Industrialized construction system and method

Abstract

Problems faced in the residential construction industry include the shortage of skilled manpower which gives rise to problems such as the inconsistencies in construction quality, time delay and cost overrun. This is because most construction work uses on-site wet concreting systems requiring expertise in numerous construction techniques and tasks. Since the progress of most tasks using these construction techniques depends on the progress of another task, most construction projects are difficult to manage. This results in an inefficient construction system that hinders provision of low-cost mass housing. Described according to an embodiment of the invention is an industrialized construction system comprising a roof support structure and a roof frame coupled to and supported by the roof support structure. The construction system further comprises a plurality of wall frames extending from a base. The roof support structure is adapted for being supported by the plurality of wall frames. The roof support structure structurally interposes the roof frame and at least one of the plurality of wall frames for directing weight of the roof flame to substantially along the plane of each of the plurality of walls.

1 . A construction system comprising:
 a roof support structure comprising:
 a first support frame; and 
 a second support frame coupled to the first support frame, the second support frame extending substantially perpendicularly to the first support frame and terminating at an edge, 
   a roof frame coupled to and extending between the edge of the second support frame and a portion of the periphery of the first support frame; and   a plurality of wall frames extending from a base, the roof support structure adapted for being supported by the plurality of wall frames with the second support frame being substantially perpendicular to at least one of the plurality of wall frames,   wherein each of the first support frame, the second support frame, the roof frame and the plurality of wall frames is planar and pre-fabricated from a plurality of studs,   wherein the roof support structure structurally interposes the roof frame and at least one of the plurality of wall frames for directing weight of the roof frame to substantially along the plane of each of the plurality of walls.   
   
   
       2 . The construction system as in  claim 1 , the base being concrete foundation. 
   
   
       3 . The construction system as in  claim 1 , the base being pre-fabricated from a plurality of studs and comprising:
 first and second base layers formed over opposing sides of the base for containing at least a portion of the plurality of studs of the base therebetween.   
   
   
       4 . The construction system as in  claim 3 , at least one of the first base layer and the second base layer comprising:
 a wire mesh; and   a cement layer formed over the wire mesh.   
   
   
       5 . The construction system as in  claim 3 , each of the first base layer and the second base layer being one of gypsum board, cement-fiber plate and sheet material. 
   
   
       6 . The construction system as in  claim 1 , each of the plurality of wall frame comprising first and second wall layers formed over opposing sides thereof for containing at least a portion of the plurality of studs of the each of the plurality of wall frame therebetween. 
   
   
       7 . The construction system as in  claim 6 , at least one of the first wall layer and the second wall layer comprising:
 a wire mesh; and   a cement layer formed over the wire mesh.   
   
   
       8 . The construction system as in  claim 6 , each of the first wall layer and the second wall layer being one of gypsum board, cement-fiber plate and sheet material. 
   
   
       9 . The construction system as in  claim 6 , at least one of the plurality of wall frames comprising:
 at least one electrical conduit extending between the first and second wall layers and at least one of an electrical socket and a electrical switch formed in the first wall layer.   
   
   
       10 . The construction system as in  claim 1 , the first support frame comprising:
 a panel extending over one side of the support frame; and   a lighting connectors extending along the support frame.   
   
   
       11 . A construction method comprising:
 forming a base;   extending a plurality of wall frames from the base;   attaching and supporting a roof support structure to the plurality of wall frames, the roof support structure comprising:
 a first support frame; and 
 a second support frame coupled to the first support frame, the second support frame extending substantially perpendicularly to the first support frame and terminating at an edge, the roof support structure adapted for being supported by the plurality of wall frames with the second support frame being substantially perpendicular to at least one of the plurality of wall frames, and 
   coupling a roof frame to the roof support structure, the roof frame extending between the edge of the second support frame and a portion of the periphery of the first support frame,   wherein each of the first support frame, the second support frame, the roof frame and the plurality of wall frames is planar and pre-fabricated from a plurality of studs,   wherein the roof support structure structurally interposes the roof frame and at least one of the plurality of wall frames for directing weight of the roof frame to substantially along the plane of each of the plurality of walls.   
   
   
       12 . The construction method as in  claim 11 , wherein forming the base comprises:
 forming the base from concrete foundation.   
   
   
       13 . The construction method as in  claim 11 , wherein forming the base comprises:
 pre-fabricating the base from a plurality of studs; and   forming first and second base layers over opposing sides of the base for containing at least a portion of the plurality of studs of the base therebetween.   
   
   
       14 . The construction method as in  claim 13 , wherein at least one of the first base layer and the second base layer comprising:
 a wire mesh; and   a cement layer formed over the wire mesh.   
   
   
       15 . The construction method as in  claim 13 , wherein each of the first base layer and the second base layer being one of gypsum board, cement-fiber plate and sheet material. 
   
   
       16 . The construction method as in  claim 11 , wherein each of the plurality of wall frame comprising first and second wall layers formed over opposing sides thereof for containing at least a portion of the plurality of studs of the each of the plurality of wall frame therebetween. 
   
   
       17 . The construction method as in  claim 16 , wherein at least one of the first wall layer and the second wall layer comprising:
 a wire mesh; and   a cement layer formed over the wire mesh.   
   
   
       18 . The construction method as in  claim 16 , wherein each of the first wall layer and the second wall layer being one of gypsum board, cement-fiber plate and sheet material. 
   
   
       19 . The construction method as in  claim 16 , wherein at least one of the plurality of wall frames comprising:
 at least one electrical conduit extending between the first and second wall layers and at least one of an electrical socket and a electrical switch formed in the first wall layer.   
   
   
       20 . The construction method as in  claim 11 , wherein the first support frame comprising:
 a panel extending over one side of the support frame; and   a lighting connectors extending along the support frame.   
   
   
       21 . A roof system comprising:
 a roof support structure comprising:
 a first support frame; and 
 a second support frame coupled to the first support frame, the second support frame extending substantially perpendicularly to the first support frame and terminating at an edge; and 
   a roof frame coupled to and extending between the edge of the second support frame and a portion of the periphery of the first support frame; the roof support structure adapted for being supported on a plurality of wall frames with the second support frame being substantially perpendicular to at least one of the plurality of wall frames,   wherein each of the first support frame, the second support frame and the roof frame is planar and pre-fabricated from a plurality of studs,   wherein the roof support structure structurally interposes the roof frame and at least one of the plurality of wall frames for directing weight of the roof frame to substantially along the plane of each of the plurality of walls.   
   
   
       22 . The roof system as in  claim 21 , the roof frame forming an incline with at least one of the plurality of wall frames.