WO1999057387A1

WO1999057387A1 - Building structure and construction method

Info

Publication number: WO1999057387A1
Application number: PCT/US1999/009421
Authority: WO
Inventors: Tary Farnholtz; Rose Farnholtz
Original assignee: Tary Farnholtz; Rose Farnholtz
Priority date: 1998-05-01
Filing date: 1999-04-30
Publication date: 1999-11-11
Also published as: AU3574099A

Abstract

A building structure and construction method where a plurality of wall panels (118) having different interconnecting portions (26/28, 33, 90/90') are positioned and held by lower channel members (34) which include at least one upwardly projecting flange (40) for the interior of the wall member and at least one downwardly projecting flange (42) for exterior wall members. The upper portions of the wall panels are held together by an upper channel wall cap (60) with clip members (70, 72) being attached to roof panels (16) and engaging the downwardly extending portions of the wall cap. Metal inserts (46, 91, 102) are provided along edges of the wall panels for providing connection with adjacent panels as well as mounting support for door and window frames.

Description

BUILDING STRUCTURE AND CONSTRUCTION METHOD

This invention relates to building structures employing structural panels and also to an improved construction method for assembling such panels to form such a building.

BACKGROUND TO THE INVENTION

The prior art is replete with modular building structures and associated construction methods, many of which suffer from a variety of problems. Amongst such problems are included the complexity of assembling elaborate framing systems to which modular panels are attached, the inconvenience attendant the use of plural individual fasteners to fix structural panels to one another, and the poor structural strength of some modular structures.

An example of a prior art module construction arrangement which employs a plurality of fasteners is U.S. Patent No. 4,853,398, in the name of Ricchini . Ricchini discloses a structure using proportionally sized panels secured together by turn-lock fasteners inserted through aligned openings in adjacent sides of panels.

A further exemplary prior art construction arrangement is that disclosed in French Patent Document No. 2,389,724, in the name of Batimpro SA. This document discloses a modular building using panels having adjacent vertical sides of complementary shapes. The panels are joined together by screws and are reinforced with metal plates at the location of the joints. One particular advantage of the applicant's method is that the panels may be conveniently fabricated at the building site.

OBJECT OF THE INVENTION

It is an object of the present invention to provide a building structure employing modular panels which overcomes or ameliorates at least some of the problems associated with the prior art.

-1- It is a further object of the invention to provide a construction method employing modular panels which is simple but maintains the structural integrity of a complete building structure, thus providing more convenient alternative to those presently available.

A yet further object of the invention is to provide a laminated modular panel adapted for use with the building structure and/or construction method which may also be expediently fabricated. Further objects will be evidenced from the following description.

SUMMARY OF THE INVENTION

In one form, although it need not be the only or indeed the broadest form, the invention resides in a building structure comprising: one or more modular panels erected on a base to form one or more walls; a plurality of tie rods extending through longitudinal cavities in said walls, to secure said walls to the base; and wherein said longitudinal cavities are defined by complementary positioning profiles formed on adjacent upright sides of engaged modular panels.

It is preferable that the complementary positioning profiles on the modular panels comprise a projection on one side of the panels and a cooperating recess on the opposite side of the panel, whereby the recess is of a depth greater than the height of the projection thereby defining the longitudinal cavity between the engaged modular panels .

Additional subsidiary longitudinal cavities for accommodating building services may also be defined in the modular panels. It is preferable that the tie rods possess high tensile strength and engage one or more load bearing members disposed on the top side of the modular panels . The top structural member of each wall is comprised of a specified steel channel used in the capacity to cap and enclose the top of the wall with the two sides of said steel channel to extend vertically onto wall face from wall top. Gauged thickness of the channel are dependent on specifications as set forth in each structure by a qualified engineer. Locating members for the bottom location of the wall panels comprise further apertured channel members, the bottom side of the modular panels being recessed to accommodate the further aperture channel members.

The modular panels are laminated construction with foamed plastics core panels having at least one outer skin member on each side.

It is preferable that the base includes a floor structure, which may optionally be of modular construction, also employing laminated panels but will most typically be of concrete slab construction.

The building structure may also include a roof structure supported by the walls, which roof may also be of modular construction, employing further laminated panels . In the preferred embodiment, the roof structure includes a roof beam and a panel member extending over the top and laterally past both sides of the roof beam with the roof panels secured to the panel members.

In a further form, the invention resides in a method of construction including the steps of:

1. erecting one or more modular panels on a base to form one or more walls;

2. engaging adjacent modular panels to define longitudinal cavities between complementary positioning profiles formed on upright sides of said modular panels;

3. inserting tie rods into the longitudinal cavities in the walls; and

4. connecting the tie rods to the base to secure the walls thereto.

In preference, the complementary positioning profiles are formed on opposite upright ends of each panel . In accordance with another aspect of the invention, the method further includes the step of disposing one or more load bearing members on the top side of each wall for engagement by one or more tie rods. In accordance with still another aspect of the invention, the method further includes the step of disposing locating members on the base for locating the bottom side of the modular panels forming each wall.

In a yet further aspect, the invention resides in a modular panel for use in the above-mentioned building structure or method of construction, wherein said modular panel comprises: a core of foamed plastics material; at least two outer skin members bonded to said core; and a projection on a first end and a complementary recess on a second opposed end which define, in use, a cavity extending along the junction between engaged modular panels .

Other objects and features of the present invention will become apparent by a review of the specification, claims and appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

To assist in understanding the invention, preferred embodiments will now be described with reference to the following figures in which: Fig. 1 is a perspective view of a house constructed of the modular panel system.

Fig. 2 is an isometric view illustrating the erection of panels to form a wall.

Fig. 3 is an enlarged detail view of the wall top, top wall steel track and the method of attachment for the modular roofing panel as delineated by line 3-3 in Fig. 2.

Fig. 4 is an enlarged detail view of the wall base showing the method of securing the walls and the necessary components to secure wall to the chosen flooring system as delineated by line 4-4 in Fig. 2.

Fig. 5 is an enlarged horizontal, sectional, detailed view showing the edge profiles of the molded panels and how the threaded rod passes vertically through the panels as delineated by line 5-5 in Fig. 2.

Fig. 5A is similar to Fig. 5 and shows an alternative embodiment of the invention. Fig. 6 is an elevational section view of modular roofing panels secured at their upper ends to a ridge I- beam.

Fig. 7 is a schematic elevational view illustrating the rain gutter of the house. Fig. 8 is a top view showing the edge profiles of the molded panels in accordance with another embodiment of the invention.

Fig. 9 is a sectional view illustrating a door casing of the house . Fig 10A is a perspective view of a wall panel including a window frame.

Fig. 10B illustrates the metal studs of the window frame of Fig. 10A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Fig. 1 shows a building structure in the nature of a small dwelling 10 constructed in accordance with the invention. The structure 10 includes a base or foundation 12 preferably of concrete slab construction, a number of walls 14 and a roof 16. The walls 14, whether external or entirely internal, are composed of modular panels 18. The modular panels 18 are fabricated to a typical module size such as, for example, 48 inches wide and up to 12 feet high. The modular panels 18 are secured to the base by tie rods (46 in Figs. 3-5) which are disposed along the walls 14 at the exemplary 48-inch centers, to the sides of openings in the walls 14 and at the corners of the building structure 10. Alternatively, the wall panels 18 may be erected on a concrete or timber floor base or foundation 12. In a situation where a concrete floor is to be utilized, a standard concrete slab is to be designed as would be used in conventional framing practices. Usually,

^■5- this would consist of concrete footers measuring 12 inches in width and extending 12 inches into undisturbed soil or compacted soil . These footers are typically poured monolithically with the concrete slab, which is normally 4 inches in thickness . Reinforcing steel and steel mesh are typically used.

A framed flooring system can be used. The framework can be either wood or steel construction supported by proper foundation and/or pier construction with provision for the secure attachment of the foundation bolts .

The overall arrangement of wall panels 18 may be better understood by reference to Figs. 2-5. In accordance with the invention, individual wall panels 18 are erected and aligned such that longitudinal vertical cavities 32, which are defined when the panels 18 engage one another and correspond to apertures 38 in lower channel members 34.

A tie rod 46 with threaded ends is inserted into a respective longitudinal cavity 32 and engaged with a foundation bolt 50 disposed at a lower extremity of the cavity 32. An upper wall cap 60 is then placed over the top of the wall panels 18. Apertures 62, sized to accommodate only the shaft of the tie rods 46, are provided in the upper wall cap 60 and spaced so as to correspond to the foundation bolts 50. Thus, the upper ends of the rods 46 protrude through the apertures 62 in the upper top cap 60 when it is positioned on the wall top. The upper threaded ends of the tie rods 46 will be engaged with a nut 63 to facilitate the tensioning thereof. The nuts 63 are engaged with the rods 46 and tightened thereby compressing the wall panel assembly to the floor 12.

The foundation bolts 50 are to be located between each wall panel and in the example of 48 inch wide panels 18 will be spaced at 48 inches on center in all panelized walls. Bolts securing posts to the floor will be located as per plan and bottom plate will govern the bolt pattern

^■6- layout of each post base. Bolts for posts will not be related to the wall panel bolts under most circumstances. Whether the bolts are extending from a concrete slab or a framed floor, they will need to extend typically 2 inches above the finished floor line. In concrete applications, each bolt should preferably have a minimum of 6 inches embedded in the concrete, and bolts should be placed in the wet concrete at the time of slab placement to assure maximum strengths are attained. The cross section of the upper wall cap 60 is cup shaped with the outer portions extending down the top of the inside and outside surfaces of the wall panels 18.

The upper wall caps 60 are joined at corners and between sections using connector plates (not shown) . These plates are typically M" steel plates that mount to the bottom side of the wall caps 60 with bolts. The wall panels will need to be notched below the connection plate to avoid a hump in the upper cap 60.

As shown in Fig. 4, recesses 32 are provided in the bottom side of the modular panels 18 for an interference fit with respective lower channel members 34 which have a central upward projection 36 through which the apertures 38 are formed passing the tie rods 46, such that the core of each panel 18 is deformed slightly in the vicinity of the recess 32 when tension is applied to the tie rods 46. This arrangement ensures more positive location and securing of the wall panels 18.

There are two profiles of bottom track or lower channel members 34, one for the perimeter wall as shown in Fig. 4, and one for the interior walls. The difference is that the perimeter wall track has one side exposed to the weather and therefore requires a drip cap 42 on the exterior to prevent water seepage under the wall.

At least certain of the outside wall panels 18 are located along the edge of the foundation 12 by the lower channel members 34 as shown in Fig. 4. The channel member 34 includes an upwardly projecting flange 40 along the inner edge and which extends along and adjacent the inside surface of the wall panel 18, and a downwardly projecting flange 42 along the outer edge of the channel member 34 adjacent the outside surface of the foundation 12. These flanged portions of channel member 34 prevent water running down the outside surface of the wall panels 18 from flowing inside the structure beyond the wall panels 18. For interior walls the upwardly projecting flanges 40 are provided on both edges of the lower channel members 34. The lower ends of the tie rods 46 are threadably secured to the foundation bolts by connector nuts 51. The use of tie rods 46, preferably of high tensile strength in accordance with the invention, overcomes problems with fasteners such as screws or the like being pulled out of the modular panels 18 in high wind load conditions. The invention also overcomes any requirement for local reinforcement of the modular panels 18 which might otherwise add to the cost and complexity of panel fabrication. Fig. 5 shows in a horizontal, sectional view a schematic of the positive positioning profiles 25 and 27 formed on the upright ends of the walls panels 18. The lightweight panels 18 comprise a core 20 of foamed plastics, such as polyurethane , and inside and outside skins 22 and 24, respectively, such as cement sheets. In the preferred embodiment, the outside skins 22 and 24 have the same finish so orientation of the wall panels 18 is not critical. The core 20 is typically 3% inches thick whilst the skins 22 and 24 are M inch for external and internal applications. Each panel is manufactured with the foam core extending approximately %" beyond the surface skin material on both top and bottom sides. This acts as a compression point when assembling the walls to tighten up the assembly when the top cap is applied and tightened. The complementary end profiles 25 and 27 comprise a projection 26 on one end profile 25 and a recess 28 on the opposite end profile 27, as shown on the panels 18 which are aligned with one another in Fig. 5. Both end profiles 25 and 27 include side recesses 29 immediately under the side skins so that the facing pairs of side recesses form a vertical subsidiary cavities 30.

When the panels 18 are brought into engagement, the vertical longitudinal cavity 32 remains between the end of the projection 26 and the bottom of the recess 28. The cavity 32 is sized for accommodating a tie rod 46 by arranging for the recess 28 to be deeper than is required for the length of the cooperating projection 26 alone. Further, the subsidiary cavities 30 may be provided immediately under the panel skins 22 and 24 for accommodating building services such as electrical wiring (not shown) .

Fig. 5A shows an alternate embodiment in which the long edges of the wall panel 18" include a recess 31 in the core material 20' between the skin members 22 and 24, and a pair of foam inserts 33 that fill the recesses 31 of adjoining wall panels 18" with the foam inserts 33 including cut-outs 35 to pass the tie rods 46 and other electrical or plumbing elements arranged to pass in between panels 18".

A first embodiment of a roof 16 for the building structure 10 is illustrated in Fig. 3. In this embodiment, the roof 16 has a minimum pitch, typically of from 6 to 15 degrees, and is supported directly by the external walls 14 and by a ridge beam comprised of back- to-back C purlins disposed across the internal walls or I- beams 80 as shown in Fig. 6 which are in turn supported by steel posts (not shown) which can be mounted on top of internal walls but preferably are bolted or cast into the foundation to lend secure anchoring to the beam thus avoiding uplift pressures during heavy wind load conditions. The intersection of the posts and the beams are bolted. All beam and post sizes are to be determined by a qualified structural engineer. The roof may be comprised of modular panels as discussed in more detail below. The roof panels are secured at one end to the external walls 14 by through bolts 66, provided with nuts 67 and washers 68 on the outside and which pass through the panels 18 and engage with prefabricated roof clips 70 and 72, respectively made, for example, from a 2 inch wide galvanized steel bar bent as shown in Fig. 3. Each of the roof clips 70 and 72 includes a lower hook portion which extends over the downwardly extending portions of one of the wall caps 60 thereby holding the roof panels 18' to the wall caps 60 and thus to the foundation via the rods 6. At the other end as shown in Fig . 6 , near the ridge , the through bolts 66 securing the roof panels engage with a plate or panel member 81 extending over or welded to the underside of the top flange of the ridge I-beam 80, which beam 80 is in turn secured by bolts to vertical posts bolted to the foundation at the lower end. The peak portion of the roof panels is covered by a ridge capping (not shown) which extends over the roof panel securing bolts 66, which capping is secured to the roof by further screws.

After the roof panels 18' have been installed, the top wall cap 60 and roof panel clips 70 and 72 are visible at the intersection of the wall and roof panels. This area is then covered with a crown molding (not shown) both on the inside and outside of the building. The crown molding on the inside of the building can be of virtually any material, however, the exterior crown molding should be of a material that will withstand moisture. The crown molding is attached by gluing and with drywall screws. As shown in Fig 3, the modular roof panels 18' in this embodiment include a ribbed steel outer skin 24' and an injected polyurethane foam core 20' which has a fibrous cement inner skin 22', typically inch thick.

The roofing panels 18' are molded with a section of roof metal protruding along one side only to provide an overlap onto the next roofing panel 18' thus making the joint waterproof. The core 20' may also be undercut in the vicinity of the projection so as to produce a

•10- longitudinal cavity when the roof panels are clipped together. This cavity may accommodate building services in the same manner as the subsidiary cavities provided in the walls panels 18. The roof skin 24' also extends past the foam core

20' at the lower end of the roof slope to overhang the guttering at the fascia end. The metal fascia or rain gutter 88 in Fig. 7 is suspended under the valleys of the overhung roof skin by screws. The rain gutter 88 serves two purposes. The first is to catch the rain run off from the roof and the second is to protect the foam from the elements. The overhanging edge of the roofing sheets are prepared to receive the rain gutter. This is accomplished by cutting the fibrous cement board back so that the metal roofing protrudes approximately two inches (50mm) past the foam and fibrous cement board. The foam must then be channeled just beneath the roofing metal to receive the metal flange of the rain gutter 88. After this channeling is finished, the rain gutter 88 is pushed into the foam and secured with self drilling sheet metal roofing screws applied down from the top through the roofing and rain gutter flange. A small "L" shaped piece of sheet metal (approximately 1" x 1" or 20mm x 20mm) is then applied at the bottom edge of the fibrous cement board and attached with sheet metal screws to the fibrous cement board and rain gutter 88. This closes the gap at the lower end of the fibrous cement board and also secured the bottom edge of the rain gutter 88.

In the preferred embodiment, a corrugated metal roof sheeting 86 shown in Fig. 7 is applied over the completed roof panels 18'. A ridge cap is located at the peak of the roof or on the hip section of the roof . It is typically fabricated of the same material as the sheet metal roofing and applied after the roofing panels are bolted into place. Self-drilling screws with rubber washers are used to secure the roofing sheets to the roof panels 18' and to secure the ridge to the roofing sheets. A bead of silicone caulking should be applied between the

^■11- surfaces of overlapping ridge cap sections to guard against water seepage .

A top connecting strap (not shown) may be attached to the top of the roof sheet 18' bridging the rain gutter thus supporting the outside edge of said gutter.

When the walls have been erected and the top cap installed, the electrical cabling can be installed in the wall panels. A hole approximately ³Λ" (20mm) needs to be drilled in the top cap directly over a panel joint so that a cable can be fed down through the top cap and through the wall at the space between two panels. The bottom end of the wire will be brought out of the panel at the location where the switch or electrical outlet is to be placed. The top end of the wire will be coiled and left hanging from the top wall track for connection at a later date. After the roof panels are in place, the wiring can be tucked into the void created between the roof panels and the wall top cap. The ridge beam is also a good raceway to run electrical cabling and is a good location for the connection for the lighting. The joints between the roof panels allow a good location for the wiring between the switching and the light fixtures. All wiring connections must be completed before the crown molding is installed. In accordance with another embodiment of the present invention as illustrated in Fig. 8, the wall and/or roof panels are initially formed with a steel channel 90 molded into one of the long edges for projecting into a corresponding recess 90' in the other long edge of the adjacent panel to provide greater strength in the joint between panels in those situations that require mechanical attachments at the vertical joints between panels.

Referring now to Fig. 9, after the wall panels are in place, the door openings will be a cut opening in the wall panels with foam exposed on three sides. A "C" shaped piece of sheet metal 91 that has been manufactured to fit inside the panel 18 is then driven into the edge of

-12- the wall panel at the inside of the doorway. In the preferred embodiment, these pieces of metal need only be about 12 inches (300mm) in length and three pieces will be installed on each side of the doorway. Drywall screws are driven in through the fibrous cement board into the flanges 92 of the metal to anchor them in place. This gives the doorway a metal section to anchor the door frame 94 into. Door casing 96 can also be anchored to these metal inserts . Figures 10A and 10B illustrate construction of window frames 100 as the wall panels 18 are assembled, a sheet metal frame 102 is inserted in an opening that is to become a window. The frame 102 should be made of "C" shaped steel with the open side of the "C" facing outwards so that when the frame is placed in the opening, it wraps the wall panel edges and locks the frame into the wall panel 18. This method gives each window opening a steel frame for attachment of the window unit .

The interior walls are typically finished like drywall with a fiberglass mesh tape applied over the joints and then a thin coating of plaster applied to float in the joints. After a smooth surface is achieved a texture may be applied if desired.

The exterior of the walls are handled in a similar fashion as the inside surfaces. A mesh tape is first applied and then a coating of exterior plaster is applied to the entire surface for an even finish. Due to the fact that the panels do continue to have a small amount of movement in them, it is preferred that a scored joint be installed at each panel joint to control cracking.

Alternatively, an expansion insert can be installed to control any cracking, which might occur.

The sequence of assembly of the house once concrete slab or floor structure in place is as follows: 1. steel posts and beams installed;

2. bottom wall track;

3. bolt connection nuts to hold down bottom track;

-13- 4. wall panel;

5. threaded rod;

6. window frames;

7. top wall cap;

8. nuts to hold wall cap on;

9. cut off excess threaded rod;

10. electrical wiring;

11. roof panels held down with roof panel clips ;

12. rain gutter, ridge capping and gable end trim;

13. door; and

14. plastering of wall and ceiling panels. Throughout the specification, the aim has been to describe the preferred embodiments of the invention without limiting the invention to any one embodiment or a specific collection of features.

^■14-

Claims

WE CLAIM :

1. A building structure including prefabricated parts attached together in an assembly upon a foundation comprising a plurality of wall panels, each having substantially centrally widthwise located upwardly projecting recesses extending lengthwise along the lower edge of the wall panels and certain of said panels for attachment along the outside edge of the foundation, a plurality of roof panels, a plurality of channel members positioned along the outside edge of the foundation for locating the bottom of said certain of said panel members, each of said channel members having: a central upward projection fitting into said recesses of said wall panels, an upwardly projecting flange along the inner edge adjacent the inside surface of said wall panels and a downwardly projecting flange along the outer edge of said channel member adjacent the outside surface of the foundation, upper wall caps extending over the top of said wall panels and down the top of the inside and the outside surfaces of said wall panels, means for holding said caps and said panels together and to the foundation, clip members attaching said roof panels to said caps and thereby to said side wall panels,

ΓÇó15- each of said clip members attached to one of said roof panels and having a portion extending over the downward extending portion of one of said wall caps, a roof beam, panel members secured to said roof beam and extending laterally past the sides of said roof beam and means for securing the roof panel to said panel members.

2. The structure of claim 1 including tie rods extending from the foundation through the long edges of at least certain of said wall panels and through said channel members and said upper wall caps and tightened to hold together those members through which said tie rods pass.

3. The structure of claim 2 in which certain of said wall panels comprise a core of foam plastic material, at least two outer skin members bonded to said core, a recess in at least one of the long edges of said wall panel, and an insert positioned in said recess and having a cut out portion for passing one of said tie rods.

4. The structure of claim 3 wherein at least an integral portion of the core material of one panel projects into said recess of the adjoining panel.

5. The structure of claim 3 wherein at least certain adjoining panels include facing recesses and at least one foam insert positioned within said adjoining recesses.

6. The structure of claim 5 wherein at least certain of said wall panels include a steel channel molded into

ΓÇó16- and projecting from one of the long edges of said wall panel and projecting into a corresponding recess in the long edge of the adjacent wall panel.

7. The structure of claim 1 wherein at least certain of said wall panels include a steel channel molded into and projecting from one of the long edges of said wall panel and projecting into a corresponding recess in the long edge of the adjacent wall panel.

8. The structure of claim 1 wherein at least certain of said wall panels include a steel channel molded into and covering one of the long edges of said wall panel and a door frame secured to said steel channel .

9. The structure of claim 1 wherein at least certain of said wall panels include C shaped steel channels embedded in portions thereof and covering portions of the long edges thereof and forming a window frame .

10. In a building structure including prefabricated parts for attachment to an assembly upon a foundation and including wall panels having substantially centrally located upwardly projecting recesses extending lengthwise along the lower edge of the panels, the improvement comprising a plurality of channel members for positioning along the outside edge of the foundation for locating said wall panels, each of said channel members having a central upward projection for fitting into the recess of the wall panels and including at least an upwardly projecting flange along the inner edge thereof adjacent the inside surface of the wall panel.

11. In the building structure of claim 10 at least certain of said channel members for positioning interior

^Γûá17- walls of the structure including upwardly projecting flanges along both edges thereof .

12. In the building structure of claim 10 at least certain of said channel members for positioning exterior walls of the structure including a downwardly projecting flange along the outer edge thereof adjacent the outside surface of the foundation.

13. In a building structure including prefabricated parts for attachment to an assembly upon a foundation and including a plurality of thick laminated wall panels the improvement comprising an upper wall cap for extending over the top of the wall panels and down the top of the inside and the outside surfaces of the wall panels and clip members for attaching roof panels to said caps and thereby to said wall members, said clip panels attachable to a roof panel and having a portion extending over the downward extending portion of one of said wall caps.

14. In a building structure including prefabricated parts for attachment to an assembly upon a foundation and including a plurality of roof panels supportable on a plurality of wall panels and a roof beam supported on the foundation and cooperating with the wall panels to support the roof panels the improvement comprising a panel member for attachment to and extension laterally past the sides of the roof beam and means for securing the roof panels to said panel member.

15. A prefabricated wall member for a prefabricated building comprising: a core of foam plastic material;

-18- at least two outer skin members bonded to said core ; a recess in at least one of the long edges of said wall member; and an insert positioned in said recess and having a cut out portion for passing one of said tie rods.

16. The wall member of claim 15 wherein at least an integral portion of the core material of the wall member projects for insertion into the recess of another wall member .

17. The wall member of claim 15 including recesses in both long edges of the wall member for receiving a foam insert positioned within a corresponding recess within an adjoining wall member.

18. The structure of claim 15 wherein said wall member includes a steel channel molded into and projecting from one of the long edges of said wall panel and for projecting into a corresponding recess in the long edge of the adjacent wall panel.

19. The structure of claim 15 wherein said wall member includes a steel channel molded into and covering one of the long edges of said wall member and a door frame secured to said steel channel .

20. The structure of claim 15 wherein said wall member includes C shaped steel channels embedded in portions thereof and covering portions of the long edges thereof and forming a window frame .

21. The method of constructing a building on a base comprising the steps of: erecting one or more modular panels on the base to form one or more walls;

-19- engaging adjacent modular panels to define longitudinal cavities between complementary positioning profiles formed on upright sides of said modular panels; 5 covering the tops of the modular panels with inverted cup shaped wall caps having outer portions extending down the top of the inside and outside surfaces of the modular panels;

10 inserting tie rods into the longitudinal cavities in the walls and through the wall caps; connecting the tie rods to the base to secure the walls thereto;

15 supporting roof panels on top of said modular panels; and clamping the roof panels to the modular panels with clips secured to the roof panels and engaging the downwardly extending outer

20 portions of the wall caps.

^Γûá20-