Residential construction method and apparatus

Abstract

Home residential construction based on the use of panels made of metal cladding with expanded polystyrene therebebetween. The metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel is strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes. A pitched roof is formed of roof panels, supported by a bar joist at the peak. Walls are formed of wall panels joined using trays for their bottom ends and caps for their top ends and sides. A residence constructed using the present materials and methods is stronger than conventional “brick and stick” homes and can be constructed more quickly and cheaply, and is less expensive to heat and cool.

1 . A method for constructing a residence, said method comprising the steps of: 
 forming a foundation for a residence;    placing trays on said foundation;    setting wall panels into said trays, said wall panels each being made of cladding with expanded polystyrene therebetween;    placing caps onto said wall panels;    fastening said trays and said caps to said wall panels; and    installing a pitched roof onto said panels.    
   
   
       2 . The method as recited in  claim 1 , wherein said pitched roof further comprises roof panels made of cladding with expanded polystyrene therebetween.  
   
   
       3 . The method as recited in  claim 1 , further comprising the step of installing a floor on said foundation, said floor further comprising floor panels made of cladding with expanded polystyrene therebetween.  
   
   
       4 . The method as recited in  claim 1 , wherein said cladding is galvanized steel.  
   
   
       5 . The method as recited in  claim 1 , further comprising the step of positioning a bar joist between said wall panels near said cap to support said roof.  
   
   
       6 . The method as recited in  claim 1 , further comprising the step of providing I-beams interior to said foundation and installing a floor on said I-Beams and said foundation, said floor comprising floor panels made of cladding with expanded polystyrene therebetween.  
   
   
       7 . The method as recited in  claim 2 , further comprising the step of sealing adjacent roof panels using liquid polystyrene.  
   
   
       8 . A residence, comprising: 
 a foundation;    trays attached to said foundation;    walls made of wall panels having a top and an opposing bottom, said bottom of said wall panels being inserted into and fastened to said trays, said wall panels made of cladding with expanded polystyrene therebetween;    caps fastened to said tops of said wall panels;    means carried by said walls for supporting a roof;    a pitched roof supported by said roof supporting means; and    a floor carried by and fastened to said foundation.    
   
   
       9 . The residence as recited in  claim 8 , wherein said pitched roof further comprises roof panels made of cladding with expanded polystyrene therebetween.  
   
   
       10 . The residence as recited in  claim 9 , wherein said roof supporting means is a bar joist.  
   
   
       11 . The residence as recited in  claim 9 , wherein said cladding of said wall panels and said roof panels is galvanized steel.  
   
   
       12 . The residence as recited in  claim 9 , wherein said polystyrene is expanded with air.  
   
   
       13 . The residence as recited in  claim 9 , further comprising: 
 plural supports; and    an I-beam attached to said supports for supporting said floor.    
   
   
       14 . The residence as recited in  claim 13 , wherein said floor further comprises floor panels attached to said I-Beam and said foundation, and wherein said floor panels are made of cladding and expanded polystyrene therebetween  
   
   
       15 . A residence, comprising: 
 a foundation;    a floor carried by said foundation;    walls carried by said foundation; and    a pitched roof carried by said walls, said pitched roof made of plural roof panels, each roof panel of said plural roof panels made of cladding with expanded polystyrene therebetween.    
   
   
       16 . The residence as recited in  claim 15 , further comprising a bar joist carried by said walls, and wherein said roof is supported by said bar joist.  
   
   
       17 . The residence as recited in  claim 16 , wherein said roof has a peak, and wherein said bar joist supports said peak of said pitched roof.  
   
   
       18 . The residence as recited in  claim 17 , wherein said roof panels are joined at said peak using liquid polystyrene.  
   
   
       19 . The residence as recited in  claim 15 , wherein said walls and said floor further comprise wall panels and floor panels, respectively, said wall panels and said floor panels being made of cladding with expanded polystyrene therebetween.  
   
   
       20 . The residence as recited in  claim 19 , wherein said polystyrene of said roof panels, said wall panels and said floor panels are made of polystyrene expanded with air.