AU2020101961B4 - Construction of a building using precast panels - Google Patents

Construction of a building using precast panels Download PDF

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Publication number
AU2020101961B4
AU2020101961B4 AU2020101961A AU2020101961A AU2020101961B4 AU 2020101961 B4 AU2020101961 B4 AU 2020101961B4 AU 2020101961 A AU2020101961 A AU 2020101961A AU 2020101961 A AU2020101961 A AU 2020101961A AU 2020101961 B4 AU2020101961 B4 AU 2020101961B4
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AU
Australia
Prior art keywords
panel
precast
precast panel
bracket member
building
Prior art date
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AU2020101961A
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AU2020101961A4 (en
Inventor
Michael Johnson
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Rezicast Solutions Pty Ltd
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Rezicast Solutions Pty Ltd
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Filing date
Publication date
Priority claimed from AU2018904947A external-priority patent/AU2018904947A0/en
Application filed by Rezicast Solutions Pty Ltd filed Critical Rezicast Solutions Pty Ltd
Priority to AU2020101961A priority Critical patent/AU2020101961B4/en
Application granted granted Critical
Publication of AU2020101961A4 publication Critical patent/AU2020101961A4/en
Assigned to Rezicast Solutions Pty Ltd reassignment Rezicast Solutions Pty Ltd Request for Assignment Assignors: M JOHNSON BUILDING PTY LTD
Priority to AU2021107586A priority patent/AU2021107586A4/en
Publication of AU2020101961B4 publication Critical patent/AU2020101961B4/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403—Connection details of the elongated load-supporting parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34321—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/41—Connecting devices specially adapted for embedding in concrete or masonry
    • E04B1/4107—Longitudinal elements having an open profile, with the opening parallel to the concrete or masonry surface, i.e. anchoring rails
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/388—Separate connecting elements
    • E04B2001/389—Brackets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2002/567—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with posts or pillars made from a plurality of smaller prefabricated elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced

Abstract

ll:\nterwoven\NRPortbI\DCC\GW\20579254 _.docx-2/08/2020 ABSTRACT A method of constructing a building using a precast panel. The method includes securing the precast panel, using a bracket member that is provided by or attachable to the precast panel, to a structural component being one of a neighboring wall panel, a ground structure, a truss, and a floor base at height; wherein a first portion of the bracket member is fastened to the structural component and a second portion of the bracket member is provided in or attachable to the precast panel.

Description

Construction of a building using precast panels
Field of the invention
[0001] The invention relates to construction of a building using precast panels. Embodiments of the invention relate to residential construction. Embodiments of the invention relate to a method and system for constructing buildings using precast panels. Embodiments of the invention relate to a device to be used during the construction of a building using precast panels.
Background
[0002] Precast panels allow for buildings to be constructed much quicker compared to traditional construction techniques. These precast panels would be manufactured off-site, cut or made to size, and transported to site for installation.
[00031 Before installing these precast panels on site, a frame or shell of the building is first formed using structural steel. The precast panels are then placed around the frame. The panels have plates. The panels are fixed to the steel frame by welding the plates to the frame. The panels are fixed to a footing foundation by way of a reinforcing bar that is inserted in a grout tube in the wall panel. Grout is then poured into the tube. Once the grout sets, the panel is held in place.
[0004] The construction method described above is expensive, consumes a large amount of time, and is labor intensive. In view of the costs involved in installing these precast panels, it is not commercially viable to construct smaller residential buildings using precast panels.
[0005] In this context, there is a need for improved method and system for constructing buildings using precast panels.
Summary of the invention
[00061 An aspect of the present invention provides a method of constructing a building using a precast panel, the method including: arranging the precast panel and a neighbouring wall panel to form a corner of the building; and securing, using a bracket member, the precast panel to the neighbouring wall panel by fastening one portion of the bracket member to a side face of one of the precast panel or the neighbouring wall panel and fastening another portion of the bracket member to an end face of the other one of the precast panel or the neighbouring wall panel.
[00071 A further aspect of the present invention provides a method of constructing a building using a precast panel, the method including:
securing the precast panel, using a bracket member that is provided by or attachable to the precast panel, to a structural component being one of:
a neighboring wall panel,
a ground structure,
a truss, and
a floor base at height;
wherein a first portion of the bracket member is fastened to the structural component and a second portion of the bracket member is provided in or attachable to the precast panel, and the method further including providing a removable spacer member in the precast panel, the spacer providing a fill level indicator to which concrete is to be filled to provide a floor slab of the building.
[00081 According to another aspect of the present invention, there is provided an assembly built according to the methods according to any of the aspects described previously above, wherein the precast panels forming the walls of the assembly includes a removable spacer providing a fill level indicator to which concrete is to be filled to provide a floor slab of the building, wherein, when the floor slab is provided, the removable spacer can be removed to provide a recess in the floor slab for collecting any moisture or condensation that runs down the precast panel
[0009] According to an embodiment of the present invention, there is provided a method of constructing a building using a precast panel, the method including:
securing the precast panel, using a bracket member that is provided by or attachable to the precast panel, to a structural component being one of:
a neighboring wall panel,
a ground structure,
a truss, and
a floor base at height; wherein a first portion of the bracket member is fastened to the structural component and a second portion of the bracket member is provided in or attachable to the precast panel.
[0010] The precast panel is preferably a wall panel of the building. The precast wall panel may be a concrete precast panel for example.
[0011] Fastening or attaching the bracket member preferably includes using a fastener and washer to press the bracket member against a respective one of the structural component or the precast panel. The fastener may be a bolt or screw for example.
[0012] The bracket member may be fastened using a bolt. For example, where the structural component is one of a neighbouring wall panel, a footing foundation, a truss, or a floor base at height, the bracket member is preferably fastened to the structural component using a bolt. The bolts may be mm high tensile bolts for example.
[00131 The bracket member may be fastened using a screw. For example, where the structural component is a truss, the bracket member is preferably fastened to a structural component using a screw.
[0014] The structural component may include an engagement feature that is engagable by a fastener for fastening the first portion of the bracket member to the structural component. Where the structural component is a precast component, the engagement feature is preferably provided in the structural component during or after a making of the structural component. Securing the precast panel to the structural component preferably includes: locating the first portion of the bracket member about the engagement feature of the structural component. Fastening the first portion of the bracket member to the structural component preferably includes engaging the fastener with the engagement feature through the first portion. By way of example, the engagement feature of the structural component includes a hole, a threaded ferrule or a threaded hole.
[0015] The method may further include fastening the second portion of the bracket member to the precast panel. The precast panel includes an engagement feature that is engagable by a fastener for fastening the second portion of the bracket member to the precast panel. The engagement feature is preferably provided in the precast panel during or after a making of the precast panel. Fastening the second portion of the bracket member to the precast panel preferably includes: locating the second portion of the bracket member about the engagement feature of the precast panel. Fastening the second portion of the bracket member to the precast panel preferably includes engaging the fastener with the engagement feature through the second portion. By way of example, the engagement feature of the precast panel includes a hole, a threaded ferrule or a threaded hole.
[00161 The bracket member may be provided in the precast panel when the precast panel is formed. In this example, the second portion of the bracket member is on a face of the precast panel or is embedded within the precast panel, while the first portion of the bracket member protrudes from the precast panel for fastening to the structural component.
[00171 The building is preferably a residential building. For example, the building may be one of a single-storey residential building, a double-storey residential building, a multi-storey residential building, a shed, or a garage.
[00181 The bracket member may include an angle bracket. The angle bracket is preferably fabricated from metal or steel. The first portion of the bracket member lies on a plane that is transverse to a plane on which the second portion of the bracket member lies.
[0019] In one example, the structural component may be a ground structure. The ground structure may be a footing foundation. In this example, the method preferably includes: arranging the precast panel above the ground structure to form a wall of the building; and securing, using the angle bracket, the precast panel to the ground structure. Arranging the precast panel above the ground structure preferably includes locating the precast panel such that the first portion of the bracket member is located on the ground structure.
[0020] In another example, the structural component may be a neighbouring wall panel. The neighbouring wall panel may be a precast wall panel. In this example, the method preferably includes: arranging the precast panel and the neighbouring panel to form a corner of the building; and securing, using the angle bracket, the precast panel to the neighbouring panel. Arranging the precast panel and the neighbouring panel preferably includes locating one or both of the precast panel and the neighbouring panel such that the first portion of the bracket member is located on the neighbouring panel.
[0021] In yet another example, the structural component is a truss. In this example, the method includes: locating the truss on the precast panel; and securing, using the angle bracket, the roof truss to the precast panel. Locating the truss on the precast panel preferably includes locating a top plate on the precast panel, securing the top plate to the precast panel using the angle bracket, and securing the truss to the top plate. The method may include securing the truss directly to the precast panel using the angle bracket.
[0022] The bracket member may include a flat plate. For example, the flat plate may be a fish bracket for example. The flat plate is preferably fabricated from metal or steel. The first portion of the bracket member lies on a same plane as the second portion of the bracket member lies.
[00231 In an example, the structural component is a neighbouring wall panel. The neighbouring wall panel may be a precast wall panel. In this example, the method preferably includes: arranging the precast panel and the neighbouring wall panel in a straight line to form a wall of the building; and securing, using the flat plate, the precast panel to the neighbouring wall panel. The precast panel and the neighbouring wall panel may be arranged to form a horizontally extended wall relative to a ground structure of the building. Alternatively, the precast panel and the neighbouring wall panel may be arranged to form a vertically extended wall relative to a ground structure of the building. Arranging the precast panel and the neighbouring panel preferably includes locating one or both of the precast panel and the neighbouring panel such that the first portion of the bracket member is located on the neighbouring panel.
[0024] In an example, the structural component is a neighbouring wall panel. The neighbouring wall panel is preferably a neighbouring precast wall panel. In this example, the method includes: arranging the precast panel and the neighbouring wall panel to form a corner of the building; and securing, using the flat plate, the precast panel to the neighbouring wall panel by fastening one portion of the flat plate to a side face of one of the precast panel or the neighbouring wall panel and fastening another portion of the flat plate to an end face of the other one of the precast panel or the neighbouring wall panel.
[0025] The bracket member may include an elongate bar. The elongate bar is preferably fabricated from metal or steel. The elongate bar is a hollow component. The elongate bar may have a square cross-section. An end of the elongate bar may be cut at an angle to expose a rear wall portion of the elongate bar that is not covered by a front wall portion of the elongate bar. The rear wall portion corresponds to the second portion of the bracket member for attaching to the precast panel. The end of the elongate bar may be cut at an angle of between about 300 and 600 inclusive. The end of the elongate bar may be cut at an angle of about 450 for example. A head of the fastener for fastening the second portion of the bracket member to the precast panel is preferably contained in a space between side wall portions of the elongate bar. The elongate bar may be cut at an angle at one end or both ends of the elongate bar.
[00261 In an example, the structural component includes a floor base at height. The floor base may be a timber frame of a floor system for example. The floor base at height is a floor base of an elevated-storey of the building. For example, in a double-storey residential building, the floor base is of a second storey of the building. In this example, the method includes: fastening the elongate bar to the precast panel; and fastening the floor base at height to the elongate bar.
[00271 Fastening the elongate bar to the precast panel may include locating the elongate bar such that a portion of the elongate bar extends beyond the precast panel. For example, a lower portion of the elongate bar is provided by or attached to the precast panel, while an upper portion of the elongate bar extends beyond the precast panel. An end of the upper portion of the elongate bar may be cut at an angle to expose a rear wall portion of the elongate bar that is not covered by a front wall portion of the elongate bar. This rear wall portion is for attaching to a neighbouring wall panel located above the precast panel to form a vertically extended wall of the building. The end of the upper portion may be cut at an angle of between about 300 and 600 inclusive. The end of the elongate bar may be cut at an angle of about 450 for example. A head of the fastener for fastening the second portion of the bracket member to the precast panel is preferably contained in a space between side wall portions of the elongate bar.
[00281 The method preferably includes providing a removable spacer member along a width of the precast panel, locating the precast panel on the ground structure, providing a floor slab to the building to reach a level of the removable spacer, and removing the spacer member to expose a recess in the floor slab adjacent to the precast panel. The removable spacer member is preferably sticky foam. In other examples, the removable member may be an elongate timber panel, a polyurethane material, or a polystyrene material. The removable spacer member may be provided along the entire width of the precast panel or over a portion of the entire width of the precast panel. The recess in the floor slab is for collecting any moisture or condensation that runs down the precast panel. The recess may have a width of between about 10mm and about 70mm inclusive. The width of the recess is preferably 20mm. The recess may have a depth of between about 10mm and 70mm inclusive. The depth of the recess is preferably about 20mm.
[0029] The method preferably includes: fastening another precast panel above the precast panel to form a vertically extended wall of the building.
[00301 In another embodiment, there is provided a building built according to the method described previously above.
[00311 The building may be a single-storey residential building, a double-storey residential building, a multi-storey residential building, a shed, or a garage.
[0032] The building preferably has one or more precast panels forming walls of the building that are secured to a ground structure using a plurality of bracket members. The bracket member may be an angle bracket.
[00331 Neighbouring precast panels forming the walls are preferably secured to each other using a bracket member. For example, two panels that are arranged in a straight line to form a horizontally extended wall or a vertically extended wall of the building are secured to each other using a flat bracket member. Two panels that are arranged to form a corner of the building may be secured to each other using an angle bracket with one portion that is provided by or attached to a side face of one precast panel and another portion that is provided by or attached to a side face of the other precast panel. Alternatively, the two panels that are arranged to form the corner of the building may be secured to each other using a flat bracket member with one portion of the flat plate being fastened to a side face of one of the precast panel or the neighbouring wall panel and another portion of the flat plate being fastened to an end face of the other one of the precast panel or the neighbouring wall panel.
[0034] A truss is secured to the walls of the building using a bracket member. The bracket member may be an angle bracket for example. The assembly includes a top plate that is attached to the bracket member, with the truss being attached to the bracket member. The top plate may be integrally formed with the bracket member as one-piece. The top plate may be an elongate member that rests on the precast panel and that is secured to the precast panel using the angle bracket. The elongate member may be a timber frame for example. The elongate member extends along a width of the panel, with the truss being secured to the elongate member.
[00351 The building may be a multi-storey building. For example, the building may be a double storey building or a triple-storey building. The elevated storey of the building is secured to the panels using a bracket member distributed at height along the precast panels. The bracket member may be an elongate bar for example. A lower portion of the elongate bar is provided by or is for attaching to a precast panel of a lower storey of the building, while an upper portion of the elongate bar is provided by or is for attaching to a precast panel of an upper storey of the building.
[00361 The bracket member may be attached to the precast panel by fastening a portion of the bracket member to the precast panel using a fastener for example. Alternatively, the bracket member may be provided by the precast panel. For example, during the making of the precast panel, a portion of the bracket member is provided in the precast panel.
[00371 Each precast panels preferably include an engagement feature that is engageable by a fastener to secure the bracket member to the precast panel. The fastener may be a screw or bolt for example. The engagement portion may be a hole, a threaded ferrule or a threaded hole for example.
[00381 The precast panels forming the walls of the building preferably includes providing a removable spacer member that extends along a width of the precast panel. The spacer member preferably defines a level to which a floor slab is to be provided to the assembly. For example, when the precast panels are secured to the ground structure, concrete is filed into a space between the precast panels defining the walls of the assembly to a level at which the spacer member is located to form the floor slab, and the removable spacer is removed to provide a recess (or rebate) in the floor slab for collecting any moisture or condensation that runs down the precast panel. The recess is preferably adjacent to or near the precast panel. The recess may have a width of between about 10mm and about 70mm inclusive. The width of the recess is preferably 20mm. The recess may have a depth of between about 10mm and 70mm inclusive. The depth of the recess is preferably about 20mm. The removable member is preferably sticky foam. In other examples, the removable member may be an elongate timber panel, a polyurethane material, or a polystyrene material. The removable spacer may be provided along the entire width of the precast panel or over a portion of the entire width of the precast panel.
Brief description of the drawings
[00391 The invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
Figures 1A andlB show a bracket member and a precast panel secured to a footing using that bracket member according to an embodiment of the present invention;
Figures 2A and 2B show a bracket member and a precast panel secured to another precast using that bracket member according to an embodiment of the present invention;
Figures 3A and 3B show a bracket member and a precast panel secured to another precast panel using that bracket member according to an embodiment of the present invention;
Figures 4A, 4B, and 4C show a bracket member and a precast panel with that bracket member for securing to a truss according to an embodiment of the present invention;
Figures 5A and 5B show a bracket member and a precast panel secured to elevated storey of the building using that bracket member according to an embodiment of the present invention; and
Figure 6 shows an assembly according to an embodiment of the present invention.
Detailed description
[0040] According to an embodiment of the present invention, precast panels are secured to each other, to a footing foundation, and to a truss using fabricated brackets. The fabricated brackets make construction of a building using precast panels faster and less labor intensive. In addition, the use of fabricated brackets makes construction of residential buildings using precast panels economically viable. For example, the building may be one of a single-storey residential building, a double-storey residential building, a multi-storey residential building, a shed, or a garage.
[0041] The method of constructing a building using a precast panel according to an embodiment of the present invention includes: securing the precast panel, using a bracket member that is provided by or attachable to the precast panel, to a structural component (being one of: a neighboring precast panel, a ground structure, a truss, and a floor base at height). The bracket member has a first portion that is fastened to the structural component and a second portion of the bracket member that is provided in (e.g. part of the precast panel during the making of the precast panel) or is attachable (e.g. can be fastened) to the precast panel.
[0042] The precast panel is a concrete precast wall panel.
[00431 The precast panels are provided with an engagement feature that is engagable by a fastener (e.g. a bolt or screw) for fastening the first portion of the bracket member to the structural component. The engagement feature is preferably provided in the structural component during or after a making of the structural component. That is, the engagement feature is provided to the panels off site. To secure the precast panel to the structural component, the first portion of the bracket member is located about the engagement feature of the structural component. The first portion of the bracket member is fastened to the structural component by engaging the fastener with the engagement feature through the first portion. The engagement feature of the structural component may be a hole, a threaded ferrule or a threaded hole for example. In other embodiments, the precast panel may not have the engagement feature.
[0044] Fastening or attaching the bracket member includes using a fastener and washer to press the bracket member against a respective one of the structural component or the precast panel. The fastener may be a bolt or screw for example. Where the structural component is one of a neighbouring wall panel, a footing foundation, a truss, or a floor base at height, the bracket member is preferably fastened to the structural component using a bolt. The bolt may be a 20mm high tensile bolt for example. Where the structural component is a truss, the bracket member is preferably fastened to a structural component using a screw.
[0045] One or more precast panels have a removable spacer. The removable spacer may be provided to the precast panel off-site or on site. The removable spacer extends along a width of the precast panel (i.e. in a direction substantially parallel to ground). The spacer defines a level to which a floor slab is to be provided to the assembly. When the precast panels are secured to a ground structure (e.g. the footing foundation), concrete is filed into a space between the precast panels that define the walls of the assembly to a level at which the removable spacer is located to form the floor slab. Once the concrete sufficiently hardens or sets (for example after 1 day), the removable spacer is removed from the precast panel to provide a recess (or rebate) in the floor slab, adjacent to the precast panel. The recess is for collecting any moisture or condensation that runs down the precast panel. The recess has a width of between about 10mm and about 70mm inclusive, preferably 20mm. The recess has a depth of between about 10mm and 70mm inclusive, preferably about 20mm. The removable member may be sticky foam, an elongate timber panel, a polyurethane material, or a polystyrene material.
[00461 Figures 1A and 1B show a bracket member in the form of an angle bracket 100 for securing the precast panel 920 to a footing foundation 940. The angle bracket is fabricated from metal or steel. The first portion of the bracket member (for securing to the footing foundation) lies on a plane that is transverse to a plane on which the second portion of the bracket member (for securing to the precast panel) lies. The precast panel is arranged above the footing foundation to form a wall of the building. In arranging the precast panel above the footing foundation, levelling components are used to ensure that the precast panels are level. When in position, the precast panel is secured to the footing foundation, using the angle bracket 100. The bracket member is fastened using 20mm high tensile bolts for example.
[00471 Figures 2A and 2B show a bracket member in the form of a flat plate 200 for securing two precast panels 920 in a straight line to form a horizontally extended wall. The flat plate 200 may be a fish bracket for example. The flat plate is fabricated from metal or steel. The first portion of the bracket member (to which one of the precast panels is secured) lies on a same plane as the second portion of the bracket member (to which the other one of the precast panels is secured) lies. The two precast panels are arranged in a straight line to form a wall of the building. When in position, the panels are secured, using the flat plate. In other embodiments, the precast panels may be arranged to form a vertically extended wall relative to a ground structure of the building. The bracket member is fastened using 20mm high tensile bolts for example.
[00481 In other examples, the flat plate 200 can be used to secure two panels forming a corner of the building. In this example, one portion of the flat plate is secured to a side face of one of the precast panel or the neighbouring wall panel and another portion of the flat plate is secured to an end face of the other one of the precast panel or the neighbouring wall panel.
[0049] Figures 3A and 3B show a bracket member in the form of an angle bracket 300 for securing two precast panels 920 that forms a corner of the building. The angle bracket is fabricated from metal or steel. The first portion of the bracket member (to which one of the precast panels is secured) lies on a plane that is transverse to a plane on which the second portion of the bracket member (to which the other precast panels is secured) lies. The precast panels are arranged to form a corner of the building. When in position, the precast panels are secured using the angle bracket. The bracket member is fastened using 20mm high tensile bolts for example.
[0050] Figures 4A to 4C show a bracket member in the form of an angle bracket 400 for securing the precast panel 920 to a truss (not shown). The angle bracket is fabricated from metal or steel. The first portion of the bracket member (to which the truss is secured) lies on a plane that is transverse to a plane on which the second portion of the bracket member (that is within the precast panel) lies. In this embodiment, the angle bracket is provided in the precast panel during the manufacture or casting process of the precast panel such that a portion of the angle bracket is located within the precast panel while a portion to which the truss is secured is extends from the panel. The truss is arranged on the precast panel. When in position, the truss is secured to the precast panel using the angle bracket. The bracket member is fastened using screws for example. A top plate is provided that is attached to the angle bracket 400. The truss is then attached to the top plate. For example, the truss may be screwed onto the top plate.
[0051] Referring to Figure 4C, the top plate 420, which is in the form of a timber frame, rests on the precast panel 920. A portion of the angle bracket 400 extends along a face of the precast panel and beyond the precast panel. The timber frame, which rests on the precast panel, is secured to the portion of the angle bracket that extends beyond the precast panel by screwing the timber frame thereto. The truss 910 is located on the top plate and secured thereto using screws.
[0052] Figures 5A and 5B show a bracket member in the form of an elongate bar 500 for securing an elevated storey 960 of the building to the precast panel 920. The elongate bar is fabricated from metal or steel.
[00531 The elongate bar is a hollow component having a square cross-section. It will be readily appreciated that other shapes of the elongate bar is possible. An end of the elongate bar is cut at an angle to expose a rear wall portion of the elongate bar that is not covered by a front wall portion of the elongate bar. The rear wall portion corresponds to the second portion of the bracket member for attaching to the precast panel. The end of the elongate bar is cut at an angle of between about 300 and 600 inclusive, preferably about 450. A head of the fastener for fastening the elongate member to the precast panel is preferably contained in a space between side wall portions of the elongate bar. The elongate bar may be cut at an angle at one end or both ends of the elongate bar.
[0054] The elevated storey 960 includes a timber frame of a floor system. For example, in a double-storey residential building, the floor system is of a second storey of the building. To install the timber frame of the floor system, the elongate bar is fastened to the precast panel. The floor base is then fastened at height to the elongate bar. A timber beam frame is attached to the elongate bar, for example by screwing the frame to the elongate bar. The timber beam runs parallel to the wall panel. A timber floor truss system is then secured to the timber beam frame, with the floor truss system including components that are substantially perpendicular to the timber beam frame.
[0055] When the elongate bar is fastened to the precast panel, the elongate bar is located such that a portion of the elongate bar extends beyond the precast panel. In particular, a lower portion of the elongate bar is provided by or attached to the precast panel, while an upper portion of the elongate bar extends beyond the precast panel. An end of the upper portion of the elongate bar is cut at an angle to expose a rear wall portion of the elongate bar that is not covered by a front wall portion of the elongate bar. This rear wall portion is for attaching to a neighbouring wall panel located above the precast panel to form a vertically extended wall of the building.
[00561 Figure 6 shows an assembly 900 with the precast walls 920 assembled to the footing foundation, to each other, and to a truss using the brackets previously described above with reference to Figures IA, 1B, 2A, 2B, 3A, 3B, 4A, and 4B. The precast panels are secured to footing foundations, which are temporary concrete pads located at each corner of the wall panels. In Figure 6, once the precast panels are secured to the footing foundation, the footing foundation is covered by infill.
[00571 An engineered slab 980 or an engineered infill located in a space between the precast walls in the center of the assembly 900. The engineered slab has a thickness of between about 300mm to 400mm. In the embodiment shown in Figure 6, the engineered slab is a waffle pod slab system. Starter bars 982 are provided from the precast walls 920 in a direction towards the engineered slab 980. These starter bars respectively engage a hole or threaded ferrule in the precast panel above the bracket that connects the precast panel to the footing foundation (shown in Figure 1B) such that the respective starter bar is held firmly in place by the precast panels. The starter bars are spaced apart from each other by a distance of between about 0.5m to 1.5m, preferably about 1.0m.
[00581 The starter bars 982 are located below the removable spacer member of the precast panel (which is described previously above). The removable spacer member may be provided to the precast panel after the precast panel is secured to the footing foundation and/or after the starter bars are installed. Alternatively, the spacer member may be provided before the precast panel is secured to the footing foundation including, for example, off-site.
[0059] Concrete is poured into the space between the wall panels to submerge the engineered slab and the starter bars, to the level of the removable spacer of the precast panel, to form a floor slab of the building. The removable spacer is then removed to provide a recess in the floor slab for trapping moisture and condensation running down the precast panels. The spacer member may for example be removed one day after the concrete is poured to give the concrete time to sufficiently harden or set so that the recess does not lose its shape or get filled by concrete with the spacer member is removed. The use of the starter bars allow for the precast panels to be securely held in place by the floor slab alone. The footing foundation, to which the precast panels are secured, is a temporary footing in the sense that once the concrete is poured into the space between the precast panels to form the floor slab, the floor slab holds the walls in place and the footing foundation becomes obsolete. The footing foundation is merely to initially locate the precast panels during installation.
[00601 While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.
[00611 The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavor to which this specification relates.
[0062] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims (5)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:
1. A method of constructing a building using a precast wall panel, the method including:
securing the precast wall panel, using a bracket member that is provided by or attachable to
the precast panel, to a neighbouring wall panel, the precast panel comprising a removable spacer
provided on an inner wall thereof;
pouring concrete into the space adjacent the secured wall panels to the level of the
removable spacer, to form a floor slab of the building; and
removing the removable spacer to provide a recess in the floor slab for use in trapping
moisture and condensation running down the wall panel.
2. A method in accordance with claim 1, further comprising:
arranging the precast panel and a neighbouring wall panel to form a corner of the building;
and securing, using a bracket member, the precast panel to the neighbouring wall panel by fastening
one portion of the bracket member to a side face of one of the precast panel or the neighbouring
wall panel and fastening another portion of the bracket member to an end face of the other one of
the precast panel or the neighbouring wall panel.
3. A method in accordance with claim 1 or claim 2, wherein the removable spacer extends
along a width of the panel.
4. A method in accordance with claim 3, further comprising installing starter bars below the
level of the removable spacer to the wall panel prior to pouring of the concrete and wherein an end
of each starter bar either locates in a hole or connects to a ferrule disposed in the inner wall of the
precast panel, the hole or ferrule disposed above a bracket connecting the panel to a footing
foundation.
5. An assembly built according to the method of any one of the preceding claims.
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USD1003695S1 (en) 2020-12-17 2023-11-07 Rezicast Solutions Pty Ltd Pre-formed concrete wall with integrated bracket
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CN204850478U (en) * 2015-07-09 2015-12-09 罗昭方 Controlling means is pour to concrete floor thickness
AU2017100525A4 (en) * 2017-05-11 2017-08-24 M Johnson Building Pty Ltd A system for residential precast wall constructed buildings that include both single and double story dwellings. System can also be used for sheds, garages, detached and attached dwellings

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