Modular Construction System and Method Utilizing Prefabricated Units for Load-Bearing Walls

Abstract

This invention presents a construction system and method for assembling load-bearing walls that integrate prefabricated components for enhanced efficiency and structural integrity. The system comprises prefabricated sheet studs, created by interlocking flange sheets and web sheets into a hollow rectangular profile, which are wrapped at their interlocks with alkali-resistant mesh. Outer sheets are attached to these studs, forming prefabricated hollow wall units with defined cavities, serving as permanent wall formwork when assembled on-site. A filler material, selected for its insulation properties and structural strength, is introduced into these cavities, completing the construction of the load-bearing walls. This approach simplifies the construction process, offering a modular, efficient method for building durable, insulated walls capable of bearing structural loads, suitable for a wide range of architectural applications.

What is claimed is: 
     
         1 . A construction system for assembling load-bearing walls, comprising:
 a plurality of prefabricated sheet studs configured to form a hollow rectangular profile, each sheet stud comprising interlocked flange sheets and web sheets, where the interlocks between the flange sheets and web sheets are wrapped with alkali-resistant mesh;   a plurality of outer sheets configured for attachment to the prefabricated sheet studs, wherein pairs of outer sheets are attached to parallel edges of corresponding pairs of prefabricated sheet studs, defining a cavity between the pair of sheet studs, to form one or more prefabricated hollow wall units that serve as a permanent wall formwork of a building structure; and   a filler material for insertion into the defined cavity of the one or more wall units to create the load-bearing walls, the filler material being selected to provide insulation and structural integrity to the wall.   
     
     
         2 . The construction system of  claim 1 , wherein the flange sheets and web sheets are selected from the group consisting of cement fiber boards, cement particle boards, and calcium silicate boards. 
     
     
         3 . The construction system of  claim 1 , further comprising one or more steel sections disposed within the plurality of sheet studs, attached to an inner surface of the hollow rectangular profile. 
     
     
         4 . The construction system of  claim 1 , wherein the outer sheets are affixed to the sheet studs by a bonding material selected from the group consisting of construction adhesive and polymer-modified mortar. 
     
     
         5 . The construction system of  claim 1 , further comprising one or more aligning guide members configured to facilitate the assembly of multiple prefabricated hollow wall units into formwork. 
     
     
         6 . The construction system of  claim 1 , wherein the filler material selected from the group consisting of foam concrete and hempcrete. 
     
     
         7 . The construction system of  claim 1 , further including one or more prefabricated hollow wall units specifically designed for corner and T-junctions, said specialised hollow wall units incorporating extended flange sheets and end sheets to alter their rectangular profiles. 
     
     
         8 . The construction system of  claim 1 , further including one or more prefabricated external wall units equipped for façade element support, incorporating insulation and outer sheets for façade attachment. 
     
     
         9 . The construction system of  claim 1 , further including one or more jamb sheet studs configured for integration into the wall formwork at positions corresponding to openings for doors and/or windows. 
     
     
         10 . The construction system of  claim 1 , further including one or more lintel units comprising sheet studs and outer sheets, and reinforced with steel sections, the lintel units being adapted for positioning over jamb sheet studs with the inclusion of fin plates for attachment. 
     
     
         11 . The construction system of  claim 1 , wherein one or more of the prefabricated hollow wall units are configured to incorporate back boxes for switches and outlets. 
     
     
         12 . The construction system of  claim 1 , wherein the alkali-resistant mesh is a fibreglass mesh. 
     
     
         13 . A method for constructing load-bearing walls, comprising the steps of:
 providing a plurality of sheet studs, wherein each sheet stud is formed by interlocking flange sheets and web sheets to create a hollow rectangular profile, and wrapping the interlocks between the flange sheets and web sheets with alkali-resistant mesh;   attaching pairs of outer sheets to the edges of corresponding pairs of sheet studs to form prefabricated hollow wall units, each unit defining a cavity between the pair of sheet studs;   assembling the prefabricated hollow wall units on-site to construct wall formwork; and   introducing a filler material into the cavities of the assembled wall formwork.   
     
     
         14 . The method of  claim 13 , further comprising the step of utilizing guide members to facilitate the vertical alignment and positioning of the prefabricated hollow wall units during assembly. 
     
     
         15 . The method of  claim 13 , further comprising the steps of assembling specialized prefabricated hollow wall units for corner and T-junctions by incorporating extended flange sheets and end sheets. 
     
     
         16 . The method of  claim 13 , further comprising the steps of preparing prefabricated external wall units equipped for façade support by incorporating insulation and attaching outer sheets for façade elements. 
     
     
         17 . The method of  claim 13 , further comprising the step of positioning jamb sheet studs within the wall formwork at locations corresponding to openings for doors and windows. 
     
     
         18 . The method of  claim 13 , further comprising the steps of fabricating and integrating lintel units into the wall formwork, wherein the lintel units are reinforced with steel sections, and securing the lintel units over jamb sheet studs using fin plates for attachment. 
     
     
         19 . The method of  claim 13 , further comprising the step of cutting the sheet studs and outer sheets to predetermined lengths to accommodate specific architectural requirements. 
     
     
         20 . The method of  claim 13 , further including the step of pre-installing back boxes for switches and outlets within the prefabricated hollow wall units prior to the introduction of the filler material.