AU2002336815B2

AU2002336815B2 - Building component

Info

Publication number: AU2002336815B2
Application number: AU2002336815A
Authority: AU
Inventors: Danny W Hills
Original assignee: Bartra Island Pty Ltd; Paxton St Pty Ltd; Petschel Invest Pty Ltd
Current assignee: Bartra Island Pty Ltd; Paxton St Pty Ltd; Petschel Investments Pty Ltd
Priority date: 2001-11-03
Filing date: 2002-11-04
Publication date: 2006-10-12
Anticipated expiration: 2022-11-04

Description

I i 01A S"Building component" SField of the Invention This invention relates to the construction industry and in particular to a building Sapparatus for forming, moulding and rendering of wall construction or the like. The invention also relates to a method of constructing a wall, footing, floor or like construction, using the apparatus and to a final construction using the apparatus and 00 method of the invention.

Background of the Invention The manufacture and construction of walls and other building elements involving cement and concrete render, typically necessitates the use and preparation of extensive formwork to provide a mould against which the concrete render can be formed, so as to provide a basis for the preparation and laying out of render, during the construction process. The use of such formwork and moulding requires labour intensive and extensive preparatory work and once the concrete render has been placed in position and set, the moulds and formwork must be removed to expose the finished construction. The removal and possible re-use of formwork and moulding is labour intensive and problematical, given the damage that generally occurs in this environment. Accordingly, the currently used techniques, involve great inefficiencies, waste and impose definite limitations on the quality and finish of the final rendered product which is quite dependent on the quality of the formwork prepared and gives little or no opportunity to address any imperfections in the rendered product, short of re-rendering the construction once the formwork is removed.

It would be highly desirable if the formwork and moulding apparatus could be provided in a manner that would allow the mould to form an integral part of the finished rendered construction and one object of the invention is to provide an improved building apparatus and method of constructing a wall or the like, involving the use of cement render.

Summary of the Invention In a first aspect the invention provides a building apparatus for forming, moulding and rendering a wall construction or the like, comprising a plurality of supporting elements, one or a plurality of permeable panels adapted for self supporting fitting to the supporting elements of said wall at a distance removed therefrom to provide a fillable cavity between said supporting elements and said panels wherein said panels are characterised by a plurality of apertures providing substantially uniform permeability for a a filler suppliable to the cavity, such that, once rendered and set, said rendered filler and said panels form an integral part of said wall.

The panels may be provided in the form of an outer skin with a plurality of parallel inner supporting ribs formed over the substantial length of the panel with each individual rib running over the substantial width of the panel.

The outer skin may be formed with a series of substantially parallel corrugations 00 running transverse to the direction of the supporting ribs, such that the space between consecutive inner supporting ribs, may form a casting space or conduit to assist in Sdirecting and controlling the flow of filler as it is directed through the fillable cavities.

The apertures formed in the skin of the panels may be formed in a substantially uniform array over the whole area of the outer skin of the panel. The apertures may be formed in linear rows along the crest, trough and inclined sides of each of the respective corrugations.

The adjacent ribs formed in the panels may be joined with a bridging means, such that adjacent bridged ribs may be formed at a first end and configured to comprise a projecting key and alternate adjacent ribs at the second end may also be bridged to form a receiving dock. In this manner, the suitably aligned key and dock of adjacent panels may cooperate for inter-engagement of adjacent panels in a first direction, most preferably being a vertical direction.

The skin of the panels at a first edge thereof, may be provided with one or a plurality of pins, with a second edge being provided with a plurality of corresponding eyes, such that the suitably aligned pins and eyes of adjacent panels may cooperate for inter-engagement of adjacent panels in a second direction which may be a horizontal direction.

The supporting elements of the wall may comprise a plurality of spacer blocks where each spacer block is sealable so as to provide an impermeable cavity in the wall.

The spacer blocks may be formed as a parallelepiped configuration so as to be adapted for ready stacking and interconnection to build a substantial and supporting interconnected pre-wall. The supporting elements (and supporting surface thereof) of the pre-wall provide the support structure for the permeable panels. The spacer blocks may include steps formed at the four corners thereof so as to define upper and lower flanges, which may in turn define mating faces for adjacent spacer blocks. The stepped corners provide hollow transverse passages formed at the juncture of four mating blocks. The transverse passages allow an interconnection between both sides of the supporting wall or pre-wall, to allow interlocking of the filler when both sides of a wall are rendered.

5 material and closed cell foams are useful. The panels may be moulded, thermoformed or pressed from metal sheet.

VThe inner panel faces may be contoured so that the expressed mix forms covings ,and skirtings and other internal features of the building. The spacers may have ends which when assembled in courses, define the multiple passages connecting the outer Sarray of panels with the inner array of panels. The term "panel" is not restricted to a two dimensional structure which produces a planar wall. Curvilinear shapes are 00 1,O possible by manufacturing the panel in the required shape.

Cc The outer face of the panel, that is the face defining the perimeter of the wall, S 10 namely the outside face and the inner face of the panel which defines the inner face of Sthe building, are perforated and may also be corrugated or dimpled or otherwise arranged to accommodate different depths of mix in order to improve the float response of the wall.

Conventional reinforcement, such as required by building regulations, is included in the wall, for example rods and bars which are wired, welded or clipped together. The term "perforations" includes slots. Circular perforations are useful. The diameter is not critical in that the quantity of mix which flows through the perforations depends on the compositions of the mix, for example the aggregate size and the water content. Diameter of 5-15mm have given useful results.

The corrugations on the panel are not essential in that acceptable results are attainable using flat panels, however the floating operation tends to push aggregate with the floor of corrugation and a smoother finish is achieved.

The invention also provides a wall construction comprising: a first plurality of permeable panels, each having a plurality of apertures; supporting elements for supporting the panels; a cavity defined partly by the panels for receiving a filler so that the filler passes through the apertures in the panel to provide an outer surface of the wall construction, with the panels permanently embedded in the filler and therefore the wall construction; and at least one space in the wall construction between the panels and a surface of the wall construction opposite said outer surface.

The invention also provides a method of constructing a wall comprising: providing a first plurality of connecting elements; assembling an array of panels having apertures on the connecting elements to )H\Luieal\Keep\Speci\HiIIS AU2002336815.doc 1/09/06 5a define a cavity on one side by the panels; filling the cavity with a filler so that the filler passes through the apertures in the panel to provide an outer wall surface and to embed the panels in the filler material; and providing at least one space between the panels and a surface of the wall opposite said outer wall surface.

The invention also provides a wall construction comprising: 00 ,O a first plurality of permeable panels, each having a plurality of apertures; 3 ~supporting elements for supporting the panels; S 10 a cavity defined by the panels for receiving a filler so that the filler passes through Sthe apertures in the panels to provide an outer surface of the wall, with the panels permanently embedded in the filler and therefore the wall construction; and the panels having a plurality of substantially parallel corrugations at least on a surface of the panels located outward of the cavity.

The invention also provides a panel for a wall construction which has a plurality of connecting elements for supporting a plurality of the said panels in the wall construction, the panel comprising: a panel body having an outer surface; a plurality of apertures through the panel body for allowing a filler to pass through the apertures to embed the panel in the filler and therefore the wall construction when constructed; and the outer surface of the panels having a plurality of corrugations.

Brief Description of the Drawings Figure 1 is a perspective view of a representative wall portion part way through construction.

Figure 2 is an enlargement of the area marked A of Figure 1 seen from direction B.

Figure 3 is an exploded view of the wall portion shown in Figure 1 with a pair of opposed panels.

Figure 4 is a close up of an edge fragment of a panel showing the peg locator.

Figure 5 is a close up of the corresponding edge portion of an adjacent panel showing the eye which receives the peg.

Figure 6 is a perspective as in Figure 1, showing part of the wall after casting.

Figure 7 is a section through the completed wall.

H.NLuia1\Keep\Speci\Hi1Ia AU2002336815doc 1/09/06

Claims

3. An apparatus according to claim 2, wherein said outer skin is formed with a series of substantially parallel corrugations transverse to the direction of said supporting ribs.
4. An apparatus according to claim 3, wherein said inner supporting ribs form a castings space or conduit to assist in directing and controlling the flow of said filler in said fillable cavity. An apparatus according to any one of claims 1 to 4 wherein said apertures are formed in a substantially uniform array over the substantial area of the outer skin of said panel.
6. An apparatus according to any one of claims 3 to 5 wherein said apertures are formed in linear rows along the crest trough and inclined margins of said corrugation.
7. An apparatus according to any one of claims 2 to 6 wherein two or more adjacent ribs may be fitted with a bridging means.
8. An apparatus according to claim 7, wherein said bridging means and bridged ribs form at a first end a projecting key and at a second end a receiving dock wherein said key and dock of adjacent panels can cooperate for interengagement in a first direction.
9. An apparatus according to claim 8, wherein said bridge at said second end is formed between two alternate adjacent ribs such that when adjacent panels are interengaged a continuous bridge is formed across the first and second ends of said ribs. An apparatus according to claim 8, wherein a first edge of the skin of said panel has one or a plurality of pins and a second edge of said skin has one or a plurality of corresponding eyes wherein said pins and eyes of adjacent panels can cooperate for interengagement in a second direction.
11. An apparatus according to any one of claims 1 to 9, wherein said supporting elements comprise a spacer block having a sealable cavity. 16
22. A method according to claim 21 where linking wires are fitted between corresponding reinforcing rods fitted to either side of said supporting wall.
23. A method according to claim 22, wherein said filler is placed into said cavity at a suitable rate to allow a position of said filler to permeate through said apertures in the skin of the panel. 00
0024. A method according to claim 23, wherein said filler is placed at a rate allowing the first placement to be rendered and begin to set such that subsequent placement builds on S 10 the previous placement to form a wave of workable render permeating through said panel skin. A wall or the like constructed in accordance with the method of any one of claims 18 to 24.
26. A wall or the like constructed according to claim 25 comprising a plurality of spacer blocks assembled to form a pre-wall of supporting elements providing at least one supporting surface, a plurality of permeable panels secured to said supporting surface and filler encasing said panels and abutting said supporting surface.
27. A wall or the like according to claim 26, wherein said filler permeates said spacer blocks at the hollow transverse passages formed at the juncture of form mating blocks.
28. A wall or the like according to any one of claims 25 to 27 wherein permeable panels and filler are fitted to both sides of said spacer blocks.
29. A wall or the like according to any one of claims 25 to 28 wherein said wall is a vertical structure.
30. A wall or the like according to any one of claims 25 to 28 wherein said wall is a non-vertical structure.
31. A wall or the like according to claim 30 wherein said structure is horizontal.
32. A wall construction comprising: a first plurality of permeable panels, each having a plurality of apertures; supporting elements for supporting the panels; H.\LuiaI\Keep\Speci\Hi11a AU2002336015.doc 1/09/06 17 a cavity defined partly by the panels for receiving a filler so that the filler passes through the apertures in the panel to provide an outer surface of the wall construction, with the panels permanently embedded in the filler and therefore the wall construction; and at least one space in the wall construction between the panels and a surface of the wall construction opposite said outer surface. oO ,O 33. A method of constructing a wall comprising: ~providing a first plurality of connecting elements; S 10 assembling an array of panels having apertures on the connecting elements to define a cavity on one side by the panels; filling the cavity with a filler so that the filler passes through the apertures in the panel to provide an outer wall surface and to embed the panels in the filler material; and providing at least one space between the panels and a surface of the wall opposite said outer wall surface.
34. A wall construction comprising: a first plurality of permeable panels, each having a plurality of apertures; supporting elements for supporting the panels; a cavity defined by the panels for receiving a filler so that the filler passes through the apertures in the panels to provide an outer surface of the wall, with the panels permanently embedded in the filler and therefore the wall construction; and the panels having a plurality of substantially parallel corrugations at least on a surface of the panels located outward of the cavity. A panel for a wall construction which has a plurality of connecting elements for supporting a plurality of the said panels in the wall construction, the panel comprising: a panel body having an outer surface; a plurality of apertures through the panel body for allowing a filler to pass through the apertures to embed the panel in the filler and therefore the wall construction when constructed; and the outer surface of the panels having a plurality of corrugations.
36. An apparatus according to any one of claims 1 to 17 substantially as hereinbefore described with reference to the examples and drawings.
37. A method according to any one of claims 18 to 24 substantially as hereinbefore H,\Luisal\Keep\Speci\Hillo AU2002336815.doc 1/09/06 18 described with reference to the examples and drawings.
38. A wall or the like construction according to any one of claims 25 to 31 substantially Sas hereinbefore described with reference to the examples and drawings. Dated this 4th day of September 2006 DANNY WAYNE HILLS 00 0 By their Patent Attorneys c GRIFFITH HACK 10 Fellows Institute of Patent and 0 Trade Mark Attorneys of Australia (N H.\Luiaa1\Keep\Speci\Hi119 AU2002336815.doc 4/09/06