AU2013100447A4 - Panel System - Google Patents

Abstract

- 17 Abstract A panel for defining a structural element of a building, the panel comprising a first slab, a second slab, a cavity defined between the first slab and the second slab 5 when the first and second slabs are in abutting relationship with respect to each other, and first fastening means for attachment of the first slab to the second slab to define the cavity. There are also provided methods for manufacturing the panel. 45 ' Fig2 10 20 44 26 16 34 18 14 45 48 42 24 Fig3

Description

- 1 Panel System Field of the Invention The present invention relates to systems for erecting buildings. The invention has been devised particularly, although not necessarily solely, in 5 relation to the manufacture of panels for buildings and the methods for manufacturing the panels. Background Art The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an 10 acknowledgement or admission that any of the material referred to is or was part of the common general knowledge in Australia or elsewhere as at the priority date of the application. Tilt-up construction technique is a technique used for erecting buildings. The 15 tilt-up construction technique consists of casting out of concrete the structural elements to be used during the erection of the building. The casting of the structural elements can be conducted on site or at a remote location and delivered to the site as required. 20 Examples of structural elements used in tilt-up construction techniques are panels. Typically, the panels define the side walls of the buildings. The panels may be casted in formworks which incorporate reinforcement meshes. The panels are casted by pouring concrete into the formwork. After 25 hardening of the concrete, the formwork may be stripped from the panels. At this stage, the panels can be lifted and braced into position together with the remaining building structural components in order to finalize erection of the building.

-2 The panels may be casted as a single element. Alternatively, the panels may be two concrete slabs joined together by structural metal ties. In this manner, sandwich panels are formed. 5 Typically, the panels are engineered such that the panels are capable to resist all forces which are applied to the panels after assembly of the building. These forces may be from the roof structures as well as the floor structures attached to the panel. Thus, the panels are typically designed to support relatively large loads. In order to resist the loads, the panels must be manufactured 10 incorporating into them metal reinforcement meshes. Also, the panel must be relatively of large thickness so as to support the loads applied to the panels. This makes the panels very heavy and cumbersome to handle. Further, the panels are solid panels. The fact that the panels are solid makes it 15 difficult to incorporate in the panels services such as electrical, plumbing and sewage services. Also, water and moister as well as heat and cold may permeate through the solids panels. It is against this background that the present invention has been developed. 20 Summary of the Invention According to a first aspect of the invention there is provided a panel for defining a structural element of a building, the panel comprising a first slab, a second slab, a cavity defined between the first slab and the second slab when the first and 25 second slabs are in abutting relationship with respect to each other, and first fastening means for attachment of the first slab to the second slab to define the cavity. Preferably, the first slab comprises a mesh included in the first slab. Preferably, the first slab comprises means for securing floor panels to the first 30 slab.

-3 Preferably, the means for securing floor panels comprises at least one ferrule that is attached to the mesh of the first slab, the ferrule defining a first opening in the first slab adapted to receive dowels for attachment of the floor panels to the first slab. 5 Preferably, the first slab comprises a plurality of second openings arranged around the periphery of the first slab, the second openings being adapted to receive second fastening means to allow handling of the panel. According to a second aspect of the invention there is provided a panel for defining a structural element of a building, the panel comprising a first slab 10 presenting a first face having at least one extension, a second slab having a second face and fastening means within the second slab, and a cavity defined between the first face and the second face, wherein the at least one extension of the first panel are configured for attachment to the second slab when the first and second faces are in abutting relationship. 15 Preferably, the first slab is attached to the second slab during casting of the second slab. In this arrangement, the at least one extension is positioned within the second slab prior to casting of the second slab. This allows the at least one extension to be casted into the second slab and, thus, attached to the second slab. In this manner, the first slab is attached to the second slab via the at least 20 one extension. Preferably, the first slab comprises a first mesh included in the first slab. Preferably, the at least one extension extend outwardly with respect to the first mesh. Preferably, the at least one extension comprises an end embedded in the first 25 slab or attached to the first mesh and an opposite end configured to be attached to the second slab. Preferably, the panel further comprises a plurality of extensions, the plurality of extensions being attached at spaced apart locations of the mesh or embedded at spaced apart locations of the first slab. 30 Preferably, the first face of the first slab comprises first openings.

-4 Preferably, the first openings extend from one side of the first slab to the other side of the first slab. Preferably, the first openings are adapted to receive dowels for attachment of panels perpendicular to the first face of the first slab. 5 Preferably, the first openings are defined by ferrules. Preferably, the ferrules are attached perpendicularly to the mesh of the first slab. Preferably, the first slab comprises second openings adapted to receive pins. Preferably, the second openings are arranged around the periphery of the first slab. 10 Preferably, the second openings are defined by sleeves comprising at least one open end. Preferably, the sleeves are incorporated within the first slab and attached parallel to the mesh of the first slab. Preferably, the second slab comprises a second mesh incorporated in the second 15 slab. According to a third aspect of the invention there is provided a formwork for casting a second slab incorporating a mesh, the formwork comprising a bottom surface, a border surrounding the bottom surface to define a periphery of the formwork, and a plurality of support means arranged around the periphery of the 20 formwork, the support means being adapted to support a first face of a first slab suspended a distance from the second slab in order to define a cavity between the first and second slab, the distance being such that at least one extension which extends outwardly from the first face reaches into the second slab for attachment to the second slab. 25 Preferably, the support means comprises a plurality of indentations extending partially into the border of the formwork in order to define a plurality of notches having a bottom end. Preferably, the notches are adapted to receive pins attached to the first slab. This allows, during lowering of the first slab into the formwork, the pins of the first -5 slab to slide into the notches. As the pins reach the bottom end of the notches, the first slab is kept suspended above the second slab to allow casting of the second slab while a portion of the at least one extension of the first slab is within the second slab. 5 According to a fourth aspect of the invention there is provided a method for manufacturing a panel in accordance to the first aspect of the invention, the method comprising the steps of: Inserting in a first formwork a mesh comprising at least one extension extending outwardly with respect to the bottom surface of 10 the mesh; Pouring concrete into the formwork in such an amount that the at least one extension are maintained outside of the concrete; Letting the concrete harden; Inserting in a second formwork a mesh; 15 Pouring concrete into the second formwork Suspending the first slab a distance from the second slab in order to define a cavity between the first and second slab, the distance being such that the at least one extension is inserted into the concrete of the second slab; and 20 Hardening of the concrete of the second slab for fastening of the at least one extension within the second slab. Preferably, the method further comprises the steps of vibrating the concrete of the second slab for facilitating insertion of the at least one extension into the concrete of the second slab. 25 In alternative arrangement, the method further comprises the steps of vibrating the first slab for facilitating insertion of the extension into the concrete of the second slab.

-6 Brief Description of the Drawings The present invention will be better understood by reference to the following description of one specific embodiment thereof as shown in the accompanying drawings, in which: 5 Figure 1 is a perspective view of building erected using panels in accordance with an embodiment of the invention. Figure 2 is a perspective view of a panel according to the first embodiment; Figure 3 is a sectional view of the panel shown in figure 2; Figure 4 is a top perspective view of a formwork used for casting of the 10 panel shown in figure 2; Figure 5 is a top perspective view of a formwork used for casting of the panel shown in figure 2 including reinforcement means; Figure 6 is a sectional view of the formwork shown in figure 5; Figure 7 is a top perspective view of the formwork shown in figure 5 having 15 the first slab of the panel; Figure 8 is a sectional view of the casting bed shown in figure 4 having the first slab of the panel; Figure 9 is a sectional view of a formwork for casting of the second slab of the panel shown in figure 2 ; 20 Figure 10 is a sectional view of the formwork shown in figure 8 being filled with wet concrete; Figure 11 is a top perspective view of the formwork shown in figure 8 showing mounting of the first panel; Figure 12a and 12b are sectional views of the formwork shown in figure 8 25 used during a first arrangement of a manufacturing process of the panel shown in figure 2.

-7 Figures 13a and 13b are sectional views of the formwork shown in figure 8 used during a second arrangement of a manufacturing process of the panel shown in figure 2. Figure 14 is transversal sectional view of the panel shown in figure 2; 5 Figure 15 is an enlarged view of a detail of figure 14 showing the ferrule; Figure 16 is a top perspective view of the panel shown in figure 2 showing stripping of the formwork from the panel; Figure 17 is a top perspective view of the panel shown in figure 2; and Figure 18 is a perspective view of the finished panel in accordance with the 10 present embodiment of the invention. Detailed Description of Specific Embodiment(s) Figure 1 shows a building 10 constructed using the tilt-up construction technique. The building 10 shown in figure 1 has been erected using panels 12 in accordance with an embodiment of the present invention. 15 Figures 2 and 3 show a panel 12 in accordance with the present embodiment of the invention. The panel 12 comprises first and second slabs 14 and 16. The slabs 14 and 16 are separated by a cavity 18. 20 The slabs 14 and 16 contain reinforcement means 20 to provide structural integrity to the slabs 14 and 16. The reinforcement means 20 comprises a reinforcement mesh 22. There are two types of reinforcement meshes 22. A first type of reinforcement 25 mesh 24 is incorporated in the first slab 14. The second type of reinforcement mesh 26 is incorporated in the second slab 16. Referring to figure 5, the first type of reinforcement mesh 24 comprises a plurality of longitudinal bars 28 located side by side and spaced apart with 30 respect to each other. A plurality of transversal bars 30 extend transversally -8 over the longitudinal bars 28. The transversal bars 30 extend side by side along the entire length of the longitudinal bars 28 and spaced apart with respect to each other. In this manner, a mesh 24 having an upper and bottom surface is defined. The longitudinal bars 28 are longer than the transversal 5 bars 30 defining a rectangular shape having two long sides 32 and two short sides 34. The first type of reinforcement mesh 24 comprises means for securing the first and second slabs 14 and 16 together. These means comprise extensions 36 10 extending outwardly from the mesh 24. The extensions 36 comprise an end 38 and an opposite end 40. The end 38 is attached to the mesh 24. As shown, for example, in figure 6, the opposite end 40 is a hooked-shaped end 40. The opposite end 40 is configured to be casted within the second slab 16. In this manner, the first slab 14 is attached to the second slab 16 via the at least one 15 extension 36. The extensions 36 are positioned over the entire mesh 24 at spaced apart locations with respect to each other. The extensions 36 extend outwardly from the upper surface of the mesh 24. 20 Further, the first type of reinforcement mesh 24 also comprises means 42 for securing, for example, floor panels to the panel 12 incorporating the reinforcement mesh 24. This means 42 for securing the floor panels comprises first openings defined by ferrules 44. The ferrules 44 are attached 25 perpendicularly to the mesh 24 such that a first portion 46 of the ferrule 44 extends outward from the upper surface of the mesh 24 and a second portion 48 of the ferrule 44 extends outward from the inner surface of the mesh 24 (see figure 3). The ferrules 44 are arranged in a straight line spanning from the long side to the opposite long side of the reinforcement mesh 24. This 30 arrangement of ferrules 44 divides the mesh 24 into two sections 50 and 52. The ferrules 44 receive dowels 54 for attachment of panels 12 defining, for example, floor sections (see figure 2).

-9 Each of the ferrules 44 comprises a cross bars 45. The cross bars 45 extend perpendicular to the ferrules 44, traversing the ferrules 44 at the centre of the ferrules 44 (see figure 2). The cross bars 45 reinforces the ferrules 44 to 5 support, for example, floor panels. Moreover, four sleeves 56 are attached to the mesh 24 (see figure 6). The sleeves 56 are attached parallel to the transversal bars 30. There is one sleeve 56 attached adjacent to each corner of the mesh 24. The sleeves 56 10 comprise a cylindrical body having at least one open end. Each sleeve 56 is attached to the reinforcement mesh 24 such that the open end is positioned at the edge of the mesh 24 and the cylindrical body of the sleeves 56 extends inwardly. In this manner, the open ends of the sleeves 56 define second openings which open to the exterior of the first slab 14 containing the 15 reinforcement mesh 24. The open ends are adapted to receive pins 58. As will be described with reference to the method of manufacture of the panels 12, the pins 58 allow handling of the slab 14. The pins 58 may be removable attached to the sleeves 56. This permits removal of the pins 58 from the panel 12, for example, after manufacture of the panel 12 or prior usage of the panel 20 12 for assembly of the building 10. As mentioned before, the second slab 16 of the panel 12 comprises a second type of reinforcement mesh 26. The second type of reinforcement mesh 26 does not include the extensions 36, ferules or sleeves 56. The second type of 25 mesh 26 comprises a conventional mesh 26 defined by a plurality of longitudinal bars 28 joined together by a plurality of transversal bars 30 extending transversally over the longitudinal bars 28. Figures 4 to 15 illustrate the method of manufacture of the panel 12 in 30 accordance with the present embodiment of the invention.

- 10 As mentioned before, the panel 12 comprises a first slab 14 and a second slab 16. In accordance with the method for manufacturing the panel 12, the first slab 14 is manufactured separately with respect to the second slab 16. And, the panel 12 is formed by joining the first and second slabs 14 and 16 5 together. The joining of the first and second slab 14 and 16 is done during manufacture of the second slab 16. Figure 4 shows a formwork 60 for manufacturing the first slab 14. The formwork 60 is mounted on a casting bed 62. The formwork 60 comprises a 10 bottom surface 64 extending on the casting bed 62 and a border 66 defining the periphery of the formwork 60. Support elements 68 extend outward the bottom surface of the formwork 60 (see figure 6). The support elements 68 are reinforcement chairs adapted to receive the reinforcement mesh 24. 15 Referring now to figure 5, the process for manufacturing the panel 12 commences by inserting the reinforcement mesh 24 inside the formwork 60. The reinforcement mesh 24 rests on the support elements 68. In this manner a space 70 is formed between the mesh 24 and the bottom surface of the formwork 60. This permits to centre the mesh 24 within the slab. 20 Further, the reinforcement mesh 24 is positioned within the formwork 60 such that the extensions 36 extend opposite to the bottom surface of the formwork 60. In this manner, the extensions 36 may reach out of the first slab 14 (see figure 7). In order for the extensions 36 to reach out of the first slab 14, the 25 amount of concrete to be poured into the formwork 60 must be such that the concrete does not cover the extensions but covers the mesh in its entirety. After positioning the mesh 24 within the formwork 60 concrete is poured into the formwork 60. The casting bed 62 also facilitates the settling of the concrete 30 within the formwork 60.

- 11 As mentioned before, the amount of concrete to be poured into the formwork 60 is such that the mesh 24 is covered in its entirety but allowing the extensions 36 to reach out of the slab. 5 Figure 8 shows a cross section of the first slab 14 lying within the formwork 60. The first slab 14 lies on the bottom surface of the formwork 60. The ferrules 44 extend from the bottom surface of the formwork 60 to the exterior surface of the slab. 10 The first slab 14 is ready to be extracted from the formwork 60 after the concrete has settled and hardened. The first slab 14 may be lifted out of the formwork 60 using ropes attached to the pins 58 located at the sides of the panel 12. Alternatively, the formwork 60 may be stripped from the slab 14. 15 Figures 9 and 10 illustrate the method for manufacturing the second slab 16 of the panel 12. Figure 9 shows a cross section of the formwork 60 used for casting the second slab 16 of the panel 12. As was the case with the framework used for casting 20 the first slab 14, the formwork 60 for casting the second slab 16 of the panel 12 is mounted on a cast bed 62. The formwork 60 comprises a border 66 defining the periphery of the formwork 60 and a bottom surface 64 extending on the cast bed 62. 25 As will be described with reference to a first arrangement of the method for manufacturing the panel 12 in accordance with the present embodiment of the invention, the casting bed may comprise a vibrating table. The border 66 of the formwork 60 comprises notches 74 extending partially 30 into the border 66 of the formwork 60. As will be described with reference to the method for joining the first and second slab 14 and 16, the notches 74 are adapted to receive the pins 58 of the first slab 14 (see figure 12). This allows - 12 suspending the first slab 14 over the second slab 16 for defining the cavity 18 of the panel 12. Similarly, to the method for manufacturing the first slab 14, the second slab 16 5 is manufactured by inserting the second type of reinforcement mesh 26 into the formwork 60. The formwork 60 comprises support elements 68 for supporting the reinforcement mesh 26. Subsequently, concrete is poured into the formwork 60. Sufficient concrete is 10 poured into the formwork 60 in order to cover the mesh 26 in its entirety and to centre the mesh within the slab. The vibrating bed 62 facilitates the settling of the concrete within the formwork 60 (see figure 10). Referring to figures 11 and 12, prior to hardening of the concrete, the first slab 15 14 is suspended above the second slab 16. For this, ropes 72 are attached to the pins 58 located at the edges of the slab 14. By lifting the ropes 72 it is possible to positioning a portion of the first slab 14 within the formwork 60 above the second slab 16. 20 The first slab 14 is located at a distance above the second slab 16 such that the extensions 36 penetrate the wet concrete of the second slab 16 (see figures 12a and 12b). In accordance with particular arrangements of manufacture of the panel 12, the penetrations of extensions 36 into the wet concrete of the second slab 16 is facilitated via vibrational means. In an 25 arrangement, the vibrational means are adapted to vibrate the cast bed 62 (see figures 12a and 12b). Vibrating the cast bed 62 facilitates the hooked shaped ends 40 of the extensions 36 of the first slab 14 to enter the wet concrete of the second slab 16. 30 In an alternative arrangement, the vibrational means are adapted to vibrate the first slab 14. Figures 13a and 13b show the manufacture of the panel 12 in accordance with the alternative arrangement. As shown in figures 13a and - 13 13b, the vibrational means comprises a plurality of vibrators 63 mounted on the first slab 14. The vibrators 63 are in direct contact with the first slab 14. In this manner, the extensions 36 together with the hooked-shaped ends 40 vibrate. Vibrating the extensions 36 facilitate entrance of the hooked-shaped 5 ends 40 into the wet concrete of the second slab. Once the hooked-shaped ends 40 of the extensions 36 are embedded in the wet concrete of the second slab 16 the first slab 14 is fastened to the second slab 16 as the concrete hardens. In this manner is the panel 12 defined. 10 Figures 12 and 13 show a side view of the formwork showing the interior of the formwork. However, it is to be noted that figure 2 is schematic only. The interior of the formwork 60 is shown in order to facilitate illustration of the method for joining the slabs 14 and 16 together. 15 As shown in figure 12, the pins 58 of the first slab 14 and the notches 74 of the formwork 60 impede that the first slab 14 slides completely into the formwork 60 and contacts the second slab 16. During lowering of the first slab 14 into the formwork 60, the pins 58 of the first slab 14 slide into the notches 74. The 20 dimensions of the notches 74 are such that the first slab 14 only partially slides into the formwork 60 and is maintained suspended above the second slab 16. In this manner is the cavity 18 of the panel 12 defined. Referring to figures 16 and 17, after the concrete of the second slab 16 has 25 hardened, the panel 12 defined by the joined slabs 14 and 16 can be removed from the formwork 60. This can be accomplished by stripping the formwork 60 from the panel 12. The panel 12 may be lifted from the casting bed 62 by using ropes 72 attached to, for example the pins 58. Alternatively, the ends of the ropes 72 may be inserted in the cavity 18 of the panel 12 for attachment to the 30 extensions 36 that unite the first slab 14 with the second slab 16.

- 14 Figure 18, shows a finished panel 12 in upright condition. The finished panel 12 include the pins 58. However, as mentioned before the pins 58 are removable pins 58 which may be removed prior to use of the panel 12. Also, dowels 54 have been inserted in the ferrules 44. As mentioned before, the 5 dowels 54 allow attaching other panels 12 to the panel 12 in order to, for example, define a floor structure. The panels 12 shown in figures 2 and 3 are rectangular panels 12 which do not include openings for defining, for example, windows or doorways. 10 However, in accordance with the present embodiment of the invention, the panels 12 may incorporate openings to define, for example, in the building 10 shown in figure 1, the exterior walls 80 which have windows. Also, other arrangements of the panels 12 in accordance with the present invention may 15 be configured to any shape. For example, the entrance of the building 10 shown in figure 1 is defined by two adjacent L-shaped panels 82. For the manufacture of the panels 12 incorporating an opening or being, for example, L-shaped, the formworks 60 in which the panels 12 will be casted 20 may be configured to the desired shape or to include the opening. Also, the reinforcement mesh 22 that provides structural integrity to the panel 12 may be configured so as to be able to fit within the formwork 60. It is evident that the embodiment of the invention as described above provides 25 a useful panel to be used for erecting buildings. The presence of the cavity 18 reduces the weight of the panel. Also, the cavity 18 allows running through the panels plumbing, electric conductors and other services. Further, the incorporation of a cavity within the panel improves the thermal properties of the panel as well as acts as a barrier for impeding moisture to enter the building. 30 Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

- 15 Further, it should be appreciated that the scope of the invention is not limited to the scope of the embodiments disclosed. As an example, the extensions which fasten the first and second slab 14 and 16 together may be attached to the first 5 slab by embedding the extensions within the wet concrete of the first slab. After the wet concrete hardens the extensions are fastened to the first slab. Throughout the specification and claims, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be 10 understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. 15 20

Claims (5)

1. A panel for defining a structural element of a building, the panel comprising a first slab, a second slab, a cavity defined between the first slab and the second slab when the first and second slabs are in abutting relationship 5 with respect to each other, and first fastening means for attachment of the first slab to the second slab to define the cavity.

2. A panel according to claims 1 wherein the first slab comprises a mesh included in the first slab.

3. A panel according to claims 1 or 2 wherein the first slab comprises means 10 for securing floor panels to the first slab.

4. A panel according to claim 3 wherein the means for securing floor panels comprises at least one ferrule that is attached to the mesh of the first slab, the ferrule defining a first opening in the first slab adapted to receive dowels for attachment of the floor panels to the first slab. 15

5. A panel according to any one of the preceding claims wherein the first slab comprises a plurality of second openings arranged around the periphery of the first slab, the second openings being adapted to receive second fastening means to allow handling of the panel.