AU773528B2 - A walling system and a method of its fabrication - Google Patents

Description

1

AUSTRALIA

Patents Act 1990 Joseph Michael Tag

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: A walling system and a method of its fabrication The following statement is a full description of this invention including the best method of performing it known to us:o* ooooo o *ooooo ooo Field of the Invention This invention relates to the erection of structures. More particularly, the invention relates to a constructional element, to a method of fabricating the constructional element, to a device for use in fabricating the constructional element and to a method of erecting a structure using the constructional element.

Background of the Invention It is known to pre-cast building panels off site, to transport the panels to site and there to erect the panels to form a structure. Various ways of precasting wall panels and, in particular, hollow core wall panels using horizontal casting beds are known. These wall panels, invariably, suffer from problems such as, in the case of solid panels, the lack of flexibility with the siting of utilities connections which have to be precast into the panels in predetermined locations. This also negates the possibility of future changes.

In addition, due to the mass of the panels, extra reinforcing needs to be provided in the floor slab to support the panels.

In the case of hollow core panels, the cores are cylindrical and cannot serve as locating and locking formations for locking the panels to the underlying floor slab.

Summary of the Invention According to a first aspect of the invention, there is provided a method of fabricating a constructional element which includes the steps of: providing a mould having a pair of opposed, spaced faces to define a mould cavity: mounting a plurality of core forming members in the mould cavity, the core forming members being arranged in spaced relationship and being ego*e spaced from the faces of the mould, at least certain of the core forming members being of tapered construction and being of smaller cross section at an operatively bottom region than at an operatively top region; charging a settable, cementitious mix into the mould cavity; allowing the cementitious mix to set to form a panel; and removing the core forming members from the panel and stripping the mould from the panel.

The method may include casting the panel in a vertical orientation.

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3 Still further, the method may include casting the panel on a mobile device, the mobile device carrying a first face-defining element.

Then, the method may include, at a first station of a production site, dressing the mobile device by erecting at least one second face-defining element in spaced relationship relative to the first face-defining element to form at least one mould cavity, the face-defining elements extending vertically with respect to the mobile device. The method may further include, at the first station, positioning the core forming members in the mould cavity.

Also, the method may include applying components to an operatively internal surface of at least one of the face-defining elements to form openings in the panel to be formed. The components may be protuberances carried on the face of the face-defining element.

The method may include mounting a second face-defining element on each side of the first face-defining element to form two mould cavities on the mobile device. Thus two panels can be cast simultaneously on the same device.

The method may include conveying the dressed, mobile device to a i :second, filling station and charging the cementitious mix into the. or each, mould cavity. Then, the method may include conveying the mobile device to a setting station to allow the cementitious mix to set to form the, or each, panel.

"'"'"Finally, the method may include, after setting of the cementitious mix, conveying the mobile device to a stripping station, stripping the face-defining elements from the, or each, panel and removing the, or each, panel from the mobile device for storage and subsequent transportation to a construction site.

S* According to a second aspect of the invention, there is provided a *eoee constructional element fabricated in accordance with the method as described above, the constructional element including a panel defining a pair of opposed surfaces, the panel having a plurality of cores extending therethrough from an operatively top edge to an operatively bottom edge of the panel, at least certain of the cores tapering inwardly from said top edge to said bottom edge.

f r 4 According to a third aspect of the invention, there is provided a unit for use in fabricating a constructional element as described above, the device including: a mobile device: a first face-defining element mounted fixedly on the mobile device; and a second face-defining element removably mountable on the mobile device in spaced relationship relative to the first face-defining element to define a mould cavity when the second face-defining element is in its in use orientation.

Preferably, the unit is configured to mould two panels simultaneously, the first face-defining element being in the form of a dividing element vertically and centrally arranged on the mobile device with two second facedefining elements, the second face-defining elements being removably mountable on opposed sides of the dividing element so that two mould cavities are formed, in use.

The unit may include core-forming members for forming hollow, tapered cores in the panels. Each core-forming member may be in the form of a plunger.

:The mobile device may comprise a substantially horizontally extending base member mounted on one or more wheeled structures.

To form window or door openings in the panel, one of the face-defining elements may have protruding members in the shape of the window or door opening, mounted thereon. The protruding members may be removably mounted on the dividing element.

According to a fourth aspect of the invention, there is provided a method of erecting a structure which includes: casting a floor slab; mounting one or more constructional elements, as described above, on the floor slab; and charging a settable substance into the cores of the constructional *elements for locating the constructional elements with respect to the floor slab.

The method may include using the vertically extending cores for insertion of utilities reticulation elements.

Further, the method may include securing adjacent panels with respect to each other by means of securing elements, the securing elements comprising securing plates which are welded together.

Brief Description of the Drawings The invention is now described by way of example with reference to the accompanying diagrammatic drawings in which: Figure 1 shows a three dimensional view of part of a structure erected with a plurality of constructional elements, in accordance with a first aspect of the invention; Figure 2 shows a schematic, sectional side view of a further part of the structure showing the constructional element; Figure 3 shows an enlarged sectional view of the part of the structure of Figure 2: Figure 4 shows a schematic plan view of the structure; Figures 5 to 7 show, on an enlarged scale, a detail of the parts encircled by circles A, B and C, respectively, in Figure 4; Figure 8 shows a three dimensional, schematic view of a part of a :i'2 device, in accordance with a third aspect of the invention, for fabricating a constructional element; Figures 9 and 10 show, respectively, on an enlarged scale, the parts encircled by circles D and E in Figure 8 of the drawings; ~Figure 11 shows an end view of part of the device of Figure 8; and Figure 12 shows a three dimensional view of an assembly line for the fabrication of the constructional elements of the first aspect of the invention.

Detailed Description of the Drawings Referring firstly to Figures 1 to 4 of the drawings, a constructional element and a structure erected in accordance with the constructional element are illustrated. The constructional element or panel 10 comprises a pair of opposed surfaces 12 and 14, a top edge 16 and a bottom edge 18. A plurality of cores 20 are formed extending vertically, in use, through the panels 10 from the top edge 16 to the bottom edge 18. The cores are tapered cores which taper inwardly towards the bottom edge 18 as shown in greater detail in Figures 2 and 3 of the drawings.

1- 'v 6 When the panel 10 is used to form an external wall of the structure, the cores 20 are typically spaced approximately 200 mm apart. Conversely, where the panel 10, as illustrated by panel 10.1 in Figure 1 of the drawings, forms an internal wall of the structure, the cores 20 are spaced about 100 mm apart. If desired, or if necessary, window openings 22 or door openings 24 are cast in the panels 10 at the time of manufacture of the panels, as will be described in greater detail below.

Further, as illustrated at 26 in Figure 1 of the drawings, if desired, external wall venting systems may be moulded into those panels 10 which constitute the external walls of the structure.

The panels 10 also have roof truss plates 28 cast into the top edges 16.

Where aligned panels 10 meet, as shown in Figure 7 of the drawings, one of the panels 10 has a channel 30 running along its vertical edge with a securing plate 32 mounted in position in the channel 30. The other panel has an outwardly protruding tongue 34 running along its vertical edge which mates with the channel 30 snugly. The tongue 34 is also covered by a securing plate 32 and the securing plates 32 are welded together. The tongue 34 is a snug fit in the channel 30 of the adjoining panel In the case of a pair of panels 10 forming a corner of the structure, one of the panels 10 has the channel 30 with its associated securing plate 32.

However, the other panel 10 has the tongue 34 protruding from the surface 12 of the panel inwardly of its end so that the tongue 34 protrudes at right angles to the end of the panel 10 to be received in the channel Where an internal panel 10.1 branches off from an external panel securing plates 32 are provided along the edge of the panel 10.1 and one of the side edges of the panel 10 as shown in Figure 6 of the drawings.

Reverting again to Figures 2 to 4 of the drawings, a structure, generally designated by the reference numeral 40 is described in greater detail. As 000• described above, the structure 40 has its walls constituted by the panels In the erection of the structure 40, a floor slab 42 is thrown or cast. Vertically extending L-shaped reinforcing bars 44 are cast into the'floor slab 42 to protrude beyond an upper surface 46 of the floor slab 42. These bars 42 are received in the cores 20 of the panels Thus, once the floor slab 42 has been cast, a bed 48 of cementitious material is laid on the surface 46 of the floor slab 42. The panels 10 are placed in position on the bed 48.

Cementitious material 50 is thrown into each core 20 into which one of the bars 44 protrudes at least to a level to cover the bar 44. This cementitious material 50 serves to anchor the panels 10 to the floor slab 42. Due to the tapered shape of the cores 20, the anchoring action is enhanced.

As indicated above, truss plates 28 are moulded into the panels 10 for securing roof trusses 52 to the panels Moreover, as illustrated in Figure 2 of the drawings, the cores 20 can be used for utilities reticulation elements such as electric cables 54.

Referring now to Figures 8 to 11 of the drawings, a unit ,in accordance with a third aspect of the invention, for use in fabricating the panels 10 is illustrated. The unit or trolley 60 is mobile and comprises a pair of platforms 62 projecting from either side of a central dividing first face-defining element or plate 64. The trolley 60 runs on wheels 66 (Figure 8).

A pair of second face-defining elements, each in the form of a shutter and one associated with each side of the central plate 64, is included for the simultaneous moulding of two panels 10, one on each side of the plate 64. It is to be noted that only one of the shutters 68 is shown in Figure 8 of the drawings. Further, it is to be noted that each shutter 68 has a bowed configuration for inhibiting flexing of the shutters 68, in use.

S 20 As shown in greater detail in Figure 10 of the drawings, the plate 64 has a centrally mounted guide rail 70 mounted on top of it. A plurality of studs 72 are provided at longitudinally spaced intervals along the rail 70 on i which a locating yoke 74 is releasably mounted. The locating yoke 74 supports plungers 76, via spring loaded pivot housings 78 arranged on top of the plungers 76. The plungers 76 are tapered to produce the tapered cores in the panel It is also to be noted in Figure 10 of the drawings that each end 80 of the yoke 74 is bifurcated to receive a locking tab 82 which locks the shutter °eeee 68 in position relative to the plate 64.

Reverting to Figure 6 of the drawings, on each platform 62, ferrules 84 are provided for receiving the bottom of the shutter 68. In addition, threaded ferrules 86 are provided on each platform 62 for receiving the bottoms of the plungers 76.

Referring now to Figure 12 of the drawings, an assembly line for the assembly of the panels 10 is illustrated. The assembly line is generally designated by the reference numeral 90. The assembly line 90 comprises a number of stations. Hence, at a first station 92, the shutters 68 are stored.

Downstream of the first station 92, a plurality of trolleys 60 are arranged. In respect of at least one of the trolleys 60, protuberant elements 94 are mounted on the plate 64. These protuberant elements 94 are used to form windows or doors in the panels 10, as desired.

The trolleys 60 are arranged in an assembly station 96 where the shutters 68 and the plungers 76 are mounted in position on the trolleys 60 to dress the trolleys 60. Thereafter, the assembled trolleys 60, as illustrated at 98, are moved to a filling station 100 where the mould cavities formed between the shutters 68 and the central panel 64 are charged with a cemnentitious mix or material. The charged trolleys are then moved to a setting station 102 where the cementitious material is allowed to set. Finally, downstream of the setting station 102. the trolleys 60 are conveyed to a stripping station 104 where the shutters 68 are removed from the trolleys for re-use and the set panels 10 are removed from the trolleys 60 for transportation to a building site.

Hence, it is a particular advantage of the invention that a hollow cored wall panel 10 is provided which can be anchored to a floor slab via the 0000% 20 tapered cores. In addition, a trolley 60 is provided which facilitates the fabrication of the panels 10 in a vertical orientation thus allowing the formation of the tapered cores.

It will be appreciated that, by vertically forming the panels, both sides of a panel-forming table are used thereby increasing production rate for the 25 same floor area. In addition, vertical forming of the panel using the trolley does not require concrete finishers to finish one side of the wall panel compared with the present flat bed system where one wall face needs to be finished reducing the production rate and having panels which are nonuniform in appearance. Still further, by vertically forming the panels, upon completion they are removed vertically from the trolley 60 and stresses, due to bending which occur in the flat bed system, are obviated.

*o In addition, by having the panels formed on a trolley 60, the panels can be formed in an assembly line production manner unlike the present fixed flat bed system. It will be appreciated that, to cast multiple panels in the flat bed system, a very large floor area is required for casting the flat bed panels and a system of trucks needs to be used to pour the concrete by driving along 9 sides of fixed tables. This arrangement is obviated with the mobile trolleys It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

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Claims (24)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1. A method of fabricating a constructional element which includes the steps of: providing a mould having a pair of opposed, spaced faces to define a mould cavity; mounting a plurality of core forming members in the mould cavity, the core forming members being arranged in spaced relationship and being spaced from the faces of the mould, at least certain of the core forming members being of tapered construction and being of smaller cross section at an operatively bottom region than at an operatively top region; charging a settable, cementitious mix into the mould cavity; allowing the cementitious mix to set to form a panel; and removing the core forming members from the panel and stripping the mould from the panel.

2. The method of claim 1 which includes casting the panel in a vertical orientation.

3. The method of claim 1 or claim 2 which includes casting the panel on a mobile device, the mobile device carrying a first face-defining element.

4. The method of claim 3 which includes, at a first station of a production site, dressing the mobile device by erecting at least one second face-defining element in spaced relationship relative to the first face-defining element to 25 form at least one mould cavity, the face-defining elements extending vertically with respect to the mobile device.

5. The method of claim 4 which includes, at the first station, positioning 6 000 the core forming members in the mould cavity.

6. The method of claim 4 or claim 5 which includes applying components 0 to an operatively internal surface of at least one of the face-defining elements to form openings in the panel to be formed. C L 11

7. The method of any one of claims 4 to 6 inclusive, which includes mounting a second face-defining element on each side of the first face- defining element to form two mould cavities on the mobile device.

8. The method of any one of claims 4 to 7 inclusive, which includes conveying the dressed, mobile device to a second, filling station and charging the cementitious mix into the, or each, mould cavity.

9. The method of claim 8 which includes conveying the mobile device to a setting station to allow the cementitious mix to set to form the, or each, panel.

The method of claim 9 which includes, after setting of the cementitious mix, conveying the mobile device to a stripping station, stripping the face- defining elements from the, or each, panel and removing the, or each, panel from the mobile device for storage and subsequent transportation to a construction site. 6

11. A constructional element fabricated in accordance with the method of S. 20 any one of the preceding claims, the constructional element including a panel .defining a pair of opposed surfaces, the panel having a plurality of cores extending therethrough from an operatively top edge to an operatively bottom edge of the panel, at least certain of the cores tapering inwardly from said top edge to said bottom edge.

12. A unit for use in fabricating a constructional element as claimed in claim 11, the device including: a mobile device; ~a first face-defining element mounted fixedly on the mobile device: and a second face-defining element removably mountable on the mobile device in spaced relationship relative to the first face-defining element to define a mould cavity when the second face-defining element is in its in use orientation.

13. The unit of claim 12 which is configured to mould two panels simultaneously. the first face-defining element being in the form of a dividing .'I 12 element vertically and centrally arranged on the mobile device with two second face-defining elements, the second face-defining elements being removably mountable on opposed sides of the dividing element so that two mould cavities are formed. in use.

14. The unit of claim 13 which includes core-forming members for forming hollow, tapered cores in the panels.

The unit of claim 14 in which each core-forming member is in the form of a plunger.

16. The unit of any one of claims 12 to 15 inclusive, in which the mobile device comprises a substantially horizontally extending base member mounted on one or more wheeled structures.

17. The unit of any one of claims 12 to 16 inclusive, in which, to form window or door openings in the panel, one of the face-defining elements has 0 protruding members in the shape of the window or door opening, mounted thereon. e

18. The unit of claim 17 in which the protruding members are removably mounted on the dividing element.

.19. A method of erecting a structure which includes: casting a floor slab; mounting one or more constructional elements, as claimed in claim 11, on the floor slab; and charging a settable substance into the cores of the constructional elements for locating the constructional elements with respect to the floor 00* 30 slab.

The method of claim 19 which includes using the vertically extending cores for insertion of utilities reticulation elements. 13

21. The method of claim 19 or claim 20 which includes securing adjacent panels with respect to each other by means of securing elements, the securing elements comprising securing plates which are welded together.

22. A method of fabricating a constructional element substantially as described herein with reference to the accompanying drawings.

23. A constructional element substantially as described herein with reference to the accompanying drawings.

24. A unit for use in fabricating a constructional element substantially as described herein with reference to the accompanying drawings. A method of erecting a structure substantially as described herein with reference to the accompanying drawings. Dated this first day of December 2000 Joseph Michael Tag Patent Attorneys for the Applicant: F B RICE CO