US20170306621A1

US20170306621A1 - An exterior wall and a method for constructing an exterior wall

Info

Publication number: US20170306621A1
Application number: US15/523,474
Authority: US
Inventors: Bjarne Laursen
Original assignee: SUPPLY HOLDING APS
Current assignee: Prodatek AS
Priority date: 2014-11-14
Filing date: 2015-11-12
Publication date: 2017-10-26
Also published as: EP3218551A1; DK178478B1; DK201470705A1; WO2016074686A1; DK201570297A1; DK178581B1; EP3051038A3; EP3051038A2

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.

Description

FIELD OF THE INVENTION

The invention relates to an exterior wall construction for a building, wherein the exterior wall comprises an inner wall and an outer wall.
The invention also relates to a method for constructing an exterior wall construction of a building.
The present invention further relates to a system for construction of a building which is erected on a foundation and which comprises a transversal roof metal profile, a transversal foundation metal profile and intermediate metal profiles, horizontal profiles and a roof structure.

BACKGROUND OF THE INVENTION

A building is normally erected by constructing an insulated foundation and subsequently placing walls on the foundation before a roof structure of the building is formed so that it is carried by at least some external walls.
The external walls of a building normally comprise an inner brick wall and an outer brick wall. The outer wall is the outside of the building and constitutes the building envelope of the building, and the inner wall is placed against the inside of the building. Between the inner wall and the outer wall, there is a cavity filled with insulation material.
This traditional construction method is time-consuming and the walls are thick, heavy and expensive.

OBJECT OF THE INVENTION

It is the object of the invention to provide for an advantageous technique for constructing exterior walls for a building.

DESCRIPTION OF THE INVENTION

The invention relates to an exterior wall construction for a building. The exterior wall comprises 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 the inner wall is provided with inner sheathing. The exterior wall also comprises 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 the outer wall is provided with outer sheathing. The inner wall and the outer wall are mutually fixed at the transversal metal roof profiles and the transversal metal foundation profiles so that a cavity is formed between the inner wall and the outer wall.
Forming the load-bearing structure of both the inner wall and the outer wall from metal profiles is advantageous in that it enables that both walls easily can transported around and be assembled in situ. This reduces the transportation cost and ensures a fast in situ assembly. And providing the inner wall with inner sheathing and the outer wall with outer sheathing is advantageous in that it hereby is possible to form a closed space inside the wall hereby lowering the thermal conductivity of the wall, and as the same time increasing the soundproof quality of the wall and protecting the inside of the house better.
One big drawback with forming the walls from metal profiles is that metal typically is an excellent thermal conductor and the risk of unwanted conducting of heat in or out of the building is therefore increased. However, air is a pour thermal conductor and by forming a cavity between the inner wall and the outer wall so that the two walls are only mutually connected at the transversal metal roof profiles and the transversal metal foundation profiles ensures that such a wall has a very low thermal conductivity—particularly in light of its weight, cost and thickness.
In an aspect of the invention, the inner sheathing and/or the outer sheathing comprises a vapour barrier.
Forming a vapour barrier on the inside surface of the inner wall is advantageous in that the risk of moisture build-up or condensing inside the wall construction is reduced.
In an aspect of the invention, the inner sheathing and/or the outer sheathing comprises a fire-resistant layer.
Providing the inside surface of the inner wall and/or the outer surface of the outer wall with a fire-resistant layer—such as gypsum boards, metal sheets, slate, concrete plates or other—is advantageous in that it reduces the risk of fire spreading and reduces the damage of a fire.
In an aspect of the invention, the outer sheathing comprises façade cladding.
Providing the outer surface of the outer wall with façade cladding is advantageous in that it hereby is possible to provide the outside of the wall with desired qualities and look.
In an aspect of the invention, the metal profiles are interconnected by connection means.
Interconnecting the metal profiles by means of connection means—such as screws, nails, rivets, welding, adhesive, interlocking geometry or other—is advantageous in that it ensures simple assembly and a more rigid structure.
In an aspect of the invention, the metal is steel.
Steel is strong in relation to its weight—particularly if it is in the form of profiled sheet metal—, it is easy to machine and it is relatively inexpensive.
In an aspect of the invention, thermal insulation means is arranged inside the cavity.
Further arranging thermal insulation means inside the cavity is advantageous in that it reduces the thermal conductivity through the exterior wall.
In an aspect of the invention, thermal insulation means is arranged between the metal profiles of the inner wall and between the metal profiles of the outer wall.
Further arranging thermal insulation means between the metal profiles of the inner wall and between the metal profiles of the outer wall is advantageous in that it reduces the thermal conductivity through the exterior wall.
In an aspect of the invention, each metal profile of the inner wall and the outer wall comprise identification means enabling that each unique metal profile can be uniquely identified.
Enabling unique identification of each unique metal profile is advantageous in that it hereby is possible to deliver the wall as an assembly kit in that the wall hereby easily can be assembled in situ according to a premade plan in which the assembly order and the specific placement of the specific metal profiles is laid out. There is therefore no need to measure the profiles as they can easily be identified from their identification means.
The term “identification means” is in this context to be understood as any kind of label, tag, inscription, marking, embossing, stamping, RFID tag, EPROM (Erasable Programmable Read Only Memory) or any other kind of manual or electrical means capable of holding information regarding the specific profile type.
In an aspect of the invention, the metal profiles are U-profiles.
Forming the metal profiles as U-profiles is advantageous in that a U-profile is strong, rigid and easy to manufacture.
In an aspect of the invention, a majority of the intermediate metal profiles of the inner wall is displaced in relation to a majority of the intermediate metal profiles of the outer wall as seen in a direction perpendicular to the inner wall.
After the wall has been assembled the wall will most likely be filled with insulation material. And to ensure that this material gets into all nooks and corners of the inside of the wall this insulation material could advantageous be blown-in granular insulation material such as shredded paper, Lightweight expanded clay aggregate (LECA), Styrofoam beads or similar insulation material suited for being injected into the inside of a metal profile cavity wall structure.
In an aspect of the invention, the transversal roof metal profile of the inner wall is parallel with the transversal roof metal profile of the outer wall and wherein the transversal foundation metal profile of the inner wall is parallel with the transversal foundation metal profile of the outer wall.
Forming the roof and foundation profiles parallel is advantageous in that it provides for parallel inner and outer walls and thus a constant thickness of the exterior wall.
In an aspect of the invention, the transversal roof metal profile of the inner wall is parallel with the transversal foundation metal profile of the inner wall and wherein the transversal roof metal profile of the outer wall is parallel with the transversal foundation metal profile of the outer wall.
Forming the roof and foundation profiles parallel in each wall is advantageous in that ensures flush wall that are easier to install.
In an aspect of the invention, the intermediate metal profiles extends perpendicular in relation to the transversal roof metal profiles and the transversal foundation metal profiles.
Forming the intermediate metal profiles perpendicular to the transversal roof metal profiles and the transversal foundation metal profiles is advantageous in that the intermediate profiles hereby will be substantially vertical in the finished erected wall—which in turn will ensure that the intermediate metal profiles will be able to carry more weight of the superjacent roof structure or superjacent floor/storey.
The invention also relates to a method for constructing an exterior wall construction of a building. The method comprises the steps of:

- assembling a number of prefabricated metal profiles according to a predefined plan to form an inner wall of the exterior wall construction of the building,
- assembling a number of prefabricated metal profiles according to a predefined plan to form an outer wall of the exterior wall construction of the building,
- mutually fixing the inner wall and the outer wall in relation to each other at a foundation of the building and at a roof of the building so that a cavity is formed between the inner wall and the outer wall.

Forming the exterior wall from metal profiles ensures a strong, thin and inexpensive wall which easily and quickly can be assembled on site by means of a premade assembly instruction in that such a wall can be made of relatively few profiles—due to the double hull wall design. And by forming the inner and outer wall so that they in respect to thermal conductivity substantially is only connected at the foundation of the building and at the roof of the building—hereby forming an substantially continuous cavity between the inner and outer wall—is advantageous in that thermal condition through the exterior wall hereby is reduced even if metal is an excellent thermal conductor.
In an aspect of the invention, the method further comprises the step of substantially covering an inside surface of the inner wall with an inner sheathing.
Providing an inner sheathing to the inside surface of the inner wall—i.e. the surface facing into the building—is advantageous in that it can aid in providing rigidity to the wall structure, it can act as a vapour barrier and/or a fire-resistant layer and it can act as a barrier for insulating material in the wall.
In an aspect of the invention, the method further comprises the step of substantially covering an outside surface of the outer wall with an outer sheathing.
Providing an outer sheathing to the outside surface of the outer wall—i.e. the surface facing away the building—is advantageous in that it can aid in providing rigidity to the wall structure, it can act as a vapour barrier and/or a fire-resistant layer and it can act as a barrier for insulating material in the wall as well as giving the building the desired façade look etc.
In an aspect of the invention, the method further comprises the step of arranging thermal insulation means inside the cavity.
Arranging thermal insulation means inside the cavity after the inner and outer walls have been erected and fixed is advantageous in that this will further reduce thermal conductivity of the wall.
In an aspect of the invention, the method further comprises the step of arranging thermal insulation means between the metal profiles of the inner wall and between the metal profiles of the outer wall.
Arranging thermal insulation means between the metal profiles of the inner wall and between the metal profiles of the outer wall after the inner and outer walls have been erected and fixed is advantageous in that this will further reduce thermal conductivity of the wall.
In an aspect of the invention, the method further comprises the step of providing identification means to metal profiles.
Different metal profiles could be uniquely identified by measuring them, visually inspecting their design or in other ways detecting how they are different from other metal profiles. But this is difficult and time consuming and it is therefore much more efficient to provide the metal profiles with identification means before the wall is to be assembled so that the onsite assembly time is reduced.
In an aspect of the invention, the method is a method for constructing an exterior wall construction according to any of the previously mentioned exterior walls.
The present invention also relates to using a system of the type initially mentioned, distinctive in that

- 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. The invention thus makes it possible to use pre-fabricated guide profiles. Such guide profiles may be manufactured from metal profiles. The metal profiles are preferably a combination of steel profiles and aluminium profiles.

The profiles are manufactured in advance and in well-defined lengths, depending on the size of the building to be made. Long profiles may be composed of several profile units, e.g. to form a sufficient length of transversal roof metal profile and transversal foundation metal profile.
As the guide profiles may be formed in advance, it is also possible to pack these in sets containing the number and the combination of guide profiles to be used for a building in question.
Using the system according to the invention achieves a certainty of correct assembly without a need for special workman skills.
As the guide profiles are provided with connecting means used for coupling of guide profiles, a predefined placing of the connecting means will ensure that correct mutual connection of the guide profiles also takes place.
Intermediate metal profiles placed between a transversal roof metal profile and transversal foundation metal profile will thus be placed and fixed in connection with tabs on transversal roof metal profile and transversal foundation metal profile. Hereby, the position of posts is determined, and the distance between transversal roof metal profile and transversal foundation metal profile will likewise be determined from the length of the posts.
As the posts are provided with a resilient tab that can engage with the hole in the first tab on transversal roof metal profile and transversal foundation metal profile, a very quick and simple assembly of these elements will be achieved.
The coupling elements are normally designed for temporary retention of the elements during mounting and will therefore be supplemented by a nailing together or other fixed coupling of the elements in the finished building.
Is is thus common for the resilient engagement between a tab and hole to be combined with a nailing together or other form of fixing. However, it may turn out that several assemblies do not require supplementing by the fixed coupling. The erection will thus be able to take place very quickly, and the mutual connections between guide profiles will have a strength defined in advance on the basis of the design of the resilient tabs.
When a structure has been made with a transversal roof metal profile and transversal foundation metal profile and posts located there between, horizontal profiles in the form of the mounting guide profile can be placed on the outside of the intermediate metal profiles. These mounting guide profiles can be used on the inside as well as the outside of the house to mount inner cladding or facade cladding. A building according to the invention will thus be made with inner wall and outer wall. In the cavity between inner wall and outer wall, insulation can be placed, and wiring and cables for the installations in the building can also be ducted here.
The roof structure may be a pitched roof or a flat roof. It may also be a flat roof with a unilateral slope. For the use of the roof structure, a lattice girder is used, which is also formed by guide profiles. In order to join the guide profiles, fifth guide profiles are provided, which are mounted jointly around the lattice girder.
If it is a pitched roof, this principle can be used in the joining of the lattice beams at the top of the roof structure. Here, opposite guide profiles will be used, which are mounted jointly around the lattice beams from each side of the roof structure.
The fifth guide profiles can be said to work according to the same principle as studding or book ends.
A pole plate can be formed by a folded plate mounted on the transversal foundation metal profile, and which is also fixed to the lattice beams. The pole plate may also be formed by two opposite guide profiles.
If it is a pitched roof, a similar principle can be used when joining the lattice beams at the top of the roof structure. Here, opposite guide profiles will also be used, which are mounted jointly around the lattice beams from each side of the roof structure.
The guide profiles used for joining around the lattice beams can be joined using nailing, riveting or in some other way. Likewise, these guide profiles for joining around the lattice beams could be joined using resilient tabs that cooperate with holes corresponding to the connecting means used between transversal roof metal profile and transversal foundation metal profile and the posts.
The horizontal profiles mounted on the intermediate metal profiles may be mounted in predefined positions, as the intermediate metal profiles may be provided with connecting means placed with predetermined cavitys and which are adapted to cooperate with corresponding connecting means on the horizontal profiles.
A very uniform placing of the horizontal profiles can thus be achieved and consequently also the facade cladding or inner cladding which is mounted subsequently.
According to a further embodiment, the system according to the invention is distinctive in that 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.
With this embodiment thermal bridges are avoided in the wall structure. As there is a cavity between the inner wall and the outer wall, and as posts located in the cavity between the inner wall and the outer wall are displaced from each other, the risk of a thermal bridge is reduced.
It is preferred that transversal roof metal profile and transversal foundation metal profile are manufactured identically. To this end, first tabs are provided having a distance corresponding to the distance between two subsequent posts located in inner wall and outer wall, respectively. The posts will thus only need to be placed in every second of the first tabs.
Alternatively, a longer distance may have been provided between the tabs, corresponding to the distance between the posts in the inner wall and the distance between the posts in the outer wall. This is merely to ensure that transversal roof metal profile and transversal foundation metal profile are placed in such a way that the first tabs in guide profile for the inner wall are continued in relation to the tabs in the first guide profile for the outer wall.
According to a further embodiment, the system according to the invention is distinctive in that the first tab is formed by a punched part of the horizontal flange, and that the first tab is connected to the horizontal flange along a folding line and is folded to a position perpendicular to the horizontal flange. By forming the tab as a punched part of the horizontal flange, a particularly appropriate manufacture is achieved. Materials savings are thus achieved while avoiding the need for loose tabs that need to be connected with the first guide profile. The first tab is folded around a folding line in the horizontal flange, so that it is perpendicular to the horizontal flange. This makes the tabs face downwards, depending on whether the first guide profile is used for the transversal roof metal profile or for the transversal foundation metal profile.
According to a further embodiment, the system according to the invention is distinctive in that the hole in the first tab is a rectangular hole. The hole being rectangular achieves a safe engagement with a tab which also has a rectangular shape. This achieves a positioning in the lateral direction by sizing the tab so that it has a width that fits into the width of the rectangular hole.
According to a further embodiment, the system according to the invention is distinctive in that the second tab in the intermediate metal profile is S-shaped and adapted to engage with the hole in a first tab. An S-shape on the first tab achieves a resilient effect in a particularly simple way. When the S-shape is folded partly out of the plane from the flange, it will be possible to fold it to such a position that it establishes a larger or smaller resilient force and thus safe engagement.
According to a further embodiment, the system according to the invention is distinctive in that the second tab is formed by a punched part of the central flange of the intermediate metal profile, and that the second tab is connected to the central flange along a folding line and is folded to an outside position on the central flange. At the second profile, the most important condition is that two opposite flanges are placed. The profile may thus have different profile shapes, as the flange element connecting the two different flanges may be placed centrally, askew or at one side.
According to a further embodiment, the system according to the invention is distinctive in that the second profile is a U-, H- or Z-shaped profile. It is merely important that two opposite flanges are established.
According to a further embodiment, the system according to the invention is distinctive in that the lattice girder is mounted to the transversal foundation metal profile via a pole plate comprising two opposite fifth guide profiles. In the roof structure, the above pole plate is used for fixing the lattice girder to the transversal foundation metal profile. As two opposite fifth guide profiles are used, the pole plate can also be manufactured in advance.
The pole plate may be joined around the lattice girder in advance or joined on-site, depending on what is more appropriate. By joining the two opposite guide profiles of the pole plate around the lattice girder on-site, there is a smaller space requirement when transporting the lattice beams compared to lattice girders which are premounted for forming the roof profile.
In a pitched roof, opposite guide profiles are also used for the mutual connection of the two lattice girders at the top where two lattice girders abut each other.
According to a further embodiment, the system according to the invention is distinctive in that the two opposite flanges of the intermediate metal profile comprise connecting means provided with a predefined mutual distance for cooperating with corresponding connecting means on the mounting guide profile.
As the intermediate metal profile used for the posts is provided with connecting means having a predefined mutual distance, it is possible to place the horizontal profiles with the distance corresponding to the mutual distance between the connecting means, or alternatively by placing the horizontal profiles between every second or third connection means in a intermediate metal profile.
This ensures correct mounting of the horizontal profiles. The connecting means used between the horizontal profiles and the intermediate metal profiles can be of the type described in a pending patent application submitted by the same inventor as the present invention.
The mounting guide profile used for the horizontal profiles, at the outside facing away from the wall structure, is provided with connecting means to which cladding elements for an external or internal facade can be mounted.
According to a further embodiment, the system according to the invention is distinctive in that a first angle bracket is fixed to posts for fixing of horizontal frame profiles for mounting of windows and doors in the wall structure, the first angle bracket comprising coupling means that cooperate with corresponding coupling means at the end of the horizontal frame profile.
As windows and doors often require special frames, it is advantageous for the posts to have angle brackets. To this end, horizontal frame profiles may be fixed, which are used at the top or bottom of a window or a door. This first angle bracket has coupling means which cooperate with corresponding coupling means at the end of the horizontal frame profile.
It is preferred that the horizontal frame profiles are identical to the intermediate metal profile. The profiles can thus be provided with holes corresponding to the holes in the second tab on the intermediate metal profile. To this end, the first angle bracket will advantageously be manufactured with resilient tabs designed for engagement with the holes on the horizontal frame profiles.
A reverse design, wherein the tabs are a part of the horizontal frame profiles and the holes are provided on the angle brackets, is also possible.
Although it is easy to have the resilient tabs placed on a central flange, it will also be possible to place the resilient tabs on two side flanges in a U-shaped profile. In this way, a coupling can be achieved of greater strength, as more tabs can be used for the coupling of guide profiles, regardless whether it is the first, second or mounting guide profile.
According to a further embodiment, the system according to the invention is distinctive in that between two horizontal frame profiles, at least one vertical frame profile for mounting of windows and doors is mounted, which has a smaller width than the distance between two posts in the wall structure, and in that on a horizontal frame profile, a second angle bracket for fixing of the vertical frame profile is mounted, the second angle bracket comprising coupling means that cooperate with corresponding coupling means at the end of the vertical frame profile.
In order to be able to mount windows or doors having a smaller width than the distance between two subsequent posts in the wall structure, at least one vertical frame profile is placed between two horizontal frame profiles located above each other.
Alternatively, a vertical frame profile can also be placed between a horizontal frame profile and a transversal roof metal profile or a transversal foundation metal profile. This depends on where the building opening is placed. On the second frame profile, a second angle bracket is mounted, to which the vertical frame profile can be fixed. The second angle bracket will preferably be designed with a C-shape or hook shape, so that it can be swung over the horizontal frame profiles and be displaced along these. In this way, it becomes possible to adjust the size of the wall opening formed in the wall structure. The second angle bracket comprises coupling means which cooperate with corresponding coupling means in the vertical frame profiles.
According to a further embodiment, the system according to the invention is distinctive in that the second angle bracket is U-shaped in order to be able to be swung over the horizontal frame profile and to be able to be displaced along this to a desired position in relation to the vertical frame profile, and in that it comprises a third tab which is folded so as to be located under an angle in relation to the horizontal frame profile, and which comprises the coupling means.
As mentioned, the displacement will enable a more flexible size of the building opening that can be formed in the wall structure.
If the displaceable horizontal frame profile is designed with a tab which is folded so as to be located under an angle in relation to the horizontal frame profile while at the same time comprising coupling means in the form of a hole, it will likewise be possible to establish the joint between the horizontal frame profiles and the vertical frame profiles by using the resilient tab already mentioned in connection with the other guide profiles.
A system according to the invention thus makes it possible to establish a very simple system, wherein the coupling of different elements can take place using similar or completely identical elements.
It is also possible that both vertical and horizontal frame profiles can be identical and that these vertical and horizontal frame profiles can be identical to the dividing profiles used for posts and/or for the transversal roof metal profiles and transversal foundation metal profiles of the wall structure.
It will thus be very simple to manufacture the guide profiles for the building structure.
It is preferred that guide profiles for transversal roof metal profile and transversal foundation metal profile are constituted by steel profiles.
In the system according to the invention, it is possible that between the horizontal profiles, mounting profiles are placed which are pre-fabricated and which are used for the mounting of e.g. socket outlets. Such socket outlet profiles may be manufactured with punched holes and may be provided with profiles, in which connecting means in the form of tabs are provided, which can be folded around the flanges of the horizontal profiles, so that the use of tools can be avoided here as well when mounting the socket outlet profiles.
When constructing the roof structure, a sixth guide profile can be used to form struts/battens.
By manufacturing such sixth guide profiles with mutual well-defined openings, wherein the lattice beams can be received, these rafters/struts may be used to ensure correct mutual positioning of the lattice girders of the roof structure.
It should be noted that the lattice beams can be mounted in a pole plate in such a way that they are extended beyond the pole plate, whereby an overhang for the building can be formed. At the outer end of the opposite fourth guide profiles of the lattice beams, a connection profile will be provided, which offers the possibility to mount different facade elements, fascia boards and similar on the overhang.
It should be noted that the lattice beams used in the roof structure can also be used as a floor structure. Lattice girders can thus be placed under a floor in the building structure and thereby form a cavity for drainage installations for sewers similar.
The floor structure can be provided by lattice girders being placed within foundation blocks on which the transversal roof metal profile is placed. The structure may be manufactured so that a crawl space is established under the lattice beams or in such a way that the lattice beams are laid on a poured foundation.
In an aspect of the invention the system is a system for construction of a building comprising exterior walls according to any of the previously described exterior walls.

DESCRIPTION OF THE DRAWINGS

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

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

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

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

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

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

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

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

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

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

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

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

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,

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

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

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

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

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

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

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

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

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

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

DETAILED DESCRIPTION OF THE INVENTION

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.
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.
In this embodiment the building 11 further comprises a roof structure 18.
In the building 11 shown, a window opening 19 is furthermore defined.
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).
Above the foundation, a vapour seal 2 is placed. This is preferably an EPDM rubber membrane. It preferably has a thickness of 5 mm.
This vapour seal can be used for levelling any unevenness for transversal roof metal profile 14 placed on top.
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.
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.
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.
In the design shown, a powerboard 7 has been used as facade cladding 5.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
FIG. 25 shows the transversal foundation metal profile 14, wherein tabs 24 are provided with mutual spacing.
FIG. 26 discloses a wall section wherein the metal profiles 9, 13, 14, 15 comprise identification means 66.
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.
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.
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.
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

1.
2. Vapour seal above the foundation
3. Insulation between the outer and inner foundation
4. Foundation block
5. Facade cladding
6. Mounting guide profile
7. Power board
8. Wall
9. Strut
10. Vapour barrier
11. Building
12. Foundation
13. Transversal roof metal profile
14. Transversal foundation metal profile
15. Intermediate metal profile
16. Horizontal profile
17. Exterior wall
18. Roof structure
19. Window opening
20. Inner wall
21. Outer wall
22. Distance profile
23. Fire-resistant layer
24. Tab
25. Vertical flange
26. Horizontal flange
27. Hole in the tab
28. Resiliently spring tab
29, 30. Flange
31. Central flange
32. Central part
33. Insulation material
34. Cavity
35. Socket outlet profile
36. Folded tab
37. First angle bracket
38. Horizontal frame profile
39. Hole in the horizontal frame profile
40. Vertical frame profile
41. Second angle bracket
42. First flange
43. Intermediate flange part
44. Third flange part
45. Folded part
46. Opening
47. Folding line
48. Lattice beam
49. Fourth guide profile
50. Fifth guide profile
51. Pole plate
52. Folded plate profile
53. Seventh guide profile
54. Sixth guide profile
55. Sixth guide profile opening
56. Overhang
57. Connection profile
58. C-profile
59. Inside surface of inner wall
60. Incisions
61. Lateral perforations
62. Outer sheathing
63. Inner sheathing
64. Outside surface of outer wall
65. Connection means
66. Identification means
67. Gap

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)