AU2010246453A1 - A Modular Building System - Google Patents

Abstract

Abstract A method for the modular construction of a building at a site includes initially forming walls of the building by erecting a plurality of pre-formed concrete panels side by side. A number of the pre-formed panels include aperture formers of predetermined dimension which define apertures in the panels for receiving pre-fabricated form-fills. The panels are then inter-connected for structural integrity and the form-fills are fastened within the apertures. The form-fills may include panels having doors or windows, weatherboard or temperature insulation, for example. The step of forming the walls may include installing a number of piers at the site along predetermined wall lines and locating the pre-formed concrete panels upon the piers. fX T fX P7 A I- kT C% 7 f-C L7 fxT fx P7

Description

AUSTRALIA PATENTS ACT 1990 Complete Patent Specification A MODULAR BUILDING SYSTEM The following statement is a full description of the best method of performing the invention: 1 A MODULAR BUILDING SYSTEM TECHNICAL FIELD The present invention relates to a method for building construction and to a building component used therein. BACKGROUND House construction in Australia and many other countries is expensive and time consuming. Many houses are custom designed and built almost entirely on site. It is possible to manufacture portable buildings in a factory and then transport them to site however these buildings are not appealing to home buyers and are not readily individualized. It would be advantageous if a building technique was provided that could address one or more of the above described problems. It is an object of the present invention to provide such a building technique. It is a further object of the present invention to provide a building component to assist in such a technique. SUMMARY OF THE INVENTION According to a first aspect of the present invention, there is provided a method for constructing a building at a site including the steps of: forming walls of the building by erecting a plurality of pre-formed concrete panels side by side; and inter-connecting the pre-formed panels for structural integrity; wherein a number of said pre-formed concrete panels include aperture formers of predetermined dimension defining apertures in said panels for receiving pre fabricated form-fills therein.

2 The pre-fabricated form-fills may include a door or a window for example. Further pre-fabricated form-fills may include fibre cement sheeting, thermal wall paneling such as aerated concrete panel, steel and foam sandwich coldroom panels such as Bondor@ for maximum thermal properties. Preferably the method further includes fastening the form-fills within the apertures. The step of forming the walls may include installing a number of piers at the site along predetermined wall lines and locating said panels upon the piers. The method may include a preliminary step of manufacturing the concrete panels on site. In a preferred embodiment the method includes manufacturing the concrete panels with a mould using said aperture formers as part of the mould in cooperation with an outer former. Preferably the outer former is reused. Preferably the method further includes a step of installing a floor structure subsequent to the step of interconnecting the pre-formed, concrete panels. A concrete building panel including: at least one aperture former defining an aperture in the concrete panel, for receiving form-fill panels therein. Preferably the aperture former is made from lengths of aluminum extrusion. Preferably said panel includes at least one ferrule. In a preferred embodiment the panel includes a system of interconnecting ferrules and steel reinforcing.

3 The panel may include lifting anchors to assist in lifting the frame by crane. According to a further aspect of the present invention there is provided a method of making a concrete building panel including: locating at least one aperture former within an outer former and pouring a concrete slurry therebetween; allowing the slurry to set to form concrete with said aperture former retained fast therewith; removing the outer former from the concrete. Preferably said aperture former is made of metal extrusions. BRIEF DESCRIPTION OF THE DRAWINGS Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: Figure 1 is a plan view of a building component, namely a concrete panel, according to a preferred embodiment of the invention. Figure 2 is a perspective view of a metal which forms a mould for concrete slurry during production of the panel. Figure 3 is a first form-fill for insertion within an aperture of the panel of Figure 1. Figure 4 is a second form-fill for insertion within an aperture of the panel of Figure 1. Figure 5 is a plan view of piers and panels used in the construction of a house by means of the panels. Figure 6 is a first detailed view of a pier footing. Figure 7 is a detailed view of a second pier footing.

4 Figure 8 is a plan detailed view of the second pier footing. Figure 9 is a perspective view of a number of panels mounted on the piers. Figure 10 is a diagram showing the interconnection of a floor joist with one of the panels. Concrete panel flooring can also be used in the mentioned wall panel system. Figures 11 to 11D comprise a roof framing diagram in plan view and details of the connection of roofing members to the panels in accordance with various embodiments of the present invention. Figures 12 to 12C comprise a bracing member diagram and details of the connection of bracing members to the panels in accordance with various embodiments of the invention. Figure 13 is an external view of a house corresponding to the panels shown in Figure 9 with form-fills fitted and finished off. Figure 14 is a plan view of the metal frame mould for forming the panel in a first stage of development, with anchors, ferrules and lifters. Figure 15 is a plan view of the metal frame mould of Figure 13 with reinforced steel located therein. Figure 16 is a plan view of the metal frame mould of Figure 14 with reinforcement mesh fitted therein prior to pouring of concrete slurry. Figure 17 is a cross sectional view of an aluminum extrusion used to form the outer border of the metal frame mould of Figures 14 to 16. Figure 18 is a cross sectional view of an aluminum extrusion used to form the inner border of the apertures of the metal frame mould of Figures 14 to 16. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Referring now to Figure 1, there is shown in plan view a metal framed concrete panel 1 according to a preferred embodiment of an aspect of the present invention. The panel that is illustrated is 6.3m high by 3.5m wide and 150cm thick and is formed with rectangular apertures 5 and 7. With reference to Figure 2, the panel is formed by pouring concrete slurry into a mould 10 comprising an outer former 3 and two internally positioned 5 aperture formers 4 and 6. The outer former 3 and the aperture formers 4 and 6 are located on a suitable casting surface 8. The concrete slurry is poured between the outer former 3 and the two internal aperture formers 4 and 6. Once poured, the concrete slurry is allowed to harden over a number of days. The outer former 10 is then removed from the set concrete panel while the rectangular aperture formers 4 and 6 are left, set into the finished panel. As will be explained in more detail later, the interior of the metal frame is fitted with reinforcing steel bar and mesh which is set into the concrete to increase the strength of the finished panel. Various features are cast into the concrete including ferrules and other features, such as lifting anchors and reinforcing bar locators, to assist in forming the panels, lifting them, interconnecting them to each other and fastening floor and roof structures to them. Further details of the manufacture of the concrete panel will be discussed later. Figures 3 and 4 depict "form-fills", which are pre-manufactured building panels sized to fit into apertures 5 and 7. For example, the form-fill of Figure 3 features a sliding window whereas the form-fill of Figure 4 features a window and a door. Many other types of form-fill are possible. Form-fills can be fabricated from > Steel studs, insulation, clad in a variety of fiber cement cladding. > Weather boards Corrugated steel sheeting > Timber feature panels > Thermal wall panelling such as aerated concrete panel > Steel & foam sandwich panels such as coldroom panels (Bondor@) for maximum thermal efficiency. As previously mentioned, in the presently discussed preferred embodiment, the concrete panel 1 is 3.5m wide. Consequently it is convenient to construct a building, such as house upon a grid based on 3.5m x 3.5m squares. However the total system includes 1 and 2 storey panels, plus panels of sizes that derived from the base size of 3.5m wide. ie. 1 and 2 storey 1.75m wide panels, with and without apertures.

6 Referring now to Figure 5, there is depicted a plan view of a layout for a house including eight 3.5m x 3.5m squares. Site preparation for the construction of a house using the panels is very simple and is as follows: o The site is cut and filled to comply with developer covenants and engineering specifications. o An excavator mounted auger is used to bore holes. (or skidsteer loaders or other machines that can bore holes can be used) o Steel reinforcing cages is placed into the bore holes and concrete is poured in to form concrete bored piers (indicated as P1, P2 and P3 in Figure 5). Vibrating concrete is necessary to comply with engineering details o The tops of the piers are levelled with a laser levelling instrument to establish level bases for the panels to sit on and the house floor level is established. A sufficient number of the concrete panels 1 are transported to the site on the back of a flat bed truck fitted with a crane, more trucks with or without cranes can be used to speed up the logistic process. The panels are located upon to the concrete bored piers and then connected together with fabricated structural members. Figures 6 to 8 illustrate the pier footings in detail whilst a perspective view of the panels, mounted on the piers and interconnected is shown in Figure 9. After the panel to panel connections are made structural members are installed. The structural members include: * Structural floor beam, illustrated in Figure 10. or concrete floor panels * Structural roof members, illustrated in Figure 11. or concrete roof panels * Vertical steel members where required and bracing as illustrated in Figures 12 to 12C.

7 At this stage the building resembles a commercial fitout, not a standard residential construction. In order to fitout the building to a residential construction standard: 1. form-fills are installed, this entails fastening the form-fills, e.g. as shown in Figures 3 and 4 into the aperture formers within apertures 5 and 7 of the concrete panels 1. 2. Where the building is two storeys, as shown in Figure 9, a floor structure is then installed over the structural floor beam. 3. FC & plasterboard sheeting is fixed to the interior of the metal framed panels 1. Finishing the house requires very few (if any) changes to existing finishing systems. Preferred methods are as follows: A. Texture sprayer to colour / texture coat the externals of the house, e.g. Taubmans@ Armawall system may be used. B. Internal walls are painted as per any other residential job. C. Floor coverings, kitchens, bathrooms are all installed as per any other residential job. D. Decorative external mouldings and awnings are fitted as per any other residential job. An example of a house according to an embodiment of the present invention, where the form-fills have been installed and the house finished as described above is illustrated in Figure 13. The process used to make the concrete panels that was previously discussed with reference to Figure 2 will now be described in more detail. Referring to Figure 14, the mould is formed with an outer former 3 made of a custom aluminium extrusion, shown in cross section in Figure 17. Internal custom aluminium cast-in extrusions 23 are used to make the aperture formers 4, 6. The aperture formers provide a controlled base around the inside of apertures 5 and 7 for the form-fills to be fastened into. The aluminium cast-in extrusions 23 are shown in cross section in Figure 17. The cast-in aperture formers 4, 6 that are made from extrusions 23 keep the aperture square and true. This in 8 turn makes the step fixing much easier. In contrast prior technologies have left the apertures not square, leaving out-of-square apertures to fix square windows for example, which is messy and time consuming. A number of features including, face lifting anchors 9, back braces 11 (for face), near face ferrules 13, edge lifting anchors 15 and cast in plates 19 are formed into the concrete before it sets. As shown in Figure 15, reinforced steel bars 21 are cut and placed in specified positions. Similarly, steel reinforcing mesh 23 is also cut and placed inside the frame as shown in Figure 16. Slurry for a concrete with a minimum strength of 30mpa (higher mpa is used for faster manufacturing) is then poured over the reinforcement steel bars and mesh and finished inside the aluminium mould. After 3 days (dependant on weather and time schedules) panels can be lifted out of the outer former 3. The aperture formers 4 and 6 are left retained within the new panel. The outer former 3 can then be reused in the manufacture of a new panel, which will also use two new aperture formers. The freshly manufactured panel is stored ready for transportation to site when required. Alternatively, the panels can be manufactured on site if desired. It will be noted that a modular building method according to an embodiment of the present invention has a number of associated advantages. For example, the metal framed building panels may be produced in large numbers at a central factory and readily transported to site on the back of a truck. Once on site the panels can be quickly lifted into position on the pre-installed piers and interconnected with steel members to quickly form walls for the buildings. Since the panels are load bearing, the interior of the building can be largely free from roof supporting columns and walls thereby allowing for large open spaces to be provided inside the building, leaving more possibilities for design.

9 In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of' is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims (19)

1. A method for constructing a building at a site including the steps of: forming walls of the building by erecting a plurality of pre-formed concrete panels side by side; and inter-connecting the pre-formed panels for structural integrity; wherein a number of said pre-formed concrete panels include aperture formers of predetermined dimension defining apertures in said panels for receiving pre-fabricated form-fills therein.

2. A method according to claim 1, wherein the pre-fabricated form-fills include a door.

3. A method according to claim 1 or claim 2, wherein the pre-fabricated form-fills include fibre cement sheeting.

4. A method according to any one of the preceding claims wherein the pre fabricated form-fills include foam sandwich coldroom panels.

5. A method according to any one of the preceding claims including fastening the form-fills within the apertures.

6. A method according to any one of the preceding claims, wherein the step of forming the walls includes installing a number of piers at the site along predetermined wall lines and locating said panels upon the piers.

7. A method according to any one of the preceding claims including a preliminary step of manufacturing the concrete panels on site.

8. A method according to any one of the preceding claims including manufacturing the concrete panels with a mould using said aperture formers as part of the mould in cooperation with an outer former.

9. A method according to claim 8, wherein the outer former is reused. 11

10. A method according to any one of the preceding claims, including a step of installing a floor structure subsequent to the step of interconnecting the pre formed, concrete panels.

11. A concrete building panel including: at least one aperture former defining an aperture in the concrete panel, for receiving form-fill panels therein.

12. A concrete building panel according to claim 11, wherein the aperture former is made from lengths of aluminum extrusion.

13. A concrete building panel according to claim 11 or claim 12, wherein said panel includes at least one ferrule.

14. A concrete building panel according to any one of claims 11 to 13, wherein the panel includes a system of interconnecting ferrules and steel reinforcing.

15. A concrete building panel according to any one of claims 11 to 14, including lifting anchors to assist in lifting the frame by crane.

16. A method of making a concrete building panel including: locating at least one aperture former within an outer former and pouring a concrete slurry therebetween; allowing the slurry to set to form concrete with said aperture former retained fast therewith; removing the outer former from the concrete.

17. A method according to claim 16, wherein said aperture former is made of metal extrusions.

18. A method of constructing a building substantially as described herein with reference to Figures 5, 9 and 13. 12

19. A method of making a concrete building panel substantially as described herein with reference to Figures 2 and 14 to 16. * * *