AU693947B2 - Forming double skin wall - Google Patents

Description

i;La~ P/00/011 28/5/91 Regulation 3.2

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

rt r r rr rr r r r o r rr i r rr r r ro .i r 1~ i r TO BE COMPLETED BY APPLICANT Name of Applicant: LES VARGA Actual Inventor: Les Varga Address for Service: CALLINAN LAWRIE, 278 High Street, Kew, 3101, Victoria, Australia Invention Title: "FORMING DOUBLE SKIN WALL" The following statement is a full description of this invention, including the best method of performing it known to us:- I~~LrLI /2 FORMING DOUBLE SKIN WALL The present invention relates to a method of forming a double skin wall and relates particularly, though not exclusively, to a method of forming a cement based double skin wall for the construction industry.

In the building industry it is well known to form concrete walls by pouring concrete into a mould of the desired height to form a single wall. The mould will have reinforcement mesh located in the concrete. The problem with forming a wall this way is that it is difficult to have an insulation layer formed on the wall and there is no cavity for electric cables and similar integers. In addition a large amount of concrete is needed to pour a wall having the desired strength.

O 00 0 :0 °It is an object of the present invention to provide a method of forming a S double skin cavity wall.

r0 .0 A further object of the invention is to provide a wall requiring less concrete 0 0: than conventional solid walls.

With these objects in mind the present invention provides a method of o forming a double skin wall, said method including the steps of inserting a plurality of support rods into a mould, pouring a first curable or settable mixture into said 0: 0 mould with said support rods protruding from said mixture to form a first skin, 0 0 00 placing a layer of granular material on the surface of said cured or set mixture with said support rods protruding from said layer of granular material, pouring a second curable or settable mixture onto said layer with said second mixture forming a second skin and removing said granular material when said second mixture is cured or set, to provide an air gap between said first and second skins.

Preferably said layer of material has a predetermined depth and said second mixture covers the protruding ends of said support rods.

-2- 2515/98jb8053np,2 Preferably said support rods are attached at each end to a reir mesh inserted in said first and second mixtures.

In a practical embodiment said support rods are formed of met alloy and are welded to reinforcement mesh contained in said first a I skins, It is preferred that said skins are formed from a cement based I In an alternate embodiment said support rods are bolts whic through respective sleeves in said second skin. Preferably said skins ar spacers placed co-axially with said bolts to provide spacing between The invention also provides a wall formed by the abovemention 1j These and other objects and aspects of the present invention v ~0 fully described with reference to the preferred non-limitative embodirr inteaccompanying daiginwhc: I :~:Figs. 1 to 4 are cross-sectional views of the various stage embodiment of the method according to the invention fojr forming a wall; L~ 0:.Fig. 5 is a cross-sectional view of the~ double skin wall; and iforcement Eal or metal nd second mixture.

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ed method.

sill be more ient shown s of a first Jouble skin Figs. 6 to 9 are cross-sectional views of the various stages of a second embodiment of the method according to the invention.

Fig. 1 shows the first stage of a first embodiment of the invention. A mould or framework 10 is constructed to define the shape of the wall to be formed. Mould 10 can be constructed from wood or any other suitable material into a formwork of the desired configuration. In the example a plank or planks 1 2 -3- 25/5/981b8053.np,3 form an end wall and a stepped end wall 14. End wall 14 could be formed of a plank with a square section nailed thereto or be cut in that manner. The formwork is typically constrained by pegs (not shown) which are hit into the ground to support planks 12 and end wall 14. Longitudinal side walls (not shown) will complete the mould. Reinforcement mesh or rods 16 are located in mould 10 to provide strength and support for concrete 18 which is poured therein. Support rods 20 are welded to reinforcement 16 and protrude upwardly. Support rods may be any shape. The preferred embodiment has the support rod comprising a vertical member 22 with oppositely directed feet 24, 26. The length of feet 24, 26 can vary depending on requirements as is easily seen with foot 24A adjacent end wall 14. If, after concrete 18 is poured, optional insulation (not shown) in the form of a sheet may be pressed into the surface of the concrete or affixed with fasteners. Concrete 18 will form a first skin of the final wall.

Fig. 2 shows the second stage where a layer of sand 28 or other suitable material is placed on concrete 18 after it has set. The depth of sand is selected ~to suit the desired air gap between the two skins to be formed. Reinforcement 1 is welded to feet 24.

Fig. 3 shows the third stage where a wooden beam 32 is placed on sand 4 28 to provide a rebate for the second skin 34. Concrete is poured onto sand 28 to form the second skin 34. The concrete will cover reinforcement 30. When 4 1 4i concrete 34 has set the formwork comprising plank 12, beam 30, side walls and 4 end wall 14 may be removed.

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3 Fig. 4 illustrates the formwork having been removed. By tipping up the formed wall 38, sand 28 will drain out to leave an air gap 36 between skins 18 and 34. The two skins 18 and 34 will be linked and supported by support rods Fig. 5 shows the use of wall 38 in the construction of a building. Wall 38 is placed on a concrete slab 40 which has a rebate 42. In this embodiment the Send of skin 18 rests on floor 44 of slab 40 and skin 34 rests on rebate 42. The wall 38 can be secured to slab 40 in any conventional manner. A timber beam is secured to the end of skin 34 and has a roof truss 48 nailed thereto. No framework for the walls of the building will be required by using the method of the invention. The air gap 36 will provide an insulation between skins 18, 34 and result in a substantial reduction in the use of concrete as opposed to a solid wall.

For abutting walls 38 at right angles the corners may include rods (not shown) angling to the corners from reinforcement 16,30. The exposed rods from abutting walls 38 may be spotwelded to secure the walls together.

Additional formwork can be inserted in mould 10 to provide apertures for 4 door and window openings, where desired. The concrete mixtures in skins 18, 34 Scan be different.

:The second embodiment in Figs. 6 to 9 will now be described. Fig. 1 004* shows the first stage of this embodiment. A mould or formwork 50, similar to that shown in Figs. 1 to 4, defines the shape of the wall to be formed. Reinforcement 4 0 9 mesh or rods 52 are located in mould 50 and a plurality of upwardly extending 100440 bolts 54 are welded to reinforcement mesh or rods 52. Concrete 56 is poured into mould 50 to form a first skin 58.

20111/95JB8053.CAP5 Fig. 7 illustrates the second stage where an insulation layer 60 is placed on first skin 58. Reinforcement mesh or rods 62 are then placed in mould Sleeves 64 are welded to reinforcement mesh or rods 62 and slipped over bolts 54. A removable countersink mould 66 is also slipped over bolt 54 to rest on sleeve 64.

Fig. 8 shows the third stage where concrete 68 is poured into mould up to the level of mould 66, to form a second skin 70. Insulation layer 60 will bond to skin 70 to allow skins 58 and 70 to be separated from one another.

Fig. 9 illustrates the final stage where skins 58 and 70 are separated and split spacer sleeves 72 are slipped between the skins and to be co-axial with bolts 54. Mould 66 is removed and leaves behind a recess 76 for nut 74 to be threaded onto bolt 54. Nut 74 will be below the top surface of skin 70. A filler (not shown) can be inserted into recess 76 and sanded to provide a flat surface to avoid the S unsightly appearance of the nut 74 and bolts 54. The wall formed can be used in 1:5 a similar manner to that shown in Fig. Insulation layer 60 can be a permanent fixture to either skin 58 or 70 or S could act as a disposable release sheet. Nut 74 could be omitted and bolt 54 S could be welded to sleeve 64, if required.

It is believed that the invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various cnanges may be made in the form, construction and arrangement of the parts and that changes may be made in the form, construction and arrangement of the method described without departing from the spirit and scope of the invention or -6a a 'a' ie 20111/95JB8053.CAP.6 sacrificing all of its material advantages, the forms hereinbefore described being merely preferred embodiments thereof.

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Claims (13)

1. A method of forming a double skin wall, said method including the steps of inserting a plurality of support rods into a mould, pouring a first curable or settable mixture into said mould with said support rods protruding from said mixture to form a first skin, placing a layer of granular material on the surface of said cured or set mixture with said support rods protruding from said layer of granular material, pouring a second curable or settable mixture onto said layer with said second mixture forming a second skin and removing said granular material when said second mixture is cured or set, to provide an air gap between said first and second skins.

2. The method of claim 1, wherein said layer of material has a predetermined depth and said second mixture covers the protruding ends of said support rods.

3. The method of claim 1 or 2, wherein said support rods are attached at each end to a reinforcement mesh inserted in said first and second mixtures.

4. The method of any one of the preceding claims, wherein said support rods are formed of metal or metal alloy and are welded to reinforcement mesh contained in said first and second skins.

The method of any one of the preceding claims, wherein said skins are formed from a cement based mixture.

6. The method of any one of the preceding claims, wherein said support rods comprise a vertical member with oppositely directed feet at either end thereof.

7. The method of claim 1, wherein said support rods are bolts which protrude through respective sleeves in said second skin.

Sl 8 25/5/98jb8053.np,8 The method of claim 7, wherein said layer of material is a sheet or insulating layer of substantially less thickness than said first and second skins.

9. The method of claim 7 or 8, wherein said sleeves are placed over respective sleeves to rest on said layer of granular material before said second skin is formed.

1 0. The method of claim 9, wherein a removable countersunk mould rests on each sleeve.

11. The method of any one of claims 7 to 1 0, wherein said second skin is fitted and spacers placed co-axially with said bolts to provide spacing between S said skins.

012. A method of forming a double skin wall substantially as hereinbefore described with reference to the accompanying drawings.

13. A double skin wall formed by the method of any one of the preceding claims. DATED this 25th day of May, 1 998. LES VARGA By his Patent Attorneys: CALLINAN LAWRIE RA4 9- 25/198jb80 4 np.9 ABSTRACT The invention discloses a method of forming a double skin wall. The method includes the steps of inserting a plurality of support rods (20,54) into a mould (12,14,50), pouring a first curable or settable mixture (18,56) into said mould (12,14,50) with said support rods (20,54) protruding from said mixture (18,56) to form a first skin (34,58), placing a layer of material (28,60) on the surface of said cured or set mixture (18,56) with said support rods (20,54) protruding from said layer of material (28,60) and pouring a second curable or settable mixture (34,70) onto said layer (28,60) with said second mixture (34,58) forming a second skin (34,70). ,1 0 4 aI i a a St t 1 i 2011 195JB8053.CAP,10