AU714693B2

AU714693B2 - Constructional element

Info

Publication number: AU714693B2
Application number: AU31557/97A
Authority: AU
Inventors: Errol Campbell
Original assignee: Individual
Current assignee: Individual
Priority date: 1996-08-16
Filing date: 1997-07-28
Publication date: 2000-01-06
Anticipated expiration: 2017-07-28
Also published as: AU3155797A

Description

1- P/00/01 1 Regulation 3.2

AUSTRALIA

Patents Act 1 990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: CONSTRUCTIONAL ELEMENT

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The following statement is a full description of this invention, including the best method of performing it known to me: GH REF: P25069A GSIMS 2 TECHNICAL FIELD This invention relates to a constructional element adapted to be employed in building construction. It has particular but not exclusive application to metal constructional elements for the construction of light duty single storey dwellings, garages, sheds and other relatively small buildings.

Such buildings usually comprise a horizontal floor slab, a plurality of upright walls in the form of wall cladding and a roof. Horizontal rail elements, known as girts are usually provided about the perimeter of the floor slab to support the wall cladding. Girts are generally cold roll-formed from light gauge steel strips and are usually in the form of C- or Z- purlins.

Girts are generally positioned along the upper edge margin of the floor slab and fastened to the slab by means of hold-down bolts or other relatively heavy duty fasteners.

The walls are usually fastened to one another by means of fasteners, such as for example, rivets or self tapping screws, and the roof is then fastened to frame members and the upper ends of the walls. The structure is then braced. The mode of attachment between the *99.99 *o**building members enables them to be rapidly assembled on site by relatively unskilled labour. However, this in itself facilitates problems of misalignment and torsional and other stresses within and between the building elements.

Traditionally construction of the floor slab requires the erection and dismantling of temporary formwork and generally produces a floor slab having o. visually obtrusive, unsightly side walls. Further a major portion of the delay between the commencement of construction of the formwork and the completion of the building can be attributed to the hardening or setting stage of the concrete slab.

An object of the present invention is to overcome or G:\users\Melb\P21311 28/7/97 3 ameliorate one or more deficiencies of the prior art.

DISCLOSURE OF INVENTION According to one aspect, the present invention provides an elongate constructional element comprising a web having support means protruding from one side of the web adapted, in use, to support wall cladding, and retention means protruding from the other side of the web adapted, in use, to facilitate anchoring of the element.

Preferably the support means comprises a longitudinally extending rib.

More preferably the rib includes a portion which lies in a plane extending transversely to the plane of the web thereby forming a ledge adapted to support wall cladding.

Preferably further the portion extends in a plane substantially perpendicular to the plane of the web.

Preferably the retention means comprises flanges extending from each longitudinal edge of the web.

Preferably further the planes of the flanges intersect, that is to say, the flanges converge.

More preferably one of the flanges is folded back 4 towards the web to define a cavity between the web and the flange.

0 It is preferred that said one of the flanges has a 0 25 terminal end directed towards the edge of the web from which the said one of the flanges protrude to form an acute angle with a plane perpendicular to the web.

Preferably at least one of the flanges is provided with a plurality of openings.

According to another aspect, the invention provides an elongate constructional element comprising a channel 0 section having a web and longitudinal edge flanges, the eoedge flanges protruding from one side of the web, the web 4.

S: being provided with a longitudinally extending rib having at least a portion which lies in a plane extending transversely of the web as a whole, said rib protruding from the other side of the web, and one of the flanges is provided with a return portion extending back towards the G:\users\Melb\P21311 28/7/97 4 web.

It is preferred that the return portion is provided with a terminal end directed towards the edge of the web from which its flange protrudes to form an acute angle with a plane perpendicular to the web.

Preferably each flange and the return portion is provided with an array of spaced apart openings with the openings of one array in register with respective openings of the other arrays.

According to a further aspect, the invention provides a constructional element adapted to be used both as a girt and a form in the construction of light duty buildings, comprising an elongate channel section having a web and two longitudinal edge flanges protruding from one side of the web, each flange converging toward the other, the web being provided with a longitudinally extending rib protruding from the other side of the web, said rib being provided with a portion which lies in a plane extending substantially transversely to the plane 20 of the web.

:More preferably said transverse plane is substantially perpendicular to the plane of the web.

Additionally one of the flanges of the channel may be provided with a return portion which extends towards the web.

Preferably each flange is provided with a plurality 9 9e of spaced apart openings with the openings of one flange in-register with the openings of the other flange.

It is preferred that each edge flange and the or 30 each return portion is provided with an array of spaced apart openings with the openings of one array in register with respective openings of the other arrays.

It is also preferred that the return portion is provided with a terminal end directed towards the edge of the web from which its flange protrudes to form an acute angle with a plane perpendicular to the web.

The invention also extends to a method of construction of a light duty single storey building G:\users\Melb\P21311 28/7/97 5 comprising the steps of providing one or more constructional elements according to any one or more of the foregoing aspects of the invention, laying and anchoring the element or elements to define a peripheral side wall of a floor slab, said anchoring being by means disposed internally of the peripheral side wall of the floor slab, and wherein the plane of web of the element or elements is disposed substantially upright and the support means or rib protrudes externally of the floor slab, erecting the wall or walls of the building and a roof, with the wall or walls supported on the support means or rib of the element or elements and fastening the wall or walls to the upper edge margin of the web of the element or elements.

Preferably the invention provides the further step of pouring plastic concrete or other flooring material into a mould formed by the element or elements thereby encasing the anchoring means, and permitting the material to harden sufficiently to be self supporting. Further i. 20 the pouring step may be effected either prior to or after mtthe step of fastening the wall cladding to the element or elements.

In use, the constructional elements may be laid to define the perimeter of the floor slab. These elements may be laid in a generally horizontal plane with the web upright and the rib protruding outwardly of the slab.

Generally, the constructional elements may be held in position by stakes or rods which have been threaded *o*through the respective sets of in-register holes of the 30 flanges and driven into the earth.

The height of the elements and hence the height of "the floor slab may readily be adjusted by moving the oe*°element up or down the respective stakes or rods.

Levelling of the elements and hence levelling of the floor slab may be similarly facilitated.

BRIEF DESCRIPTION OF THE DRAWING In order that the invention may be fully explained a preferred embodiment of the invention and its application G:\users\Melb\P21311 28/7/97 6 will now be described by way of example and with reference to the accompanying drawing, in which:- Figure 1 illustrates a cross sectional view of a constructional element according to the invention and a manner of utilising the element.

BEST MODE OF CARRYING OUT THE INVENTION The elongate constructional element illustrated in figure i, generally indicated by the arrow i, may be relatively simply and economically formed from a length of light gauge flat metal strip by cold-rolling. The element 1 is formed into a channel section comprising a longitudinally extending central web 2, having a longitudinally extending rib 3 projecting from one side of the web and a pair of substantlally parallel longitudinal edges, and a pair of edge flanges 4, projecting from the other side of the web. The edge flanges 4, 5 generally converge towards one another.

The element illustrated in figure 1 is laid on a generally horizontal plane with the plane of the web 2 in 20 a generally upright position.

The rib 3 extends continuously along the length of the element and includes a portion 13 having a plane i substantially perpendicular to the plane of the web thereby providing a ledge 13 upon which wall cladding 12 or other wall members may be supported. The ledge 13 forms a substantially flat surface so that the end of wall cladding 12 sits substantially flush thereon thereby strengthening the joint formed between the wall cladding and the element. Additionally, gaps therebetween are 30 minimised thus minimising the risk of vermin entering the building.

**The rib is disposed towards the central portion of the web so that the ledge forms a step with the upper edge margin of the web. The step facilitates assembly of the building members, minimises the risk of rainwater entering the building from below the wall cladding and enables the lower edge margin of the wall cladding to fit snugly against the upper edge margin of the web so that G:\users\Melb\P21311 28/7/97 7 the wall cladding can be secured directly to the floor slab by means of screw fasteners, rivets or other fasteners driven through the face to face edge margins of the wall cladding and web.

The height of the step, that is to say, the distance between the upper edge of the web and the ledge must be sufficient to enable fastening of the lower edge margin of the wall cladding to the upper edge margin of the web consistent with the necessary structural strength of the joint. The load forces in the structure are primarily transferred through the wall cladding directly to the floor slab through the joint.

One of the flanges, the upper flange 4, is folded back towards the web 2 to provide a return flange portion 6, having a terminal end directed somewhat upwardly towards the upper edge of the web 2, to form an acute angle a with a plane perpendicular to the web so as to, in use, enhance adhesion and wedging of the upper flange with the concrete of the floor slab and to form a ~20 concrete free cavity into which fasteners driven through :the upper edge margin of the web may protrude unhindered.

The other or lower flange 5 is provided with a plurality of spaced apart openings 7.

The upper flange is also provided with a plurality of spaced apart openings 8, 9 in both the convergent flange 4 portion and the return flange portion 6, the openings 9 of the return flange portion 6, the openings 8 of the converged flange 4 and the openings 7 of the lower flange 5 being in-register so that a rod or stake 10 may 30 be threaded through the in-register sets of three openings 7, 8, 9 and driven into the ground thereby to hold the element in position.

Figure 1 illustrates the edge margin of a floor slab 11, the lower edge margin of wall cladding 12 in a light duty building and the constructional element 1 according to the invention which functions both as a girt to support the wall cladding 12 and as a permanent form in the construction of a floor slab 11.

G:\users\Melb\P21311 28/7/97 8 In the construction of the floor slab 11, a plurality of construction elements 1 are laid end to end to define the perimeter of the floor slab 11.

The elements 1 are positioned with the plane of the web 2 of these elements upright so that the web defines the upper edge margin of the side wall of the proposed floor slab 11, with the ledge 13 extending outside the proposed floor slab 11 and the flanges 4, 5 extending into the proposed floor slab 11 to be encased by concrete or other flooring material.

A stake or rod 10 is then threaded through each set of in-register openings 7, 8, 9 in the upper 4, 6 and lower flanges 5 and driven into the ground. Wedges or chairs 14 may be used to enhance the rigidity of the formwork formed by the element 1 and stakes 10. The floor level is adjusted by adjusting the level of the constructional elements on the stakes or rods.

The elements are then stayed, anchored or otherwise prevented from sliding down the stakes by known means, 20 such as, for example, wedges 14 driven between the element web and the stakes or impact drivable fasteners driven into the stakes.

~Once the elements 1 are stayed or anchored by the S"stakes 10, plastic concrete is poured into the formwork and allowed to set.

~As illustrated in Figure i, the upper edge of the web 1 forms the upper edge of the floor slab 11, with the flanges 4, 5, 6 encased in the concrete, thereby the elements 1 form the permanent side wall of the floor slab 30 11. Additionally the upper edge margin of the side wall includes a substantially concrete free cavity 15 of substantially triangular cross-section into which screw S"fasteners 16 or other fastening means may protrude as they are driven through the web. The cavity 15 is primarily formed by the upper flange 4, 6 and upper edge margin of the web 2. The provision of the cavity facilitates the use of screw fasteners, blind rivets or other elongate fasteners in attaching wall cladding 12 to G:\users\Melb\P21311 28/7/97 9 the upper edge margin of the web 2 by enabling the ends of the fasteners 16 to protrude unhindered into cavity.

After the concrete has set, the wall cladding 12 can be erected about the floor slab 11 with the wall cladding 12 supported by the ledge 13 of the element i. The provision of the ledge facilitates alignment of the wall cladding and minimises the risk of assembly errors by relatively unskilled labour.

The cladding 12 is then fastened to the web 2 of the element 1 by means of screw fasteners 16 or other fastening elements extending or driven through both the lower edge margin of the cladding 12 and the upper edge margin of the web 2 of the element i.

Alternatively the erection of the wall cladding 12 may occur prior to the setting of the concrete. In fact, the present invention makes it possible to erect a light duty building prior to pouring of the concrete to form the proposed floor slab 11.

The constructional elements of the present invention 20 are adapted to be anchored to provide a girt/form of sufficient rigidity to facilitate the erection of the walls and roof of a light duty building prior to the production of a rigid floor slab.

.9 .9 Additionally, the constructional elements of the present invention enable the wall cladding to be fastened directly to the floor slab thereby the load forces and 99*9 stresses in the structure are transferred directly to the floor slab through the cladding. Hence the invention enhances bracing of the building members, reduces load *9e9 forces and stresses in the frame, braces, connectors and the other components of the structure and thus reduces the strength requirements of these components.

The present invention hence enables the construction of a light duty building quickly using lighter duty frames, braces, and other components of the structure than conventionally used.

Indeed the present invention enables the construction of small light duty buildings without the G:\users\Melb\P21311 28/7/97

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use of a conventional or even a lighter duty frame.

A particular embodiment of the invention has been described and illustrated by way of example, but it will be appreciated that other variations of and modifications to the invention can take place without departing from the spirit and scope of the invention.

For example, in some embodiments, levelling of the elements and preventing the elements sliding down the stakes during construction may be facilitated by using a stake having a threaded upper end and a nut having a head larger than the size of the openings adapted to support the element. The position of the nut, and hence the position of the element supported by the nut on the stake may be adjusted by turning the nut.

In other embodiments, the elements may be held in place by ties or other fastening means between the elements and say the metal mesh 17 or held in place by anchor means other than the above described stakes or rods threaded through the said openings.

Further, in the above described embodiment the rib S" extends continuously along the length of the element, S however, in some embodiments, the rib may extend intermittently along the length of the element. That is to say, the rib may, for example, comprise a number of short ribs regularly spaced along the length of the element.

o* Additionally, in the above described embodiment the element is formed of sheet metal material, however, in other embodiments, the element may be formed of plastics material.

oo G:\users\Melb\P21311 28/7/97

Claims

1. An elongate constructional element comprising a web having support means protruding from one side of the web adapted, in use, to support wall cladding, and retention means protruding from the other side of the web adapted, in use, to facilitate anchoring of the element.

2. An element as defined in claim 1 wherein the support means comprises a longitudinally extending rib.

3. An element as defined in claim 2 wherein the rib includes a portion which lies in a plane extending transversely to the plane of the web thereby forming a ledge adapted to support wall cladding.

4. An element as defined in claim 3 wherein the portion extends in a plane substantially perpendicular to the plane of the web.

An element as defined in any one of the preceding claims wherein the retention means comprises flanges protruding from each longitudinal edge of the web. 20

6. An element as defined in claim 5 wherein the flanges converge.

7. An element as defined in claim 5 or claim 6 wherein one of the flanges is folded back towards the web to define a cavity between the web and said one of the 25 flanges.

8. An element as defined in claim 7 wherein said one of the flanges has a terminal end directed towards the edge of the web from which the said one of the flanges protrude to form an acute angle with a plane perpendicular to the web. G:\users\Melb\P21311 28/7/97 12

9. An element as defined in any one of claims 5 to 8 wherein at least one of the flanges is provided with a plurality of openings.

An elongate constructional element comprising a channel section having a web and longitudinal edge flanges, the edge flanges protruding from one side of the web, the web being provided with a longitudinally extending rib having at least a portion which lies in a plane extending transversely of the web as a whole, said rib protruding from the other side of the web, and one of the flanges is provided with a return portion extending back towards the web.

11. An element as defined in claim 10 wherein each edge flange and the return portion is provided with an array of spaced apart openings with the openings of one array in register with respective openings of the other arrays.

;12. An element as defined in claim 10 or claim 11 wherein the return portion is provided with a terminal end directed towards the edge of the web from which its flange protrudes to form an acute angle with a plane perpendicular to the web.

13. A constructional element adapted to be used both as a girt and a form in the construction of light duty 25 buildings, comprising an elongate channel section having Coo a web and two longitudinal edge flanges protruding from one side of the web, each flange converging toward the other, the web being provided with a longitudinally C. extending rib protruding from the other side of the web, said rib being provided with a portion which lies in a plane extending substantially transversely to the plane of the web.

14. An element as defined in claim 13 wherein said G:\users\Melb\P21311 28/7/97 13 transverse plane is substantially perpendicular to the plane of the web.

An element as defined in claim 13 or 14 wherein each flange is provided with a plurality of spaced apart openings with the openings of one flange in-register with the openings of the other flange.

16. An element as defined in any one of claim 13 to wherein one of the flanges of the channel is provided with a return portion which extends towards the web.

17. An element as defined in any one of claims 13 to 16 wherein each edge flange and the return portion is provided with an array of spaced apart openings with the openings of one array in register with respective openings of the other arrays.

18. An element as defined in any one of claims 13 to 17 wherein the return portion is provided with a terminal end directed towards the edge of the web from which its flange protrudes to form an acute angle with a plane perpendicular to the web.

19. A method of construction of a light duty single storey building comprising the steps of: providing one or more constructional elements according to any one of the preceding claims; laying and anchoring the element or o elements to define a peripheral side wall of a floor oe 25 slab, said anchoring being by means disposed internally of the peripheral side wall of the floor slab, and wherein the plane of web of the element or elements is S"disposed substantially upright and the support means or rib protrudes externally of the floor slab, erecting the wall or walls of the building and a roof, with the wall or walls supported on the support means or rib of the element or elements; and fastening the wall or walls to the upper edge margin of the web of the element or G:\users\Melb\P21311 28/7/97 -14 elements.

A method as defined in claim 19 comprising the further steps of: pouring plastic concrete or other flooring material into a mould formed by the element or elements thereby encasing the anchoring means; and permitting the material to harden sufficiently to be self supporting.

21. A method as defined in claim 20 wherein further the pouring step is effected either prior to or after the step of fastening the wall or walls to the element or elements.

22. A method as defined in any one of claims 19 to 21 further comprising the step of laying constructional elements to define a perimeter of the floor slab with the elements laid in a generally horizontal plane with the web upright and the rib protruding outwardly of the slab.

23. A method as defined in any one of claims 19 to 22 further comprising the step of holding constructional elements in position by means of stakes or rods disposed a. internally of the peripheral side wall. a

24. A method as defined in claim 23 wherein 9 the stakes or rods are threaded through respective sets of in-register holes formed in flanges of the elements and driven into the earth. ooe• a

25. A method as defined in claim 23 or claim :"24 wherein the height of the elements and hence the height of the floor slab is adjusted by moving the element up or down the respective stakes or rods.

26. A method as defined in any one of claims 23 to 25 wherein levelling of the floor slab is effected by adjusting the height of the elements up or down the G:\users\Melb\P21311 28/7/97 respective stakes or rods.

27. An element substantially as hereinbefore described with reference to the drawing.

28. An method substantially as hereinbefore described with reference to the drawing. Dated this 28th day of July 1997 ERROL CAMPBELL By his Patent Attorneys GRIFFITH HACK Fellows Institute of Patent Attorneys of Australia aOa a G:\users\Melb\P21311 28/7/97