AN EXTERIOR WALL AND A METHOD FOR CONSTRUCTING AN EXTERIOR WALL

Abstract

Disclosed is an exterior wall (17) for a building (11). The exterior wall (17) comprises an inner wall (20) including a load-bearing structure formed by a transversal roof metal profile (14) and a transversal foundation metal profile (13) between which a number of intermediate metal profiles (15) extend, and wherein an inside surface (59) of the inner wall (20) is provided inner sheathing (63). The exterior wall (17) also comprises an outer wall (21) including a load-bearing structure formed by a transversal roof metal profile (14) and a transversal foundation metal profile (13) between which a number of intermediate metal profiles (15) extend, and wherein an outside surface (64) of the outer wall (21) is provided outer sheathing (62). The inner wall (20) and the outer wall (21) are mutually fixed at the transversal metal roof profiles (13) and the transversal metal foundation profiles(14) so that a cavity (34) is formed between the inner wall (20) and the outer wall (21). A method for constructing an exterior wall (17) of a building (11) is also disclosed.

Claims

1. An exterior wall for a building, said exterior wall comprising: an inner wall including a load-bearing structure formed by a transversal roof metal profile and a transversal foundation metal profile between which a number of intermediate metal profiles extend, and wherein an inside surface of said inner wall is provided with inner sheathing, and an outer wall including a load-bearing structure formed by a transversal roof metal profile and a transversal foundation metal profile between which a number of intermediate metal profiles extend, and wherein an outside surface of said outer wall is provided with outer sheathing, wherein said inner wall and said outer wall are mutually fixed at said transversal metal roof profiles and said transversal metal foundation profiles so that a cavity is formed between said inner wall and said outer wall.

2. The exterior wall according to claim 1, wherein said inner sheathing and/or said outer sheathing comprises a vapour barrier.

3. The exterior wall according to claim 1, wherein said inner sheathing and/or said outer sheathing comprises a fire-resistant layer.

4. The exterior wall (17) according to claim 1, wherein said outer sheathing comprises façade cladding.

5-6. (canceled)

7. The exterior wall according to claim 1, wherein thermal insulation means is arranged inside said cavity.

8. The exterior wall according to claim 1, wherein thermal insulation means is arranged between said metal profiles of said inner wall and between said metal profiles of said outer wall.

9. The exterior wall according to claim 1, wherein each metal profile of said inner wall and said outer wall comprises identification means enabling that each unique metal profile can be uniquely identified.

10. (canceled)

11. The exterior wall according to claim 1, wherein a majority of said intermediate metal profiles of said inner wall is displaced in relation to a majority of said intermediate metal profiles of said outer wall as seen in a direction perpendicular to said inner wall.

12. The exterior wall according to claim 1, wherein said transversal roof metal profile of said inner wall is parallel with said transversal roof metal profile of said outer wall and wherein said transversal foundation metal profile of said inner wall is parallel with said transversal foundation metal profile of said outer wall.

13. The exterior wall according to claim 1, wherein said transversal roof metal profile of said inner wall is parallel with said transversal foundation metal profile of said inner wall and wherein said transversal roof metal profile of said outer wall is parallel with said transversal foundation metal profile of said outer wall.

14. The exterior wall according to claim 1, wherein said intermediate metal profiles extends perpendicular in relation to said transversal roof metal profiles and said transversal foundation metal profiles.

15. A method for constructing an exterior wall of a building, said method comprising the steps of: assembling a number of prefabricated metal profiles according to a predefined plan to form an inner wall of said exterior wall of said building, assembling a number of prefabricated metal profiles according to a predefined plan to form an outer wall of said exterior wall of said building, mutually fixing said inner wall and said outer wall in relation to each other at a foundation of said building and at a roof of said building so that a cavity is formed between said inner wall and said outer wall.

16. The method according to claim 12, wherein said method further comprises the step of substantially covering an inside surface of said inner wall with an inner sheathing.

17. The method according to claim 12, wherein said method further comprises the step of substantially covering an outside surface of said outer wall with an outer sheathing.

18. The method according to claim 12, wherein said method further comprises the step of arranging thermal insulation means inside said cavity.

19. The method according to claim 12, wherein said method further comprises the step of arranging thermal insulation means between said metal profiles of said inner wall and between said metal profiles of said outer wall.

20. The method according to claim 12, wherein said method further comprises the step of providing identification means to said metal profiles.

21. The method according to claim 12, wherein said method is a method for constructing an exterior wall according to any of claims 1-114.

22. The system for construction of a building erected on a foundation, and which comprises a transversal roof metal profile, a transversal foundation metal profile and intermediate metal profiles between transversal roof metal profile and transversal foundation metal profile, horizontal profiles as well as a roof structure, the system comprising: the transversal roof metal profile and the transversal foundation metal profile comprise a first guide profile for an inner wall and a first guide profile for an outer wall in a wall structure as well as a spacing element located between these first guide profiles, which first guide profile comprises an angle profile having a horizontal flange in use and a vertical flange in use, wherein in the horizontal flange with a predefined mutual distance, first tabs are provided which are folded so as to be located under an angle in relation to the horizontal flange, and which each comprise a hole, the transversal foundation metal profile can act as a wall plate in a floor separation or a wall plate to support the roof structure, each post comprises a intermediate metal profile located between the first guide profiles in the inner wall or the outer wall at a position in line with the first tabs, which intermediate metal profile comprises two opposite flanges located in parallel planes, which are mutually connected by a central flange, wherein at each end of the central flange of the intermediate metal profile, a second tab is provided, which is resilient in relation to the central flange, and which are each adapted for resilient engagement in the hole in the first tab, each horizontal profile comprises a mounting guide profile which comprises two opposite flanges located in parallel planes, which are mutually connected by a central flange, the first of the opposite flanges being adapted for mounting on the posts, and the second of the opposite flanges being adapted for mounting of inner cladding or facade cladding of the inner wall, respectively the outer wall, and the roof structure comprises a lattice girder formed by two opposite fourth guide profiles, between which fifth guide profiles are mounted to form the lattice structure.

23. A system according to claim 19, wherein posts in the inner wall and the outer wall are displaced in relation to each other, and that the posts are preferably mounted in every second of the first tabs in the first guide profiles.

24-34. (canceled)

Description

DESCRIPTION OF THE DRAWINGS

[0115] In the following, the invention will be described in detail with reference to the accompanying drawings, where

[0116] FIG. 1 shows a principle design of a building in which a system according to the present invention is used,

[0117] FIG. 2 shows a detail in the design of the foundation and a transversal foundation metal profile in the building shown in FIG. 1,

[0118] FIG. 3 shows an enlarged image of the design shown in FIG. 2,

[0119] FIG. 4 shows a principle sketch of a wall having an inner wall and an outer wall each comprising a transversal foundation metal profile,

[0120] FIG. 5 shows a detail of the mounting of a post on a transversal foundation metal profile,

[0121] FIG. 6 shows an enlarged image in partial cross-section through the connection shown in FIG. 5,

[0122] FIG. 7 shows a principle sketch for mounting of inner cladding on a wall structure,

[0123] FIG. 8 shows a detail in the construction of the inner wall cladding,

[0124] FIG. 9 shows a detail of the mounting of a socket outlet profile in an inner wall,

[0125] FIG. 10 shows an enlarged image of the socket outlet profile shown in FIG. 9,

[0126] FIG. 11 shows a detail of the mounting of the socket outlet profile shown in FIGS. 9 and 10,

[0127] FIG. 12 shows a principle sketch for formation of an opening for mounting of a window in the wall structure, constructed using a system according to the invention,

[0128] FIG. 13 shows details of the structure shown in FIG. 12,

[0129] FIGS. 14 and 15 show further details of the mounting of the frame profiles shown in FIGS. 12 and 13,

[0130] FIG. 16 shows an image of a pole plate used for mounting a lattice girder on the transversal roof metal profile,

[0131] FIGS. 17 and 18 show details of the joining of two lattice girders to each other in a pitched roof structure,

[0132] FIG. 19 shows how the lattice girders of the roof structure are mutually connected using a sixth guide profile,

[0133] FIG. 20 shows the sixth guide profile used in FIG. 19,

[0134] FIG. 21 shows the termination of a lattice girder at a roof overhang,

[0135] FIG. 22 shows a second embodiment for a building having unilateral roof slope, and wherein a system according to the invention is used,

[0136] FIGS. 23-25 show different guide profiles forming part of a system according to the invention, and

[0137] FIG. 26 discloses a wall section wherein the metal profiles comprise identification means.

DETAILED DESCRIPTION OF THE INVENTION

[0138] In the following, the invention will be described in more detail with reference to different figures, wherein identical or similar elements have the same reference designation. All structure elements will thus not be explained in detail in connection with each figure.

[0139] FIG. 1 shows a building 11 erected on a foundation 12. The building comprises a transversal roof metal profile 14, a transversal foundation metal profile 13 and intermediate metal profiles 15 placed between the transversal roof metal profile 14 and the transversal foundation metal profile 13. The building also comprises horizontal profiles 16. These elements 13, 14, 15, 16 are used for the load-bearing structures of the exterior wall structure 17 of the building. In this embodiment the load-bearing structure is the structure carrying the superjacent roof structure 18 but in another embodiment it could also or instead be another floor or other.

[0140] In this embodiment the building 11 further comprises a roof structure 18.

[0141] In the building 11 shown, a window opening 19 is furthermore defined.

[0142] FIGS. 2 and 3 contain a more detailed figure of the construction of the foundation 12. In this embodiment the foundation is composed of foundation blocks 4. These are preferably provided with an EPS core. Between the outer and inner foundation blocks 4, an insulation 3 is placed. This is preferably EPS (expanded polystyrene).

[0143] Above the foundation, a vapour seal 2 is placed. This is preferably an EPDM rubber membrane. It preferably has a thickness of 5 mm.

[0144] This vapour seal can be used for levelling any unevenness for transversal roof metal profile 14 placed on top.

[0145] The transversal foundation metal profile 13 comprises a guide profile 1, provided in the form of an L-shaped steel profile. A first guide profile 1 is provided at the bottom end of an inner wall 20 and at an outer wall 21.

[0146] Between the two first guide profiles 1, a distance profile 22 is provided. The distance profile 22 ensures the correct mutual placing of the two first guide profiles 1, so that a well-defined thickness of the wall structure 17 and the cavity 34 between the inner wall 20 and outer wall 21 is thus achieved. However in another embodiment the inner wall 20 and/or outer wall 21 could be connected more or less directly (e.g. through some thermal insulating pad or material) to the roof structure 18 and/or the foundation 12—i.e. without a distance profile 22—or the distance profile 22 could be attached to the inner wall 20 and/or outer wall 21 by means of connection means such as screws, rivets, adhesive or other.

[0147] As can be seen from FIGS. 2 and 3, the outside surface 64 of the outer wall 21 is provided with outer sheathing 62 which in this embodiment comprises façade cladding 5. The facade cladding 5 can be shale, slate, painted aluminium, facade stone, fibre cement and other facade claddings that may be desirable for use.

[0148] In the design shown, a powerboard 7 has been used as facade cladding 5.

[0149] The facade cladding 5 is mounted on a mounting guide profile 6. This guide profile is Z-shaped and preferably manufactured from salt water resistant aluminium. This mounting guide profile 6 is mounted on gypsum boards connected to the intermediate metal profiles 15 of the outer wall 21. In this embodiment the gypsum boards will act as a fire-resistant layer 23.

[0150] FIG. 4 shows more clearly how the outside surface 64 of the outer wall 21 is provided with a fire-resistant layer 23. In another embodiment also the inside surface 59 of the inner wall 20 would be provided with fire-resistant layer 23.

[0151] In this embodiment the transversal foundation metal profile 14 is formed as an L-shaped profile having a vertical flange 25 and a horizontal flange 26. The tabs are folded along a folding line 47 from the horizontal flange 26. The tabs are used, as explained in the following, for mounting of intermediate metal profiles 15.

[0152] FIGS. 5 and 6 show more clearly how a tab 24 is folded out of the plane of the horizontal flange 26. The tab 24 is provided with a hole 27. The hole 27 serves to receive a resiliently springy tab 28 in the intermediate metal profiles 15.

[0153] The intermediate metal profiles 15 comprises two opposite flanges 29, 30, which are mutually connected by a central flange 31, so that a U-shaped profile is formed. The tab 28 is punched and pressed out from the central flange 31.

[0154] The tab 28 has an S-shaped configuration, so that a central part 32 of the tab in a resilient way is pressed into the hole 27 when the intermediate metal profile 15 is pressed down into abutment with the first guide profile 1. Hereby, a mutual retention and a correct positioning of the two guide profiles is established. This mutual retention establishes a safe fixing during mounting of the building. Subsequently, the two guide profiles will be fixed permanently to each other, e.g. by nailing using a gas-powered gun or by riveting or by other appropriate permanent connections between the two guide profiles.

[0155] However, in another embodiment the metal profiles 13, 14, 15, 16 could instead or also be connect by means of connection means 65 such as screws, rivets, adhesive or other from the start so that the described tap system could be avoided.

[0156] FIGS. 7 and 8 show a mounting of an inner wall 20. In this embodiment the inner wall 20 comprises the gypsum boards will act as a fire-resistant layer 23. FIG. 7 also shows a vapour seal 10 which is mounted on the outside of insulation 33 in the cavity 34 between the inner wall 20 and the outer wall 21. However, in a preferred embodiment the vapour barrier 10 would be placed on the inside surface 59 of the inner wall 20.

[0157] The inner wall 20 is in this embodiment provided with horizontal mounting guide profiles 6 corresponding to mounting guide profiles 6 used for the cladding of the outside surface 64 of the outer wall 21.

[0158] Regardless whether the issue is cladding of the external wall or the inner wall, the mounting guide profiles 6 can be a Z-shaped profile having a flange in abutment with the intermediate metal profiles 15 and the inner sheathing 63 and/or the outer sheathing 62. However, in another embodiment the mounting guide profiles 6 would be designed differently or the would not be present at all, so that the inner sheathing 63 and/or the outer sheathing 62 would be mounted directly on the inner wall 20 and the outer wall 21.

[0159] As can be seen from FIG. 8, there is a gap 67 between the back side of the fire-resistant layer 23 and the insulation 33. This gap 67 is designed for ducting of cables and pipes. All ducting work can thus be performed on the inner side of the vapour seal 10 which is mounted on the insulation 33. There is thus no risk of penetration of the vapour seal.

[0160] As is apparent from the above, and as can be seen in particular from FIG. 4, the intermediate metal profiles 15 are located displaced from each other in the inner wall and the outer wall. This minimises the risk of thermal bridges through the wall structure and ensures a more even distribution of injected insulation material.

[0161] FIGS. 9-11 show certain special conditions around the mounting of a socket outlet profile 35. The socket outlet profile 35 is mounted between a mounting guide profile 6 and a first guide profile 1. The socket outlet profile may be provided with different openings. It is preferred that openings are stamped with Ø63 to match the standard dimensions for junction boxes.

[0162] It will be possible to mount a total of three openings above each other between each of the mounting guide profiles 6 which form the horizontal profiles, respectively the first guide profile 1 which forms the transversal roof metal profile. It should be noted that the socket outlet profile 35 can be displaced in horizontal direction. The socket outlet profile 35 is mounted without the use of tools. At each end, the socket outlet profile has a folded tab 36. As can be seen from FIG. 11, this tab will be used for engagement in a cavity in the mounting guide profile 6 and will be folded around a central part of this Z-shaped profile. This fixes the socket outlet profile 35. Following the temporary mounting, the socket outlet profile can be nailed or riveted for a permanent fixing.

[0163] FIGS. 12 and 13 show how a window opening 19 or door opening is formed in a building structure. FIGS. 14 and 15 show the details of this window opening.

[0164] It can be seen here that on the intermediate metal profile 15, a first angle bracket 37 is fixed. To this, a horizontal frame profile 38 is fixed. The frame profile is mounted at an angle profile 37 at each end, the angle profile having a resiliently springy tab 28 corresponding to the tab shown in FIGS. 5 and 6. The resiliently springy tab 28 cooperates with a hole 39, which is punched in the horizontal frame profile 38 at the end of this frame profile 38. However, other connection systems that the tab system can obviously be used.

[0165] Between two horizontal frame profiles 38, at least one vertical frame profile 40 is provided for delimitation of a window opening or door opening, which has a smaller width than the distance between two subsequent intermediate metal profiles 15 which constitute the posts of the wall structure.

[0166] On the horizontal frame profile 38, as shown in FIG. 15, a second angle bracket 41 is mounted. This is placed displaceably in the longitudinal direction of the horizontal frame profile 38. The angle bracket has a first flange 42 for engagement with the underside of the frame profile and an intermediate flange part 43 which is in engagement against the side of the frame profile 38 as well as a third flange part 44 which is designed to abut the upper side of a frame profile, respectively the underside of a frame profile, depending on whether the frame profile is placed at the upper or lower end of a vertical frame profile 40. In the third flange part 44 is a folded part 45, wherein an opening 46 is provided. The opening 46 serves for cooperation with a resilient tab 28 from the vertical frame profile 40. The second angle bracket can be displace to a desired position which depends on the width of the window opening that is desired to be established.

[0167] The first angle bracket 37 can be displaced in the height direction along the intermediate metal profile 15, so that the horizontal frame profile 38 is placed at a desired height.

[0168] Following the temporary fixing, the elements can be mutually fixed permanently by nailing with a gas-powered gun, riveting or by another permanent fixing. However in another embodiment other connection types could be used e.g. connecting directly by means of connection means and thus without the use of angle bracket.

[0169] FIG. 16 shows details of the roof structure 18. As can be seen from FIG. 1, the structure comprises two lattice girders 48. Each lattice girder is formed from two opposite fourth guide profiles 49, in between which fifth guide profiles 50 are mounted to form the lattice structure. The lattice girder is mounted on the transversal foundation metal profile 13 using a pole plate 51. The pole plate 51 is formed by a folded plate profile 52, so that a side flange is formed on each side of the lattice girder 48, and a bottom flange that can be fixed to the transversal foundation metal profile.

[0170] FIGS. 17 and 18 show the structure of a pitched roof 18, wherein the two lattice girders 48 are mounted using two seventh guide profiles 53 mounted on each side of the lattice beams. As shown in FIG. 18 the seventh guide profiles are mounted by nailing using a gas-powered gun, riveting or another permanent joining on the two adjoining lattice girders. The two seventh guide profiles are identical.

[0171] FIGS. 19 and 20 show a sixth guide profile 54 used as bracing for the lattice beams 48 in the roof structure. In the sixth guide profile 54, openings 55 are provided with a well-defined mutual distance. Hereby, the lattice beams are positioned correctly in the roof structure in relation to each other. The sixth guide profiles 54 thus act as rafters/struts.

[0172] FIG. 21 shows that the lattice beams are mounted on the pole plate 51, so that they are extended beyond the pole plate. This forms an overhang 56 for the building. At the outer end of the lattice beams 48, a connection profile 57 is provided. This allows for mounting of covering elements, such as fascia boards or similar on the overhang 56.

[0173] FIG. 22 illustrates a building, wherein the roof structure is made with unilateral slope. It can thus be seen that the lattice beams 48 are placed under an angle in relation to horizontal. Alternatively, the building may be provided with a flat roof, and the lattice beams 48 will then be placed horizontally on top of the transversal foundation metal profile 13.

[0174] When a roof structure is placed, a reinforcement profile may be placed at the top of the external wall. This reinforcement profile may be a C-shaped profile, which ensures an upper side that is level with the upper side of the inner wall. Such a C-profile 58 is illustrated in FIG. 23. Here, it can be seen that at each end of the C-profile, two juxtaposed resiliently springy tabs 28 are provided, corresponding to those shown in FIGS. 5 and 6.

[0175] FIG. 24 shows the fifth guide profile 50 which can be used in the lattice girder. By providing the beam with incisions 60 and lateral perforations 61, it is possible to make a zig-zag folding of the guide profile 50 so that it can be placed inside the opposite guide profiles 49 of the lattice girder structure.

[0176] FIG. 25 shows the transversal foundation metal profile 14, wherein tabs 24 are provided with mutual spacing.

[0177] FIG. 26 discloses a wall section wherein the metal profiles 9, 13, 14, 15 comprise identification means 66.

[0178] In this embodiment a digital representation of the building 11 is first constructed in a computer program such as a CAD program. From these CAD information the different metal profiles 9, 13, 14, 15 are manufactured—or at least cut to length—in an automated process. Substantially at the same time these metal profiles 9, 13, 14, 15 are provided with identification means 66 so that each type of metal profile 9, 13, 14, 15 can be uniquely identified from the identification means 66. In this embodiment the identification means 66 are letters A, B, C and D written on the profiles by an inject printer. However numerous other identification means 66 could be used for this purpose.

[0179] All the metal profiles 9, 13, 14, 15—forming the entire building 11—or at least forming an entire exterior wall 17 will be delivered unassembled to the erection site, where the metal profiles 9, 13, 14, 15 can be correctly assembled using an assembly plan showing how the uniquely marked metal profiles 9, 13, 14, 15 shall be assembled. This approach severely reduces transportation cost in that only small packages of metal profiles 9, 13, 14, 15 has to be shipped instead of complete buildings or large building modules. And given the identification means 66 the wall 17 and the building 11 can still be assembled quickly.

[0180] After assembly of the entire exterior wall 17—and most likely the entire building—inner sheathing 63 and outer sheathing 62 is provided where after insulation material will be injected into the walls in most cases.

[0181] The invention has been exemplified above with reference to specific examples of inner walls 20, outer walls 21, metal profiles 9, 13, 14, 15, 16 and other. However, it should be understood that the invention is not limited to the particular examples described above but may be designed and altered in a multitude of varieties within the scope of the invention as specified in the claims.

LIST

[0182] 1. [0183] 2. Vapour seal above the foundation [0184] 3. Insulation between the outer and inner foundation [0185] 4. Foundation block [0186] 5. Facade cladding [0187] 6. Mounting guide profile [0188] 7. Power board [0189] 8. Wall [0190] 9. Strut [0191] 10. Vapour barrier [0192] 11. Building [0193] 12. Foundation [0194] 13. Transversal roof metal profile [0195] 14. Transversal foundation metal profile [0196] 15. Intermediate metal profile [0197] 16. Horizontal profile [0198] 17. Exterior wall [0199] 18. Roof structure [0200] 19. Window opening [0201] 20. Inner wall [0202] 21. Outer wall [0203] 22. Distance profile [0204] 23. Fire-resistant layer [0205] 24. Tab [0206] 25. Vertical flange [0207] 26. Horizontal flange [0208] 27. Hole in the tab [0209] 28. Resiliently spring tab [0210] 29, 30. Flange [0211] 31. Central flange [0212] 32. Central part [0213] 33. Insulation material [0214] 34. Cavity [0215] 35. Socket outlet profile [0216] 36. Folded tab [0217] 37. First angle bracket [0218] 38. Horizontal frame profile [0219] 39. Hole in the horizontal frame profile [0220] 40. Vertical frame profile [0221] 41. Second angle bracket [0222] 42. First flange [0223] 43. Intermediate flange part [0224] 44. Third flange part [0225] 45. Folded part [0226] 46. Opening [0227] 47. Folding line [0228] 48. Lattice beam [0229] 49. Fourth guide profile [0230] 50. Fifth guide profile [0231] 51. Pole plate [0232] 52. Folded plate profile [0233] 53. Seventh guide profile [0234] 54. Sixth guide profile [0235] 55. Sixth guide profile opening [0236] 56. Overhang [0237] 57. Connection profile [0238] 58. C-profile [0239] 59. Inside surface of inner wall [0240] 60. Incisions [0241] 61. Lateral perforations [0242] 62. Outer sheathing [0243] 63. Inner sheathing [0244] 64. Outside surface of outer wall [0245] 65. Connection means [0246] 66. Identification means [0247] 67. Gap