# US 8,769,891 B2 · Building method using multi-storey panels > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,769,891 B2 - Document ID: US8769891B2 - Status: Granted - Kind: B2 - Application number: 14/003,553 - Filed: 2012-04-04 - Published: 2014-01-16 - Granted: 2014-07-08 - Earliest claimed: 2011-04-05 - Applicants: Ian Kelly - Inventors: Ian Kelly - Web page: https://patentgrep.com/patent/US8769891B2 ## CPC - E04C 2/46: {specially adapted for making walls (E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72)} - E04B 1/08: the elements consisting of metal - E04B 1/14: the elements being composed of two or more materials (of reinforced concrete E04B1/04) - E04B 1/161: {with vertical and horizontal slabs, both being partially cast in situ} - E04B 1/3505: {characterised by the in situ moulding of large parts of a structure (E04B1/3511, E04B1/3516, E04B1/3522, E04B1/3533, E04B1/3544, E04B1/355 take precedence)} - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) ## Abstract A method is provided for erecting a multi-story building on a foundation using a plurality of pre-manufactured multi-story wall panels. A plurality of wall panels are erected on the foundation to form a perimeter of wall panels which extend vertically to span two or more stories of the building. A plurality of floor joists are joined between multi-story wall panels to extend generally horizontally therebetween. Optionally, once erected, concrete can be placed between the studs of the wall panels and in channels between joists. Various methods and materials for finishing the exterior side of the wall panels and reinforcing the wall panels and the joists are also provided. ## Claims ### Claim 1 A method of erecting a multi-story building on a foundation, the method comprising: forming a plurality of wall panels, each wall panel comprising spaced apart vertical studs and exterior sheathing material spanning at least an exterior side of the studs; erecting the wall panels on the foundation to form a perimeter of wall panels, at least some of the perimeter wall panels being multi-story wall panels extending vertically to span two or more stories of the building; joining a plurality of floor joists to the multi-story wall panels to extend generally horizontally therefrom, the floor joists being joined to the multi-story wall panels at an intermediate location between top and bottom ends thereof; placing a barrier member in a channel space between adjacent joists, a top of the barrier member being recessed to define an upper recess between the top of the barrier member and a top plane of the joists; and filling at least the upper recess with concrete to encase the top of the adjacent joists for forming an upper floor surface of concrete. ### Claim 2 (depends on 1) The method of claim 1 wherein the joining of floor joists further comprising extending the joists generally horizontally between opposing multi-story panels of the one or more one multi-story panels. ### Claim 3 (depends on 1) The method of claim 1 further comprising, after joining the floor joists, applying interior sheathing material to an interior side of the wall panels. ### Claim 4 (depends on 1) The method of claim 1 wherein the forming of the plurality of wall panels further comprises: applying an exterior rigid insulation layer over the exterior sheathing material; and applying a base layer of finishing material over the rigid insulation layer. ### Claim 5 (depends on 4) The method of claim 4 wherein after erecting the wall panels on the foundation, applying a final finishing layer to the base layer. ### Claim 6 (depends on 5) The method of claim 5 wherein prior to applying the final finishing layer, caulking vertical seams between adjacent wall panels at the exterior side of the panels. ### Claim 7 (depends on 1) The method of claim 1, wherein prior to joining a plurality of floor joists to the multi-story panels, further comprising forming a plurality of floor panels by incorporating the floor joists; and joining the floor joists of the floor panels to the studs of the multi-story wall panels. ### Claim 8 (depends on 1) The method of claim 1, further comprising filling spaces between the studs of the wall panels with concrete. ### Claim 9 (depends on 8) The method of claim 8 wherein the forming of the plurality of wall panels further comprises, between the studs and the exterior sheathing material, applying a plurality of spacer members arranged perpendicular to the studs and spanning therebetween, each spacer member spaced vertically from each other spacer member; wherein the filling of the spaces between the studs at least partially encases the studs with concrete. ### Claim 10 (depends on 1) The method of claim 1, wherein at least a lower portion of at least some of the wall panels are below grade, further comprising: filling spaces between the studs of at least the lower portion of said wall panels with concrete. ### Claim 11 (depends on 10) The method of claim 10 wherein at least a lower portion of at least some of the wall panels are below grade, further comprising: installing a moisture resistant membrane on the exterior side of the lower portion of the exterior sheathing prior to erecting the panels. ### Claim 12 (depends on 1) The method of claim 1 wherein the forming of the upper floor surface of concrete further comprises filling spaces between the studs of the wall panels with concrete. ### Claim 13 (depends on 1) The method of claim 1 further comprising a barrier member of rigid insulation. ### Claim 14 (depends on 1) The method of claim 1 further comprising supporting each barrier member with ceiling sheathing spanning across a bottom of the joists. ### Claim 15 (depends on 1) The method of claim 1 wherein prior to joining the plurality of floor joists to the multi-story panels, further comprising: forming a plurality of floor panels by incorporating the floor joists; and placing the barrier member in a channel space between adjacent joists of the floor panels for supporting the concrete of the upper floor surface, the top of the barrier member being recessed to define the upper recess between the top of the barrier member and the top plane of the joists, supporting the barrier members with ceiling sheathing spanning across a bottom of the joists; and joining the floor joists of the floor panels to the studs of the multi-story wall panels. ### Claim 16 A method of erecting a multi-story building on a foundation, the method comprising: forming a plurality of wall panels, each wall panel comprising spaced apart vertical studs and exterior sheathing material spanning at least an exterior side of the studs; erecting the wall panels on the foundation to form a perimeter of wall panels, at least some of the perimeter wall panels being multi-story wall panels extending vertically to span two or more stories of the building; extending a plurality of floor joists generally horizontally between opposed multi-story wall panels at an intermediate location between top and bottom ends of the opposed wall panels; and joining opposing ends of each floor joist of the plurality of floor joists directly to respective studs which are aligned with each other in the opposed wall panels, each opposing end overlapping a side of its respective stud, fasteners extending through the overlapping opposing end for joining to its respective stud for joining the joist thereto. ### Claim 17 (depends on 16) The method of claim 16 wherein the joining of floor joists comprising extending the joists generally horizontally between the respective studs of the opposed one or more one multi-story panels. ### Claim 18 (depends on 16) The method of claim 16 further comprising, after joining the floor joists, applying interior sheathing material to an interior side of the wall panels. ### Claim 19 (depends on 16) The method of claim 16 wherein the forming of the plurality of wall panels further comprises: applying an exterior rigid insulation layer over the exterior sheathing material; and applying a base layer of finishing material over the rigid insulation layer. ### Claim 20 (depends on 19) The method of claim 19 wherein after erecting the wall panels on the foundation, applying a final finishing layer to the base layer. ### Claim 21 (depends on 20) The method of claim 20 wherein prior to applying the final finishing layer, caulking vertical seams between adjacent wall panels at the exterior side of the panels. ### Claim 22 (depends on 16) The method of claim 16, wherein prior to joining a plurality of floor joists to the multi-story panels, further comprising forming a plurality of floor panels by incorporating the floor joists; and joining the floor joists of the floor panels to the studs of the multi-story wall panels. ### Claim 23 (depends on 16) The method of claim 16, further comprising filling spaces between the studs of the wall panels with concrete. ### Claim 24 (depends on 23) The method of claim 23 wherein the forming of the plurality of wall panels further comprises, between the studs and the exterior sheathing material, applying a plurality of spacer members arranged perpendicular to the studs and spanning therebetween, each spacer member spaced vertically from each other spacer member; wherein the filling of the spaces between the studs at least partially encases the studs with concrete. ### Claim 25 (depends on 16) The method of claim 16, wherein at least a lower portion of at least some of the wall panels are below grade, further comprising: filling spaces between the studs of at least the lower portion of said wall panels with concrete. ### Claim 26 (depends on 25) The method of claim 25 wherein at least a lower portion of at least some of the wall panels are below grade, further comprising: installing a moisture resistant membrane on the exterior side of the lower portion of the exterior sheathing prior to erecting the panels. ### Claim 27 (depends on 16) The method of claim 16, further comprising forming an upper floor surface of concrete spanning over the joists. ### Claim 28 (depends on 27) The method of claim 27 wherein the forming of an upper floor surface of concrete further comprises filling spaces between the studs of the wall panels with concrete. ### Claim 29 (depends on 27) The method of claim 27, wherein forming an upper floor surface of concrete spanning over the joists further comprises: placing a barrier member in a channel space between adjacent joists for supporting the concrete of the upper floor surface, a top of the barrier member being recessed to define an upper recess between the top of the barrier member and a top plane of the joists, and filling at least the upper recesses with concrete to encase at least the top of the joists. ### Claim 30 (depends on 29) The method of claim 29 wherein the barrier member is rigid insulation. ### Claim 31 (depends on 27) The method of claim 27 wherein prior to joining a plurality of floor joists to the multi-story panels, further comprising: forming a plurality of floor panels by incorporating the floor joists; and placing a barrier member in a channel space between adjacent joists for supporting the concrete of the upper floor surface, a top of the barrier member being recessed to define an upper space between the top of the barrier member and a top plane of the joists, supporting the barrier members with ceiling sheathing spanning across a bottom of the joists; and joining the floor joists of the floor panels to the studs of the multi-story wall panels. ### Claim 32 (depends on 16) The method of claim 16 further comprising supporting each barrier member with ceiling sheathing spanning across a bottom of the joists. ### Claim 33 A method of erecting a multi-story building on a foundation, the method comprising: forming a plurality of wall panels, each wall panel comprising spaced apart vertical studs and exterior sheathing material spanning at least an exterior side of the studs; erecting the wall panels on the foundation to form a perimeter of wall panels, at least some of the perimeter wall panels being multi-story wall panels extending vertically to span two or more stories of the building; forming a plurality of floor panels by incorporating a plurality of floor joists; placing a barrier member in a channel space between adjacent joists, a top of the barrier member being recessed to define an upper space between the top of the barrier member and a top plane of the joists, forming an upper floor surface of concrete spanning over the joists, the barrier member supporting the concrete of the upper floor surface; supporting the barrier members with ceiling sheathing spanning across a bottom of the joists; and joining the plurality of floor joists to the multi-story wall panels to extend generally horizontally therefrom, the floor joists being joined to the multi-story wall panels at an intermediate location between top and bottom ends thereof.