AU785414B2 - Precast concrete building system - Google Patents

Precast concrete building system Download PDF

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AU785414B2
AU785414B2 AU71452/00A AU7145200A AU785414B2 AU 785414 B2 AU785414 B2 AU 785414B2 AU 71452/00 A AU71452/00 A AU 71452/00A AU 7145200 A AU7145200 A AU 7145200A AU 785414 B2 AU785414 B2 AU 785414B2
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building system
profile
panel
profiles
panels
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Roger A Farquhar
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Description

1
AUSTRALIA
Patents Act 1990 STANDARD COMPLETE SPECIFICATION FOR THE INVENTION ENTITLED: PRECAST CONCRETE BUILDING SYSTEM Applicantls: Roger A Farquhar The invention is described in the following statement: ;0.1895527 2 PRECAST CONCRETE BUILDING SYSTEM Field of the invention The present invention relates to a building system. In particular, although not exclusively, the invention relates to improvements in a building system for manufacturing and erecting, precast and tilt-up concrete building components.
Background to the invention Although the existing tilt-up concrete building systems have considerably reduced the construction time and cost of industrial and commercial buildings, the existing construction techniques are still 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: """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.
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.
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.
In the conventional system the perimeter wall panels merely rest in the slab edge rebate and have no positive connection or retaining mechanism to prevent lateral movement or provide a permanent seal.
)0.1895527 3 The panels also lack provision for conduits or voids to accommodate building services such as plumbing pipes or electrical cables.
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.
It is an object of the present invention to provide a building system which overcomes or addresses at least one of the aforementioned disadvantages or at least provides the public with a useful choice over known systems.
Summary of the invention 10 In accordance with a first aspect of the present invention, there is provided a building system including: ego a plurality of concrete components; and a locking device for securing adjacent concrete components together, wherein each concrete component has a first edge profile which is engageable o •15 with a second edge profile provided on another concrete component, wherein each of the first and second edge profiles are shaped profiles whereby at least a portion of the first edge profile is adapted to abut with at least a portion of the second edge profile while receiving the locking device between the first and second profiles.
The preferred features of the invention relate particularly to the edge profiles of adjoining precast concrete wall panels and to concealed locking devices that align, seal and secure the panels to one another and the concrete footing or floor slab upon which they rest.
Preferred features of the invention include: SThe edge profile of the various concrete components 0 The formwork used to create the edge profiles C>,1895527 4 The weather and vermin proof sealing strips Gravity activated locking mechanism Wall panel restraining anchors and hook bolts The panels could be manufactured in a factory out of aerated, autoclaved concrete.
The lightweight concrete panels may be used for a wide variety of residential applications including: Internal walls only (substituting for conventional timber frame) A combination of internal walls and ceiling panels.
0 Internal and external walls Internal and external walls with flat or raking ceilings Two storey applications, including structural floor panels Roof panels incorporating solar panels o:ooe Panels can be manufactured to a diverse range of textures and finishes: Internal walls o Hard plaster o Lightly textured External walls o Rendered o Imitation stone Imitation brick Weatherboards The system may use pressed metal or extruded plastic formwork to create the edge profiles. The formwork may become permanently attached to the concrete panels to protect the edges from damage and to ensure that the various components of the locking mechanism are retained in their correct position during placement of the concrete.
041895527 The locking mechanism may include a tapered square hollow pin (male) and a square hollow keeper (female).
The formwork may further include semi-circular recesses designed to retain the fluted plastic sealing strips that will be brought into contact with the salient angles of abutting edge profiles adjacent wall panels during the erection process, to prevent weather and vermin from passing between the adjoining edges of the wall panels.
To attach and fasten the wall panels to the floor slab and perimeter footings on which they rest, a variety of floor slab retaining anchors and hook bolts may be used.
Description of the Embodiments :10 Figure 1 is a plan view of a sample cross section taken through a typical straight wall panel junction of two adjacent wall panels 10, 12, about ilm above the floor slab (not shown).
The sketch illustrates the matching profiles (male female) of the adjoining panel vertical edges, 14, 16 and shows how they interlock following the assembly process.
Each of the edges 14, 16 is defined by the formwork 20, 22 which in this embodiment is retained with the panels 10, 12. The formwork may be pressed metal or extruded plastic formwork 20, 22 (as illustrated in Figures 3 and 4) that is permanently attached to each wall panel, 10, 12.
•The basic geometry of the joint surfaces provides lateral restraint and automatically aligns the finished faces of the adjoining panels 10, 12.
You can also see the fluted plastic strips 18 (fitted into the semicircular recesses of the female formwork 22) that are brought into contact with the salient angles of the adjoining panel 10 to form a weather and vermin proof seal. The plastic strips 18 could alternatively be in the form of compressible plastic tubes (not shown).
.0.1895527 6 The formwork 20, 22 guarantees the accuracy of the panel edge profile and ensures that the locking device 27 (see Figure 2) is held in the correct position during concrete placement. The formwork will also protect the edges from damage.
Service ducts 24, 26 may also be formed within the panels 10, 12.
For ease of explanation, reference is now made to Figures 6a to 6d which illustrate the entire edge profile 14, 16 of two adjacent wall panels 10, 12. For the most part, the edge profiles 14, 16 are the same as illustrated in Figure 1 which is replicated by Figure 6b.
The adjacent panels 10, 12 also include a locking device 7 which comprises a locking pin 28 provided on the panel 10 and a keeper 30 provided on the panel 12. The form of the locking pin 28 and keeper 30 are explained in greater detail in connection with Figures 2-5 and 7.
oi The profile of the female edge 16 is provided with recesses 32 above each of the keepers 30. The locking pins 28 each engage with a respective keeper 30 when the panels 10, 12 are in edgewise abutting relationship. In order to assemble the panel with the panel 12, the panel 10 is raised above the level of the panel 12 so that the locking pin 28 is received in the recess 32. The panel 10 is then lowered until the locking pin 28 is at least partially received in the keeper Figure 2 is a more detailed cross section corresponding to Figure 6d showing the profile of adjoining wall panels 10, 12 prior to their assembly and shows the male and female components of the concealed gravity activated locking devices 28, 30 that secure the panels together during the erection process.
The locking devices 28, 30 are attached to the respective slab edge formwork 22 in the factory and become permanently secured to the concrete wall panels 10, 12 by a number of deformed bars 45 (see Figure 5 for further details) whose ends have been cogged so that they become embedded into the concrete.
3041895527 7 The number of locking pins 28 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 Figure 3 is a more detailed cross sectional view through the vertical wall edge formwork 22 (female) showing a gravity activated locking pin keeper 30 attached.
The sketch also shows the grub screws 36 that are used to attach the locking pin keeper 30 to the formwork 22 in the factory.
The outer extremities of the formwork 22 have been perforated and folded back at an angle of 45 degrees, so that they become permanently embedded into the concrete panel 12 during the casting process.
You can also see semi-circular recesses 37 that are used to hold the fluted plastic weather and vermin proof strips 18 (see Figure 1) in place prior to the assembly process.
°•15 The formwork 22 can be manufactured of pressed metal or extruded plastic, depending on the corrosive nature of their environment.
Figure 4 is a more detailed cross sectional view through the vertical edge wall formwork 20, (male), showing the gravity activated locking pin 28 attached.
The sketch also shows the grub screws 38 that are used to attach the locking pin 28 to the formwork prior to placing the concrete.
The outer extremities of the formwork 20 have been perforated and folded back at an angle of 45 degrees, so that they become permanently embedded into the concrete panel 10 during the casting process.
U4895527 8 You can also see the salient angles of the protruding ribs 40 that will compress the fluted plastic sealing strips 18 located in the semi circular recesses 37 of the female panel 12 (see Figure 3).
The formwork 20 can be manufactured of pressed metal or extruded plastic depending on the corrosive nature of their environment.
Figure 5 illustrates the gravity activated locking device 27 (that is concealed within the internal recesses of the cross sectional profile of each wall panel 10, 12) that progressively draws the panels closer together during the assembly process.
The locking pin 28 is made up of two components, a tapered pin 42 and a square hollow keeper 44 (refer Figure 5a). The tapered pin is 150mm long section of 19mm i 4 square hollow tubing 42 that is fitted inside a 75mm long piece of 25mm hollow tubing 44.
One end of each piece 42, 44 is placed so that it is flush with the other so that of the 19mm square tubing 42 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 to Figure A piece of flat mild steel 48 with a 10mm internal thread 50 is welded to the bottom of the female keeper 30 that will be located closest to the top of the wall panel 12, to accommodate a 10mm bolt 52 for final fastening.
Each component of the locking devices is attached to their respective formwork hosts 20, 22 with grub screws 36, 38 prior to placing the concrete and are permanently attached to the concrete wall panels 10, 12 by deformed bars 45 that have had their ends cogged.
Figure 5 illustrates the various components of the gravity activated locking device 28, 30 and shows it before (Figure 5a) and after assembly (Figure J0.1895527 9 Figure 6 is a plan view, section and end elevation of the male and female wall panel edge profiles 14, 16, as discussed above.
Figure 7 is an isometric projection of a typical wall panel 10 (not to scale).
The diagram shows the interlocking profile of the panel edge 14 together with the male section 28 of the concealed, gravity activated locking device that has been secured to the panel 10 during the casting process.
The tapered pin 42 that engages with the corresponding keeper 30 on the female panel 12 is clearly visible.
The elliptical voids that provide service ducts 24 for plumbing and electrical 10 services are also clearly visible on the top of the panel Figure 8 is a cross section taken through the junction of the external wall panel 10/12 and the slab edge rebate 54 and perimeter footing 56 upon which the wall panel 10/12 rests.
The drawing illustrates the cross sectional profile of the bottom edge 58 of the 15 external wall panel 10, 12 and shows how the outermost inclined surface 60 has been extended downward to provide a drainage outlet for any moisture that may accumulate within the slab edge rebate 54.
Purpose made metal formwork 62 will be used to create the slab edge profile and hold the wall panel retaining devices (see Figure 10) securely in place during the casting process.
The fluted plastic, weather and vermin sealing strips 18' are also visible in the semi-circular recesses 37' on the internal face of the panel edge.
Figure 9 is a cross section taken through the bottom edge 58 of an external wall panel 10, 12 and clearly shows the shape of the formwork 64 used to achieve the finished profile.
)04895527 The sketch illustrates how the outer inclined surface 60 has been extended downward to allow the drainage of any moisture that may accumulate within the slab edge rebate 54.
As with the wall edge formers 20, 22, the inner and outer extremities 66 of the bottom edge formwork 64 have been perforated and folded back at an angle of degrees so that they become embedded into the concrete and permanently attach the formwork to the panels 10, 12.
The metal or plastic formwork 64 will protect the edges from damage during handling and transportation.
Figure 10 is a cross sectional profile of the formwork 62 that is used at the t, perimeter strip footing 78 which forms part of the floor slab formwork 76.
The formwork is made of heavy gauge pressed metal and incorporates escape holes 68 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 62 will mould the profile of the concrete to match the bottom edge of the adjoining wall panel 10, 12.
•i Grub screws 70 will be used to secure wall panel restraining brackets 72 to the formwork 62 prior to placement of concrete. These brackets cooperate with restraining anchors in the wall panels 10, 12 as described in connection with Figures 11 to 14. The location and frequency of the restraining wall anchors would depend on the length of wall panel 10, 12 involved and be specified during the detailed design stage.
The formwork 62 would be suitably braced to resist the loads applied during the placement of concrete.
Figure 11 provides detail of the anchor system 71 to provide a means of securing the wall panel 10, 12 to the floor slab 76. A wall panel restraining bracket 72 is cast into the floor slab 76.
)04895527 11 The retaining bracket 72 is attached to the perimeter formwork 62 at predetermined intervals (depending upon the length of the wall panel being placed) prior to placing the concrete.
A pair of deformed bars 80 with cogged ends attached to the underside of the restraining bracket 72, permanently secures it to the floor slab and resist any physical or mechanical loads that may be applied (via wind etc).
Once a wall panel 10, 12 has been attached to its neighbour and is resting on the slab edge rebate 54, it is secured to the restraining bracket 72 in the following way. The wall panel 10, 12 has a keeper 30 closest to the slab which includes a high tensile pin 82 from which a hook bolt 84 may be depended. The hook bolt 84 is firstly manoeuvred so that it engages with the high tensile pin 82. The turnbuckle 86 is then rotated so that the thread 88 is extended enough to allow the V shaped head 90 to pass between the angular faces of the retaining bracket 72. The V shaped bolt head 90 is then turned at right angles so that the wings of the head 90 fit under the inclined surfaces of the retaining bracket 72. The turnbuckle 86 is then tightened and as the bolt becomes shorter, the V shaped head 90 is progressively moved closer to a vertical position directly beneath the hooked bolt 84 and keeper The turnbuckle 86 is progressively turned until the required tension is reached.
The wall panel 10/12 is now permanently secure and the anchor system will be 20 concealed within the joint as the next wall panel 10/12 is placed.
ooool Figure 12 is a cross sectional profile of an internal wall panel 92 showing a modified form of the anchoring system 71' used to locate it and restrain it to the floor slab 76.
A retaining strip 94 is made of heavy gauge steel and is attached to the floor slab 76 with dyna bolts 96.
'01895527 12 Strategically located penetrations provide access for the installation of the standard hook bolts 84 to enable the free end of the wall panel 92 being placed to be secured to the floor slab.
Mastic would be applied to the underside of the retaining strips 94 to seal any gaps and the salient angles 98 of the inverted angles would make contact with the fluted plastic strips 18' located in semicircular grooves in the bottom edge of the wall panel 92 to complete the seal.
Each of the retaining strips 94 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.
StFigure 13 is a cross section through a bottom edge former 100 for an internal wall panel 92.
The profile is similar to the corresponding external panel, bottom edge former 20/22 with the exception that the protruding ribs are of equal height.
The profile also incorporates semi circular recesses 37' for the fluted plastic sealing strips 18' and has its inner and outer edges 66' folded back and perforated to allow them to become embedded in the concrete panel 92 during the casting process.
Figure 14 is a more detailed side view of the retaining bracket 72 with hook bolt 84 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 various combinations of the Wall, Footing, Floor slab, Ceiling or Roof panels.
)0,1895527 13 Figure 15 is a plan view of a typical, right angled wall junction between an external wall panel 10/12, and internal wall 92.
The sketch illustrates the cross sectional shapes and edge profiles of the respective wall panels 10/12, 92 and shows the location of the gravity operated locking device 27 and the fluted plastic weather and vermin seals 18.
As with the straight wall junction, (refer to Figure 5) the uppermost gravity activated locking pin 28 has provision for the installation of a retaining bolt 52 to make the joint fast and secure the panels firmly together.
The external panel 10/!12 would be placed first and be secured to the concrete slab 76 using the anchoring system 71 as described in Figures 11 and 14.
The sketch also shows the location of the service ducts 24 to accommodate plumbing and electrical items.
oo:oo :0 Most of these junctions would involve internal wall panels 92 that would be 000 0 secured to the floor slab 76 using the anchoring system 71' illustrated in Figure 12.
15 Figure 16 illustrates a plan view of a typical external corner and shows the cross 60" sectional profile of the adjoining panel edges.
0000 The sketch illustrates corner panels 10', 12' that incorporates imitation quoins 102 as an architectural feature on the corner of the wall panels 10', 12'.
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 18.
In the situation illustrated, the right hand panel 12' (female) would be erected first and once in position would be fastened to the floor slab at each end using the anchoring system 71 as illustrated in Figures 11 and 14.
)0,1695527 14 Temporary props (not shown) would be required to brace the first panel 12' and could be removed as soon as the adjoining wall panel 10' had been locked in place.
Figure 17 illustrates a plan view of the edge formwork 22' for an external corner female panel 12' and shows the gravity locking device keeper The sketch shows how the extremities 66" of the formwork have been folded back at 45 degrees and perforated so that they become permanently embedded into and attached to the panel 12'.
The sketch also illustrates the grub screws 38 that attach the keeper 30 to the formwork 22' prior to concrete placement.
10 Deformed bars attached to the rear of the keeper 30 (omitted for clarity) have oo. ~their ends cogged to secure the keeper 30 to the concrete wall panel 12' during the casting process.
Figure 18 illustrates a plan view of the edge formwork 20' for an external corner male panel 10' and shows the gravity activated locking pin 28.
,15 The sketch shows how the extremities 66"' of the formwork have been folded Sback at 45 degrees and perforated so that they become permanently embedded into and attached to the panel The sketch also illustrates the grub screws 36 that attach the locking pin 28 to the formwork 20' prior to concrete placement and the semicircular recesses 32' that hold the fluted plastic sealing strips (not shown).
Deformed bars (omitted for clarity) attached to the rear of the keeper 44 have their ends cogged to secure the keeper 44 to the concrete wall panel 10' during the casting process.
)10-895527 Figure 19 is a cross section of a house 104 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 locking devices 27 and anchoring systems 71, 71' described on the previous pages.
All of the panels used 10, 12, 10', 12', 92 would be manufactured off site in a factory to a standard shape, form and finish before being transported to the site.
The concrete slab 76 would have been poured using the standard rebated edge formwork 62 also previously described in this specification.
S.:10 The panels 10, 12, 10', 12', 92 would be loaded onto the delivery trucks and placed in racks (not shown) containing timber mouldings to protect their bottom edge profiles. A crane would lift the panels into position carefully following the predetermined assembly sequence previously described.
The erection process begins with the placement of an external panel 12' on the 15 furthermost corner of the site. The first corner panel 12' would be lifted into position and carefully lowered to rest on the protruding ribs 40 of the perimeter slab edge rebate 54.
S Once adjusted for lateral alignment (using the gauge provided) the panel would be bolted to the floor slab 76 using the anchoring system 71 provided. The panel 12' would then be temporarily braced and the lifting bridle removed.
The crew would then attach the crane to the adjoining corner panel 10' and manoeuvre it into position above the upstanding ribs 40 of the slab edge rebate 54 and slowly lower the panel 10' so that the gravity activated locking pins 28 engaged the keepers 30. Once in position the uppermost locking pin would be made fast by inserting and tightening a bolt 52 (see Figure 5a) and the free end of the panel 10' would be secured to the floor slab 76 using the anchoring system 71 (see Figure 14).
)0,1895527 16 At this point the panels 10', 12' 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 92 to complete the first room. Before these panels 92 can be erected the site crew would need to place and secure the pressed metal locating and restraining strips 94 that are shown in Figure 12.
As with the external walls, the internal wall panels 92 would be lifted and manoeuvred into position over the upstanding ribs 19 of the restraining floor strips 94 and gradually lowered to engage the gravity activated locking device 27. The hook bolt 84 would be manoeuvred and hooked onto the high tensile pin 82 located in the bottom end of the keeper 30 and the V shaped bolt head 90 inserted into the restraining strip 94 and then tightened to the required tension.
This process would be continued until all of the panels had been placed.
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 S- 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 Flat ceiling panels a Raking ceiling and structural roof panels )0,1895527 17 An example of such a building has been illustrated in Figure 19.
The drawing shows the manner in which the structural ceiling panels 106 interlock with the top edges of the supporting wall panels 10/12, 92 using minor variations of the edge profiles (14, 16). They are fastened in position using the locking device 27 previously described in this specification.
As with the standard male and female wall profiles, the fluted plastic strips 18 provide a barrier against weather and vermin and are protected by their internal location from physical and mechanical damage. Erection of the panels 106 follows a predetermined sequence with the lateral restraint (or sliding restraint) of the structural ceiling panels 106 being provided by engagement of the iocking devices 27 at the apex of the ceiling panels.
:A timber or metal fascia 108 (see Figure 21) would be screwed directly to the outer edge of the trimmed end of the structural ceiling panel 104 and a roof gutter 110 °attached.
Metal roof sheeting 112 with an appropriate vapour barrier would be screwed directly into the structural ceiling panel 106 using proprietary fasteners. The roof would be completed in the traditional fashion using standard sheet metal trimming and flashings.
S* Alternately battens (not shown) could be screwed directly onto the structural ceiling panels 106 and a conventional tiled roof provided.
Figure 20 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 106.
As indicated, each of the structural ceiling and roof panels 106 incorporate a series of hollow tubes 114 (elliptical in shape) that run the full length of the panel to provide access for plumbing and electrical services.
)0,1895527 18 These voids 114 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 114 would be turned downward so that they penetrated the face of the panel 117 in the area adjacent the eaves (Figure 21) and terminate in a plenum chamber formed at the ridge.
A vapour barrier 116 (sisalation 450 or similar) would be placed over the roof panels 106 and colorbond roof sheeting 112 fixed directly to the upper surface of the structural roof panel 106.
Referring to figure 21, as the air in the ventilatio ducts 114 becomes heated by 10 the radiant energy from the sun, it expands and gradually rises up the ducts 114.
Replacement air would enter the void through the aperture 118 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 120 and a thermostat and climate control would determine whether the hot air would be evacuated to the outside on hot summer days or be pumped into the house during the cooler days of autumn, winter or spring.
ooo• Removable covers 122 would keep the ducting vermin proof and facilitate S seasonal cleaning.
Figure 21 is a cross section drawn through the junction of an external wall 10/12 and the structural, solar roof panel 106 at the eaves. The sketch illustrates how air enters the ducts 114 through the underside of the structural solar roof panel 106 adjacent to the eaves and journeys up the sloping ducting toward the ridge.
Figure 22 is an elevation of the ridge end of a typical structural solar roof panel 104 and shows the elliptical shaped voids 114, the roof sheeting connection detail and the gravity activated locking devices 27 that would be used to secure adjoining panels.
Alternatively, mechanical or manual locking devices 130 may be used (see Figure 3-895527 19 These panels 104 would be joined at the ridge using the typical interlocking profile illustrated in Figure 19 and secured by locking device 27 or the type described in Figure The panels would also be secured to their supporting walls 10, 12 using an anchoring system of the type illustrated in Figure 11.
Figures 23 and 24 are sectional views drawn through a number of structural, solar roof panels 104 that have been joined together and extend along the ridge 109.
The sketch shows the rebated section 124 of the panel that has been removed above the elliptical shaped ducting 114 and the remaining lower section that will form the floor of the plenum chamber 120.
The interlocking profile of the adjoining panels 104 and the locking devices 27 that secure them together are also visible in Figure 24.
SoThe solar roof panels 104 could be manufactured in a range of widths depending on the width of the rooms below.
.ooo The semicircular plenum chamber panels may also be manufactured in various widths and lengths.
Figure 23 is a longitudinal section through a typical structural solar roof panel and shows the rebated section 124 that has been removed to form the plenum chamber.
Figure 25 is an elevation of a typical solar panel roof 104 showing how the panels are assembled and connected together at the hip 126.
The sketch shows the elliptically shaped ducting 114 and the rebate 124' of the panels that have been removed along the top edge adjacent to the hip 126 to form a small plenum chamber.
)).1895527 For clarity the sketch has been drawn to separate the lower section of the roof panels 104 from the fascia 108 to illustrate how the hinged, fly proof screen panels 128 align with the ventilation ducting 114.
The panels 104 will be joined to one another and attached to the walls 10/12 upon which they rest using a combination of manually and mechanically activated locking devices 130 similar to those illustrated in Figure Figure 26 is a cross section of a pressed metal fascia 108 that has been designed for use with the lightweight concrete, solar panels 104.
The fascia 108 is attached to the roof panels 104 by inserting the bottom edge S. :10 134 into a circular recess 132 that has been formed in the underside outer edge of the 0: panel 104 during the casting process.
The fascia 108 is then rolled so that the top edge 136 rests on top of the outer edge of the roof panel 104 and is screwed into place.
The fascia 108 has a series of removable, perforated, sliding screen panels 128 15 that align with the hollow ventilation ducts 114 (elliptically shaped) located in the centre of the solar panels 104. The profile of the removable sliding shutter, incorporates semicircular ribs around its perimeter to accommodate fluted plastic strips (not shown) that will be used to secure the flywire into position.
•ooo° Figure 27 is a cross section of another version of the metal fascia 108' 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 108' 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 128 is better protected from the weather.
J0,4895527 21 Although the fascia profile is different, the sliding ventilation shutter 128 would be exactly the same and be interchangeable with the previous version.
Figure 28 is a section and elevation of the sliding fascia panel 128.
The panel is attached to the pressed metal fascia by forming a series of crenellations 140 along the upper edge of the ventilation panel 128.
The bottom edge of the sliding panel has also been rolled back to form a spring clip that secures the panel to the lower protruding rib on the fascia 108.
Figure 29 is an elevation of typical external corner arrangement of a hip roof using solar panels 104 and the pressed metal fascia with sliding fly proof panel 128.
10 Figure 26 illustrates how the roof gutter 110 fits onto the uppermost stiffening rib and affords some overhanging protection from rain beating against the panel 128.
Figure 29 also illustrates the optional sliding shutter 128 which is attached to the hinged panel and used in time of dust storms or bush fires.
Figure 30 shows the construction details of the manually and mechanically activated locking devices 130. These are used in situations where it is not possible to use the standard gravity activated locking mechanism 27 i.e. where the placement of a panel requires a compound or multi directional movement to place it in its final resting place. A typical situation includes the placement of a roof panel 104 where the panel rests upon the v shaped protrusions located on the top of the supporting walls 10/12 and then must be moved sideways to close the joint. (The sideways movement is to effect the joint at the ridge 109 by means of the locking device 27).
As with previous embodiments, facing edges of each adjoining panels 104 would be provided with keepers 150 as shown in Figure Manually activated locking pins 152 would be inserted in the top (adjacent to the ridge) and the bottom (adjacent to the fascia) keepers 150 and driven into place. A bolt 154 would be inserted and tightened to make the joint fast.
)04895527 22 As shown in Figure 30a, to secure the mid section of the panels 104 the mechanically activated locking pins 152' would be engaged by placing a spanner onto a hexagonal headed bolt provided in a recess, the bolt being connected to a pinion 156 and the pinion turned to move the rack 158 and attached locking pin 152' into the keeper 150 on the panel.
Figure 31 is a cross section through a typical two storey house 104' in which all of the wall 10/12, 92, floor 160 and roof panels 106 are manufactured of precast concrete.
The sketch shows how the panels are assembled and connected to one another.
:10 Figure 32 shows the connection details of the external and internal wall floor, wall roof panels and the devices used to fasten them together.
Figure 33 is an illustration of a polyethylene roof sheeting system 162 that incorporates a solar water heating device.
In the system illustrated, the profile of the sheeting 112 is similar to custom orb 15 and contains a series of split hollow pipes 164 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 166 that would be thermo welded to the sheeting. The split tubes would be connected to a split pipe 164 at the ridge end of the sheeting using tee shaped, moulded split fittings 168.
Cold water would be pumped through the bottom section 172 of the split tube via the split tube manifold and travel down the roof sheeting 112 toward the fascia 108. The water would transfer to the top section 170 of the split tube adjacent to the fascia 108 and be further heated as it travels up the tube toward the ridge end of the roof sheeting 112.
0,1895527 23 The hot water would enter the top half 170 of the split tube piping 164 via the tee fittings 168 at the ridge and be conveyed back to a storage vessel (not shown).
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, dishes and clothes washing or for floor slab heating, depending on the storage capacity and the environment it is used in.
The features and benefits that result from this invention are as follows: 0 Lower cost *0 Consistent, high quality finish see Unlimited range of external wall textures, colours and finishes Reduces on site construction time Minimises the amount of trades required Minimises construction waste and on site rubbish and debris 15 0 As the building is manufactured entirely of concrete: o Floor slab and footings o Internal and external wall panels o Ceiling panels o Roof panels ooo•• Is it 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 104895527 24 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.
These problems have been overcome by at least preferred embodiments of the present invention: 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 o• 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 edge incorporates two semi circular recesses into which fluted, compressible plastic tubes are inserted (refer Figure 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 0,1895527 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 Figures 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 :I incorporate elliptically shaped voids that are located in the centre of the wall o: i panels and extend from the top of the panel to a point 150mm from the bottom (refer Figure 3).
eoeo

Claims (24)

1. A building system including: a plurality of concrete components; and a locking device for securing adjacent concrete components together, wherein each concrete component has a first edge profile which is engageable with a second edge profile provided on another concrete component, wherein each of the first and second edge profiles are shaped profiles whereby at least a portion of the first edge profile is adapted to abut with at least a portion of the second edge profile while receiving the locking device between the first and second profiles. "o O
2. The building system as claimed in claim 1 wherein the first and second profiles S° are such to substantially conceal the locking device therebetween when engaged. :i
3. The building system as claimed in claim 1 or 2 wherein the first and second profiles are substantially uniform throughout their length.
4. The building system as claimed in any one of the preceding claims wherein each of the first and second profiles extend for the length of the associated edge of the component.
5. The building system as claimed in any one of the preceding claims wherein the first profile comprises two spaced ridges defining a recess therebetween to receive an associated first part of the locking device.
6. The building system as claimed in claim 5 further including a second part of the locking device associated with the second profile, wherein the second profile comprises a recess to accommodate the two spaced ridges the first part of the locking device and the second part of the locking device.
7. The building system as claimed in claim 5 or 6 wherein the first profile includes two spaced substantially flat surfaces on either side of the spaced ridges which engage with corresponding flat surfaces provided on the second profile. )01695527 27
8. The building system as claimed in claim 7 wherein the two flat surfaces are level with each other.
9. The building system as claimed in claim 7 wherein the two flat surfaces are offset from each other.
10. The building system as claimed in any one of claims 6 to 9 wherein the first and second parts of the locking device are fixed relative to their respective profiles.
11. The building system as claimed in any one of claims 6 to 9 wherein at least a portion of one of the first and second parts of the locking device is moveable relative to the other.
12. The building system as claimed in claim 11 wherein the moveable part is manually operable.
13. The building system as claimed in any one of claims 6 to 12 wherein one of the oooee S first and second parts of the locking device includes a tapered pin and the other of the first and second parts includes a keeper to receive the pin.
14. The building system as claimed in claim 13 wherein the tapered pin and the keeper are of substantially square cross section, the keeper having side dimensions that are commensurate with the side dimensions of the recess in the first profile.
The building system as claimed in claim 13 or 14 wherein each tapered pin forms ooooo part of a tapered pin assembly having portions which are cast into the associated concrete component and each keeper also has portions which are cast into its associated concrete component.
16. The building system as claimed in any one of the preceding claims wherein the second profile includes recesses to receive fluted plastic strips for weather or vermin deterrence.
17. The building system as claimed in any one of the preceding claims wherein the concrete components are wall panels. )C8895527 28
18. The building system as claimed in claim 17 wherein the wall panels are pre-cast or tilt-up wall panels.
19. The building system as claimed in claim 17 or 18 wherein the wall panels each have said first profile on an end edge and said second profile on the other end edge.
20. The building system as claimed in claim 17 or 18 or 19 wherein the wall panels have said first profile on an end edge of one wall panel and said second profile on a side face of another wall panel or vice versa.
21. The building system as claimed in any one of claims 17 to 20 wherein the wall panels have said first profile on an end edge of one wall panel and a second profile on an end edge of another wall panel wherein the wall panels meet substantially orthogonally to each other.
22. The building system as claimed in any one of claims 1 to 21 wherein the concrete components include a slab or building footings having one of said first and second profiles and at least one wall panel having the other of said first and second profiles.
23. The building system as claimed in any one of claims 1 to 22 wherein the concrete components include at least one wall panel having one of said first and second profiles *I and at least one ceiling panel having the other of said first and second profiles. S*
24. The building system as claimed in any one of the preceding claims wherein the first and second profiles are defined by formwork components on the concrete °ogo° components. The building system substantially as hereinbefore described with reference to the accompanying figures. Dated 1 February 2007 Freehills Patent Trade Mark Attorneys Patent Attorneys for the Applicant/s: Roger A Farquhar
AU71452/00A 2000-11-08 2000-11-08 Precast concrete building system Ceased AU785414B2 (en)

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WO2008014551A1 (en) * 2006-08-01 2008-02-07 Bluescope Steel Limited Wall cladding
CN112324136B (en) * 2020-10-15 2022-05-17 中铁八局集团第三工程有限公司 Sealing strip for building secondary structure template caulking and sealing construction method
CN113323182B (en) * 2021-05-24 2022-03-25 无锡市新兴建筑工程有限公司 House building wall structure and construction method
CN116290756B (en) * 2023-05-13 2023-08-11 山西二建集团有限公司 Bottom die supporting device of steel bar truss floor supporting plate
CN117646459B (en) * 2024-01-29 2024-04-09 广州市市政工程设计研究总院有限公司 Reinforced structure with extra-long underground structure additionally provided with induced joint anti-cracking function and construction method of reinforced structure

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GB2093085A (en) * 1981-02-16 1982-08-25 Jackpack Ltd Sealed panel joint
EP0127542A1 (en) * 1983-05-27 1984-12-05 SMAC ACIEROID Société dite: Modular thermally insulating building block having a facing, and method of constructing a building
DE3841040A1 (en) * 1988-12-06 1990-06-07 Alfons Klos MOLDED STONE AND CONNECTING PROFILE DAFUER

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2093085A (en) * 1981-02-16 1982-08-25 Jackpack Ltd Sealed panel joint
EP0127542A1 (en) * 1983-05-27 1984-12-05 SMAC ACIEROID Société dite: Modular thermally insulating building block having a facing, and method of constructing a building
DE3841040A1 (en) * 1988-12-06 1990-06-07 Alfons Klos MOLDED STONE AND CONNECTING PROFILE DAFUER

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