AU2016202540B2

AU2016202540B2 - A base block for supporting a panel

Info

Publication number: AU2016202540B2
Application number: AU2016202540A
Authority: AU
Inventors: Christopher John Adams
Original assignee: Greenblock Fencing Pty Ltd
Current assignee: Greenblock Fencing Pty Ltd
Priority date: 2011-06-30
Filing date: 2016-04-21
Publication date: 2018-07-19
Anticipated expiration: 2032-06-28
Also published as: AU2016202540A1; AU2018204639A1

Abstract

A fencing panel comprising a core of hardened foam and having an upper edge and a lower edge, at least one elongate support member in the core and extending at least from adjacent the upper end of the core to adjacent the lower end of the core, and at least one footing member extending from the lower edge of the core.

Description

COMPLETE SPECIFICATION

A BASE BLOCK FOR SUPPORTING A PANEL

The following statement is a description of the invention:

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2016202540 07 Apr 2017

A BASE BLOCK FOR SUPPORTING A PANEL

TECHNICAL FIELD

The present invention is directed to a base block to support a vertical panel.

The panel may comprise a fence panel or panels, a garden wall, a pool barrier and the like. The base block can function as a retaining wall.

BACKGROUND ART

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

Vertical panels comprising hardened foam rendered and painted to provide an aesthetic appearance are popular as garden wall panels, property boundary fences, and pool fencing.

These panels need to be securely fixed in place and this can be achieved by pouring a concrete footing to which the panels are attached. One technique has steel posts/rods extending from the bottom of the panel which pass into the footing prior to the concrete pour.

For uneven or sloping ground, this can present a problem as the panels are usually rectangular. Infill panels may be required below the bottom of the panel to provide a smooth finish. Sometimes a retaining wall is required on top of which the panel sits. Building a retaining wall for the panel can be a slow and time consuming process.

A disadvantage with known panels attached to a retaining wall is the lack of aesthetic appearance. That is, the retaining wall is visually quite separate from the panel. There would be an advantage to provide a retaining wall to which a panel can be attached and which can provide a smooth flush appearance when finished off.

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It is an object of the invention to provide a panel that may be used as a base block to which a panel can be attached and which can overcome at least some of the abovementioned disadvantages.

SUMMARY OF THE INVENTION

In one form, the invention comprises a panel for use in fencing comprising wall members attached relative to each other to define a void adapted to receive concrete.

The panel is typically of special design. The panel may be substantially hollow to allow for concrete and steel to the required height. The panel may be manufactured off site in suitable lengths and heights and then fixed into position. The panel may comprise a block having a length of between 1-6 meters, a height of between 0.5-2meters, and a thickness of between 100600mm, although these dimensions may vary to suit. A number of panels may be fixed into position to provide a retaining wall of suitable length. The panels may be supported on top of concrete foundations and function as base blocks for subsequent panels placed upon them.

The wall members may be made from any suitable material or materials which can at least partially withstand the lateral forces of concrete/grout poured into the panel. The wall members may comprise an expanded foam material which can make the panel a relatively lightweight structure. The foam material may be coated or rendered to provide a tough outer skin. The wall members may comprise a building board.

To enable the panel to have a relatively thin design and a relatively low weight, the wall members, or at least the side wall members may be supported against bowing during the concrete pour. A support means may therefore be provided. The support means may comprise reinforcement members which can be temporarily fixed to the wall members to provide

2016202540 07 Apr 2017 temporary reinforcement and then removed. The reinforcement members may comprise timber formwork such as boards/planks etc.

A fixing means may be provided to fix the support means. The fixing means may comprise one or more bolts extendible through the block to fix one or more support means to the panel. Clamps or other fixing means are also envisaged.

The support means may also comprise a base support means which can support the lower base part of the base block panel against bowing. The base support means may comprise a rebate in the footing to accommodate a bottom or base part of the block. A non-limiting example of a rebate is illustrated in figure 2.

The internal void in the panel may have a width of between 40-120mm. the thickness of the wall members may be between 40-150mm. The internal void may have substantially planar walls defining the void, see for instance figure 8 as a non-limiting example, or may have non planar walls - see for instance figure 9 as a non-limiting example.

If the panel is to be used as a base block panel and an upper panel is to be fixed to the top of the base block panel, the upper panel may have a modified design to facilitate filling of the base block panel and to provide additional strength to the upper panel. In this form, the invention comprises a fencing panel particularly suited for fixing to the top of a base block, the fencing panel being generally as described above but additionally comprising at least one passageway extending from a top wall of the panel to a bottom wall of the panel to allow cement to be pumped through the passageway and into the base block panel. Suitably, the passageway is adapted to be at least partially filled with cement to provide additional strength to the panel.

In another form, the invention comprises a method to form a retaining wall containing at least one fixed fencing panel on top of the retaining wall, the method comprising providing at least one panel for fencing in the form of a

2016202540 07 Apr 2017 base block panel which is be substantially hollow to allow for concrete and steel to the required height, positioning a fencing panel on top of the base block panel, the fencing panel comprising hardened foam containing embedded support members, the panel containing at least one passageway extending from a top wall of the panel to a bottom wall of the panel to allow cement to be pumped through the passageway, the panel containing at least one extending footing member which extends into the hollow ofthe base block panel, and, pouring/pumping concrete or other suitable settable material through the passageway to fill the hollow in the base block panel and then to at least partially fill the passageway.

The base block panel is suitably placed on a foundation. The foundation suitably has a rebate to support the lower part of the base block panel.

The fencing panel that locates above the base block panel can comprise a further part of a fence that includes the base block panel. The fence may comprise a dividing fence, a pool fence, a decorative wall, a partition, or any other type of dividing wall, privacy wall and the like, and is typically non load bearing.

The fencing panel for mounting atop the base block panel may have any suitable shape and size. It is expected that a common shape for the panel will be substantially rectangular. However, there may be circumstances where it is convenient for the panel to have a shape other than substantially rectangular.

The size of the fencing panel can vary however it is envisaged that the size will be such that the panel can be conveniently handled either manually or using a crane or other mechanised equipment. As an example, the fencing panel may be substantially rectangular and may have a length of between 0.56 m and a height of between 0.5-2.5 m although this can vary. The thickness of the panel can also vary but it is considered that a suitable thickness will be between 100-600 mm and preferably between 150-300 mm and most preferably about 200 mm.

2016202540 07 Apr 2017

It should be appreciated that no unnecessary limitation should be placed on the invention merely by exemplification of certain shapes and sizes.

The panel preferably comprises a core of hardened foam. A suitable core material comprises expanded polystyrene which is also known as EPS. The expanded polystyrene is a commercially available product and typically comprises at least three grades being a low density expanded polystyrene (SL grade], a medium density (M grade] expanded polystyrene and a higher density (H grade] expanded polystyrene. The M grade EPS is considered a suitable but non-limiting example of a core material. The core may comprise different types and/or grades of hardened foam. Preferably the EPS has been treated with pest repellant and also is fire resistant. The core may comprise parts or sections which are joined to form the core. The core may comprise a layered or laminate structure. The core may comprise voids or cavities if considered suitable. It is considered convenient that the core is of substantially uniform thickness, but there may be instances where it is useful for the core to have a non-uniform thickness. For instance the core may have a tapered configuration. The core will suitably have a substantially flat outer surface especially if a neat seamless finished look is required for the fence.

However the core may have other configurations such as a corrugated configuration, a grooved configuration and the like. It is also envisaged that there may be circumstances where the core does not consist entirely of the foam material and may contain areas of other materials which may not comprise expanded material. However, it is considered most convenient that the panel is made substantially of the expanded material.

The core contains at least one embedded support member. Suitably, the core has an upper edge and a lower edge and the at least one support member extends from at least adjacent the upper edge of the core to at least adjacent the lower edge of the core. Preferably, a plurality of support members is provided in the core with the number of support members depending, inter alia, on the size and shape of the core. The support members may be in a spaced apart side-by-side orientation in the core and the spacing between adjacent support members may vary at least between 100-500 mm. Of

2016202540 07 Apr 2017 course, no unnecessary limitation should be placed on the invention merely by exemplification of certain spacings.

Suitably, at least some of the support members extend below a lower edge of 5 the core. Preferably all, or most, of the support members extend from a lower edge of the core. The extending part of the support members may comprise at least part of the footing members.

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. Figure 2.

Figure 3. Figure 4.

Figures 5-7.

Figures 8-9.

Illustrates a fence

Illustrates a retaining wall in the form of at least one base block panel on which a fence panel can be fixed.

Illustrates the fence panel positioned above the retaining wall. Illustrates a cut away view of the fence panel in place on top of the retaining wall with concrete poured in place.

Illustrate views of temporary formwork to hold the base block panel panel against unwanted deformation during the concrete pour.

Illustrate two different internal hollow configurations of the base block panel.

Figures 10-11. Illustrate a top fence EPS panel and the panel on a base block panel.

Figures 11-13. Illustrate a base block panel by itself.

2016202540 07 Apr 2017

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Figure 1 is an illustrative example only of a finished fence which can be supported by a fencing panel in the form of a base block panel in a manner whereby the base block panel is not noticed and becomes part of the overall fence design. Thus in the overall design, the lower part (the base block panel 54) is load bearing and the upper part (the fence 10) is typically non-load bearing, and the two parts are designed and finished off to become indistinguishable.

Reference will now be had to figures 2-4 which illustrate an embodiment of the invention where the fencing panel is fixed on top of a retaining wall of special design. The retaining wall has a special design to make it more convenient to install, quick to install, a more lightweight system and requiring less fil (e.g. concrete).

The fencing panel (see figure 3) is provided with at least one passageway 51 which extends entirely through the panel from a top wall 52 to a bottom wall 53. These passageways are hollow sections (also sometimes called droppers) to allow cement to be pumped in to fill the retaining wall which is below the panel and which can then fill the passageways 51 to provide extra strength to the fencing panel.

The retaining wall comprises at least one hollow base block panel 54. Base block panel 54 can be of any suitable length width and height and in the particular embodiment has a length of about 2.5 m, a height of about 1.2 m, and a thickness of about 200 mm. The base block panel comprises a pair of opposed side wall members 55 which are made of polystyrene, or comprise building panels or other suitable material. These side wall members 55 have a thickness of approximately 70 mm and as the panel has a width of about 200 mm, these results in the panel being substantially hollow with the internal void having a width of about 60 mm.

The base wall panel 54 can be manufactured off site and transported in a relatively easy and convenient manner. If the base wall panel 54 is to be a

2016202540 07 Apr 2017 retaining wall, it will be supported on a footing 56 typically dug into the ground. Footing 56 can be of any suitable dimension depending on the load characteristics. The footing will contain steel reinforcement 57 as is usual. As well, vertical steel starters 58 are provided.

The footing has a particular design which is that a rebate 59 is formed in the top of the footing and this can be done by any convenient means such as by using formwork. The rebate typically has a depth of between 10-50 mm and a width which is sufficient to accommodate the bottom of the base wall panel 54 into the rebate. This rebate can also be called the base support means and functions to support the lower edge of each side wall member 55 against bowing as concrete is poured into the base wall panel 54.

To position the base block panel, a trench is initially dug into the ground and steel is placed into the trench and vertically extending starters 58 are positioned in place. Concrete is then poured into the trench and over the steel to provide a footing having the required engineering strength requirements. Once the footing has cured sufficiently, the base block panel 54 can be placed on top of the footing with the lower end of panel 54 locating within the rebate 59. The steel starters 58 extend into the hollow inside panel 54.

Once base block panel 54 is in position, the fencing panel 50 can be placed on top of base block panel 54 in the manner illustrated at least in figure 3 and figure 4. The fencing panel 50 has lower extending footing members 60 which extend into the hollow inside panel 54. Once fencing panel 50 is in place, concrete/grout or other suitable material can be pumped into the hollows. Specifically, a concrete pump hose is pushed through the passageway 51 in fencing panel 50 such that the end of the hose is in the hollow of base block panel 54. Concrete can then be pumped through the hose to fill the base block panel. Vibrators can be used as is normal. The hose can be positioned into all the passageways 51 to ensure that the base block panel is completely filled with concrete. Each passageway 51 can also be filled with the same concrete/suitable material. The finished product is illustrated in section view in figure 4.

2016202540 07 Apr 2017

To further assist in supporting the side wall members 55 of base block panel 54, separate temporary formwork can be provided an example of which is illustrated in figures 5-7. The formwork comprises timber planks 61 which can be positioned on each side of base block panel 54 prior to the concrete pour.

The planks are held together by a fixing means which, in the particular embodiment comprises long bolts 62 which extend through and across the base block panel 54 to connect a pair of opposed planks 61. A small tube or pipe 63 can initially be positioned in the base block panel 54 (see particularly figure 7) and prior to the concrete pour and the long bolts 62 can pass through a respective tube 63 such that the bolts can be removed after the concrete has been poured. The tubes 63 are sacrificial and remain in the filled base block panel 54. Thus, prior to the concrete pour the temporary formwork can be bolted in place in the manner illustrated in figures 5-7. After the concrete has been poured and gone off, the bolts and the planks can be removed.

Figure 8 and figure 9 illustrates two embodiments of the internal hollow shape of the base block panel. In figure 8, the internal hollow shape is defined by traditional flat plain are internal walls 64 and in figure 9 the internal hollow shape is defined by curved corrugated internal walls 65.

Referring to figure 11, there is illustrated a variation. This variation illustrates an upper fence panel 20 and a lower base block panel 27. Upper fence panel includes a number of spaced apart passageways or cavities 21 which are 100 mm in diameter and which may be lined with PVC pipe to prevent efflorescence and also to provide a measure of internal formwork. Each cavity contains a N-12 deformed bar steel support member 22 glued in with the use of concrete core fill. The base block panel 21 contains a N-12 deformed bar frame 23 to support the wall for retaining purposes. The base block panel 21 has a corrugated cavity design 24 to reduce the amount of concrete needing while still achieving maximum strength.

Figure 10 illustrates a detail of an upper fence panel 30 which can be fixed to a base block panel 21 as described in fig 11, but if the base block panel is not required, the fence panel can also be secured to existing concrete footing 31. The panel 30 is an expanded polystyrene panel 200 mm thick of the required ίο

2016202540 07 Apr 2017 height (1800 mm in the particular embodiment) and the required length (2500 mm in the particular embodiment). The thickness of the panel is 200 mm in the particular embodiment. The panel contains a number of hollow passageways or cavities 32 extending entirely through the panel from a top face 33 to a bottom face 34. Each cavity 32 contains a 12 mm N bar deformed steel 35 which is tied into the concrete footing 31 and which extends below bottom face 32 by the required amount which will depend on the footing type and the anticipated loads on the panel. The cavities 32 can be lined with a PVC 37 liner to increase strength and to decrease the possibility of line and salts leaching. The PVC liner can also act as internal formwork. Each cavity 32 also contains a 12 mm N-bar deformed steel rod 36 extending through the cavity.

Figures 12-14 illustrate a base block panel by itself and particularly illustrating the vertical reinforcing bars 40 embedded in the footing 41 and extending into the core void 43 and the horizontal bars 44 tied in or otherwise attached to the vertical bars. This assists in providing retaining properties to the wall while still providing a slim cavity design to reduce the amount of corefill concrete required.

An advantage of the arrangement as illustrated in figures is that a fencing panel of the present invention can be quite easily attached to a retaining wall which itself comprises long relatively lightweight panels that can be concreted. The fencing panel and a retaining wall can form an aesthetically pleasing flush finish which can be rendered and painted to form a relatively seamless feature.

If we need to retain soil, up to 1.2 meters high, the EPS block has an internal cavity consisting of a specifically designed corrugated void allowing for a minimum amount of solid re-enforced concrete core fill while maintaing more strength that what is traditional available. In engineering tests loads exceed that of a traditional concrete block wall by 500kg. In that circumstance the wall would only be built to the height needed to retain, and would not include a section that is only selectively corefilled if no more height past what is required for retention of soil is needed.

2016202540 07 Apr 2017

If it is needed to extend the wall past the height of the section to be retained, a wall on top of the retaining section will be provided that allows for a higher wall with the same aesthetics. In that circumstance a wall that is selectively filled with re-enforced concrete is provided that also allows the base block to be filled all at the same time. Commonly but not always the cavity is lined with a PVC tube so to prevent any calcification or lime deposits that are present in the concrete and can leach out should any water ingress or efflorescence occur.

A section of the fence may extend over an old existing concrete footing or small existing concrete retaining wall if necessary.

The retaining wall can be formed with less concrete than previously required and, for instance, the internal hollow of the retaining wall (the base block panels 54) can be 60 mm wide (thereby requiring much less concrete) than traditional Besser blocks which have an internal width of about 180 mm and therefore require much more concrete fill.

In an embodiment, there is provided a unitary piece of M Grade EPS with pre made holes ready to accept steel support members. These would be used over existing concrete or a strip footing would be poured first in preparation for installation. If it is to go over existing concrete, holes would be drilled into the concrete at the same intervals as the holes in the panel and steel support member would be chemically set into them anchoring them into the footing. If the concrete strip footing was to be laid especially for the fence panel there would also be the option of placing the steel support members into the wet concrete at the same intervals to set with the concrete alternatively they may be chemically set in later as above. Next the panel would be placed over the steel, the panel would then be braced in place and then the holes in the panel would be filled with concrete core fill to fix the steel to the panel.

The fencing system is cost-effective and lightweight and therefore the footings do not need to be as large resulting in a saving in trench mesh and concrete.

The fence panels have a very high sound rating and are considered to be superior to concrete blocks. The panels can be manufactured at the factory

2016202540 07 Apr 2017 and readily assembled on-site. If desired, adjacent panels can be glued together and quite easily trimmed or shape prior to rendering. Additional parts can be added to the panels such as a decorative top cap which can be glued and screwed in place. The panels can also be bolted to a side support using modified footings.

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.

Throughout the specification and claims (if present), unless the context requires otherwise, the term substantially or about will be understood to not be limited to the value for the range qualified by the terms.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

2016202540 25 Jun2018

Claims

The claims defining the invention are as follows:

1. A panel for use in fencing, comprising:

a non-reinforced hardened foam having two or more spaced apart and unconnected internal voids formed therein to receive concrete; and a base support means to support the lower base part of the panel against bowing, the base support means comprising a rebate in a footing to accommodate a bottom or base part of the block.
2. The panel according to claim 1, having an upper edge and a lower edge, with at least one of said internal voids extending from the upper edge through to the lower edge.
3. The panel according to claim 1 or claim 2, comprising wall members attached relative to each other to define said voids.
4. The panel of claim 1 or claim 2, formed as a single piece.
5. The panel as claimed in any one of the preceding claims, wherein each void has a corrugated wall configuration.
6. The panel as claimed in any one of the preceding claims having a length of between 0.5-6 meters, a height of between 0.5-2.5 meters, and a thickness of between 100-600mm.
7. The panel as claimed in claim 3, wherein the wall members are supported against bowing during a concrete pour into said voids by the support means which further comprises reinforcement members adapted to be temporarily fixed to the wall members to provide temporary reinforcement and then removed.
8. The panel of claim 7, wherein a fixing means is provided to fix the support means and which comprises one or more bolts extendible through the panel to fix one or more support means to the block.

2016202540 25 Jun2018
9. The panel as claimed in any one of the preceding claims, wherein the void has a width of between 40-120mm and the thickness of the wall members is between 40-150mm.
10. The panel as claimed in any one of the preceding claims, wherein the panel is supported underneath by a base block panel, and the internal voids of the panel allow cement to be pumped through the internal voids and into the base block panel.
11. The panel of claim 10, including at least one reinforcement bar extending along the internal voids.
12. The panel of claim 10 or claim 11, including a plastic sleeve lining the internal voids.
13. A method for installing a panel for use in fencing according to any one of the preceding claims, the method including:

anchoring the panel to the ground with a reinforced strip footing.
14. A method according to claim 13, further including installing steel support members for the panel.
15. A method according to claim 14, wherein the steel support members are installed by placing them into a footing whilst wet.
16. A method according to claim 14 wherein the steel support members are installed into a preexisting footing by drilling hole and anchoring said support members therein with a suitable adhesive.
17. A method according to any one of claims 14 to 16 further including filling said voids with concrete to thereby anchor the panel to the support members.

2016202540 25 Jun 2018
18. A method to form a retaining wall containing at least one fixed fencing panel on top of the retaining wall, the method comprising providing at least one base block panel which is substantially hollow to allow for concrete and steel to the required height, positioning a fencing panel on top of the base block panel, the fencing panel comprising a non-reinforced hardened foam, the panel containing at least two spaced apart unconnected passageways extending from a top wall of the panel to a bottom wall of the panel to allow cement to be pumped through the passageway, the panel including a base support means to support the lower base part of the panel against bowing, the base support means comprising a rebate in a footing to accommodate a bottom or base part of the block, wherein the footing extends into the hollow of the base block panel, and, pouring/pumping concrete or other suitable settable material through the passageway to fill the hollow in the base block panel and then to at least partially fill the passageway.

2016202540 21 Apr 2016

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