US20080010920A1

US20080010920A1 - Method of building construction

Info

Publication number: US20080010920A1
Application number: US11/517,498
Authority: US
Inventors: Erwin Andersen
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-09-07
Filing date: 2006-09-07
Publication date: 2008-01-17

Abstract

A method of building construction wherein blocks and panels made from autoclaved aerated concrete are used as structural elements, and roof panels, including insulated panels having a rigid polyurethane/polyiscocyanurate foam core, are attached to structural elements via metal anchoring caps, ridge flashing, rake trim, beams, end plates, clips, and/or various fasteners. Preferably, anchoring caps are secured over external and internal bearing walls via large tube nails that engage inner reinforcement structures embedded within the walls during manufacture to provide enhanced uplift resistance, with the roof panels and anchoring caps secured together via clips and fasteners. Alternatively, large deck screws and rake trim can anchor roof panels to exterior walls. Roof panels not connected to anchoring caps are connected to beams attached between end plates secured to the opposing faces of external and interior bearing walls. Applications include, but are not limited to, residential, commercial, government, educational, and industrial construction.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to the subject matter of the provisional patent application filed on Sep. 7, 2005, which was given the Ser. No. of 60/741,613. Although the provisional patent application was filed in the names of Erwin J. Andersen and Christopher G. L. Welles-Pryor, the subject matter of the claims herein is attributable only to the first named inventor on the provisional patent application, Erwin J. Andersen. As a result, the applicant herein respectfully requests that any patent grant be in his name only and that he be given all appropriate benefit attributable to the prior U.S. provisional patent application.

BACKGROUND

1. Field of the Invention
This invention relates to building construction and the use of building materials, specifically to a method of building construction that can be used to rapidly create low cost and affordable housing. The finished structures are thermally insulated, fire retardant, energy efficient, low maintenance, pest resistant, sound absorbent, and mildew resistant. They do not need the installation of independent moisture barriers and they are also sufficiently strong for use in areas subject to adverse forces of nature, such as but not limited to hurricanes and earthquakes. The method combines two energy efficient building materials. Structural blocks and panels are made from autoclaved aerated concrete, while insulated roof panels, including those having a sandwiched construction and a rigid polyurethane/polyiscocyanurate foam core, are connected to the structural blocks and structural panels via a variety of fasteners and attachment devices, with the fasteners and attachment devices used being selected according to whether the structural elements are load bearing. The shells of residential buildings can be formed quickly using the present invention, with structures used in affordable housing projects typically being formed in less than two working days. The attachment devices most often used in the present invention to connect metal roof panels to structural blocks and structural panels, and/or otherwise support or anchor metal roof panels in their usable position, include but are not limited to, anchoring caps, ridge flashing, rake trim, beams, end plates, clips, fasteners, large tube nails, large deck screws, and bolts. Panels containing an inner reinforcement structure are typically used in external and interior bearing wall applications. Metal anchoring caps secured with large tube nails over the top ends of the panels strengthen the connection between walls and applied roof panels. Since the large tube nails are arranged in a staggered pattern and positioned to engage the inner reinforcement structure within the wall panels, they provide enhanced uplift resistance. Also, clips and fasteners preferably anchor the metal roof panels to each anchoring cap used in the present invention. Flashing is typically secured over the ends of adjacent metal roof panels that form a ridge, such as the adjacent metal roof panels secured over an interior bearing wall. An alternative preferred means of anchoring metal roof panels to exterior walls in the present invention employs large deck screws and rake trim. To support the ends of metal roof panels situated between interior bearing walls and exterior walls, beams are extended via end plates between opposing wall panel faces, with clips and fasteners typically anchoring the metal roof panels to the beams. Applications include, but are not limited to, residential, commercial, government, educational, and industrial construction.
2. Description of the Related Art
Globally there is a need for affordable entry level housing that is resistant to earthquakes, windstorms, infestation, mold, and fire. It is also advantageous to the owners, and the communities in which they live, when such housing is well-built, cost efficient, energy efficiency, and less labor intensive to build. It is also desirable globally for commercial and industrial structures to have resistance to earthquakes, windstorms, infestation, mold, and fire. Although autoclaved aerated concrete is a structural building material that has been popular in Europe for nearly a century and insulating panels having a rigid polyurethane/polyiscocyanurate foam core have been previously used in cold storage constructions, they have never before been combined in building construction as in the present invention, whereby the needed structural elements of a building are created with blocks and panels made from autoclaved aerated concrete, and its roof structure is made at least in part from insulated sandwiched metal and non-metal panels having a rigid polyurethane/polyiscocyanurate foam core.

BRIEF SUMMARY OF THE INVENTION

It is the primary object of this invention to provide a method of building construction that employs structural and roofing materials that are inherently sound absorbent, fire resistant, and thermally insulated, and result in cost efficient construction at least in part by avoiding the additional labor and material expense of on-site installation of independent materials capable of providing such characteristics in a finished structure. It is also an object of this invention to provide a method of building construction that uses materials that are lighter in weight than conventional construction materials and easy to install for fast construction. A further object of this invention is to provide a method of building construction that creates structures that are energy efficient, require reduced operating costs, permit reduced insurance premiums, and need little maintenance. It is also an object of this invention to provide a method of building construction that creates strong and durable structures better able to withstand hurricanes and earthquakes than structures made from conventional materials, as well as structures that are impervious to mold, rot, and infestation. It is a further object of this invention to provide a method of building construction that uses materials that are versatile and can be worked like wood without chipping or cracking. It is also an object of this invention to provide a method of building construction that uses materials that are recyclable, inert, and non-toxic. It is a further object of this invention to provide a method of building construction that uses materials made from raw materials that are in abundant supply and made without the creation of by-products.
The present invention method, when properly implemented, will provide residential, commercial, government, educational, and industrial buildings that are sound absorbent, fire resistant, moisture blocking, and thermally insulated without the cost of independent materials and on-site labor to provide such benefits, as the materials used for structural elements in the present invention, including the walls and roof, will already exhibit such characteristics. In addition, the materials used for structural elements and the roof are impervious to mold, rot, and infestation. The first material used as a part of the present invention to achieve the above-stated objectives and benefits is autoclaved aerated concrete, which is employed for structural elements. It is lighter in weight that conventional construction materials and easy to install, typically weighing between approximately one-half and one-fifth of the weight of conventional concrete. Further, autoclaved aerated concrete also yields readily and can be worked like wood, with conventional construction tools easily cutting and shaping the autoclaved aerated concrete without chipping or cracking it. Autoclaved aerated concrete is also desired as a building product in the present invention since it is inert, non-toxic, and needs little maintenance. Pictures can be easily hung on a finished wall of autoclaved aerated concrete. Since the autoclaved aerated concrete is aerated, it has a high porosity that provides excellent thermal resistance and sound absorption. Roofs made via the present invention method are constructed at least in part from sandwiched panels having a rigid polyurethane/polyiscocyanurate foam core, the second material used as a part of the present invention to achieve the above-stated objectives and benefits. Sandwiched roof panels are attached via elongated fasteners and caps to the top ends of vertically-extending autoclaved aerated concrete wall panels secured in load bearing applications, so as to engage the inner reinforcement structure within the autoclaved aerated concrete panels and provide enhanced uplift resistance. The elongated fasteners used are preferably, but not limited to, anchor screws and/or tube nails having a length dimension of approximately six inches. The roof panels of the present invention have a low thermal conductivity and are very energy efficient, they have a high mechanical strength and are very durable, and they also have an extremely high resistance to fire. Thus, the combined use of autoclaved aerated concrete panels and roof panels having a rigid polyurethane/polyiscocyanurate foam core leads to faster construction and an improved product for the consumer. It also creates strong and durable structures able to better withstand hurricanes and earthquakes than structures made from conventional materials, energy efficient structures that have reduced operating costs, and structures that are impervious to mold, rot, and infestation. In addition, due to the reduced risk of damage from hurricanes, earthquakes, fire, rot, mold, and infestation, insurance premiums in structures made via the present invention are reduced. Further, the materials used in the present invention method are recyclable, made from raw materials that are in abundant supply, and made without the creation of by-products.
The description herein provides preferred embodiments of the present invention but should not be construed as limiting its scope. Instead, the scope of the present invention should be determined by the appended claims and their legal equivalents, rather than being limited to the examples given.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a center wall in the most preferred embodiment of the present invention that is made from one or more autoclaved aerated concrete panels, with an anchoring cap secured to the center wall via staggered/offset tube nails and the isosceles triangle shaped top portion of the anchoring cap being usable for reinforcing the connection of roof panels to the autoclaved aerated concrete walls so as to provide enhanced uplift resistance to the finished roof.
FIG. 2 is a sectional view of an exterior wall in the most preferred embodiment of the present invention that is made from one or more autoclaved aerated concrete panels, with an anchoring cap secured to the exterior wall via staggered/offset tube nails and the right triangle shaped top portion of the anchoring cap being usable to reinforce the connection of roof panels to the autoclaved aerated concrete walls so as to provide enhanced uplift resistance to the finished roof.
FIG. 3 is a sectional view of a gable end/rake wall in the most preferred embodiment of the present invention that is made from one or more autoclaved aerated concrete panels, with an anchoring cap secured to it via staggered/offset tube nails and the flat top portion of the anchoring cap being usable to reinforce the connection of roof panels to the autoclaved aerated concrete walls so as to provide enhanced uplift resistance to the finished roof
FIG. 4 is an end view of a support beam in the most preferred embodiment of the present invention that is connected to an interior wall made from autoclaved aerated concrete panel via an end plate and bolts, with a roof panel supported in its usable position by the support beam.
FIG. 5 is an end view of a support beam in the most preferred embodiment of the present invention that is connected to an exterior wall made from autoclaved aerated concrete panel via an end plate and staggered/offset tube nails, with a roof panel supported in its usable position by the support beam.
FIG. 6 is a sectional view of an interior bearing wall in the most preferred embodiment of the present invention that is made from autoclaved aerated concrete, with an anchoring cap having an isosceles triangle shaped top portion secured over the top end of the wall via staggered/offset tube nails and the adjacent ends of two roof panels each having a vertical ridge being secured to the anchoring cap via fasteners and clips extending over the vertical ridge, and further with ridge flashing or other ridge closure secured via additional fasteners to the vertical ridge of each roof panel.
FIG. 7 is a sectional view of an exterior wall in the most preferred embodiment of the present invention that is made from autoclaved aerated concrete, with an anchoring cap having a right triangle shaped top portion secured over the top end of the wall via staggered/offset tube nails and the end of a roof panel secured to the anchoring cap via fasteners and a clip, and further with eave trim or other closure extending from the end of the roof panel downwardly over the anchoring cap and being secured to both the roof panel and exterior wall via small fasteners.
FIG. 8 is a sectional view of an exterior gable end or rake wall in the most preferred embodiment of the present invention that is made from autoclaved aerated concrete, with an anchoring cap having a flat top portion secured over the top end of the wall via staggered/offset tube nails and the end of a roof panel supported upon the anchoring cap, and further with the upper end of a piece of rake trim or other closure extending horizontally over the top surface of the roof panel and the opposing lower end of the rake trim or other closure extending downwardly over the end of the roof panel and also over at least part of the anchoring cap, with the upper end of the rake trim or other closure and the roof panel being secured to both the anchoring cap and exterior wall via elongated fasteners and the lower end of the rake trim or other closure being secured to the anchoring cap and wall via at least one small fastener.
FIG. 9 is a sectional view of a roofing panel with a vertical ridge in the most preferred embodiment of the present invention that is secured to a support beam via fasteners and a clip, with the clip positioned over the roof panel's vertical ridge.
FIG. 10 is an end view of a center hollow support beam having a pentagon shape that is used in the most preferred embodiment of the present invention for HVAC, with the adjacent ends of two roof panels secured to the top of the support beam via fasteners and clips, and further with ridge flashing or other ridge closure secured via additional fasteners to the vertical ridge of each roof panel, and the bottom surface of the support beam situated upon an interior bearing wall made from autoclaved aerated concrete and secured thereto via a coil thread bolt, nut, and washer.
FIG. 11 is a sectional view of an interior wall of autoclaved aerated concrete used in the most preferred embodiment of the present invention that is pre-cast to contain an anchor plate having multiple elongated reinforcement bars, with the anchor plate allowing for shim tolerance and a welded connection of a support beam usable for roof panel connection.
FIG. 12 is a sectional view of a wall in the most preferred embodiment of the present invention that is made from one or more autoclaved aerated concrete panels and positioned above a concrete foundation in a two story structure, the wall being secured to the foundation via the connection of a coil thread bolt extending through the entire vertical length of wall and a vertically-extending criss-cross loop coil insert embedded into the concrete foundation and configured for receiving the lower end of the coil thread bolt, the insert engaging at least one reinforcement structure also embedded within the concrete foundation, and with the upper end of the coil thread bolt secured within a steel channel positioned in a cutout area in the top end of the wall by use of a washer and coil nut.
FIG. 13 is a sectional view of a wall in the most preferred embodiment of the present invention autoclaved that is made from one or more autoclaved aerated concrete panels and positioned above a concrete foundation in a one story structure, the wall being secured to the foundation via a vertically-extending flat steel plate that is attached to the wall via staggered/offset tube nails and connected to the foundation via a coil bolt and a horizontally-extending loop coil insert embedded into the concrete foundation during manufacture that is configured for receiving the distal end of a coil bolt, the insert engaging at least one reinforcement structure also embedded within the concrete foundation.
FIG. 14 is an enlarged perspective view of the most preferred connection of roof panels and support beams in the present invention, whereby several fasteners are used to secure the bottom of a clip to a roof panel and its supporting beam, the upper end of the clip is secured to the vertical ridge by crimping, and a second roof panel is secured over the fasteners and clip via crimping and a tongue-in-groove connection respectively to the top and bottom portions of the first roof panel.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention method, when properly implemented, provides residential, commercial, government, educational, and industrial buildings that are sound absorbent, fire resistant, and thermally insulated with reduced labor and material expense. Instead of the on-site addition of independent materials to provide thermal insulation, fire resistance, sound absorbency, pest resistance, mildew resistance, and the like, the two energy efficient materials used respectively for structural elements and the roof already provide such benefits. For example, the autoclaved aerated concrete used for structural elements in the present invention provides one hour of fire resistance per inch of thickness dimension. The resulting reduced labor and material expense helps to provide low cost residential construction for affordable and low income housing. The low cost of structures built using the present invention method is also due in part to the speed with which the structural elements can be installed in their usable positions. Thus, when small lifts (not shown) are used to orient and align wall and roof panels, such as panels 2 and 6 in the accompanying illustrations, the shell of a single-family residential building is typically finished in a time period of two working days or less. In addition, the materials primarily used for structural elements and the roof are also impervious to mold, rot, and infestation. First, autoclaved aerated concrete panels and block, as shown by the designation 2 in FIGS. 1-3, 6-8, and 11-13 are used for structural elements. In load bearing interior and exterior applications, it is preferred that autoclaved aerated concrete panels 2 be used instead of autoclaved aerated concrete block, and for such panels 2 to have an inner reinforcement structure, such as the reinforcement structures designated by the line 25 in FIGS. 12 and 13. Further, tiny air pockets (not shown) in the autoclaved aerated concrete panels 2 provide dead space that stops the transfer of noise and enhances thermal insulation. Although the thickness of autoclaved aerated concrete panels and block 2 in the present invention can vary from a minimum width dimension of approximately four inches to a maximum thickness dimension of approximately twelve inches, exterior walls, center walls, and interior bearing walls of the present invention preferably include eight-inch thick autoclaved aerated concrete wall panels 2 and an STC rating of 50. For non-bearing interior walls, autoclaved aerated concrete wall panels 2 having a thickness dimension of approximately four to six-inches are preferably used. Autoclaved aerated concrete panels 2 are lightweight and easy to handle on a jobsite, when compared to conventional construction materials, and have less than one-half the weight of conventional concrete. Autoclaved aerated concrete panels 2 are also yielding in structure and can be worked like wood using conventional construction tools without chipping or cracking, with any nailing device that can be used with wood also being usable with autoclaved aerated concrete panels 2. Further, the strength of autoclaved aerated concrete panels 2, when compared to that of a cement block wall, is much greater, with the force of a sledge hammer (not shown) that places a hole through a cement block wall only placing dents in panels 2 made from of autoclaved aerated concrete. In addition, autoclaved aerated concrete panels 2 provide further advantage for the present invention as they are also inert, non-toxic, and need little maintenance. Also, since autoclaved aerated concrete panels 2 are aerated, they have a high porosity that provides excellent thermal resistance and noise blocking. In contrast, the roof of the present invention is constructed from sandwiched panels 6 having a rigid polyurethane/polyiscocyanurate foam core and spaced-apart vertically extending steel ribs 11 (shown in FIGS. 6, 7, 9, and 14) which add more strength and rigidity to finished present invention structures, and are used in the attachment of clips 12 and for the connection of adjacent roof panels 6 via crimping. Sandwiched panels 6 are thermally fused and can vary in thickness from approximately one-and-one-half inches to approximately six inches. Support beams 4 and 7 may comprise tubular steel or poured/molded materials. Further, sandwiched panels 6 in the present invention may comprise a steel core with a baked enamel finish (not shown), and be attached to autoclaved aerated concrete panels 2 via elongated fasteners 17, having a length dimension of approximately six inches, positioned so as to engage anchoring cap 1, which in turn is secured to the autoclaved aerated concrete panel 2 by tube nails 3 positioned to engage an inner reinforcing structure (such as but not limited to reinforcing structure 25 shown in FIGS. 12 and 13) embedded within the autoclaved aerated concrete panels 2 during manufacture, and therein provide enhanced uplift resistance in the finished roof construction. The sandwiched panels 6 used in the present invention have a low thermal conductivity, they are very energy efficient, they have a high mechanical strength, they are very durable, and they also are non-combustible and have an extremely high resistance to fire. Thus, the combined use of autoclaved aerated concrete panels 2 and sandwiched panels 6 having a rigid polyurethane/polyiscocyanurate foam core in the present invention leads to faster construction and an improved product for consumers. It also creates strong and durable structures able to better withstand hurricanes and earthquakes than structures made from conventional materials, energy efficient structures that have reduced operating costs, and structures that are impervious to mold, rot, and infestation. In addition, due to the reduced risk of damage to present invention structures from hurricanes, earthquakes, fire, rot, mold, and infestation, owner insurance premiums are reduced. Further, most of the materials used in the present invention to construct the shell of a structure are recyclable, including those used to create the autoclaved aerated concrete panels 2 and sandwiched roof panels 6. In addition, the autoclaved aerated concrete panels 2 and sandwiched panels 6 are made from raw materials that are in abundant supply and each is made without the creation of by-products.
FIGS. 1, 2, and 3 show the use of anchoring caps 1 on top of load bearing structural walls in the present invention for attachment of roof panels, such as but not limited to the roof panels 6 shown in FIGS. 4-10 and 14. FIG. 1 shows a center wall made of at least one autoclaved aerated concrete panel 2, FIG. 2 shows an exterior wall made of at least one autoclaved aerated concrete panel 2, and FIG. 3 shows an exterior gable end/rake wall made of at least one autoclaved aerated concrete panel 2. Although not shown, the same anchoring cap 1 attachment means disclosed in FIGS. 1-3 and 6-8 for securing exterior and bearing walls made from autoclaved aerated concrete 2 to roof panels (preferably the roof panels 6 shown in FIGS. 4-9), may also be used for securing roof panels to non-bearing interior walls. However, alternative attachment means (not shown) meeting local building code requirements can also be substituted in non-bearing interior wall roof panel attachment applications. Since the center wall in FIG. 1, made from at least one autoclaved aerated concrete panel 2, is load bearing, it preferably has a thickness dimension of at least eight inches, although not limited thereto. Further, FIG. 1 shows the center wall of autoclaved aerated concrete 2 having an anchoring cap 1 secured to its top end via at least two staggered/offset tube nails 3 per panel 2. Preferably for enhanced strength and enhanced uplift resistance for the roof panels 6 attached to anchoring caps 1 in a finished structure, tube nails 3 are preferably large in diameter and approximately six inches in length, and positioned to engage an inner reinforcing structure embedded within autoclaved aerated concrete panel or panels 2 (such as but not limited to that shown by the number 25 in FIGS. 12 and 13). The portion of the anchoring cap 1 shown in FIG. 1 above autoclaved aerated concrete panel 2, has the cross-sectional configuration of an isosceles triangle, which remains separated from the top end of the center wall of autoclaved aerated concrete 2 to provide a means of attachment for fasteners, such as the fasteners 13 shown in FIG. 5 that secure clips 12 or other attachment devices (not shown) used for connection of roof panels 6 to autoclaved aerated concrete 2. Although not limited thereto, where autoclaved aerated concrete panels 2 have a thickness dimension of approximately eight inches, such as in the center wall load bearing application shown in FIG. 1, the anchoring caps 1 used with autoclaved aerated concrete panels 2 are preferably made from 16-gauge galvanized metal. FIGS. 2 and 3 both show exterior walls used in the most preferred embodiment of the present invention that are made from one or more autoclaved aerated concrete panels 2. Since they are also load bearing, such exterior walls made of autoclaved aerated concrete 2 preferably have thickness dimensions of at least eight inches, although not limited thereto, with a top anchoring cap 1 secured to them via staggered/offset tube nails 3. Preferably for enhanced strength and uplift resistance, tube nails 3 are large and positioned to engage an inner reinforcing structure (not unlike the plate and bars designated by the number 15 in FIG. 11 or the reinforcement structure 25 shown in FIGS. 12 and 13) embedded within the autoclaved aerated concrete panel or panels 2 during manufacture. The portion of the anchoring cap 1 shown in FIG. 2 above autoclaved aerated concrete panel 2, has the cross-sectional configuration of a right triangle, which remains separated from the top end of the exterior wall autoclaved aerated concrete panel or panels 2 to provide a means of attachment for fasteners, such as the fasteners 13 shown in FIGS. 6 and 7 that secure clips 12 or other attachment devices used for connection of roof panels 6 to autoclaved aerated concrete panels 2. Similarly also, although not limited thereto, where the autoclaved aerated concrete panels 2 have a thickness dimension of approximately eight inches, the anchoring caps 1 used with exterior wall autoclaved aerated concrete panels 2, are preferably made from 16-gauge galvanized metal. In contrast, the top portion of the anchoring cap 1 shown in FIG. 3 is flat and remains closely associated with the top end of the adjacent exterior wall autoclaved aerated concrete panel or panels 2, whereby fasteners, such as the fasteners 17 shown in FIG. 8 that secure rake trim 17 or other devices to roof panels 6 and/or autoclaved aerated concrete panels 2, extend through anchoring cap 1 and into the connected autoclaved aerated concrete panel 2. If the autoclaved aerated concrete panels 2 in FIG. 3 applications have a thickness dimension of approximately eight inches, the anchoring caps 1 associated therewith are also preferably made from 16-gauge galvanized metal, although not limited thereto.
For the support and securing of roof panels in the present invention to interior and exterior bearing walls made from autoclaved aerated concrete 2, including but not limited to the insulated sandwiched panels 6 with substantially vertically extending ribs 11 (as shown in FIGS. 9-10 and 14), pairs of end plates 5 are attached to opposed autoclaved aerated concrete panels 2 and support beams 4 are extended between and secured to such end plate 5 pairs. FIG. 4 shows a preferred interior wall connection, while FIG. 5 shows a preferred exterior wall connection. FIG. 4 shows an interior support beam 4 used in the most preferred embodiment of the present invention with its remotely positioned end being secured via an end plate 5 and bolts 8 to a load bearing interior wall formed from at least one autoclaved aerated concrete panel 2. Although in FIG. 4 the interior wall of autoclaved aerated concrete 2 would be visible and positioned behind end plate 5, the connected autoclaved aerated concrete panel 2 has not been delineated or otherwise marked in FIG. 4. Support beams 4 may comprise tubular metal beams or poured/molded materials, and/or comprise hollow cavities for HVAC purposes, as is shown by the center hollow support beam identified by the number 7 in FIG. 10. Similarly, FIG. 5 shows an interior support beam 4 used in the most preferred embodiment of the present invention for support of roof panels 6, with the remote end of support beam 4 being secured via an end plate 5 and tube nails 3 to a load bearing exterior autoclaved aerated concrete panel or panels 2 positioned behind end plate 5. However, as in FIG. 4, the supporting panel 2 has not been delineated or marked with any component designation in FIG. 5. It is preferred in the present invention that at least eight large tube nails 3 be used to secure end plate 5 to an exterior wall made from autoclaved aerated concrete panels 2, and that at least four bolts 8 be used to similarly secure end plate 5 to an interior load bearing wall made from at least one autoclaved aerated concrete panel 2. A greater number of tube nails 3 are generally preferred for exterior wall connections using end plates 5 than the number of bolts 8 used for interior wall connections, since interior wall connections are strengthened by the bolts 8 typically being sufficiently long to extend through the autoclaved aerated concrete panel 2 and secure together two end plates 5 positioned against opposing wall faces. In the most preferred embodiment of the present invention the connection of support beams 4 to end plates 5 is accomplished via welding.
FIG. 6 shows an interior load bearing wall made from one or more autoclaved aerated concrete panels 2 that are used in the most preferred embodiment of the present invention method with a top anchoring cap 1 secured thereto via at least two staggered/offset tube nails 3 per panel that for enhanced strength and uplift resistance are preferably large and positioned to engage an inner reinforcing structure (not unlike the plate and bars designated by the number 15 in FIG. 11 or the reinforcing structures 25 shown in FIGS. 12 and 13) embedded during manufacture within autoclaved aerated concrete panel or panels 2. FIG. 6 shows the top portion of the anchoring cap 1 having the configuration of an isosceles triangle and extending above autoclaved aerated concrete panel 2 where it can be used for the attachment of clips 12 or other roof panel connection devices (not shown) via fasteners 13. In addition, FIG. 6 shows flashing or other ridge closure 10 extending across the top surfaces of the two vertically extending steel ribs 11 atop the two roof panels 6 that are supported by the interior load bearing wall of autoclaved aerated concrete 2. FIG. 6 further shows the ends of roof panels 6 secured via fasteners 13 and clips 12 to the isosceles triangle shaped top portion of anchoring cap 1, and fasteners 9 securing flashing or other ridge closure 10 to roof panels 6, as well as clips 12 to each roof panel 6. Fasteners 13 may extend into autoclaved aerated panels 2, however doing so is not critical. Similarly, FIG. 7 shows an exterior wall made from one or more autoclaved aerated concrete panels 2 that are used in the most preferred embodiment of the present invention method with a top anchoring cap 1 secured thereto via staggered/offset and preferably large tube nails 3. FIG. 7 further shows the end of a roof panel 6 having a vertically extending rib 11 secured via fasteners 13 and a clip 12 to the right triangle shaped top portion of an anchoring cap 1. In addition, FIG. 7 shows eave trim or other closure 14 extending downwardly across the connection of roof panel 6 to autoclaved aerated concrete panel or panels 2 and being secured to the top of anchoring cap 1 via fasteners 13 and a clip 12. The configuration of eave trim or other closure 14 is not limited to that shown in FIG. 7, nor is its positioning, which could also extend upwardly over vertical rib 11 or to a greater distance below anchoring cap 1. Further, the configuration and size of fastener 16 is not limited to that shown in FIG. 7 and is limited only by the ability to securely hold eave trim or other closure 14 in place. Therefore, eave trim or other closure 14 should be attached with one or more fasteners 16 to securely cover the connection of roof panel 6 to anchoring cap 1 and autoclaved aerated concrete 2, however their configuration and size should not be so great as to involve additional material expense without appropriate benefit. FIG. 8 shows a third type of connection used between roof panels 6 and an exterior wall of at least one autoclaved aerated concrete panel 2 in the most preferred embodiment of the present invention. FIG. 8 shows an anchoring cap 1 with a flat top portion attached via staggered/offset tube nails 3 to an exterior gable end/rake wall made from autoclaved aerated concrete 2. Rake trim 18 is then extended over the connection of roof panel 6 and anchoring cap 1. The roof panel 6 and the upper end of rake trim 18 are each attached to the anchoring cap 1 with elongated fasteners 17 that extend through rake trim 18, through anchoring cap 1, and into autoclaved aerated panel 2. FIG. 8 further shows the lower end of rake trim 18 extending over the end of roof panel 6 and being secured to autoclaved aerated concrete panel 2 via a smaller fastener 16 that extends through anchoring cap 1 and into autoclaved aerated concrete panel 2. The configuration and size of rake trim 18, elongated fasteners 17, and smaller fastener 16 are not critical and can vary from that shown in FIG. 8 as long as they fulfill their intended functions.
FIG. 9 shows the connection means used in the most preferred embodiment of the present invention to secure roof panels 6 to a support beam 4 at each connection between adjacent roof panels 6. Clip 12 hooks over vertical rib 11 on the roof panel 6 and is secured to the support beam 4 by fasteners 13. Although not limited thereto, it is preferred for a minimum of two clips 12 to be used with each support beam 4 employed as a part of the present invention, and a minimum of two fasteners 13 with each clip 12. Crimping of the top of clips 12 and vertical ribs 11 is also preferably used, and a dove-tail or tongue-in-groove connection for adjacent roof panels on their bottom ends, such as that shown by the number 33 in FIG. 14. FIG. 10 shows an alternative and preferred configuration for a center hollow support beam 7 used in the present invention for HVAC purposes. The connection means used in the most preferred embodiment of the present invention to secure roof panels 6 to center hollow support beam 7, and beam 7 to panel 2, are similar to that shown respectively in FIGS. 9 and 12.
FIG. 11 shows an alternative connection means used in the present invention to secure support beam 4 to autoclaved aerated concrete panels 2. Unlike FIGS. 4 and 5, the support beam 4 rests on the steel plate of an embedded support 15 having multiple legs also embedded in the autoclaved aerated concrete 2. The steel plate of embedded support 15 is cast in place by the manufacturer of the autoclaved aerated concrete panel 2 and then secured within an aerated concrete panel 2 by a minimum of two twelve inch or longer reinforcement bars (which comprise the legs of embedded support 15) that are welded to the base of the steel plate 15. On exterior walls made from autoclaved aerated concrete 2 in the most preferred embodiment of the present invention, it is preferred for the embedded plate 15 to be a length equal to the width of the support beam 4 and a width of at least one half of the depth of the exterior autoclaved aerated concrete wall 2. The autoclaved aerated concrete panel 2 will be notched, such as but not limited to the notch 29 shown in FIG. 11, creating a pocket for support beam 4 that allows it be directly positioned on the plate portion of embedded support 15. The embedded steel plate of embedded support 15 will be cast approximately one half inch below the designed elevations to allow for site variations in the foundation work. Steel shim plates 9, if needed, will be utilized to raise the support beam 4 to its desired elevation. The support beam 4, shim plates 9, and the steel plate of embedded support 15 are then welded together for a rigid connection between the support beam 4 and autoclaved aerated concrete panel 2. On interior walls made from autoclaved aerated concrete 2 in the most preferred embodiment of the present invention, it is preferred for the plate of embedded support 15 to be a length equal to the width of the support beam 4 and a width of one half inch less than the depth of the interior autoclaved aerated concrete wall 2. Shim plates 9 and a welded connection will be utilized for present invention interior walls of autoclaved aerated concrete 2 in a similar manner to that disclosed for exterior wall connection in FIG. 9.
FIG. 12 shows the means used in the most preferred embodiment of the present invention to secure a two story autoclaved aerated concrete structure to the concrete foundation/footing 23 of the structure. A crisscross loop coil insert 24 is embedded within the concrete footing or foundation 23 during its manufacture and configured for receiving a coil thread bolt 22 which is sufficiently long to pass through the entire elevation extending from the coil insert 24 to the top of the autoclaved aerated concrete 2 on the uppermost floor. Such a connection is preferred for exterior and interior bearing walls of autoclaved aerated concrete 2. Although not shown, an anchoring cap 1 can be placed over the top of the autoclaved aerated concrete wall panel 2 to secure roof panels 6. Although the configuration of coil insert 24 shown in FIG. 12 is preferred, the size and configuration of coil insert 24 can be different from that shown. FIG. 12 also shows at least one reinforcement bar 25 engaging the coil insert 24 positioned within the concrete foundation/footing 23 for enhanced uplift resistance in any roof panels 6 connected to autoclaved aerated concrete wall panel 2. The top of the uppermost autoclaved aerated concrete 2 panel has a notch 30 configured and dimensioned to receive a continuous steel channel 19 that extends the length of the exterior walls and any center ridge wall. The steel channel 19 is secured to the top end of the autoclaved aerated concrete 2 by a washer 21 and a coil nut 20 that together also fix in position the top end of the coil thread bolt 22 that extends through the autoclaved aerated concrete panel 2 and engages the coil insert 24 embedded within the foundation/footing 23. It is preferred for any anchoring caps 1 (not shown in FIG. 12) used over the steel channel 19 to be substantially similar to those shown in FIG. 1-3.
FIG. 13 shows the means used in the most preferred embodiment of the present invention to secure the autoclaved aerated concrete 2 to the typical concrete foundation/footing 23 in a one story structure. A single loop coil 27 with a female thread is embedded into the foundation/footing 23 during its manufacture and recessed approximately three quarters of one inch into the concrete foundation/footing 23. Such a connection is particularly preferred for exterior walls made from autoclaved aerated concrete 2. Also, although the configuration of loop coil 27 shown in FIG. 13 is preferred, the size and configuration of loop coil 27 can be different from that shown. Further, as shown in FIG. 13, it is preferred that at least two reinforcement structures, such as but not limited to the reinforcement bars 25, extend through loop coil 27 for enhanced uplift resistance in any roof panels 6 connected to the autoclaved aerated concrete wall 2 positioned above concrete foundation/footing 23. FIG. 13 shows the entire vertically extending surface of concrete foundation/footing 23 and the autoclaved aerated concrete panel 2 located over the loop coil 27 having a recess 31 approximately three quarters of an inch along its vertical face to receive a steel flat plate 26 that is secured to the foundation/footing 23 with a coil bolt 28 inserted into loop coil 27, and plate 26 being further secured to the autoclaved aerated concrete 2 with multiple tube nails 3. The number, size, and/or configuration of additional reinforcement bars 25 or other reinforcing structures within concrete foundation/footing 23 and the autoclaved aerated concrete panel 2 may vary and are not critical. Further, the number and spacing of the tube nails 3 used to secure plate 26 to autoclaved aerated concrete 2 can vary, and may be different from that shown in FIG. 13.
FIG. 14 shows one preferred configuration for the vertical ridge 11 upwardly depending from the top surface of a roof panel 6, which is used in the connection of clips 12 and fasteners 13 to secure roof panel 6 to the top surface of a support beam 4, and adjacent roof panels 6 together. When the three fasteners 13 shown in FIG. 14 are secured through the three holes below them in clip 12, the fasteners 13 will extend through the top surface of support beam 4 to securely fix the lower end of clip 12 to support beam 4. The upper end of clip 12 is also secured in place by folding and crimping it together with the vertical ridge 11 to which it is attached. A conventional hand tool (not shown) can be used to perform the crimping step. However, when a next adjacent roof panel 6 is to be attached along support beam 4 and connected to a roof panel 6 already secured in place by a clip 12 and fasteners 13, the vertical ridges 11 of both of the roof panels 6 become crimped together with the clip 12 and fasteners 13 sandwiched in between, and via fasteners 13 to support beam 4. Although not critical thereto and not marked with separate numerical designations, FIG. 14 shows roof panel 6 having a generally corrugated upper surface 32 and a tongue-in-groove configuration 33 usable for connecting adjacent roof panels 6.
Thus, in summary, the most preferred embodiment of the present invention method of building construction combines two energy efficient building materials to produce low cost structures, including affordable housing. Blocks and panels made from autoclaved aerated concrete 2 are first connected together using conventional construction means of attachment (not shown), such as but not limited to tongue-and-groove connection, to form the vertically-extending walls, interior and exterior, and other structural elements needed for the building shell. It is preferred for added strength and enhanced uplift resistance in the connection of roof panels 6 to the autoclaved aerated concrete 2, that wall panels 2 having an inner reinforcement structure (not shown) be used for exterior and load bearing walls, instead of the exterior walls being constructed from block. Since the blocks and panels made from autoclaved aerated concrete 2 are lighter in weight and stronger than conventional concrete, and wall panels of autoclaved aerated concrete 2 can be worked like wood without chipping or cracking, they are easily handled on a construction jobsite for rapid assembly of a building shell. Roof panels 6 are then secured to the blocks and panels made from autoclaved aerated concrete 2 to complete the building shell, the interior of which can then be finished according to need. It is not unexpected for a building shell and roof combination made via the present invention to be completed in two days or less. Preferably, roof panels 6 are insulated and have a sandwiched construction with a rigid polyurethane/polyiscocyanurate foam core and are connected in the most preferred embodiment of the present invention to the autoclaved aerated concrete blocks and panels 2 in several ways, using varying combinations of anchoring caps 1, ridge flashing 10, rake trim 18, beams 4, end plates 5, clips 12, fasteners 13 and 17, large tube nails 3, long fasteners 17, and bolts 8. One preferred attachment is that of galvanized roof panels 6 to interior bearing walls made from autoclaved aerated concrete 2, wherein metal anchoring caps 1 having an upper cross-sectional configuration of an isosceles triangle are secured over the top of the wall with large tube nails 3 arranged in a staggered/offset pattern. The galvanized roof panels 6 are then anchored to each isosceles triangle shaped anchoring cap 1 with a minimum of two clips 12 per panel 2 and a minimum of two fasteners 13 per clip 12. Also, ridge flashing 10, is typically secured over the respective ends of adjacent roof panels 6 that are attached to an isosceles anchoring cap 1, and which together form a roof ridge. As an alternative, for attachment of the galvanized roof panels 6 to exterior walls of autoclaved aerated concrete 2, metal anchoring caps 1 having an upper cross-sectional configuration of a right triangle are secured over the tops of the wall panels 2 with large tube nails 3 arranged in a staggered pattern. The galvanized roof panels 6 are then anchored to each right triangle shaped anchoring cap 1 with a minimum of two clips 12 per panel and a minimum of two fasteners 13 per clip. In addition, in the most preferred embodiment of the present invention galvanized roof panels 6 can be anchored to exterior gable end/rake walls using anchoring cap 1 with a flat upper configuration, tube nails 3, large deck screws 17, and rake trim 18. Between interior bearing walls and exterior walls, beams 4 fixed in position by end plates 5 are preferably used to support the galvanized roof panels 6. The beams 4 can be hollow steel tubes, include cutouts for HVAC (such as the center hollow support beam 7 shown in FIG. 10), or be made from poured/molded materials.
Further, the preferred embodiment of the present invention provides for the anchoring of autoclaved aerated concrete panels 2 to the foundation/footing 23 in both single and two story structures. In one story structures, the autoclaved aerated concrete panel 2 in exterior walls is preferably anchored to the foundation/footing 23 via a vertically extending steel strap 26 that is secured within aligned vertically extending recesses in both the foundation/footing 23 and autoclaved aerated concrete panel 2 positioned thereabove. Also, strap 26 is preferably secured to foundation/footing 23 via a coil bolt 28 fastened to a horizontally extending single loop coil insert 27, with reinforcing structure 25 embedded within the foundation/footing 23 engaging coil insert 27 and providing enhanced uplift resistance to any roof panels 6 secured to the top portion of autoclaved aerated concrete panels 2 supported by foundation/footing 23. Strap 26 is also preferably secured to the autoclaved aerated concrete panels 2 supported by foundation/footing 23 via multiple tube nails 3. Depending upon the application, interior walls of autoclaved aerated concrete panels 2 can be similarly constructed. In two story structures made according to the present invention, autoclaved aerated concrete panels 2 in exterior and interior bearing walls are preferably anchored to the foundation/footing 23 utilizing a vertically extending criss-cross loop coil insert 24 embedded in the foundation/footing 23 which receives a continuous vertically extending coil thread bolt 22 that passes upwardly through the autoclaved aerated concrete panel 2 positioned above foundation/footing 23 and ends within a continuous channel 19 extending longitudinally along the top of the center ridge wall and exterior walls and positioned within a recess or notch (not numbered in FIG. 12). The top end of coil thread bolt 22 is secured in place with a washer 21 and coil nut 20. To provide enhanced strength and uplift resistance to any roof panels 6 secured to the top portion of autoclaved aerated concrete panels 2 supported by foundation/footing 23, it is preferred that reinforcing structure 25 embedded within the foundation/footing 23 engage coil 27. Also in the most preferred embodiment of the present invention, for further support of roof panels 6, beams 4 are preferably secured on each of their ends to opposing wall panel faces of autoclaved aerated concrete 2 via end plates 5 secured to the autoclaved aerated concrete 2 via tube nails 3 or bolts 8, with the galvanized roof panels 6 being secured to support beams 4 via clips 12 and fasteners 13. In addition, for attachment of an end plate 5 to an interior non-bearing wall of autoclaved aerated concrete 2, it is preferred that bolts 8 are used, while it is preferred that large tube nails 3 be used to attach end plates 5 to an interior bearing or exterior wall face of autoclaved aerated concrete 2. One set of bolts 8 can be attached to end plates 5 in opposing positions on opposite sides of a single interior non-bearing wall of autoclaved aerated concrete 2. An alternative method of securing the support beams 4 used in the most preferred embodiment of the present invention employs a steel plate 15 embedded within an autoclaves aerated concrete panel 2 that is welded to the support beam 4 to create a secure connection between the support beam 4 and the autoclaved aerated concrete panel 2.
One should recognize that all of the illustrations herein are not strictly to scale, and only generally represent the preferred structure, proportion, and placement of present invention components. Thus, the illustrations herein should not be relied upon for determining the relative size or configuration of such components, or any size and/or configuration limitations in the present invention.

Claims

1. A method of building construction that uses at least two energy efficient building materials to produce low cost structures, including affordable housing, that are rapidly assembled, thermally insulated, fire retardant, energy efficient, low maintenance, pest resistant, sound absorbent, mildew resistant, and sufficiently strong for use in areas subject to adverse forces of nature, including hurricanes and earthquakes, said method comprising the steps of:

providing a plurality of structural members made from autoclaved aerated concrete, a plurality of insulated roof panels having a sandwiched construction and a rigid foam core made from polyurethane and polyiscocyanurate, and a plurality of attachment devices;

using said structural members made from autoclaved aerated concrete to form interior and exterior walls and other needed structural elements; and

using said attachment devices to connect said roof panels to said interior and exterior walls.

2. The method of claim 1 wherein said structural members are selected from a group consisting of panels and blocks, and said exterior walls are made from said panels.

3. The method of claim 1 wherein said attachment devices are selected from a group consisting of anchoring caps, anchoring caps having an isosceles triangle shaped upper portion, anchoring caps having a right triangle shaped upper portion, anchoring caps having a flat top end, ridge flashing, rake trim, support beams, end plates, clips, fasteners, large tube nails, large deck screws, and bolts.

4. The method of claim 1 wherein said attachment devices comprise anchoring caps and some of said interior walls are load bearing, and wherein said step of attaching said roof panels to said exterior walls and said load bearing interior walls further comprises the steps attaching at least one of said anchoring caps to each said exterior wall and each said load bearing interior wall and attaching of said roof panels to said anchoring caps.

5. The method of claim 4 wherein said anchoring caps are made from metal and said walls comprise vertically-extending interior bearing wall panels and vertically-extending exterior wall panels each having a top end, wherein said attachment devices comprise large tube nails, and wherein said step of attaching said anchoring caps to said interior bearing walls and said exterior walls further comprises the attaching of said anchoring caps to said top ends of said interior bearing walls and said exterior walls with said large tube nails arranged in a staggered pattern.

6. The method of claim 4 wherein said attachment devices comprise clips and fasteners, and wherein said step of attaching said roof panels to said anchoring caps further comprises the using of said clips and fasteners to attach said roof panels to said anchoring caps.

7. The method of claim 6 further comprising attachment devices selected from a group consisting of ridge flashing and eave trim.

8. The method of claim 1 wherein said walls comprise a vertically-extending exterior wall with a top end and said attachment devices comprise an anchoring cap having a flat top end, at least one large deck screw, at least one small fastener, and rake trim having an upper end and a lower end, and said step of attaching one of said roof panels to said vertically-extending exterior wall further comprises the steps of securing of said anchoring cap to said top end of said vertically-extending exterior wall, using said at least one large deck screw to secure said upper end of said rake trim to said roof panel, said anchoring cap, and said vertically-extending exterior wall, and using said at least one small fastener to secure said lower end of said rake trim to said vertically-extending exterior wall.

9. The method of claim 1 wherein said walls comprise interior bearing walls and exterior walls each having a panel face, and wherein said step of providing further comprises the providing of at least one support beam and at least two end plates, and further comprising a step of securing said end plates to opposing ones of said panel faces to create at least one opposing pair of end plates and a step of extending said at least one support beam between said at least one pair of end plates wherein said steps of securing said end plates and extending said at least one support beam between said at least one pair of end plates causes said at least one support beam to be positioned where said at least one support beam supports said ends of the one of said roof panels situated between said interior bearing walls and said exterior walls.

10. The method of claim 9 wherein said attachment devices comprise bolts, and wherein said step of securing said end plates to opposing ones of said panel faces further comprises the using of said bolts for attaching said end plates to said panel faces of said interior bearing walls.

11. The method of claim 9 wherein said attachment devices comprise large tube nails, and wherein said step of securing said end plates to opposing ones of said panel faces further comprises the using of said large tube nails for attaching said end plates to said panel faces of said exterior walls.

12. The method of claim 9 wherein said attachment devices comprise clips and fasteners, and further comprising a step of attaching said roof panels to said at least one support beam using said anchoring clips and fasteners.

13. The method of claim 1 wherein said insulated roof panels are selected from a group consisting of insulated metal panels having a rigid foam core made from polyurethane and polyiscocyanurate and insulated non-metal panels having a rigid foam core made from polyurethane and polyiscocyanurate, insulated roof panels having steel cores, and insulated roof panels having baked enamel finishes.

14. The method of claim 9 further comprising foundation attachment devices selected from a group consisting of embedded plates with at one elongated bar attached thereto, embedded reinforcement bars, shim plates, coil bolts, vertically extending criss-cross loop coil inserts, notches, channels, washers, coil nuts, tube nails, vertically-extending plates, tube nails, recesses, and single loop coils.

15. The method of claim 14 wherein said step of providing further comprises the providing of at least one structural member made from autoclaved aerated concrete having a notch and a metal plate with at least one elongated bar adjacent to said notch, at least one shim plate, and welding means, and further comprising the steps of positioning one of said support beams within said notch, adjusting the elevation of said support beam within said notch via said at least one shim plate, and using said welding means to weld said support beam and said at least one shim plate to said embedded metal plate.

16. The method of claim 14 wherein said step of providing further comprises the providing of a foundation with at least one vertically extending embedded criss-cross loop coil insert and at least one embedded reinforcement structure engaging said coil insert to provide enhanced uplift resistance, at least one structural member made from autoclaved aerated concrete having a notch in its top end, a coil bolt with an upper end and a lower end, a channel, a washer, and a coil nut, and further comprising the steps of inserting said coil bolt vertically through said structural member, supporting said structural member upon said foundation while aligning said lower end of said coil bolt with said insert, connecting said lower end of said coil bolt to said insert, inserting said channel into said structural member notch so that said upper end of said coil bolt extends upwardly beyond said channel, and securing said upper end of said coil bolt with said washer and said coil nut.

17. The method of claim 14 wherein said step of providing further comprises the providing of a foundation with at least one horizontally extending embedded loop coil and at least one embedded reinforcement structure engaging said loop coil to provide enhanced uplift resistance, said foundation also having a vertically extending recess, at least one structural member made from autoclaved aerated concrete having a vertically extending recess, a coil bolt, an elongated plate, and a plurality of tube nails, and further comprising the steps of supporting said structural member upon said foundation while aligning said vertical recess in said foundation with said vertical recess in said structural member, placing said elongated plate in said recesses against said foundation and said structural member, connecting said elongated plate to said foundation via connection of said coil bolt to said loop coil, and connecting said elongated plate to said structural member via connection of said tube nails to said structural member.

18. The method of claim 1 wherein said structural members comprise an inner reinforcing structure and said attachment devices comprise elongated fasteners, and further comprising a step of attaching said insulated roof panels to said structural members with said elongated fasteners so that said elongated fasteners engage said inner reinforcing structure and provide enhanced uplift resistance to said roof panels.

19. The method of claim 1 wherein said roof panels each have at least one vertical ridge and at least one tongue-in-groove structure, and connection of adjacent ones of said roof panels to one another is selected from a group consisting of crimping adjacent ones of said vertical ridges together and interconnecting adjacent ones of said tongue-in-groove structures.

20. The structure produced by the method of building construction in claim 1.