AU2006200160A1 - A prefabricated wall unit - Google Patents
A prefabricated wall unit Download PDFInfo
- Publication number
- AU2006200160A1 AU2006200160A1 AU2006200160A AU2006200160A AU2006200160A1 AU 2006200160 A1 AU2006200160 A1 AU 2006200160A1 AU 2006200160 A AU2006200160 A AU 2006200160A AU 2006200160 A AU2006200160 A AU 2006200160A AU 2006200160 A1 AU2006200160 A1 AU 2006200160A1
- Authority
- AU
- Australia
- Prior art keywords
- wall unit
- prefabricated wall
- building
- floor slab
- outer face
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- Load-Bearing And Curtain Walls (AREA)
Description
P/00/011 Regulation 3.2
AUSTRALIA
Patents Act 1990
ORIGINAL
COMPLETE SPECIFICATION STANDARD PATENT Invention Title: "A PREFABRICATED WALL UNIT" The following statement is a full description of this invention, including the best method of performing it known to me/us: o TITLE "A PREFABRICATED WALL UNIT" ~FIELD OF THE INVENTION The invention relates to a wall unit. In particular, although not exclusively, the invention relates to a prefabricated wall unit used to complete the outer shell O of a building, preferably a multi-storey building.
0 BACKGROUND TO THE INVENTION 0 With expanding residential and commercial density, there has been an increase in the number of multi-storey commercial and residential buildings being constructed. As is known in the art, multi-storey buildings are generally constructed using steel reinforced concrete pylons which support reinforced concrete floor slabs. Window units are then located at intervals between the concrete pylons for each floor and non-structural wall units then complete the outer shell of the building.
The wall units are generally of two different types. The first is formed from concrete blocks that are assembled on the concrete floor slab at the location of the wall unit. An exterior outer finish is then applied to an outer face of the wall unit. The outer finish may be a material that is fastened to the wall unit or the outer face is rendered and painted. An inner finish is then fastened to an inner face of the. wall unit. The inner finish is generally in the form of plasterboard to complete the inner wall of the building.
Alternatively, the wall units are formed from steel framed walls that are constructed on site and have inner and outer finishes applied after construction.
The location of these wall units to complete the space between the concrete pylons and the window units is labour intensive and requires the skills of several types of tradesmen for completion.
This is an inefficient construction process due to many different tradesmen being required to complete the wall unit and requires significant use O of the building tower crane in order to lift the raw materials each tradesperson 0 I requires to complete the wall unit to the floor under construction.
Additionally, it is often difficult for the building construction manager to efficiently schedule the construction process in order that the various tradesmen required are on site at the appropriate time.
Furthermore, as this process requires tradesmen to work on the exterior of the building to apply the outer finish to the outer face of the wall unit, there exists the risk of significant injury due to tradesmen falling from a height or dropping tools and/or material. As such, it is necessary to erect scaffolding which adds to the construction costs and time required to construct the building.
Hence, it is desirable to provide for a new wall unit design to complete the outer shell of a multi storey building that overcomes or at least alleviates one or more of the above problems.
DISCLOSURE OF THE INVENTION In one form, although it need not be the only or indeed the broadest form, the invention resides in a prefabricated wall unit for completing the outer shell of a building comprising: a supporting frame; a finished outer face fastened to the supporting frame; and a fastening portion for securing the prefabricated wall unit to a building
IND
o floor slab.
In another form, the invention resides in a method of locating a prefabricated wall unit on a building including the steps of: fastening a finished outer face to a supporting frame to form the prefabricated wall unit; ot(ii) locating a lower portion of the prefabricated wall unit upon a floor slab N of the building; and 0(iii) fastening the prefabricated wall unit to at least the floor slab to thereby secure the prefabricated wall unit in position.
In still a further form, the invention resides in a method of locating a prefabricated wall unit on a building including the steps of: locating a lower portion of the prefabricated wall unit upon a floor slab of the building; and fastening the prefabricated wall unit to at least the floor slab to thereby secure the prefabricated wall unit in position; whereby, the prefabricated wall unit has a finished outer face prior to it being located upon the floor slab.
Further features of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect preferred embodiments of the invention will be described by way of example only with reference to the accompanying drawings, wherein: FIG 1A shows a perspective view of a partially complete building having o an outer shell partially formed from a plurality of prefabricated wall units according to an embodiment of the invention; FIG 1B shows a perspective view of a partially complete building having an outer shell partially formed from a plurality of prefabricated wall units according to an embodiment of the invention; o FIG 2A shows a cutaway partial perspective view of a prefabricated wall 0 Iunit shown in FIG 1A and FIG 1B; oFIG 2B shows a cutaway partial perspective view of a prefabricated wall unit shown in FIG 1A and FIG 1 B; FIG 3 shows a sectional side view of two prefabricated wall units according to an embodiment of the invention fastened to a floor slab of a building; FIG 4 shows a sectional side view of a prefabricated wall unit according to an embodiment of theinvention fastened to a floor slab of a building; FIG 5 shows a sectional side view of a prefabricated wall unit according to an embodiment of the invention fastened to a floor slab of a building; FIG 6A shows a cut away perspective view of an embodiment of a prefabricated wall unit of the invention fastened to a window unit; FIG 6B shows a sectional top view of an embodiment of a prefabricated wall unit of the invention fastened to a window unit; and FIG 7 shows a rear cut away perspective view of an embodiment of a prefabricated wall unit of the invention located below a window unit.
DETAILED DESCRIPTION OF THE INVENTION FIG 1A and FIG 1B each show a partially complete building having an outer shell constructed using a plurality of prefabricated wall units 100 according
IND
O to an embodiment of the invention and window units 200 as known in the art. As 0 seen, each of the wall units 100 and window units 200 span the space between respective concrete floor slabs 10 in order to complete the outer shell of the
IND
building.
o 5 FIG 2A and FIG 2B each show a cutaway partial perspective view of the o prefabricated wall unit 100 of the invention. Each prefabricated wall unit 100 is 0 formed from a supporting frame 110, a finished outer face 120, an inner face 130 (not shown in FIGs 2A and 2B) and insulation 140.
Supporting frame 110 provides a durable substructure for wall unit 100.
Supporting frame 110 is formed from a plurality of support members 111 suitably arranged. Preferably, each support member 110 is formed from galvanized steel, aluminum or the like.
Finished outer face 120 at least partially encompasses supporting frame 110. Preferably, outer face 120 is in the form of an AlpolicTM panel that is cut to suit the dimensional requirements of the wall unit 100 and fitted around support frame 110. The outer face 120 is fastened to the supporting frame by means of a chemical fastener, rivets or the like.
AlpolicTM is produced by Mitsubishi Chemical Corporation and is a prefinished composite aluminum panel that is acknowledged in the building industry as providing a lightweight, superior finish for outer faces of buildings.
Alternatively, the outer face 120 may be formed from other known building materials used to provide an aesthetic finish to an outer face of a building such as aluminum, glass, rendered concrete or the like.
Prefabricated wall unit 100 further comprises an inner face 130 (not shown in FIG 2A and 2B13). inner face 130 is preferably formed from a Gyproc T M
IND
o plasterboard sheet or the like. Preferably, inner face 130 is fastened to supporting frame 110 by means of a chemical fastener. As is known in the art, one or more layers of plasterboard sheets may form inner face 130.
IND
Insulation 140 is located within a cavity of the prefabricated wall unit 100 o 5 formed by the supporting frame 110 and the outer face 120 and the inner face
IND
o 130. Insulation 140 is adhered to an internal face of wall unit 100.
0 Preferably, insulation 140 is in the form of a fiberglass based insulation in order that the prefabricated wall unit 100 does not conduct heat and also to provide acoustic insulation.
Prefabricated window unit 100 is located upon an extrusion 210 extending along, and fastened to, an outer edge of floor slab 10 (not shown in FIG 2A or FIG 2B). Preferably, a fastening portion 150 extends from supporting frame 110 in a plane substantially parallel to extrusion 210 and a fastener 151 extends through fastening portion 150, extrusion 210 and terminates in floor slab 10 in order to securely locate prefabricated wall unit 100 in position. Optionally, a member of supporting frame 110 may act as the fastening portion 150. This will be discussed in greater detail below.
Prefabricated wall unit 100 is preferably assembled and manufactured prior to being transported to a building site. Each wall unit 100 is manufactured to have dimensions in order that the wall units complete the outer shell of the building. Once the wall units 100 arrive at site they are transported to designated floors by a tower crane or a mobile crane. In this way, the construction of the entire outer shell of the building may be completed quickly, safely and without the requirement for several differently skilled contractors on the building site. This will be discussed in greater detail below.
o Optionally, the inner face 130 of each prefabricated wall unit 100 is fastened to the prefabricated wall unit 100 on site after wall unit 100 has been fastened to the building in order that the inner face conforms with the interior design of the respective floor.
FIG 3 shows a sectional side view of two prefabricated wall units 100 O fastened to building floor slab 10. A poly packer 300 is located on a step 11 in 0 I the floor slab 10 and extrusion 210 is located upon poly packer 300. A lower Sportion of upper wall unit 100OA is then located upon extrusion 210. Upper wall unit 100OA is located upon extrusion 210 from within what will be the inside of the to be completed building.
Fastener 151A in the form of a structural anchor bolt passes through fastening portion 150A of upper wall unit 100A and poly packer 300 and terminates within floor slab 10 in order that wall unit 100A is firmly secured in place to floor slab 10. Preferably, fastening portion 150A is integrally formed with supporting frame 110A of upper wall unit 100A. Alternatively, fastening portion 150A is formed separately and secured to supporting frame by means of adhesive, structural screws, bolts or the like.
Preferably, wall unit 100A is secured to floor slab 10 at a number of locations along extrusion 210 as described above. Suitably, fastener 151A is water sealed at it's penetration point with extrusion 210.
An upper portion of lower wall unit 100B is fastened to an underside of floor slab 10. In this embodiment, the fastening portion 150B is formed separately from supporting frame 110 OB. The fastening portion 150B is secured to the supporting frame 110OB by means of bolts 152B attached to a threaded screw as is known in the art. As before, the fastening portion 150B is secured to o the floor slab 10 by means of a fastener in the form of a structural anchor bolt 0 151B extending through fastening portion 150B and terminating in floor slab nin order to secure lower wall unit 100 in place.
The outer face 120B of lower wall unit 100B has an upwardly extending 0 5 portion 121B that terminates within a cavity formed by the supporting frame S110A, outer face 120A and inner face 130A of upper wall unit 100A. This IND provides an aesthetic exterior appearance for the outer shell of the building as the wall units 1 00A/B completely cover the concrete floor slab A lower portion 121A of outer face 120A of upper wall unit 100A terminates adjacent upper portion 121B of outer face 120B of lower wall unit 100B. A chemical sealant 310 is applied at this termination to ensure that bugs water and other undesirable elements are not able to pass within the cavity of upper wall unit 100A and thus potentially from the outside of the building shell to within the interior of the building.
Additionally, upper portion 121B of outer face 120B of lower wall unit 100B terminates adjacent extrusion 210. Again, a chemical sealant 320 is applied at this intersection.
Furthermore, a drainage hole 160A is located at a lower extent of upper wall unit 100A in order that any water that enters the cavity in upper wall unit 100A is expelled.
The combination of sealants 310,320, the poly packer 300 and the cavity formed in each wall unit 100 provides an effective sealant barrier to prevent ingress of bugs, water and other undesirable material from outside of the building to within.
FIG 3 shows an embodiment of two wall units 120A/B when wall unit
IND
o 120A is located vertically above lower wall unit 120B to form an outer shell of a 0 building. Typically, an upper portion and a lower portion of each wall unit 100 is secured to floor slab 10 as shown in FIG 3 and described above. However, it is also desirable to locate a wall unit 100 above and below a window unit 200 and hence a wall unit 100 located in this way differs structurally to accommodate this O configuration as will be discussed below; 0 N FIG 4 shows a sectional side view of a prefabricated wall unit 100 secured 0 0to floor slab 10 as previously described. A window unit 200 is secured to an underside of floor slab 10 as is known in the art. Window unit 200 is fastened within a channel 211 secured to floor slab 10 and is of a type that is doubled glazed having an outer window pane 220A and an inner window pane 220B.
In this embodiment of prefabricated wall unit 100, lower portion 121 of outer face 120 terminates adjacent extrusion 210. A chemical sealant 320 as is known in the art is applied at this termination in order to prevent ingress of materials to within a cavity of the prefabricated wall unit 100. As before, the poly packer 300 prevents ingress of material through the channel formed between outer face 120 and floor slab 10 to within the interior of the building.
FIG 5 shows a sectional side view of a prefabricated wall unit 100 secured to floor slab 10 vertically below a window unit 200. Prefabricated wall unit 100 is secured to floor slab 10 as previously discussed. Upper portion 121B of outer face 120 of wall unit 100 terminates in a channel formed between extrusion 210 and a face of floor slab 10. As previously discussed, poly packer 300 prevents ingress of material to within the building.
Optionally, upper portion 121B is fastened to a face of floor slab 10 by means of an adhesive or the like.
Va FIG 6A shows a cut away perspective view of a prefabricated wall unit 100 fastened to a window unit 200. Window unit 200 has a vertically extending extrusion 230 from which window pane 220 extends. Outer face 120 of prefabricated wall unit 100 terminates adjacent vertically extending extrusion 5 230. A joining member 350 is sandwiched between a face of vertically extending Va o extrusion 230 and outer face 120. Preferably, joining member is simply an off 0 I cut of the material used to form outer face 120. Optionally, joining member may 0be formed from any suitable material as is known in the art or be in the form of a chemical joining member.
Additionally, a chemical sealant joint 340 is sandwiched between a face of vertically extending extrusion 230 and outer face 120 of wall unit 100.
Preferably, this chemical sealant joint 340 is a rapidly curing polyurethane adhesive in order to fasten wall unit 100 to window unit 200. A sealant 360 is also sandwiched between a face of vertically extending extrusion 230 and outer face 120 of wall unit 100 in order to prevent ingress of material to within the inside of the building.
FIG 6B shows a sectional top view of prefabricated wall unit 100 located adjacent a window unit 200. In FIG 6B the window unit 200 is a double glazed window as previously discussed. The wall unit 100 is fastened to the window unit 200 as discussed above.
As the prefabricated wall units 100 of the present invention may be fabricated in a factory prior to arrival at site, the fabrication process is able to use highly accurate manufacturing equipment and hence the delivered wall units are of a higher quality than those that are constructed in place on a building site.
Furthermore, the manufacturing process is not subject to delay caused by 11 Va 0 unsuitable weather as would be the case on a building site.
Furthermore, the fabrication of the wall units may commence prior to the building structure being in place thus reducing scheduling delays for the construction manager. The wall units are rapidly transported to site when a floor 5 is ready to have the outer shell completed, the wall units are hoisted to the Va o appropriate floor and they are rapidly secured in place.
As it is not necessary to employ several types of tradesmen on site, the 0 olikelihood of industrial disputes delaying the completion of the building construction is effectively reduced.
Additionally, as the wall units are secured in place from within the interior of the building, it is not necessary for the building construction manager to arrange for scaffolding or similar safety measures that would otherwise be necessary if it was required to have contractors applying finishes to an outer face of the wall panel as in the prior art.
These benefits reduce the construction costs of the project and reduce the chance of the building construction being delayed due to resource scheduling issues and the like.
Throughout the specification the aim has been to describe the invention without limiting the invention to any one embodiment or specific collection of features. Persons skilled in the relevant art may realize variations from the specific embodiments that will nonetheless fall within the scope of the invention.
For example, FIG 7 shows a rear perspective view of prefabricated wall unit 100 located below window unit 200. In this embodiment of the invention, the combination of the prefabricated wall unit 100 and the window unit 200 together form the outer shell of a building for a particular floor.
12 This embodiment of the prefabricated wall unit 100 includes additional supporting members 111' in supporting frame 110 in order to bear the weight of nwindow unit 200. Outer face 120 of prefabricated wall unit 100 extends over an upper face of the wall unit 100 in order that a window extrusion may be fastened thereon as is known in the art.
o It will be appreciated that various other changes and modifications may be 0 N made to the embodiment described without departing from the spirit and scope of the invention.
Claims (11)
1. A method of locating a prefabricated wall unit on a building including the steps of: fastening a finished outer face to a supporting frame to form the o 5 prefabricated wall unit; of(ii) locating a lower portion of the prefabricated wall unit upon a floor slab Dof the building; and o(iii) fastening the prefabricated wall unit to at least the floor slab to thereby secure the prefabricated wall unit in position.
2. The method of claim 1, further including the step of (iv) fastening an inner face to the prefabricated wall unit.
3. The method of claim 2, wherein step (iv) occurs prior to step (ii).
4. The method of claim 1, wherein the finished outer face is in the form of a composite aluminum panel which is fastened to the support frame by means of a chemical adhesive.
5. A prefabricated wall unit for completing the outer shell of a building, the prefabricated wall unit comprising: a supporting frame; a finished outer face fastened to the supporting frame; and a fastening portion for securing the prefabricated wall unit to a building floor slab. IND
6. The prefabricated wall unit of claim 5, wherein the prefabricated wall unit further comprises an inner face fastened to the supporting frame. IND
7. The prefabricated wall unit of claim 5, wherein the prefabricated wall unit 0 further comprises insulation located within a cavity formed by the supporting 0 I frame. 0
8. The prefabricated wall unit of claim 5, wherein the prefabricated wall unit further comprises a drainage hole located through a lower portion of the outer face.
9. A method of locating a prefabricated wall unit on a building including the steps of: locating a lower portion of the prefabricated wall unit upon a floor slab of the building; and fastening the prefabricated wall unit to at least the floor slab to thereby secure the prefabricated wall unit in position; whereby, the prefabricated wall unit has a finished outer face prior to it being located upon the floor slab.
The method of claim 9, further including the step of fastening an inner face to the prefabricated wall unit.
11. A prefabricated wall unit as substantially herein described with reference to the figures. Dated this 16th day of January 2006 LINTON PACIFIC PTY LTD By their Patent Attorneys FISHER ADAMS KELLY
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2006200160A AU2006200160A1 (en) | 2006-01-16 | 2006-01-16 | A prefabricated wall unit |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2006200160A AU2006200160A1 (en) | 2006-01-16 | 2006-01-16 | A prefabricated wall unit |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2006200160A1 true AU2006200160A1 (en) | 2007-08-02 |
Family
ID=38346019
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2006200160A Abandoned AU2006200160A1 (en) | 2006-01-16 | 2006-01-16 | A prefabricated wall unit |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2006200160A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104060839A (en) * | 2014-06-19 | 2014-09-24 | 中国五冶集团有限公司 | Construction control method special for steel-structure vertical keels of metal curtain wall of large gymnasium |
| CN106930448A (en) * | 2017-04-25 | 2017-07-07 | 沈阳远大铝业工程有限公司 | Adjustable-angle cell curtain wall is in indoor mounting structure |
-
2006
- 2006-01-16 AU AU2006200160A patent/AU2006200160A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104060839A (en) * | 2014-06-19 | 2014-09-24 | 中国五冶集团有限公司 | Construction control method special for steel-structure vertical keels of metal curtain wall of large gymnasium |
| CN104060839B (en) * | 2014-06-19 | 2016-05-25 | 中国五冶集团有限公司 | Be exclusively used in large stadium metal curtain wall steel construction vertical keel construction control method |
| CN106930448A (en) * | 2017-04-25 | 2017-07-07 | 沈阳远大铝业工程有限公司 | Adjustable-angle cell curtain wall is in indoor mounting structure |
| CN106930448B (en) * | 2017-04-25 | 2022-11-22 | 沈阳远大铝业工程有限公司 | Indoor side mounting structure of angle-adjustable unit curtain wall |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MK1 | Application lapsed section 142(2)(a) - no request for examination in relevant period |