Residential construction method and apparatus

Abstract

Home residential construction based on the use of panels made of metal cladding with expanded polystyrene therebebetween. The metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel is strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes. A pitched roof is formed of roof panels, supported by a bar joist at the peak. Walls are formed of wall panels joined using trays for their bottom ends and caps for their top ends and sides. A residence constructed using the present materials and methods is stronger than conventional “brick and stick” homes and can be constructed more quickly and cheaply, and is less expensive to heat and cool.

Description

[0001] Generally, the present invention relates to residential construction. In particular, it relates to a material for use as wall material and methods for using that material. [0002] Historically, homes, some apartments and smaller offices are built on the jobsite using bricks and lumber, plus other materials such as shingles and insulation panels. These materials can be used to construct an endless variety of residences, from simple tract homes to elaborate custom-built homes. [0003] Although great strides have been made in pre-assembling some components, such as roof trusses and windows and doors, in factories where they can be made more quickly and cheaply, still most of residential construction is made at the jobsite, laying one brick and nailing one “2 by 4” at a time. As a result, a significant component of residential construction cost is for labor. [0004] Another disadvantage of residential construction that is related to the fact that homes are largely built on site is t...

AI Technical Summary

Benefits of technology

[0007] In particular, the present invention is characterized by the use of panels made of metal cladding with expanded polystyrene between. The panels are adapted to meet the strength requirements and dimensional requirements of residential specifications. For example, the metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel will be strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes so that further modifications of construction techniques and materials (i.e., window units) will be unnecessary. When these panels are supported and joined as described herein, with their bottom ends set in trays and their top ends capped, they form strong, weather-tight, energy-efficient floors, walls, and roofs and result in homes that appear to be much like conventional “brick and stick” homes but can be constructed more quickly and cheaply and are less expensive to heat and cool. They are also quieter.

[0009] Another feature of the present invention is the use of a bar joist to support the roof panels at the peak of the roof. A bar joist avoids the need for roof trusses. Bar joists are commonly found in supporting flat surfaces such as flat roofs and floors. They are not found as supports for pitched roofs. Roof trusses work well in traditional homes but make attic space largely unusable other than for storage of boxes because the existence of the trusses require those walking around in an attic to keep their heads low to avoid injury. By eliminating trusses, there is more usable space just under the roof. Furthermore, bar joists, in combination with the structural strength of the panels, provides a sufficiently strong roof.

[0010] Another feature of the present invention is the use of trays and caps in combination with the panels to provide a rigid structure for a roof, a wall or a floor.

[0011] A particular feature of the present invention is the use of EPS several inches thick. EPS has considerable thermal efficiency and makes the present method and materials especially attractive in very cold and very warm climates, particularly those that are subject to strong winds or heavy snows.

Problems solved by technology

These panels are known in warehouse construction as “freezer panels.” Some types of freezer panels, namely those with urethane between the cladding, are unsuitable for residential construction because of the gases given off by the urethane.

However, those that are made of expanded polystyrene (EPS, known more commonly under the trademark STYROFOAM), preferably those made of EPS foamed with air, are unknown in residential construction.

Roof trusses work well in traditional homes but make attic space largely unusable other than for storage of boxes because the existence of the trusses require those walking around in an attic to keep their heads low to avoid injury.

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