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.

Description

TECHNICAL FIELD

The present invention relates generally to using prefabricated insulated building panels for constructing a multi-storey building.

BACKGROUND

Constructing a multi-storey building (a building that includes one or more sections having two or more storeys) is typically an extensive project involving significant amounts of time and/or resources (labour, energy, materials, etc.). For example typical conventional construction techniques for residential or commercial buildings of multiple storeys may utilize cast-in-place concrete floors and pillars. The carbon footprint of a building built using such existing systems and methods can be large. Traditional building construction methods using cast-in-place concrete requires the use of expensive materials and requires allocating significant amounts of time for allowing concrete to cure, resulting in long construction times. Furthermore, concrete construction techniques are inflexible and offer little opportunity for modification after the buildings are completed.

Techniques of modular building construction using prefabricated structural components have been disclosed in the prior art. Such techniques comprise prefabricating panels and walls in a factory and then shipping them to a construction site where they are assembled into the final building. Modular building techniques have many advantages such as lower greenhouse gas emissions as compared to traditional cement building techniques, faster erection of buildings, and safer building practices.

However, prior art modular building techniques using prefabricated panels are limited by the desire for modularity and universality, wherein the prefabricated panels have little to no variance in their material properties and are therefore not optimized for their specific applications. Due to the desire for uniformity in prior art prefabricated panels, the prior art building techniques fail to provide for the variable needs for specific prefabricated panels in different parts of multi-storey buildings, resulting in a decreased flexibility for the environments in which those buildings can exist. These variable needs include weight, structural strength, fire resistance, acoustic insulation, and temperature insulation, for example.

There remains a general need for systems and methods of constructing multi-storey buildings using prefabricated panels which are optimized for their specific application and which are cost effective and can be readily assembled.

The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

SUMMARY

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.

This invention has a number of aspects. These include, without limitation:

• • constructing a multi-storey building out of prefabricated wall panels and floor panels, where prefabricated panels of each storey span between a building foundation and roof panels;
  • constructing a multi-storey building out of prefabricated panels in which some of the prefabricated panels comprise cross bracing embedded within an insulative core of the panel and/or comprise a frame disposed about a perimeter of the panel;
  • constructing a multi-storey building out of prefabricated panels with cementitious layers in which some of the different prefabricated panels comprise different cementitious layers;
  • constructing a multi-storey building using prefabricated wall panels forming demising walls, the panels comprising a cavity providing acoustic dampening;
  • constructing a multi-storey building out of prefabricated panels in which some floor panels extend exteriorly and are cantilevered by one or more prefabricated wall panels; and
  • constructing a multi-storey building using prefabricated roof panels, which when connected together, form a roof profile having a water drainage channel.

In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.

FIG. 1 is a perspective view of a single storey of a multi-storey building comprising a plurality of different prefabricated panels.

FIG. 2A is a perspective view of a multi-storey building comprising a plurality of the single storeys shown in FIG. 1.

FIG. 2B is an elevation view of the multi-storey building of FIG. 2A.

FIG. 2C is a cross-sectional elevation view of the multi-storey building of FIG. 2A along lines C-C of FIG. 2B. FIG. 2D is a cross-sectional plan view of the multi-storey building of FIG. 2A along lines D-D of FIG. 2B.

FIG. 3A is a perspective view of a partially complete exterior wall panel according to an example embodiment. FIG. 3B is a perspective view of an exterior wall panel according to an example embodiment. FIG. 3C is a schematic view of a demising wall according to an example embodiment.

FIG. 4 is a perspective view of a floor of a single storey comprising a plurality of prefabricated panels.

FIGS. 5A to 5E are schematic views illustrating a number of different ways in which floor panels may be positioned relative to corresponding wall panels.

FIG. 6 is a perspective view, partially exploded, of a single storey comprising a plurality of prefabricated panels forming a floor and walls.

FIG. 7 is a perspective view of a roof comprising a plurality of prefabricated panels.

FIG. 8 is a perspective view of a partially complete multi-storey building showing the positioning of roof panels, partially exploded, over the top storey of the building.

FIG. 9 is a block diagram illustrating an example method for constructing a multi-storey building.

DESCRIPTION

Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

FIG. 1 is a perspective view of a single storey 10 of a multi-storey building comprising walls formed from a plurality of different prefabricated panels. A multi-storey building 100, as illustrated in FIG. 2C, is constructed by constructing a first storey 10A on a foundation 102, then constructing a second storey 10B on the first storey 10A, followed by constructing a third storey 10C on the second storey and so on. Multi-storey building 100 may be a residential apartment building, an institutional building, a commercial office building, or the like. In the illustrated FIG. 1 embodiment, storey 10, which may be a first or any subsequent storey, comprises a plurality of exterior walls 12, demising walls 14, corridor walls 16, and core walls 18.

Different ones of walls 12, 14, 16 and 18 serve to form different portions of a storey 10, which is best illustrated with reference to FIG. 1. Exterior walls 12 are disposed about and define an outer perimeter of storey 10. Demising walls 14 of storey 10 are used for the purpose of separating individual residential or commercial units 20. Corridor walls 16 of storey 10 are used for the purpose of separating a building unit 20 from a corridor 27, corridor 27 leading to different building units 20. Core walls 18 of storey 10 are used for defining the perimeter of stairwells, elevator shafts and service shafts. It is not necessary that instances of walls 14, 16 and 18 are present on every storey 10 or at all in multi-storey buildings described herein. The use of any combination of these walls is possible in practicing the present invention. Specific traits and desirable properties of individual ones of walls 12, 14, 16 and 18 are described in further detail below.

Multi-storey buildings built according to the present invention generally rely on prefabricated panels having an insulative core between two layers of a structural element. In some embodiments, the prefabricated panels used for walls 12, 14, 16 and 18 may be structurally insulated panels (SIPs) comprising a foam core sandwiched between two layers of structural board.

According to a preferred embodiment of the invention, the prefabricated panels used herein may be similar to panels described in detail in Canadian Patent No. 2,994,868 filed on Feb. 13, 2018 entitled PREFABRICATED INSULATED BUILDING PANEL WITH CURED CEMENTITIOUS LAYER BONDED TO INSULATION, which is hereby incorporated by reference in its entirety. Prefabricated panels described in Canadian Patent No. 2,994,868 comprise an insulative foam core covered on inner and outer surfaces in a composite cementitious layer.

Different constituent materials making up the cementitious layers may have different performance characteristics and material properties as disclosed in corresponding United States Provisional Application No. 63/000,942 filed on 27 Mar. 2020 entitled PREFABICATED PANEL WITH MULTI-LAYER CEMENTITIOUS COVERINGS, the contents of which are incorporated herein by reference. For example, some cementitious materials used may feature higher fire protection and/or sound dampening, while other cementitious materials may have higher structural support characteristics. These different properties may advantageously be used for obtaining desirable characteristics specific to the function performed by each of walls 12, 14, 16 and 18 and by any other prefabricated panels described herein.

Individual ones of prefabricated panels forming walls 12, 14, 16 and 18 or other structural elements contained therein may be coupled to one another in a number of possible ways, as disclosed in corresponding U.S. Provisional Application No. 63/003,401, filed 1 Apr. 2020 entitled SYSTEMS AND METHODS FOR COUPLING PREFABRICATED PANELS TOGETHER, the contents of which are incorporated herein by reference. The use of reinforcing frames having connectors with lifting points as described in U.S. Provisional Application No. 63/003,401 may advantageously be used in facilitating ease of transportation and assembly of prefabricated panels when constructing multi-storey buildings.

It is advantageous that certain ones of the prefabricated panels used in the present invention comprise a greater fire resistance construction than in other prefabricated panels. For example, prefabricated panels used for the construction of exterior walls 12 preferably do not comprise any combustible materials or materials which may melt under certain fire conditions. Prefabricated panels fabricated from non-combustible materials may be referred to herein as “fire walls”.

In some embodiments, prefabricated panels used for the construction of fire walls comprise a mineral wool insulative core. In some embodiments, one or both of the cementitious layers surrounding the insulative core of a fire wall comprise perlite, which provides stronger fire resistance properties. In this manner, different fire ratings may be selectively achieved for different surfaces of buildings described herein.

As an example, for exterior walls 12 situated on zero-lot-lines, it is preferable that walls 12 are fire walls having a high fire resistance rating in the range of 2 to 4 hours to ensure that fires which may occur within building 100 are not spread to adjacent properties. In embodiments where building 100 is immediately adjacent other properties on one or more sides, but not on the remaining sides, exterior walls 12 adjacent the other properties may comprise fire walls while exterior walls 12 on the remaining sides comprise prefabricated panels not made with fire rated materials (e.g. having an expanded polystyrene insulative core).

Fire walls may be employed for other walls (including demising walls, core walls and corridor walls) of the present invention where it is important in the circumstances to prevent the spread of fire or to be in compliance with building regulations and codes, such as for a fire-proof enclosure of a boiler room. In some embodiments, building 100 may be subdivided into a number of discrete compartments, for example, where building 100 is large or long. In such embodiments, walls separating different compartments may advantageously comprise fire walls, thereby restricting the spread of fire within a large building 100.

FIGS. 2A-2D show a number of different views of an example multi-storey building 100 comprising a plurality of storeys 10. FIG. 2C is a cross-sectional elevation view of building 100 along lines C-C of FIG. 2B. FIG. 2D is a cross-sectional plan view of building 100 along lines D-D of FIG. 2B.

Building 100 comprises foundation walls 19 extending into ground 11, as best shown in FIG. 2C. A portion of foundation walls 19 is shown to extend slightly above the surface of ground 11, although this is not necessary. As illustrated, foundation walls 19 rest on top of and are supported by a foundation 102. In some embodiments, foundation 102 is a spread footing foundation wherein the foundation has a wider bottom portion than the load-bearing foundation walls it supports, the wider portion distributing the weight of building 100 over a greater area. In some embodiments, foundation 102 comprises cast in place concrete. In other embodiments, foundation 102 comprises precast concrete which is cured in a plant and then transported to the construction site for installation.

In some embodiments, foundation 102 extends farther down beneath the surface of ground 11 to a deeper subsurface layer of earth. The use of a deep foundation may be desirable for a variety of reasons, such as for accommodating larger design loads or where the quality of soil is poor at shallower depths. Suitable prefabricated panels for the construction of foundation walls 19 are described in detail in U.S. Provisional Application No. 63/001,194 filed on 27 Mar. 2020 entitled SYSTEMS AND METHODS FOR CONSTRUCTING A SINGLE-STOREY BUILDING, which is hereby incorporated by reference in its entirety. Prefabricated panels for use as foundation walls described in U.S. Provisional Application No. 63/001,194 comprise a variety of features for imparting higher axial load-bearing capacity, higher capacity for bearing lateral forces due to back fill tendencies of excavated soil, and higher capacity for bearing shear forces stemming from seismic events.

In embodiments where foundation 102 is located far beneath the surface of ground 11, foundation walls 19 may comprise a plurality of adjoined tall prefabricated panels. In such embodiments, individual panels forming foundation walls 19 may have a height to width ratio of around 2:1 to 6:1 or more. In other embodiments, foundation walls 19 comprise a plurality of adjoined horizontal prefabricated panels. Individual horizontal prefabricated panels forming foundation walls 19 in this embodiment may have a width to height ratio of 2:1 to 6:1 or more. It is also possible that foundation walls 19 comprise both horizontal and vertical prefabricated panels. In some embodiments, a plurality of vertically stacked prefabricated panels are used for forming foundation walls 19 having a desirably high height.

It will be appreciated that alternative means for providing suitable structural foundation elements are possible in constructing multi-storey buildings of the present invention. For example, a plurality of drilled vertical piles may be installed within ground 11 to support building 100. The piles may be formed from any suitable materials such as wood, reinforced concrete, or a composite material. According to a specific embodiment, the piles are steel screw piles.

Referring to FIG. 1, exterior walls 12 are disposed about and define an outer perimeter of storey 10. It is preferred that exterior walls 12 are load-bearing. Therefore, it is desirable for exterior walls 12 to be formed from prefabricated panels which have a high capacity for bearing compressive loads. Generally, the structural strength of prefabricated panels employed herein can be increased by strengthening interior/exterior facing surfaces of the panels and/or by embedding structural elements within the insulative core of the prefabricated panels. Such possible options described herein for imparting structural strength to prefabricated panels may be pursued individually or in combination with one another.

In some embodiments, prefabricated exterior wall panels 22 used for forming exterior walls 12 comprise one or more metal reinforcing bars embedded within the cementitious layer along the vertical length of the panel for providing additional structural strength. The metal reinforcing bars may be embedded in an inner layer of cementitious material facing the interior of building or in an outer layer of cementitious material or both. The reinforcing bars may be disposed and spaced apart along a horizontal direction of walls 12 and may also be disposed and spaced apart along a thickness of the cementitious layer(s). Additionally or in the alternative, a reinforcing substrate spanning both lateral and longitudinal directions of the exterior panels 22 is provided within the cementitious layer(s). The reinforcing substrate may be formed, for example, from fibreglass scrim or carbon fiber mesh.

In some embodiments, structural reinforcing members are embedded along a vertical length of the insulative core at opposite horizontal ends of exterior panels 22. In doing so, the resilience of panels 22 to withstand axial, shear and transverse forces may be improved. In some embodiments, corresponding vertical ends of the structural members are connected to one another through horizontally oriented structural members to form a rectangular-shaped reinforcing frame around the perimeter of exterior panel 22. In some embodiments, the vertical reinforcing members and/or the reinforcing frame (referred to collectively as “reinforcing elements”) are formed of a suitably rigid and strong metal such as steel or aluminum. These various reinforcing elements may comprise a wide variety of possible cross-sectional shapes, such as wide flange (I-beams), hollow structural section (HSS), U-channel, and angled bars, for example. Other suitable materials for the reinforcing element(s) include extruded fiberglass and composite cementitious materials. In scenarios where the load-bearing requirements of the panels 22 are lower, such as on higher storeys of building 100, the reinforcement elements may comprise reinforcing bars. In some embodiments, the reinforcing elements described herein are bonded to the insulative core by a cured cementitious casting.

FIGS. 3A and 3B illustrate an example exterior wall panel 122, which may be used as an exterior wall panel 22 in the FIG. 1 embodiment. FIG. 3A shows the same exterior wall panel 122 of FIG. 3B with the omission of the cementitious layer on one side to display a structural frame 136. Exterior panel 122 comprises an insulative core 132 having layers of cementitious material 134 on opposing faces of panel 122. A structural frame 136 is embedded within insulative core 132 around the perimeter of panel 122. Structural frame 136 comprises vertical framing members 136-1, 136-2 and 136-3 at spaced apart horizontal locations of panel 122. The addition of framing members between the vertical ends of frame 136 imparts structural rigidity and strength to panel 122. Advantageously, such a design permits panel 122 to feature a greater length to height ratio, allowing for comparatively larger panels to be used. Using such example framing methods, prefabricated panels described herein may comprise heights of 14 feet and lengths of 60 feet or more.

Exterior wall panel 122 comprises a plurality of connectors 138, a number of which are shown in FIGS. 3A and 3B. In some embodiments, connectors 138 serve to facilitate coupling distinct elements of frame 136 together. Connectors 138 may be embedded into the insulative core 132 of panel 122 such that connection of frame 136 to connectors 138 additionally serves to rigidly couple frame 136 to panel 122. In some embodiments, connectors 138 are substantially similar to connectors disclosed in U.S. Provisional Application No. 63/003,401. In some embodiments, connectors 138 comprise an HSS body formed from a suitably rigid material such as steel, extruded aluminum, or extruded fiberglass. In other embodiments, connectors 138 comprise a solid block connector formed from a suitably rigid material such as steel, aluminum, or fiberglass. Certain surfaces of connectors 138 may remain uncovered during and after fabrication of panel 122 so that an interior space of connectors 138 can be accessed to install and/or remove fasteners.

In the illustrated embodiment, the rectangular perimeter of frame 136 and intermediate transverse framing members 136-1, 136-2 and 136-3 comprise a monolithic frame 136. In such embodiments, the components of structural frame 136 are integrally formed or the individual components are suitably joined to one another, such as through welding, bolting, or adhesive bonding. In some embodiments, the fabrication of exterior wall panel 122 comprising such a monolithic frame 136 comprises positioning frame 136 around connectors 138 embedded within insulative core 132 and then subsequently installing a plurality of suitable fasteners to connect frame 136 to the connectors 138 to thereby securely install structural frame 136 onto panel 122.

According to another example embodiment, portions of frame 136 interposed between each connector 138 (e.g. framing member 136-1) comprise distinct structural elements. These distinct elements may each be suitably fastened to connectors 138 to thereby collectively form frame 136. Structural frame 136 of panel 122 may comprise any appropriate materials or cross-sectional shapes suitable for sustaining expected loads during operation. Structural frame 136 may comprise the design features and considerations discussed above in relation to reinforcing elements of exterior wall panel 22.

Preferably, exterior walls 12 are made to be resistant to shear forces stemming from seismic events and high winds. Shear forces from winds are generally in plane and transverse to the interior and exterior facing surfaces of walls 12. When the exterior face of walls 12 is engaged by direct wind pressure, the interaction between the external cementitious layer and the insulative core transfers the load to structural elements disposed within the insulative core, which in turn transfers the load to the building foundation. Shear forces from seismic events may be in a transverse direction (similar to forces from wind) and/or in a horizontal direction co-planar to the interior and exterior facing surfaces of walls 12.

In some embodiments, cross-bracing may be implemented within a structural frame disposed within the insulative core of exterior panels 22. Applying a system of cross-bracing to exterior panels 22 advantageously imparts high structural shear resilience by allowing panels 22 to support both tensile and compressive forces imposed by shear loads resulting from wind and seismic activity. Suitable methods for implementing cross-bracing within prefabricated panels are described in detail in U.S. Provisional Application No. 63/001,194. In some embodiments, cross-bracing is applied only to prefabricated panels 22 forming exterior walls 12 on lower storeys of a building 100 where the load-bearing requirements are generally higher. In other embodiments, exterior panels 22 of all of the storeys of building 100 comprise cross-bracing, which may be desirable in environments where there is increased risk of high winds and/or seismic activity. In some embodiments, a system of cross-bracing may be applied to exterior wall panels 122 of the FIGS. 3A and 3B embodiment.

Some embodiments of the present invention provide for prefabricated panels having a greater height to length ratio, allowing for comparatively taller panels to be used. Such tall panels may advantageously employ techniques described herein for achieving the desired height to length ratio. For example, tall vertical prefabricated panels herein may comprise a number of intermediate vertical framing members (similar to vertical framing members 136-1, 136-2 and 136-3 shown in FIG. 3A) spaced apart along a horizontal length of the panel. The tall vertical prefabricated panels may also advantageously employ a method of cross-bracing described above to better withstand shear loads. Tall prefabricated panels may also optionally feature intermediate horizontal framing members spaced apart along a vertical length of the panel. Different ones of adjoined tall vertical panels in a multi-storey building may comprise any combination of these or other appropriate reinforcing methods depending on the specific structural requirements at a panel's location in the building.

Using such example framing methods, prefabricated panels described herein may comprise lengths of 14 feet and heights of 60 feet or more. In some embodiments, multi-storey buildings comprising a lower number of storeys comprise a series of adjoined tall prefabricated panels forming exterior wall panels 22 substantially spanning the entire height of the building above grade. For example, multi-storey buildings having 2, 3, 4 or 5 storeys can be constructed from tall exterior wall panels 22 which span the entire height of the building. Advantageously, this reduces the need for different prefabricated panels to be coupled together. It is also possible for prefabricated panels forming interior walls (such as demising walls 14 and core walls 18) to span several storeys using the described tall prefabricated panels. In some embodiments, larger multi-storey buildings (such as building 100), comprise tall prefabricated wall panels which can span 2, 3, 4 or 5 storeys.

In embodiments employing the use of tall vertical prefabricated panels, appropriate couplings should be located at intermediate vertical locations of the panels to accommodate the attachment of floor panels 32 at different storeys. Intermediate openings may also be defined in the tall prefabricated panels to interface with openings defined in floor panels 32 for allowing ducts, pipes, wire bundles and such to pass. Methods for constructing multi-storey buildings, described later herein, may be suitably adapted to accommodate the use of tall wall panels spanning multiple storeys. For example, temporary bracing may be applied to support and level the installation of floor panels after a number of, but not all, of the tall wall panels have been installed.

In some embodiments, walls 12 on lower storeys of building 100 have a greater load-bearing capacity than walls 12 on higher storeys. In the illustrated FIG. 2C embodiment, exterior walls 112A and 112B on first and second storeys 10A and 10B comprise a greater thickness than exterior walls 112C on third storey 10C. Exterior walls 112A and 112B may comprise prefabricated exterior panels 22 having thickened composite cementitious layers. A greater number or a greater thickness of metal reinforcing bars or other reinforcing materials may optionally be disposed within the thickened cementitious layer. In this manner, multi-storey building 100 is afforded higher structural capacity while reducing the weight of the building structures on the higher storeys.

As illustrated in the FIG. 1 embodiment, exterior walls 12 may comprise openings which define windows 13 or doors 15, such as to an exterior fire escape stairwell or to a balcony. In some embodiments, window openings are cast into the cementitious layers and insulative core of panels 22 with an appropriate mold. In some embodiments, the casting process may be used to form drip edges and sloped window sills. To avoid introducing any thermal bridges, which may diminish the insulative capabilities of exterior walls 12, it is preferable that inner and outer cementitious layers of exterior wall panels 22 do not come in contact with one another, such as at the outer edges of panels 22 or at interior edges defined by any openings.

It is also desirable that an exterior facing surface of exterior walls 12, which may be exposed to humidity and rain, has properties of reduced moisture permeability. This may be achieved by providing a cementitious layer in exterior wall panels 22 having a higher density. Additionally, by providing internal channels at the interface of the exterior-facing cementitious layer and the insulative core of panels 22, exterior walls 12 are able to equalize pressure and to drain moisture which has penetrated the outer cementitious layer. As discussed below, a suitable cladding or finishing may be applied to an exterior-facing surface of panels 22 to provide waterproofing properties.

Multiple exterior wall panels 22 may be joined together in any appropriate manner and configuration to form the exterior of storey 10 (i.e. exterior wall 12). As illustrated in FIG. 1 by adjacent exterior wall panels 22A and 22B, exterior wall panels 22 may be joined perpendicularly to one another. As illustrated by adjacent exterior wall panels 22C and 22D, wall panels 22 of walls 12 may be joined co-planar to one another. Other configurations not illustrated are possible, such as where adjacent exterior wall panels are joined to one another at an oblique angle.

Demising walls 14 of storey 10 are used for the purpose of separating individual residential or commercial units 20. Building unit 20 may define distinct private dwellings or the offices of separate businesses operating in the same storey. Demising walls 14 may generally have a lower insulative capacity and weather proofing capacity compared to that of exterior walls 12. Demising walls 14 preferably provide strong acoustic insulation so as to prevent sound from travelling between adjacent building units 20. The levels of desired acoustic insulation may be guided by relevant building codes. As an illustrative example, under the National Building Code of Canada, partitions separating dwelling units must meet a minimum sound transmission class of 50, mitigating around 50 dBA of noise. Furthermore, demising walls 14 preferably feature high fire resistance so that fires which start in a building unit 20 are not readily spread to other building units 20. Preferably, demising walls 14 are fire rated assemblies or are fire walls and have a fire resistance rating between 1 to 4 hours.

FIG. 3C is a schematic illustration of an example demising wall 114, which may be used as demising wall 14 in the FIG. 1 embodiment. Demising wall 114 comprises two individual prefabricated panels 150A and 1506 (which may be collectively referred to herein as prefabricated panels 150). Each prefabricated panel 150 comprises an insulative core 152 and a cementitious layer 154 bonded to the respective surfaces of each of panels 150A and 1506 facing the interior of separate building units 20. This construction of prefabricated panels 150 differs from that of other prefabricated panels described herein which generally comprise structural layers of material disposed on both sides of an insulative core.

Structural cementitious layers on the inner surfaces of insulative cores 152 of panels 150A and 1506 may be omitted where demising walls 14 have lower load-bearing requirements, for example. This is advantageous in keeping the overall weight of demising walls 114, and therefore building 100, to a minimum. In some embodiments, both interior and exterior surfaces of panels 150A and 1506 comprise a layer of cementitious material for providing additional structural rigidity. Metal reinforcing bars are optionally disposed within cementitious layers 154 for adding structural strength. In some embodiments, cementitious layers 154 comprise a lower density cementitious material containing perlite, which provides stronger fire resistance properties.

It is also possible to provide demising walls 114 which are able to sustain structural sheer and axial loads by embedding structural elements within the insulative core of one or both of panels 150A and 1506 by employing methods described above in relation to exterior wall panels 22. Although this has the disadvantage of making demising walls 114 heavier, such a design increases the versatility of demising walls 114 in permitting walls 114 to provide structural support to multi-storey buildings of the present invention.

Prefabricated panels 150A and 1506 are spaced apart such that a cavity 156 comprising dead air space is defined in demising wall 114. Cavity 156 generally prevents waves and vibrations from travelling therewithin, thereby allowing demising wall 114 to provide acoustic insulation between adjacent units 20. In some embodiments, electrical wires and cables are disposed in cavity 156. Panels 150 may comprise appropriate openings in the insulative core(s) 152 and in the cementitious layer(s) 154 for receiving such components in building units 20.

In other embodiments, demising walls 14 of the present invention do not rely on having a dead air space for achieving desired acoustic ratings. Demising walls 14 may comprise prefabricated panels having a monolithic insulative core formed from materials having high acoustic performance. For example, demising walls 14 comprise an insulative core formed of rigid mineral fiber to achieve a desirably high acoustic rating. In some embodiments, one or more cementitious layers of demising walls 14 feature the multi-layer cementitious coverings disclosed in U.S. Provisional Application No. 63/000,942. The multi-layer coverings may be advantageously used to provide increased fire protection, sound dampening, and structural support characteristics.

Individual prefabricated panels 150A and 150B may be rigidly connected to one another in any appropriate manner to form a demising wall 114. In some embodiments, structural shims having a thickness substantially spanning the thickness of cavity 156 are disposed at spaced apart locations within cavity 156. The shims may be installed between panels 150A and 150B using any appropriate means, such as through an interference fit, adhesives, bolted connectors, and the like. In other embodiments, panels 150A and 150B are not connected to one another and individually connect to floor/roof panels on adjacent storeys using suitable connectors.

Corridor walls 16 of storey 10 are used for the purpose of separating a building unit 20 from a corridor 27, corridor 27 leading to different building units 20. Corridor walls 16 generally have lower requirements for providing acoustic insulation than that of demising walls 14 such that the dual-panel configuration of FIG. 3C is not necessary. Corridor walls 16 comprise prefabricated corridor panels 26, wherein multiple ones of panels 26 may be coupled to define a suitably shaped corridor 27. Corridor wall panels 26 may optionally feature reinforcing elements described herein for adding structural strength to corridor wall panels 26, such as through embedded metal reinforcing bars and structural frames. Corridor wall panels 26 may comprise openings for providing doors 29 which facilitate access between building units 20 and corridor 27. Corridors in multi-storey buildings generally form portions of fire exit routes and building codes commonly require corridor walls to be constructed with a 1 hour fire rating, which may be achieved using the methods described herein.

Core walls 18 of storey 10 are used for defining the perimeter of stairwells, elevator shafts and service shafts, as illustrated by prefabricated core wall panels 28A, 28B and 28C, respectively, in FIG. 1. Other applications of core walls 18 within storey 10 are possible. In the event of a fire, building occupants must evacuate, and first responders must enter, through the elevators and/or stairwells of building 100. It is therefore of particular importance that fires within building 100 present outside of elevators, stairwells and the like are unable to penetrate through core walls 18. As such, it is highly preferable that walls 18 enclosing such building features feature a high fire resistance rating and are non-combustible “fire walls”. As an illustrative example, under the ULC-S101 fire resistance testing standard employed in Canada, core walls 18 may have a fire resistance rating of 2 hours. In some embodiments, core walls 18 have a fire resistance rating of up to 4 hours.

As described previously herein, the use of lower density cementitious materials containing perlite can be advantageously employed in core wall panels 28 to provide stronger fire resistance properties. Core wall panels 28 may additionally comprise thicker cementitious layers for obtaining maximal fire protection. In some embodiments, the thickness of the cementitious layer is between the range of ¼″ to 2.5″. In some embodiments, core wall panels 28 comprise an exterior cementitious layer (i.e. opposite the interior of the passageways) which is thicker than an interior cementitious layer in order to prevent fires from entering building escape routes.

Core wall panels 28 may optionally feature reinforcing elements described herein for adding structural strength to core walls 18. In some embodiments, the cementitious layers of core wall panels 28 feature the multi-layer cementitious coverings disclosed in United States Provisional Application No. 63/000,942. The multi-layer coverings may be advantageously used to provide increased fire protection and structural support characteristics.

Although only one or a few instances of each of walls 12, 14, 16 and 18 and their corresponding prefabricated panels are labelled, it will be apparent from the foregoing description and figures that storey 10 and building 100 comprises a plurality of each type of wall and their corresponding prefabricated panels. Any interior facing or exterior facing surfaces of walls 12, 14, 16 and 18 may be coated with a cladding, siding or finish to protect the building materials and/or to achieve a desired aesthetic effect. Cladding may be achieved as disclosed in corresponding U.S. Provisional Application No. 63/002,142 filed 30 Mar. 2020 titled SYSTEMS AND METHODS FOR ADHERING CLADDING, the contents of which are incorporated herein by reference.

In some embodiments, it is desirable that certain faces of walls 12, 14, 16, 18 and any other prefabricated panels described herein are water-resistant or waterproof. Water-resistance and waterproofing may be added to prefabricated panels through a variety of methods. For example, liquid waterproofing materials including paint, mineral coating and clear sealer may be applied to the surface of prefabricated panels. Rigid cladding including ceramics, metals, wood, elastomers, and glass may also be applied to surfaces of prefabricated panels to provide waterproofing. A combination of materials and application techniques may be utilized to provide a level of desired waterproofing and for ensuring impermeability between joints. As an illustrative example, metal flashing may be applied between joints of adjacent prefabricated panels whereupon a liquid or reinforced metal sheet/membrane is applied over the surface of the panels.

Preferably, surfaces of prefabricated panels exposed to the external environment (e.g. exterior panels 22, roof panels 34 and floor panels 32 forming a balcony) comprise a suitable means of providing waterproofing, such as through the application of the techniques described above. Prefabricated panels having water-resistant or waterproof properties may also be desirable for certain interior-facing surfaces of prefabricated panels described herein. For example, a waterproof cladding or finish may be applied to the surfaces of prefabricated panels defining the walls, floors, and ceilings of high humidity rooms such as indoor pools, bathrooms and the like.

FIG. 4 illustrates a plurality of adjoining floor panels 32 which collectively form a storey floor 200. A plurality of storey floors 200 may be provided in a building 100 and each storey floor 200 may be positioned and be secured to the prefabricated walls which collectively form each storey 10 in any appropriate manner. Attachment of a storey floor 200 to a storey 10 forms a ceiling of that storey 10 and serves as the floor of an immediately higher storey 10. This concept is illustrated in FIG. 2C which shows storey floor 200A simultaneously serving as the ceiling of storey 10A and as the floor of storey 10B.

FIGS. 5A-5E illustrate a number of different ways in which floor panels 32 may be positioned (or framed) relative to corresponding wall panels of storey 10, shown as generic prefabricated wall panel 21. FIG. 5A shows an example configuration wherein a floor panel 32 is positioned on top of and is supported by a wall panel 21A of a lower storey. Floor panel 32 in this configuration in turn supports a wall panel 21B of a higher storey.

FIG. 5B shows an example configuration wherein multiple floor panels 32 are positioned on top of and are supported by a single wall panel 21A. Floor panels 32 correspondingly both support a wall panel 21B on a higher storey. In this sense, the configuration of 5B is similar to that of FIG. 5A. However, it will be understood that the dual-sided configuration illustrated in FIG. 5B is applicable to other floor-wall panel configurations described herein and may be appropriately employed depending on the circumstances. The dual-sided configuration of FIG. 5B may be appropriate where the interface between floor panels 32 and wall panels 21 is within building 100, such as where wall panels 21 comprise demising walls 14. In contrast, the single-sided configurations of FIGS. 5A, 5C, 5D and 5E may be appropriate where the floor-wall interface is at the perimeter of the building, such as where panels 21 comprise exterior wall panels 22.

FIG. 5C shows an example configuration wherein a floor panel is positioned on top of and is supported by a lip 21A-1 of panel 21A. Wall panel 21B is accordingly supported by both floor panel 32 and wall panel 21A. FIG. 5D shows an example configuration wherein Floor panel 32 is positioned and attached at the top and bottom side surfaces of wall panels 21A and 21B, respectively, and wherein upper wall panel 21B rests directly on top of lower wall panel 21A. FIG. 5E shows a configuration similar to that of FIG. 5D, except that floor panel 32 is attached only to lower wall panel 21A. The opposite is possible wherein floor panel attaches only to a side surface of upper wall panel 21B.

The selection of the particular configuration may be informed by a number of design considerations and constraints, where each configuration has their own advantages and disadvantages. For example, floor panel 32 in the FIG. 5A embodiment is a simply supported beam which does not transfer bending moments to wall panel 21A. Panel 21A is therefore only required to support an axial load. However, one disadvantage is that there are a greater number of distinct surfaces in the FIG. 5A configuration. The junctions between these surfaces may require suitable sealing or cladding, for example, to provide adequate sound protection or weatherproofing.

The configurations of FIGS. 5D and 5E advantageously comprise a lower number of potential sealing surfaces compared to the FIG. 5A configuration. However, floor panel 32 in these configurations comprises a fixed beam which requires wall panels 21 to bear bending moments. Such configurations further require connectors at the floor-wall interface to suitably transfer loads encountered on floor panels 32 to wall panels 21. Any appropriate connectors, including those disclosed in U.S. Provisional Application No. 63/003,401, may be suitable for this purpose.

The configuration of FIG. 5C in providing a lip 21A-1 on which floor panel 32 rests remedies a number of above limitations of the FIGS. 5A, 5D and 5E configurations by reducing the number of surfaces requiring sealing and by requiring panel 21A to bear only axial loads. However, the design and manufacture of panel 21A is accordingly more complex. It will be appreciated that the foregoing example floor-wall configurations and any other possible configurations may be employed, individually or in combination with one another, within the same building 100 in practicing the present invention.

FIG. 6 shows a storey floor 200 and a storey 10, comprising a plurality of walls, disposed thereon. In the illustrated FIG. 6 embodiment, prefabricated floor panels 32 interpose prefabricated wall panels of storey 10 according to the FIG. 5A floor-wall configuration. However, it will be appreciated that other configurations are possible, such as those described by FIGS. 5C-5E.

Floor panels 32 comprise an insulative core covered on top and bottom surfaces in a composite cementitious layer. Floor panels 32 are designed such that the span of floor panels 32 between its supports is appropriate for bearing expected loads experienced thereon. As an illustrative example and with reference to FIGS. 1 and 4, floor panel 32A may be supported on the top edges of each of prefabricated wall panels 22A, 22B, 22E and 28A. As illustrated, floor panel 32A has a span S. Based on the measurement of span S, the maximum bending moment and deflection based on expected loads can be measured, which panel 32A must be designed to support whilst considering a relevant safety factor. In some embodiments, span S may be 24 feet. In other embodiments, span S may be 32 feet or more. In some embodiments, floor panels 32 comprise a total thickness between the range of 8 to 28 inches. In some embodiments, the thickness of the cementitious layers in floor panels 32 is between the range of ¼″ to 2.5″.

At larger values of span S, the vibration and deflection of floor panels 32 becomes an issue. Generally, weight may be added to floor panels 32 to dampen vibration. This may be achieved by making the cementitious layers thicker and/or by forming the cementitious layers from a higher density material. However, adding excessive weight to floor panels 32 becomes a problem for shipping panels 32 to the construction site and for adding to the overall weight of building 100. In some embodiments, pretensioned or prestressed joists are embedded within the insulative core of floor panels 32 to provide greater resistance to shear loads.

In some embodiments, water pipes are embedded at the factory within the insulative core of floor panels 32 wherein flowing water pumped through the pipes stiffen and dampen floor panels 32, allowing for a greater span S. A reservoir stored underneath building 100 and a suitable plumbing system may supply the water to be circulated at different storeys 10 in such an embodiment. Advantageously, in the summer, water contained in the reservoir and water pumped through building 100 is heated by the hot weather. This heated water may then be used in winter to provide heating through the pipes embedded in floor panels 32. Methods for providing radiant heating to the interior of a building using prefabricated floor panels and for improving the load-bearing capacity of floor panels are discussed in detail in U.S. Provisional Application No. 63/001,194 and are applicable in the present circumstances.

In some embodiments, floor panels 32 can be made fire resistant using the methods described herein. In some embodiments, mechanical chases are defined in floor panels 32 which allow ducts, pipes, wire bundles and such to pass from units 20 into the interior of floor panels 32. For example, electrical wiring may be run through the insulative core of panels 32 which connects to a ceiling lighting box and which interfaces with wiring from a unit 20. Example methods for providing electrical conduits along an interior length of floor panels 32 and for providing interfacing elements in adjoining prefabricated panels are discussed in detail in U.S. Provisional Application No. 63/001,194 and are applicable in the present circumstances. Floors and ceilings separating units on adjacent floors must typically meet a minimum sound transmission class of 50. In some embodiments, an acoustic underlayment is installed on prefabricated floor panels 32 during manufacturing or after installation into building 100.

As shown in FIGS. 2A, 2D and 6, a portion of floor panel 32B forms a balcony. In the illustrated embodiment, the balcony is cantilevered and projects from exterior wall panel 22F. However, it is not necessary that balconies of the present invention are cantilevered. In other embodiments, the portion of floor panel 32 forming a balcony rests on one or more exterior wall panels 22 which protrude outward from the general envelope of building 100.

In some embodiments, there is a correspondence between floor panels 32 and the various areas present in each storey 10. For example, with reference to FIGS. 2A and 6, floor panels 32A and 32B correspond to and are adapted for use with a building unit 20A. Floor panel 32A corresponds to the floor of an area disposed entirely within the interior of storey 10 and unit 20A. In contrast, floor panel 32B defines a portion which serves as a balcony, while remaining portions of panel 22B are disposed interiorly of storey 10. With reference to FIGS. 1 and 4, floor panel 32C corresponds to and is adapted for use with a corridor 27. The use of standard floor panel shapes which correspond to areas of storey 10 defined by the prefabricated wall panels advantageously improves the ease and efficiency with which different building components are assembled together.

A possible disadvantage of the illustrated configuration of providing balconies using an externally protruding portion of floor panel 32B is that floor panel 32B may act as a thermal bridge. Cementitious materials used in prefabricated panels herein (e.g. panel 32B) may have a relatively high thermal conductivity such that the illustrated configuration of providing balconies may diminish the insulative strength of building 100. In other embodiments of the invention, thermally broken balconies are provided. For example, separate balcony panels may be coupled to floor panels 32 such that a thermal break is formed therebetween. In other embodiments, separate balcony panels are coupled to exterior wall panels 22, with exterior wall panels 22 or the interface between respective balcony panels and exterior wall panels 22 providing a thermal break.

FIG. 7 illustrates a plurality of adjoining roof panels 34 which collectively form a roof 250. FIG. 8 is an illustration of a partially complete building 100 showing the placement of roof panels 34 overtop of the highest storey 10. Roof panels 34 and roof 250 may share some common features and design considerations with floor panels 32 and storey floor 200. For example, roof panels 34A and 34B may correspond to floor panels 32A and 32B in being adapted for enclosing the same vertical area of the same building unit 20A. As shown in FIG. 2A, a portion of roof panel 34B may form a cantilevered portion of roof 250. Roof panels 34 may similarly provide conduits and appropriate interfacing elements for integrating various electrical components into a storey 10 and building 100.

In contrast to floor panels 32, it is of relatively greater importance that roof panels 34 and roof 250 feature strong thermal insulation properties and are impermeable to moisture. As previously discussed herein, strong thermal insulation properties may be achieved by the use of a thicker insulative core and by avoiding the creation of thermal bridges. Additionally, as previously discussed herein in relation to exterior wall panels 22, impermeability to moisture may be provided by providing cementitious layers in roof panels 34 that have a higher density and by additionally applying a finish, coating, or membrane which provides weather proofing properties to roof panels 34 and roof 250. In some embodiments, a membrane is applied to roof panels 34 as part of the prefabrication process at the plant, where only the joints between panels 34 are sealed with an overlapping membrane (e.g. a splice) during installation.

FIG. 7 shows roof 250 having a roof panel 34C which defines a drainage channel. A drainage channel advantageously collects water present on the roof 250 and diverts the water to another location in order to mitigate water leakage through the roof. In some embodiments, roof panel 34C comprises a plurality of prefabricated panels which, when joined, slope inwards toward an internal drain on roof 250. Alternatively, the plurality of adjoined panels forming roof panel 34C slopes outwards toward an external drain.

In some embodiments, panels 34 comprise flat prefabricated panels positioned at an angle over the uppermost storey 10 of building 100. In some embodiments panels 34 are angled such that water present on roof 250 collects at an internal drainage channel on roof 250 (e.g. roof panel 34C). In other embodiments, panels 34 are angled outwards such that water is directed toward an external drain (i.e. roof 250 is a pitched roof). Alternatively, roof panels 34 are positioned flat over the uppermost storey 10 of building 100 and comprise a non-uniform cross-section along both a height and width to create an internal sloping profile as described in U.S. Provisional Application No. 63/001,194. This sloping profile may be used and adapted for achieving any desired roof arrangement.

FIG. 9 is a block diagram showing an example method for constructing a multi-storey building 100. Block 305 comprises establishing a building foundation in an excavated area of land. Block 305 may further comprise embedding receiving connectors in the foundation. At block 310, structural elements for supporting building 100 are attached to the foundation. This attachment may be facilitated using the receiving connectors. In some embodiments, the structural elements comprise drilled vertical piles. In other embodiments, the structural elements comprise prefabricated foundation wall panels.

Method 300 proceeds to block 315 where prefabricated floor panels are connected to the structural elements to form a floor 200 of the first storey of building 100. At block 320, wall panels are installed overtop of the below floor 200 to form a storey 10 of building 100. In some embodiments, temporary bracing is applied to support and level the wall panels during the installation at block 320. Additionally, as part of the installation of the wall panels at block 320, joints between adjoining panels may be sealed to provide weatherproofing, acoustic insulation, or structural rigidity.

Method 300 proceeds to decision block 325 which evaluates whether the storey 10 installed at block 320 is the top storey of building 100. If the evaluation at block 325 is negative, then method 300 proceeds to block 330. At block 330, floor panels are installed over the uppermost storey 10. Method 300 then returns to block 320 wherein another storey 10 is installed. If the evaluation at block 325 is positive, then method 300 proceeds to block 335. At block 335, prefabricated roof panels are installed overtop of the walls of the uppermost storey 10 to form roof 250. A sealant or waterproof membrane may be applied overtop of the prefabricated panels of roof 250 at block 335 to provide weatherproofing to building 100.

Using the systems and methods described herein, multi-storey buildings can be assembled and disassembled in an expedient manner. Prefabricated panels may be added to or subtracted from a building throughout the building's lifecycle depending on the tenant's needs. As disclosed in corresponding U.S. Provisional Application No. 63/003,401, connectors within reinforcing frames or in other parts of prefabricated building panels can be adapted to be easily accessible during the life of the building. This advantageously allows prefabricated panels within a completed building 100 to be disconnected and re-connected to facilitate the addition or subtraction of prefabricated panels.

In some embodiments, one or more storeys can be added to or subtracted from building 100. This may comprise first removing a roof 250 of building 100 before adding or subtracting one or more storeys. Removal of a roof 250 may comprise first removing a waterproof membrane covering individual roof panels. Connectors of the roof panels of roof 250 may then be exposed by appropriately removing a sealant or covering. This permits the subsequent disconnection and removal of the roof panels.

Following the removal of roof 250, interior and exterior wall panels of a storey 10 may be removed to subtract a storey from building 100. Similar to the removal of roof panels, removal of wall panels may comprise a step of exposing connectors by appropriately removing a sealant or covering. In some embodiments, additional storeys may be added to building 100 by performing the steps outlined in blocks 320, 325, and 330 of method 300.

In some embodiments, the arrangement of interior and exterior walls of a particular storey 10 may be modified following the removal of roof 250. It is also possible for the arrangement of floor panels of a particular storey 10 to be modified. Such modifications may be performed by the appropriate disconnection of connectors of the prefabricated panels described herein and then subsequently re-connecting them in the desired configuration.

In some embodiments, modular building components can be advantageously employed in building scenarios where modifications to building 100 are anticipated. For example, moveable partition walls, the positions of which are easily modified, may be employed in defining certain interior spaces of storey 10. Bathroom and kitchen pods which are easily re-configurable may also be employed to add further modularity to the design of units 20 and storeys 10 within building 100.

Using the systems and methods described herein, multi-storey buildings comprising 3 to 20 or more storeys may be constructed in a cost effective, environmentally friendly and efficient manner.

Interpretation of Terms

Unless the context clearly requires otherwise, throughout the description and the claims:

• • “comprise”, “comprising”, and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”;
  • “connected”, “coupled”, or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof;
  • “herein”, “above”, “below”, and words of similar import, when used to describe this specification, shall refer to this specification as a whole, and not to any particular portions of this specification;
  • “or”, in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list;
  • the singular forms “a”, “an”, and “the” also include the meaning of any appropriate plural forms.

This description employs a number of simplifying directional conventions. Directions are described in relation to a building having an existing vertical building wall and an existing horizontal roof. Directions may be referred to as: “external”, “exterior”, “outward” or the like if they tend away from the building; “internal”, “interior”, “inward” or the like if they tend toward the building; “upward” or the like if they tend toward the top of the building; “downward” or the like if they tend toward the bottom of the building; “vertical” or the like if they tend upwardly, or downwardly, or both upwardly and downwardly; “horizontal”, “sideways” or the like if they tend in a direction orthogonal to the vertical direction. Those skilled in the art will appreciate that these directional conventions are used for the purpose of facilitating the description and should not be interpreted in the literal sense. In particular, the invention may be adapted for buildings which have walls that are not strictly vertically oriented and/or roofing structures that are inclined.

For example, while processes or blocks are presented in a given order, alternative examples may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, or may be performed at different times.

In addition, while elements are at times shown as being performed sequentially, they may instead be performed simultaneously or in different sequences. It is therefore intended that the following claims are interpreted to include all such variations as are within their intended scope.

Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.

Various features are described herein as being present in “some embodiments”. Such features are not mandatory and may not be present in all embodiments. Embodiments of the invention may include zero, any one or any combination of two or more of such features. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible).

It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

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; anda fifth plurality of prefabricated insulated panels comprising prefabricated floor panels forming a floor; andiii) 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; andthe fourth plurality of prefabricated insulated panels;

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; andvi) a plurality of prefabricated floor panels forming a floor; andb) a roof, the roof comprising a plurality of prefabricated roof panels.