Systems and methods for constructing a multi-storey building

Abstract

Example systems and methods of constructing multi-storey buildings utilizing a plurality of prefabricated insulated panels, each prefabricated insulated panel comprising a first cementitious layer, a second cementitious layer, and an insulative core, wherein the insulative core is disposed between first and second cementitious layers. The systems and methods comprise constructing a building foundation and constructing a plurality of storeys on said foundation. Each storey may comprise a plurality of prefabricated insulated panels forming a load-bearing exterior wall disposed on an outer perimeter of the storey. Each storey may comprise a plurality of prefabricated insulated panels forming core walls, wherein the first and second cementitious layers of the core wall panels comprise a fire resistant material. Each storey may comprise a plurality of prefabricated insulated panels forming demising walls. Each storey may comprise a plurality of prefabricated insulated panels forming corridor walls. Each storey may comprise a plurality of prefabricated insulated panels forming a floor. The systems and methods further comprise constructing a roof on top of the last storey thereby constructed, the roof comprising a plurality of prefabricated roof panels.

1 . A method of constructing a multi-storey building utilizing a plurality of prefabricated insulated panels, each prefabricated insulated panel comprising a first cementitious layer, a second cementitious layer, and an insulative core, wherein the insulative core is disposed between the first and second cementitious layers, the method comprising:
 i) constructing a building foundation;   ii) constructing a plurality of successive storeys of said multi-storey building, wherein a first storey is constructed first on said foundation and subsequent storeys are constructed on the previous storey thereby constructed; wherein each storey comprises a plurality of prefabricated insulated panels, each storey comprising:
 a first plurality of prefabricated insulated panels comprising prefabricated wall panels forming a load-bearing exterior wall disposed on an outer perimeter of the storey; 
 a second plurality of prefabricated insulated panels comprising prefabricated wall panels forming core walls wherein the first and second cementitious layers of the second plurality of prefabricated panels comprise a fire resistant material; 
 a third plurality of prefabricated insulated panels comprising prefabricated wall panels forming demising walls; 
 a fourth plurality of prefabricated insulated panels comprising prefabricated wall panels forming corridor walls; and 
 a fifth plurality of prefabricated insulated panels comprising prefabricated floor panels forming a floor; and 
   iii) constructing a roof on the last storey thereby constructed, the roof comprising a plurality of prefabricated roof panels.   
     
     
         2 . A method according to  claim 1  wherein the building comprises a foundation wall constructed on the building foundation, the foundation wall comprising a sixth plurality of prefabricated insulated panels disposed on an outer perimeter of the building, wherein at least one of the first and second cementitious layers are structurally reinforced and wherein the foundation wall interposes the foundation and the exterior wall of the first storey. 
     
     
         3 . A method according to  claim 2  wherein each of the sixth plurality of prefabricated insulated panels has a height to width ratio of at least 2.5 to 1. 
     
     
         4 . A method according to  claim 1  wherein one or more of the prefabricated insulated panels each comprise a cross brace, the cross brace comprising a plurality of intersecting diagonal supports. 
     
     
         5 . A method according to  claim 1  wherein one or more of the prefabricated insulated panels each comprise a frame disposed about a perimeter of the panel. 
     
     
         6 . A method according to  claim 4  wherein each of the plurality of intersecting diagonal supports are fixedly connected at different corresponding corners of a frame disposed about a perimeter of the panel. 
     
     
         7 . A method according to  claim 4  wherein each of the plurality of intersecting diagonal supports comprises hollow structural section steel. 
     
     
         8 . A method according to  claim 4  wherein the cross brace is embedded within the insulative core of each of the one or more prefabricated insulated panels. 
     
     
         9 . A method according to  claim 4  wherein the one or more prefabricated insulated panels comprising cross braces include each of the first plurality of panels forming the exterior wall. 
     
     
         10 . A method according to  claim 1  wherein the insulative core of the third plurality of prefabricated panels comprises a cavity providing acoustic dampening. 
     
     
         11 . A method according to  claim 11  wherein the cavity comprises a discontinuity between first and second sections of the insulative core. 
     
     
         12 . A method according to  claim 1  wherein the first and second cementitious layers of one or more of the prefabricated insulated panels comprise multi-layer coverings. 
     
     
         13 . A method according to  claim 1  wherein the insulative core of one or more of the prefabricated insulated panels comprises mineral wool for providing fire resistance. 
     
     
         14 . A method according to  claim 1  wherein one or both of the first and second cementitious layers of one or more of the prefabricated insulated panels comprise perlite for providing fire resistance. 
     
     
         15 . A method according to  claim 1  wherein the one or more of the fifth plurality of prefabricated insulated panels extends exteriorly of and is cantilevered by one or more of the first plurality of prefabricated insulated panels. 
     
     
         16 . A method according to  claim 1  wherein one or more of the prefabricated insulated panels comprise a waterproof cladding or finish. 
     
     
         17 . A method according to  claim 5  wherein the frame disposed about a perimeter of the panel is coupled to the panel using a plurality of connectors, each of the connectors comprising an opening for accessing fasteners. 
     
     
         18 . A method according to  claim 17  wherein the one or more of the panels comprising a frame additionally comprise one or more transverse framing members coupled to the frame. 
     
     
         19 . A method according to  claim 18  wherein the one or more transverse framing members are coupled to the frame at corresponding ones of the plurality of connectors. 
     
     
         20 . A method according to  claim 1  wherein the fifth plurality of prefabricated insulated panels interpose the first, second, third and fourth plurality of prefabricated insulated panels on adjacent storeys. 
     
     
         21 . A method according to  claim 1  wherein corresponding top and bottom ends of the first, second, third and fourth pluralities of prefabricated insulated panels abut on adjacent storeys. 
     
     
         22 . A method according to  claim 21  wherein a top end of the first, second, third and fourth pluralities of prefabricated insulated panels comprise a lip and wherein the lip supports an end of the fifth plurality of prefabricated insulated panels interposed between the lip and a corresponding panel on an adjacent higher storey. 
     
     
         23 . A method according to  claim 1  wherein the plurality of prefabricated roof panels are positioned at an angle for creating a sloping roof profile. 
     
     
         24 . A method according to  claim 1  wherein the plurality of prefabricated roof panels comprise a non-uniform cross-section along both a height and width for creating a sloping roof profile. 
     
     
         25 . A method according to  claim 1  wherein the first and second cementitious layers of the first plurality of prefabricated insulated panels are structurally reinforced. 
     
     
         26 . A method according to  claim 1  wherein one or more of:
 the second plurality of prefabricated insulated panels; 
 the third plurality of prefabricated insulated panels; and 
 the fourth plurality of prefabricated insulated panels; 
 
       form load-bearing walls. 
     
     
         27 . A system for constructing a multi-storey building on a foundation, the system comprising:
 a) a plurality of individual storeys, each storey comprising:   i) a plurality of prefabricated wall panels, the prefabricated wall panels comprising a first cementitious layer, a second cementitious layer, and an insulative core, wherein the insulative core is disposed between the first and second cementitious layers;   ii) a first plurality of the prefabricated wall panels comprising exterior wall panels to form an exterior wall disposed on an outer perimeter of the storey;   iii) a second plurality of the prefabricated wall panels comprising core wall panels to form core walls wherein the first and second cementitious layers of the second plurality of prefabricated panels comprise a fire resistant material;   iv) a third plurality of the prefabricated wall panels comprising demising wall panels to form demising walls, wherein the insulative core of the third plurality of prefabricated panels comprises a cavity along a longitudinal length of the insulative core;   v) a fourth plurality of the prefabricated wall panels comprising corridor wall panels to form corridor walls; and   vi) a plurality of prefabricated floor panels forming a floor; and   b) a roof, the roof comprising a plurality of prefabricated roof panels.