AU638928B2

AU638928B2 -

Info

Publication number: AU638928B2
Application number: AU3530393A
Authority: AU
Priority date: 1993-03-17
Filing date: 1993-03-17
Publication date: 1993-07-08
Anticipated expiration: 1995-12-21
Also published as: AU3530393A

Description

638928

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A PETTY PATENT

ORIGINAL

o i r r Applicant(s): BARRIER ENGINEERING CONSTRUCTION CO PTY LTD A.C.N. 006 598 429 Actual Inventor(s): John O'Connor McCabe Address for Service: PATENT ATTORNEY SERVICES 26 Ellingworth Parade Box Hill Victoria 3128 Australia Title: PREFABRICATED BUILDING CONSTRUCTION Associated Provisional Applications: No(s).: The following statement is a full description of this invention, including the best method of performing it known to me/us:-

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PREFABRICATED BUILDING CONSTRUCTION This invention relates to prefabricated building construction and particularly to prefabricated building structures.

In the past it has been known to construct prefabricated building panels of reinforced concrete. For standard sizes reusable formwork can be designed and constructed for enabling the panels to be cast. When particular panels of non-standard shape are required, special formwork must be constructed and this is quite expensive.

The erection and use of specially designed formwork is well known on building sites such as for the construction of reinforced concrete columns, stairways, stair wells, lift wells, wall sections as well as floor slabs. The construction and use and later disassembly of special formwork whether on site or off site is time consuming and expensive. The advantages of prefabricated building sections are well known, particularly the speed with which building sections can be erected compared to fabrication on site.

One particular problem with concrete structures whether made of prefabricated sections assembled on site or of building sections fabricated on site is that the concrete lacks aesthetic appeal both in colour and texture. Frequently also concrete leeds external covering for protection against weathering and to prevent unsightly finishes both upon completion and well as over periods of time when unsightly staining develops.

The use of building blocks or bricks is known. The laying of the blocks or bricks at a building site can be time consuming thus 25 2 being a significant factor in the total construction time for a particular project. Also the laying of blocks or bricks on site can be interrupted by inclement weather leading to significant disruptions to project schedules.

It is an object of the present invention to provide a 30 prefabricated building structure using building blocks which are assembled at one site and which can be transported to the final desired location, According to the present invention there is provided a prefabricated structure having upright walls composed of substantially horizontal courses of building blocks, the upright walls defining a substantially closed shape of the structure in horizontal section and courses of the building blocks extending around the contour of the walls in horizontal section, the structure II I I including at least one reinforcing piece being located so as to extend between adjacent courses of blocks and being shaped to extend around at least a part of the contour of the walls between adjacent courses of building blocks, the reinforcing piece being embedded within grout so as to form a reinforced beam extending between adjacent courses and following the contour of the walls along the length of the reinforcing piece, the reinforced beam extending around the substantially closed shape of the structure, the structure further including a transverse reinforcing rod extending transverse to the lines of the courses of blocks and through aligned holes in the blocks of the courses, the transverse reinforcing rod being contained within a passage defined by the aligned holes, the passage being filled with grout so as to form an upright reinforced column, the generally horizontal reinforced beam and the upright reinforced column contributing to rigidity of the structure so that the structure can be transported from the site of its construction to another site for use.

The upright walls may define a completely closed ring in horizontal section, the horizontal reinforced beam being in the form 20 of a closed ring between adjacent courses of blocks.

In the case where the upright walls define a completely closed shape in horizontal section, one of the upright walls may have an opening therethrough which extends vertically over part of the height :of that wall.

Instead of forming a closed ring, the upright walls may define a generally C-shaped structure in plan view, the opening in the C-shape being defined within a front wall of the structure which is interrupted over the full height of the structure.

~Each adjacent pair of upright walls may meet at a respective a" 30 angled corner, the courses of blocks extending continuously around the angled corners and the reinforcing piece between adjacent courses being bent at the required angle so as to extend around the angled corner thereby forming with the grout a reinforced beam having the desired angled shape in plan view.

I I The prefabricated structure may further include an anchor member comprising an externally accessible portion which is accessible from externally of the structure, the anchor member also including an anchuring portion which is located between two adjacent courses of blocks, the aLchoring portion having an aperture therethrough which is aligned with the aligned holes in the courses of blocks, the reinforcing rod which extends through the aligned holes also passing through the aperture in the anchoring portion whereby the upright reinforced column passes through the aperture in the anchoring portion.

Preferably the transverse reinforcing rod extends throughout substantially the entire height of the structural component, the structure further including a lifter coupled to the upright reinforcing rod so that lifting forces can be applied to the lifter and the lifting force can be transmitted to the reinforced column extending through the height of the structure.

A base plate may be provided at or beneath the bottom course of blocks, the reinforcing rod extending upwardly from the base plate through the passage, a lifter being provided at the upper end of the reinforcing rod so that lifting force applied to the reinforcing rod is transferred to the base plate so that lifting force is applied from the bottom of the structure. The reinforcing rod in the passage may be grouted through a lower portion of its length, an upper S• portion of the length of the reinforcing rod being surrounded by a sleeve allowing movement between the reinforcing rod and the sleeve whereby lifting force applied to the upper end of the reinforcing rod sufficient to cause stretching of the rod at its upper portion will be taken up by sliding movement between the rod and the sleeve.

SThe prefabricated structure may further include a female S 30 coupling for coupling the structure to a vertically abutting structure; the female coupling having a plate which is generally co-planar with a top or bottom edge of the structure, reinforcing rods extending from the plate within the structure, the reinforcing rods being embedded in grout so as to structurally unite tlh female coupling to the structure, the plate further including an aperture for receiving a male projecting portion of the vertically abutting structure.

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The structure may include a male coupling for coupling the structure to a vertically abutting structure; the male coupling comprising a plate for location at the top or bottom edge of the structure, reinforcing rods projecting from the plate and extending into the structure and being embedded in grout so as to structurally unite the male coupling tu the structure, the male coupling further including a projecting rod projecting beyond the top or bottom edge of the structure for being received within a female aperture within the vertically abutting structure.

In the embodiment of the prefabricated structure having a female coupling, the female coupling may further include a bore which opens outwardly through the aperture in the plate so that in use the male projecting portion of the vertically abutting structure projects through the aperture in the plate into the bore, the bore being defined by a sleeve having a closed inner end, the sleeve projecting into the structure frrm the plate.

0 0 0. The prefabricated structure may further include a coupling 0000 channel in a face of the structure, the coupling channel opening outwardly through the face and having a restricted mouth, the 20 coupling channel being defined by a length of channel having a reinforcing rod welded to the inner base web of the coupling channel section so that the reinforcing rod extends beyond the end of the c coupling channel into the structure, the reinforcing rod being embedded within grout within the structure so as to structurally unite the coupling channel to the structure, the reinforcing rod being stepped inwardly so as to locate the reinforcing rod generally -centrally within the thickness of the wall of the structure.

The structure may include courses which extend around angles, at least one of the reinforcing pieces at each angle conforming to the general shape of the line of the course so as to extend continuously through the angle. The angles through which the courses are laid can be right angles so that the structural component is generally C shaped in plan view and forms three walls of a substantially enclosed space within the building structure.

Alternatively, the structural component can extend through three right angles and form in plan view a closed box structure having four walls and an access opening in one wall, the reinforcing pieces between adjacent courses of blocks extending around through each of

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the three right angled corners, any reinforcing pieces terminating along one wall being overlapped with continuation reinforcing pieces so as to splice the reinforcing pieces together within the grout and form a substantially continuous reinforced beam between adjacent courses.

Possible and preferred features of the present invention will now be described with particular reference to the accompanying drawings. However it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. In the drawings: Fig. 1 is a schematic perspective view of a portion of first and second courses of blocks, Fig. 2 shows a fragment of a wall made of acoustic blocks and a post tensioning tube extending vertically, Figs. 3, 4 and 5 show three possible lifters for use in the present invention, Fig. 6 shows schematically a lifting frame for a structure such as the lift well section illustrated, Fig. 7 shows the reinforcing rod extending vertically and having a sleeve allowing stretching during lifting, Fig. 8 is a side elevational view of an anchor member, Fig. 9 is a sectional view showing male and female coupling members for vertically abutting building structures, and Fig. 10 shows a coupling channel for mounting in a structure.

The method of manufacturing and the features of prefabricated e. structures or structural components (hereinafter referred to as "structures") will be described with reference to the drawings. The i first step involves laying a course 10 of construction blocks or 30 bricks 11 (hereinafter referred to "blocks"), the blocks having upright holes 12 arranged to align with corresponding holes in an adjacent course 15 of similar blockG. The blocks are laid on a flat bed from which they are lifted later. String lines may be run to guide the laying of the blocks as is known in the brick laying trade. The initial course 10 of blocks 11 may be provided with a groove or channel 16 in its upper face so that a continuous groove or channel is defined along the upper face of the course 10. The front

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and back upright faces of the blocks can be generally conventional so that the groove or channel 16 is not visible.

The process further includes the step of laying a reinforcing rod 20 or, if desired, two reinforcing rods along the channel 16 so as not to block the holes. The rod(s) 20 may be generally conventional, e.g. may be 9mm deformed high tensile galvanised reinforcing rod(s) of the general kind used in pipe reinforcement.

If two rods 20 are used without a channel 16, 6mm rods may be used.

Preferably, at least one of the holes in the blocks along the 10 length of the initial course 10 is plugged with a member 21 which l0 conforms substantially to the shape of the hole 12 in plan view. The plug 21 has a handle 22 extending upwardly from the plug, The purpose and use of the plug member 21 will be described further below.

A second course of blocks 15 is laid along the first course .o .with mortar or other grout or bonding agent 17 (herein called "grout" for convenience) between the courses, the second course 15 having Sblocks with holes 12 aligned at least with the hole or holes In the first course 10 having the plug members 21. The grout may be a 3 in S 20 1 mix of finely washed coarse sand and A grade cement.

20 After the second course 15 has been laid, the or each plug member 21 is drawn upwardly from the first course 10 into the respective aligned hole in the second course 15 making a clear bore 18 through the mortar or other bonding agent layer 17 between the first and second courses. This drawing of the plug member 21 25 .upwardly may be achieved by grasping the handle 22 at the top of the plug member and drawing the plug member upwardly into the second course, ~The steps of laying further courses and drawing the plug 30 member(s) 21 up through the intervening mortar or other binding agent 30 layer can be repeated as often as desired so that as the number of courses increases and an upright structure is formed, there is also formed a continuous passage 18 extending generally vertically through the entire height of the structure.

If desired, and depending on the height and use of the structure, further courses beyond the first 10 may be provided with the grooved or channelled blocks into which reinforcing rods are laid along the courses. This provides with the grout laid between the courses a continuous lateral reinforced beam. For example, at every of height there may be provided a lateral reinforced beam defined by the grout in the grooved blocks, When the desired height of the structure has been reached, the plug member(s) 21 may be removed from the top course thereby exposing the vertical passage 18 through the entire number of courses. Into this passage 18 there may be inserted a reinforcing rod 30 and the passage 18 may be filled with mortar, grout or bonding cement 31 or the like (herein called "grout") so that there is formed a continuous reinforced column extending the whole height of the structure. As mentioned above, there may be several vertical passages 18 created for receiving reinforcing rods 30 and for filling with grout 31 so as to define several reinforced concrete columns extending through the height of the structure.

With the method described above it is possible to prefabricate structures substantially closed shapes. For example, structures having a C shape or closed box shape in plan view may be erected. In the case of structures having corners, the grooves or channels 16 in the first course 10 and higher courses of blocks may extend around the corners. In this case, or when the channels 16 are not provided, the reinforcing rods 20 are preferably bent at the required angles so as to pass around the corner thereby forming with the grout a reinforced beam of the desired angled shape.

It is possible to prefabricate generally box shaped structures. In particular it is possible to prefabricate lift well e or stair well sections which can be generally C shaped or closed rings in plan view having continuous back and opposed side walls and a front wall which is interrupted over part or over the full height 30 of the structure by an opening. Such a structure can be 30 prefabricated off site to specifications and transported for use at another site, e.g. by being manoeuvred into position with similar structures being mounted one on top of another.

Anchor members 40 can be assembled into the structure and arranged to project externally of the face or faces, the anchor members 40 being usable for connection to the structure to other building components or structures. The anchor member 40 in the drawings has an embedded portion 41 which is laid between adjacent courses lla, 12b (Fig. The embedded portion 41 includes an aperture 42 therethrough which is aligned with a hole through which a vertical reinforcing bar 30 is to be inserted so that the anchor member 40 is firmly secured when the vertical reinforcing rod and surrounding grout is inserted and passes through the anchor member The portion 43 of the anchor member 40 projecting externally from the structure may be provided with anchoring points such as anchoring apertures 44 for co-operation with mating formations provided, say, by associated building components.

The anchor member 40 in Fig. 8 comprises a face plate 45 which lies along the face of the courses of blocks lla, lib, llc. The support plate 43 projects laterally so that the structure extends downwardly from the face plate 45 and the support plate 43. Two anchoring plates 41, 41a are spaced so as to receive a brick course lb between them, the anchoring plates 41, 41a being embedded in the .grout between the adjacent courses lla, lilb, llc and the vertical reinforcing bar 30 passing through the apertures 42 in the anchoring plates.

20 The construction preferably further includes the step of coupling a lifter 50 to the vertical reinforcing bar 30 so that after insertion and setting of the grout 31 around the vertical reinforcing bar 30, the lifter 50 is partially embedded in the reinforced column. A portion of the lifter 50 is exposed at the top of the reinforced column and at the top of the structure so that a lifting attachment may be coupled to the lifter 50 and a lifting force applied to the lifter to lift the structure. The lifting force applied to the lifter will be passed through the vertical reinforcing rod 30 to substantially the entire height of the structure.

The coupling of the lifter 50 to the vertical reinforcing rod may be achieved as shown in Figs. 3 and 5 by providing a coupling hole 51 or other co-operating formation at the lower end of the lifter, the upper end of the vertical reinforcing rod 30 being provided with, say, an inverted U shape 52 for co-operating with the lower end of the lifter. In another arrangement (Fig. the lower end of the lifter 50 is spliced with the vertical reinforcing rod In particular, the lifter 50 is provided with a downward extension portion 53 whici is a generally linear rod provided with deformations such as helically arranged thickened ribs or the like of the general kind known to be provided on reinforcing rods. By overlapping the lower extension portion 53 of the lifter with the upper end of the vertical reinforcing rod 30, the grout effectively splices the lifter 50 and reinforcing rod 30 together.

The upper end of the lifter 50 may be provided with a formation such as an eye 54 (Fig. 3) or an enlarged head 55 (Figs. 4 and 5) for co-operation with a crane mounted lifting hook or the like. The upper end of the lifter 50 may be recessed slightly below the upper edge of the upper course of blocks so as not to project substantially above the structure.

In Fig. 7 the reinforcing rod 30 is grouted along a lower portion of its length 32. An upper portion 33 of the length of the reinforcing rod is surrounded by a sleeve 34 which allows movement between the rod 30 and the sleeve 34. With this arrangement, lifting •forces applied to the upper end of the rod 30 sufficient to cause some stretching of the rod at its upper portion 33 will be taken up •,oo ••by the sliding movement between the rod and the sleeve 34.

For some applications of the structure, (he method may include 20 the step of providing a generally vertical tube 35 (Fig. 2) extending through the entire height of the structure. The tube 35 is arranged to extend the full height of the structure through aligned holes in blocks so that a clear passage 36 without mortar or grout extends through the entire height of the structure at the location of the tube. Grout may be placed around the outside of the tube 35 after the completion of the top course blocks, however, the upper and ago4 lower ends of the tube are open so that there remains a clear passage through the entire height of the structure. This method of erection it enables the insertion through the passage 36 of a rod through the 30 entire height of the structure, the rod being tensioned on site by tightening of a nut or the like onto a top plate on the structure so that the structure is effectively post tensioned on site so as to be usable as a free standing structure without further support. A base plate (not shown) can be located at the bottom course from which the vertical rod extends.

The invention as described above can be seen to provide a structure having the structural, insulating and aesthetic appeal of solid block. The construction can be carried out within a suitable building so that the work of erecting the structure can continue regardless of weather conditions. The structures can be erected and allowed to stand so that the mortar, grout and cement can cure to full strength before being lifted in the same general manner as pre-cast concrete panels and transported and erected at the final site. Because the structures are made of blocks -using substantially conventional block laying techniques, the structures can be readily made to varying shapes and sizes according to specifications without the need for construction of special formwork or the likce, Also surface damage to a prefabricated structure can be readily repaired by cutting out the surface portior~ of a damaged block and refacing the block with an undamaged block face so that the repair is completely invisible and no structural integrity is jeopardized.

The completed prefabricated structure comprises multiple courses of building blocks, between some of which a reinforcing rod runs, the rod being embedded in mortar or grout so as to define with the rod a reinforced beam through the structure, the Gtructure *~:also including one or more generally vertical reinforced columns defined by a reinforcing rod 30 through a passage extending through 20 the entire height of the structure, the passage being filled with mortar or grout so as to define with the vertical rod a reinforced upright column.

At the upper ends of the reinforced concrete columns-there are provided lifters 50 coupled to the associated vertical reinforcing rods 30 so that lifting forces applied to the lifters are passed through the lifters to the respective vertical reinforcivg rods.

9***In Fig. 9 the structure 60 includes coupling means 61 for coupling the structure to a vertically abutting building structure 62. The structure 62 includes a female coupling 63 wihich is S 30 structurally united with the structure 62. In particular, the f emale coupling 63 has a plate 64 which is built into the structure so as to be co-planer with the top edge 65 of the structure 62. rkeinforcing rods 66 are welded to and extend from the plate 64 within the structure 62, the reinforcing rods 66 passing through holes in the blocks of the structure 62 and then being embedd---d in grout. The plate 64 includes an aperture 67 for receiving a male projecting portion 71 of the vertically abutting building structure 60. The aperture 67 opens into a bore which is defined by a sleeve 68 having a closed inner end 69. The sleeve 68 also projects into the holes in the blocks. The male projecting portion passes 71 through the aperture 67 into the sleeve 68 and can be grouted in that position to join the structure 62 to the vertically abutting building structure The male coupling 61 comprises a plate 70 which is located at the edge 72 of the building structure 60. Reinforcing rods 73 are welded to and projected from the plate 70 and are also embedded in grout in the holes in the blocks to structurally unite the male coupling 61 into the building structure 60. A projecting rod 71 which can also have an inner end 75 grouted into the building structure 60 projects beyond the edge 72 so as to be received and grouted within the female aperture 67.

In Fig. 10 there is shown a coupling channel 80 which in use is mounted in a face 81 of the structure 2. The coupling channel opens outwardly and has a restricted mouth 83 so that a nut or the like can be located within the channel and resist being drawn out through the mouth. The channel 80 has a reinforcing rod 84 welded to the base web of the channel section, the reinforcing rod 84 extending 20 beyond the ends of the channel being stepped inwardly at 85 so that the reinforcing rod 84 is located generally centrally within the thickness of the wall of the structure 82. The reinforcing rod 84 is embedded within grout within the panel 85 so that the coupling channel is united structurally to the structure. The channel may be similar to the known "Unistruts" used in precast concrete panels.

The blocks 11 used in erecting the structures may be generally conventional sized bricks having vertical holes 12 through the entire height, the holes being spaced from the brick ends so that holes in Sone block in one course align with corresponding holes in the courses 30 above and below. In the Fig. 2 possible embodiment of a structure having sound irsulating properties, each block 11 is provided with cavities 18 having openings 19 in the front face of the block, the cavities extending vertically through the entire height of the block. In plan view such a block 11 may be E shaped with the two cavities 18 having restricted mouths 19 opening to the front face of the block. The cavities 18 align when similar blocks are overlapped and laid in courses in conventional block laying fashion. The mouths 19 to the cavities enable sound impinging on the front face to penetrate the cavities 18 and be dispersed.

Fig. 6 shows an apparatus for handling prefabricated upright structures having variable shape in plan view, The apparatus includes a lifting frame 90 for placement over a prefabricated structure 91. The frame includes at least one longitudinal member 92 provided with at least two lifting points 94 for attachment to the upper portion of the structure 91. The longitudinal frame member 92 is extendable, preferably telescopically, so as to enable the separation between the lifting points 94 to be varied so that structures having variable shape can be lifted fromnt points of differing separation. The longitudinal member 92 is substantially rigid against bending transverse to its longitudinal extent, The frame 90 also includes a transverse member 95 which is also provided with at least two lifting points 94, one of which is a o lifting point provided on the longitudinal member 92 at the *intersection of the transverse member 95, the transverse member also '*being extendable, preferably telescopically, and being rigid against bending transverse to its length.

20 With this arrangement of frame, both longitudinal and transverse members 92, 95 may be telescopically adjustable so that at least three lifting points can be utilised to lift structures of variable shape.

U In the illustrated embodiment the lifting frame 90 is generally rectangular and all four edges 92, 93 95, 96 are telescopically extendable. Lifting points 94 may be provided at the four corners of *o the rectangular frame. This frame 90 is particularly suitable for lifting a prefabricated structure having a rectangular plan but of variable dimensions, such as a prefabricated lift well structure 91.

30 It will be seen that the present invention enables the prefabrication of brick or building block structures having greater ease of manufacture than precast concrete panels particularly for irregular or small job lots built to specifications. The structures have the insulating and aesthetic characteristics of bricks or blocks while having the required strength for structural purposes and for high rise buildings.

Although the description herein of the manufacturing process and structures made is directed to substantially closed shape structures such as C shaped or closed box shapes in horizontal section or plan view, the process steps and individual features of the structures can be applied to other building components such as individual panels, walls, and L shaped components. These other building components are not claimed in the present application, but such components and/or the process steps and/or the individual constructional features may be the subject of divisional patent applications.

It is to be understood that various alterations, modifications and/or additions may be made to the features of the possible and preferred embodiment(s) of the invention as herein described without departing from the spirit and scope of the invention.

a Soto

Claims

1. A prefabricated structure having upright walls composed of substantially horizontal courses of building blocks, the upright walls defining a substantially closed shape of the structure in horizontal section and courses of the building blocks extending around the contour of the walls in horizontal section, the structure including at least one reinforcing piece being located so as to extend between adjacent courses of blocks and being shaped to extend around at least a part of the contour of the walls between adjacent courses of building blocks, the reinforcing piece being embedded within grout so as to form a reinforced beam extending between adjacent courses and following the contour of the walls along the length of the reinforcing piece, the reinforced beam extending around the substantially closed shape of the structure, the structure further including a transverse reinforcing rod extending transverse to the lines of the courses of blocks and through aligned holes in ~the blocks of the courses, the transverse reinforcing rod being contained within a passage defined by the aligned holes, the passage being filled with grout so as to form an upright reinforced column, the generally horizontal reinforced beam and the upright reinforced column contributing to rigidity of the structure so that the structure can be transported from the site of its construction to another site for use.

2. A prefabricated structure as claimed in claim 1 wherein the upright walls define a completely closed ring in horizontal section, the horizontal reinforced beam being in the form of a closed ring t* between adjacent courses of blocks.

3. A prefabricated structure as claimed in claim 1 or 2 wherein the upright walls define a completely closed shape in horizontal section, *I*o 30 one of the upright walls having an opening therethrough which extends vertically over part of the height of that wall. Dated this 16th day of February, 1993 PATENT ATTORNEY SERVICES Attorneys for BARRIER ENGINEERING CONSTRUCTION CO PTY LTD ABSTRACT A prefabricated structure having upright walls composed of substantially horizontal courses of building blocks, the upright walls defining a substantially or completely closed shape in horizontal section. Reinforcing pieces extend between adjacent courses of blocks and are shaped to extend around the contour of the walls between adjacent courses of building blocks, the reinforcing pieces being embedded within grout so as to form a reinforced b' m extending between adjacent courses and around the closed contour of the walls. Transverse reinforcing rods extend transverse to the lines of the courses of blocks and through aligned holes in the blocks of the courses, the transverse reinforcing rod being contained within passages defined by the aligned holes, the passages being filled with grout so as to form upright reinforced coluins. The generally horizontal reinforced beam and the upright reinforced columns contribute to rigidity of the structure so that the structure can be transported from the site of its construction to another site for use. One of the upright walls may have an opening therethrough which extends vertically over part of the height of that wall.

4. •2 Reinforcing pieces which terminate along a wall are overlapped with r* continuation reinforcing pieces. e *4 f(C