U.S. patent application number 12/671855 was filed with the patent office on 2011-08-11 for building panel and locking device therefor.
This patent application is currently assigned to MACH SYSTEMS PTY LTD. Invention is credited to Roger A. Farquhar.
Application Number | 20110192107 12/671855 |
Document ID | / |
Family ID | 40303810 |
Filed Date | 2011-08-11 |
United States Patent
Application |
20110192107 |
Kind Code |
A1 |
Farquhar; Roger A. |
August 11, 2011 |
BUILDING PANEL AND LOCKING DEVICE THEREFOR
Abstract
A concrete component connecting system includes first and second
precast components (112, 118) adapted to be arranged in abutting
relationship in an assembled configuration, the first and second
precast concrete (112, 118) having respective first and second
edges (116, 120) which face each other in the assembled
configuration. A locking mechanism (122, 126) is also provided
including mutually engageable components disposed at the facing
edges (116,120). The locking mechanism (122, 126) including a
remote actuating means to effect locking of the mutually engageable
components (122, 126) at or beyond a third edge of one of the first
and second precast components (112, 118), to secure the first and
second precast components (112, 118) together. One of the building
components may comprise a building panel (12) which is generally
planar in form. The building panel (12) has a core (14) which is
substantially planar in form with opposite sides and is
substantially aligned with the plane of the building panel.
Cementitious material is disposed on both sides of the core (14).
The core being formed with a series of substantially parallel open
channels (16) which are arranged with the openings on alternate
sides of the core (14). Some of the channels are filled with the
cementitious material.
Inventors: |
Farquhar; Roger A.;
(Victoria, AU) |
Assignee: |
MACH SYSTEMS PTY LTD
Hoppers Crossing ,Victoria
AU
|
Family ID: |
40303810 |
Appl. No.: |
12/671855 |
Filed: |
July 30, 2008 |
PCT Filed: |
July 30, 2008 |
PCT NO: |
PCT/AU2008/001105 |
371 Date: |
February 2, 2010 |
Current U.S.
Class: |
52/582.2 ;
52/742.14; 52/794.1 |
Current CPC
Class: |
F16B 21/02 20130101;
F16B 21/09 20130101; F16B 21/16 20130101; E04B 1/04 20130101 |
Class at
Publication: |
52/582.2 ;
52/794.1; 52/742.14 |
International
Class: |
E04C 2/284 20060101
E04C002/284; E04C 2/40 20060101 E04C002/40; E04C 2/288 20060101
E04C002/288 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 2, 2007 |
AU |
2007904163 |
Aug 13, 2007 |
AU |
2007904338 |
Claims
1. A connecting system for cementitious precast components
including: first and second precast cementitious components adapted
to be arranged in abutting relationship in an assembled
configuration, the first and second precast components having
respective first and second edges which face each other in the
assembled configuration; and a locking mechanism including mutually
engageable components disposed at the facing edges, the locking
mechanism including a remote actuating means to effect locking of
the mutually engageable components at or beyond a third edge of one
of the first and second precast concrete components, to secure the
first and second precast components together.
2. The connecting system as claimed in claim 1 wherein the two
precast components are arranged side by side to one other and the
third edge is on top of one of the components.
3. The connecting system as claimed in claim 1 wherein the precast
concrete components are arranged one atop the other and the third
edge is atop the upper component.
4. The connecting system as claimed in claim 1 wherein the locking
mechanism includes: a pin having a head extending from the first
edge of the first component; and a locking device including a
locking member which is disposed at the second edge of the second
component, the locking member being movable between an unlocked
configuration and a locked configuration whereby it is adapted to
receive the head of the pin, the locking device further including
an elongate member connected to the locking member and extending to
the third edge of the second component, wherein operation of the
locking member may be effected from the third edge by the elongate
member.
5. The connecting system as claimed in claim 4 wherein the pin is
cast into the first component and a semicircular recess is formed
about the pin such that it does not protrude beyond the main
surface of the first edge.
6. The connecting system as claimed in claim 4 wherein the locking
member is rotatable about a pivot axis for movement between the
unlocked configuration and the locked configuration.
7. The connecting system as claimed in claim 6 wherein the locking
member has axial spigots.
8. The connecting system as claimed in claim 7 wherein the axial
spigots are received into a shaped plastic spacer which is cast
into the second component.
9. The connecting system as claimed in claim 6 wherein the locking
member is a part-cylindrical shell, with the pivot axis defined at
the rotational centre thereof.
10. The connecting system as claimed in claim 9 wherein the
part-cylindrical shell is one-half to two-thirds of a cylindrical
wall, with a gap defined in the cylindrical wall to receive the
head of the pin.
11. The connecting system as claimed in claim 4 wherein the
elongate member comprises a rod or a bar.
12. The connecting system as claimed in claim 6 wherein the
elongate member comprises a rod or a bar and wherein the locking
member is interconnected with the rod or bar such that lineal
movement of the rod or bar effects rotational movement of the
locking member.
13. The connecting system as claimed in claim 12 wherein the
elongate member is pivotally connected to the locking member.
14. The connecting system as claimed in claim 12 wherein the
elongate member is connected to the locking member through one or
more cable portions.
15. The connecting system as claimed in claim 14 wherein there are
two cable portions allowing movement of the locking member between
the locked configuration and the unlocked configuration and also
between the unlocked and the locked configuration.
16. The connecting system as claimed in claim 4 wherein there is a
plurality of said locking members, each of which are connected to a
common elongate member.
17. The connecting system as claimed in claim 4 wherein the first
component is a slab or footing and the second component is a wall
panel and the elongate member extends upwards through the height of
the wall panel and is connected to a roofing component.
18. The connecting system as claimed in claim 1 wherein one of the
concrete components includes an inspection shaft to check the
configuration of the locking mechanism.
19. A locking device for use with a precast concrete component to
lock the component to another precast concrete component, the
device including a locking member adapted to receive the head of a
pin extending from the edge of the other component; and an elongate
member connected to the locking member, the elongate member being
adapted for remote operation of the locking member.
20. The locking device as claimed in claim 19 wherein lineal
movement of the elongate member effects operation of the locking
member.
21. The locking device as claimed in claim 20 wherein the locking
member is rotatable about a pivot axis for movement between the
unlocked configuration and the locked configuration.
22. The locking device as claimed in claim 21 wherein the locking
member is a part-cylindrical shell, with the pivot axis defined at
the rotational centre thereof.
23. The locking device as claimed in claim 20 wherein the elongate
member comprises a rod or a bar and wherein the locking member is
interconnected with the rod or bar such that lineal movement of the
rod or bar effects rotational movement of the locking member.
24. The locking device as claimed in claim 23 wherein the elongate
member is pivotally connected to the locking member.
25. The locking device as claimed in claim 23 wherein the elongate
member is connected to the locking member through one or more cable
portions.
26. The locking device as claimed in claim 20 wherein there are a
plurality of said locking members, each of which are connected to a
common elongate member.
27. A building panel which is generally planar in form, having a
core which is substantially planar in form with opposite sides, the
core being substantially aligned with the plane of the building
panel, with cementitious material disposed on both sides of the
core, the core being formed with a series of substantially parallel
open channels which are arranged with the openings on alternate
sides of the core, some of the channels being filled with the
cementitious material.
28. The building panel as claimed in claim 27 wherein the core has
top and bottom edges and the channels extend from the top to the
bottom edges of the core and are substantially aligned with the
height dimension of the building panel.
29. The building panel as claimed in claim 27 wherein the core
extends from one lateral edge of the building panel to the
other.
30. The building panel as claimed in claim 27 wherein the building
panel is of a width to accommodate a plurality of cores arranged in
side by side abutting relationship and extending from one lateral
edge of the building panel to the other.
31. The building panel as claimed in claim 27 wherein the core has
top and bottom edges and the building panel has top and bottom
edges, the top and bottom edges of the core being spaced from the
top and the bottom edges of the building panel thereby defining
beams of cementitious material adjacent the top and bottom edges of
the building panel.
32. The building panel as claimed in claim 27 wherein the core is
corrugated.
33. The building panel as claimed in claim 32 wherein the core is
of a regular zig-zag formation.
34. The building panel as claimed in claim 27 wherein the core
comprises insulative material.
35. The building panel as claimed in claim 34 wherein the core is
formed of rigid cellular plastics material, preferably expanded
polystyrene, expanded polypropylene or expanded polyethylene.
36. The building panel as claimed in claim 27 wherein the building
panel includes reinforcing material and the core is provided with
holding means for the reinforcing material.
37. The building panel as claimed in claim 27 further including
void formers in the form of inserts which fit with or into the
channels in the core to preclude one or some of the channels from
being filled with cementitious material to facilitate the creation
of service ducting.
38. The building panel as claimed in claim 27 wherein the panel
also includes a lifting bracket comprising one or more lifting rods
extending into the channels and embedded in the cementitious
material.
39. The building panel as claimed in claim 27 wherein different
grades of cementitious material are used on either side of the
core.
40. The building panel as claimed in claim 39 wherein the building
panel has a higher density cementitious material on one side of the
core and relatively lower density cementitious material on the
other side of the core.
41. A building constructed using a plurality of building panels as
claimed in claim 40 wherein the building panels are installed with
the higher density cementitious material on the inside of the
building and the relatively lower density cementitious material on
the outside of the building.
42. A method of casting a building panel, the method including:
using cementitious material of at least two different densities
including a relatively higher density material and a relatively
lower density material; placing a first layer of the lower density
material into a mould; placing a core assembly over the first
layer, the core assembly being substantially planar in form; and
placing a second layer of the relatively higher density material
over the core assembly.
43. The method as claimed in claim 42 wherein the core assembly
includes a core which is substantially planar in form.
44. The method as claimed in claim 42 wherein the core is of a
regular zig-zag formation.
45. The method as claimed in claim 42 wherein the core is formed of
rigid cellular plastics material, preferably expanded polystyrene,
expanded polypropylene or expanded polyethylene.
46. The method as claimed in claim 42 wherein the core assembly
includes reinforcing material and the core is provided with holding
means for the reinforcing material.
47. The method as claimed in claim 42 wherein the core assembly
also includes a lifting bracket comprising one or more lifting rods
extending into the channels and embedded in the cementitious
material.
48. A method of constructing a building using a plurality of
building panels cast according to the method as claimed in claim 42
wherein the panels are installed with the higher density material
on the inside of the building and the lower density material on the
outside of the building.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a building panel. In
particular, although not exclusively, the invention relates to a
precast concrete building panel. The invention also relates to a
method of casting a building panel. While the building panel is
commonly described herein in terms of a wall panel, the invention
may have application to other types of precast panels including
ceiling, roof and floor panels.
[0002] The present invention also relates to a connecting system
for precast cementitious components. In particular, although not
exclusively, the invention relates to a connecting system which is
used to secure precast concrete wall panels into edgewise abutting
relationship with each other. Thus, it may be used to secure two
panels side by side or one panel atop another. The invention may
also have application to connecting a wall panel to a slab. The
invention also relates to a locking device for concrete
components.
BACKGROUND OF THE INVENTION
[0003] Traditionally, precast concrete panels are formed as
substantially solid bodies of concrete, albeit with reinforcing
material. The thicker the concrete panel, the greater its
insulative properties. Thermal insulative properties are measured
in terms of R value and an R value of 1.5 is desirable for building
walls. However, solid concrete panels would need to have a
theoretical thickness of 375 mm millimetres in order to exhibit an
R value of 1.5 and therefore achieve satisfactory thermal
insulative properties.
[0004] It is known to provide locking devices that interconnect
precast concrete panels or other components. See for example, my
earlier Australian patent application no 71452/00. In this patent
application, the locking devices comprise pins and keepers.
[0005] The pins are connected to one concrete component and are
received in a keeper connected to another concrete component. The
pin and associated keeper are disposed upon respective mating edges
of the two concrete components. Thus, once the two edges are
brought into mating engagement, it can be difficult to align the
parts of the locking device and therefore difficult to effect the
locking operation.
[0006] It is therefore one object of the present invention to
provide a building panel or a method of casting a building panel
which overcomes at least some of the aforementioned
disadvantages.
[0007] It is an alternative object of the present invention to
provide a connecting system for concrete components which may be
remotely actuated. It is also an object of the present invention to
provide a locking device for concrete components which addresses
the abovementioned disadvantage. Yet another alternative object of
the present invention is to provide products which at least provide
the public with a useful choice over known products.
[0008] Reference to any prior art in the specification is not, and
should not be taken as, an acknowledgment or any form of suggestion
that this prior art forms part of the common general knowledge in
Australia or any other jurisdiction nor that this prior art could
reasonably be expected to be ascertained, understood and regarded
as relevant by a person skilled in the art.
SUMMARY OF THE INVENTION
[0009] In accordance with a first aspect of the present invention
there is provided a building panel being generally planar in form
and having a core which is substantially planar in form with
opposite sides, the core being substantially aligned with the plane
of the building panel, with cementitious material disposed on both
sides of the core, the core being formed with a series of
substantially parallel open channels which are arranged with the
openings on alternate sides of the core, some of the channels being
filled with the cementitious material.
[0010] The channels in the core may extend from top to bottom of
the core and be generally aligned with the height dimension of the
finished building panel. Thus the channels are arranged to
alternate from one side to the other across the width of the core.
The core may have a uniform cross-section over its height.
Consequently, the form of the core could be described as
corrugated, undulating, sinusoidal or crenellated. Preferably the
corrugations are of a regular formation. The term corrugated
includes a zig-zag formation, preferably a regular zig-zag
formation. A preferred profile is one which reduces waste. The core
may be of uniform thickness so that the crests on the first side of
the core define the openings on the second side of the core and the
openings on the first side of the core define the troughs on the
second side of the core.
[0011] In one form, each of the channels has a necked region at or
adjacent the opening and a main void, wherein the necked region is
of narrower dimension(s) than the main void. In this form, the
cross-section of the channels may be described as dovetailed.
[0012] In the finished panel, the cementitious material will be
provided on both sides of the core, extending into some or most of
the channels thereby creating alternating "columns" of cementitious
material on either side of the core, with columns on the same side
of the core being joined by a common plane of cementitious
material. In the form with dovetails, the cementitious material on
each side of the core is interlocked with the core by virtue of the
necked regions.
[0013] The building panels according to the present invention may
be precast building panels. The precast building panels may be part
of a building system where the building panels are shaped so as to
mesh with each other and also a building slab. For example, one
possible building system is described in Australian patent no
785414 in the name of MACH Systems Pty Ltd. While the specification
describes the invention in the context of precast building panels,
the invention is not limited thereto and the present invention may
also be applied to a building panel which is poured in situ.
[0014] The core of the building panel may comprise insulative
material. The core may also be moisture impervious to minimise the
penetration of water or moisture from the outside of a building to
the inside. The core may be moulded or extruded to shape. In a
preferred form of the invention, the core is formed of rigid
cellular plastics material, for example, expanded polystyrene,
expanded polypropylene or expanded polyethylene. The core may be
cut from a solid block of cellular plastics material, for example
by a hot wire. The core may have a smooth outer skin.
Alternatively, the outer surface of the core could be shaped or
roughened or deformed to enhance bonding with the cementitious
material.
[0015] The building panel may also include reinforcing material.
For example, traditional steel reinforcing mesh may be employed.
However, alternative reinforcing materials may be used. These
include steel mesh or fabric such as expanded metal, fibreglass
fabric or carbon fibres. The core may incorporate holding means for
the reinforcing material. For example, the core may include
integral protrusions to create a seat for the reinforcing material.
Alternatively, reinforcing sheet material such as fibreglass fabric
may be permanently bonded to the outermost surfaces of one or both
sides of the core.
[0016] Within the building panel, the core may extend from edge to
edge and top to bottom. However, preferably the core does not
extend all the way to the top and the bottom so that the two
concrete sides of the panel may be joined to create concrete
`beams` at the top and bottom of the panel.
[0017] Rather than extending edge to edge, the core size may
instead be a standard width (and height), with the building panels
being of a width to accommodate a single core or multiple cores
arranged side by side.
[0018] The cementitious material is preferably concrete, which is
usually a composition of gravel, sand, cement and water. It is
possible that different grades of cementitious material may be used
on either side of the core. For example, a different density of
concrete may be used on one side of the panel compared to the other
side. This may be to reduce the overall weight of the panel while
balancing strength and thermal performance characteristics.
[0019] Apart from concrete, other cementitious materials may be
employed such as the newly developed cementitious materials. One
such example is HySSIL developed by CSIRO in Australia. This modern
cementitious material does not generally employ aggregate. It is
aerated by the use of chemicals to produce insulated cementitious
material which is lighter in weight than traditional concrete.
[0020] In a preferred form of the invention, the building panel has
a higher density cementitious material e.g. 50 MPa concrete on one
side of the core and relatively lower density cementitious material
on the other side of the core, such as HySSIL or other forms of
lightweight concrete (the units MPa refer to compressive strength).
This arrangement improves the thermal performance of the panel when
installed with the higher density cementitious material on the
inside wall of a building and the relatively lower density
cementitious material on the outside wall of the building. The use
of the lower density material reduces the overall weight of the
panel. A building so constructed constitutes a second aspect of the
present invention.
[0021] The building panel may also employ void formers. The void
formers may be in the form of inserts which fit with or into the
channels in the core to preclude one or some of the channels from
being filled with cementitious material. This facilitates the
creation of service ducting for cabling, water pipes, air ducts for
space heating or ducts for thermal heating pipes. These void
formers are suitably attached to the core prior to pouring of the
cementitious material.
[0022] The panel may also include a lifting bracket. The lifting
bracket may comprise one or more lifting rods which extend into the
channels to become embedded in the cementitious material.
Preferably, the lifting rod(s) extends the full length of the
panel. The lower ends of the lifting rods may have flanged ends.
Preferably, there are three lifting rods with two positioned in
adjacent channels on one side of the core and the other in an
intermediate channel on the other side of the core. The three rods
are united at the upper end by a lifting frame.
[0023] In accordance with a third aspect of the present invention,
there is provided a method of casting a building panel, the method
including:
[0024] using cementitious material of at least two different
densities including a relatively higher density material and a
relatively lower density material;
[0025] placing a first layer of the lower density material into a
mould;
[0026] placing a core assembly over the first layer, the core
assembly being substantially planar in form; and
[0027] placing a second layer of the relatively higher density
material over the core assembly.
[0028] The mould may be vibrated and allowed to set.
[0029] The core assembly may include any of the features described
above in connection with the first aspect of the invention such as
reinforcing material, void formers, lifting brackets, cabling,
water pipes, heating conduits etc.
[0030] In accordance with a fourth aspect of the invention, there
is provided a method of constructing a building using a plurality
of building panels cast according to the method as set out above in
the third aspect wherein the panels are installed with the higher
density material on the inside of the building and the lower
density material on the outside of the building.
[0031] In accordance of the fifth aspect of the present invention
there is provided a connecting system for precast cementitious
components including:
[0032] first and second precast cementitious components adapted to
be arranged in abutting relationship in an assembled configuration,
the first and second precast components having respective edges
which face each other in the assembled configuration; and
[0033] a locking mechanism including mutually engageable components
disposed at the facing edges, the locking mechanism including a
remote actuating means to effect locking of the mutually engageable
components at or beyond a third edge of one of the first and second
precast components, to secure the first and second precast
components together.
[0034] Where the two precast components are arranged adjacent to
one other then the third edge may be on top of one of the
components. Where the precast components are arranged one atop the
other then the third edge may also be atop the upper component.
This renders the remote actuating means most accessible when the
components are being assembled. Typically, at least one of the
components is substantially planar in form having a length, width
and thickness. Side edges will be therefore defined across the
thickness dimension at the sides. Also, top and bottom edges will
be defined across the thickness dimension at the top and
bottom.
[0035] More particularly, the present invention provides a
connecting system including:
[0036] first and second precast cementitious components adapted to
be arranged in abutting relationship, the first and second precast
components having respective first and second edges which face one
another in the assembled configuration;
[0037] a pin having a head extending from the first edge of the
first component; and
[0038] a locking device including a locking member which is
disposed at the second edge of the second component, the locking
member being movable between an unlocked configuration and a locked
configuration whereby it is adapted to receive the head of the pin,
the locking device further including an elongate member connected
to the locking member and extending to a third edge of the second
component, wherein operation of the locking member may be effected
from the third edge by the elongate member.
[0039] The precast cementitious components may comprise wall panels
which may be secured side by side to each other (in edgewise
abutting relationship or alternatively may be secured one atop the
other. The connecting system might also be used to join a wall
panel to a slab or a concrete footing. Also, precast cementitious
roof panels could be interconnected using the system. The system
could also be used to join and fasten precast cementitious floor
panels together.
[0040] In a system where one panel is disposed atop the other, the
pin may dually serve as a lifting pin to move the panels into
position. Such lifting pins are supplied by Reid Construction
Systems Pty Ltd of Australia. These pins are cast into the
component. Additionally, a semicircular recess is formed about the
pins such that they do not protrude beyond the main surface of the
associated edge but access to the pins can still be obtained.
[0041] The first and second facing edges of the precast
cementitious components may have a complimentary profile as
described in my Australian patent no 785414.
[0042] The elongate member forming part of the locking device may
be movable linearly by the actuating means to effect operation of
the locking member. The elongate member may comprise a rigid member
such as a rod or a bar or alternatively may comprise a flexible
member such as a cable. Where the elongate member is a rod, the rod
may be threaded at the upper end. By screwing a nut onto the upper
end of the elongate threaded rod, this will serve to draw the rod
out of the concrete component once the nut abuts against the third
edge. However, other means of moving the elongate member may also
be employed. For example, if the elongate member is a cable, a
cable actuating device may be used. The elongate member may also be
a combination of a cable and a rigid member such as a rod.
[0043] In one particular form of the invention, there may be a
plurality of locking members, each of which is connected by a short
length of cable to a common elongate rod which extends to the third
edge. Thus a plurality of locking members may be operated
simultaneously.
[0044] Where the present invention is used to connect a wall panel
to a slab or footing, the threaded rod may extend upwards through
the height of the wall panel and be connected to a roofing
component. This effectively ties the roofing component to the floor
slab which may be a requirement in some cyclone areas.
[0045] The locking member may comprise any suitable member which is
adapted to engage with the pin. Preferably, the locking member is
an arcuate member with a recess formed to receive the head of the
pin. For example, the locking member may be arcuate member which is
forked. More particularly, the locking member may be a
part-cylindrical shell. For example, the locking member is
preferably one-half to two-thirds of a cylinder with the missing
part defining a gap to receive the head of the pin.
[0046] The locking member may be pivotally mounted to the second
component. An axial spigot may be incorporated into the locking
member for this purpose. Preferably, the two ends of the spigot are
received into a shaped plastic spacer which is cast into the
concrete component.
[0047] Preferably, the locking member is pivotally connected to the
elongate member. Most preferably, the interconnection in the
unlocked configuration is at a point further from the third edge
than the pivot axis to effect rotation of the locking member.
[0048] In accordance with a sixth aspect of the present invention
there is provided a locking device for use with a precast concrete
component to lock the component to another precast concrete
component, the device including a locking member adapted to receive
the head of a pin extending from the edge of the other component;
and an elongate member connected to the locking member, the
elongate member being adapted for remote operation of the locking
member.
[0049] The locking device may be cast into the concrete component.
The locking device may include any of the features described above
in accordance with the fifth aspect of the present invention.
[0050] As used herein, the term "comprise" and variations of the
term, such as "comprising", "comprises" and "comprised", are not
intended to exclude other additives, components, integers or
steps.
[0051] This invention may also be said broadly to consist in the
parts, elements and features referred to or indicated in the
specification of the application, individually or collectively, and
any or all combinations of any two or more of said parts, elements
or features, and where specific integers are mentioned herein which
have known equivalents in the art to which this invention relates,
such known equivalents are deemed to be incorporated herein as if
individually set forth.
[0052] The invention consists in the foregoing and also envisages
constructions of which the following gives examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] In order that the invention may be more fully understood,
some embodiments will now be described by way of example with
reference to the figures in which:
[0054] FIG. 1 is a horizontal cross-sectional view through a
portion of a building panel according to a preferred embodiment of
the present invention;
[0055] FIG. 2 is a horizontal cross-sectional view through a
portion of a building panel slightly modified from that shown in
FIG. 1;
[0056] FIG. 3 is a schematic longitudinal cross-section showing a
lower detail of the building panel of FIG. 2;
[0057] FIG. 4 is a schematic longitudinal cross-section showing an
upper detail of the building panel of FIG. 1;
[0058] FIG. 5 is a horizontal cross-sectional view showing a corner
junction between two building panels of the type illustrated in
FIG. 1 or 2;
[0059] FIG. 6 is a perspective view of a core assembly, further
illustrating a lifting bracket assembled with the core
assembly;
[0060] FIG. 7 is a perspective view showing the lifting bracket in
isolation;
[0061] FIG. 8 is a perspective view showing an upper frame forming
part of the lifting bracket of FIG. 7;
[0062] FIG. 9 is a schematic top view of a building panel
illustrating the lifting bracket in position;
[0063] FIG. 10 is a vertical cross-section aligned with the general
plane of the building panel showing the inclusion of heating
conduits;
[0064] FIG. 11 is a vertical section through B-B of FIG. 16,
illustrating the airflow through the building panel;
[0065] FIG. 12 is an exploded perspective view of an insert
assembly for a service conduit for the building panel;
[0066] FIG. 13 is a perspective view of a heating conduit for the
building panel;
[0067] FIG. 14 is an exploded view of a space heating conduit for
the building panel;
[0068] FIG. 15 is a cross-sectional view through a building panel
showing the arrangement of service conduits and heating conduits of
FIGS. 12-14 assembled with the core assembly;
[0069] FIG. 16 is a partial perspective view of a connecting system
in accordance with a preferred embodiment of the present
invention;
[0070] FIG. 17 is a partial perspective view showing the connecting
system of FIG. 16 with the two concrete components in assembled
configuration;
[0071] FIG. 18 is a diagrammatic view illustrating the locking
mechanism for use in the connecting system shown in FIG. 16 prior
to interconnection;
[0072] FIG. 19 is a view of the components of FIG. 18 just prior to
engagement;
[0073] FIG. 20 is a perspective view of the components of FIG. 18
in full engagement;
[0074] FIG. 21 is a sectional view through the connecting system of
FIG. 18;
[0075] FIG. 22 is a front view of concrete components connected
using the connecting system of FIGS. 16 to 21;
[0076] FIG. 23 is a front view of a connecting system according to
another preferred embodiment of the present invention;
[0077] FIG. 24 is a front view of a connecting system according to
FIG. 23, except shown in the locked configuration;
[0078] FIG. 25 is a diagram illustrating the mating profile of the
two concrete components;
[0079] FIG. 26 is a schematic perspective view showing the mating
profile of the two concrete components;
[0080] FIG. 27 is a detail of the connecting system of FIG. 23
shown in the unlocked configuration;
[0081] FIG. 28 is a detail of the connecting system of FIG. 23
shown in the locked configuration;
[0082] FIG. 29 is a detailed view of two positions of the locking
member.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0083] FIG. 1 is a horizontal cross-section through a core assembly
10 incorporated into a building panel 12. The core assembly 10
includes a core 14 which is constructed of high density expanded
polystyrene. A suitable material is sold under the brand name
Isolite VH. The core has a substantially uniform cross-section
throughout its height. The cross-section is in the shape of a
regular zig-zag of uniform thickness. The cross-section defines
channels 16, albeit rather shallow channels which extend
substantially parallel to each other in the height direction of the
finished panel. The channels open towards alternating sides of the
core 10. The resulting shape of the core 14 is zig-zag as
shown.
[0084] The zig-zag core is cut by hot wire from a solid block of
polystyrene having dimensions of 5.5 m long.times.1220 mm wide and
600 mm thick. The cross-section selected is easy to cut and reduces
waste.
[0085] The core has dimensions of length (which may equate to
height in a wall panel), width (the other major dimension besides
length/height) and thickness. The width of the core 14 may be
substantially commensurate with the width of the building panel
12.
[0086] The zig-zag core 14 defines external points 22. On both
sides of the core 14, steel reinforcing mesh 24 is bonded/secured
to the external points 22 to extend across the opening 17 of each
of the channels 16. The reinforcing mesh 24 extends on both sides
of the core 14 and is substantially commensurate with the length
(i.e. height) and width dimensions of the core 14. Instead of steel
reinforcing mesh, fibreglass reinforcing mesh may be used.
[0087] Alternatively, as shown in FIG. 2, the core assembly 10 may
be formed of sheets 14a, 14b of a standard width which may be
joined to make up the required width in the building panel 12. FIG.
2 illustrates a join 30 between two polystyrene core sheets 14a and
14b having complementary edge profiles.
[0088] As shown in FIGS. 1 and 2, the core assembly 10 is disposed
essentially within the building panel so as to be substantially
aligned with the general plane of the building panel 12. The core
assembly 10 is inserted into a mould so that cementitious material
extends on both sides of the core assembly 10 and in most cases
extends into the channels 16. As will be appreciated, this creates
parallel spaced columns of cementitious material within the
boundary defined by the channels 16. These columns are joined by
the concrete which extends along the outside of the building panel.
The cementitious material conforms to the shape of the dovetail
channels 16.
[0089] The cementitious material used in the building panel 12 may
be concrete. A preferred material is aerated cementitious material
such as HySSIL developed by CSIRO in Australia.
[0090] The current Australian government guidelines for home
insulation provide that in temperate zones, the insulation value
for building walls should be R-1.5 or preferably R-2. It is
believed that the present invention can achieve an R value of 1.74
by adopting the following design guidelines: [0091] a. Core
material to be Isolite VH (expanded polystyrene) of 50 mm thick,
providing an R value of around 1.28. [0092] b. HySSIL cementitious
material of 115 mm in thickness is believed to give an R value of
0.46.
[0092] R1.28+R0.46=R1.74
[0093] It is understood that further improvements in the R value
could be achieved if HySSIL cementitious material of 1500
kg/cm.sup.3 was used for one side of the building panel and HySSIL
cementitious material of 900 kg/cm.sup.3 was used for the other
side of the building panel 12.
[0094] While most of the channels 16 are intended to be filled with
cementitious material, one or a number of these channels 16 may
remain unfilled to provide service conduits. Void formers in the
form of tubular plastic inserts 34 may be used for this purpose.
FIG. 12 also shows an insert assembly comprised of a conduit 88
having a lower port 90 and a guide insert 92 for guiding cables or
heating conduits 82. See also the discussion below in connection
with FIGS. 12 to 15.
[0095] Cabling (not shown) may also be inserted into the core
assembly 10, prior to being placed into the mould.
[0096] The left hand panel of FIG. 5 shows one embodiment where the
width of the core 14 is substantially commensurate with the width
of the building panel 12. On the other hand, FIGS. 3 and 4
illustrate the vertical extent of the core 14 relative to the
building panel 12. At the bottom, the core 14 does not extend to
the bottom of the building panel 12 but falls short by about 80 mm
to provide a lower `beam` of concrete or cementitious material. At
the top, the core 14 provides an upper beam height of approximately
100 mm.
[0097] The concrete building panels 12 of the present invention may
be compatible with known precast concrete building systems. In
particular, the building panels 12 of the present invention may be
constructed in accordance with the principles set down in
Australian patent no 785414 in the name of MACH Systems Pty Ltd,
the details of which are incorporated herein by reference. For
example, as described in this Australian patent the building panel
12 may be mounted on a slab 40 provided with a rebate 42 to
accommodate the building panel 12. The profile of the rebate 42 and
the bottom edge of the panel 12 may be complementary or meshing to
maintain the building panel 12 relative to the slab 40.
Additionally, locking means (not shown) may be provided to secure
the building panel 12 to the slab 40 and the panels to each other.
Details of the edge profiles and the locking mechanism are
disclosed in the abovementioned Australian patent and the reader is
directed to that earlier specification for further information.
Further, the reader is also directed to the locking device for
precast concrete components, discussed further below in FIGS. 16 to
19.
[0098] FIG. 5 shows the engagement between two building panels 12
arranged at 90.degree. to define a corner of a building. The two
panels 12 may be locked together by means of any suitable locking
mechanism as mentioned above.
[0099] FIGS. 6 to 9 illustrate the form of a lifting bracket which
may be used to lift the building panel 12 once it has been cast.
FIG. 6 simply illustrates the lifting bracket 44 relative to the
core assembly 10. FIG. 7 illustrates the form of the lifting
bracket 44 by itself. The lifting bracket 44 comprises three
elongated rods 46. The rods may be threaded or the ends of the rods
may be threaded. At the lower end of the rods 46, the rods are
coupled to nuts with winged flanges 48. At the upper end, the rods
46 are coupled to an upper lifting frame 50 which includes three
triangularly spaced nuts 52 which engage with the upper ends of
respective rods 46. The lifting frame 50 further includes a lifting
eye 54.
[0100] As can be seen most clearly in FIG. 9, the three rods 46
extend into three adjacent concrete columns 17, two on one side of
the building panel 12, and one on the other. The rods 46 may extend
the full height of the building panel 12 or may extend partially
into the building panel 12 as depicted in FIG. 6.
[0101] The lifting bracket 44 may be preassembled as part of the
core assembly 10, prior to insertion of the core assembly 10 into
the casting mould. Thus, the elongate rods 46 may be attached to
the reinforcing material 24 in the core assembly 10. Suitably,
there would be two lifting brackets 44 employed in each building
panel 12, thereby distributing the load over six columns 17 in the
cast building panel 12.
[0102] The mould used to cast the building panel comprises a
casting bed of conventional form. The building panel 12 is cast on
the casting bed with its general plane being horizontally disposed
on the casting bed. The outside perimeter of the building panel 12
will be defined by formwork attached to the casting bed. The
casting bed 62 will thereby define one side of the finished
building panel 12.
[0103] Once the mould 60 is ready, a first layer of HySSIL aerated
cementitious material (or other lightweight concrete) is placed in
the base of the mould. The HySSIL is screeded to a predetermined
depth that will allow for expansion of the material due to the
contained gas producing additives (assume expansion of about
30%).
[0104] The core assembly 10 is positioned within the mould so as to
allow a desired amount of cementitious material to form on both
sides of the core 14. The desired position of the core assembly is
achieved through the used of Nirvana Connectors 32 (see FIG. 15).
These are tapered fibreglass rods manufactured by Reid
Constructions Pty Ltd of Australia. The Nirvana Connectors pierce
through the polystyrene core 14 and protrude beyond either side of
the core 14 to act as spacers to hold the core at a predetermined
spacing from the casting bed. The Nirvana Connectors may also be
adapted to hold the steel reinforcing in place.
[0105] A layer of high density concrete (50 MPa) is then placed on
top of the foam core and the casting bed is vibrated in the
conventional fashion to enable the cementitious material to settle
in the mould. This will also enable the cementitious material to be
worked into the channels 16 of the core 14, on the lower side of
the core 14 within the mould 60.
[0106] Those skilled in the art will be aware that the polystyrene
core will have buoyancy tending to urge the core 14 upwards during
vibration. Pascals Principal provides: where a body is wholly or
partly immersed in a fluid it is acted upon by an upthrust equal to
the weight of fluid displaced. In this configuration with the high
density concrete disposed above the lower density HySSIL, Pascal's
Principal is exploited to maintain the core in position.
[0107] In this case the upthrust=1,500 kg/cm (weight of HySSil)
whereas the weight of the concrete on top of the foam core is 2,500
kg/cm.
[0108] It should be noted that the depth of the layer of HySSil
concrete will be screeded to a predetermined level to allow for the
expansion of the material as the chemicals produce the hydrogen
bubbles, allowing for a 30% expansion rate.
[0109] As will be understood from FIG. 1, the angular ribs of the
foam core will tend to sink into the HySSil to the point where the
core 14 is supported by the Nirvana connectors.
[0110] The heavier density concrete will then resist the upthrust
and force the expanding HySSil to progressively fill the V-shaped
channels 16.
[0111] The side of the panel presenting the upper surface as it
lies on the casting bed is then hand finished and the cementitious
material is allowed to set.
[0112] Once the cementitious material has set to a satisfactory
level, the building panel 12 can be lifted via the lifting brackets
44 (FIGS. 6 to 9) to an upright or near vertical position (as per
FIG. 6). The formwork may be stripped from the perimeter of the
building panel 12. From this position, the panel 12 is moved to a
rack (not shown) for curing and storing. The casting bed is then
ready for casting the next building panel.
[0113] FIG. 10 illustrates a heating assembly 80 that may be
incorporated into the building panel 12 in accordance with the
present invention. The heating assembly 80 may incorporate the
features described in our earlier International application no
PCT/AU2006/000737 entitled Solar "Earth Module", the details of
which are incorporated herein by reference.
[0114] The heating assembly 80 includes a conduit 82 formed from
black polypropylene pipe arranged in a U-shape having upper ends,
the first of which forms an inlet for the heating fluid and the
second of which forms the outlet for the heating fluid. The heating
fluid may be heated by any conventional means such as a gas or oil
boiler or solar heating. Particular reference is made to our
earlier application PCT/AU2006/000737 which teaches methods and
apparatus for solar heating.
[0115] As shown in FIG. 10, the conduit 82 extends through two
adjacent channels 16 of the core 14, the two channels 16 being
arranged on the same side of the core 14. The conduit 82 extends
through the higher density concrete layer. The U-shaped conduits 82
extend from the top of the building panel 12 down through the
higher density concrete layer created in channel 16, through the
concrete `beam` at the bottom of the building panel 12 and then up
the higher density concrete layer defined by adjacent channel 16.
Alternatively, the two links of the conduits 82 may be arranged to
extend within the same channel 16 as depicted in FIG. 15.
[0116] In another embodiment, the conduits 82 may be arranged
within a space heating conduit 88 of the type depicted in FIG.
12.
[0117] The heating fluid e.g. water carried by the conduit 82 may
be heated by any known means such as a fossil fuel boiler or a
solar collector unit. The heating fluid passes through the conduit
82 to heat the panel 12. The heat retained within the building
panel 12 is given off as radiated heat over a period of time.
Additionally, the heat may be distributed by means of a convection
current which flows through the space heating conduit 88 as
depicted in FIG. 11. The space heating conduit includes a lower air
inlet port 90 and an upper outlet port 91. FIG. 14 illustrates the
form of the space heating conduit 88 which is inserted into one of
the channels 16 of the core, prior to casting.
[0118] FIGS. 16 to 22 illustrate a connecting system which may be
used to connect the building panels 12 together. However, the
concrete component connecting system has application beyond this
and may be used on any suitable precast cementitious
components.
[0119] The connecting system 110 in FIG. 16 includes a first
concrete slab 112, only a portion of which is illustrated in FIG.
16. FIG. 16 depicts an outer periphery 114 of the slab 112. Along
the upper edge of the outer periphery 114 is formed a first edge
116 of the slab 112. FIG. 16 also illustrates a portion of a
precast concrete wall component in the form of a panel 118 which
defines a second edge 120. The second edge 120 is located on the
lower periphery of the precast concrete panel 118. The second
mating edge 120 faces the first edge 116 in the assembled
configuration which is illustrated in FIG. 17. These facing edges
116, 120 are substantially complimentary in profile as described in
my Australian patent no 785414, the details of which are
incorporated herein by reference.
[0120] Protruding from the first edge 116 is a pin 122 which is
cast into the concrete slab 112. The pin 122 has a head 124 which
is uppermost. The panel 118 incorporates a locking device which
includes a locking member 126 disposed at the second edge 120 of
the panel 118 and a threaded rod 128 which extends from the locking
member 126 at the second edge 120 to a third edge 130 of the slab
118. The third edge 130 is opposite the second edge 120. The
locking member 126 is received in a void former 132 comprised of
plastic so that the locking member 126 may be secured relative to
the concrete panel 18. The locking member 126 is shown in greater
detail in FIGS. 18 to 21.
[0121] Referring to FIG. 18, it can be seen that the locking member
126 is in the form of a partly cylindrical shell 134 which is
formed with spigots 136 which are rotatable within the plastic void
former 132 (FIG. 16). The threaded rod 128 is connected to the
part-cylindrical shell 134 through a connecting pin 138. In the
unlocked configuration shown in FIG. 18, the connecting pin 138 is
disposed further away from the third surface 130 than the spigots
136 so that when the threaded rod 128 is pulled in the upward
direction, the part-cylindrical shell 134 will be caused to rotate
in a clock-wise direction around the spigots 136.
[0122] The part-cylindrical shell 134 is only one-half or two
thirds of a full cylinder, defining a gap 140 in the cylindrical
wall which can be most clearly seen in FIG. 20. However, in the
disposition of FIGS. 18 and 19, the gap 140 is disposed downwardly
so that when the locking member 126 approaches the pin 122, the
head of the pin 24 can be received in the gap 140.
[0123] It can also be seen in the Figures that the part-cylindrical
shell 134 is split, with the opening of this split 142 defined at
the edge of the part-cylindrical shell. This enables the two parts
of the cylindrical shell on either side of the pin head 124 to
engage underneath the head 124 as the shell 134 is rotated. When
the connecting pin 138 reaches its uppermost position shown in FIG.
20, the part-cylindrical shell 134 will be fully engaged with the
head of the pin 124, forming a secure connection.
[0124] Reverting to FIGS. 16 and 17, it can be seen that a truss
support bracket 144 is mounted on the third edge 130 with the
threaded rod 128 extending through an aperture 146 in the bracket
144. When a nut (not shown) is attached to the threaded rod 128 and
engages against the support bracket 144, continued turning of the
nut will draw the threaded rod 128 in a direction out of the panel
118 to rotate the locking member 126 to the engaged configuration
illustrated in FIG. 17.
[0125] FIG. 22 illustrates a front view of a precast concrete wall
panel 118 mounted on a slab 112. The precast concrete wall panel
118 is cast with openings defining the windows and doors.
Additionally, the panel 118 may be cast so as to simulate
overlapping wallboards as shown. Additionally, other joinery
elements such as architraves, window sills and doorsills may be
simulated in concrete by being precast into the concrete panel 118.
The timber joinery such as window frames, windows, door frames and
doors may be later installed.
[0126] The wall panel 118 is shown with four locking members 126
which engage with respective pins 122 cast into the slab 112. While
the above describes the locking of a wall panel 118 onto a slab
112, this embodiment may also have application to lock two slabs
together.
[0127] FIGS. 23 to 28 illustrated another embodiment of the
concrete component connecting system 110' whereby two wall panels
118' and 118'' may be connected to each other. However, it could
also have application to a wall-slab connection or to the
connection of other types of concrete components. This embodiment
utilises similar components to the first embodiment and like
numerals are used to represent like parts. Prime symbols (') are
used to indicate where the parts have been modified to adapt to
this embodiment.
[0128] The first wall panel 118' is provided with two pins 122
which are located in spaced disposition at intermediate locations
along a first edge 116' of the panel 118'. The first edge 116'
faces a second edge 120' on the other wall panel 118'' and the two
edges have a complimentary profile as illustrated in FIG. 25. At
corresponding heights along the second edge 120' are located two
locking members 126' which are adapted to receive respective heads
124 of the pins 122 in a similar manner as described in the first
embodiment. Each of the locking members 126 is connected to the
threaded rod 128' by means of two short portions of cable 150 and
152 as shown most clearly in FIGS. 27 and 28.
[0129] FIGS. 27 and 28 illustrate the detail of the modified
concrete component connecting system 110'. In this embodiment, the
locking members 126' still comprise a part-cylindrical shell 134'.
However, instead of being pivotally connected to the threaded rod
128', the part-cylindrical shell 134' is connected by means of two
short cable portions 150 and 152. The first cable portion 150 is
connected to the perimeter of the cylindrical shell 134' at one
edge of the gap 140' formed in the part-cylindrical shell 134' by a
swaged connection 154. The first cable portion 150 then passes
around an upper side of a cable guiding pin 156. The first cable
portion 150 then passes downwardly to be connected to the threaded
rod 128' at a first forged steel sleeve 158.
[0130] The second cable portion 152 is connected to the perimeter
of the part-cylindrical shell 134' at the upper edge of the gap
140', where the second cable portion 152 is swaged at 160 as shown.
The second cable portion 152 then passes under the cable guiding
pin 156 and then passes upwardly to be connected to the threaded
rod 128' by a second forged steel sleeve 162. The second forged
steel sleeve 162 is above the first forged steel sleeve 158.
[0131] As shown in FIGS. 27 and 28, the threaded rod 128' may be
housed in a PVC conduit 164. FIG. 27 also illustrates the location
of the threaded nut 166 at the top of the threaded rod 128'. In
this embodiment, the threaded nut 166 is received within a recess
168 formed in the third edge 130' of the wall panel 118''. By
rotating the threaded nut 166, the threaded rod 128' may be drawn
upwardly. As the threaded rod 128' is drawn upwardly, so to are the
forged steel sleeves 162 and 158. The raising of the second forged
steel sleeve 162 will draw the second cable portion 152 to pass
underneath the cabling guiding pin 156 and draw the swaged end 160
towards the cable guiding pin 156. This will urge the
part-cylindrical shell 134' to rotate about the spigot 136' in the
clockwise direction. At the same time, the swaged end 154 of the
first cable portion 150 will be drawn in a clockwise direction and
the cable 150 will pass over the cable guiding pin 156. This
passage of the first cable portion 150 is facilitated by the upward
movement of the forged steel sleeve 158. The part-cylindrical shell
134' will thus adopt the position illustrated in FIG. 28.
[0132] This system has some benefits over the previous embodiment
of the concrete component connecting system 110 because in this
embodiment, the part-cylindrical shell 134' may be moved to the
locked configuration shown in FIG. 28 and also reverted to the
unlocked configuration shown in FIG. 27. To revert to the unlocked
configuration, the threaded nut 166 is rotated in the opposite
direction to move the threaded rod back down again. Thus, the
downward movement of the first steel sleeve 158 will tend to draw
the first cable portion 150 over the top of the cable guiding pin
156, thus drawing the part-cylindrical shell 134' in the
anticlockwise direction about spigot 136'.
[0133] FIG. 28 shows some other features of the connecting system
110' which may be adopted. Beyond the nut 166, the threaded rod 128
may extend through a roofing truss 170 which is placed on top of
the third edge 130'. The threaded rod 128' may pass through the
roofing truss 170 where it is received by another threaded nut 172.
The threaded nut may be rotated by the use of a hollow tube spanner
174. The existence of the threaded rod 128' above the nut 172 can
provide evidence of the relative position of the rod 128' and that
will provide some indication as to whether or not the
part-cylindrical shell 134' has engaged with the locking pin
122.
[0134] For greater certainty, the locking member 126' may include
an indicator to indicate whether or not the part-cylindrical shell
134' has moved to the locked configuration (See FIG. 29). The
part-cylindrical shell 134' may include a pair of diametrically
aligned grooves 180. Further, the locking member 126' may include a
non-movable part which is provided with a second pair of
diametrically aligned grooves 182. The non-movable part may be
provided as part of the plastic void former 132'. When the
part-cylindrical shell 134' is rotated from the unlocked
configuration to the locked configuration as shown in the
right-hand side of FIG. 29, it will be understood that the grooves
180 will align with the grooves 182.
[0135] The alignment of the two pairs of grooves 180, 182 can be
visually inspected when an inspection shaft (not shown) is provided
in the panel 118'', the inspection shaft having a longitudinal axis
which aligns with the axis of rotation of the part-cylindrical
shell 134'. The inspection shaft may comprise simply a cylindrical
void extending through the side wall panel 118'' to check the
position of the part-cylindrical shell 134' and thus verify that
engagement with the pin 122 has taken place. The inspection shaft
may be formed by a PVC conduit which is put in place prior to
casting.
[0136] The inspection shaft may also be put to use when one of the
locking members 126' fails to engage. The locking member 126' may
be provided with a hexagonal spigot 184 which may be manually
rotated to rotate the part-cylindrical shell 134', in the event
that it fails to rotate, due to some malfunction of the concrete
component connecting system 110'.
[0137] The inspection shaft may facilitate visual inspection of the
locking mechanism or give a tactile indication. For example, the
inspection shaft may receive an insert (not shown). The insert may
have a key which engages with the pairs of grooves 180, 182 if and
only if they are correctly aligned. The insert may be in the form
of a plastic plug which remains in the inspection shaft to seal the
inspection shaft once the inspection is complete.
[0138] Reverting to FIGS. 23 and 24, it can be seen, that in
addition to the two locking mechanisms provided at the abutting
first and second edges 116' and 120', a locking mechanism is also
provided at a fourth lower edge 186 of the panel 118''. The locking
mechanism includes a locking member 126''. This locking member
126'' is similar to the locking member 126' in that it uses two
cable portions. However, the location of the cable guiding pin 156
is different. The locking member 126'' engages with a pin 122
provided in slab 112. The locking member 126'' can be locked and
unlocked as described above in connection with FIGS. 27 and 28.
[0139] The foregoing only describes only one embodiment at the
present invention and modifications may be made thereto without
departing from this scope of the invention.
* * * * *