AU2016201900A1 - Building system - Google Patents

Abstract

A building system, and method of constructing a building, using fibre reinforced polymer (FRP) members. The building has a foundation having FRP posts, a frame having a base portion of FRP beams located on top of the foundation, and flooring and walls affixed to the base portion. The walls can be affixed to the base portion using reinforcement members such as cyclone rods. The resultant building is sturdy, simple to construct, and corrosion resistant.

Description

BUILDING SYSTEM

FIELD OF THE INVENTION

[0001] The invention relates to a building system. In particular, the invention relates, but is not limited, to a building system for houses, or the like, using pultrusion formed fibre-reinforced polymer (FRP) beams for the frame.

BACKGROUND TO THE INVENTION

[0002] Reference to background art herein is not to be construed as an admission that such art constitutes common general knowledge.

[0003] Buildings, such as housing, have been an area of constant improvement over many years. For example, many modern buildings are safer, stronger, more insulated, and energy efficient than their older counterparts.

[0004] In many areas it is desirable to construct buildings quickly and cost effectively. Buildings made from preformed panels assist with constructing a building in a cost effective, efficient manner. Once the building components have been delivered to site the building itself can be constructed fairly quickly. Such buildings are particularly suited to small to medium sized houses, but can be modified and/or scaled as needed.

[0005] Many buildings, especially those made from preformed panels, are constructed with a metallic frame that is usually steel. The vast majority of nontemporary buildings have foundations or basework that supports the building on the ground. The foundations are also often made of steel. Steel foundations and frames are not only relatively expensive, but also heavy. Transporting the heavy foundation and frame beams is costly and, in cases where adequate roadways are not in place, such as in a country with poor quality or unsealed roads, may present a significant logistical burden.

[0006] Furthermore, steel framework and other components are susceptible to corrosion. Over time, particularly in coastal environments, the steel framework rusts and can lose its structural integrity. Even before the framework loses structural integrity the rust can be unsightly.

OBJECT OF THE INVENTION

[0007] It is an aim of this invention to provide a building system which overcomes or ameliorates one or more of the disadvantages or problems described above, or which at least provides a useful alternative.

[0008] Other preferred objects of the present invention will become apparent from the following description.

SUMMARY OF INVENTION

[0009] In one form, although it need not be the only or indeed the broadest form, there is provided a building system comprising: a foundation; a building frame having a base portion located on top of the foundation; flooring affixed to the base portion of the building frame; and walls extending upwards from the base portion; wherein the base portion comprises fibre-reinforced polymer (FRP) members.

[0010] Preferably the FRP members are pultrusion formed FRP members. Preferably the FRP members are beams. Preferably the beams include I-beams. Preferably the beams include C-beams. Preferably the beams include a combination of I-beams and C-beams.

[0011] Preferably at least a portion of the C-beams comprise an angle bar mounted to the C-beam. Preferably the C-beam comprises a base portion and two perpendicular portions extending in a first direction and preferably the angle bar extends in the opposite direction to the perpendicular portions. Preferably a plurality of angle bars are provided. Preferably the angle bars are arranged such that the C-beam resembles an I-beam. Preferably the angle bars are mounted to the C-beam using glue and/or screws.

[0012] Preferably the foundation comprises a plurality of foundation supports. Preferably the foundation supports comprise foundation posts. Preferably the posts are FRP posts. Preferably the posts are affixed to a footing. Preferably the footing is a concrete footing. Preferably the posts are affixed inside the footing. Preferably the posts have a bolt located inside the footing. Preferably the posts extend upwardly from the footing.

[0013] Preferably the posts have a flange on an end distal from the footing. The flange may be integral with the post or, in a preferred form, the flange is affixed to the post. Preferably the flange is a plate affixed to the post, preferably using at least one of angle brackets, screws, and glue. In a preferred form the flange is an FRP plate affixed to the post using four angle brackets, screws, and glue between the post and the FRP plate.

[0014] Preferably the base portion comprises a plurality of FRP members arranged in a substantially planar configuration. Preferably the base portion supports the flooring and walls on the foundation.

[0015] Preferably the base portion comprises perimeter members. Preferably the base portion comprises cross members which extend between perimeter members. Preferably the base portion is square or rectangular, having four perimeter members and at least one cross member. Preferably the base portion comprises a plurality of cross members. Preferably the cross members are a combination of I-beams and C-beams.

[0016] Preferably the cross members have a protrusion that is received between flange portions of the perimeter members. Preferably the I-beams and/or C-beams comprise two parallel flange portions separated by a web portion. Preferably the protrusion is formed from the web portion. Preferably the parallel flange portions of the I-beams and/or C-beams are recessed to form the protrusion from the web portion. Preferably the protrusion is located at an end of the beams.

[0017] In a preferred form the perimeter members are I-beams with a centrally located I-beam extending between two sides of the perimeter. A plurality of C-beams preferably cross the area defined by the I-beams. Preferably the base portion defines a grid of beams. Preferably the base portion defines a rigid flooring frame that is suspended above the ground on the foundation.

[0018] Preferably the flooring comprises flooring members affixed to the base portion of the building frame. Preferably the flooring members comprise flooring panels affixed to the base portion of the building frame. The flooring panels may be corrugated. Preferably the flooring panels are insulated panels. Preferably the insulated panels comprise a foam insulator contained between skin layers. Preferably the foam insulator comprises polyurethane foam. Preferably the skin layers are metallic.

[0019] Preferable the flooring comprises a floor surface that covers an area defined by the flooring members. The floor surface may comprise flooring panels such as particleboard panels. Preferably the flooring members are affixed to the base portion of the building frame using floor fasteners. Preferably the floor fasteners are floor screws. Preferably the floor fasteners extend through at least a portion of the flooring members into at least a portion of the base portion of the building frame.

[0020] Preferably the walls comprise wall panels. Preferably the wall panels are preformed. Preferably the flooring panels are insulated panels. Preferably the insulated panels comprise a foam insulator contained between skin layers. Preferably the foam insulator comprises polyurethane foam. Preferably the skin layers are metallic.

[0021] Preferably the wall panels are affixed to the building frame. Preferably the wall panels are mounted on the flooring and are affixed to the building frame via the flooring. Preferably wall panels are affixed to the building frame by wall reinforcement members. Preferably the wall reinforcement members are tie-down members. Preferably the wall tie-down members comprise rods, even more preferably cyclone rods. Preferably an end of the wall reinforcement members passes through the flooring. Preferably the wall reinforcement members are affixed to the base portion of the building frame.

[0022] Preferably glue is used to adhere abutting FRP beams to one another. Preferably the glue comprises a polyurethane adhesive. Preferably the glue comprises an elastomeric adhesive. Preferably the glue is a moisture curing polyurethane construction adhesive sealant.

[0023] Preferably the glue has a shore A hardness of more than 40. Even more preferably the glue has a shore A hardness of between 40 and 60. In a preferred form the glue has a shore A hardness of approximately 50. Preferably the glue has a modulus of between 0.6 and 1.0 MPa acc. In a preferred form the glue has a modulus of approximately 0.8 MPa acc. Preferably the glue has a elongation at break of between 70 and 90% acc. In a preferred form the glue has an elongation at break of approximately 80% acc.

[0024] Preferably the screws are corrosion resistant. Preferably the screws are stainless steel screws. Preferably the bolts are corrosion resistant. Preferably the bolts are stainless steel bolts. Non-exposed bolts, such as bolts located inside concrete footings, may be galvanised steel bolts.

[0025] In another form there is provided a method of constructing a building comprising: forming a building foundation; constructing a fibre-reinforced polymer (FRP) base portion of a building frame on top of the building foundation; placing a flooring over the base portion of the building frame; and erecting walls above the base portion of the building frame.

[0026] Preferably the step of forming a building foundation comprises forming a plurality of footings. Preferably the step of forming a plurality of footings comprises setting a FRP post in a concrete footing. Preferably the step of forming a building foundation comprises affixing an FRP plate to the top of the FRP post. Preferably the FRP plate is affixed to the top of the FRP post by gluing the FRP plate to the FRP plate. Preferably the FRP plate is affixed to the top of the FRP post by affixing, preferably screwing, angle brackets to the FRP post and the FRP plate.

[0027] Preferably the step of constructing the FRP base portion comprises connecting a plurality of FRP beams to form a grid in a plane over the building foundation. Preferably the beams comprise I-beams and/or C-beams. Preferably the step of constructing the FRP base portion comprises connecting a plurality of I-beams and/or C-beams together. Preferably the step of constructing the FRP base portion comprises forming a perimeter of I-beams. Preferably the step of constructing the FRP base portion comprises placing cross-members between the beams that form the perimeter. Preferably the cross members have a protrusion and the step of placing the cross-members between the beams that form the perimeter comprises locating the protrusion within between parallel flange portions of the beams that form the perimeter.

The method may further comprise the step of forming a protrusion from the I-beams and/or C-beams by cutting a notch out of parallel flange portions of the beams.

[0028] Preferably the step of erecting walls above the base portion comprises erecting the walls on top of the flooring. Preferably the step of erecting the walls comprises tying down the wall to the base portion. Preferably the step of tying down the wall to the base portion comprises connecting a wall reinforcement member to the base portion. Preferably the wall reinforcement member is a rod, even more preferably a cyclone rod, which is received by the base portion. Preferably the method comprises passing the wall reinforcement member through a portion of the flooring.

[0029] Preferably the method comprises connecting FRP components together with glue. Preferably the method comprises connecting FRP components together with fasteners, preferably screws.

[0030] Further features and advantages of the present invention will become apparent from the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS [0031 ] By way of example only, preferred embodiments of the invention will be described more fully hereinafter with reference to the accompanying figures, wherein: [0032] Figure 1 illustrates a cross sectional view of a portion of a building system; [0033] Figure 2 illustrates a perspective view of a portion of a building system; [0034] Figure 3 illustrates a side elevation view of a portion of a building system; and [0035] Figure 4 illustrates a top plan view of a portion of a building system.

DETAILED DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 illustrates a building system 10 having a foundation 100, a building frame having a base portion 200 on top of the foundation 100; flooring 300 affixed to the base portion 200, a wall 400 extending upwards from the base portion 200. The building system 10 is constructed primarily of pultrusion formed fibre-reinforced polymer (FRP) members.

[0037] The foundation 100 includes a FRP post 110 which is set into a concrete footing 112. A foundation bolt 114 is located inside the concrete footing 112. The post has a flange, in the form of a FRP plate 116, at an end that is distal to the concrete footing 112. The plate 116 is affixed to the post 110 by a suitable glue and also with angle brackets 118. The angle brackets 118 are preferably also screwed to the post 110 and the plate 116 using stainless steel screws. An angle bracket 118 is preferably located on each of four sides of the post 110 such that four angle brackets 118 affix post 110 to plate 116.

[0038] The base portion 200 of the building frame has an FRP I-beam 210 which has two parallel flange portions, namely a lower flange portion 212 and an upper flange portion 214, separated by a web portion 216. The I-beam 210 is affixed to the flange plate 116 of the post 110 by glue. The I-beam 210 is typically also affixed by stainless steel bolts (shown in figure 3). The base portion 200 also includes a square hollow section (SHS) base member 218 and a cover sheet 220, which is preferably a fibre cement sheet, that conceals an outer side of the base portion 200.

[0039] The flooring 300 has a flooring member in the form of a flooring panel 310 which is located on top of the upper flange portion 214 of the I-beam 210. The flooring panel 310 is a form core insulated panel having a polyurethane foam insulator 312 sandwiched between two skin layers. The flooring panel 310 is affixed to the I-beam 210 by glue. The flooring panel 310 is also affixed to the I-beam 210 by floor screws 314. A floor surface 316 is provided on top of the flooring panel 310. The flooring surface 316 is preferably a particleboard, or similar. The flooring panel 310 may be corrugated (not shown) in which case the flooring surface 316 is typically affixed to ridges of the corrugations of the corrugated flooring panel 310.

[0040] The wall 400 is located on top of the flooring 300. The wall 400 comprises a wall panel 410. The wall panel 410 is a form core insulated panel having a polyurethane foam insulator 412 sandwiched between two skin layers. The wall 400 also has a wall reinforcement member in the form of a cyclone rod 414. The wall reinforcement member extends through the wall panel 410, through the flooring 300, and is affixes the wall 400 to the base portion 200 of the building frame where it is tied down with a cyclone rod nut 416. The cyclone rod 414 is received within a channel 418 formed in the wall panel 410.

The channel 418 is preferably a square hollow section (SHS) wall member located inside the wall panel 410.

[0041 ] Figure 2 illustrates a larger portion of the base portion 200 sitting on a foundation post 110. The base portion 200 illustrated in figure 2 has a perimeter I-beam 210 and two cross members. The first cross member is a cross I-beam 240 located adjacent the post 110 and the second cross member is a cross C-beam 260. The cross I-beam 240 has two parallel flanges, namely a lower flange 242 and an upper flange 244, separated by a web portion 246. The cross C-beam 260 also has two parallel flanges, namely a lower flange 262 and an upper flange 264, separated by a web portion 266. In the I-beam the web portion 246 is located centrally with respect to the flanges and in the C-beam the web portion 266 is located to one side of the flanges.

[0042] Both cross members 240, 260 have a protrusion that is received by the perimeter I-beam 210. The cross I-beam 240 has a protrusion 248 that extends between the flanges 212, 214 of the perimeter I-beam 210 and abuts the web portion 216 of the perimeter I-beam 210. The protrusion 248 is effectively an extension of the web portion 246 of the cross I-beam 240 which can be formed by forming recesses in the flanges 242, 244 at an end of the I-beam 240.

[0043] Similarly, the cross C-beam 260 has a protrusion 268 that extends between the flanges 212, 214 of the perimeter I-beam 210 and abuts the web portion 216 of the perimeter I-beam 210. The protrusion 268 is effectively an extension of the web portion 266 of the cross C-beam 260 which can be formed by forming recesses in the flanges 262, 264 at an end of the C-beam 260. The cross C-beam also has two angle bars 270 mounted thereon. The angle bars 270 have one side which is mounted to the web portion 266 and a free side which extends in an opposite direction to the C-beam flanges 262, 264.

[0044] The cross I-beam 240 and cross C-beam 260 are both connected to the perimeter I-beam 210 by glue and angle connectors 272 which are also glued and screwed using stainless steel screws.

[0045] Figure 3 is similarly to figure 1 but illustrates cross I-beam 240 extending perpendicularly to perimeter I-beam 210. It also illustrates ends of further cross beams, namely a cross C-beam 280 and cross I-beam 290 which extend perpendicularly to the cross I-beam 240. The plurality of cross beams 210, 280, 290 form a grid of beams in a substantially horizontal flooring plane.

[0046] Figure 4 illustrates a top view of an example base portion 200 arrangement that is rectangular in shape. It has perimeter I-beams 210A-D with perimeter I-beams 210A and 210C being perpendicular to perimeter I-beams 210B and 210D. A single cross I-beam 240 is provided that extends longitudinally between the shorter perimeter I-beams 210A and 210C. A plurality of cross C-beams 280 are provided which divide the area defined by the perpendicular I-beams 210A-D into a grid. Where beams abut they are connected to one another, preferably with glue, angle connectors, and stainless steel screws.

[0047] To construct a building using the building system 10 a building foundation 100 is formed. The FRP posts 110 are set into concrete footings 112 at desired locations and the FRP plates 116 are affixed to the top of the FRP posts 110 using glue and angle brackets 118. The base portion 200 of the building frame is constructed on top of the foundation 100 by connecting FRP beams together in a substantially horizontal plane such as illustrated in figure 4.

[0048] Flooring 300 is then placed on top of the base portion 200 by affixing flooring panels 310 to the base portion 200 using floor screws 314 and then placing a flooring surface 316 on top of the flooring panels 310. The walls 400 are then erected above the base portion 200 on the flooring 300. The walls 400 are tied down to the base portion 200 by the cyclone rod 414 which is passed through the flooring 300 to be received by the base portion 200. A suitable roof or further story can then be constructed on top of the walls 400.

[0049] Advantageously the building system 10 provides a simple, easy to construct building that is corrosion proof. Furthermore, the FRP beams are easier to transport and handle. This results in various efficiency improvements, particularly in regions where logistical issues arise and construction machinery may be limited. A further advantage of using lighter and easier to handle FRP beams is that there is less likelihood of injury or overexertion from construction personnel. The lighter weight of the building can mean reduced foundation requirements, providing further costs and time saving improvements. With the use of insulated preformed panels for the walls and floor, the building system is not only quick, but it is also highly energy efficient once constructed.

[0050] Although the invention has primarily been described with respect to a single level building with the base portion 200 being located on foundations 100, it will be appreciated that similar principals apply to multi-level buildings and that a further base portion 200 may be located on top of a lower story to construct a further story.

[0051] In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not to be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step etc.

[0052] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention.

[0053] In this specification, the terms ‘comprises’, ‘comprising’, ‘includes’, ‘including’, or similar terms are intended to mean a non-exclusive inclusion, such that a method, system or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.

Claims (20)

1. Claims:

   1. A building system comprising: a foundation; a building frame having a base portion located on top of the foundation; flooring affixed to the base portion of the building frame; and walls extending upwards from the base portion; wherein the base portion comprises fibre-reinforced polymer (FRP) members.
2. 2. The building system of claim 1, wherein the FRP members are pultrusion formed FRP members.
3. 3. The building system of claim 1 or 2, wherein the FRP members are beams.
4. 4. The building system of claim 3, wherein the beams include one or both of I-beams and C-beams.
5. 5. The building system of claim 4, wherein at least a portion of the C-beams comprise an angle bar mounted to the C-beam.
6. 6. The building system of claim 5, wherein the C-beam comprises a base portion and two perpendicular portions extending in a first direction and the angle bar extends in the opposite direction to the perpendicular portions.
7. 7. The building system of claim 5 or 6, wherein one or more angle bars are mounted to the C-beam using glue and/or screws.
8. 8. The building system of any one of the preceding claims, wherein the foundation comprises a plurality of foundation supports.
9. 9. The building system of claim 8 wherein the foundation supports comprise FRP foundation posts affixed to, or inside, a concrete footing.
10. 10. The building system of any one of the preceding claims, wherein the base portion comprises a plurality of FRP members arranged in a substantially planar configuration that supports the flooring and walls on the foundation.
11. 11. The building system of any one of the preceding claims, wherein the base portion comprises perimeter members and cross members that extend between the perimeter members, wherein the cross members have a protrusion that is received between flange portions of the perimeter members.
12. 12. The building system of any one of the preceding claims, wherein a plurality of wall panels are affixed to the building frame by wall reinforcement members.
13. 13. The building system of claim 12, wherein the wall reinforcement members comprise tie-down members.
14. 14. The building system of claim 13, wherein the tie-down members comprise cyclone rods that pass through the flooring and are affixed to the base portion of the building frame.
15. 15. The building system of an one of the preceding claims, wherein an elastomeric adhesive having a shore A hardness of more than 40, a modulus of between 0.6 and 1.0 Mpa acc, and an elongation at break of between 70 and 90% acc is used to adhere abutting FRP beams to one another.
16. 16. A method of constructing a building comprising: forming a building foundation; constructing a fibre-reinforced polymer (FRP) base portion of a building frame on top of the building foundation; placing a flooring over the base portion of the building frame; and erecting walls above the base portion of the building frame.
17. 17. The method of claim 16, wherein the step of forming a building foundation comprises forming a plurality of footings by setting a FRP post in a concrete footing.
18. 18. The method of claim 16 or 17, wherein the step of constructing the FRP base portion comprises connecting a plurality of FRP beams to form a grid in a plane over the building foundation.
19. 19. The method of claim 18, wherein the step of constructing the FRP base portion comprises placing cross-members having a protrusion between beams that form the perimeter by locating the protrusion between parallel flange portions of the beams that form the perimeter.
20. 20. The method of any one of claims 16 to 19, wherein the step of erecting walls above the base portion comprises: erecting the walls on top of the flooring; and tying down the wall to the base portion by connecting a wall reinforcement member to the base portion.