished panel cores can be held in stock ready for final cladding, lining and final internal services fitting out to a specific customer order.
The truncated 'tail ends' or intermediate terminations of in-panel services are connected within services ducts in the frame assembly and between panels and frame. Service pathways and installed services are covered with removable trims which form skirtings and architraves, with surroundings matching surfaces, such as hardwood or carpet. Floor panels can be prefabricated up to a finished floor level and can incorporate heating provision, again connected with services conduit within and between beams through connection manifolds. Jacking, bracing and support legs or struts, along with location and clamping fastener access for internal partition walls can be concealed behind marginal skirting boards. Elevator shaft work can be installed and housed, from the build outset or as a retrofit, within the frame for occupant powered transfer between floor levels. A shaft frame can contribute to local and overall frame stiffness and can also serve as a service core between floor levels. Solar collectors and/or photovoltaic panels can be fitted to sloping roof surfaces, orientated in relation to the prevailing sun celestial orbit. Again, supporting service conduit can be incorporated in the roof construction. Movable panel and/or frame elements could be fitted with capture hooks and/or apertures for crane sling lift and man oeuvre. A partially erected frame upright could itself support suspended lift of other frame elements or infill panels. Thus a swing derrick or jib could be mounted upon a frame upper end. Movable, tiltable, lift up or removable local roof sections could be fitted for specialist use, such as to create an open air deck or viewing platform or helicopter landing deck. Outer panels, with a wearing inner face, could be bottom hinged to form a cantilevered fold-down balcony when deployed, with swivel side arm bracing and peripheral pop-up hand rails. In certain specialist applications, such as industrial units housing movable processing equipment installations on ledges, a frame supporting an enclosure could be mounted upon a movable platform upon ground wheels, tracks or guide rails, such as a turntable or conveyor, for transit between indexed work stations, to present equipment to other process locations and facilities.
Although a combination of principally timber frame infill panel and metal (steel) frame has been described as a prime example, greater use of metal and/or composite materials could be made for the panels. Similarly, timber might substitute for certain frame elements, with appropriate adaptation of section size, profile and jointing inter fit. In any event, account would be taken of different rates of thermal expansion and contraction with ambient external and heated internal air temperature, for which resilient panel edge seals provide some cushion accommodation. Floor depths and so floor-to- ceiling heights could be varied by adjustable (say clamp bolt or bearer stud or pin fastener) mounting of floor beam assemblies upon outer side uprights. Greater depth and span internal voids, say from basement or ground floor to loft levels, could be combined with more regular single storey room depths. Adopting an open format outer frame as a principal structure provides greater freedom and flexibility in internal layout than, say, one interrupted or permeated by an 'intrusive' post and beam structure, such as a Huff (TM) House. Larger openings can be incorporated into the outer wall by local bounding frame reinforcement, such as by consolidation, combination or doubling up, of bounding frame members. An internally (truss) braced roof canopy, along with deep overlap with or intrusion by a perimeter frame, helps stabilise underpinning peripheral walls . A deeper, again (truss) braced perimeter wall construction can be used. Similarly, intermediate floor depth bracing can contribute to overall stability. This aside from floor suspension from a roof truss.
Sliding, fold-up or pop-out beams or panels could be accommodated within appropriately wider (conduit) spaces between paired beams. For example, mutual facing ('U' or 'C' section) open-sided beams would be mounted as greater separation by longer spacer end plates, whilst leaving room for diverse collective services passage within the section profiles. By mutual alignment of such spaces over successive floor levels, beams or panels could transit between floors. Thus internal floor sub- division could be altered with re-deployable partition walls. By creating an external access slot, with a (re-)movable closure panel or door in the outer perimeter wall, beams or panels could be inserted or removed, so the entire internal layout changed without re-building the outer supporting framework. A sufficiently wide space to accommodate service personnel or operatives could be contrived where frequent access for services or room divider re-positioning was required. That could also serve as an emergency (fire) access or exit route. Climbing studs, bars or ladder rungs could be fitted to the frame elements along with suspension and winch provision.
Component List
11 spine core / lattice frame
12 infill panel
13 perimeter frame
14 internal partition
15 cross-beam
21 insulation
22 fasteners
23 mounting plate
24 footings
25 mounting legs
26 floor beam
27 edge sealing gasket
31 aperture
32 conduit
33 services
34 external cladding
35 barrier membrane
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