AU7145200A - Precast concrete building system - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT 9r

I,

MANUFACTURING SYSTEM

FOR

PRECAST CONCRETE BUILDINGS *9 99*9 The following statement is a full description of this invention, including the best method of performing it known to me Manufacturing and assembly system for precast concrete buildings This invention relates to improvements in the methods used for manufacturing and erecting, precast and tilt-up concrete building components.

The design improvements relate particularly to the cross sectional profile of adjoining wall panels and the concealed devices that align, seal and secure them to one another and the concretefooting orfloor slab upon which they rest.

For clarity the document has been divided into two separate sections viz Section 1, Generally describes the invention and illustrates the various devices and components that are used in the manufacturing process ie: The profile of the various panel edges Theformwork used to create the profiles The weather and vermin proof sealing strips N U Gravity activated locking mechanism Wallpanel restraining anchors and hook bolts •Section 2, Describes a number of applications where the wall panels can be used with particular advantage in the residential housing industry and introduces a lightweight concrete, passive solar roofing system that can warm and cool a building at various times of the year and a polyethylene roof sheeting system for solar heating water.

Although the basic hardware used to manufacture and assemble panels for residential use would be similar to those for the "tilt up" system, the materials and finishes would be superior as the panels would be manufactured in afactory out of aerated, autoclaved, concrete.

The lightweight concrete panels can be usedfor a wide variety of residential applications including Internal walls only (substitutingfor conventional timberframe) A combination of internal wall and ceilingpanels.

Internal and external walls Internal and external walls with flat or raking ceilings Two storey applications, including structuralfloorpanels Passive solar roofpanels.

Polyethylene roof sheeting system with solar water heater Panels can be manufactured to a diverse range of textures and finishes Internal walls Hardplaster o Lightly textured External walls o Rendered o Imitation stone o Imitation brick a Weatherboards EDITORIAL NOTE No. 71452/00 Pages 2 to 5 are claims pages Manufacturing system for precast concrete buildings To assist with understanding the invention, reference will now be made to the accompanying drawings that illustrate one example of the invention.

Figure 1 is a plan view of a cross section taken through a typical straight wall panel junction, about Im above the floor slab.

The sketch illustrates the matching profiles (male female) of the adjoining panel vertical edges, and shows how they interlock following the assembly process.

The basic geometry of the joint surfaces provides lateral restraint and automatically aligns the finished faces of the adjoining panels.

You can also see the fluted plastic strips (fitted into the semicircular recesses of the female formwork) that are brought into contact with the salient angles of the adjoining panel to form a weather and vermin proof seal during the erection process.

The profile is achieved by using pressed metal or extruded plastic formwork (as illustrated in figures 3 and 4) that is permanently attached to each wall panel.

The formwork not only guarantees the accuracy of the panel edge profile and ensures that the lock mechanism is held in the correct position during concrete placement but will protect the edges from damage.

Pressed metal or plastic edge formers permanently attached to wall panel Insert fluted plastic weather strip to recess in cast wall profile Aerated autoclaved concrete wall panels Figure 1 Straight wall connection detail Manufacturing system for precast concrete buildings Figure 2 is a plan view of a cross section showing the profile of adjoining wall panels prior to their assembly and shows the male and female components of the concealed gravity activated locking devices that secure the panels together during the erection process.

The locking devices are attached to the respective slab edge formwork in the factory and become permanently secured to the concrete wall panels by a number of deformed bars whose ends have been cogged so that they become embedded into the concrete.

The number of locking pins that would be required for a particular panel would depend on the height of the panel and the loads or forces to be applied and would be determined by a structural engineer, during the detailed design stage.

Further detail of the locking pins is provided in figure Finished face of panel Gravity activated locking mechanism Sfemale conponent a.

a tivated locking mechanism male component Figure 2 Cross sectional profile ofadjoining wall panels showing concealed gravity activated locking mechanism components Manufacturing system for precast concrete buildings Figure 3 is a cross sectional profile through the vertical wall edge formwork, (female) showing a gravity activated locking pin keeper, attached.

The sketch also shows the grub screws that are used to attach the locking pin keeper to the formwork in the factory.

The outer extremities of the formwork have been perforated and folded back at an angle of degrees, so that they become permanently embedded into the concrete during the casting process.

You can also see the semi circular recesses that are used to hold the fluted plastic weather and vermin proof strips in place prior to the assembly process.

The edge formers can be manufactured of pressed metal or extruded plastic, depending on the corrosive nature of their environment.

Formwork remains part of panel Face of precast concrete panel Attach ocking pin keeper End of formwork perforated to formv ork with grub screw to permanently secure to wall p nel Galvanised, pressed metal formwork Figure 3 Section through female panel, edge formwork with gravity activated locking pin keeper attached Manufacturing system for precast concrete buildings Figure 4 is a cross sectional profile through the vertical edge wall former, (male) showing the gravity activated locking pin attached.

The sketch also shows the grub screws that are used to attach the locking pin keeper to the formwork prior to placing the concrete.

The outer extremities of the formwork have been perforated and folded back at an angle of degrees, so that they become permanently embedded into the concrete during the casting process.

You can also see the salient angles of the protruding ribs that will compress the fluted plastic sealing strips located in the semi circular recesses of the female panel.

The edge formers can be manufactured of pressed metal or extruded plastic depending on the corrosive nature of their environment.

4* 4 S 4 Formwork remains part of panel Galvanised, pressed metal formwork Section through male panel, edge formwork showing gravity activated locking pin attached Manufacturing system for precast concrete buildings Figure 5 illustrates the gravity activated locking device (that is concealed within the internal recesses of the cross sectional profile of each wall panel) that progressively draws the panels closer together during the assembly process.

One version of the connecting device is made up of two components, a tapered pin and a square hollow keeper (refer figure The tapered pin is 150mm long section of 19mm square hollow tubing that is fitted inside a 75mm long piece of 25mm hollow tubing.

One end of each piece is placed so that it is flush with the other so that 75mm of the 19mm square tubing protrudes beyond the end of the 25mm section. The outermost portion of the protruding section is then squeezed on each of its four faces to form a taper that extends for two thirds of its length (refer illustration below).

A piece of flat mild steel with a 10mm thread is welded to the bottom of the keeper that will be located closest to the top of the wall panel to accommodate a bolt for final fastening.

Each component of the connection device are attached to their respective formwork hosts with grub screws prior to placing the concrete and are permanently attached to the concrete wall panels by deformed bars that have had their ends cogged.

Figure 5 illustrates the various components of the gravity activated locking device and shows it before and after assembly.

4 II II I I I I I I I I II II I

II

ELEVATION OF ASSEMBLED UNIT PLAN VIEW PLAN VIEW 10mm dlam bolt x160mm long 25mm square tubing x 75mm long Deformed il l i II :I I II I 19mm square tubing x 75mm long welded Inside 25mm tube and crlpped to form 10.5mm dlam hole In base 25mm square tubing x 75mm long with 10mm diam threaded washer Deformed welded Inside base EXPLODED ELEVATION OF ASSEMBLED LOCKING PIN WITH RETAINING BOLT 11.

Manufacturing system for precast concrete buildings Figure 6 is a plan view, section and end elevation of the male and female wall panel edge profiles Elevation of vertical edge of male panel Elevation of vertical edge of female panel Section through female panel edge form Section through male panel edge form Plan view of male panel Plan view of female panel Figure 1 (b) Plan, section elevation of male female panels 12.

Manufacturing system for precast concrete buildings Figure 7 is an isometric projection of a typical wall panel (not to scale).

The diagram shows the interlocking profile of the panel edge together with the male section of the concealed, gravity activated locking device that has been secured to the panel during the casting process.

The tapered pin that engages with the corresponding keeper on the female panel is clearly visible.

As you will see a steel washer has been located on the top end of the uppermost connector to accommodate the 10mm anchoring bolt that permanently secures the panels together following the assembly process (also refer figure 4).

The elliptical voids that provide access for plumbing and electrical services are also clearly visible on the top of the panel.

You can also see the salient angles that come into contact with the compressible plastic tubes and form the weather and vermin proof seals during the assembly process.

Typical wall panel end elevation showing interlocking profile and concealed locking device Manufacturing system for precast concrete buildings 9 9 9 99*9 Figure 8 is a cross section taken through the junction of the external wall panel and the slab edge rebate and perimeter footing upon which it rests.

The drawing illustrates the cross sectional profile of the bottom edge of the external wall panel and shows how the outermost inclined surface has been extended downward to provide a drainage outlet for any moisture that may accumulate within the slab edge rebate.

Purpose made metal formwork will be used to create the slab edge profile and hold the wall panel retaining devices securely in place during the casting process.

The fluted plastic, weather and vermin sealing strips are also visible in the semicircular recesses on the internal face of the panel edge.

Insert fluted plastic weather seal to recesses Form double bevelled rebate to bottom of aerated, autoclaved wall panels.

Form double bevelled rebate to slab edge Typical slab edge connection detail Manufacturing system for precast concrete buildings Manufacturing system for precast concrete buildings Figure 9 is a cross section taken through the bottom edge of an external wall panel and clearly shows the shape of the formwork used to achieve the finished profile.

The sketch illustrates how the outer inclined surface has been extended downward to allow the drainage of any moisture that may accumulate within the slab edge rebate.

As with the wall edge formers, the outer extremities of the bottom edge formwork have been perforated and folded back at an angle of 45 degrees so that they become embedded into the concrete and permanently attach the formwork to the panels.

The metal or plastic formwork will protect the edges from damage during handling and transportation.

0* 9 @9 9.

9 @9 9 @999 9

I

I

Il Line of finished faces of panel Ends of formwork perforated to permanently secure to panel Recesses for fluted plastic weather vermin proof strips 16/

I

Pressed metal formwork Detail of pressed metal formwork for tilt up concrete panel, external wall, bottom edge Manufacturing system for precast concrete buildings Figure 10 is a cross sectional profile of the perimeter strip footing and floor slab formwork.

The formwork is made of heavy gauge pressed metal and incorporates escape holes in the apex of the protruding ribs to release any air bubbles that may have become entrained during the concrete placement and vibrating process.

The sketch illustrates how the slab edge formwork will mould the profile of the concrete to match the bottom edge of the adjoining wall panel.

Grub screws will be used to secure the wall panel restraining brackets to the formwork prior to placement of concrete. The location and frequency of the restraining wall anchors would depend on the length of wall panel involved and be specified during the detailed design stage.

The formwork would be suitably braced to resist the loads applied during the placement of concrete.

V V

V.

0 000 V

V

22 guage galvanised pressed metal formwork and stiffening panel with brackets for steel pegs

F

Top of slab 6mm diam holes to evacuate air during concrete placing and vibrating -7/ Attach wall panel retaining anchors to slab edge formwork with grub screws

S.

S

SODS

5*5*

S

OSVS

Pressed metal wall panel retaining anchors cast into floor slab at predetermined intervals Typical slab edge formwork showing wall panel retaining anchor 16.

Manufacturing system for precast concrete buildings Figure 11 provides detail of the wall panel, restraining anchor that is cast into the floor slab to provide a means of securing the wall panel to the floor slab.

The retaining anchor is attached to the perimeter formnwork at predetermined intervals (depending upon the length of the wall panel being placed) prior to placing the concrete.

A pair of deformed bars with cogged ends attached to the underside of the restraining anchor, permanently secures them to the floor slab and resist any physical or mechanical loads that may be applied (via wind etc).

Once a wall panel has been attached to its neighbour and is resting on the slab edge rebate, it is secured to the restraining anchor in the following way. The hook bolt is firstly manoeuvred so that the hook bolt engages with the high tensile pin located in the bottom edge of the keeper closest to the floor slab. The turnbuckle is then rotated so that the thread is extended enough to allow the V shaped head to pass between the angular faces of the retaining bracket.

The V shaped bolt head is then turned at right angles so that the wings of the bolt head fit under the inclined surfaces of the retaining anchor. The turnbuckle is then tightened and as *the bolt becomes shorter, the V shaped head is progressively moved closer to a vertical position directly beneath the hooked end and locking keeper.

The turnbuckle is progressively turned until the required tension is reached.

The wall panel is now permanently secure and the restraining mechanism will be concealed within the joint as the next wall panel is placed.

Gravity activated Iockin& mechanism keeper *.**with diagonally located, high tensile retaining pin Hgh tensile retaining pin Hook Bolt Right hand thread High tensile retaining pin Left hand thread 4 Tumbukie ~recessed metal keeper V shaped bolt head Plan view of square hollow section with high tensile retaining pin [eformed retaining bars Universal retaining anchor and hook bolt 17.

Manufacturing system for precast concrete buildings Figure 12 is a cross sectional profile of an internal wall showing the devices used to locate it and restrain it to the floor slab.

The retaining strip is made of heavy gauge steel and is attached to the floor slab with dyna bolts.

Strategically located penetrations provide access for the installation of the standard hook bolts to enable the free end of the wall panel being placed to be secured to the floor slab.

Mastic would be applied to the underside of the retaining strips to seal any gaps and the salient angles of the inverted angles would make contact with the fluted plastic strips located in the semi circular grooves in the bottom edge of the wall panel to complete the seal.

Each of the retaining strips would be purpose made for each particular wall panel and clearly marked and cut to length in the factory prior to delivery to maintain accuracy and reduce on site erection time.

*Squr holl w section *Ul" recessed matal bolt head Sof floor slab Dyna bolt to floor slab Pressed metal floor guide and retaining strip 18.

Manufacturing system for precast concrete buildings Figure 13 is a cross section through an internal wall bottom edge former.

The profile is similar to the corresponding external panel, bottom edge former with the exception that the protruding ribs are of equal height.

The profile also incorporates semi circular recesses for the fluted plastic sealing strips and has its external edges folded back and perforated to allow them to become embedded in the concrete panel during the casting process.

Finished faces of wall panel I Ends offorwork perforated Semicircular recesses and folded so that it is permanently for plastic weather proof strips embedded in bottom cf concrete panel I I Pressed metal bottom edge former Section through bottom of internal wall formwork 19.

Manufacturing system for precast concrete buildings Figure 14 is a cross sectional profile of the bottom, gravity activated wall panel locking mechanism with the wall floor retaining anchor and hook bolt attached.

The illustration shows the fully assembled joint and an exploded view.

For clarity, the surrounding wall and floor sections have been omitted.

This combination is used to secure all of the Wall Footing, wall, Floor slab and wall Ceiling or Roof panels.

S. Elevation Elevation

U

I

e Exploded view Elevation of gravity activated locking mechanism and wall floor restraining anchor and hook bolt Manufacturing system for precast concrete buildings Figure 15 is a plan view of a typical, right angled wall junction.

The sketch illustrates the cross sectional profiles of the respective wall panels and shows the location of the gravity locking system and the fluted plastic weather and vermin seals.

As for the straight wall junction, (refer figure 1 2) the uppermost gravity activated locking pin has provision for the installation of a retaining bolt to make the joint fast and secure the panels firmly together.

The panel with the female cross sectional profile would be placed first and be secured to the concrete slab using the universal anchor as described in figures 15 and 17.

The sketch also shows the location of the service ducts to accommodate plumbing and electrical items.

Most of these junctions would involve internal walls that would be secured to the floor slab using the alignment and retaining strips illustrated in figure 12.

21.

Manufacturing system for precast concrete buildings Figure 16 illustrates a plan view of a typical external corner and shows the cross sectional profile of the adjoining panel edges.

The sketch illustrates a panel that incorporates imitation quoins as an architectural feature on the corner of the wall panels.

As with all other panels the cross sectional profile conceals the standard gravity activated locking mechanism and the semi circular recesses for the fluted plastic weather and vermin sealing strips.

In the situation illustrated the right hand panel (female) would be erected first and once in position would be fastened to the floor slab at each end using the universal retaining anchor and hook bolt system as illustrated in figures 11 and 13.

Temporary props would be required to brace the first panel erected and could be removed as soon as the adjoining wall panel had locked in place.

Immitation quoins to ouside corner face of panel L Service ducts Fluted plastic vNeather and vermin strips Concealed, gravity activated locking mechanism Reinforcing fabric shown dotted Typical plan view of external corner connection detail Manufacturing system for precast concrete buildings Figure 17 illustrates a plan view of the edge formwork for an external comer male panel and shows the gravity locking mechanism keeper.

The sketch shows how the extremities of the formwork have been folded back at 45 degrees and perforated so that they become permanently embedded into and attached to the panel.

The sketch also illustrates the grub screws that attach the locking mechanism to the formwork prior to concrete placement.

Deformed bars attached to the rear of the keeper (omitted for clarity) have their ends cogged to secure the keeper to the concrete wall panel during the casting process.

Attach locking pin keeper to formwork with grub screw Ends of formwork perforated to permanently secure to panel Details of pressed metal formwork vertical edge, external corner, male profile Manufacturing system for precast concrete buildings Figure 18 illustrates a plan view of the edge formwork for an external corer female panel and shows the gravity activated locking pin.

The sketch shows how the extremities of the formwork have been folded back at 45 degrees and perforated so that they become permanently embedded into and attached to the panel.

The sketch also illustrates the grub screws that attach the locking mechanism to the formwork prior to concrete placement and the semicircular recesses that hold the fluted plastic sealing strips.

Deformed bars attached to the rear of the keeper (omitted for clarity) have their ends cogged Ends of formwork perforated to permanently secure to panel I t Attach locking pin keeper to formwork with grub screw Recesses for fluted plastic weather vermin proof strips Line of finished faces of panel Details of pressed metal formwork, external corner, vertical edge, female profile to secure the keeper to the concrete wall panel during the casting process.

24.

Figure 19 Custom orb roof sheeting scremed directly to ceiling panel Construction details of house With raking ceilings Manufacturing system for precast concrete buildings SECTION 2 Figure 20 on the preceding page, is a cross section of a house in which all of the internal and external walls and ceilings panels are made of, aerated, autoclaved, precast concrete panels.

The drawing shows how each of the panels join together using the manufacturing, fastening and sealing system described on the previous pages.

All of the panels used would be manufactured off site in a factory to a standard shape, form and finish before being transported to the site.

The concrete slab would have been poured using the standard rebated edge formwork also previously described in this specification.

!The panels would be loaded onto the delivery trucks and placed in racks containing timber mouldings to protect their bottom edge profiles. A crane would be used to lift the panels into position carefully following the predetermined assembly sequence previously described.

The erection process begins with the placement of an external panel on the furthermost corner of the site. The first panel would be lifted into position and carefully lowered to rest on the protruding ribs of the perimeter slab edge rebate. Once adjusted for lateral alignment with the adjoining corner panel (using the gauge provided) the panel would be bolted to the floor slab using the standard restraining anchors and hook bolts provided. The panel would then be temporarily braced and the lifting bridle removed.

The crew would then attach the crane to the adjoining corner panel and manoeuvre it into position above the upstanding ribs of the slab edge rebate and slowly lower the panel tso that the gravity activated locking pin engaged the keepers. Once in position the uppermost locking pin would be made fast by inserting and tightening a bolt and the free end of the panel would be secured to the floor slab (using the restraining anchors that had been already cast into the floor slab) using the hook bolts provided.

At this point the panels become self supporting, as they are firmly secured to one another and the concrete floor slab on which they rest and therefore require no additional bracing.

The erection sequence would proceed with the placement of progressive internal wall panels to complete the first room. Before these panels can be erected the site crew would need to place and secure the pressed metal locating and restraining strips that are shown in figure 12.

As with the external walls, the internal wall panels would be lifted and manoeuvred into position over the upstanding ribs of the restraining floor strips and gradually lowered to engage the gravity activated locking mechanism. The hook bolt would be manoeuvred and hooked onto the high tensile pin located in the bottom end of the female gravity activated mechanism keeper and the V shaped bolt head inserted into the restraining anchor attached to the floor slab and the tightened to the required tension.

This process would be continued until all of the panels have been placed.

Manufacturing system for precast concrete buildings One of the greatest advantages of the system described is the speed of erection.

This is achieved by manufacturing the panels to a high degree of accuracy and quality in a controlled environment using purpose made forms.

It is envisaged that there would be a number of panels that would become standard enabling a multitude of different house designs and configurations to be achieved using a minimum number of different panels.

The system also has the flexibility to be used for a multiplicity of uses such as Internal walls only Internal and external walls roe* N Flat ceiling panels SRaking ceiling and structural roof panels fee.

o6, An example of such a building has been illustrated in figure The drawing shows the manner in which the structural ceiling panels interlock with the top •edges of the supporting wall panels using minor variations of the inverted v profile. They are fastened in position using the restraining anchor and hook bolt system previously described in this specification.

As with the standard male and female wall profiles, the fluted plastic strips provide a barrier against weather and vermin and are protected by their internal location from physical and mechanical damage.

Erection of the panels follows a predetermined sequence with the lateral restraint (or sliding action of the structural ceiling panels being provided by the locking pins cast into the apex of each of the ceiling panels.

A timber or metal fascia would be screwed directly to the outer edge of the trimmed end of the structural ceiling panel and a roof gutter attached.

Metal roof sheeting with an appropriate vapour barrier would be screwed directly into the structural ceiling panel using proprietary fasteners. The roof would be completed in the traditional fashion using standard sheet metal trimming and flashings.

Alternately battens could be screwed directly onto the structural ceiling panels and a conventional tiled roof provided.

27.

Manufacturing system for precast concrete buildings Figure 21 is a section drawn through the assembled precast concrete house and illustrates a solar heating and cooling system that can be incorporated into buildings that use the structural ceiling and roof panels.

As indicated, each of the structural ceiling and roof panels incorporate a series of hollow tubes (elliptical in shape) that run the full length of the panel to provide access for plumbing and electrical services.

These voids could also be used as solar ventilation ducts and the heated air expelled to cool or captured to heat the house.

In one example of the invention, the ventilation ducts would be turned downward so that they •penetrated the face of the panel in the area adjacent the eaves and terminate in a plenum chamber formed at the ridge (refer sketch below).

A vapour barrier (sisalation 450 or similar) would be placed over the roof panels and colorbond roof sheeting fixed directly to the upper surface of the structural roof panel.

As the air in the ventilation ducts becomes heated by the radiant energy from the sun, it expands and gradually rises up the ducts. Replacement air would enter the void through the aperture in the panel under the eaves and journey inside the panel to escape through the aperture adjacent the ridge. This heated air would be collected in the plenum chamber and a thermostat and climate control would determine whether the hot air would be evacuated to 0 0 the outside on hot summer days or be pumped into the house during the cooler days of autumn, winter or spring.

Removable covers would keep the ducting vermin proof and facilitate seasonal cleaning.

Plenum chamber Rolled colorbond roof sheeting to barrel vaulted plenum chamber This fan evacuates hot air in summer Tapered locking pin installed Colorbond flashing to secure solar roof panels at apex Cisalation 450 orbond fsimilashing Sisalation 450 or similar L ,V-c Standard restraining anchor and hook bolt Cross section through solar roof panels and plenum chamber Manufacturing system for precast concrete buildings Figure 22 is a cross section drawn through the junction of an external wall and the structural, solar roof panel assembly at the eaves. The sketch illustrates how air enters the ducts through the underside of the structural solar roof panel adjacent to the eaves and journeys up the sloping ducting toward the ridge.

Colorbond roof sheeting 125mm colorbond D Plasterboard cornice to wall ceiling junctions Ceiling panels connected to wall panels using standard retaining anchor and hook bolt Cool air is drawn into ducts as air heated in ceiling panel rises 0 0 Detail of eaves treatment for solar heating and cooling system for pre cast concrete buildings Figure 23 is an elevation of the ridge end of a typical structural solar roof panel and shows the elliptical shaped voids, the roof sheeting connection detail and the gravity, mechanical or manually activated locking mechanisms that would be used to secure adjoining panels.

These panels would be joined at the ridge using the typical interlocking profile illustrated in figure 19 and secured by a hand placed locking pin identical to the pin described in figure The panels would also be secured to their supporting walls using the typical connection illustrated in figure 11, with a combination of mechanically and manually activated locking pins.

Colorbond roof sheeting screwed directly to solar roof panel Vapour barrier (sisalation 450)/ Fluted plastic weather Eliptical shaped air ducts and vermin sealing strips Universal locking mechanism keeper End elevation of solar roof panel Manufacturing system for precast concrete buildings Figure 24 is a cross section drawn through a number of structural, solar roof panels that have been joined together using the universal interlocking profile and locking mechanism, adjacent to the ridge.

The sketch shows the rebated section of the panel that has been removed above the elliptical shaped ducting and the remaining lower section that will form the floor of the plenum chamber.

The interlocking profile of the adjoining panels and the locking mechanism that secur them together are also visible.

The solar roof panels could be manufactured in a range of widths depending on the width of the rooms below.

The semicircular plenum chamber panels may also be manufactured in various widths and lengths.

Figure 21 also includes a longitudinal section through a typical structural solar roof panel and shows the rebated section that has been removed to form the plenum chamber.

Trim end at fascia Longitudinal air duct Connection detail at ridge showing RHS keeper f j Longitudinal section through solar roof panel Eliptical voids cast in panels Typical gravity activated locking mechanism C C C c: 2k 1 <Z C End elevation of solar roof panels Manufacturing system for precast concrete buildings Figure 25 is an elevation of a typical solar panel roof showing how the panels are assembled and connected together at the hip.

The sketch shows the elliptically shaped ducting and the section of the panels that have been removed along the top edge adjacent to the hip to form a small plenum chamber.

For clarity the sketch has been drawn to separate the lower section of the roof panels from the fascia to illustrate how the hinged, fly proof panels align with the ventilation ducting.

The panels will be joined to one another and attached to the walls upon which they rest using a combination of manually and mechanically activated locking devices similar to those illustrated in figure 27.

Solar heated air expands and rises up the toward the ridge and cool air enters the di the fascia to take its place I _I Pressed metal fascia with fly proof vents and sliding fire shutter Elevation of solar roof panels at hip Manufacturing system for precast concrete buildings Figure 26 is a cross section of a pressed metal fascia that has been designed for use with the lightweight concrete, solar panels.

The fascia is attached to the roof panels by inserting the bottom edge into a circular recess that has been formed in the under side outer edge of the panel during the casting process.

The fascia is then rolled so that the top edged rests on top of the outer edge of the roof panel and screwed into place.

The fascia has a series of removable, perforated, sliding panels that align with the hollow ventilation ducts (elliptically shaped) located in the centre of the solar panels. The profile of the removable sliding shutter, incorporates semicircular ribs around its perimeter to accommodate fluted plastic strips that will be used to secure the flywire into position.

Colorbond roof sheeting Rolled metal fascia panel Metal fascia retained in groove in base of structural roof panel Pressed metal fascia with removable fly screen and sliding fire panel Manufacturing system for precast concrete buildings Figure 27 is a cross section of another version of the metal fascia described in figure 26 in which the ventilation air intake is located under the soffit.

This is achieved by leaving the ends of the solar roof panels square and extending the fascia as illustrated.

This arrangement may be particularly suited to extremely hot climates where the air under the eaves is in the shade and therefore cooler and the ventilation shutter is better protected from the weather.

.i Although the fascia profile is different the sliding ventilation shutter would be exactly the same and be interchangeable with the previous version.

Colorbond roof sheeting Roof sheeting fixed directly to solar roof panel 125mm D gutter

Q

0 ,1 0.

Rolled metal fascia 1 Elongated slots in fascia to retain sliding shutter Perforated ventilation shutter with fly screen Air entres Pressed metal fascia with removable fly screen version 2 Manufacturing system for precast concrete buildings Figure 28 is a section and elevation of the hinged fascia panel.

The panel is attached to the pressed metal fascia by forming a series of circular hollow crenellations along the upper edge of the ventilation panel.

The hinged panel is then manoeuvred so that the hollow sleeves slide onto the corresponding fixed wire pins that have been inserted into the rolled hollow crenellations located along the top edge of the cut out section of the metal fascia.

The bottom edge of the hinged panel has also been rolled back to form a spring clip that secures the panel to the lower protruding rib on the fascia.

A perforated clip on shutter, similar in section to the hinged panel (refer sketch) which has its top and bottom edges rolled into a three quarter circular shape of a diameter that enables it to fit snugly over the semicircular ribs of the hinged panel. Once clipped onto the hinged panel, the shutter is able to slide sideways so the solid sections of the panel cover the perforation in the hinged panel (refer sketch below).

0 0.0.

0 000.

TI

Fluted plas SFlywire Fluted pl; Bottom section of hir pressed metal crennelations fit into slots in fascia and retain top of panel and facilitate sideways movement to allow perforations to be covered I-I E] I-1 -1 E1 -1 sticbQ gbin ;ed panel folded to form spring clip

[C~EEEEEEE

Cross section and elevation of sliding ventilation panel Manufacturing system for precast concrete buildings Figure 29 is an elevation of typical external corner arrangement of a hip roof using solar panels and the pressed metal fascia with sliding fly proof panel. The sketch illustrates how the roof gutter fits onto the uppermost stiffening rib and affords some overhanging protection from rain beating against the hinged panel.

The sketch illustrates the manner in which the bottom edge of the hinged panel has been folded back to form a clip that will secure the hinged panel to the lower stiffening rib on the pressed metal fascia.

The sketch also illustrates how the optional sliding shutter will be attached to the hinged panel and used in time of dust storms or bush fires.

0* Roof sheeting fixed directly to solar roof panel 125mm D gutter Removable ventilation panel with fly wire screen 000000d0o0000000000000000000 0000000000000000000000000000 0000000000000000000000000000 000000000000000000OC00000 0000 Rolled metal fascia panel Pressed metal fascia with removable fly screen sliding fire shutter Manufacturing system for precast concrete buildings Figure 30 shows the construction details of the manually and mechanically activated locking devices. These are used in situations where it is not possible to use the standard gravity activated locking mechanism ie where the placement of a panel requires a compound or multi directional movement to place it in its final resting place. A typical situations includes the placement of solar roof panels where the panel rests upon the v shaped protrusions located on the top of the supporting walls and then must be moved sideways to close the joint.

Manually activated locking pins would be inserted in the top (adjacent to the ridge) and the bottom (adjacent to the fascia) RHS keepers and driven into place. A bolt would be inserted and tightened to make the joint fast.

To secure the mid section of the panels the mechanically activated locking pins would be engaged by placing a spanner onto the recessed hexagonal headed bolt in the recess provided and the pinion turned to move the rack and attached locking pin into the Rhs keeper on the female panel.

*c *c 0 69 .9@

S

RHS metal keeper with threaded base attached to female panel 9 *5 a 9*S* r. a 0S.6 Tapered locking pin attached to RHS keeper on male panel and activated by rack and pinion mechanism extended to finish flush with face of panel Mechanically activated locking mechanism Tapered pin installed manually and secured with hexagonal bolt RHS metal keeper with threaded base attached to female panel RHS keeper attached to male panel Manually activated locking mechanism Typical locking mechanisms for joining panels 6 36.

Manufacturing system for precast concrete buildings Figure 31 is a cross section through a typical two storey house in which all of the wall, floor and roof panels are manufactured of precast concrete.

The sketch shows how the panels are assembled and connected to one another.

Plenum chamber This fan evacuates SI hot air in summer Cross section through two storey house showing construction detail 37.

Manufacturing system for precast concrete buildings Figure 32 shows the connection details of the external and internal wall floor, wall roof panels and the devices used to fasten them togethe Uppel section extral wall

T

showi rpical pl ig univ ri#eer wall footing profile r c lking mechanism keepers slabs Precast loor slabs AA. A A. A.

slabs Cross section through two storey house showing construction detail k. 4 Manufacturing system for precast concrete buildings Figure 33 is an illustration of a polyethylene roof sheeting system that incorporates a solar water heating device.

In the system illustrated, the profile of the sheeting is similar to custom orb and contains a series of split hollow pipes that are integrally formed during the extrusion process.

The split tubes would be connected together at the fascia end of the sheeting using injection moulded fittings that would be thermo welded to the sheeting. The split tubes would be connected to a split pipe at the ridge end of the sheeting using tee shaped, moulded split fittings.

Cold water would be pumped through the bottom section of the split tube via the split tube manifold and travel down the roof sheeting toward the fascia. The water would transfer to the top section of the split tube incorporated in the roof sheeting adjacent to the fascia and be further heated as it travels up the tube toward the ridge end of the roof sheeting.

The hot water would enter the top half of the split tube piping via the tee fittings at the ridge and be conveyed back to the storage vessel.

The circulating pump would be thermostatically controlled and turn off during the night to avoid heat loss.

This system could be used for providing hot water for general domestic uses, showers dish and clothes washing or for floor slab heating, depending on the storage capacity and the environment it is used in.

Profile compatible with custom orb Roof sheeting attached to supports using proprietory fasteners in crests of flutes without splittubing Extruded polyethelene roof sheeting to incorporate split pipe system Cross section through sheeting showing location of split pipe ql Coa HaW 4- Cod XW rr77r-,-,*A rr---v- Split pipe return end cap Longitudinal section through split pipe collector Split pipe tee connector Polyethylene roof sheeting with split pipe solar collector 4 Manufacturing system for precast concrete buildings The features and benefits that result from this invention are as follows 0 Lower cost Consistent, high quality finish a Unlimited range of external wall textures, colours and finishes.

Reduces on site construction time S: Minimises the amount of trades required.

Minimises construction waste and on site rubbish and debris As the building is manufactured entirely of concrete o Floor slab and footings a Internal and external wall panels 13 Ceiling panels o Roof panels It is fire proof.

There are minimal skills required to assemble the building o (installation of locking pins and bolts).

Preserves natural resources The building is energy efficient.

o Thermal capacity of aerated autoclaved concrete walls is high o Passive solar roof panels will reduce energy demand Therefore heating and cooling costs will be lower.

The system has universal application and can be used for an enormous range of buildings from agricultural, public, residential, commercial and industrial.

EDITORIAL NOTE No. 71452/00 The claims are on pages 1 to EDITORIAL NOTE No. 71452/00 The claims are on pages 2 to

Claims (2)

1.1 A system for manufacturing pre cast or tilt up concrete wall panels, that uses pressed metal or extruded plastic formwork to create an interlocking profile that will retain and conceal the devices used to secure and seal the panels to one another and thefloor slab orfootings, upon which they rest. 1.2 The formwork described in claim no 1.1, wherein the formwork becomes permanently attached to the concrete panels to protect the edges from damage and to ensure that the various components of the gravity activated locking device are retained in their correctposition duringplacement of the concrete. 1.3 The formwork described in claim no 1.1, whereas a tapered square hollow pin (male) and square hollow keeper (female) form the respective components of the gravity activated locking mechanism 1.4 The formwork described in claim no 1.1, which contains semi circular recesses """designed to retain the fluted plastic sealing strips that will be brought into contact with the salient angles of the corresponding wall panel profile during the erection process, to prevent weather and verminfrom passing between the adjoining edges of the wallpanels. The formwork described in claim no 1.1, wherein a variety offloor slab retaining anchors and hook bolts are used to attach and fasten the wall panels to the floor slab andperimeterfootings on which they rest. 1.6 Theformwork described in claim no 1.I, whereas the basic interlocking profile has been adapted and slightly modified to enable the various wall, ceiling, secondfloor and roofpanels to be secured and sealed to one another. Manufacturing system for precast concrete buildings SECTION 2, A PASSIVE SOLAR ROOFING SYSTEM (for heating air and water).

2.1 A lightweight concrete roofing system that uses precast concrete panels manufactured by a process similar to that described in claim no 1.1, in which a series of hollow tubes running the entire length of the panel are used to convey air and ventilate the panel The air enters the ducting through perforated screens located in theface of a pressed metalfascia and travels up the inclined ducting to a plenum chamber adjacent to the ridge. 2.2 A lightweight concrete roofing system as described in claim no 2.1, in which a portion of the top end of the panel, on either side of the ridge (above the hollow tubes (elliptical shaped ducting) has been removed to form a rebate, that becomes the floor of a plenum chamber created by attaching semicircular lightweight concrete panels to the top edges of the roofpanels (referfigure 19). 2.3 A passive solar roof panel as described in claim 2.1. in which the panel edges are moulded using similar formwork to that described in claim 1.1 and 1.3 and the panels are connected to one another and their supporting walls using a range of gravity, mechanically or manually activated locking devices similar to those described in claims 1.3 and 2.4 A passive solar roofing system as described in claim 2.1 whereas a thermostat and climate control mechanism will be used to determine if the hot air is to be evacuated to the outside during the summer time or pumped back into the house during the autumn, winter or spring time. A pressed metalfascia system as described in claim 2.1, is attached the solar roof panels using clips and screws and is used inter alia, to support the roof water gutter and incorporates cut out sections that align with the rows of ducting in the middle of the roofpanels. Perforated, sliding,fly proofpanels are used to cover the cut out sections and allow air to enter the elliptical ducting. The sliding shutters are removablefor cleaning andflywire replacement. 2.6 A perforated shutter in which pressed metal crenellations located along its top edge fit into elongated slots in the fascia thus allowing the shutter to slide sideways so that the perforated sections can be covered to prevent the entry of dust during a dust storm or radiant heat andflames during a bush fire. 2.7 A polyethylene roof sheeting system that incorporates and uses split hollow pipes to convey water along the upper and lower internal surfaces of the roof sheeting to absorb the solar radiation and heat the water. 2.8 The roof sheeting system described in claim 2. 7 in which the heated water is used for domestic cooking and washing andfloor slab and space heating. Manufacturing system for precast concrete buildings Section 1 1.7 Although the existing tilt-up concrete building system has considerably reduced the construction time and cost of industrial and commercial buildings, the existing construction techniques are somewhat agricultural and lack the architectural and engineering refinements that would make it universally acceptable for domestic residential applications. The major features that contribute to the current systems lack of acceptability are as follows a) The current method of manufacture is to cast each wall panel with square edges so that when the panels are erected, there is a significant gap between them. o 0: oo••• b) Once placed in position, the adjoining panels are attached to one another by bolting on steel plates or by welding steel rods onto the exposed reinforcement. This method is slow, tedious and unattractive. *0 c) To prevent weather and vermin from entering the building the gaps between the adjoining panels are filled with mastic. This system is unsightly, ~susceptible to mechanical damage and seasonal deterioration. d) In the conventional system the perimeter wall panels merely rest in a recess in the slab edge rebate and have no positive connection or retaining mechanism to prevent lateral movement or provide a permanent seal. e) The panels also lack provision for conduits or voids to accommodate building services such as plumbing pipes or electrical cables. f) In addition, every panel must be individually braced and propped until they have been finally secured together and therefore require a forest of props that restrict access and movement within the building envelope. Manufacturing system for precast concrete buildings Theseproblems have been overcome by thepresent invention 1.8 The design improvements of the present invention relate specifically to the cross sectional profile of the side and bottom edges of adjoining wall panels. a) This is achieved by using pressed metal or extruded plastic wall edge formwork (that will become permanently attached to the concrete) that moulds the concrete to the desired shape. The panel edge formwork will be manufactured in pairs to a predetermined profile that enables each panel to engage and interlock with its adjoining member, during the erection process (refer figure 1). b) The wall panel edge formwork incorporates a concealed, gravity activated :fastening mechanism, that automatically aligns and secures the adjoining panels as they are manoeuvre into their final position (refer figures 2 3). c) The top edge of the uppermost connecting bracket is located so that it finishes flush with the top of the wall panel and has provision for a bolt that will permanently secure the panels together (refer figures 3 4). d) To provide a weatherproof seal, the cross sectional profile of the female panel S* .edge incorporates two semi circular recesses into which fluted, compressible plastic tubes are inserted (refer figures 1). e) During the erection process, these plastic tubes are brought into contact with the corresponding salient angles of the adjoining panel and become ~progressively compressed as the panel is lowered into its final resting position. The resilient property of the plastic tube exerts constant pressure against the angular faces of the adjoining panels and forms a permanent vermin and weatherproof seal. The internal location of the sealing devices affords protection from mechanical damage and seasonal deterioration. f) The bottom edge of each external wall panel incorporates a similar cross sectional profile to that of its vertical edges, but has its outermost inclined surface extended downwards so that any accumulated moisture can be drained from the slab edge rebate (refer figure 5 6). g) Purpose made perimeter slab edge formwork provides a matching profile to accommodate the profile of the bottom panel edge (refer figure 6). h) As each of the perimeter wall panels is placed into position, its free end is fastened to the footings by a specially designed hook bolt (refer Figure 7). i) To provide access for plumbing pipes and electrical cables the wall panels incorporate elliptically shaped voids that are located in the centre of the wall panels and extend from the top of the panel to a point 150mm from the bottom (refer figure 3).