AU2021209232A1

AU2021209232A1 - Building construction

Info

Publication number: AU2021209232A1
Application number: AU2021209232A
Authority: AU
Inventors: Aidan Chu
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-12-08
Filing date: 2021-07-28
Publication date: 2022-06-23

Abstract

P1723AUAU ABSTRACT A method of constructing a building 7 on a building site. The method comprises fabricating 100 (on the building site about-horizontal wall members 5, 5'), fabricating 300 (on the building site a roof 3), lifting 500 the roof, and raising the 5 wall members to define walls 5i bracketing a space under the roof. 116 3g,3g' 3a G3c 3e 3 5a 5 5g 5e__ 5a 5' FIG. 1 5 A 3g 5i FIG. 2 9g 3 . .7 9c 9,9a 5ci 5,5a 9e FIG. 3

Description

3g,3g' G3c 3e 3a

5a 5 5g

5e__ 5a ' FIG. 1 5 A

3g

3

5i

FIG. 2

9g

3

. .7 9c

9,9a 5ci 5,5a 9e FIG. 3

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BUILDING CONSTRUCTION FIELD OF THE INVENTION

The invention relates to the construction of buildings.

BACKGROUND TO THE INVENTION

Gable clad sheds to suit, for example, factories and warehouses are sometimes constructed by first fabricating a roof on site at about ground level. The roof is then craned to about its finished position. Columns are installed. Horizontal members known as wall girts (or'girts' simpliciter) are installed across the columns to define wall frames and then cladding such as steel sheet is fastened to the exterior of the frames.

The present inventors have recognised that fabricating the walls on site in this way has significant drawbacks. Cranes are required to remain in place until the columns are installed and stabilized to take the weight of the roof and such cranes are typically charged out at significant hourly rates. Cladding the upper reaches of the walls entails lifting equipment such as scissor lifts. This not only slows the work (therefore calling for more work hours) but also adds the costs associated with the lifting equipment. Moreover, working at height is dangerous.

Tilt up construction is an alternative mode of construction that entails prefabricated wall panels which are often formed of concrete. The wall panels are craned into place and propped before a roof is built in situ. Once the roof is completed the building becomes self-supporting and the props can be removed. Fabricating the roof on site in this way also entails significant costs associated with working at height.

Accordingly, the invention in its various aspects aims to provide improvements in and for the construction of buildings, or at least to provide alternatives for those concerned with constructing buildings.

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SUMMARY

One aspect of the invention provides a method, of constructing a building on a building site, comprising

fabricating on the building site about-horizontal wall members;

fabricating on the building site a roof;

lifting the roof; and

raising the wall members to define walls bracketing a space under the roof.

Preferably the roof is connected to the about-horizontal wall members via connections such that lifting the roof raises the wall members.

The connections may comprise

guides fixed with respect to the roof; and

connecting elements connected to the wall members and mounted to run along the guides as the roof is lifted.

The connecting elements may be connecting arms. Preferably at least one of the connecting elements is an arm defining a girt accommodating cove. Preferably lifting the roof moves the cove relatively-away from the girt.

The method may comprise lifting the roof beyond a finished position of the roof to, via the connections, turn the wall members outwardly beyond finished positions of the wall members to define a roof-receiving space; and

lowering the roof to its finished position in the roof receiving space.

The lowering may be to inwardly move the wall members to their finished positions.

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The method preferably comprises, after the lowering, fastening the wall members to the roof.

The about-horizontal wall members are preferably hingedly connected relative to ground. Most preferably tops of the about-horizontal wall members define exteriors of the walls.

The fabricating on the building site about-horizontal wall members may comprise cladding frames. The fabricating on the building site about-horizontal wall members may comprise attaching girts to columns to define the frames.

Another aspect of the invention provides an assembly, for building a building on a building site, comprising

about-horizontal wall members;

a roof;

connections connecting the roof to the wall-members such that the roof is liftable to raise the wall members;

the connections comprising

guides fixed with respect to the roof; and

connecting elements;

the connecting elements being connected to the wall members and mounted to run along the guides such that the roof is

liftable beyond a finished position of the roof to turn wall members outwardly beyond finished positions of the wall members to define a roof-receiving space;

lowerable to its finished position in the roof receiving space.

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The roof may be lowerable to its finished position in the roof receiving space to inwardly move the wall members to their finished positions.

Preferably at least one of the connecting elements is an arm defining a cove accommodating a girt and arranged to move relatively-away from the girt as the roof is lifted.

The roof may span in-plan at least 45m 2, e.g. at least 90m 2 or more preferably at least 180m 2 .

about-horizontal wall members;

a roof spanning in-plan at least 45m 2, e.g. at least 90m 2 or more preferably at least 180m 2 ;

connections connecting the roof to the wall-members such that the roof is liftable to raise the wall members to define walls bracketing a space under the roof.

Preferably the connections comprise

guides fixed with respect to the roof; and

The connecting element may be connecting arms. Preferably at least one of the connecting elements is an arm defining a cove accommodating a girt and arranged to move relatively-away from the girt as the roof is lifted.

The about-horizontal wall members may be hingedly connected relative to ground.

Tops of the about-horizontal wall members may define exteriors of the walls. Preferably finished positions of the wall members are at least 15m apart. Preferably

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each wall member in its finished position is at least 5m horizontally-long. The roof may comprise a ridgeline.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a perspective view of a ready-to-lift assembly;

Figure 2 is a perspective view of a building;

Figure 3 is an enlargement of detail A in Figure 1;

Figures 4a to 4d are elevation views of a lifting sequence;

Figures 5a to 5d are elevation views of a lowering sequence;

Figure 6 is a perspective view of an alternative connection;

Figure 7 is a perspective view of an end of a building part way through a lifting operation;

Figure 8 schematically illustrates another ready-to-lift assembly;

Figure 9 schematically illustrates another building; and

Figure 10 is a flow chart charting a method of construction.

DETAILED DESCRIPTION

The ready-to-lift assembly 1 comprises a roof 3 and a pair of about horizontal wall members 5, 5'. The assembly 1 forms part of a preferred method of constructing the building 7. The method commences with wall fabrication step 100. Fabrication is a process that entails bringing together components. Terminology such as 'fabrication on site' is used herein in contradistinction to offsite prefabrication.

The wall fabrication step 100 preferably commences with laying down 101 columns 5a, e.g. on the bare earth, on crushed rock or on a pre-prepared concrete slab. Girts

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5c are then attached 103 to the columns 5a to form a wall frame 5e. The frame may be cross braced. The wall frame 5e is then clad 105 with wall cladding 5g.

When the assembly 1 is deployed the walls 5i support the roof 3. During deployment the tops of the wall members 5, 5', bearing the wall cladding 5g, become the exteriors of the walls 5i. This is advantageous in that it is preferred that the wall cladding 5g sit on the exterior of the wall frame 5e and is also convenient to apply fasteners from above the horizontal wall member 5 to fasten the wall cladding 5g to the wall frame 5e.

There are other options. Potentially blind fasteners might be applied to attach cladding to the underside of horizontal wall frame. Indeed other variants of the wall member 5 may do without wall cladding 5g. By way of example, one variant of the wall member 5 might substantially consist of a plurality of mutually connected panels.

In this example, the wall members 5, 5' are hingedly mounted with respect to the ground. This may entail any convenient form of footing. Footing cages and chemset rods are preferred options. A simple single-axis pivotal connection is preferred. More elaborate hinge systems, such as gear hinges, are possible. Hingeless systems are also possible. By way of example, lower ends of the columns 5a might be arranged to fall into stump holes during the lifting sequence. Indeed, whilst it is preferred that the bottom of each wall 5i is tied down, the bottoms could potentially simply sit on an underlying surface (such as on bare earth and/or on a concrete slab). The walls 5i might be tied down after the lifting sequence. By way of example, the lifting sequence may entail lifting the walls so that they are suspended and can then be guided back down onto base plates or other suitable mounting points.

Roof fabrication 300 preferably also occurs on site, most preferably after wall fabrication step 100. Roof fabrication 300 may comprise positioning 301 frames 3a. The frames might be prefabricated. They preferably take the form of trusses and may well be planar. Elongate supports, such as girders, other than the frames 3a are possible. After positioning 301 the frames 3a, purlins 3c are attached 303. 'Batten' is another word for'purlin'. The sub-structure 3a, 3c may be cross braced. The purlins 3c are then clad with roof cladding 3e.

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This example of the roof 3 is a gable roof comprising a ridgeline 3g capped by capping strip 3g'. This example of the ridgeline 3g is a central ridgeline running parallel to each wall 5i. Other variants of roof may not have a ridgeline, e.g. the roof might be flat, mono-pitched or curved.

The roof 3 is connected to the wall 5 via a connection 9 comprising a guide arm 9a and a guide 9c. The arm 9a is mounted to turn with respect to the wall 5, again a simple (i.e. single axis) pivotal connection is preferred although there are other options. In this example, the hinge 9e sits on an underside of the horizontal wall member 5. The arm 9a extends from the hinge 9e to follower 9g. In this example the guide 9c takes the form of a simple slot and the follower 9g takes the form of a pin mounted to slide along the slot.

The arm 9a has a hooked shape defining an elbow by which the arm 9a passes around the girt 5ci. The inside of this shape is a girt-accommodating cove in which the girt 5ci resides when the assembly 1 is in its ready-to-lift configuration.

This example of the guide 9c takes the form of a J-shaped member bolted to the lower cord of frame 3a so that the long arm of the J runs parallel to the cord and the shorter arm projects a short distance downwards. The slot is a J-shaped slot running along the centre line of the guide member.

There are other options. By way of example, the slot might simply be cut into a bottom cord of the truss. That said, releasable fastening is preferred to allow the guide 9c to be removed after the lifting operation, e.g. after the building has been made self-supporting.

Preferably at least most of the connection 9 is removable. In this example, the connecting element 9a and the guide 9c are both removable. Threaded fasteners are preferred although other means of releasable attachment may be used. Stripping away 900 these components after the lifting operation avoids unnecessary impingement into the useful internal volume of the building.

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The connection 9 may be completed at any convenient time before, during or after the initial fabrication steps 100, 300. Preferably the wall members are fabricated 100 and then stands (not shown) are placed to allow the roof 3 to be fabricated 300 in situ over the walls. Preferably the connecting element 9a and the guide 9c are attached after the roof is fabricated 300.

The arm 9a is a preferred example of a connection element. A chain would be another workable example. Rigid connecting elements (such as arms) are preferred over flexible pulling elements (such as chains).

The roof 3 is preferably rectangular in plan and most preferably in the ready-to-lift assembly 1 the horizontal wall members 5, 5' are at least mostly, or more preferably substantially wholly, under the roof 3 as viewed in plan. Whilst rudimentary implementations of the concept might entail the horizontal wall members 5, 5' lying horizontally adjacent to the roof 3, this would require a clear working area well beyond the roof area (as viewed in plan). It may well also require any cranes to be positioned further away from a centre of the roof which may call for larger, and thus costlier, cranes.

The roof 3 is preferably lifted 500 from its ready-to-lift position by pulling from above, e.g. with the aid of a self-motivating road-going crane, although there are other options. By way of example, in some contexts convenient lifting points such as overhead gantries may be available. The roof 3 might be lifted in other ways, e.g. underlying lifting mechanisms might be arranged to lift the roof from below.

In this example the roof 3 is connected to the crane via a respective line 11 (e.g. chain) at each of its four corners.

As the roof 3 is lifted away from its ready-to-lift position (Figure 4a), the arm 9a is placed into tension to begin lifting the wall member 5 away from its about horizontal ready-to-lift position (Figure 4b). As the wall 5 is lifted it turns about its hingedly mounted base 5k. Within continued rising of the roof 3, the follower 9g runs outwardly along the guide 9c to continue turning the wall member 5.

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In this example, the roof 3 is lifted upwardly beyond its finished position (Figure 4d) to turn the wall member 5 beyond its finished position. For this purpose, the hinge 9e (Figure 3) is mounted on the underside of the horizontal column 5a and the guide 9c projects outwards beyond an end mounting portion 3i, e.g. haunch, of the roof 3. There are other options. By way of example, the guide 9c and hinge 9e may each be moved leftward as drawn in Figure 4d. The haunch 3i is preferably at least 600mm high.

Figure 5b substantially corresponds to Figure 4d and shows the roof 3 at its highest point prior to being lowered 700. In this configuration, the follower 9g sits some distance down into, e.g. at the end, of the upright (preferably vertical) run of the guide 9c.

As the roof is lowered (to the position of Figure 5b), the follower 9g moves relatively upwards along the upright portion of the guide 9c whereby the roof 3 is lowerable into the receiving space defined by the mutually splayed wall members 5, 5'.

The long run of the guide 9c extends inwardly at a shallow inclination upwards from horizontal. As the roof 3 is lowered from the position of Figure 5b to the position of Figure 5c, the follower 9g is driven relatively upwards along this incline so as to move inwardly and in turn inwardly draw the wall 5. The roof 3 continues downwardly and the wall member 5 continues turning inwardly until it reaches its finished position illustrated in Figure 5d. At this position, the wall member 5 (or more specifically the inside flanges of the columns 5a in this case) sit in abutment with the mounting portions 3i of the roof 3. At this point the wall 5 can be attached to the roof 3, e.g. by welding and/or bolting or otherwise fastening.

In this example, the finished position of the wall member 5, at which the wall member 5 defines the wall 5i, is vertical although non-vertical walls are also possible. By way of example, a roof receiving space may be defined between two vertical walls whereby as the roof is lowered into that space, the walls are drawn inwardly to upwardly convergent finished positions.

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Preferred variants of the guide 9c comprise a run running inwardly at an inclination upwards from horizontal. Most preferably this run runs from an upright guide portion.

Figure 9 illustrates an alternative connection 9' comprising a guide 9c' and an arm 9a'.

The guide 9c' includes a long run akin to the long shallowly inclined portion of the guide 9c but includes differing outer portions in place of the downward end portion of the guide 9c. In operation the follower 9g' runs outwardly along the long shallowly inclined portion of the guide 9c as the roof 3' is lifted. When the roof 3' reaches its maximum position, the follower 9g reaches the end of this inclined run. When the roof 3' is then lowered from the position of Figure 6, the follower 9g runs upwardly along an upward guide portion and is inwardly directed (by the guide) to inwardly draw the wall 5".

Figure 7 illustrates an alternate building 1000 comprising a roof 3000 and walls 5000. The side walls are fully clad except for strips in the vicinity of the columns to provide clearance for connections 9000. The building 1000 further comprises an end wall 11000.

Preferably the end wall 11000 is fabricated on site outwardly beyond the end of the roof 3000 and connected to the roof 3000 via chains to also be raised as the roof 1000 is raised. When the roof 3000 is at its highest, the wall 11000 might be manipulated, e.g. with a forklift and/or cranes and/or winches, into position and to mate with the roof 3000 as the roof 3000 is lowered.

In this way, large buildings (e.g. spanning areas of 180m 2 or more) can be constructed with less need to work at height than is called for by some other methods and without the cost of transporting large prefabricated panels. By way of example road-transporting a roof, roof-half or roof-quarter spanning 45m2 or more is costly.

Figure 8 schematically illustrates an assembly in its ready-to-lift configuration and comprising an alternative connection. In this ready-to-lift configuration, the about horizontal wall members 5000' sit directly under the roof 3000'whilst the end wall

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members 11000' are constructed flat on the ground outward beyond the footprint of the roof 3000'. The connection arrangement 9000' takes the form of flexible pulling element (FPE) 9000a. The FPE 9000a is fixed to roof 3000' inboard from the outer edge of the roof 3000'. The FPE 9000a is also attached to the wall member 11000' in the vicinity of what becomes a top corner of the end wall. The FPE 9000a is laced through a guide 9000b (e.g. eyelet) towards the inboard edge of the wall member 5000'. In this way, the connection 9000' connects the roof 3000', wall member 5000' and wall member 11000' to each other. When the roof 3000' is lifted, the FPE 9000a is placed in tension so as to lift the wall members 5000', 11000'.

Various examples are described above. The invention is not limited to these examples, e.g. whilst prefabrication is preferred, the various elements of the examples might be used in combination with precast concrete wall panels. Whilst preferred examples of the assembly are metallic, e.g. steel, other materials are possible. The walls and/or ceiling may be framed with lengths of timber and/or skinned with timber such as weather boards or plywood. Some variants of the assembly may comprise precast and/or reinforced blockwork e.g. for structural elements such as for frame members. The skin may comprise pliable material, e.g. a frame may be skinned with a tarp.

The term 'comprises' and its grammatical variants has a meaning that is determined by the context in which it appears. Accordingly, the term should not be interpreted exhaustively unless the context dictates so.

Claims

P1723AUAU 12 CLAIMS

1. A method, of constructing a building on a building site, comprising

fabricating on the building site about-horizontal wall members;

fabricating on the building site a roof;

lifting the roof; and

raising the wall members to define walls bracketing a space under the roof.

2. The method of claim 1 wherein the roof is connected to the about-horizontal wall members via connections such that lifting the roof raises the wall members.

3. The method of claim 2 wherein the connections comprise

guides fixed with respect to the roof; and

4. The method of claim 3 wherein the connecting elements are connecting arms.

5. The method of claim 4 wherein at least one of the connecting elements is an arm defining a girt accommodating cove; and

lifting the roof moves the cove relatively-away from the girt.

6. The method of any one of claims 2 to 5 comprising lifting the roof beyond a finished position of the roof to, via the connections, turn the wall members outwardly beyond finished positions of the wall members to define a roof-receiving space; and

lowering the roof to its finished position in the roof receiving space.

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7. The method of the claim 6 wherein the lowering is to inwardly move the wall members to their finished positions.

8. The method of claim 6 or 7 comprising, after the lowering, fastening the wall members to the roof.

9. The method of any one of claim 1 to 8 wherein the about-horizontal wall members are hingedly connected relative to ground.

10. The method of any one of claims 1 to 9 wherein tops of the about-horizontal wall members define exteriors of the walls.

11. The method of any one of claims 1 to 10 wherein the fabricating on the building site about-horizontal wall members comprises cladding frames.

12. The method of claim 11 wherein the fabricating on the building site about horizontal wall members comprises attaching girts to columns to define the frames.

13. An assembly, for building a building on a building site, comprising

about-horizontal wall members;

a roof;

the connections comprising

guides fixed with respect to the roof; and

connecting elements;

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lowerable to its finished position in the roof receiving space.

14. The assembly of the claim 13 wherein the roof is lowerable to its finished position in the roof receiving space to inwardly move the wall members to their finished positions.

15. The assembly of claim 13 or 14 wherein at least one of the connecting elements is an arm defining a cove accommodating a girt and arranged to move relatively away from the girt as the roof is lifted.

16. The assembly of claim 13, 14 or 15 wherein the roof spans in-plan at least 45m2 .

17. An assembly, for building a building on a building site, comprising

about-horizontal wall members;

a roof spanning in-plan at least 45m 2 ;

connections connecting the roof to the wall-members such that the roof is liftable raise the wall members to define walls bracketing a space under the roof.

18. The assembly of claim 17 wherein the connections comprise

guides fixed with respect to the roof; and

19. The assembly of claim 18 wherein the connecting elements are connecting arms.

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20. The assembly of claim 19 wherein at least one of the connecting elements is an arm defining a cove accommodating a girt and arranged to move relatively-away from the girt as the roof is lifted.

21. The assembly of any one of claim 13 to 20 wherein the about-horizontal wall members are hingedly connected relative to ground.

22. The assembly of any one of claims 13 to 21 wherein tops of the about horizontal wall members define exteriors of the walls.

23. The assembly of any one of claims 13 to 22 wherein finished positions of the wall members are at least 15m apart.

24. The assembly of any one of claims 13 to 23 wherein in each wall member in its finished position is at least 5m horizontally-long.

25. The assembly of any one of claims 13 to 24 wherein the roof comprises a ridgeline.