Steel-frame construction systems and methods

Abstract

A wall stud includes a steel member having a generally rectangular cross-sectional shape and having at least first, second and third sides, the first and second sides being opposite one another. The wall stud also includes a first foam member having a generally rectangular cross-sectional shape. The first foam member is affixed to the first side of the steel member. The wall stud also includes a second foam member having a generally rectangular cross-sectional shape. The second foam member is affixed to the second side of the steel member. The wall stud also has a ridged cap affixed to a side of the first foam member opposite the steel member.

1 . A wall stud, comprising: 
 a steel member having a generally rectangular cross-sectional shape and having at least first, second and third sides, the first and second sides being opposite one another;    a first foam member having a generally rectangular cross-sectional shape, wherein the first foam member is affixed to the first side of the steel member;    a second foam member having a generally rectangular cross-sectional shape, wherein the second foam member is affixed to the second side of the steel member; and    a ridged cap affixed to a side of the first foam member opposite the steel member.    
   
   
       2 . The wall stud of  claim 1 , wherein the steel member comprises two-inch square tubular steel having a wall thickness in the range of 14 to 16 gauge.  
   
   
       3 . The wall stud of  claim 1 , wherein the first and second foam members comprise two-inch square closed cell structural foam having a density in the range 6 to 8 pounds per cubic foot.  
   
   
       4 . The wall stud of  claim 1 , further comprising an adhesive material affixing the first foam member and the second foam member to the steel member.  
   
   
       5 . The wall stud of  claim 1 , wherein the ridged cap further comprises tabs that extend along opposite sides of the first foam member.  
   
   
       6 . A wall panel, comprising: 
 a top plate having a generally rectangular cross-sectional shape;    a bottom plate having a generally rectangular cross-sectional shape; and    a plurality of studs affixed in a generally parallel configuration between the top plate and the bottom plate thereby forming a generally planer frame, each stud, the top plate, and the bottom plate, comprising: 
 a steel member having a generally rectangular cross-sectional shape and having at least first, second and third sides, the first and second sides being opposite one another;  
 a first foam member having a generally rectangular cross-sectional shape, wherein the first foam member is affixed to the first side of the steel member;  
 a second foam member having a generally rectangular cross-sectional shape, wherein the second foam member is affixed to the second side of the steel member; and  
 a ridged cap affixed to a side of the first foam member opposite the steel member.  
   
   
   
       7 . The wall panel of  claim 6 , wherein the steel members comprises two-inch square tubular steel having a wall thickness in the range of 14 to 16 gauge.  
   
   
       8 . The wall panel of  claim 6 , wherein the first and second foam members comprise two-inch square closed cell structural foam having a density in the range 6 to 8 pounds per cubic foot.  
   
   
       9 . The wall panel of  claim 6 , further comprising an adhesive material affixing the first foam members and the second foam members to the steel members.  
   
   
       10 . The wall panel of  claim 6 , further comprising sheeting adjacent the second foam member of each stud, the top plate, and the bottom plate.  
   
   
       11 . The wall panel of  claim 10 , wherein the sheeting comprises a closed-cell, structural foam material.  
   
   
       12 . The wall panel of  claim 11 , wherein the sheeting, the top plate, the bottom plate, and the plurality of studs form one or more cavities, the wall panel further comprising, insulating foam disposed within the cavities.  
   
   
       13 . The wall panel of  claim 12 , wherein the insulating foam comprises a closed cell, spray-on foam.  
   
   
       14 . A method of constructing a wall panel, comprising: 
 a) assembling a generally planer steel frame comprising: 
 a top plate having a generally rectangular cross-sectional shape and at least first, second, and third sides, the first and second sides being opposite one another;  
 a bottom plate having a generally rectangular cross-sectional shape and at least first, second, and third sides, the first and second sides being opposite one another and generally co-planer with the first and second sides of the top plate; and  
 a plurality of steel members affixed in a generally parallel configuration between the top plate and the bottom plate, wherein each steel member has a generally rectangular cross-sectional shape and at least first, second, and third sides, the first and second sides being opposite one another and co-planer with the first and second sides of the top plate and the bottom plate;  
   b) affixing first foam members having a generally rectangular cross-sectional shape to the first sides of the top plate, the bottom plate, and the steel members;    c) affixing second foam members having a generally rectangular cross-sectional shape to the second sides of the top plate, the bottom plate, and the steel members;    d) affixing sheeting to the top plate, the bottom plate, and the steel members, wherein the sheeting is disposed adjacent the second foam members to thereby form cavities together with the top plate, the bottom plate, the steel members, the first foam members, and the second foam members;    e) affixing a rigid cap to a side of each first foam member opposite each steel member to which each first foam member is affixed; and    f) applying insulating foam into the cavities.    
   
   
       15 . The method of  claim 14 , wherein at least steps a), b), and d) take place at a first location and at least steps c) and e) take place at a second location.  
   
   
       16 . The method of  claim 15 , wherein the first location comprises a production facility and the second location comprises a job site, the method further comprising transporting the panel at least 0.25 miles between the production facility and the job site.  
   
   
       17 . The method of  claim 15 , wherein the first location comprises a controllable environment.  
   
   
       18 . The method of  claim 14 , wherein affixing first foam members comprises using adhesive to affix the first foam member to the steel member.  
   
   
       19 . The method of  claim 14 , wherein affixing a rigid cap comprises using fasteners to affix the ridged cap to the first foam member by penetrating the first foam member and anchoring the fastener into the steel member.  
   
   
       20 . The method of  claim 14 , wherein the steel members comprises two-inch square tubular steel having a wall thickness in the range of 14 to 16 gauge.