GB2497099A - Construction element and module formed from the element - Google Patents

Abstract

A construction element is cross shaped, having four arms, with arms 3 and 4 being in a linear arrangement with the arm 3 being positioned above arm 4. There are also two arms 5,6 that are again in alignment and are at substantially right angles to arms 3,4. There is a core 2 for the cruciform structure where all four arms meet that provides strength to the whole structure. The cruciform structure can be used to provide a building framework that has good thermal integrity, strength and versatility. A linear array of the elements may support a pair of elongate elements on the upper surfaces of the horizontal arms and have a further two elongate elements fixed to the lower surfaces of the horizontal arms. Cladding may be affixed to the ends of the arms to enclose the array of cruciform elements and the four elongate elements and form a composite beam. The element may be used in a building, as part of the roof or such that glazing is supported between inner and outer leaves of a wall of the building without a separate frame.

Description

Construction Element and a Construction Modules using Said Construction Element

Field of the Invention

The current invention relates to a construction element and a construction module using such a construction element. In particular but not exclusively the method relates to a construction element and system for producing buildings, for example wooden buildings that retain their thermal integrity.

Background of the Invention

Historically, buildings have been built using solid material to form walls of the building, such as stone, concrete blocks or bricks. Older buildings were constructed of single walls and the thermal insulation of such buildings was very poor. In more recent times, buildings have been constructed from double walls which have a cavity between them. Insulation material can be pumped into the cavity to increase the thermal insulation of such buildings, but there are problems in that often cavity walls have tie bars in them that form a bridge between the two walls and which help to prevent bowing of the walls. Because there is a metal bridge between the two walls, there can be thermal leakage from the building due to the conductivity of the metal and composite tie bars.

More recently buildings are constructed by using an internal frame to which walls are attached either by using a cladding method where sheets of material such as plaster board are attached to the frame. Alternatively the frame forms the main supporting structure of the building and walls, typically made of concrete blocks provide an infill for the frame. Usually the framework for a building is made from metal girders, typically steel. The walls of the building are made from a separate material from the frame and because there are separate elements which have to be joined or abutted against one another there are going to be points in the building structure where there can be thermal leakage, which leads to a less energy efficient building and increased costs to heat the building. For new builds having reduced thermal efficiency can mean that a building may not be able to meet the energy efficiency standards that regulatory authorities require new buildings to meet. Furthermore, known buildings do not allow for the provision of service ducts which are integral with the building and which allow for easy access to those service supplies, such as electricity wires or water supplies, once the building is constructed.

The present invention seeks to overcome the problems of the prior art by a thermally efficient building structure which has an integral construction element that allows for building with ease of access to services. Furthermore the invention allows for a building that is flexible in its ability to adapt to the occupants' needs and desires and changing technology.

Summary of the Invention

According to a first embodiment of the invention there is provided a construction element formed as a body having first and second arms which are in alignment and third and fourth arms in alignment with one another, said first and second arms being substantially at right angles to the third and fourth arms with the first and second arms being of lesser thickness than the third and fourth arms. In effect the construction element is provided as a cruciform member to support building elements and in particular linear building elements.

It is envisaged that the first arm is longer than the second arm.

Preferably third and fourth arms are of substantially equal length Tn a preferred anangement when in use the first arm is positioned such that said first arm is uppermost of the second arm.

Tn a preferred arrangement one or more of the arms are made of a material with thermal qualities.

According to a second embodiment of the invention there is provided a construction module including one or more construction elements according to a first embodimcnt of the invention arranged in a linear array in combination with at least one building element which is supported by the cruciform elements.

Preferably the building element is a cross beam.

it is envisaged that the construction module is provided with a plurality of construction elements placed in a linear arrangement with the first and second anus of the cruciform element being arranged substantially vertically and the third and fourths arms being perpendicular to the first and second arms, the third and fourth arms having respective upper and lower surfisces that provide the fiucility whereby up to four cross beams can be attached to the construction element thereby providing a box beam or box truss having a composite structure.

Preferably the construction elements are arranged at a distance of at least 400mm from one another in a linear direction.

It is envisaged that the construction element is made of wood or a wood composite. However is envisaged that other material may be used as they are developed in the construction industry.

In a prefrrred arrangement the construction module forms a separation between an upper and lower floor of a building.

It is also envisaged that the construction module forms a support to the roof ofa building.

In a further embodiment of the invention there is provided a building having one or more construction modules according to the invention. The construction modules, typically form supports for the roof and ceiling between floors in a building. The construction modules are particularly suited to forming a roof structure as separate modules can be joined to one another forming a continuous structure, an in particular one having a change in angle of the piofile.

According to yet a further embodiment there is provided a glazing system wherein edges of a glazing unit are positioned between an outer and an inner wall of a building formed from construction modules described in other embodiments. The glazing unit is sandwiched between walls without the need for a separate frame.

Preferably the inner wall of the building has a section positioned in proximity to where the at least one edge of the glazing units abuts the inner wall and said section (or sections) being removable so that an inner face of the glazing can be revealed allowing the glazing unit to be removed from the wall of the building. This allows for replacement of glass without the need for damaging the wall of the building, which conventional frame systems do and it is also a much easier system to use as the wall itself supports the glass.

The invention has particular advantages in that it allows for a cost effective building system, which minimizes the materials used, it provides a good thermal rating for the building whilst allowing for adaptability of the building structure.

Brief Description of the Figures

An embodiment of the invention will be described with reference to and as illustrated in the accompanying figures by way of example only, in which: Figure 1 shows: a number of different known types of composite beam structures that can be used to foim frames, trusses, beams and purlins in a building; Figure 2 shows: a number of construction elements according to an embodiment of the invention in situ; Figure 3 shows: a side view of the arrangement of Figure 2, with cladding in position; Figure 4 shows: a view from above and the spaced relationship of the construction elements with there being apertures between them for receiving services; Figure 5 shows: a cross section through the Composite Box Beam' and composite wall; Figure 6 shows: a Composite Box Beam Truss', roof arrangement with a number of construction elements joined to one another to provide a support for the roof of a building; and Figure 7 shows: a glazing structure used with a building constructed using a system as described.

Detailed Description of Embodiments of the invention Figure 1 shows a series of known construction elements that are used in buildings to date.

Typically the building elements are provided as either vertical or horizontal elements that provide the framework for the building and cladding is nailed or screwed to the elements. There has to be a specific fixing of the cladding to the construction element rather that the construction clement having inherent fcatures that allow it to support the building element. Furthermore, the construction elements provide a solid vertical wall, there is generally no spacing to allow for the introduction of services such as drainage, water, media or electrical supplies and these have to be included in the building outside of the wall. This means that the service ducts are visibk or alternatively they have to be embedded in the wall itself once the wall is built, they are not incorporated in cavities formed as part of the wall structure so there are problems in retaining ease of access to these service ducts.

Figure 2 shows a series of construction elements according to an embodiment of the invention which are in situ. These construction elements are generally sho\vn as I in the figure. The construction clement has four arms, with arms 3 and 4 being in a linear arrangement with the arm 3 being positioned abovc arm 4. There are also two arms 5,6 that are again in alignment and are at substantially right angles to arms 3,4. Typically arm 3 is longer then arm 4. There is a corc 2 for the cruciform structure where all four arms meet that provides stability to the whole structure.

Tn this arrangement the building is a timber building but other materials may be used. Timber is a particularly usethl material to use for the buildings that include the construction elements of the invention because timber is readily available and also it has thermal insulation qualities and also timber is a sustainable which is particularly important for eco buildings.

The arm 3 ends in an end surthce 7. Similarly there is an end surface on the lower arm 4. The end surface 7 abuts a floor or a roof member positioned above the construction element 1 and provides a strengthening element, while the end surface of the lower arm 4 is visible to a room beneath and may be covered with a decorative finish. The arms 5,6 have an upper cross surface 8 which forms a shoulder onto which a cross beam 10 can be placed and this cross beam will run parallel to the floor and ceiling and will provide strength. The composite walls (18, ISa, 19, 19b figures 4 & 5, and 31, 31b of figure7) provide weather proofing, thermal insulation and racking stability to the composite box beam truss. The arms 5,6 also have an underside to which other cross beams can be attached so forming a secure structure to which walls can be attached. The arms 5, 6 have respective end surfaces 9 to which a facing can be attached to cover the cross beams and the cruciform elements. The facing, which is typically birch ply may be secured to the end surfaces by gluing, which avoid the need for separate fixings, which are typically metal, which not only are unsightly but which means that heat can be lost through conduction via the metal.

The cruciform clement can have four cross beams 10 (timber booms) placed edge on onto the cruciform element, two on the upper arms of the cross and two below the arms of the cruciform element. The cruciform elements 2 together with the four cross beam elements 10 (commonly referred to in the construction industry as a boom) form what we will call a construction module or "composite" box beam. It is preferable to use SC24 structural grade timber or above for its structural pruperties, ad these beams can be glued in accordance with TRADA best practice and or screwed to the construction elements or fixed using other types of mechanical fixings that are known in the construction industry.

The construction elements are typically made from a mortised piece of wood and the upper mortise (which we refer to as an arm) is extended above the beam (to the depth of joist/roof members) to allow for joining to floor and roof members. It is preferable for the upper arm 3 to be 75mm or greater, to allow for a service void in the beam -and allows 75mm of timber to remain in-between the two rebates that receive the booms. The cruciform that is formed with the column, and which is mortised, takes the load path through the centre of the column to prevent the cross beams 10 from being damaged by compression actions. The construction elements are placed preferably at 400mm from centre to centre from one another in a linear direction. Thermal insulation is placed/glued in-between the upper and lower beams 10 on the, and should equal the thickness of the beams.

The cross beams 10 are supported by columns 1 I. The colunrns are preferably 3 pieces of SC24 grade timber 145 x 195mm for intermediate columns and at the corners/ends of a building, and the direction of growth rings set in apposing orientation to each other in line with accepted best practice to reduce the risk of the column twisting and these are glued together. The middle membcr acts as the main load/actions support, with some transference of actions to the outer members. The outer two members to have housing joints cut 12, 1 2b (rebated) to receive the beams 10. The cross beams 10 arc to be structurally glued jin accordance with TADA best practice) or secured by other mcchanical fixings to the column 11. The elements of the Composite Box Beam' together with the columns form a Composite Box Beam Truss'.

Typically columns that are internal in a building (intermediate columns) are made of three sections and columns that end on the outside of a building are made from two sections. For the centre section of the column (for intermediate columns) and the section on the outside end of corner columns -these can be extended into the building 1 lb figure (column 1 lc figure 2 cut out on drawing for illustrative purposes) there can be attached a portal beam (not shown) that extends perpendicularly to the composite box beam truss. A portal beam can be attached to the extended column in line with current building best practices to provide a portal or moment frame. Or on the external perpendicular wall, the outer member of the column has housing joints cut (rebated) to receive the portal beam 14 (see Figure 6) that is running perpendicular to the Box Beam Truss'. This system is preferable to the conventional way of securing beams to a supporting upright using L' shaped steel (angle bracket) facing out from the column, as this would seriously compromise thermal integrity, and most likely cause thermal bridging and subsequent condensation/damp problems. Optionally there may be a timber portal that is perpendicular to the box beams and this avoids the need for walls to provide racking stability for the structure. The avoidance of the need for walls produces a building with more open spaces.

Joists 30 extend between the composite box tmss structures on opposite walls to provide strength to the arrangement.

A webbing or facing 13 of preferably birch ply (not birch faced) is glued to both sides of the beam 10, and or can be nailed or other mechanical fixing to the beam 10 and column II. Birch ply is used for its higher resistance to shear actions, and if nailed, preferably nailed with 50mm galvanised ring shanks at 50mm centres for 400mm past high stressed areas such as junctions

S

with colunms and changes in the angle of beams. However a method of attaching parts can be the use of a structural glue joint according to TRADA best practice (Timber Research and Development Association).

The columns 11 can be secured to a building foundation via appropriately sized bolts protruding from the foundations and connected to a metal shoe/bracket (not shown). In earth quake prone areas the metal shoe to be substituted with a shock absorbing shoe already on the market and used with steel frames. The bolts and shoe method allows for a very easy and accurate levelling of the building frame. This gives a big advantage over other panel type buildings, as in practice slight imperfections in levels of the foundations are exaggerated in poorly fitting panels as the building height increases. As an alternative the columns 11 can be set in concrete.

Figure 3 shows a side view of a construction module with facing ply 13. The upper arm 3 of the cruciform element can be seen and there is spacing 15 between each of the elements. This spacing forms a cavity through which services such as pipes for a water supply or sewage may be run. At the upper end of the arm 3, a flooring element 16 such as plasterboard or fire board for containment of fires between floors and to provide mass for sound retention/insulation between floors and attached buildings. On top of this there may be a sound insulating layer I ba, followed by the actual flooring layer itself which may be boarding or a laminate 16b. The joist 30, adjacent arms 3 provide further support for the flooring.

As can be seen in Figure 4 which shows a view from above not only are there spaces that run in the same linear direction as portal beams (shown as 15 in Figure 3) but there are also spaces that extend between the spaces between upper surface of arms 3. Such spaces allow for the running of services between floors of a building and from one side of a room to another in the space that is provided between the ends of the arms 3,4 and 5,6. The column 11, with central section 11 a provides a supporting structure and there is a facing layer 1 8a attached to a main racking board, and thus is attached to the cross beam 10 of the construction module. There is also an insulation layer 18 followed by an exterior layer 19, which may be wooden shingles, or any other finishing material. The structural timber skeleton provides support for the main loads/actions associated in buildings. With a composite extemal skin laminated in situ, the external skin and internal composite stress diaphragms provide for the main racking actions of the building. It is envisaged that towards the centre of each bay (the area in between two Box Beam Trusses') running parallel to the Box Beam Trusses' is a section of dropped ceiling approximately 600mm wide with easily removable panels, and deep enough to allow for appropriately sized and fall for waste pipes, ventilation pipes and other services.

Figure 5 shows and end view of a section cut through the external wall and Composite Box Beam'. The core 2 of the construction element is shown with four arms. As am-i 5 is to be located at an area of the building where there may be particular heat leakage, it may be coated with or made from a material which has particularly good insulating properties but which retains its strength to support beams 10. The outer skin of the material may be shingles or rendering 19, which may be one layer or more preferably is multilayered. Inwardly of the outer skin there is a vapour/moisture layer 1 9a and then an orientated strand board layer I 9b. There is then an rigid insulation layer 18, which may be foam or a natural material such as compressed paper of animal hair fibres, e.g. sheep's wool all bonded together. The other side of the insulation layer has a repeat of the orientated strand board. There are beams 10 and the cruciform construction element with the central part of the element being shown as 2. Joists 30 (or portal beams) run at right angles to the plane of the cruciform element and form the support for a ceiling of a floor below.

A building structure can be seen in Figure 6. The individual rooms a,b,c,d,e,f and g are shown and different floors of the building are separated by construction modules including a series of construction elements which form the structure for the support of floors/ceilings 20, 21. The structure is supported using columns 11, which for intermediate columns have three uprights, while for the end columns there are two uprights. The three pail colunms in particular allow for the support of portal beams 14. At the top of the building the construction modules form a hippcd roof structure formed of a flat roof section 22 from which extend sloped roof sections 23. These roof sections connect with vertical wall of the building. The beams can go from horizontal to a pitch roof angle without the need for column or load bearing wall support as the construction modules form an integral load supporting arrangement. The construction provides for a complete thermal insulation layer 22a that surrounds the building. The modules are mechanically fixed with glue to columns/booms and studs (cruciform element) at spaced locations, typically 400mm centres. Again the gluing complies with TRADA structural gluing requirements. The construction which uses the construction modules as suppoTt for the roofing rather than having conventional A frame beams allows for a greater use of roof space as a usable inhabitable area for the buildings use -especially in building height restricted areas, as there is less requirement for internal structures to support the roof structure.

All floor and roof timbers run perpendicular to Box Beam Truss' (except roof timbers that are on a hipped root), and arc fixed to protruding studs (not shown), preferably by gluing or other mechanical fixing. This also allows for easy fitting and updating of services within the building.

The sizes of the beams/columns and its component parts will depend on what actions/loads they will need to take in each particular building. When building a wooden structure the construction system uses less timber volume than conventional timber frame buildings and provides a very high level of thermal integrity over and above other methods of construction. Furthermore the building system will have a higher thermal integrity than a Structural Insulated Panel (SIP's) system which has an integral strengthening system using the cruciform construction elements described allows for more storeys to be included in a building as they are of greater strength then known systems and have higher thermal integrity. Furthermore as the verticals are an integral pan of the building, they can be incorporated in the foundations of the building easily. This may be via bolting the uprights to plates in the ground which allow for a degree of movement in geographically unstable areas such as earth quake prone areas. Alternatively rather than using plates in the ground, the uprights may be fixed to for example vertical pins that have areas of resilience that allow for movement in the building. The building securing system is generally shown as 24 in the figure. As the modular construction system forms the structural framework of the building, it is particularly strong as it in effect provides a monocoque structure which itself is load supporting.

Finally, the building system described where the construction modules for a strong supporting structure for a building also allow for a direct framclcss glazing system as shown in Figure 7.

This figure shows a view from above of a glazing system incorporated in a building structure of the invention. The glazing is shown as triple glazing 25 formed of three pieces of glass separated by layers of air or other gases such as Argon, which provides good insulation. As well as triple glazing, double or multiple glazing systems could be used. The cnds of the panes of glass have thermal insulation layers 26, which provide insulation between the glazing and the building itself The gap between the face of a glazing panel and a wall 27a that forms the external wall of a building is sealed with a sealant 33 such as silicon beading which again maintains the thermal integrity of the structure and keeps the glazing system water tight. There may also be an aluminium plate to provide thrther protection at this joint. At the ends of the glazing there may also be a foam layer 34 which provides further thermal integrity. The inner wall 27b abuts against an inner face of the glazing structure. On the inner side of the glazing there is another sealing entity, which is non-bonded. Next to the non-bonded sealing layer there is an internal insulation part 35, which not only protects the internal seal, but also further helps with thermal integrity of the system, 27b, 28 and 35 are bonded together to form a glazing bead. Typically for ease of access the glazing bead is push fitted into place. The inner wall 27b extends to a block 28 which has a channel 36. The channel may be lined with a material that provides a protective surface such as a plastic or a metal such as aluminium. The channel can receive primary sheathing/racking 31 that is supported by the channel 36 in the thickened part 28 of the wall so providing a strengthening support. There is also surface layer 30 such as plaster board which provides a wall and this is backed by insulation layer 32 to keep the whole wall thermally insulated.

If the glazing is to be removed, the block 28, 35 and wall 27b can be detached. This allows for the glazing to be brought away from external wall 27a and detached from its position so it can removed and replaced if required. The way that the construction elements allow for the build up of construction modules means that the glazing can be incorporated in the building structure itself by being clamped between two walls rather than having to use window frames. Again the modular system described forms an integral monocoque structure with high strength and thermal integrity because of the reduction of the need for scparate building elements which have to be secured together thereby creating lines of weakness with regard to strength and for retaining heat rithin the construction.

This glazing system has particular benefits in that under current building regulations in the UK, windows and doors are restricted to a certain percentage ofabuilding's floor area. The windows and doors are measured over the opening into which they are to be inserted, including the frames.

The glazing system of the current invention not only exceeds current heat transfer coefficient values (Ii values) by three times, but it also increases the amount of light going into a building.

so making the building much more pleasant for occupants.

Furthermore, the present invention allows for a much slimmer wail profile (being 255mm -including a 32 mm service void) compared with a conventional wall which is typically 327 mm, and depending on the accuracy of construction, with no service void. This means that the wall is substantially slimmer (typically 104mm) and at the same time has far superior thermal properties and this is due in part to wall not taking direct loads. The present invention therefore also allows for constructing buildings having more space for the building footprint as walls are thinner but at the same time providing a very thermally efficient structure, which minimiscs environmental impact as less heating will be needed to heat such structures due to the minimization of heat leak.

It is to be understood that the above embodiments have been provided only by way of exemplification of this invention, such as those detailed below, and that further modifications and improvements thereto, as would be apparent to persons skilled in the relevant art, arc deemed to fall within the broad scope and ambit of the present invention described. Furthermore where individual embodiments arc discussed, the invention is intended to cover combinations of those embodiments as well.

Claims (1)

1. <claim-text>Claims 1. A construction element (1) having a main body (2) and first (3) and second arms (4) which are in alignment in a first direction and third (5) and fourth (6) arms in alignment with one another in a second direction, said first and second arms (3,4) being substantially at right angles to the third and fourth arms (5,6), the third and fourth arms having upper surfaces onto which building elcmcnts can be secured.</claim-text> <claim-text>2. A construction element according to claim I, wherein thc cross section of thc first and second arms in thc first direction being lcss than the cross section of thc third and fourth arms in thc sccond direction.</claim-text> <claim-text>3. A construction element (I) according to claim I or claims 2, whcrein the first arm (3) is longer than thc sccond arm (4).</claim-text> <claim-text>4. A construction elcmcnt (1) according to any prcccding claim wherein thc third and fourth arms (5,6) arc of substantially cqual lcngth.</claim-text> <claim-text>5. A construction element according to any preceding claim wherein at least part of one or more of the arms (3,4,5,6,) are made of a material with thermal qualities.</claim-text> <claim-text>6. A construction module including a plurality of construction elements (1) according to a any preceding claim said construction elements (1) being arranged in a linear array with two building elements (10) being supported by respective upper surfaces of arms (5,6) and a ifirther two linear building elements being attached to lower surfaces of arms (5,6).</claim-text> <claim-text>7. A construction module according to claim 6, including facing panels (13) attached to end surfacc (9) or arms (5,6).</claim-text> <claim-text>8. A construction module according to claim 7, attachcd to cross beams (14) which arc positioncd so an end of cach crossbeam (14) cxtcnds into a space (15) bctwccn respective construction elements that are in a linear array, said crossbeams (14) being substantially at right angles to the construction elements (1).</claim-text> <claim-text>9. A construction module according to claim 6 or claim 7, wherein the construction elements (1) are alTanged at a distance of at least 400mm from one another in a linear direction.</claim-text> <claim-text>10. A construction module according to any of claims 6 to 9 where the construction elements are of wood or a wood composite.</claim-text> <claim-text>11. A building including one or more construction elements of claims 1 to S or construction modules of claims 6 to 10.</claim-text> <claim-text>12. A building according to claim II, wherein the construction elements or construction modules form aroofofa building.</claim-text> <claim-text>13. A glazing system incorporated in a building formed using construction elements of claims I to 5 or construction modules of claims 6 to tO.</claim-text> <claim-text>14. A glazing system according to claim 13, wherein at least one edge of a glazing unit (25) are positioned between an outer and an inner wall (27a,27b) of a building formed from construction modules of claims 6 to 10 and sandwiched there between without the need for a separate frame.</claim-text> <claim-text>15. A glazing system according to claim 14, wherein the inner wall (27b) of the building has a section positioned in proximity to where the at least one edge of the glazing unit abuts the inner wall and said section is removable so that an inner face of the glazing unit can be revealed allowing the glazing unit to be removed from a wall of the building.</claim-text> <claim-text>16. A construction element which is substantially as herein described with reference to the accompanying illustrative drawings.</claim-text> <claim-text>17. A construction module which is substantially as herein described with reference to the accompanying illustrative drawings.</claim-text> <claim-text>18. A building including a construction element or construction module as herein described with reference to the accompanying illustrative drawings.</claim-text> <claim-text>19. A glazing system as herein described with reference to the accompanying illustrative drawings.</claim-text>