System and method for constructing modular wall structures

Abstract

A modular wall assembly structure capable of withstanding adverse external forces such as extreme weather conditions is disclosed. The modular structure is formed from a plurality of substantially parallel framing studs. A wallboard panel is affixed to the framing studs, and a support component is attached to the rear side of the framing studs to provide tensile strength to the wall structure. The modular wall assembly structure can be used to prepare solid wall panels, window panels, door panels, and corner panels. The wall assembly structure is sufficiently strong to withstand hurricane force winds without being destroyed. A method for constructing a modular wall exterior wall structure is also provided.

1 . A modular exterior wall assembly structure capable of withstanding adverse external forces, the wall modular assembly comprising: 
 a plurality of framing studs having a front side, a rear side, a top end, and a bottom end, wherein the framing studs are arranged in a substantially parallel orientation relative to one another;    at least one wallboard panel comprising a force resistant layer and a top layer that is adhered to the force resistant layer, wherein the force resistant layer is affixed to the front side of the plurality of framing studs; and    at least one support component attaching to the rear side of the framing studs in a substantially orthogonal orientation relative to the framing studs, the support component located at substantially the mid-point between the top end and bottom end of the framing studs, the support component providing tensile support for the framing studs.    
   
   
       2 . The modular wall assembly structure according to  claim 1 , wherein: 
 each of the framing studs has not more than two openings, each opening having an area no larger than about  6  square inches, wherein the openings provide an increased structural strength to the wall assembly structure; and    each framing stud has a surface area of about  4 . 5  square feet.    
   
   
       3 . The modular wall assembly structure according to  claim 1 , wherein the maximum stud separation for the framing studs is about  16  inches, wherein the maximum stud separation provides an increased structural strength to the wall assembly structure.  
   
   
       4 . The modular wall assembly structure according to  claim 1 , further comprising a top track affixed to the top end of the framing studs, the top track for maintaining the framing studs in a substantially parallel orientation.  
   
   
       5 . The modular wall assembly structure according to  claim 4 , further comprising an angle iron attached to the top track, the angle iron for supporting a roof truss.  
   
   
       6 . The modular wall assembly structure according to  claim 1 , further comprising a bottom track affixed to the bottom end of the framing studs, wherein the bottom track receives securing means for anchoring the wall assembly to a fixed location.  
   
   
       7 . The modular wall assembly structure according to  claim 6 , wherein the securing means comprises: 
 at least two anchor attachments for securing opposite ends of the bottom track to the fixed location; and    at least two screw attachments for securing the bottom track to the fixed location, the two screw attachments attached adjacent to at least one of the framing studs.    
   
   
       8 . The modular wall assembly structure according to  claim 7 , wherein the anchor attachments further comprise a washer for further stabilizing the bottom track to the fixed location.  
   
   
       9 . The modular wall assembly structure according to  claim 7 , wherein the fixed location is a monolithic slab.  
   
   
       10 . The modular wall assembly structure according to  claim 8 , wherein the washer is a square washer having a side length of at least 3 inches and a thickness of at least 0.25 inches.  
   
   
       11 . The modular wall assembly structure according to  claim 1 , wherein the structure is free of wood-containing materials.  
   
   
       12 . The modular wall assembly structure according to  claim 1 , wherein the framing studs are constructed from galvanized steel.  
   
   
       13 . The modular wall assembly structure according to  claim 1 , wherein the top layer of the wallboard panel is constructed of a cementous material.  
   
   
       14 . The modular wall assembly structure according to  claim 1 , wherein the force resistant layer is constructed from galvanized steel and provides an increased resistance to in-plane loads.  
   
   
       15 . The modular wall assembly structure according to  claim 1 , wherein the support component, the top track, the bottom track, and the framing studs are constructed from steel.  
   
   
       16 . The modular wall assembly structure according to  claim 1 , wherein the support component is affixed to each of the framing studs using a minimum of three screws.  
   
   
       17 . The modular wall assembly structure according to  claim 15 , wherein the support component is a metal bracing strap having a width of about 6 inches.  
   
   
       18 . The modular wall assembly structure according to  claim 1 , wherein the wall assembly structure is a solid wall panel, a window panel, a panel adjacent to a window, a door panel, a panel adjacent to a door, or a corner panel.  
   
   
       19 . The modular wall assembly structure according to  claim 1 , wherein: 
 the wall assembly structure comprises four framing studs, each separated by about 16 inches; and    the wall assembly structure is about 4 feet long.    
   
   
       20 . The modular wall assembly structure according to  claim 1 , wherein the wall assembly structure is capable of passing the High-Velocity Hurricane Building Zone code requirements of Miami-Dade County (Florida).  
   
   
       21 . A method of constructing a modular exterior wall structure capable of withstanding extreme environmental conditions, the modular exterior wall structure comprising a wallboard panel having a force resistant layer, a support component, and a plurality of substantially parallel oriented framing studs, the method comprising the steps of: 
 (a) distributing the framing studs at a predetermined horizontal separation distance;    (b) attaching the wallboard panel to the framing studs;    (c) attaching a top and bottom track to each end of the framing studs to maintain the framing studs in a substantially parallel relationship; and    (d) attaching a support component at a substantially central location between the top and bottom end of the framing studs.    
   
   
       22 . The method according to  claim 21 , further comprising the step of: 
 (e) securing the bottom track to a foundation using a plurality of fixture components, the fixture components comprising:    at least two wedge anchors driven into the foundation at each end of the bottom track; and    at least two screw devices driven into the foundation adjacent to a framing stud which is not located at either end of the wall structure.    
   
   
       23 . The method according to  claim 22 , further comprising the step of: 
 (f) coupling an end stud located at one end of the wall assembly structure with a respective end stud associated with a second wall structure constructed in accordance with steps (a)-(d) to obtain an exterior wall formed from a plurality of modular wall assembly structures.    
   
   
       24 . The method according to  claim 23 , further comprising the step of: 
 (g) coupling an angle iron to the top track of the a modular exterior walls for maintaining straight line alignment between the plurality of modular exterior walls.    
   
   
       25 . The method according to  claim 24 , wherein the foundation is a monolithic slab.  
   
   
       26 . The method according to  claim 21 , wherein the framing studs are formed from steel.  
   
   
       27 . A modular exterior wall assembly structure capable of passing the High-Velocity Hurricane Building Zone code requirements of Miami-Dade County (Florida).  
   
   
       28 . The modular exterior wall assembly structure according to  claim 27 , wherein the wall assembly structure comprises a plurality of framing studs, a wallboard panel, and a support component.