Method of constructing a multi-storey building using prefabricated modular panels

Abstract

A method of constructing a multi-storey building entails using prefabricated modular wall panels and floor panels. The prefabricated wall panels have a frame that includes studs, rebar and an upright channel into which concrete is poured and cured to form a concrete column (or a hybrid steel-and-concrete column). Prefabricated floor panels have a frame that includes joists, sheathing and a trench-like track that forms a trough for receiving concrete that cures in the trough to create a concrete beam (or a hybrid steel-and-concrete beam). This novel method is extremely efficient for constructing multi-storey buildings, substantially reducing both construction costs and construction time.

1 . A method of constructing a building, the method comprising steps of:
 preparing a construction site by pouring a floor slab with upright rebar positioned to align with load-bearing concrete columns that are to be poured;   erecting an assembly of modular prefabricated wall panels by connecting the wall panels to define one or more walls of the building, the wall panels comprising a frame having a plurality of substantially vertical members, a subset of the plurality of substantially vertical members being closed channels;   laying modular prefabricated floor panels onto a top end of the assembly of modular prefabricated wall panels, the floor panels comprising a frame having a plurality of horizontally arranged joists and a sheathing mounted onto the frame, each of the floor panels further comprising a trench-like track that acts as a trough for receiving concrete; and   pouring concrete into the troughs in the floor panels for flowing into the channels, the concrete curing in the troughs to form horizontal concrete beams and curing in the channels to form concrete columns.   
   
   
       2 . The method as claimed in  claim 1  further comprising a step of adding rebar prior to pouring concrete. 
   
   
       3 . The method as claimed in  claim 1  wherein the concrete beams are aligned with and supported from below by the load-bearing concrete columns. 
   
   
       4 . The method as claimed in  claim 1  wherein the steps of erecting the wall panels and laying the floor panels comprises erecting two storeys of modular prefabricated wall panels and two floors of floor panels before pouring the concrete. 
   
   
       5 . The method as claimed in  claim 4  further comprising building additional storeys of the building by repeating the steps of erecting wall panels, laying floor panels, pouring concrete beams and columns within the troughs and channels in the wall and floor panels. 
   
   
       6 . The method as claimed in  claim 1  wherein the frame of each wall panel is prefabricated by:
 fastening a plurality of spaced-apart, vertically arranged studs and a vertically arranged box channel to top and bottom tracks, the top track having a hole in the track above the box channel to thereby enable concrete to flow through the hole in the top track into the box channel; and   fastening cross-bracing and stiffeners to the studs and box channel.   
   
   
       7 . The method as claimed in  claim 6  wherein each wall panel is prefabricated by attaching an exterior wall sheathing to one side of the frame. 
   
   
       8 . The method as claimed in  claim 1  wherein the frames of the floor panels are spaced apart by a predetermined distance defining an elongated gap into which is placed a trench-like track that acts as the horizontal trough for receiving concrete which, when cured, forms each concrete beam. 
   
   
       9 . The method as claimed in  claim 8  wherein the predetermined distance defining the gap between the frames is equal to a depth of the joists. 
   
   
       10 . The method as claimed in  claim 1  further comprising steps of:
 temporarily bracing the wall panels;   checking that the wall panels are plumb; and   fastening the wall panels to the floor slab.   
   
   
       11 . The method as claimed in  claim 1  further comprising steps of:
 fastening floor panels to a top portion of the wall panels;   removing bracing from the wall panels; and   shoring an underside of the floor panels.   
   
   
       12 . A modular prefabricated wall panel for use in constructing a building, the wall panel comprising:
 a frame having a plurality of spaced-apart vertically arranged studs and a vertically arranged closed channel within which concrete can be poured and cured; and   a sheet of exterior sheathing attached to one side of the frame.   
   
   
       13 . The modular prefabricated wall panel as claimed in  claim 12  further comprising top and bottom tracks connected to the studs and channel, the top track having holes aligned with a top of the channel to permit poured concrete to flow into the channel. 
   
   
       14 . The modular prefabricated wall panel as claimed in  claim 12  comprising two channels for receiving concrete to form respective load-bearing columns, the two channels being spaced apart to permit an aperture for a window to be disposed between the channels. 
   
   
       15 . A modular prefabricated floor panel for use in constructing a building, the floor panel comprising:
 a pair of spaced-apart frames, each frame comprising a plurality of spaced-apart horizontally arranged joists and a sheathing attached to each frame; and   a trench-like track connected to each of the pair of spaced-apart frames panels to thereby define a trough between the frames for receiving concrete.   
   
   
       16 . The modular prefabricated floor panel as claimed in  claim 15  wherein the frame comprises:
 a plurality of joists connected back to back with fasteners;   top and bottom tracks connected to the top and bottom sides of the joists; and   a sheathing mounted to the top track or to one or more of the plurality of joists.   
   
   
       17 . The modular prefabricated floor panel as claimed in  claim 15  further comprising stiffeners interconnecting adjacent joists. 
   
   
       18 . A multi-storey building comprising:
 a plurality of modular prefabricated wall panels assembled together to form the walls of the building, the wall panels comprising upright channels into which concrete is poured and cured to form hybrid steel-and-concrete load-bearing columns; and   a plurality of modular prefabricated floor panels assembled together to form the floors of the building, the floor panels comprising horizontal troughs into which concrete is poured and cured to form hybrid steel-and-concrete horizontal beams.   
   
   
       19 . The multi-storey building as claimed in  claim 18  wherein the columns of each upper floor are aligned with and are supported by the beams of the floor immediately below. 
   
   
       20 . The multi-storey building as claimed in  claim 19  wherein the beams of each upper floor are aligned with and are supported by the columns of the floor immediately below.