AU2009202728A1 - A panel - Google Patents

Description

AUSTRALIA 5 Patents Act 1990 COMPLETE SPECIFIATION 10 STANDARD PATENT A PANEL 15 The following statement is a full description of this invention, including the best method of performing it known to me: E:\Stainable Hug\Gree Fram\Completed Patent\0090707 P78134l.AU - A panl v4 spciiatos~o 7/01/09 -2 A PANEL Field of the invention The present invention relates to a panel, which may 5 be used in wall and/or roof applications. DN Background It is known to use structural concrete insulated 10 panels in buildings in wall and roof applications. Typically, these panels have an insulated core that separates two reinforced concrete sections. The reinforcing is formed by a welded metal mesh of wires that is parallel to the insulated core. The mesh 15 reinforcements are joined by metal ties that pass through the insulated core. The insulated core is incorporated within these panels to help regulate temperatures within the building. 20 In the case of an external fire, such as a bush fire, the insulated core provides some thermal protection to the contents of the building. However, the large number of metal ties used these walls readily allow heat to be conducted across the insulated core, which at least 25 partially counteracts the effectiveness of the insulation. The present invention has been conceived to provide an alternative concrete panel and associated construction method. 30 E\utainble Housing\Green Fram\Competd P~aen\009( N2 P28131.AU - A pane v4 spcfcrtn~o 7/02/09 -3 Summary of the invention The present invention provides a panel comprising: a core section that has a polymeric frame and insulation material supported within the polymeric frame; 5 two concrete sections, one on each side of the core section, the concrete sections each having a corrugated metal reinforcing sheet embedded within the concrete; and a plurality of ties that extend through the core section and secure the reinforcing sheets to one another, 10 each tie comprising a steel inner and a polymeric sleeve, the polymeric sleeves thermally insulating the steel inners from the reinforcing sheets. Thus, securing the metal reinforcing sheets to the 15 polymeric frame minimizes heat transfer across the core section. Preferably, the reinforcing sheets comprise perforations that allow concrete to flow through the 20 reinforcing sheet during pouring. Preferably, the polymeric frame includes channel members each having one or more channels for locating and supporting the insulation material. 25 Preferably, the polymeric frame includes firstI channel members, each having a plurality of apertures through which the plurality of ties can extend. 30 Preferably, the first channel members extend vertically within the polymeric frame, and the reinforcing sheets are positioned with lateral edges co-incident with the first channel members. E\ut~anble Housing\Green F'rm\Completed Patent\0090707 P278131.AU - A pane v4 spcfctin~o 7/07// -4 N Preferably, the polymeric frame further includes second channel members, and the panel further comprises: a plurality of fasteners that fasten the reinforcing 5 sheets to the second channel members, each fastener extending into the second channel members a distance that is less than half the width of the core section. N In some embodiments, the core section further has 10 permanent form boards that sandwich the insulation material, and the polymeric frame locates and supports both the form boards and the insulation material. Preferably, the insulation material is supported in 15 reinforcing sheet sections. Preferably, each reinforcing sheet is arranged within the respective concrete section with the corrugations parallel to the direction of concrete flow during 20 construction. In certain embodiments, the reinforcing sheet further comprises an indentation formed adjacent each perforation. 25 In some embodiments, the panel can further comprise a plurality of concrete baffles for supporting setting concrete, each being located within a concave corrugation of the reinforcing sheet and on an external side of the respective reinforcing sheet relative to the core section. 30 Preferably, the baffles are formed of a mesh-like material. More preferably, the baffles are formed of an expanded metal. E:\Sutainble Hug\Gree Fram\Completed Patent\O090707 P78134.AU - A pae v4 specificton~o 7/07/09 5 Preferably, the metal reinforcing sheets are embedded in the respective concrete sections to create a series of elongate, open cells when viewed vertically. 5 Preferably, the cells have a generally hexagonal cross-sectional shape. The present invention also provides a method of 10 constructing a panel, the method comprising: forming a footing; erecting a core section of the panel on the footing, the core section having a polymeric frame and insulation material, which is supported within the polymeric frame; 15 erecting corrugated metal reinforcing sheets on either side of the core section, each metal reinforcing sheet having perforations that allow concrete to flow through the reinforcing sheet during pouring; securing the reinforcing sheets to one another with a 20 plurality of ties that extend through the core section, each tie having a steel inner and a polymeric sleeve that thermally insulates the steel winners from the reinforcing sheets; and forming concrete sections by pouring concrete between 25 the core section and each of the metal reinforcing sheets. Prefraby, he mtho futhe inolmesi working that concrete after t flowsrthroug the reinforcingst Inombingcncrtiwhceoe sectionrngcncluestwe p5temane fetorm bards tah sandwhe etrinsfrcnghes inslatonrateri, the method further ovecorkiseth concretebafterGit flw through Pt~he\O(Y reinforcing- A s~~ heet to/ -6 locating the boards and the insulating material within the polymeric frame. In embodiments in which the concrete sections include 5 concrete baffles, the method can further comprise locating the baffles in the concave corrugations of the metal reinforcing sheets externally of the core section. The present invention also provides a metal 10 reinforcing sheet for use in a panel, the reinforcing sheet having a corrugated profile with a plurality of perforations formed therein through which concrete can flow during construction; and a plurality of concrete baffles for supporting 15 setting concrete, each being located within a concave corrugation of the metal reinforcing sheet and on one side of the reinforcing sheet. Preferably, the baffles are formed of a mesh-like 20 material. More preferably, the baffles are formed of an expanded metal. Preferably, each metal reinforcing sheet further comprises an indentation formed adjacent each perforation. 25 The present invention also provides a method of constructing a panel, the method comprising: forming a footing; erecting a core section of the panel on the footing, 30 the core section having a polymeric frame and insulation material, which is supported within the polymeric frame; erecting corrugated metal reinforcing sheets on either side of the core section, each metal reinforcing E:\Sutaiable Housin\Green Frame\Completed Patnt\090707 P78134.AU - A panel v4 pe fia on.doc 2/02/CA sheet having perforations that allow concrete to flow through the reinforcing sheet during pouring; pouring concrete between the core section and each of the metal reinforcing sheets; and 5 working the concrete that flows through the perforations in the reinforcing sheets to form external N wall surfaces of the panel. Thus, the method does not require the use of external 10 formwork to construct the wall panel. Brief description of the drawings In order that the invention may be more easily 15 understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1: is a plan view of a concrete panel according to a first embodiment of the 20 present invention; Figure 2: is an enlarged view of region A of the panel shown in Figure 1; Figure 3: is a side elevation of the reinforcing sheet of the panel shown in Figure 1; 25 Figure 4: is a vertical section of the panel of Figure 1; Figure 5: is a schematic view of a concrete panel according to a second embodiment of the present invention; 30 Figure 6: is a vertical section of the panel of Figure 5, as viewed along the line B-B in Figure 5; E:Ssaial Housin\Green Frame\Completed Patent\0090707 P7813H.AU - A panl v4 spcfctin~o 7/07/09 -8 Figure 7: is a vertical section of the panel, as viewed perpendicular to the line B-B in Figure 5; and Figure 8: is a plan view of a panel connector 5 according to a third embodiment of the present invention. NA Detailed description 10 Figures 1 to 4 show a concrete panel 10 according to a first embodiment of the present invention. In this embodiment, the panel 10 is arranged vertically to form part of a building wall. The panel 10 has a core section that is disposed between two cast in-situ concrete 15 sections 12a, 12b (hereinafter referred to collectively as "concrete sections 12") . Each of the concrete sections 12 is reinforced, as will be described in further detail later. In this embodiment, the concrete sections 12 are made from a concrete mixture containing an aerating agent, 20 such that the final concrete section 12 is aerated concrete. In this embodiment, the core section includes insulation material 14 that is sandwiched by permanent 25 form boards 16a, 16b. These boards 16a, 16b provide a formwork to separate the insulation material 14 from the concrete during pouring. The insulation material 14 can be, for example, stone wool or similar, which is suitable in a concrete wall panel that is to have high fire 30 resistance. As will be appreciated, for handling purposes, stone wool is typically provided in reinforcing sheet sections of nominal sizes. E:\Sustail Housng\Green Frame\Cmpleted Patn\009('7'2 p28134.AU - A pael v4 speciicrinsdo 2/02/l6 -9 The core section includes a polymeric frame and insulation material 14, which is supported within the polymeric frame, as will be described in detail later. In addition, in this embodiment, the boards 16 are also 5 supported within the polymeric frame. )C The reinforcing of the concrete sections 12 is formed by metal reinforcing sheets 18a, 18b, one of which is shown in Figure 3. In this embodiment, the metal 10 reinforcing sheets 18a, 18b are formed with a corrugated profile and are embedded within the concrete sections 12. The metal reinforcing sheets 18a, 18b are arranged with the corrugations extending vertically with respect to the panel 10 orientation. Thus, in this configuration, the 15 corrugations are parallel to the predominant direction of buckling loads. In addition, the corrugations are arranged such that they extend parallel to the preferred concrete pouring direction. 20 The metal reinforcing sheets 18a, 18b are secured to one another by a plurality of ties 32 that each extend through the polymeric frame. Each tie 32 consists of a steel inner and a polymeric sleeve. Accordingly, there is no metal-to-metal contact between the steel inner of each 25 tie 32 and the metal reinforcing sheets 18a, 18b. In this way, a thermal barrier is formed between the metal reinforcing sheets 18a, 18b. In this embodiment, the corrugations are formed of 30 alternating distinct sections: first planar sections, which are parallel sections 20a, 20b to the transverse direction of the reinforcing sheet 18; and second planar sections 22a, 22b, which are oblique to the transverse E\Sustainble Housing\Green Frm\Completed Patent\0090202 P28134.AU - A panel v4 specifiation.doc 2/02/09 - 10 direction of the reinforcing sheet 18. The first planar sections 20a, 20b are at the "peaks" (that is, the ridges and troughs) of the corrugations, while the second planar sections 22a, 22b connect the first planar sections 20a, 5 20b. The reinforcing sheet 18 is formed with perforations 24, which facilitate efficient rheological flow of concrete mixture through the reinforcing sheet 18 when poured in-situ. 10 As shown in Figure 2, the metal reinforcing sheets 18a, 18b are embedded in the respective concrete sections 12a, 12b to create a structure similar to a series of elongate, open cells when viewed vertically. The core section 14 extends through the middle of series of cells. 15 This arrangement maximizes structural strength and rigidity of the panel. In this embodiment the cells have a generally hexagonal cross sectional shape. However, it is will be appreciated that the cells can have any suitable cross sectional shape, including square, 20 octagonal or an irregular shape. In this embodiment, the panel 10 also includes concrete baffles 26, which are illustrated in Figures 1 and 2 by double broken lines. The concrete baffles 26 are 25 made from a mesh-like material, such as expanded metal. Concrete that is poured into each cavity between the board 16 and the reinforcing sheet 18 will flow through the perforations in the reinforcing sheet 16, and also through the apertures in the baffles 26. 30 The aerated concrete that is used in the concrete sections 12 can have a low flow rate and be relatively fast setting. Subsequent to the concrete pour, the E:\Sust~ail Housing\Green Fram\Copleted Patent \0090707 P78134.AU -A panel v4 speifatinsdo 7/07/0 - 11 external surfaces of the concrete sections 10 can be N worked (e.g. rendered) to provide a flat, smooth surface. The baffles 26 provide additional support to the concrete section 12 during the surface working process. In this 5 way, external formwork is not required in the construction of the panel 10. OO The baffles 26 extend between adjacent second planar sections 22a, 22b in each corrugation. In other 10 words, each baffle 26 is located within a concave portion of the corrugations, and on the external side (with respect to the insulation material 14). In certain embodiments, each baffle 26 can be secured 15 in place on the reinforcing sheet 18 prior to construction of the panel 10, for example by tack welding. In some alternative embodiments, each baffle 26 can be installed in location during construction of the panel 10. 20 As shown in Figures 1 and 2, the reinforcing sheets 18a, 18b are arranged in the panel 10 with the first planar sections 20a, 20b being aligned. In addition, the concave, or "trough", portions of the corrugations (being the portion closest to the corresponding portion on the 25 opposing sheet 18b, 18a, and thus also the core section 14) are also aligned. The transverse ends of each reinforcing sheet 18a, 18b terminate with a first planar section 20a, which forms a "trough". These ends can be considered as terminal first planar sections. 30 As most clearly shown in Figure 2, the polymeric frame of the core section has first channel members 28 that extend between the terminal ends of the reinforcing E:\Sustil Housing\Green F'aeCopee P~atet\0090202 P28134.AU - A panel v4 spciiatos o 2/02/00 - 12 sheets 18a, 18b. The first channel members 28 are made of N plastics material to minimize heat transfer between the concrete sections 12a, 12b of the panel 10. Each first channel member 28 has an H-shaped cross-section; that is, 5 the first channel member 28 has a web that separates two flanges, to define two opposing channels. The boards 16 CN and insulation material 14 of the panel 10 are held in N place by the first channel members 28. 10 Apertures 30 extend through the web of the first channel members 28. Each aperture 30 forms a throughway through which one of the ties 32 extends to fasten the reinforcing sheets 18a, 18b to each other. As previously noted, the lack of direct contact between the metal 15 reinforcing sheets 18a, 18b and the steel within each tie 32 reduces heat transfer between the concrete sections 12. Laterally adjacent reinforcing sheets 18a, 18b within each concrete section 12a, 12b are connected by an 20 overlapping joint (not shown) of the terminal ends of the respective reinforcing sheets 18a, 18b. The overlapping sections of the reinforcing sheets 18a, 18b in each concrete section 12a, 12b are jointed by the ties 32. 25 The polymeric frame of the core section also has second channel members that also work to hold the boards 16 and insulation material 14 of the panel 10 in place. The second channel members extend vertically and horizontally as required to support the boards 16 and 30 insulation material 14 between the first channel members 28. The second channel members are obscured by the other elements of the panel 10 in Figures 1 to 4, and are thus not visible. E:Ssaial Housing\Green Fram\Completed Paten\0090/7 P78L1.AU -A panl v1 spcft ion.do 2/02/l - 13 The second channel members are made of plastics material to minimize heat transfer between the concrete sections 12a, 12b of the panel 10. Each second channel 5 member has an H-shaped cross-section; that is, a web separates two flanges, to define two opposing channels. The reinforcing sheets 18a, 18b are also fastened directly to the second channel members by fasteners (also 10 not shown in Figures 1 to 4). The fasteners extend into the second channel members by a distance that is less than half the width of the core section. In this way, two fasteners that extend into the web from opposing sides of the second channel member are spaced. In other words, the 15 second channel members of the polymeric frame form a barrier between the fasteners in the second channel members. Thus, heat transfer between the fasteners is minimized. 20 In this embodiment, the first channel members 28 and second channel members co-operate to form the polymeric frame that supports and locates the core section of the panel 10. 25 The lowermost reinforcing sheets 18, 18b within the panel 10 rest on a footing (not shown in Figures 1 to 4). Reinforcing sheets 18a, 18b that are positioned vertically above the lowermost reinforcing sheets are initially held in place by the ties 32 and the fasteners that secure the 30 reinforcing sheets 18a, 18b to the second channel members. However, as will be appreciated, once the concrete in the sections 12 has hardened the concrete supports the reinforcing sheets 18a, 18b. E:Ssaial Housin\Gree Fram\Copleted Patent\0090202 P78134.AU - A panel v4 spcfctin~o 2/02/9 - 14 Reinforcing bars 34 extend from within the footings vertically through the panel 10. In this embodiment, each reinforcing bar 34 is located against the first planar 5 sections 20a that form the "troughs" in the corrugation, when viewed from the external side of the panel 10. The reinforcing bars 34 in combination with the ties 32 provide support against shear load deformation in the concrete sections 12, particularly at the interface 10 between vertically adjacent reinforcing sheets within a concrete section 12a, 12b. Figures 5 to 7 show a concrete panel 110 according to a second embodiment of the present invention. In this 15 embodiment, the panel 110 is arranged vertically to form part of a building wall. The panel 110 has a core section that is disposed between two cast in-situ concrete sections 112a, 112b (hereinafter referred to collectively as "concrete sections 112"). Each of the concrete 20 sections 112 is reinforced, as will be described in further detail later. In this embodiment, the concrete sections 112 are made from a concrete mixture containing an aerating agent, such that the final concrete section 112 is aerated concrete. 25 In this embodiment, the core section includes an insulation material 114 that is sandwiched by permanent form boards 116a, 116b. These boards 116a, 116b provide a formwork to separate the insulation material 114 from the 30 concrete during pouring. The insulation material 114 can be formed of any suitable insulating material, such as stone wool. E:Ssaial Houin\Gee Fram\Completed Patent\0090202 P28134.AU - A panel v'4 specfctin~o 2/07/4 - 15 The core section includes a polymeric frame and the insulation material 114, which is supported within the polymeric frame, as will be described in detail later. In addition, in this embodiment, the boards 116 are also 5 supported within the polymeric frame. N9 The metal reinforcing sheets 118a, 118b are secured N9 to one another by a plurality of ties 132 that each extend Ni through the polymeric frame. Each tie 132 consists of a 10 steel inner and a polymeric sleeve. Accordingly, there is no metal-to-metal contact between the steel inner of each tie 132 and the metal reinforcing sheets 118a, 118b. In this way, a thermal barrier is formed between the metal reinforcing sheets 118a, 118b. 15 The reinforcing of the concrete sections 112 is formed by metal reinforcing sheets 118a, 118b. In this embodiment, the metal reinforcing sheets 118a, 118b are formed with a corrugated profile. The metal reinforcing 20 sheets 118a, 118b are arranged with the corrugations extending vertically with respect to the panel 110 orientation. In this embodiment, the corrugations are formed of 25 alternating distinct sections: first planar sections, which are parallel sections 120a, 120b to the transverse direction of the reinforcing sheet 118; and second planar sections 122a, 122b, which are oblique to the transverse direction of the reinforcing sheet 118. The first planar 30 sections 120a, 120b are at the "peaks" (that is, the ridges and troughs) of the corrugations, while the second planar sections 122a, 122b connect the first planar sections 120a, 120b. The reinforcing sheet 118 is formed E:\Ssa able Housin\Green Frm\Completed p Pa 27 P28131.AU -- A p~ane v4 spcfctos~o /70 - 16 with perforations 124, which allow concrete to flow through the reinforcing sheet 118 during pouring. As shown in Figure 5, the metal reinforcing sheets 5 118a, 118b are embedded in the respective concrete sections 112a, 112b to create a structure similar to a )C series of elongate, open cells when viewed vertically. The core section 114 extends through the middle of the hexagonal cells. This arrangement maximizes structural 10 strength and rigidity of the panel. In this embodiment, the cells also have a generally hexagonal cross sectional shape. The aerated concrete that is used in the concrete 15 sections 112 can have a low flow rate and be relatively fast setting. Subsequent to the concrete pour, the external surfaces of the concrete sections 110 can be worked (e.g. rendered) to provide a flat, smooth surface. Again, it is relevant to note that in this embodiment, 20 external formwork is not required in the construction of the panel 110. As shown in Figure 5, the reinforcing sheets 118a, 118b are arranged in the panel 110 with the first planar 25 sections 120a, 120b being aligned. In addition, the "trough" portions of the corrugations (being the portion closest to the core section) are also aligned. The transverse ends of each reinforcing sheet 118a, 118b terminate with a first planar section 120a, which forms a 30 "trough". These ends can be considered as terminal first planar sections. E:\Sustaiable Housing\Green Fram\Completed Patent\0090707 P78134.AU - A panel v4 specifications.doc 7/07/09 - 17 As most clearly shown in Figures 5 and 6, the N polymeric frame of the core section includes first channel members 128 that extend between the terminal ends of the reinforcing sheets 118a, 118b. The first channel members 5 128 are made of plastics material to minimize heat transfer between the concrete sections 112a, 112b of the 00 N9 panel 110. Each first channel member 128 has an H-shaped CN cross-section; that is, the first channel member 128 has a N web that separates two flanges, to define two opposing 10 channels. The boards 116 and insulation material 114 of the panel 110 are held in place by the first channel members 128. Apertures 130 extend through the web of the first 15 channel members 128. Each aperture 130 forms a throughway through which one of the ties 132 extends to fasten the reinforcing sheets 118a, 118b to each other. Laterally adjacent reinforcing sheets 118a, 118b 20 within each concrete section 112a, 112b are connected by an overlapping joint (not shown) of the terminal ends of the respective reinforcing sheets 118a, 118b. The overlapping sections of the reinforcing sheets 118a, 118b in each concrete section 112a, 112b are jointed by the 25 ties 132. The polymeric frame of the core section also has second channel members 136 that also work to hold the boards 116 and insulation material 114 of the panel 110 in 30 place. The second channel members 136 are made of plastics material to minimize heat transfer between the concrete sections 112a, 112b of the panel 110. Each second channel member 136 has an H-shaped cross-section; E\utainble Houin\Green Frm\completed Patent\0090707 P78134.AU - A panel -v4 specfiaios~o 7/07/A9 - 18 that is, a web separates two flanges, to define two opposing channels. As shown in Figure 6, the second channel members 136 extend vertically and horizontally as required to support the boards 116 and insulation material 5 114. N] The reinforcing sheets 118a,- 118b are also fastened N] to the second channel members 136 by fasteners 138 (shown in Figure 5). The fasteners 138 extend into the web of 10 the second channel members 136 by a distance that is less than half the width of the core section. In this way, two fasteners 138 that extend into the web from opposing sides of the second channel member 136 are spaced from one another. Thus, heat transfer between the fasteners 138 is 15 minimized. The first channel members 128 and second channel members 136 co-operate to form a polymeric frame that supports the boards 116 and insulation material 114. 20 The lowermost reinforcing sheets 118, 118b within the panel 110 rest on footings 140. Reinforcing sheets 118a, 118b that are positioned vertically above the lowermost reinforcing sheets are initially held in place by the ties 25 132 and the fasteners that secure the reinforcing sheets 118a, 118b to the second channel members. However, as will be appreciated, once the concrete in the sections 112 has hardened the concrete supports the reinforcing sheets 118a, 118b. 30 Reinforcing bars 134 extend from within the footings vertically through the panel 110. For illustrative purposes, reinforcing bars have only been shown in F'igure - 19 5 in concrete section 112b. However, it will be appreciated that reinforcing bars 134 extend through both sections 112a, 112b. The reinforcing bars 134 in combination with the ties 132 provide support against 5 shear load deformation in the concrete sections 112, particularly at the interface between vertically adjacent reinforcing sheets within a concrete section 112a, 112b. Figure 8 shows schematically a panel connector 210 10 according to a third embodiment of the present invention. The panel connector 210 is used in a building constructed according to an embodiment the present invention. The panel connector 210 facilitates joining of adjacent wall panels according to embodiments of the present invention. 15 The panel connector 210 consists of a hollow metal post 212 with arms 214, 216 that extend radially outwardly from the post 212. The metal reinforcing sheets within the concrete sections of the adjacent wall panels are to 20 be secured to the arms 214, 216. Each arm 214, 216 can be connected to the post 212 in any of a plurality of attachment positions (indicated by broken lines in Figure 8). In this embodiment, there are 25 eight equiangularly spaced attachment positions. Thus, adjacent wall panels can be connected at angles of 450, 9Q0, 1350, 1800, 2250, 2700 and 3150. Aerated concrete is poured in-situ into the hollow of 30 the post 212 to provide increased rigidity. The external surfaces of the panel connector 210 and the connected adjacent panels can be (for example) rendered to provide an appropriate external surface. E:\Ssainble Housin\Gee Frame\completed Patent\090.707 P28134.AU - A panel v4 spcft ionsdoc 7/07/l - 20 N A concrete wall panel according to an embodiment of the present invention can be constructed by the following method: 5 e forming a footing; 0 erecting a core section of the panel on the footing, the core section having a polymeric frame and insulation material, which is supported within the polymeric frame; 10 erecting corrugated metal reinforcing sheets on N either side of the core section, each metal reinforcing sheet having perforations that allow concrete to flow through the reinforcing sheet during pouring; 15 e securing the reinforcing sheets to one another with a plurality of ties that extend through the core section, each tie having a steel inner and a polymeric sleeve that thermally insulates the steel inners from the reinforcing sheets; and 20 * forming concrete sections by pouring concrete between the core section and each of the metal reinforcing sheets. Reinforcing bars can be cast into the footings such 25 that bars extend vertically from the footings at desired intervals . Erecting the metal reinforcing sheets can further include securing the metal reinforcing sheets to one 30 another with ties, as described in connection with Figures 1 and 2. E:\Sustinble Housing\Gee Fram\Completed Patet\0090707 P78134.AU - A panel v4 spcfcain.doc 7/07/09 - 21 Concrete can be poured into the space between the core section and each metal reinforcing sheet, and the concrete can flow through the perforations in the reinforcing sheets. Subsequently the external surfaces of 5 the concrete sections can be worked to form external wall surfaces. Erecting the core section can further involve constructing a frame that supports permanent form boards 10 that sandwich sections of an insulation material. The frame, boards and insulation material sections can be constructed progressively with the metal reinforcing sheets. 15 In some embodiments in which the concrete sections include mesh concrete baffles, the above-described method can further involve locating the baffles in the corrugations of the metal reinforcing sheets. This can be done either prior to erection of the metal reinforcing 20 sheets, or during erection of the metal reinforcing sheets. In certain embodiments, the metal reinforcing sheets can be formed with an indentation adjacent each 25 perforation in the metal reinforcing sheets. In these embodiments, the metal reinforcing sheets have perforations and indentations that resemble a cheese grater. The indentations can enhance dispersion of concrete during the pouring process as it flows outwardly 30 through the reinforcing sheets. The first channel members and second channel members can be made of any suitable polymer or polymer blend, E:\Sstainble Huin\Gree Frm\Cpletd Paent\0090702 P78134.AU - A panel v4 spcfctin~o 7/07/rm - 22 including (but not limited to): polystyrene, polyethylene N and polyvinylchloride. Furthermore, in embodiments in which polymer blends are used, the first and second channel members can be recycled can be recycled. In 5 addition, the polymer blend can have any one or more of the following properties: N High thermal resistance; N Non-combustible; N Non-toxic; and 10 * High acoustic attenuation. The metal reinforcing sheets can be made of any suitable metal or metal alloy, including (but not limited to): steel, aluminium, ferrous and non-ferrous materials. 15 The metal reinforcing sheets can be made of recycled materials. As previously described, the concrete within the concrete sections can be made of aerated concrete. Such 20 aerated concrete can be a mixture of sand, cement and an aerating agent. Thus, when the aerated concrete is poured in-situ, the aerated concrete forms relatively low density concrete, which has any of the following characteristics: * High thermal insulation; 25 * Reduced spalling on direct application of intense heat; and * High acoustic attenuation. Concrete panels according to embodiments of the 30 present invention can be used in wall, roofing and suspended slab applications. E:\Sustaiable Housing\Gree Fram\Copleted Patent\0090207 P28134.AU - A panel v4 specification do 7/07/G9 - 23 It will be understood to persons skilled in the art N of the invention that many modifications may be made without departing from the spirit and scope of the invention. 5 In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as 10 "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. E:Ssaial Hosn\re Fram\Completed Patent\A090707 P28134,AU - A panel v4 spcifctinsdo 7/07/09 23a Description The present invention relates to a panel, which may be used in wall and/or roof applications.

Claims (22)

1. A panel comprising: a core section that has a polymeric frame and 5 insulation material supported within the polymeric frame; two concrete sections, one on each side of the core section, the concrete sections each having a corrugated metal reinforcing sheet embedded within the concrete; and a plurality of ties that extend through the core 10 section and secure the reinforcing sheets to one another, each tie comprising a steel inner and a polymeric sleeve, the polymeric sleeves thermally insulating the steel inners from the reinforcing sheets. 15

2. A panel according to claim 1, wherein the polymeric frame includes channel members that each have one or more channels for locating and supporting the insulation material. 20

3. A panel according to either claim 1 or 2, wherein the frame includes first channel members, each having a plurality of apertures through which one of the plurality of ties can extend. 25

4. A panel according to claim 3, wherein the first channel members extend vertically within the polymeric frame, and the metal reinforcing sheets are positioned with lateral edges co-incident with the first channel members. 30

5. A panel according to any one of claims 2 to 4, wherein the polymeric frame further includes second channel members, and the panel further comprises: E:\Sutainable Hug\Gree fram\Completed Patent\0090202 P28134.AU - A panel v4 specificaios o 7/07/09 - 25 a plurality of fasteners that fasten the metal N reinforcing sheets to the second channel members, each fastener extending into the second channel members a distance that is less than half the width of the core 5 section. N

6. A panel according to any one of claims 1 to 5, N9 wherein the core section further has permanent form boards that sandwich the insulation material, and the polymeric 10 frame locates and supports both the form boards and the insulation material.

7. A panel according to any one of claims 1 to 6, wherein the insulation material is supported in 15 reinforcing sheet sections.

8. A panel according to any one of claims 1 to 7, wherein each metal reinforcing sheet is arranged within the respective concrete section with the corrugations 20 parallel to the direction of concrete flow during construction.

9. A panel according to claim 8, wherein the metal reinforcing sheet further comprises an indentation formed 25 adjacent each perforation.

10. A panel according to any one of claims 1 to 9, further comprising a plurality of concrete baffles for supporting setting concrete, each being located within a 30 concave corrugation of the metal reinforcing sheet and on an external side of the respective metal reinforcing sheet relative to the core section. E:\Sustainable Housing\Gee Frm\Completed Patent\0090702 P78131.AU - A panel v4 spcfctin o 2/07/09 1 - 26

11. A panel according to claim 12, wherein the baffles N are formed of a mesh-like material.

12. A panel according to claim 11, wherein the baffles 5 are formed of an expanded metal. OO

13. A method of constructing a panel, the method comprising: forming a footing; 10 erecting a core section of the panel on the footing, the core section having a polymeric frame and insulation material, which is supported within the polymeric frame; erecting corrugated metal reinforcing sheets on either side of the core section, each metal reinforcing 15 sheet having perforations that allow concrete to flow through the reinforcing sheet during pouring; securing the reinforcing sheets to one another with a plurality of ties that extend through the core section, each tie having a steel inner and a polymeric sleeve that 20 thermally insulates the steel inners from the reinforcing sheets; and forming concrete sections by pouring concrete between the core section and each of the metal reinforcing sheets. 25

14. A method according to claim 13, wherein the method further involves working the concrete after it flows through the reinforcing sheets to form external wall surfaces. 30

15. A method according to either claim 13 or 14, wherein the core section includes permanent form boards that sandwich sections of an insulation material, and the E:Ssaial Hug\Gree Fram\Cpleted Patent\0090707 P78134.AUJ - A panel v4 specifcaion.doc 7/C07/09 - 27 method further comprises locating the boards and the insulating material within the polymeric frame.

16. A method according to any of claims 13 to 15, wherein 5 the concrete sections include concrete baffles, and the method further comprises locating the baffles in the 7- concave corrugations of the metal reinforcing sheets externally of the core section. 10

17. A metal reinforcing sheet for use in a concrete panel, the metal reinforcing sheet having a corrugated profile with a plurality of perforations formed therein through which concrete can flow during construction; and a plurality of concrete baffles for supporting 15 setting concrete, each being located within a concave corrugation of the metal reinforcing sheet and on one side of the reinforcing sheet.

18. A metal reinforcing sheet according to claim 17, 20 wherein the baffles are formed of a mesh-like material.

19. A metal reinforcing sheet according to either claim 17 or 18, wherein the baffles are formed of an expanded metal. 25

20. A metal reinforcing sheet according to any one of claims 17 to 19, wherein each metal reinforcing sheet further comprises an indentation formed adjacent each perforation. 30 E:\Stainble Housing\Green rmeCopleted Paten\0090707 P78134.AU - A panel v4 spciictinsdo 7/D2/09 - 28

21. A method of constructing a panel, the method comprising: forming a footing; erecting a core section of the panel on the footing, 5 the core section having a polymeric frame and insulation material, which is supported within the polymeric frame; erecting corrugated metal reinforcing sheets on either side of the core section, each metal reinforcing sheet having perforations that allow concrete to flow 10 through the reinforcing sheet during pouring; pouring concrete between the core section and each of the metal reinforcing sheets; and working the concrete that flows through the perforations to form external wall surfaces of the panel. 15

22. A method according to claim 21, wherein working the concrete after it flows through the perforations involves rendering the external surfaces. E:Ssaial Hug\Gree F'am\Copleted Patent\O090707 P78134.AU - A pane vi spciiatos o 7/07/09