AU2018203654A1 - A prefabricated wall structure - Google Patents

Abstract

A PREFABRICATED WALL STRUCTURE Abstract Reinforcement bars 15, 16 are important in adding structural strength to poured concrete in the completed wall. Therefore the spacer 21 includes one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork cavity. The spacers 21 provide a means that tends the reinforcing bars 15, 16 in the horizontal or vertical manner to a spaced location. The spacers 21 still allow receipt of concrete in a formwork manner and provide the strength by the spaced reinforcing bars. . .. .. . ... 14 '-'

Description

A PREFABRICATED WALL STRUCTURE

Field of the Invention [001] The present invention relates to a prefabricated wall structure and in particular to a 5 prefabricated wall structure having a substantial concrete component requiring formwork.

[002]The invention has been developed primarily for use in/with a prefabricated wall structure which is fully prefabricated offsite or is partially formed offsite and concrete poured into the partially prefabricated wall structure onsite and used to form commercial buildings made with large planar panels and will be described hereinafter with reference 10 to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

Background of the Invention [003] A prefabricated wall structure is generally formed by preformed concrete panels that 15 have been formed offsite. These panels are then transported by semitrailers to the location and craned into position. While awaiting the next connecting concrete panels to be delivered, the panels already onsite are positioned on the site and held up by braces which connect into supporting links built into the wall surface.

[004] After connection of the adjacent concrete panels when they are transported to site 20 a concrete substructure building is created and locked into floors that are usually cantilevered from central lift wells or central support.

[005] After this internal shell is finished a plurality of external surface panels are attached to the external surface of the concrete shell. Similarly internal surface panels are attached to the external surface of the concrete shell.

[006] Alternatively a full render or other surface treatment is undertaken directly onto the external and/or internal surfaces [007] It can be seen that therefore the wall surface is broken by the connectors to the braces. It can be seen that the surfaces of the concrete wall structure are not sufficient quality or style but must be further processed or hidden. It can be seen that there are 30 substantial building, logistics efficiency complications in these processes.

2018203654 23 May 2018 [008]Therefore it can be seen that known prior art prefabricated wall systems have one or more of the problems of:

a) Inefficiencies in construction

b) Requiring offsite formwork for creation offsite of concrete panels

c) Inefficiencies in transport

d) Requiring weighty concrete articles to be transported in large forms from offsite construction site to onsite building site;

e) Inefficiencies in building progress

f) Requiring completion of building with prefabricated concrete panels but still needing a total build of an external surface to the built concrete building

g) Not allowing prefabrication of final surfaces

h) Requiring fixing of separate final wall elements to the concrete walls forming final surfaces

i) Requiring fixing of separate final wall elements forming final surfaces [009]The present invention seeks to provide a prefabricated wall structure, which will overcome or substantially ameliorate at least one or more of the deficiencies of the prior art, or to at least provide an alternative.

[0010] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Invention [0011] According to a first aspect of the present invention, a prefabricated wall structure is provided by a prefabricated wall structure having two wall elements mounted on and spaced by a spacing system to create formwork for receiving and holding concrete therebetween to form a finished wall.

[0012] It can be seen that the invention of a prefabricated wall structure provides the benefit of better efficiency in construction technique.

2018203654 23 May 2018 [0013] According to a second aspect of the present invention, a prefabricated wall structure is provided by having two walls elements mounted on and spaced by a spacing system to create formwork for receiving and holding concrete therebetween with one wall having a finished surface to form a finished wall [0014] It can be seen that the invention of a prefabricated wall structure provides the benefit of providing final presentable wall surfaces without requiring covering facades.

[0015] According to a third aspect of the present invention, a prefabricated wall structure is provided by a spacing system for a prefabricated wall structure having two walls elements mounted on and spaced by the spacing system to create formwork for 10 receiving and holding concrete therebetween with one wall having a finished surface to form a finished wall.

[0016] In one form the invention provides a prefabricated wall structure comprising one or more modules formed by a spacing system; and two wall elements having external surfaces forming the completed inner and outer wall surfaces of a wall and the respective 15 inner walls of the two wall elements are spaced parallel by said spacing system; wherein the prefabricated wall structure create formwork for receiving and holding elongated reinforcing and concrete therein to form the completed wall, and wherein the prefabricated wall structure having two walls elements and the spacing system has a finished surface on at least one outer surface of one of the two wall elements to form a finished external 20 wall surface of the completed wall such that the prefabricated wall structure can be substantially assembled with improving effectiveness including the benefits of any one or more of the following:

i. improvements in structure and assembly including construction techniques;

ii. Improvements in better construction to give greater flexibility in design and construction control offsite and onsite;

iii. Improvements in providing single article construction wherein the prefabricated wall structure acts as formwork and final completed wall;

iv. Improvements in building procedures to provide quicker, more efficient and cost effective operation;

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v. Improvements in concrete handling procedures in commercial building; and vi. Improvements in modularity of construction.

[0017] It can be seen that the invention of a prefabricated wall structure provides one or more benefits over the prior art or at least ameliorates the problems of the prior art or provides a viable alternative.

[0018] Other aspects of the invention are also disclosed.

Brief Description of the Drawings [0019] Notwithstanding any other forms which may fall within the scope of the present invention, a preferred embodiment / preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig. 1 is a perspective view of a spacing system for use in forming a prefabricated wall structure in accordance with a preferred embodiment of the present invention;

Fig. 2 is a diagrammatic cross sectional view of a prefabricated wall structure in accordance with a preferred embodiment of the present invention showing the spacer system of Fig. 1 between two wall elements to enable receiving and holding elongated reinforcing and concrete therein to form the completed wall;

Fig. 3 are diagrammatic cross sectional and plan views of elements of the spacing system of Fig. 1 for the prefabricated wall structure of Fig. 2 in accordance with the preferred embodiment of the present invention showing above and side view of the spacer, side view of the face piece and side view of the rail;

Fig. 4 is an overhead and cross sectional view of a base track for mounting at the base of a wall module of the prefabricated wall structure of Fig. 2 to close off the spacing at the bottom between the two wall elements;

Fig. 5 is a diagrammatic cross sectional view of the spacer of Fig. 3;

Fig. 6 is a diagrammatic perspective view of a detail of the spacer of Fig. 3 for the spacing system of Fig. 1;

Fig. 7 is a diagrammatic cross sectional view of two modules and base plate forming a prefabricated wall structure in accordance with a preferred embodiment of the

2018203654 23 May 2018 present invention in which the formation of the prefabricated wall has the linear alignments of multiple spacers each in one of two different orientations;

Fig. 8 is a diagrammatic perspective view of a section of a prefabricated wall structure in accordance with a preferred embodiment of the present invention showing receipt of horizontal and vertical reinforcement bars;

Fig. 9 is an exploded view of a detail of Fig. 8;

Figs, 10 to 15 show various arrangements and sizings of horizontal and vertical reinforcement bars for different wall uses in a prefabricated wall structure in accordance with a preferred embodiment of the present invention;

Figs 16 and 17 shows diagrammatic cross sectional view and detail of view of the forming of a completed wall using prefabricated wall structure in accordance with an embodiment of the invention;

Figs 18 and 19 show two different embodiments of modules with linear arrangements of spacers;

Fig. 20 shows various edgings of different modules;

Figs 21 and 22 show various stages of interconnection of different modules;

Figs 23 and 24 show various stages of interconnection of spacing systems aiding interconnection of different modules of Fig 22;

Figs 25 to 28 show diagrammatic views of the use of the modules of the 20 prefabricated walls in accordance with the invention to fulfil different usual commercial building construction requirements; and

Fig 29 shows a flow diagram of a method of construction of a prefabricated wall structure in accordance with an embodiment of the invention.

Description of Preferred Embodiments [0020] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[0021] Referring to the drawings and particularly Fig. 1 and Fig, 2 there is shown a prefabricated wall structure having one or more modules 12, 13 formed by a spacing system 14 comprising a spacer 21, a face piece 31, and a rail 41 which together connect 30 between and space two wall elements 60, 61 to form the prefabricated wall structure module. This prefabricated wall structure 10 creates formwork for receiving and holding elongated reinforcing bars 15,16 in vertical and horizontal orientations between the space

2018203654 23 May 2018 two parallel wall elements 60, 61 and by receipt of concrete therein forms the completed wall.

[0022] Each of the two wall elements 60, 61 have externa! surfaces 63 forming the completed inner and outer wall surfaces of the completed wall. The respective inner 5 surface 64 of the two wall elements 60, 61 of the two wall elements 60, 61 are spaced parallel by said spacing system 21,31,41 of a spacer 21, a face piece 31, and a rail 41.

[0023] It can be seen therefore that the prefabricated wall structure 10 not only provides a preformed formwork but also provides completed external surfaces to provide the final product without the need for after surfacing. An important element of this process 10 is to have a system that does not require breach of the outer surfaces to effect construction.

[0024] Components:

[0025] Referring to Figure 2, the skeletal frame that connects the two composite 15 sheets 60, 61, is made of highly durable ABS plastic. This ABS plastic is also fireresistant. The skeletal frame consists of three main components of spacer 21, a face piece 31, and a rail 41.

a) Rail 41 - extends along the full length of the composite sheets, bonded by epoxy, and minimum 2 mechanical fasteners per rail. This is the item that allow the system to “click” together. A rail is provide at each of the panel, there is 4 rails per panel.

There is sufficient tolerance that the expressed joint is allowed to vary from 6mm to 14mm to ensure that correct geometry is maintained.

b) Face piece 31 - slots into the rail at 500 or 250 cts, to provide the required min. reo. spacing of 500 for a 125mm concrete as per AS3600. Typically there is 11 face pieces per rail.

c) Spacer 21 - is the bracket that essentially forms the 125mm gap between composite sheets, and allows for the multiple placement positions of reo. (depending on the application). Two spacers for each pair of face pieces, effectively form a strong cube, with obvious integral strength. The spacer 21 is

2018203654 23 May 2018 provided for concrete to be poured into the internal formwork cavity. In particular the spacing system includes a spacer to form an internal formwork cavity.

[0026] Reinforcement bars 15, 16 are important in adding structural strength to poured concrete in the completed wall. Therefore the spacer 21 includes one or more 5 spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork cavity.

[0027] An important element is that it is necessary to avoid substantial time consuming systems of placing the reinforcement in location while maintaining spacing. In 10 the present case the spacers 21 provide a means that tends the reinforcing bars 15, 16 in the horizontal or vertical manner to a spaced location. The spacers 21 still allow receipt of concrete in a formwork manner and provide the strength by the spaced reinforcing bars.

[0028] The spacer 21 has shaped internal surfaces of the two opposing walls have 15 external wall 25 and shaped internal wall 26. This shaped internal wall 26 forms the one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity. In particular the elongated surface of the shaped internal wall 26 includes first second and third surfaces 27, 28 and 29 which are each concave and therefore provide a nadir point in each concave shaping that tends the 20 reinforcing bar to that location. The first second and third surfaces 27, 28 and 29 are vertically above each other and therefore provide spaced locations of the nadir of each concave shaping. In this way the natural positioning of the reinforcing rods are spaced without requiring fixing in place. However the central nadir is offset from the top and bottom nadirs of the concave shapings and therefore provide a spacing greater that the 25 relative position of the concave shaping due to the offset of the concave shapings. This extra spacing helps strength as it spaces further the reinforcing without requiring fixing in place.

[0029] The spacer has opposing walls 23 extending between upper and lower tops 22 and each of the opposing walls 23 with outer surface 25 and inner surface 26 and 30 spaced to form an internal cavity 30. A central post 24 extends and supports the upper

2018203654 23 May 2018 and lower tops 22 in a spaced arrangement and allow receipt of a reinforcement bar therethrough.

[0030] The face piece 31 is attached to the top and bottom of the spacer 21 to allow connection of the spacer 21 between the rail plates 41 attached to the spaced two 5 separate wall elements.

[0031] The rail 41 is a shaped substantially planar piece attachable on one side to an internal surface of one of the two separate wall elements. On the inner side are shapings which provide shallow interconnections to the face piece 31 attached to the one of the spacer 21. The shapings are particularly arranged to allow 90° variation of connection 10 such that there can be a difference of the connection to the spacer 21.

[0032] Overall Module Structure [0033] The wall elements 60, 61 can be formed of:

a) Two separate wall elements such as an exterior weather resistant sheet and an inner insulating sheet

b) A sandwich layered structure having two separate outer surfaced wall elements with insulation such as Rockwool sandwiched therebetween to form a single laminated panel

c) A composite panel having a finished outer surface and amorphous body of material.

[0034] In one form a prefabricated wall structure having two wall elements mounted on and spaced by a spacing system to create formwork for receiving and holding concrete therebetween to form a finished wall. This can be achieved in which [0035] The prefabricated wall structure 12 having two walls elements 60, 61 spaced by the spacing system 21, 31, 41 to create formwork for receiving and holding concrete therebetween with one wall having a finished surface to form a finished wall. This will be detailed further.

[0036] In a particular form the spacing system for a prefabricated wall structure having two walls elements mounted on and spaced by the spacing system are modules 12, 13

2018203654 23 May 2018 which click together to create formwork for receiving and holding concrete therebetween with one wall having a finished surface to form a finished wall.

[0037] Reinforcement [0038] Referring to Figures 5, and 10 to 15 for retaining walls, there are three positions

27, 28 and 29 on the internal shaped wall 25 available for horizontal reinforcement bars 15 and two positions 30, 31 near for vertical reinforcement bars 16.

[0039] In particular, it can be seen than embodiments of the invention as shown in the Figures, allow a single spacing system 14 to be used in varying ways to provide differing 10 wall structures.

[0040] Reinforcement has different effects due to the sizing of the reinforcement bars, the spacing both horizontal and offset to the horizontal to give greater spacing, the vertical to the horizontal so greater reinforcement density and strength in different directions, and the spacing of the spacers for applying regimentation to the positioning of the 15 reinforcement bars within the structure while also allowing for ready receipt of concrete as a formwork throughout and around the reinforcement bars.

[0041] Allowing the maximum utilisation of the 125mm concrete core, by providing a lever of at least 75mm (equivalent central reo. within a 150 concrete wail). For propped retaining walls the vertical reinforcement bars 16 within the wall should be located to the 20 front face, with starter bars to the rear face.

[0042] An excellent concrete cover is provided by 125mm of concrete, which is still maintained even with installation of much larger reinforcement bars as sometimes required for large bondbeams. Up to N32 horizontal central reinforcement bars can be received within the aligned spacers 21.

[0043] Referring in further detail to Figs. 10 to 15 in Figure 10 there is shown a detail of a reinforcement array suitable for a wall structure as a portal frame in which a single reinforcement bar of thickness N28 is located horizontally in the middle position 28 and tended to remain in that position due to the concave curve of the middle position 28. Two vertical reinforcement bars are located within the spacer 21 on either side of the single 30 horizontal reinforcement bar and due to the line of spacers and horizontal bar are retained in spaced arrangement without being locked in position.

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2018203654 23 May 2018 [0044] In Figure 11 there is shown a detail of a reinforcement array suitable for a prop retaining wall in which a single reinforcement bar of thickness N12 is located horizontally in the alternative side positions 27, 29 and tended to remain in that position due to the concave curve of the side positions 27, 29. A single vertical reinforcement bars of larger 5 dimension N20 is located within the spacer 21 on alternating sides of the single horizontal reinforcement bar and due to spacing provided by the spaced side positions 27, 29 and alternating positions of the horizontal bar are retained in a central vertical position of the vertical line of spacers 21 without being locked in position.

[0045] In Figure 12 for typical walls, N12 reinforcement bars can be provided vertical 10 central, with N12 horizontal reinforcement bars staggered each side. This gives good opportunity for concrete flow and ensure Perform Panels are well filled with concrete (as opposed to difficulties often realised with walls that are only 100mm wide of concrete).

[0046] In Figure 13 there are two horizontal reinforcing bars 15 of thickness N12 located in the spaced shallow concave shapings side positions 27, 29 of internal shaped 15 wall 25 of spacer 21. Two larger N20 reinforcing bars 16 are substantially coextensive to form a more solid vertical reinforcement.

[0047] In Figure 14 a single larger horizontal reinforcing bar 15 of thickness N40 can rest in the larger concave central shaping 28 so as to be tended to the central position without the need for fixing. Two vertical thinner reinforcing bars 16 of thickness N12 can 20 extend vertically within the line of spacers 21 and on either side of the horizontal bar 15 so as to be retained in spaced arrangement without need for locking into fixed position.

[0048] It can be seen that the system allows a multitude of different reinforcing to provide a plurality of different uses with a plurality of different strength elements. Architects and engineers can then create a greater number of engineered concrete wall 25 and floor structures with this system.

[0049] In Figure 15 there is shown an ultimate strength version with maximum reinforcing in both directions.

[0050] Other ABS plastic componentry are as follows:

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a) Trim - this surrounds the composite sheet, and ensures waterproofing is maintained. This also has a 2mm drip groove

b) Base track - This is used on the slab or floor level, to guide and position the individual panels. A tolerance of 2mm is preferred for the flatness of the slab.

However, a tolerance of up to 5mm is still acceptable. The base track may be pinned or epoxied to the concrete.

[0036] Referring to Figs. 1 to 5 the spacing system for the prefabricated wail structure including: a spacer having two spaced opposing walls between a top and bottom to form an internal formwork cavity for receiving reinforcement bars to reinforce concrete poured 10 into the internal formwork cavity a spacer connector for connecting the top and bottom of the spacer to opposing internal walls of two wall elements to maintain the wall elements spaced from each other wherein the spacing system allows a prefabricated wall structure to be formed which can act as formwork for receiving and holding elongated reinforcing and concrete therein to form the completed wall.

[0037] The spacer 21 includes one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork cavity.

[0038] The spacer 21 includes shaped internal surfaces of the two opposing wails to form one or more spacing rests for receiving reinforcement bars and maintaining them at 20 spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork cavity.

[0039] The internal surfaces of the spacer form a plurality of spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity and wherein adjacent spacing rests are offset to each other so as to vary 25 the alignment and thereby strengthen reinforcement.

[0040] The internal surfaces of the spacer are symmetrical and form a plurality of opposing spacing rests for receiving reinforcement bars and maintaining them at spaced locations in consistent parallel planes within the internal formwork cavity and wherein adjacent spacing rests so as to maintain consistent spacing and thereby strengthen 30 reinforcement.

2018203654 23 May 2018 [0041] Interconnection of Spacing System [0042] A pacing system 14 comprises the spacer 21 and includes a rail 41 attachable or integral to the internal surface of the wall element 60, 61; and a face piece 31 attachable or integral to the top or bottom of the spacer 21; wherein the face piece 5 engages and locks to the rail to connect the spacer to the internal wall of a wall element forming the completed wall.

[0043] Each of the top and bottom of the spacer include a spacer connector attachable or integral with the opposing internal surfaces of each wall element wherein the face piece engages and locks to the rail to connect the spacer to the respective 10 internal wall of a wall element to maintain the two wall elements spaced and forming the completed wail without any fixing elements to the external surfaces of the wall elements forming the external surfaces of the completed wall.

[0044] The spacer connector has respective mating surfaces on rail and the face piece allowing for interfitting connection in a first orientation or in a second orientation 15 orthogonal to the first orientation.

[0045] It can be seen that at location the inner walls 60, 61 can have strips of rail 41 attached thereto. The rail 41 has tracks that can readily receive and hold the facepiece 31 of the spacer 21 to allow the spacer to be located in linear arrangement along the parallel tracks of the rail 41. In this way a plurality of spacers 21 can be located on one 20 wall 60 and readily be connected and spaced in a similar way to the other wall [0046] All of this construction can be made into modules 12, 13 that can be formed offsite and transported as a lightweight but finished module to the site to act as a formwork and final external and/or internal surfaces. The reinforcing bars 15, 16 can be transported separately and located in place within the formwork at the site.

[0047] Construction using modules [0048] Various modules can be linked together in a clipped manner. Referring to Figs 25 to 28 there is shown that the modules themselves can be interconnected in a clipped manner by way of locking spacing systems 14 due mainly to the interconnecting lateral 30 sides 43, 44 of the rail 41. Each of the lateral sides 43, 44 have a rigidty and resilient flexibility with opposing inwardly or outwardly end formations. In this way the

2018203654 23 May 2018 interconnecting lateral sides 43, 44 bend away from each other to allow the opposing inwardly or outwardly end formations to slide over each other and then in effect clip by not allowing the inwardly or outwardly end formations to slide away from each other and effectively lock the top end of two spacing systems.

[0049] The other or bottom end of the spacer 21 also has its own interconnecting lateral sides 43, 44 of the rail 41 which bend away from each other to allow the opposing inwardly or outwardly end formations to slide over each other and then in effect clip by not allowing the inwardly or outwardly end formations to slide away from each other and effectively lock the top end of two spacing systems.

[0050] Therefore the modules are clipped fitted together at top and bottom of each adjacent spacers at the edge of each module.

[0051] Method of construction of pre-form in-situ concrete wall.

[0052] Referring to Fig 29 there is shown a method of construction of a prefabricated 15 wall structure including the step 151 of providing two wall elements 60, 61, providing a spacing system having a spacer and spacing connection system and attaching one element of the spacing connection system to each of matching positions on the internal opposing surfaces of the two wall elements.

[0053] Then in step 152 there is the step of connecting the spacer 21 to the respective 20 one elements in one of two orientations so as to provide a fixed spacing between the two wall elements. This is the connection of the rail 41 attached to the inner surface of the wall elements 60, 61 mating in one of two orientations to the face piece on the top and bottom of the spacer 21.

[0054] However a plurality of spacers 21 are needed to form large module walls and 25 therefore step 153 is the repeat of steps 151 and 152 in linear arrangement but with variation of the orientation of the spacer all along the length of the module.

[0055] In step 154 there is the step of inserting elongated reinforcing bars 15 and the step of 155 in which the prefabricated wail structure 12 that has been can act as formwork for receiving and holding elongated reinforcing and concrete therein to form the 30 completed wall.

2018203654 23 May 2018 [0056] Example 1 [0057] The Panels of the invention in one embodiment consists of two pre-finished Rockwool composite sheets with a 125mm concrete core created by a skeletal frame that allows the panels to simply “click” together on site.

[0058] Based on many year of acquired structural engineering knowledge, the 125mm concrete core gives the most practical and most versatile abilities in the most range of structural applications. The optimum width of concrete core has been provided, avoiding the common confusion over applicable widths of concrete.

[0059] Modular panels of the invention are typically for use in low rise apartment 10 buildings, but would be able to be used for buildings up to 8 storeys high, and high-end architectural residences.

[0060] The typical size of a Panel is 2990mm X 990mm. With a typical 10mm expressed joint, a geometry of 3m x 1m is typically adopted. Obviously, this will vary depending on the requirements of the building, however.... Architects and building 15 designers are encouraged to consider this 3m x 1m size panel in their layouts, to maximise the efficiency of the system. Typically 3000 floor-to-floor heights are adopted, and allowance for 200 thick slab is common. Internal composite sheets are limited to 2790 (allowing the 2800 = 3000 - 200).

[0061] Internal composite sheets at height of 3000 for atriums and stairwells are 20 available.

[0062] The Rockwool composite sheets are 50mm thick all up, with 5mm fibre cement sheet, 40mm Rockwool, 5mm fibre cement sheet. The Rockwool has thermal conductivity of 0.47 w (m.k). At a width of 40mm, the Rockwool of each composite sheet provides an R value of 0.85.

[0063] KEY BENEFITS:

[0064] Neat and clean - As a “click” together system, the used of screws and glue is dramatically reduced. Reducing site mess and waste.

[0065] Speed - As each wall is constructed it is installed “completed” with all acoustic, 30 thermal, structural, and aesthetic requirements, already catered for. When adopted with

2018203654 23 May 2018 a structurally trussed formwork system such as TRUDEK (which can have no propping for up to a 7m span), each level of a building can have the internal walls installed as soon as the slab over and external walls are poured.

[0066] Safety - When integrated with the specialist bracing system, there is no 5 requirement for any trades to be on the outside of the building. Hence there is no reason to scaffold the external perimeter of the building, providing further saving costs.

[0067] Efficiency - when standard sizing is adopted, which is not difficult, given the flexibility of the 3m X 1m geometry. The 3m edge can be horizontal or vertical. Of course it can be reduced if needed.

[0068] Acoustic abilities - The use of Rockwool within the composite sheets, has been primarily chosen because of its acoustic properties. Testing data provided, shows that the wall provides more than the required Rw+Ctr of 50.

[0069] Versatility - And is sufficient to be regarded equivalent to non-continuous construction, as required for bathrooms, and wet rooms. There is some opportunity to 15 run water pipes (or similar, up to 32mm) within the Rockwool acoustic layer. This may also reduce the acoustic abilities.

[0070] Fire abilities - The other and potentially the most important advantage of the use of Rockwool, is that it has a high fire-proof level. At fire-proof level: A ROCKWOOL IS 100% NON-COMBUSTIBLE. As Perform Panels have 40mm Rockwool on either side 20 of a 125mm concrete core. It is clear that fire performance would be excellent.

[0071] Example 2 [0072] In one embodiment this can be achieved by:

1. All ln-situ concrete walls to be constructed In accordance with A.S.J600

Concrete Code, and slump of 180-220 (with option to use additives to achieve high concrete flow).

3. All free standing walls above 1500mm height shall be temporary braced at 1.0 metre maximum, with props or perpendicular (buttress) wall.

4. All end fittings, caps etc. to be correctly Installed prior to pour of concrete.

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5. Outer face to form shutter for next slab pour where applicable.

6. All starter bars to be cast-ln-situ, or drilled (epoxy not required, provided wall concrete slump as mentioned above is achieved)

7. All bondwalis and bondbeams to be poured as soon as possible from adjoining slob elements, to achieve maximum bonding ability. Ifwalledgeis exposed more than one week, apply bondcrete prior to slab pour.

8. All bondwalls and minimum and reached

9. All bondbeams to the wails to have slabs slabs below them to be fully propped for 28 days the design strength as Indicated In schedule be fully propped for 28 days minimum and reached below to reached the design strength as be fully propped for 14 days minimum and

Indicated In schedule for next level slab may be Installed, to allow

11. Bandek trays (or formwork) adequate access for sufficient pouring of concrete in TECHNII<FORU walls,

Alternatively wall can be poured from trestles no higher than 2m [0073] INSTALLATION PROCEDURE: SET-UP AND BRACING

1. Ensure Slab is flat (2mm total tolerance), and clean

2. Glue down TRACK at locations required

3. Drill and epoxy N12 starter bars typically 80mm from slab edge, at 300/300/400 cts to achieve typical 3 bars per panel

4. Place first PERFORM Panel on (Inside) TRACK, and check position. (Leading edge is that with click tab extending beyond the panel)

5. Locate additional SPACERS at PROP positions.

6. Provide 90 X 45 MGP10 (specially prepared) brace, and

6mm threaded rod at min. top, middle and bottom positions.

Do not tighten.

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7. Place second PERFORM Panel on (Inside) TRACK, click into the previous panel.

(approx. 6mm total tolerance) typically ensure leading dimension Is always multiple of 1000's

Tighten threaded rods to braces. Connect braces to slob at 60 degrees. MB power fix is recommended

8. Place next PERFORM Panel on (Inside) TRACK, click· into the previous panel.

Repeat step 7 throughout [0074] Example A - INSTALLATION PROCEDURE:

1. Prior to concrete pour ensure that all FORMS are plumb, and located correctly

2. Use Continuous flow concrete pump only (DO NOT USE PNEUMATIC

PUMP)

4. Allow that 100mm fixing will insert into the FORM, by approx. 600mm.

5. With continuous flow pump only, push concrete Into the FORM.

6. Fill to 1/3 wall height or max. 1200 evenly throughout wall.

7. Allow minimum 3 hours before returning to original position.

8. Following some order, fill another 1/3 wall height or max. 1200 evenly throughout wall.

9. Allow minimum 3 hours before returning to original position.

10. following some order, fill FINAL 1/3 wall height or max. 1200 evenly throughout wall.

11. Note, use of a 125 IFC (X 3000 long with special holes) placed at top of form will ensure top of wall remains true and In-line

2018203654 23 May 2018 [0075] Example B - INSTALLATION PROCEDURE:

[0076] Site installation Details: Typically Perform Panels are intended to be used on

3-4 storey apartment buildings. They can also be used in domestic residences, working with timber framing. They can also be used in 8-10 storey buildings, depending on the arrangement. For a 3-4 storey apartment buildings, a typical site installation is done as follows:

[0077] 1. Arrangement of Panels

a) Concrete slab (at ground level) to be completed. Minimum flatness required is +_5mm.

b) BASE TRACK is glued and pinned to the concrete slab at the wall locations.

c) N12 Dowell bars (300 long) are drilled and epoxied at 333 cts (3 per 1m panel) with 100mm embedment into the slab (allowing 200 projection)

d) First panels (typically with a stop-end) is placed onto the BASE TRACK. Panel must be lifted approx. 300mm of the slab to achieve this (to get over the starter bars). Mechanical lifting is recommended, (leading edge is that with the locking clip extending beyond the panel)

e) Install the “Propping” SPACERS that are to be located at the open panel end. These are located typically at the top, mid-height and bottom of the panel.

f) Provide 30 X 3 SHS (specially prepared) brace, and 3mm (1/8”) threaded rod at min. top, middle and bottom positions, on both sides of the panel. Do not tighten.

g) The next panel is placed onto the BASE TRACK. Ensure the next panel is located close enough (10mm) to the previous panel to clear the dowell bars. Ensure the dowell bars are in a suitable position, before placing the panel. Remove and replace dowell bars if required.

h) With next panel on the BASE TRACK slide the next panel closer to the previous such that locking clip is enagaged.

i) Now tighten the nuts on the threaded rods to lock-in the 30 X 3 SHS vertical brace.

j) Connect the vertical brace to the diagonal brace, via the bolt available. The dynabolt the base of the diagonal brace to the slab at approx. 45 degrees, (to the wall).

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k) First panel is now secure.

l) Locate the next panel and repeat the steps to secure the previous panel.

[0080] 2. Reinforcement placement

a) With panels fully installed the project is now ready for reo. placement. Small sites with poor access may require the reo. to be installed whilst the panels are being installed. For a typical concrete wall, the horizontal reinforcement is placed first. It should be located at staggered positions at 500 cts, as per the typical installation drawings UNO. These horizontal reo. Bars form a grid that then allow simple and accurate placement of the vertical bars. With the system the reo. is well-locked in 10 and unlikely to move during the concrete placement.

b) A last final check of the panels should prior to the concrete pour, to ensure the panels are secure and plumb.

[0081] 3. Concrete filling of Panels

a) Prior to concrete pour ensure that all FORMS are plumb, and located correctly.

We recommend the use of a continuous flow concrete pump only (DO NOT USE

PNEUMATIC PUMP)

b) Strap 100mm PVC or Steel (approx. 750mm long) to inside of 4 pump line, by 150mm.

c) Allow that 100mm fixing will insert into the FORM, by approx. 600mm.

d) With continuous flow pump only, push concrete into the FORM.

e) Fill to 1/3 wall height or max. 1200 evenly throughout wall.

f) Allow minimum 3 hours before returning to original position.

g) Following same order, fill another 1/3 wall height or max. 1200 evenly throughout wall.

h) Allow minimum 3 hours before returning to original position.

i) Following same order, fill FINAL 1/3 wail height or max. 1200 evenly throughout wall.

2018203654 23 May 2018 [0082] Note, use of a 125 TFC (X 3000 long with special holes) placed at top of form will ensure top of wall remains true and in-line, this can dragged along during the pour but re-used every time

Interpretation

Embodiments:

[0083] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in 10 connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill 15 in the art from this disclosure, in one or more embodiments.

[0084] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of 20 streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims 25 following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[0085] Furthermore, while some embodiments described herein include some but not 30 other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

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Different Instances of Objects [0086] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different 5 instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details [0087] In the description provided herein, numerous specific details are set forth.

However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology [0088] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a 20 similar manner to accomplish a similar technical purpose. Terms such as forward, rearward, radially, peripherally, upwardly, downwardly, and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

Comprising and Including [0089] 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 “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to 30 preclude the presence or addition of further features in various embodiments of the invention.

2018203654 23 May 2018 [0090] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention [0091] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and 10 it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[0092] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability [0093] It is apparent from the above, that the arrangements described are applicable to the building and prefabricated wall structure industries.

Claims (5)

Claims The claims defining the invention are as follows:

1. A prefabricated wall structure comprising one or more modules formed by:

a. a spacing system; and

5 b. two wall elements having external surfaces forming the completed inner and outer wall surfaces of a wall and the respective inner walls of the two wall elements are spaced parallel by said spacing system;

wherein the prefabricated wall structure create formwork for receiving and holding elongated reinforcing and concrete therein to form the completed wall.

10

2. A prefabricated wall structure according to claim 1 wherein the prefabricated wall structure having two walls elements and the spacing system has a finished surface on at least one outer surface of one of the two wall elements to form a finished external wail surface of the completed wall.

3. A prefabricated wall structure according to claim 1 wherein at least the outer one

15 of the two walls elements is mounted to at least one element of the spacing system without visible external fixings.

4. A prefabricated wall structure according to claim 1 wherein both of the two wall elements are mounted by the spacing system to opposing internal surfaces of the spaced wall elements without external fixings on the external surfaces of the wall

20 elements which form the outer surfaces of the completed wall.

5. A prefabricated wall structure according to claim 1 wherein the spacing system is able to receive concrete poured from a lateral side between the spaced wall elements without affecting the finished external completed wall surface.

6. A prefabricated wall structure according to claim 1 wherein the spacing system is

25 able to receive concrete poured from a lateral side through a defined opening between the spaced wall elements and spread within the spacing system forming the formwork for receiving and holding elongated reinforcing and concrete therein to form the completed wall.

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7. A prefabricated wall structure according to claim 1 wherein the spacing system is able to receive concrete poured from a lateral side through a defined opening and spread within the spacing system.

8. A prefabricated wall structure according to claim 1 wherein a prefabricated wall

5 structure forms a wall module and a plurality of wall modules interleave to form a continuous wall.

9. A prefabricated wall structure according to claim 1 wherein the plurality of modules interleave by a module connection system without external fixings.

10. A prefabricated wall structure according to claim 1 wherein the plurality of modules

10 interleave by a resilient clicking of related side fixings of adjacent modules to provide connection without external fixings.

11. A prefabricated wall structure according to claim 1 wherein the spacing system provides an internal formwork cavity for receiving reinforcement bars to reinforce concrete poured into the internal formwork cavity.

15

12. A prefabricated wall structure according to claim 1 wherein the spacing system includes a spacer to form an internal formwork cavity.

13. A prefabricated wall structure according to claim 1 wherein the spacer includes one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced

20 reinforcement of concrete poured into the internal formwork cavity.

14. A prefabricated wall structure according to claim 1 wherein shaped internal surfaces of the two opposing walls form the one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity.

25 15. A prefabricated wall structure according to claim 1 further comprising a spacing system for a prefabricated wall structure having two walls elements mounted on and spaced by the spacing system to create formwork for receiving and holding concrete therein with one wall having a finished surface to form a finished wall

16. A prefabricated wall structure according to any one of the preceding claims 30 wherein

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17. A spacing system for a prefabricated wall structure including:

a. a spacer having two spaced opposing walls between a top and bottom to form an internal formwork cavity for receiving reinforcement bars to reinforce concrete poured into the internal formwork cavity

5 b. a spacer connector for connecting the top and bottom of the spacer to opposing internal walls of two wall elements to maintain the wall elements spaced from each other wherein the spacing system allows a prefabricated wall structure to be formed which can act as formwork for receiving and holding elongated reinforcing and 10 concrete therein to form the completed wall.

18. A spacing system according to claim 17 wherein the spacer connector includes a rail attachable to a wall element and a face piece attached to the end of e spacer and which is complementary fittable to the rail to allow connection of the spacer between the two spaced opposing walls.

15 19. A spacing system according to claim 17 wherein the spacer includes one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork cavity.

20. A spacing system according to claim 17 wherein the spacer includes shaped

20 internal surfaces of the two opposing walls to form one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork cavity.

21. A spacing system according to claim 17 wherein the internal surfaces of the spacer

25 form a plurality of spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity and wherein adjacent spacing rests are offset to each other so as to vary the alignment and thereby strengthen reinforcement.

22. A spacing system according to claim 17 wherein the internal surfaces of the spacer

30 are symmetrical and form a plurality of opposing spacing rests for receiving

2018203654 23 May 2018 reinforcement bars and maintaining them at spaced locations in consistent parallel planes within the internal formwork cavity and wherein adjacent spacing rests so as to maintain consistent spacing and thereby strengthen reinforcement.

23. A spacing system according to claim 17 wherein the spacer connector includes

5 a. a rail attachable or integral to the internal surface of the wall element; and

b. a face piece attachable or integral to the top or bottom of the spacer;

wherein the face piece engages and locks to the rail to connect the spacer to the internal wall of a wall element forming the completed wall.

24. A spacing system according to claim 17 wherein each of the top and bottom of the

10 spacer include a spacer connector attachable or integral with the opposing internal surfaces of each wall element wherein the face piece engages and locks to the rail to connect the spacer to the respective internal wall of a wall element to maintain the two wall elements spaced and forming the completed wall without any fixing elements to the external surfaces of the wall elements forming the external 15 surfaces of the completed wail.

25. A spacing system according to claim 17 wherein the spacer connector has respective mating surfaces on rail and the face piece allowing for interfitting connection.

26. A spacing system according to claim 17 wherein the spacer connector has

20 respective mating surfaces on rail and the face piece allowing for interfitting connection in a first orientation or in a second orientation orthogonal to the first orientation.

27. A spacer for a spacing system for a prefabricated wall structure including two spaced opposing walls between a top and bottom to form an internal formwork

25 cavity for receiving reinforcement bars to reinforce concrete poured into the internal formwork cavity and the spacer including shaped internal surfaces of the two opposing wails to form one or more spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity to improve spaced reinforcement of concrete poured into the internal formwork 30 cavity.

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28. A spacer according to claim 26 wherein the internal surfaces of the spacer form a plurality of spacing rests for receiving reinforcement bars and maintaining them at spaced locations within the internal formwork cavity and wherein adjacent spacing rests are offset to each other so as to vary the alignment and thereby strengthen 5 reinforcement.

29. A spacer according to claim 26 wherein the internal surfaces of the spacer are symmetrical and form a plurality of opposing spacing rests for receiving reinforcement bars and maintaining them at spaced locations in consistent parallel planes within the internal formwork cavity and wherein adjacent spacing rests so 10 as to maintain consistent spacing and thereby strengthen reinforcement.

30. A spacer according to claim 26 wherein the top and bottom engage with or are integral with an element of a spacer connector for connection of the top and bottom of the spacer to the respective internal surfaces of two wall elements to maintain the two wall elements spaced and forming the completed wall without any fixing 15 elements to the external surfaces of the wall elements forming the external surfaces of the completed wall.

31 .A method of forming a prefabricated wall structure including the steps of:

a. Providing two wall elements

b. Proving a spacing system having a spacer and spacing connection system

c. Attaching one element of the spacing connection system to each of matching positions on the internal opposing surfaces of the two wall elements

d. Connecting the spacer to the respective one elements in one of two orientations so as to provide a fixed spacing between the two wall elements

e. Repeat steps c and d in linear arrangement but with variation of the orientation of the spacer

f. Inserting elongated reinforcing bars

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g. prefabricated wall structure to be formed which can act as formwork for receiving and holding elongated reinforcing and concrete therein to form the completed wall.

5 32. A method according to claim 30 wherein a plurality of modules are connected by the steps of:

a. Providing the attaching one element of the spacing connection system attached to internal surfaces of the wall elements adjacent an edge of the wall element to have a module connection element;

b. Providing two wall modules with relatively located module connection elements

c. Connecting the two wall module connection elements so as to connect the two wall modules without any external fixings.