U.S. patent application number 09/819995 was filed with the patent office on 2002-01-17 for pre-cast concrete panels for construction of a building.
Invention is credited to Khoo, Tian.
Application Number | 20020005021 09/819995 |
Document ID | / |
Family ID | 19749721 |
Filed Date | 2002-01-17 |
United States Patent
Application |
20020005021 |
Kind Code |
A1 |
Khoo, Tian |
January 17, 2002 |
Pre-cast concrete panels for construction of a building
Abstract
Pre-cast concrete panels bodies for constructions in building
industry and a method of construction of structure using the
pre-cast panel bodies is disclosed. The pre-cast concrete panels
bodies includes pre-cast beams (3) at an upper edge and at least
one bore (6) extending longitudinally from one end to the other.
The bore is adapted to receive starter bars (16) reinforcement
steel bars (19), wires, pipes or concrete. The upper edges of the
panel bodies include cornices (4) casted simultaneously with the
casting of the panel body. All the pre-cast concrete panels and
pre-cast concrete slabs (26) are interlocked together by the
introduction of steel bars (28) through links (8) extending from
the pre-cast concrete panels, adding wires mesh (38) and top bars
(40) on the pre-cast concrete slab and pouring concrete over the
steel bars, wire mesh and top bars to provide a sturdy
structure.
Inventors: |
Khoo, Tian; (Taman Desa,
MY) |
Correspondence
Address: |
TOWNSEND AND TOWNSEND AND CREW
TWO EMBARCADERO CENTER
EIGHTH FLOOR
SAN FRANCISCO
CA
94111-3834
US
|
Family ID: |
19749721 |
Appl. No.: |
09/819995 |
Filed: |
March 28, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09819995 |
Mar 28, 2001 |
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09011420 |
Apr 30, 1998 |
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6223480 |
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Current U.S.
Class: |
52/86 ; 52/234;
52/236.9; 52/240; 52/241; 52/250; 52/251; 52/300; 52/600; 52/606;
52/648.1; 52/650.1; 52/651.07; 52/745.05; 52/745.09; 52/745.17;
52/783.1; 52/795.1 |
Current CPC
Class: |
E04B 1/04 20130101; E04C
2002/008 20130101; E04B 5/043 20130101; B28B 7/02 20130101; E04C
2/044 20130101 |
Class at
Publication: |
52/86 ; 52/234;
52/236.9; 52/240; 52/241; 52/250; 52/251; 52/300; 52/600; 52/606;
52/783.1; 52/795.1; 52/648.1; 52/650.1; 52/651.07; 52/721.1;
52/721.2; 52/724.1; 52/745.05; 52/745.09; 52/745.17 |
International
Class: |
E04B 001/32; E04H
001/00; E04H 003/00; E04H 005/00; E04H 006/00; E04H 014/00; E04B
001/00; E04H 012/00; E04C 002/04; E04B 005/04; E04C 003/34; E04G
021/00; E04G 023/00; E04C 002/54; E04C 002/34 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 7, 1996 |
SG |
PCT/SG96/00012 |
Sep 8, 1995 |
MY |
PI9502668 |
Claims
1. Pre-cast concrete panel for the construction in building
industry characterised in that each pre-cast concrete panel
consists of concrete panel body with pre-cast concrete beam at an
upper edge, and at least one bore (6) extending longitudinally from
one end to the other, wherein said bore is adapted to receive
starter bars (16), reinforcement steel bars (19) wires, pipes or
concrete.
2. Pre-cast concrete panel for construction in building industry as
claimed in claim 1 wherein the upper edges of the pre-cast concrete
panel body includes cornices casted simultaneously with the casting
of the concrete panel body.
3. Per cast concrete panel for construction in building industry as
claimed in claim 1 wherein the pre-cast concrete panel body
includes door opening (10) or window opening (12) on the planar
surface.
4. Pre-cast concrete panel of construction in building industry as
claimed in claim 1 wherein the pre-cast concrete panel body indudes
cornices, patterns, impressions, abutments (14) all casted
simultaneously with the casting of the concrete panel body.
5. Pre-cast concrete panel for construction of building industry as
claimed in any of the claims 1 to 4 characterised in that the
pre-cast concrete panel body includes a longitudinal recess
extending from one end to the other end, on at least one terminal
end of the pre-cast concrete wall panel body.
6. Pre-cast concrete panel for construction in building industry
characterised in that pre-cast concrete panel consists of a
rectangular pre-cast concrete slab comprising of pre-cast concrete
beam (34) along the perimeter of the slab and a recess at central
region of the concrete slab.
7. A system of constructing structures using pre-cast concrete
panel characterised in that the pre-cast concrete panel are
selected from one or more of the following: a) `I` shaped panel in
cross section and `I` shaped panel with door or window opening. b)
`L` shaped panel and `L` shaped panel with door or window opening
c) `T` shaped panel and `T` shaped panel with door or window
opening d) `cross` cross-sectional shaped panel and `cross`
cross-sectional panel with door or window opening and wherein the
panels consist of concrete panel body, with or without pre-cast
concrete beam at an upper edge, and at least one bore extending
longitudinally from one end to the other, the said bore is adapted
to received starter bards (16) reinforcement steel bars (19),
wires, pipes or concrete.
8. A system of constructing structures using pre-cast concrete
pane) body which is supported by at least two cast in situ columns
at both ends of the panel body.
9. A system of constructing structures using pre-cast concrete
panel as claimed in any of the claims 1 to 6 wherein a plurality of
adjacently disposed bores of the panel are in-filled with
reinforcement steel bars and concrete to form cast in-situ columns
and wherein the columns so formed, as a substitution of a single
big column.
10. A system of constructing structures incorporating a pre-cast
concrete wall panels characterised in that longitudinal recess
extending from one end to the other end of one pre-cast concrete
wall panel is aligned apposite to a corresponding recess in another
panel in linear alignment with the former.
11. A system of constructing structures incorporating pre-cast
concrete panel as claimed in claims 1 to 5 and pre-cast concrete
slab as claimed in claim 6 wherein all the pre-cast concrete panel
and pre-cast concrete slabs are interlocked together by the
introduction of steel bars through he links extending from the
pre-cast concrete beam of the pre-cast concrete panel, adding wire
mesh and top bars on the pre-cast concrete slab and pouring
concrete over the steel bars, wire mesh and top bars.
12. A method of constructing structures consisting of pre-cast
concrete panel characterised in that the method consists one or
more of the following steps: a) casting a ground floor concrete
with starter steel bars at pre determined positions b) constructing
concrete kicker at pre determined positions c) positioning pre-cast
concrete panel over the casted concrete kicker and starter steel
bars d) introducing steel reinforcement bars into selected bores of
the pre-cast concrete panel e) introducing concrete into the bores
selected in step (d) above f) positioning pre-cast concrete slab
over the pre-cast concrete panel. g) inserting steel bars through
steel links extended from pre-cast concrete beam of the pre-cast
concrete panel h) introducing wire mesh on top of the pre-cast
concrete slab and introducing top steel bars over the steel bars
introduced in step (g) above and across two adjacent pre-cast
concrete slabs. i) introducing concrete to cover the wire mesh and
top bars
13. A method of constructing structures consisting of pre-cast
concrete panel as claimed in claim 12 consisting the further step
of introducing `U` shaped steel bars linking two adjacent bores in
the re cast concrete panel and thereafter introducing concrete into
the bores.
14. A method of constructing structures consisting of pre-cast
concrete panel as claimed In claim 12 wherein the pre-cast concrete
panel between two fixed positions include `I` shaped panels in
cross-section and/or `I` shaped panels with door or window opening
and wherein the `I` shaped panels can be of different lengths and
are casted from the same formwork mould.
15. A system of constructing structures incorporating pre-cast
concrete panels characterised in that reinforced concrete beams
comprise of a first part consisting of pre-cast concrete beams at
an upper edge of the pre-cast concrete panel and a second part
consisting of cast in situ concrete beams and wherein the first and
second part are inter-linked to form a solitary concrete beam
structure.
16. A system of constructing structures incorporating pre-cast
concrete panels as claimed in claim 15 above where the reinforced
concrete beams further include a third part consisting of pre-cast
concrete beam of a pre-cast concrete slab wherein the first, second
and third parts are inter-linked to form a solitary concrete beam
structure.
17. A structure consisting of pre-cast concrete panel consisting of
panels according to any of the claims 1 to 6.
18. A structure consisting of pre-cast concrete panel constructed
according to any of the claims 7 to 14.
Description
[0001] The invention relates to set of pre-cast concrete panels for
construction of a building and a method of using the same in the
building industry.
[0002] In building construction, it is often necessary to construct
the structural frame work, floor slab and followed by the erection
of in-fill panels (normally they are brick walls). Thereafter
additional construction work has to be done in the installation of
electrical wires, gas and water plumbing connections and eternal
wall furnishing of the building has to be completed. All these
require skilled workers and are time consuming and is expensive.
The mould formwork set for pre-cast concrete industries in prior
art is expensive because a specific mould only can be used for a
particular project.
[0003] The objectives of this invention are to mitigate these
disadvantages by the use of various types of pre-cast concrete
panels, adoption of a universal mould formwork set and the adoption
of a new system of construction of a building using the pre-cast
concrete panels.
[0004] According to the first aspect of the invention, the pre-cast
concrete wall panels comprise of:
[0005] 1. `I` shape panels (straight line in cross-section width
wise) and `I` shape panels with door or window opening,
[0006] 2. `L` shape panels and `L` shape panels with door or window
opening,
[0007] 3. `T` shape panels and `T` shape panels with door or window
opening,
[0008] 4. `Cross` shape cross-sectional panels and `Cross` shape
cross-sectional panels with door or window opening on one or more
sides.
[0009] According to a second aspect of the invention, the pre-cast
concrete wall panels, include a pre-cast concrete beam and a
pre-cast concrete cornice finishing at one edge.
[0010] According to a third aspect of the invention, a plurality of
steel links extend from the pre-cast concrete beam of the pre-cast
concrete panels. An interlocking system of reinforced concrete
beams if formed by the insertion of reinforcement steel bars
through the links and the pouring in-situ concrete to construction
joints formed by pre-cast concrete slabs and pre-cast concrete
beams of the pre-cast concrete wall panels.
[0011] According to a fourth aspect of the invention, the length of
`I` shape pre-cast concrete wall panel can be adjusted at the
construction stage to comply with the architectural and engineering
requirements by adjusting the edge formwork of moulding formwork
set. The arms of `L` shape, `T` shape and `Cross` shape panels can
also be adjusted if necessary, but normally they are constant in
single size.
[0012] According to a fifth aspect of the invention, the pre-cast
concrete slab includes recesses at the central region of the slab
panel and pre-cast concrete beams along the perimeter of the slab
panel.
[0013] According to a sixth aspect of the invention, the sizes of
the pre-cast concrete slab panels can be adjusted at the casting
stage to comply the architectural and structural requirements.
[0014] According to seventh aspect of the invention, the height of
the pre-cast beam of the pre-cast concrete slab panel can be
adjusted at the casting stage to comply with the structural
engineering requirements.
[0015] Hollow cores extend longitudinally from one end to the other
in the pre-cast wall and in the pre-cast slab panel. The hollow
cores are designed to accommodate structural, mechanical and
electrical requirement. A reinforced concrete column is formed in a
bore by inserting reinforcement steel bars into the hollow core of
the pre-cast concrete panel and thereafter in-filled with
cast-in-situ concrete.
[0016] Walls can be erected and supported by introducing
reinforcement steel bars and in-fill cast-in-situ concrete into the
cores at both ends of the pre-cast concrete wall panels or by
introducing reinforcement steel bars and in-fill cast-in-situ
concrete to longitudinal recesses which form core when two pre-cast
walls are placed in straight-line alignment to each other.
[0017] It would understood that the cores can be provided to `T`
shape, `L` shape and `cross` shape pre-cast concrete panels but
cores may not be necessary to pre-cast concrete wall panels like
`I` shape (straight in cross section). The `I` shape pre-cast
concrete panel may be provided with longitudinal recesses at the
both ends of the panel without any cores in between.
[0018] The structural linking of pre-cast concrete wall panels and
pre-cast concrete slab panels is carried out by introducing
reinforcement steel bars through the links extending from the
pre-cast concrete beams of the wall panels, adding wire mesh and
top bars to the top surface of pre-cast slab panels and pre-cast
beams respectively, then pouring concrete into troughs formed by
pre-cast concrete slabs and the pre-cast concrete beams to form
construction joints. For single storey building, `U` shape steel
bars are inserted into the cast in-situ concrete columns next to
each other from the two linearly aligned adjacent pre-cast concrete
wall panels.
[0019] In-fill wall panel between comers of pre-cast concrete wall
panels or between any two desired points can be obtained by using a
single panel or plural number of `I` shape straight wall panels
placed in a linear alignment to each other. The length of any panel
can be adjusted at the casting stage by sliding an adapter without
altering the moulding formwork set.
[0020] The invention will be described in detail by reference to
preferred embodiment and system of construction with reference to
accompanying drawings in which:
[0021] Fig (1A). Shows a top plan view, FIG. (1B) shows side
elevation and Fig (1C) shows section cut through a core (6) of `I`
shape (straight line in cross section) pre-cast concrete wall panel
complete with pre-cast concrete beam (2), pre-cast concrete cornice
(4) finishing and steel links. (8)
[0022] Fig (1D) shows a top plan view of a `I` shape pre-cast
concrete wall panel without any longitudinal cores within.
[0023] Fig (2A) & (2B) shows the plan and side view
respectively of the `I` shape panel as stated in Fig (1A), (1B),
(1C) & (1D) but with door opening. (10)
[0024] Fig (3A) & (3B) shows the plan and side view
respectively of the `I` shape panel as stated in Fig (1A), (1B),
(1C) and (1D) but with window opening. (12)
[0025] Fig (4A) shows a top view plan, Fig (4B) shows side
elevation and Fig (4C) shows section cut through a core of `L`
shape pre-cast concrete wall panel complete with pre-cast concrete
beam (2) and pre-cast concrete cornice (4) finishing.
[0026] Fig (5A) & (SB) shows the plan and side view
respectively of the `L` shape as stated in Fig (4A), (4B) &
(4C) but with door opening. (10) on an extended arm.
[0027] Fig (6A) shows a top view plan, Fig (6B) shows side
elevation and Fig (6C) shows section cut through a core of `T`
shape pre-cast concrete wall panel complete with pre-cast concrete
beam (2) and pre-cast concrete cornice (4) finishing.
[0028] Fig (7A) & (7B) shows the plan and side view
respectively of the `T` shape as stated in Fig (6A), (6B) &
(6C) but with door opening (10) on an extended arm.
[0029] Fig (8A) & (8B) shows the a plan and side view
respectively of a `T` shape as stated in Fig (6A), (6B) &
(6C)but with two door openings (10) on two extended arms.
[0030] Fig (9A) shows a top view plan, Fig (9B) shows side
elevation and Fig (9C) shows section cut through a core of `Cross`
shape pre-cast concrete wall panel complete with pre-cast concrete
beam (2) and pre-cast concrete cornice (4) finishing.
[0031] Fig (10) shows the section of vertical casting moulding
formwork set for casting a pair of pre-cast concrete wall panels as
above stated.
[0032] Fig (11) shows a perspective cut out view of the vertical
casting moulding framework shown in Fig (10) Fig (11A) shows an
enlarged section of an extendable adapter between two spaced apart
edge panels.
[0033] Fig (11B) shows an adjustable bottom plate for vertical
casting moulding framework set (FIG. 10)
[0034] Fig (12), (13) & (14) show a cross-sectional view of
pre-cast concrete slab panels of varying widths.
[0035] Fig (15A) illustrates the first step in constructing a wall
using pre-cast concrete walls whereby a ground floor concrete slab
is casted and starter bars are placed at pre-determined
positions.
[0036] Fig (15B) illustrates the second step after FIG. 15A whereby
concrete kicker is constructed and the level is adjusted to receive
the pre-cast concrete wall panels.
[0037] Fig (15C) shows a section A-A cut through Fig (15B)
[0038] Fig (16) shows a partially completed building wall where
pre-cast concrete wall panels show in FIGS. 1A, 1B, 1C; 4A, 4B, 4C
and 6A, 6B, 6C have been erected.
[0039] Fig (17A) shows a top plan view of the partially completed
building wall shown in FIG. 16.
[0040] Fig (17B) shows a partially completed building wall with
reinforcement steel bars in some of the hollow cares.
[0041] Fig (18) shows a sectional view of the connecting joint
between two adjacent pre-cast concrete wall panels.
[0042] Fig (18A) shows a sectional perspective view of a pre-cast
concrete wall panel and pre-cast concrete beams with a cap over a
hollow core.
[0043] Fig (18B) shows a perspective view of a cap that is designed
and configured to be placed over a hollow core.
[0044] Fig (19) shows the positioning of the pre-cast floor slabs
on the pre-cast concrete beams of the pre-cast concrete panels.
[0045] Fig (20) shows a perspective view of partially completed
building where reinforcement steel bars are introduced through the
links extending from the pre-cast concrete beam of pre-cast
concrete panels shown in Fig (19).
[0046] Fig (20A) is a perspective view of an assembly of pre-cast
concrete floor slabs positioned over a plurality of pre-cast
concrete wall panels.
[0047] Fig (21A) is a sectional view showing in detail the
positioning two adjacent pre-cast concrete floor slabs.
[0048] Fig (21B) shows two numbers of pre-cast concrete slab panels
laid on the pre-cast concrete beams of a pre-cast concrete wall
panel.
[0049] Fig (22) shows a perspective view of the assembly of wire
mesh and top bars on the pre-cast concrete floor slab before
pouring the concrete.
[0050] Fig (22A) shows a perspective view of an assembly shown in
FIG. 22.
[0051] Fig (23) shows a perspective view of two adjacent linearly
aligned pre-cast concrete walls being locked in position in single
storey building.
[0052] Fig (24A) shows top view plan of pre-cast concrete panels
combination by using two numbers of `L` shape and one number of `I`
shape whereby the length of `I` shape panel can be adjusted at the
casting stage to comply with architectural and structural
requirements.
[0053] Fig (24B) shows a side elevation view of combination of
panels shown in Fig (24A)
[0054] Fig (25A) shows the top view plan of pre-cast concrete
panels combination by using two numbers of `L` shape, two numbers
of `I` shape and one number of `T` shape panel whereby the length
of `I` shape can be adjusted at the casting stage to comply with
architectural and structural requirements in FIG. 24A.
[0055] Fig (25B) shows a side elevation view of combination of
panels shown in Fig (25A).
[0056] Fig (26A) shows top view plan of pre-cast concrete panels
combination by using one number of `cross` shape, one number of `T`
shape, one number of `L` shape and two numbers of `I` shape panel
whereby the length of `I` shape can be adjusted at the pre-casting
stage.
[0057] Fig (26B) shows a side elevation view of combination of
panels shown in Fig (26A)
[0058] Fig (27A) shows a top plan view of pre-cast concrete panels
combination by one number of `L` shape, one number of `L` shape
with door opening one number of `I` shape panel.
[0059] Fig (27B) shows a side elevation view of combination
pre-cast concrete panels shown in Fig (27A)
[0060] Fig (28A) and Fig (28B) to Fig (32A) and Fig (32B) shows
various combinations of pre-cast concrete wall panels by using same
method of combination as described from Fig24A, 24B to 27A &
27B.
[0061] Fig (33A) shows a top plan view of pre-cast concrete wall
panels combination by using two numbers of `cross` shape pre-cast
concrete panels and one number of `I` shape pre-cast concrete panel
with a recess at both sides of the panel and without cores in
between.
[0062] Fig (33B) shows a side view of the elevation combination of
pre-cast concrete wall panels shown in Fig (33A)
[0063] Fig (33C) shows section A-A view cut through the `I` shape
pre-cast concrete panel in the combination shown in Figs (33A) and
(33B).
[0064] Fig (34A), (34B) and (34C) show a same combination as Figs
(33A), (33B) and (33C) but with one core in the `cross` shape
panel.
[0065] Various modular pre-cast concrete panels will now be
described. A first pre-cast concrete panel is a planar wall with
`I` shape with or without pre-cast concrete beam (2) and pre-cast
concrete cornices (4) at the top edge (FIG. 1A, 1B and 1C). The
wall includes a plurality of evenly spaced apart cores (6)
extending from the top edge to the-bottom edge of the wall and
steel links (8). The length (x) of the pre-cast concrete wall panel
can be varied according to the structural design and architectural
requirements of the building.
[0066] A second pre-cast concrete panel is a planer wall with `I`
shape as described in FIG. 1A & 1B) but with a door opening
(10) (See FIGS. 2A & 2B). A third pre-cast concrete panel is a
`I` shaped planar wall as described in FIG. 1A, 1B & 1C) but
with a window opening (12) (See FIGS. 3A & 3B). A fourth
pre-cast concrete panel is a `L` shaped panel (See FIGS. 4A, 4B
& 4C). Each arm of `L` shape panel includes a longitudinal core
(6). The external sides (14) can be plain or patterned. The upper
edges can include pre-cast concrete beam (2) and cornices (4) or be
without the pre-cast concrete beam or cornice.
[0067] A fifth pre-cast concrete panel is `L` shape unit as
described in FIG. 4A, 4B & 4C) but with one arm extended (see
FIGS. 5A & 5B). The extended arm can include a door opening
(10) or alternatively include window opening (12). A sixth pre-cast
concrete panel is a `T` shape unit with pre-cast concrete beam and
pre-cast cornice as described in Fig 1A, 1B & 1C (see FIGS. 6A,
6B & 6C). A seventh pre-cast concrete panel is another `T`
shape unit where the middle arm in perpendicular relation to the
other arm is extended and includes a door opening (10) or
alternatively a window opening (12) as described in FIG. 1A,1B and
1C. A eighth pre-cast concrete panel is a `T` shape wall structure
with two door openings (12) (see FIG. 8A & 8B). A ninth
pre-cast concrete panel `cross` sectional columnar unit, with at
least one bore (6) in the panel (see FIGS. 9A, 9B & 9C). All
the concrete panels described above may optionally include steel
links (8) secured to the reinforcement steel bars (3) in the
concrete beam (2) of the concrete wall panels. Further all the
panels described above can be casted with or without pre-cast
concrete beams and cornices.
[0068] It will be appreciated that the individual dimensions of the
various parameters such as height, length and thickness of the
panel, shapes and designs of the window opening or door opening,
patterns on the side wall can be different depending on
architectural requirements. The combination selected from the above
described pre-cast concrete panels will form any design and any
size of a building the except some length of the `I` shaped panel
will have to adjusted at the casting stage. Pre-cast concrete panel
of other cross-sectional types can be envisaged for other
requirements. Such pre-cast concrete panels would be within the
scope of this invention.
[0069] The mould (100) comprises of a twin set of mould formworks.
Each set of mould formwork comprises of a pair of horizontally
placed but spaced apart guide plates (102) and a pair of side panel
plates (104). The vertical length of the concrete wall panel to be
casted can be varied by adjusting the height of the bottom guide
plate (102) upward and downward utilising conventional means known
to the art (see FIG. 11B). In the preferred embodiment, the bottom
guide plate (102) is raised or lowered by means of slot and bolt
means (see FIG. 11B).
[0070] The mould (100) includes a means to vary the length of the
yet to be casted concrete wall panels. The means include a pair of
vertical adapter(106) extending from the top of bottom guide plate
to under-side of top guide plate (102). A pair of shafts (108) are
introduced through the holes (110) in the horizontal guide plates
(102), top and bottom. A plurality of extendable arms (112) are
arranged spaced apart between the shaft and the vertical
adapter(106). The extendable arms (112) extend from one vertical
adapter to the other, whereby the distance apart between the
vertical adapters can be varied over a pre-determined range.
Collapsible cylindrical tubes (114) are introduced into the holes
in the horizontal guide plates. After the wire mesh was placed in
position, concrete is introduced into the mould by pouring the
concrete across the inverted V shape ledge (116). The concrete is
introduced into both sides of the inverted V shaped ledge (116)
until the moulds are field with concrete.
[0071] It will be appreciated that concrete beam (2) and various
designs such as cornices (4) and patterns (14) can be incorporated
onto the side panels (104) of the mould. An example of a pattern
incorporated into the side panels is shown in FIG. 6B and 6C. The
cornices (4) and the patterned sides (14) can be provided on one
side or on both sides.
[0072] FIG. 12, 13 and 14 shown pre-cast concrete slabs of
different lengths. Each pre-cast concrete slab is a rectangular
slab, with a concrete beam around the perimeter. The concrete beam
can include a hollow core if necessary. The perimeter edge further
includes pre-cast concrete beam (34). The heights of the concrete
beam and the corresponding depth of the recess can be adjusted at
casting stage in accordance with architectural and engineering
requirements.
[0073] In constructing a building, the pre-cast concrete panels as
stated above will be erected, supported and interlocked together by
the following methods.
[0074] Step 1. Cast the ground floor concrete (13) and extend the
starter bars (16) out at the predetermined column position (15).
Fig (15A)
[0075] Step 2. Constructed the concrete kicker (18) and adjust the
level to receive the pre-cast concrete wall panels and cast-in-situ
columns Figs(15B)(15C).
[0076] Step 3. Lift up the pre-cast concrete wall panels and erect
to the respective positions. FIG. 16.
[0077] Step 4. Insert the reinforcement steel bars (19) to the
respective cores at column positions, and complete with the in fill
concrete. Figs(17A)(17B).
[0078] Step 5. Seal up the gaps in between linearly aligned
adjacent pre-cast concrete wall panels by fitting in P.V.C gasket
(20) introducing sealant compound (22) then introducing in-fill
concrete. Figure(18). Unused hollow cores in the pre-cast concrete
wall panels are covered by inserting P.V.C caps (24) before pouring
the concrete into the mould. Figs(18A)(18B).
[0079] Step 6. Lift up the pre-cast concrete slab (26) and lay on
the pre-cast concrete beams (2) of pre-cast concrete wall panels.
Fig (19)
[0080] Step 7. Insert the reinforcement steel bars (28) through the
links (8) extending from the pre-cast concrete beam(2) of the
pre-cast concrete walls. Figure(20) and Fig (20A)
[0081] Step 8. Add the wire mesh (38) to the top of the pre-cast
concrete floor slabs and top bars (40) to the top of pre-cast
concrete beams. Figure(22) and Figure (22A)
[0082] Step 9. Pour the concrete to the assembly in Fig (22A). All
the pre-cast concrete walls, pre-cast concrete beams and pre-cast
concrete slabs will be inter-linked and interlocked together to
produce a unified overall structure.
[0083] Step 10. Repeat the steps 3 to 9 for the next floor.
[0084] For single storey, the pre-cast concrete wall panels will be
inter-linked and interlocked together by inserting U shape steel
bars (42) after pouring the concrete to column positioned next to
each other from two linearly aligned adjacent pre-cast concrete
wall panels. Figure (23).
[0085] One edge of a concrete slab is connected to the edge of
another adjacent concrete slab by placing the two concrete slabs
adjacent to each other and inter-linking pre-cast concrete beam of
the pre-cast concrete slab by steel bars (33). Any crevice or gap
at the joint of the two concrete slabs is sealed with a suitable
sealant (32) (See FIG. 21A).
[0086] Where a reinforced concrete beam is to be constructed
between two adjacent concrete slabs, or where a wall is to be
erected from one storey to another, than the each concrete slab
(26) is placed on the concrete beam (2) of a concrete wall panel.
One side of a concrete slab is placed spaced apart from the side of
an adjacent concrete slab. A trough is formed by the side edges of
the concrete slabs and the top surface of the concrete wall panel.
Additional steel bars (28) are placed in the trough and secured to
the steel links (8) to form a steel cage. Concrete is poured into
the trough so formed and allowed to set to form a reinforced
concrete beam. If desired additional concrete wall can be erected
above this reinforced concrete beam by placing a concrete wall
panel over the reinforced concrete. (See FIG. 22)
[0087] The advantage of this invention is that the various shapes
of pre-cast concrete panels can be assembled, concrete columns are
constructed by the introduction of reinforcement steel bars and
concrete into the desired cores, cast in-situ reinforcement
concrete beams are constructed on top of pre-cast concrete walls
and adjacent concrete slab panels, and all reinforcement steel bars
can be inter-linked to form a rigid and sturdy building structure.
The system provides great flexibility in constructing various types
of buildings by the judicious selection of the appropriate types of
pre-cast concrete panels. The length of `I` shaped concrete panels
can be varied according to architectural requirements and the
length adjusted by adjusting the universal moulding formwork set.
The Figures (24) to Figure (32) showing the plans and elevations
for the various type of combination from pre-cast concrete wall
panels to form the different designs according to architectural
requirements. The specific design of the surface of the wall panel
cornices, door frames, window frames and other structures can be
easily formed or modified prior to the casting. Furthermore, it is
easy to handle the casting and construction and quality is under
control at casting plants instead of depending on inconsistent
human factor. There is no plastering and no ceiling because the
wall and ceiling furnishings can be formed during the process of
casting through the moulding formwork set.
[0088] The gap between linearly aligned concrete wall panels
provides for Fig (18) for central to central alignment/adjustment
and also serves the purpose of expansion join for structural
requirement. It will be understood that the gap can also be used as
the cast in-situ column by introducing steel bars and concrete into
a core formed by two adjacently placed concrete wall panels.
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