AU1530300A - A ceiling panel, a method of construction, and a building construction system - Google Patents

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (Original) APPLICATION NO:

LODGED:

COMPLETE SPECIFICATION LODGED:

ACCEPTED:

PUBLISHED:

RELATED ART: 4 4 NAME OF APPLICANT: ACTUAL INVENTOR: ADDRESS FOR SERVICE: JOHN WILLIAM BAVERSTOCK

APPLICANT

LORD COMPANY Patent Trade Mark Attorneys 4 Douro Place West Perth, Western Australia, 6005

AUSTRALIA.

INVENTION TITLE: "A CEILING PANEL, CONSTRUCTION, AND CONSTRUCTION SYSTEM" A METHOD OF A BUILDING DETAILS OF ASSOCIATED PROVISIONAL APPLICATION NO'S: Australian Provisional Patent Application Number PP8624 filed on February 11, 1999.

The following Statement is a full description of this invention including the best method of performing it known to me/us: The present invention relates to a ceiling panel, a method of construction, and a building construction system, particularly for use in construction of short span structures.

Conventional building methods for construction of residential dwellings and short span structures rely on the construction of composite outer walls upon or over a floor base to provide a "self-supporting" outer wall structure ready to receive and support a roof frame or upper floor frame. The roof or upper floor frame is not intended to provide lateral support to the outer wall. Rather, the outer wall structure provides compressive support for the roof or upper floor frame. The roof frame is structured or 10 based off from strutting beams and wall plates, and requires in-filling, decorating with gypsum linings and so forth upon completion.

It is known to provide pre-fabricated wall panels as an alternative to walls constructed S•on-site from masonry brick, composite brick, calcium brick, metal and timber, rammed earth, hessian, straw and the like. The pre-fabrication wall panels may be manufactured from normal premixed concrete, light weight concrete composite board, stud wall, plastic, fibreglass, timber, timber panel and composite compounds. The •oo* wall panels may be so configured to form an outer building shell or superstructure •ooo• S"ready to receive appropriate finishing applications and a roof frame structure.

It is necessary to brace the wall panels with adjustable steel or similar braces before roof beams, upon which the roof frame is constructed, are inserted and bolted into position. Conventional construction methods also include the erection of concrete wall panels which are pre-braced and then tied together with prefabricated steel, timber or concrete beams and/or trusses. In some instances, particularly in high rise structures, in sitit concrete floor slabs and beams are used.

The effort expended in pre-bracing the wall panels and then preparing the roof frame is labour intensive, time consuming and therefore costly. Internal or building cross walls are also installed to prevent vertical collapse of the roof beams. Furthermore, there are numerous secondary tasks including float-and-set plastering, ceiling frame work, installation of fibrous ceiling lining, formwork to suspended slabs and stairs, steel reinforcement and steel bar fixing which must also be completed before further construction and internal and external finishing activities can be commenced.

The present invention seeks to overcome at least some of the aforementioned disadvantages.

In accordance with one aspect of the present invention there is provided a construction system for laterally supporting walls of a building without an extraneous bracing system, said system including at least one ceiling panel and a plurality of walls, wherein each wall is interconnected with at least one other wall and a ceiling panel, is mounted on the interconnected walls such that load transference of the ceiling panel to the interconnected walls and load transference between the S"interconnected walls prevents inward or outward collapse of the walls.

In accordance with a second aspect of the present invention there is provided a ceiling ooooo panel with at least one elongate recess, the elongate recess being arranged, in use, to receive an upper portion of a wall of a building wherein the ceiling panel is arranged, in use, to span and laterally support the walls of the building thereby preventing outward or inward collapse of the walls.

In accordance with a third aspect of the invention there is provided a method of constructing a building, said method including the steps of:a) constructing walls of the building upon a floor base; and 4 b) spanning the walls of the building with a ceiling panel, wherein an upper portion of the walls is received within an elongate recess in the ceiling panel, whereby the outer walls of the building are laterally supported and prevented from outward or inward collapse.

In accordance with a fourth aspect of the present invention there is provided a construction system for laterally supporting walls of a building, said system including the walls of the building being constructed upon a floor base, and a ceiling panel with at least one elongate recess, wherein the ceiling panel is arranged, in use, to span the walls of the building, an upper portion of the walls being received in the or each recess of the ceiling panel, thereby preventing outward or inward collapse of the walls.

The present invention will now be described, by way of example only, with reference to the accompanying drawings in which:- Figure 1 is a diagrammatic side plan view of a single storey building structure in accordance with one embodiment of the present invention; S-.Figure 2 is a diagrammatic side plan view of a double storey building structure in accordance with an alternative embodiment of the present invention; and Figure 3 is a diagrammatic top plan view of a building structure in accordance with one embodiment of the present invention.

Referring to Figure 1 there is shown a single storey building structure 10, including a plurality of base footings 20, a floor slab 30, a plurality of outer walls 40, and a ceiling panel 50. The base footings 20 are spaced apart at a distance in accordance with a floor plan (not shown) of the building structure 10. The floor slab 30 is arranged to laterally span the base footings 20, whereby an outer portion 32 of the floor slab 30 is disposed to rest on an inner portion 22 of an upper surface 23 of each base footing 20. Each outer wall 40 extends substantially vertically from an outer portion 24 of the upper surface 23 of the respective base footing The ceiling panel 50 includes a double-sided elongate recess 52, disposed in a lower surface 54 of the ceiling panel 50. The double-sided elongate recess 52 is spaced apart from an outer surface 56 of the ceiling panel 50, such that the double-sided elongate recess 52 is substantially vertically aligned with the outer wall 40. The ceiling panel 50 is arranged to laterally span the outer walls 40, whereby the doublesided elongate recess 52 is arranged to receive an upper portion 42 of the outer wall 0The double-sided elongate recess 52 is configured such that a transverse cross section ooo.

of the double-sided elongate recess 52 is substantially U-shaped. The double-sided :::elongate recess 52 is also configured such that an upper portion 42 of the outer wall oeooe is receivable in the double-sided elongate recess 52 of the ceiling panel Referring to Figure 2 there is shown a building structure 100 including a lower storey 101, and an upper storey 102.

S•The lower storey 101 includes a plurality of base footings 20, a floor slab 30, a plurality of first outer walls 140 and a first ceiling panel 150. The base footings .:o.oi the floor slab 30 and the plurality of first outer walls 140 are constructed and disposed as previously described with reference to Figure 1.

The first ceiling panel 150 includes a plurality of shoulder portions 156 outwardly extending from an upper portion of the first ceiling panel 50. An outer surface 158 of the shoulder portion 156 is substantially vertically aligned with an outer surface 141 of the first outer wall 140. An outer surface 155 of a lower portion of the first ceiling panel 150 is spaced apart from the outer surface 158 of the shoulder portion 156 at a distance marginally greater that the width of a first outer wall 140.

6 A lower surface 157 of the shoulder portion 156 is disposed to rest on an upper surface 152 of the first outer wall 140, whereby an inner surface 143 of the upper portion 142 of the first outer wall 140 is adjacent the outer surface 155 of the lower portion of the first ceiling panel 150.

The configuration of shoulder portions 156 which outwardly extend from upper portions of the first ceiling panel 150 provide, in effect, a single-sided elongate recess 120 in the outer portions of the first ceiling panel 150. The single-sided elongate recess 120 is configured such that a transverse cross-section of the single-sided elongate recess is substantially L-shaped.

The first ceiling panel 150 is arranged to laterally span the first outer walls 140, whereby the single-sided elongate recess 120 is arranged to receive an upper portion 142 of the first upper wall 140.

S•The shoulder portion 156, of the first ceiling panel 150 is interconnected with the plurality of first outer walls 140 by substantially vertically disposed safety dowels The upper storey 102 includes the first ceiling panel 150, a plurality of second outer .o walls 240, and a second ceiling panel 250.

oo00 Each second outer wall 240 extends substantially vertically from an upper surface 154 of the shoulder portion 156 of the first ceiling panel 150. The shoulder portions 156 of the first ceiling panel 150 are interconnected with the second outer walls 240 by substantially vertically disposed safety dowels The second ceiling panel 250 includes a double-sided elongate recess 52, disposed in a lower surface 54 of the second ceiling panel 250. The double-sided elongate recess 52 is substantially vertically aligned with the outer wall 240. The double-sided elongate recess 52 is also configured such that a transverse cross section of the double-sided elongate recess 52 is substantially U-shaped. The double-sided elongate recess 52 is also configured such that an upper portion 248 of the outer wall 240 is receivable in the double-sided elongate recess of the second ceiling panel 57.

The second ceiling panel 250 is interconnected with the outer walls 240 by substantially vertically disposed safety dowels 60. It is within the scope of the present invention to fix an outer wall in position relative to an elongate recess of the ceiling panel by means of safety dowels. However, it will be appreciated that the outer walls and ceiling panel may be interconnected by any other suitable interconnecting means, for example, bolt connections.

Referring to Figure 3 there is shown a building structure 200 including a plurality of first outer walls 210, a plurality of second outer walls 215, a plurality of inner walls o oo 220 including a first inner wall 222, a second inner wall 224, a third inner wall 226, a ceiling panel 230, and a plurality of interconnecting safety dowels S"The outer and inner walls 210, 220 are spaced apart at a distance in accordance with a floor plan (not shown) of the building structure 200.

oo The ceiling panel 230 is arranged to laterally span the outer walls 210. A lower surface of the ceiling panel 230 is interconnected to an upper surface of each outer ••co and inner wall 210, 220 by substantially vertically disposed safety dowels 60 (not °.oeo shown).

Alternatively it is within the scope of the present invention for the lower surface of the ceiling panel 230 to include a double-sided elongate recess 52 (not shown) or single-sided elongate recess 120 (not shown), whereby the double-sided or singlesided recess 52, 120 is arranged to receive an upper portion of an outer or inner wall 210, 220.

8 The outer or inner walls 210, 220 may be further secured in the double-sided or single-sided recess 52, 120 of the ceiling panel 230 by vertically disposed safety dowels The first and the second outer walls 210, 215 are endwise interconnected. The first outer wall 210 includes a single-sided vertically extending recess 212 in the outermost portion 211 of the first outer wall 210. The recess 212 is configured such that an outermost portion 217 of the second outer wall 215 is receivable in the single-sided elongate recess 212 of the first outer wall 210.

As shown in Figure 3, the first inner wall 222 spans a plurality of first outer walls 210 ".9.10 of the building structure 200. A first outermost portion 221 of the first inner wall 222 is interconnected to an intermediate portion 216 of the first outer wall 210. The intermediate portion 216 includes a double-sided vertically extending elongate recess .ooooi 214. The elongate recess 214 is configured such that the first outermost portion 221 of the first inner wall 222 is receivable in the double-sided vertically extending elongate °ooo recess 214 of the first outer wall 210.

•"In a similar fashion, a first outermost portion 228 of the third inner wall 226 is receivable in the double-sided vertically extending elongate recess 214 disposed in an .ooo.i intermediate portion 216 of another first outer wall 210.

A second outermost portion 223 of the first inner wall 222 is interconnected to two adjacent outermost portions 211 of two adjacent expanses of first outer walls 210.

Each outermost portion 211 includes a single-sided vertically extending recess 212.

However, it will be evident from Figure 3, that a pseudo double-sided vertically extending recess 214a is formed when two single-sided recesses 212 are disposed adjacent to one another. Thus, the pseudo double-sided recess 214a is configured such that the second outermost portion 223 of the first inner wall 222 is receivable in the 9 pseudo double-sided recess 214a formed by two adjacent expanses of first outer walls 210.

It is also within the scope of the present invention for an inner wall 220 to be interconnected to another inner wall 220. For instance, as illustrated in Figure 3, a first outermost portion 225 of the second inner wall 224 is interconnected to an intermediate portion 213 of the first inner wall 222. The intermediate portion 213 includes a double-sided vertically extending elongate recess 233. The elongate recess 233 is configured such that the first outermost portion 225 of the second inner wall 224 is receivable in the double-sided vertically extending elongate recess 233 of the first inner wall.

A second outermost portion 227 of the second inner wall 224 is interconnected to a second outermost portion 229 of the third inner wall 226. The second outermost ooo i portion 229 includes a single-sided vertically extending recess 230. The elongate recess is configured such that the second outermost portion 227 of the second inner ego* wall 224 is receivable in the single-sided vertically extending elongate recess 230 of the third inner wall 226.

It is within the scope of the present invention for interconnections between inner walls S220, an inner wall and an outer wall 220, 210, and a first outer wall 210 and a second outer wall 210, 215 to be secured by safety dowels 60 and by any other suitable interconnecting means. It is also within the scope of the present invention that the corresponding vertically extending elongate recess be configured such that alternatively shaped outermost portions of the inner or outer walls are receivable in the elongate recess.

The upper portion of each outer wall 210 and each inner wall 220 locates in a corresponding single- or double sided elongate recess of the ceiling panel, such that the inner surface of the upper portion of the outer or inner wall 210, 220 is adjacent to a substantially vertical surface of the elongate recess of the ceiling panel, the effect of which is that, in use, the outer and inner walls 210, 220 are laterally supported against inward or outward collapse. The upper surface of the upper portion of the outer or inner wall is contiguous with a substantially lateral surface of the elongate recess of the ceiling panel, the effect of which is that, in use, the outer and inner walls compressively support the ceiling panel.

Alternatively, the upper surface of the upper portion of the outer or inner walls is contiguous with a substantially lateral lower surface of the ceiling panel, the effect of which is that, in use, load transference of the ceiling panel to the outer and inner walls prevents the inward or outward collapse of the outer and inner walls of the building structure.

In use, a building structure is constructed by first erecting the outer walls and inner walls of the building structure upon or over a floor base in a configuration in a accordance with a particular building floor plan. Interconnection between two walls is ""effected by engagement of an outermost portion of the first wall with a recess in the second wall. The recess is configured and arranged, in use, to receive an outermost portion of the first wall. In use, the interconnection may be further secured by safety dowels and by any other suitable interconnecting means.

Structural members of the building structure, including the base footings, the floor slab, the outer walls, the inner walls and the ceiling panel may be pre-fabricated in appropriate dimensions in accordance with the design of the intended building. The pre-fabricated structural members are manufactured from suitable building composites, preferably but not limited to normal premixed concrete, light weight I1 concrete, composite board, stud wall, plastic fibreglass, timber panel, or composite compound.

Furthermore, structural members may be prefabricated to include internal castings for installation of utility services, thereby reducing labour later expended on incorporating such facilities.

The ceiling panel is then installed by locating an upper portion of each outer wall in the corresponding elongate recess of the ceiling panel such that an inner surface of the upper portion of each outer and inner wall is adjacent with a substantially vertical surface of the corresponding elongate recess. In this way, the outer and inner walls are laterally supported and prevented from inward or outward collapse. Further structural °oeo support may be provided by interconnecting the ceiling panel to the outer and inner walls by suitable interconnecting means, preferably safety dowels.

ooooo Alternatively, the ceiling panel is then installed by placing the ceiling panel on an "upper surface of the outer and inner walls and interconnecting the ceiling panel to the outer and inner walls by suitable interconnecting means, preferably safety dowels.

The ceiling panel provides a safe and economical working platform for simple roof framing operations. Alternatively, as shown in Figure 2, a first ceiling panel may, in ooo oI turn, become a second floor base upon which a second storey comprising outer walls may be constructed. The ceiling panel also provides a safe and weatherproof covering for internal fit out to proceed simultaneously with external finishing. This allows a decrease in overall construction time of between 40 and It will be appreciated that although the present invention has been described with reference to a ceiling panel comprising one continuous expanse, the invention is equally applicable to a ceiling panel comprising several smaller dimension expanses 12 interconnected by suitable interconnecting means, including but not limited to dowels, clips, plates, plated insets, and keys.

It will also be appreciated that although the present invention has been described with reference to a short span single storey and a double storey building construction, the invention is equally applicable to a short-span multi-storey building construction.

Similarly, the present invention is equally applicable to a long span building construction when pre-stressed ceiling panels are used.

It will also be appreciated that although the present invention has been described with reference to the use of ceiling panels to laterally support the outer walls of a building structure, the invention is equally applicable to the use of the ceiling panel to laterally support internal walls of building structure, such that separate internal rooms or compartments may be constructed.

°•o°i Modifications and variations such as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

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Claims (22)

1. A construction system for laterally supporting walls of a building without an extraneous bracing system, said system including at least one ceiling panel and a plurality of walls, wherein each wall is interconnected with at least one other wall and a ceiling panel is mounted on the interconnected walls, such that load transference of the ceiling panel to the interconnected walls and load transference between the interconnected walls prevents inward or outward collapse of the walls.

2. A construction system according to claim 1, wherein the ceiling panel is provided with at least one elongate recess, the elongate recess being arranged, in use, f e to receive an upper portion of at least one wall.

3. A construction system according to claim 2, wherein the elongate recess is 5556 5 single-sided. S. S see.

4. A construction system according to claim 2, wherein the elongate recess is oooo double-sided. @OSSSS S S S

5. A construction system according to any one of claims 1 to 4, wherein a first wall is provided with at least one vertically extending elongate recess, the elongate recess being arranged, in use, to receive an outermost portion of a second wall.

6. A construction system according to claim 5, wherein the vertically extending elongate recess is single-sided. 14

7. A construction system according to claim 5, wherein the vertically extending elongate recess is double-sided.

8. A construction system according to any one of claims 1 to 7, wherein each wall is interconnected with at least one other wall and a ceiling panel by an interconnecting means.

9. A ceiling panel with at least one elongate recess, the elongate recess being arranged, in use, to receive an upper portion of a wall of a building wherein the ceiling panel is arranged, in use, to span and laterally support the walls of the building thereby preventing outward or inward collapse of the walls.

A ceiling panel according to claim 9, wherein the elongate recess is single- sided. i

11. A ceiling panel according to claim 9, wherein the elongate recess is double- sided. ooooo

12. A method of constructing a building, said method including the steps of:- a) constructing walls of the building upon a floor base; and b) spanning the walls of the building with a ceiling panel, wherein an upper portion of the walls is received within an elongate recess in the ceiling panel, whereby the outer walls of the building are laterally supported and prevented from outward or inward collapse.

13. A construction system for laterally supporting walls of a building, said system including the walls of the building being constructed upon a floor base, and a ceiling panel with at least one elongate recess, wherein the ceiling panel is arranged, in use, to span the walls of the building, an upper portion of the walls being received in the or each recess of the ceiling panel, thereby preventing outward or inward collapse of the walls.

14. A construction system according to claim 13, wherein the elongate recess is single-sided.

A construction system according to claim 13, wherein the elongate recess is double-sided.

16. A construction system according to any one of claims 13 to 15, wherein a first wall is provided with at least one vertically extending elongate recess, the elongate recess being arranged, in use, to receive an outermost portion of a second wall.

17. A construction system according to claim 16, wherein the vertically extending elongate recess is single-sided.

18. A construction system according to claim 16, wherein the vertically extending elongate recess is double-sided. 16

19. A construction system according to any one of claims 13 to 15, wherein the upper portion of the walls is interconnected with the ceiling panel by an interconnecting means.

20. A construction system substantially as hereinbefore described with reference to accompanying Figures 1 to 3.

21. A ceiling panel substantially as hereinbefore described with reference to accompanying Figures 1 to 3.

22. A method of constructing a building substantially as hereinbefore described with reference to accompanying Figures 1 to 3. DATED THIS 10 T" DAY OF FEBRUARY 2000. JOHN WILLIAM BAVERSTOCK By his Patent Attorneys LORD AND COMPANY PERTH, WESTERN AUSTRALIA