CN103140639A - A building structure - Google Patents

Abstract

The present invention relates to the construction of buildings as well as elements, structures and methods used in their construction. There is described a pre-fabricated formwork module (12) for a building portion. The module 12 includes two or more panels (14) each including a boundary portion (18) and one or more projecting structures (16). In the module (12) the panels are arranged such that their boundary portions (18) together define a first substantially continuous boundary for forming concrete and the projecting structures (18) project from the boundary into the concrete. The module (12) also include one or more reinforcing bars (30A) fixed, e.g. fixed to the projecting structures, in position relative to the boundary for transport and to reinforce the concrete.

Description

a building structure

technical field

The present invention relates to the construction of concrete buildings, and elements, structures and methods used in their construction. The invention will be described with respect to the construction of tall buildings. However, single story buildings and low rise buildings can also be constructed using aspects of the invention.

Background technique

Buildings with concrete elements are constructed using frames to create a temporary or permanent cast into which concrete is poured to form the structure of the building. The temporary frame is removed after the concrete cures, while the permanent frame remains as part of the building structure after the concrete cures. Current methods of providing concrete frames are very labor intensive and potentially dangerous to workers.

Traditionally, wooden frames are used. The timber frame is constructed on site using timber by a carpenter who uses the timber to create a mold in which the concrete will be shaped. Typically, multiple pieces of plywood are used to define the sides and bottom of the molds, and more solid wood frames and posts are used to hold the plywood in place. The use of wooden frames has certain disadvantages, for example, a wooden frame can only be reused a very limited number of times, it also has inherent dimensional and structural irregularities associated with natural products. Furthermore, because the frame is manually installed on site, installation tolerances are relatively loose.

Conventional wood framing for vertical walls typically consists of a pair of boards spaced apart by the thickness of the wall to be created. The panels define opposing surfaces of the wall. The boards are supported and braced on their exterior sides by wooden beams and other struts to hold them in place. The panels are also tied together at intervals to keep the walls of the frame from moving apart under the pressure of the concrete being poured into the frame. The bindings may be located along the edge of the panel or arranged so that they protrude through the wall of the panel to the panel facing in the opposite direction.

For a horizontal structure, such as a slab, the underside of the slab is defined by one or more pieces of wood (for example made of plywood) supported on wooden beams. For elevated slabs, temporary support structures need to be erected before the slabs of the frame structure are installed. Such installation is very time consuming and potentially hazardous, especially when workers install wooden panels on the bottom of frame sections so that structures like floors or beams extend horizontally to these supporting beams.

Around the edge of the wooden floor, walls are erected so as to define a volume for concrete to be poured in. Before the concrete is poured, however, many other elements need to be laid into the frame so that they can be poured into the concrete. Among these the emphasis is on reinforcing steel bars and pipes for post-tensioning tendons, openings and connectors for pipe connections and other auxiliary services (services).

The arrangement of each of these additional elements is done on site after the frame has been formed, with each additional work becoming more and more difficult and detrimental to the worker as the work area is further cluttered with other elements . For example, to install a plumbing connection in a floor slab, an installer may have to arrange multiple components between many layers of reinforced steel or other elements of the building. These elements will also need to be carried or manipulated across one of the frames to reinforce the reinforcement bars, associated straps for holding the steel together and other elements across spaced surfaces.

After the concrete has cured, the temporary frame needs to be removed. It is also time consuming and potentially harmful. In this case, workers are removing supports and structures above their heads.

More recently, modular temporary frame systems have been designed. These consist of panels with frames, typically metal, to provide structural strength. The panel surface defines the inside of the concrete mold. These systems include multiple corner modules, flat panels, etc., and these can be joined together to create the desired frame shape. These systems can be deployed faster than traditional wood framing because they can be trimmed or bolted together and typically can be used more times than traditional wood framing, but otherwise have similar disadvantages.

One way to partially avoid the labor associated with temporary frames is to use permanent frames. Steel panels, for example, can replace slabs framed on horizontal surfaces. These panels are positioned in a manner very similar to the wooden floor panels of conventional wooden frames, but do not need to be removed afterwards as they are formed into the underside of the concrete they have been used to create. In other respects, however, these systems resemble conventional wood framing.

There are also framing systems for creating standing walls, such as the AFS system, which include a series of vertically extending slab studs to which a cement board is attached on each side to define a wall cavity. These wall structures can be used as is or filled with concrete in order to create a structural wall. If they are used as frames, the panels are first erected on the site and braced. If reinforcement is required, reinforcement bars are then inserted into the interior cavity as required. Auxiliary devices can be inserted through this wall before the final pour of concrete. They can then be finished as desired.

One way to ameliorate the complexity, cost and risk of using a frame as described above is to pre-cast these concrete elements off-site, and in some cases this is only feasible.

It is therefore an object of the present invention to address one or more of the disadvantages of these prior art systems and/or to provide them with a useful alternative.

It is not admitted that any information in this specification was common general knowledge as at the priority date, or that a person skilled in the art could reasonably be expected to have identified it or understood it, regarded it as relevant or combined it in any way .

Contents of the invention

The present inventors have realized that structures similar to those described in the applicant's prior patent applications could be used as permanent frames in the construction of concrete structures. For example, frame modules for building cores, spaces or structures may be formed from elements similar in construction to those building units described in PCT/AU2009/001236 in the name of the applicant. Furthermore, if prefabricated frame modules (e.g. for slabs, beams, band beams, walls and cores) include panel assemblies similar to those described in International Patent Application PCT/AU2011/000298, then Special advantages can also be obtained.

Thus, the present invention in its various aspects provides buildings and building parts as well as different components and methods for constructing buildings.

One aspect of the invention provides a prefabricated frame module for a building section, the module comprising:

Two or more panels, each comprising a boundary portion and one or more projecting structures, the panels being arranged such that their boundary portions together define a first substantially continuous boundary for shaped concrete , the protrusions protrude from the boundary into the concrete; and

One or more reinforcement bars are fixed in position relative to the boundary (eg to the overhanging structures) for transport and for strengthening the concrete.

The protruding structures preferably comprise one or more receiving voids opening outwardly from the first boundary for receiving one or more reinforcing bars. The projecting structures defining the receiving voids are shaped to carry a reinforcing steel bar at a predetermined distance from the boundary, or more preferably at least two different predetermined distances from the first boundary. Carry at least two reinforcement bars.

Preferred forms of the module further include a retaining structure for capturing the reinforcement bars in the receiving spaces. The retention structure preferably comprises apertures which in use contact and pass through protrusions of the corresponding panel to which the retention structure is welded. The retention structure or additional structure preferably defines a second substantially continuous boundary for forming concrete spaced from the first boundary.

The receiving voids are shaped such that the panels can be formed from blanks cut from a common sheet of material, the blanks being arranged on the sheet such that at least one projecting feature of one blank is identical to a similar projecting portion of an adjacent blank. The output structures are offset and positioned within these receiving spaces of the other blank.

The module may further comprise two or more spaced apart beam members supporting the panels.

The beam members preferably have a profiled section comprising a face arranged to shape the concrete. The profile can be, but not limited to, an L, C or S or Z shaped profile.

Preferably, at least a portion of each protrusion spans the space between the beam members. The protrusions may (but are not limited to) have an L, C, S or Z-shaped profile.

The protruding structures may include openings carrying the reinforcement bars. Optionally, each protruding structure terminates in a hook for keying into concrete. The protrusions may further include a plurality of concrete flow openings through which concrete may surround a portion of the protrusion to engage the protrusion.

Preferably, each projecting structure defines a support structure carrying a reinforcing steel bar. Preferably, the support structure includes a channel.

Another aspect of the invention provides a prefabricated frame module for a building section, the module comprising:

a feature defining a substantially continuous boundary for forming concrete; and

one or more projecting structures;

The projecting structures protrude from the boundary into the concrete and define a support structure carrying a reinforcing steel bar.

The support structure may include a channel. Preferably, the support structure and the reinforcing steel bars it carries are positioned to reinforce the underlying layer of concrete.

Another aspect of the invention provides a floor slab comprising one or more modules and concrete. In a floor slab comprising modules with overhanging structures, the border portions may be positioned horizontally such that the overhanging structures overhang outwards and the concrete may cover upper extensions of the overhanging structures.

Another aspect of the invention provides a wall comprising one or more modules and concrete between the modules. In a wall comprising modules with protrusions, these protrusions may each be connected to a corresponding protrusion of another module in order to tie the modules to each other.

Another aspect of the invention provides a prefabricated frame module for a building section, the module comprising:

one or more features defining voids for forming concrete; and

positioning structure by which the module can be positioned relative to a vertically adjacent like or analogous module.

Optionally, the locating structure includes a locating element including an engagement portion by which the locating element is fixed relative to the features; and a lead-in portion for locating the vertically adjacent similar or Similar modules. Preferably, the features are complementary to those of the like module when mounted atop the like module. The module may further include an internal feature and an external feature. The outer feature may at least partially surround the inner feature to define the void around the inner feature, in which case each of the features may be tubular, whereby the defined void is tubular .

A portion of one of the features may project upwardly beyond another portion of the features to form an interior edge of a concrete structure over the other portion.

Another aspect of the present invention provides a positioning element comprising: an engagement portion configured to engage a frame module in use; and a lead-in portion for positioning a frame module in use. Similar or similar modules that are vertically adjacent.

The engagement portion may include a flange insertable to engage a frame module, and a stop portion for limiting insertion of the flange. The lead-in portion and the stop portion may form respective sides of a triangular portion. The triangular portion may be tubular.

The module preferably includes one or more reinforcing bars fixed in position relative to the features for transport and for reinforcing the concrete.

At least one of these features may include two or more panels. Each panel may include a border portion and one or more of these protrusions. Each panel is preferably at least predominantly integrally formed of sheet material. Most preferably, the panels within each feature are arranged such that their boundary portions together define a substantially continuous boundary for forming the concrete.

Each panel may include an edge portion of the panel deflected relative to the boundary portion to form an overhang extending from the boundary into the concrete.

An area adjacent the deflected edge portion may be recessed relative to the display surface of the sheet to receive an edge portion of an adjacent panel opposite the deflecting edge of the adjacent panel, whereby the adjacent panels The display surfaces of the panels are substantially aligned.

The receiving voids may be shaped for forming the panels from staggered blanks. The portions of the projecting structures defining the receiving voids may be shaped to carry a reinforcing steel bar at a predetermined distance from the boundary. The portions of the projecting structures defining the receiving voids may be shaped to carry at least two reinforcing bars at at least two different predetermined distances from the boundary.

Each projecting structure may define a support structure carrying a reinforcement bar. The support structure may include a channel.

Another aspect of the invention provides a building section comprising modules with positioning structures and concrete.

Another aspect of the invention provides a panel for a building section, the panel comprising:

a boundary section for shaped concrete, and

a projecting structure projecting from the boundary into the concrete and including openings for receiving reinforcing steel bars; and

is integrally formed at least predominantly of sheet material;

Each protrusion can terminate in a hooked form for keying into concrete.

An edge portion of the sheet material may be deflected relative to the boundary portion to shape the protrusion. A region adjacent the deflected edge portion may be recessed relative to the display surface of the sheet so as to receive an edge portion of a similar adjacent panel opposite the deflected edge of the adjacent panel, whereby the adjacent panels The display surfaces are substantially aligned.

The protrusions preferably include concrete flow openings through which the concrete may surround a portion of the protrusion to engage the protrusion.

Another aspect of the invention provides an assembly comprising two or more of the panels arranged such that their boundary portions together define a substantially continuous boundary for forming the concrete .

Another aspect of the invention provides a beam for use in a building comprising one or more features for forming concrete and concrete formed by the features. The beam may comprise modules with one or more reinforcing bars and at least one of these features is in the form of the modules.

Another aspect of the invention provides a panel for a building section, the panel comprising:

a boundary section for shaped concrete, and

One or more projections projecting from the boundary portion into the concrete and defining one or more receiving voids that open outwardly from the boundary to receive one or more reinforcing steel bars .

In some examples, the protrusion(s) may be shaped to allow the border to be folded perpendicular to the protrusions of the panel. To allow this, the protruding structure(s) may have notches therein. The panels (or before or after being connected to an adjacent panel) may be folded through the notches to create a depression in the panel, for example a channel-shaped depression.

Another aspect of the invention provides a building section comprising:

one or more panels and the concrete formed by those panels;

Each panel includes:

a boundary section; and

A protrusion protrudes from the boundary portion into the concrete.

Another aspect of the invention provides a prefabricated module for walls comprising:

two spaced apart features each defining a corresponding boundary of a void for shaped concrete;

Each feature includes one or more protrusions that protrude from the boundary into the void.

Where the protrusions are each connected to a corresponding protrusion of another feature so as to bind the features.

Another aspect of the present invention provides a method for constructing a building section, the method comprising: installing at a construction site one or more of the modules described above to create at least part of a concrete frame structure; Fill the concrete frame structure; allow the concrete to cure. Another aspect of the present invention provides a method for constructing a building section, the method comprising installing modules with positioning structures at a building site to provide a frame structure for at least a section of the building; filling with wet concrete The concrete frame structure; a similar module is mounted on top of this module.

Preferably, the concrete is allowed to at least partially cure in order to strengthen the building section prior to installation of the like modules. Optionally, the module can be left in place to protect the cured concrete during the life of the building.

Another aspect of the present invention provides a prefabricated frame module for a building section, the module comprising: a feature defining a substantially continuous boundary for formed concrete; and one or more reinforcing steel bars, The reinforcement bars are fixed in position relative to the feature for transportation and for strengthening the concrete.

The prefabricated frame module preferably includes one or more projecting structures protruding from the boundary into the concrete and defining a support structure carrying a reinforcing steel bar.

In a further aspect there is provided a prefabricated module for a wall comprising two spaced apart features each defining a corresponding boundary for a void of shaped concrete; at least one of these features Including one or more protruding structures protruding from the boundary into the void; wherein at least some of the protruding structures are connected to another feature so as to bind the features.

The various aspects of the invention are complementary. It should be appreciated that each aspect may combine features described with respect to one or more other aspects.

As used herein, unless the context requires otherwise, the term "comprise", and variations of that word such as "comprising" and "comprises" and "comprised " is not intended to exclude other additives, components, whole things or steps.

Description of drawings

A preferred embodiment of the invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a partially constructed building;

Fig. 2 is the plan view of the partially constructed building of Fig. 1;

Figure 3 is a cutaway perspective view of different parts of the building in Figures 1 and 2;

Figure 4 is an exploded view of the column;

Figure 5 is a cross-sectional view of a column;

Figure 6 is a perspective view of a prefabricated module for forming a floor slab;

Figure 7 is a perspective view of a prefabricated module for forming a beam;

Figure 8A is a cross-sectional view of a panel;

Figure 8B is a perspective view of a panel assembly;

Figure 9 is a close-up view of detail A from Figure 8A;

Figure 10 is a close-up perspective view of a portion of the building of Figure 1;

Figure 11 is a longitudinal sectional view of the floor;

Figure 12 is a transverse cross-sectional view of the floor in Figure 11;

Figure 13 is a longitudinal sectional view of the belt beam;

Figure 14 is a transverse cross-sectional view of the belt beam in Figure 13;

Figure 15 is an exploded view of a module for forming a building core;

Figure 16 is a plan view of the module in Figure 15;

Figure 17 is a plan view of another module for forming a building core;

Figure 18 is a close-up view of detail B in Figure 16;

Figure 18B is a close-up view of detail 18B in Figure 18;

Figure 19 is a perspective view of a portion of the building in Figure 1; and

Figure 20 is a close-up perspective view of a portion of a module for forming a building core;

Figures 21 to 31 illustrate a series of steps for assembling frame modules for a building core according to another embodiment of the present invention;

Figures 32A to 32D illustrate a series of steps for forming a panel from a flat plate according to an embodiment of the present invention;

Figure 33 shows an arrangement of reinforcing steel in an alternative corner arrangement to Figures 21 to 31.

34A to 34D illustrate four steps in a process for assembling and positioning a plurality of vertically adjacent wall sections formed from frame modules according to one embodiment of the invention;

Figure 34E is an enlargement of detail 34E in Figure 34A;

Figure 35 shows a side view of a protective portion of a panel used in another embodiment of the invention;

Figure 36 shows the panel of Figure 35 bearing a plurality of reinforcement bars;

Figures 37A to 37F show in more detail the process for forming frame modules using the panels shown in Figures 35 and 36;

Figure 38 shows a cross-section of a frame module constructed according to Figures 35 to 37;

Figure 39 illustrates yet another alternative panel profile which in one embodiment of the invention is specially adapted for forming a floor slab;

Figure 40 illustrates another panel profile similar to that of Figure 39, except that this profile requires about 20% less concrete than the embodiment of Figure 39 to form a slab;

Figure 41 shows a portion of a module comprising a plurality of panels of the type shown in Figure 40;

Figure 42 is a cross-sectional view of a portion of a slab formed using the panels of Figure 40;

Figure 43 shows a detail of the frame assembly of two wall modules and one slab module according to an embodiment of the invention;

Figure 44 shows a series of panels prior to being formed into a frame module manufactured according to another embodiment of the present invention;

Figure 45 shows an end view of the panels of Figure 44; and

Figure 46 shows a perspective view of a portion of the completed frame module of Figures 44 and 45.

Detailed ways

FIG. 1 shows a partially constructed building 1 . The building will eventually consist of several floors, but only two are shown in Figure 1 . In Figure 1, the structure of this part of the building 1 consists of prefabricated modules assembled so as to define an external frame structure carrying concrete reinforcement bars to strengthen the concrete (once the concrete has been poured). Concrete is not shown in Figure 1. The structure of the building shown in Figure 1 is assembled from a number of prefabricated frame modules on site, on a suitable foundation (which can be constructed using methods similar to those shown for the upper floors or conventionally), as described below of.

The building 1 comprises different building parts including floors 2 , beams 4 , columns 6 , walls 8 and a central core 10 . As shown in FIG. 2, the core layer 10 is composed of two core layer portions 10A and 10B.

As will be described, these floor sections 2 and beam sections 4 have a similar configuration. As best shown in Figure 3, the floor sections 2 and the beam sections 4 together define a floor surface 2A. The beam portions 4 are deeper than the floor portions and protrude some distance below the underside of the adjacent floor portions 2 in order to structurally support the floor 2 as well as other parts of the building. In this example, beam sections extend around the perimeter of each floor of the building and two additional parallel beams extend across the floor adjacent to the core 10 .

These floors 2 are formed by a number of prefabricated floor modules corresponding to the floor sections 2.1 to 2.9. Likewise, these beams 4 are formed by a plurality of prefabricated beam modules corresponding to the beam sections 4.1 to 4.4. The core sections 10A and 10B are formed from separate prefabricated frame modules and are separated by a beam module 4 . These columns (eg 6A to 6C) are also formed from individual prefabricated frame modules. Although not shown in Figure 1, the outer perimeter or full slab defined by the outer edges of the beam modules includes a vertical boundary for the containment of concrete within the frame. Concrete can be poured into the framework created by the modular components to create the final structure of each slab. The concrete can be poured into the entire slab in one go or in several parts.

The process for constructing a part of a building of this type generally proceeds as follows:

1. Prefabrication of the multiple frame modules required for the building. These frame modules will typically include pre-positioned within them all or most of the concrete reinforcement members required for the finished construction. Pipes for carrying other elements that need to run through or along the final concrete form (such as post tensioning tendons, etc.) are preferably pre-installed in these prefabricated frame modules. Openings or fittings extending through the final concrete form are also preferably pre-placed in the frame modules during fabrication.

2. Transport the modules to the job site. For efficiency, delivery will preferably be done in order of installation.

3. Place the frame modules on the job site to construct the required frame structure. Installation may require some temporary support to the frame modules.

4. Connect multiple frame modules to multiple adjacent modules (if required). Connections may be made by welding, bolting or other suitable means of mechanical fastening, alternatively a plurality of adjacent modules may be configured to interlock sufficiently sufficiently that no additional fastening is required prior to concrete pouring. As will be described, certain modules are designed to cooperate so as to be permanently interlocked by one continuous phase of concrete.

5. Connect reinforcements, auxiliary devices, pipes or other elements between adjacent modules if required.

6. Pour concrete into this assembled frame either part by part or all at once for the entire floor and finish the concrete as required.

7. After the concrete has fully cured, the temporary supports are removed.

As will be appreciated, other steps in the construction of a building will be carried out in a generally conventional manner.

In the example of the building of Figure 1, after the frame modules for the lower floor have been manufactured, they can be assembled on site. This starts by arranging the modules for the lower belt beam 4 and the core 10 . Floor frame modules 2.1 to 2.9 are placed between these belt beams in order to complete the floor frame. Concrete for at least the floor slab can then be poured. The lower column module 6 can then be installed. It may also be advantageous to pour the lower horizontal columns and core at this point or wait until after the upper floor slabs have been poured.

Once the framing is in place on the core and column tops, it is then fitted with the beamed framing modules of the floor slab above. These may need to be supported from below while the concrete is curing. The floor frame modules can be placed between the beams to complete the floor frame for the upper floor. The slab frame may also require temporary support. Concrete can then be poured into the upper floor frame and lower columns and core frame. This process may continue in order to create additional levels.

Construction of an exemplary floor module 12 is illustrated in FIGS. 6 , 8A, 8B and 9 . Each module 12 includes a plurality, in this case a pair, of transversely spaced apart beams 28 extending in the longitudinal direction. The plurality of panels 14 extend laterally so as to span the spaces between the beams 28 . As will be described, these panels 14 are positioned adjacent each adjacent panel so as to present a substantially continuous boundary for the shaped concrete, ie, without significant holes or gaps through which the concrete can escape. In this embodiment the panels are formed from coils of galvanized steel of around 1.6mm thickness and a number of adjacent panels are joined. It will be described that the module 12 is left in place so as to form a permanent part of the building structure. It is contemplated that the panels 14 may be formed from thicker materials in order to strengthen the permanent structure. In a preferred form, the prefabricated frame module is generally a panel assembly similar to that described in PCT/AU2011/000298. However, the structure was modified to facilitate the flow of concrete and to support and position the reinforcing steel within the module.

The panels may be formed using any suitable technique, such as roll forming, pressing, bending or molding, and the like. In addition, the panels may be preformed to have a deflected shape (for example by molding or extrusion), or may be preformed from a planar material) which is then bent to form the deflected shape, for example after folding In bending or roll forming operations.

In this embodiment, the panel 14 is roll formed to include a planar border portion 18 and an overhang 16 . The protrusion 16 extends along one of the long edge portions of the panel 14 . In the assembled module, the panels are arranged such that the protruding structure 16 protrudes into the concrete. Each protrusion 16 includes a vertical (ie, perpendicular to the boundary portion 18 ) web 16A extending from the boundary portion 18 to a horizontal flange portion 16B projecting away from the boundary portion 18 . The horizontal flange 16B terminates in a short downward return segment 16C. The flange 16B and return section 16C together form a hooked form.

The border portion 18 includes three stiffeners 20 extending along the length of the panel 14 . In this embodiment, each rib 20 is a shallow dimple (ie, deformation towards the concrete side of the panel 14 ) approximately 50mm wide by 2mm deep. The stiffeners 20 are used to stiffen the border portion 18 and resist rattling.

The border portion 18 includes a display surface 18A on the non-concrete side of the panel 14 . In this embodiment, the display surface 18A is relatively flat and includes only minor deformations in the form of small depressions associated with the ribs 20 .

As best shown in FIG. 9 , the panel 14 includes a joint region 22 that extends along the length of the panel 14 and is immediately adjacent the protrusion 16 . The junction area 22 is recessed by approximately 2 mm. The recess is approximately 50 mm wide and is adapted to receive a corresponding length of trailing portion 24 like an adjacent panel. Using such a structure, when multiple similar panels are stacked such that the tail of one panel is located in the joint area of the other panel, the display surfaces 18A of the panels are substantially aligned. A panel assembly 26 having three panels 14 arranged in this manner is shown in FIG. 8B. Within the assembly 26 a plurality of adjacent panels 14 are interconnected to each other and held in relative position, for example by spot welding along the elongated regions of overlapping material 22 , 24 .

It will be appreciated that the panels 14 of the assembly 26 together present an attractive common display surface. In the finished building, this surface can be left as is or receive a different surface treatment as required.

The projection 16 of each panel 14 constitutes a purlin integrally formed with the panel 14 in order to strengthen the panel against bending about an axis perpendicular to its length (ie about an axis parallel to the length of the module 12 ). Therefore, the panels 14 and the assembly 26 are stronger in this direction. The overhang 16 is desirably sized such that the overhang provides sufficient strength to the panel such that a frame module incorporating the panel 14 is self-supporting.

Returning to FIG. 6 , within the module 12 the pair of longitudinal beams 28 carry the free ends of the panels 14 . These beams 24 are formed by an L-shaped cross-section (ie the beam has a pair of perpendicular arms in cross-section). One of the arms of each beam is located below the panels 14 to provide support, while the other arm of each beam projects upwards to about the same level as the protrusion 16 (ie in the direction of the concrete).

These beams 28 have a dual function. They strengthen the module by resisting bending about an axis perpendicular to the module and provide an edge for shaping the concrete, as will be described in more detail below. 11 and 12 are cross-sectional views of a floor 2 incorporating modules 12 and concrete 34 . The variant of module 12 shown in these figures does not include return section 16C.

Each web 16A includes a series of apertures 30 spaced along its length (ie, across the module 12). Each opening 30 carries a corresponding reinforcement bar 30A. Thus, the position of the openings 30 protruding from the structure 16 determines the position of the reinforcement bars 30A within the concrete 34 . As shown, in the slab 2 the openings 30 are positioned low down the web 16A such that the reinforcing bars 30A are loaded towards the bottom of the concrete 34 to resist the load on the slab 2. Tension associated with weight.

A series of concrete flow apertures 32 are arranged along the length of the web 16A. In this embodiment, the concrete flow apertures 32 are spaced at the same pitch as the apertures 30 and are staggered therefrom. The apertures 32 each have a triangular form with the apex pointing downward. As such, the apertures 32 are relatively narrow, leaving more material in the lower portion of the web 16A around the apertures 30 . These concrete flow openings are relatively large to allow wet concrete to flow through them and to form a continuous phase of solid concrete as the wet concrete cures. Thus, the concrete flow openings 32 allow stress to be transferred between portions of the concrete floor passing through the web 16A and allow a portion of the overhang 16 to be surrounded by a continuous phase of concrete so that the concrete and the overhang Out structure 16 interlocks. The horizontal flange portion 16B of this variant in FIG. 11 and the hooked forms 16B, 16C of this variant in FIG. 8A also enhance the engagement of the projecting structure 16 with the concrete 34 . It should also be noted that reinforcing steel bars may be installed on these panels via intermediate members, or in some cases may be placed and retained on these overhangs instead of (or otherwise) on In the opening formed therein.

As already described, the underside of the floor 2 presents a rather attractive display surface 18A, forming a ceiling for the lower floor of the building.

The module 12 is prefabricated, ie manufactured at the fabrication facility and transportable to the building's site. In this embodiment, the reinforcement bars 30A are secured relative to the panels 14 for transportation by cooperating with the openings 30 . Each side of the openings 30 is about 1 mm larger than the outer diameter of the reinforcing bars 30A. While this is often considered to be a rather loose fit, by virtue of the rough textured nature of the reinforcing bar and tolerances in its straightness, when a reinforcing bar engages the openings 30 along the length of the module 12, it is found that An adequate fixation exists between the rebars 30A and the panels 14 for the modules 12 to be transported to the worksite with an acceptable degree of movement of the rebars 30A. If the slippage of the reinforcing bars is excessive, they may be tied by wire to one or more projections 16 of these panels in the manner in which reinforcing bars are conventionally tied to other such bars or straps Way. Other rebar fastening structures are also considered.

The engagement between the reinforcing bars 30A and the openings 30 also provides a function in use. When these reinforcing bars 30A are positioned at points along their length, they are restrained from buckling outwardly when placed under compression. In this way, the apertures 30 replace the time consuming straps associated with prior art reinforcement structures.

The floor 2 is formed by providing the module 12 (including its panels 14, reinforcement 30A and beams 28) to the building site as a pre-assembled unit. The module 12 is placed in place. For larger spans, such as in building 1 in FIG. 1 , more structural support can be provided to the module 12 . For example, one or more pillars or supports may be placed low between the underside of the module 12 and the floor to temporarily support the module 12 . The end portions of the module 12 may be capped by a separate frame part, or may cooperate with another frame module as will be described. Concrete is then poured into the modules 12 to a depth slightly deeper than the height of the protruding structures 16 so that the surface 2A of the finished concrete is desirably not marred by the protruding frames and so that the reinforcement bars have the required coverage for durability. In this embodiment the overhangs 16 are about 100mm high and the concrete 34 is about 130mm deep such that the upper extent of the overhangs 16 is about 30mm below the surface 2A.

It will be appreciated that the preferred form of the panel construction of the present invention may form a protective skin around the concrete. In particular, the skin may be relatively impervious to water and thereby help prevent degradation of the concrete over time, for example by reducing water penetration into the concrete. Another advantage is that the metal skin prevents moisture loss from the concrete and reduces shrinkage normally associated with concrete structures.

The beam module 12' in Figure 7 is similar to the floor module 12, however, it has different dimensions to provide additional strength. Its overhang 16' is slightly deeper than that of the floor module. In this embodiment, these protrusions 16' are about 300mm deep. As best shown in Figures 13 and 14, the concrete flow apertures 32 take the form of larger hexagonal apertures spaced along the length of the web 16A'. Reinforcement openings 30' are spaced along the upper and lower portions of the web 16A'. The lower reinforcement openings carry reinforcements in the same way as the openings 30 of the wall module. These upper reinforcement openings 30' also carry reinforcements positioned in the upper layer of concrete to resist tension in this area.

Unlike the L-shaped beams 28 of the floor module 12, the beam module 12' includes more complex "Z-shaped" beams 28' extending along its sides. Each beam 28' includes an L-shaped portion arranged in a manner similar to that of the L-shaped beam 28, and also includes a horizontal flange portion 28A' outwardly on either side of the module 12'. stick out. The horizontal flanges 28A' are arranged at a height slightly lower than the upper extent of the protrusions 16'. These flanges 28A' form a structure interoperable with another module, such as the floor module 12.

In use, a floor module 12 may be arranged in a direction perpendicular to the beam module 12' with its end seated on one of the flanges 28A'. In this way, the open concrete receiving area of the floor module 12 opens into the open concrete receiving area of the beam module 12'. When filled with wet concrete, the concrete is able to flow between the modules to form a continuous concrete phase. The corresponding heights of the protrusions 16 and 16' and of the flanges 28' are chosen so that when installed the upper extents of the protrusions 16 and 16' are at about the same height and both are buried in the concrete. About 30mm below surface 2A.

Figure 10 is a cutaway view showing a plurality of floor modules 12, arranged for co-operation with beam modules 12'. As can be seen, the floor modules 12 each span between two adjacent beam modules 12' and are supported atop flanges 28' of the beam modules 12' in the manner described above.

15-20 illustrate exemplary modules for forming the core of a building.

Figure 15 shows the general construction of these core modules. The modules 36 comprise an inner frame structure 36A surrounded by an outer frame structure 36B so as to define a tubular void 40 therebetween for receiving concrete (see FIG. 16 ). When filled with concrete, these modules form a tubular wall which forms part of the core 10A of the building. This tubular wall has a height corresponding to the level of the building 1 and can, for example, delimit a lift shaft, fire escape or other core structure of the building. Doors, windows or other openings may also be formed through the frame structure by providing suitable walls in the frame. The inner frame 36A and outer frame 36B structures are formed from a plurality of panel assemblies similar to those used in frame modules for floor slabs, held to each other by a plurality of vertically extending edge angles. It will be appreciated, however, that other attachment means may be used.

Figure 18 shows a detail of the two wall sections of the module 36 and how they come together at a corner. The portion 38 includes a pair of opposed panel assemblies 26' which define a void 40 therebetween for receiving concrete. The protrusions 16" of the panel assemblies 26' protrude into the void 40. In this embodiment, each protrusion 16" protrudes halfway into the void 40 and abuts a corresponding protrusion of the other panel assembly 26'. Projections 16". The adjacent projections 16" are connected to each other so as to tie the panel assemblies 26' against outward bulging caused by the weight of the wet concrete within the void 40.

As best shown in Figure 18B, the protrusions 16 may be connected by means of clips 42 in the form of simple extruded C-sections, enclosing the return flanges 16C" of the respective protrusions 16'A'. The clips 42 may engage either or both of these flanges 16B" or return segments 16C". A range of other connection forms are possible.

It is also contemplated that the extent to which these protrusions protrude into the concrete on each panel assembly 26' may vary with complementary variations in the corresponding dimensions of its paired protrusions 16", such that the paired protrusions The relative position of the connections between the outgoing structures 16" varies from one pair to one pair. In this way, the weak points associated with the connection will not be aligned along the length of the wall. As in the previous embodiments, the projecting structure of one or both wall structures forming the core module may have openings for carrying reinforcement reinforcement.

Figure 18 also shows vertical L-shaped beams 48A and 48B, also referred to as edge angles, which connect the panel assemblies 26' of the interior feature 36A and exterior feature 36B, respectively.

Figure 17 shows a second prefabricated frame structure 50 for the building core. In this case, the module 50 is used to construct a stairwell, for example as a fire escape. As can be seen, except for the outer tubular structure, similar to the core of core module 36 in FIG. 16 , the module 50 includes a plurality of interior walls (eg, 52 ). The walls are formed as part of the core module, or may be provided by separate wall modules. In either case, the frame members for forming the wall comprise complementary pairs of panel assemblies 26' bound to each other in some secure manner, for example by connecting corresponding pairs of projecting structures in the manner described above. connect.

Multiple independent wall framing modules may or may not incorporate multiple pre-assembled reinforcing steel bars. Wall modules may be configured to form a simple planar wall, or may form part of a more complex structure such as the modules 50 used to form the building core. Curved walls can also be made using multiple non-planar wall sections of the frame structure.

Figure 20 shows the top of a core frame module in situ. The inner feature 36A extends higher than the outer feature 36B. Structure for cooperating with other modules in the form of a horizontal flange 28A" extends horizontally outward from the top of this exterior feature 36B. This flange 28A" is configured for interfacing with the frame modules of the previous floor ( Typically, the beam modules 12') cooperate in a manner similar to the cooperation between the flanges 28A' of the modules 12' and the floor modules 12 described above. In use, the beam module 12' sits on the flange 28A", such that its open concrete receiving area opens into the void 40 of the module 36, so that the beam module 12' and the module 36 can be filled with wet concrete simultaneously. Filled, the wet concrete defines a continuous phase of solid concrete when cured that closely connects the walls of the building core 10A with the beams 4 formed by the modules 12'. Thus, the feature 36A defines The inner extent of the beam 4.

In this embodiment, the upper extent of the interior feature 36A terminates in a locating structure 46 around its upper perimeter. In this embodiment, the positioning structure 46 takes the form of a portion that flares out at an angle so as to define a lead in for guiding a similar module atop it into an aligned position. The lower extent of the interior feature 36A of the similar module 36 will have a correspondingly shaped lead-in so that the top core module is forced into alignment with the module 36 when it is lowered. The void 40 defined by this module 36 is complementary to, eg cooperates with, the void formed by the above-adjacent similar module 36 . In this embodiment, the voids cooperate to form a continuous tubular structure surrounding the elevator shafts.

FIG. 19 shows the building module 36 in place and spaced apart from another building module 50 defining a stairwell 54 . The module 36 is spaced apart from the module 50 so as to define a corridor 52 . Beam 4' defines the ceiling of corridor 52 (part of the floor structure of the adjacent building level above) and structurally interconnects the core portions 10A and 10B defined by modules 36 and 50, respectively.

A preferred form of frame module column 58 is shown in FIGS. 4-5 . The column comprises an upwardly projecting casing 56 of reinforcing steel bars surrounded by sleeve-like modules 58 .

The casing 56 includes a plurality of vertically extending reinforcement bars 57 surrounded by a set of straps 59 . The vertical bars 57 are tied to the straps 59 in a conventional manner to resist outward buckling.

The sleeve structure 58 comprises a pair of sleeve wall sections 12"' similar to the floor module section 12, except that the relative positioning of the openings in the web 16 has been reversed in order to move the module towards the center of the column 6 12"' of these reinforcement bars. The module 58 further includes a pair of elongated panel assemblies 26"' which cooperate with the extended L-shaped portions of the module sections 12"' to form a continuous sleeve carrying a plurality of reinforcing steel bars. Note that the openings of these webs and the reinforcing bars of the modules 58 are not shown in FIG. 4 .

These enclosures 56 have a height corresponding to that of the building level, but are offset by half the spacing so that the connection between vertically adjacent enclosures is at the floor and ceiling of the respective corresponding building levels. Appears near the midpoint between them, which corresponds to the midpoint of the thread, so that the weak point of the chain relative to the connection point between the housings is relative to the connection point between the vertically adjacent modules 58 The weak point of the link deviates. Thus, a portion of the housing 56 protrudes upwardly from below when forming the slabs of each building floor.

It will be observed in Figure 3 that the upper extent of the module 58 terminates in a plurality of outwardly extending flanges closely similar to the flanges 28A described with regard to other module aspects. The flange is configured for cooperating with the beam modules forming the upper floor such that the columns 6 and the upper floor are integral with the continuous phase of concrete.

Figure 21 shows another embodiment of a panel 2100 that may be used to form part of a wall or other structure of a building. However, the panel 2100 is similar to those of the previous embodiments, but instead has receiving voids in the form of holes or openings in its protruding portion into which reinforcing steel bars are inserted during manufacture Or in the opening, the protruding structure of the panel 2100 includes a plurality of open-ended receiving voids to enable a plurality of reinforcing steel bars to be inserted transversely into the building module. As can be seen, panel 2100 includes a generally planar border portion 2102 and an overhanging structure 2104 . The extension structure 2104 includes a plurality of upstanding extensions (eg, 2106 and 2108 ). The protruding structure 2104 is deflected substantially at a plurality of right angles relative to the border portion 2102 of the panel 2100 . In use, the projecting structure 2104 will be surrounded by concrete poured into the frame. As will be apparent from the further description below, these projecting features (eg, 2106 and 2108 ) are shaped to define a pair of notches 2110, 2112 which, in use, are used to hold and position multiple Root reinforcement.

Figure 22 shows more than 2200 panels 2100 which have been joined together to form an elongated boundary structure which may form part of a frame module. As described in the previous embodiments, the panels 2100 are preferably connected to each other by welding. The overhangs of these panels (eg, 2108 and 2106 ) are aligned with the corresponding overhangs of each other panel to provide an aligned row of overhangs for supporting reinforcement reinforcement, as illustrated in FIG. 23 . A partially assembled frame module 2300 is shown in FIG. 23 .

The assembly 2300 includes a plurality of panels 2200 from FIG. 22 and additionally includes reinforcing steel in the form of a grid 2302 of reinforcing rods. The bars of reinforcement grid 2302 are pre-welded into grid structure 2302, which can be inserted laterally between adjacent protruding structure sections (e.g., 2106 and 2108) and lowered to reinforce A mesh 2302 is suspended from these protruding structural parts 2106,2108. Preferably, the reinforcing grid 2302 may be welded to the panel structure 2200 to hold it in the correct position relative to the module. As will be appreciated, individual reinforcement bars may be inserted into the panel structure 2100 at appropriate locations, rather than using a pre-welded grid.

Figure 24 shows a structure 2400 comprising the assembly 2300 of Figure 23 and a similar frame structure 2402 placed adjacent to each other. The two panels 2300 and 2402 form the inside walls of a right-angled, corner-shaped frame module. The two structures 2300 and 2402 may be welded together at 2404 down their adjoining vertical edges. The reinforcing bars held by the two frame panel sections 2300 and 2402 can be effectively connected to each other using L-shaped reinforcing bar sections such as 2500 (as shown in FIG. 25 ). As will be appreciated by those skilled in the art, the L-shaped reinforcement bars 2500 are placed relative to the reinforcement grid of the panels 2300 and 2402 so that they overlap to the extent required by building codes. When forming walls, it may be necessary to provide multiple layers of reinforcement at predetermined distances from the boundary portions of the frame structure. FIG. 26 shows a more complex result 2600 in which the structure additionally includes a second layer of reinforced steel 2602 . This is suspended in the outermost notches in the protruding structural parts of these panel structures 2300 and 2402, as shown in FIG. connections, as shown in Figure 27.

Then, when forming the walls, it is necessary to provide the frame modules with a second border portion or skin. The initial stages of this process are shown in Figure 28. The partially assembled frame module 2800 having a first flat plate 2802 applied to a portion of a panel 2402 is shown in FIG. 28 . The sheet of material 2802 is rectangular in configuration and generally planar, and has a plurality of openings or holes 2804 formed therein. Each hole 2804 is aligned with a corresponding flange of a corresponding protrusion of the panel to which it is mounted. During assembly, the protruding structural portions of the panel structure 2402 are welded to the inside edges of the openings 2804 to mechanically connect the sheet 2802 to the panel structure 2402 . This process is repeated and as shown in Figure 29, thereby providing an outer skin on the frame module. The sheets 2802 may be positioned such that they overlap in an area along the longitudinal edges (eg, 2900). To facilitate this, the panels (eg 2802) may be provided with a small 2mm step along the overlapping edge to allow overlapping of adjacent panels such that a substantially planar outer surface results.

Next, as shown in FIG. 30 , the corners of the module 3000 can be completed by welding on the corner panels 3002 . The corner panel is generally simply an L-shaped panel covering the corners of the adjoining panel structures.

Figure 31 shows a completed frame module 3100 which may be used in a stairwell or similar part of a building. The building frame module 3100 includes double skin walls using the structure shown in connection with Figures 21 to 30 and carrying reinforcing steel between the two skins. Doors and other openings through the wall structure may be provided in such frame modules as demonstrated in previous embodiments. This is typically done by providing suitably shaped panels for configuring the opening.

Figures 32A-32D illustrate the four stages of forming a panel similar to that used in the Figures 20-31 embodiment. In an initial step shown in Figure 32A, a flat plate 3200, for example made of steel, is provided. Next, two panel blanks 3202 and 3204 are punched from each sheet of material 3200 . The panel blanks 3202 and 3204 are identical and are formed such that the protruding portion of one of the panels 3202 sits within the open receiving void of the other panel 3204 . In this manner, the two panels 3202 and 3204 may be formed from a single sheet of material 3200 with a minimal amount of wastage. Each panel blank (eg 3206) shown in Figure 32C is extracted from the pair and the profile extensions are folded as shown in Figure 32D. The panel is folded along the junction between the overhanging portion 3208 and the border portion 3210 of the panel blank 3208 and also forms an inverted flange 3212 on the distal end of the overhanging portion 3208 . The folding process may be performed using a press brake, pan break press or similar folding equipment, or alternatively may be formed with a roll forming machine. In an alternative embodiment at least some of the folding operations may be performed before the individual blanks 3206 are separated or punched from the panel 3200 .

Figure 33 shows a detail of the corner of two walls similar to that shown in Figure 31. However, a portion of the frame module 3300 shown in Figure 33 differs from the previously described corner design in that the layout of the reinforcing steel is different. The frame portion 3300 includes an outer skin 3302 that defines a first boundary for shaped concrete and an inner skin 3304 that defines another boundary for shaped concrete. These skins 3302 and 3304 are formed from panels similar to those described above. The inner skin 3304 includes a plurality of protruding structures, such as 3306, 3308, 3310, etc., on which reinforcing bars 3312, 3314, 3316, and 3318 are supported. The corner is reinforced using a pair of substantially U-shaped reinforcing bars 3322 . At the corners the U-shaped ribs overlap at their bends. These reinforcing portions 3320 and 3322 together define a loop 3324 into which a vertically extending reinforcing bar 3326 can be inserted. These reinforcing bars are tied to adjacent reinforcing bars in a manner that will be well known to those skilled in the art. As will be recognized by those skilled in the art, a range of additional reinforcing bar configurations may be used in embodiments of the present invention.

Figures 34A to 34D show how a plurality of vertically adjacent walls comprising frame modules can be stacked on top of each other in use. In general, Figures 34A-34D show the following components:

a lower frame module 3400,

an upper frame module 3402,

A pair of similar positioning elements 3404 and 3406.

These frame modules 3402 and 3400 are similar to each other, which is often the case when forming buildings with multiple floors. These frame modules have first and second skins (eg, 3400A and 3400B) as described in previous embodiments. Each module additionally includes a plurality of protrusions (eg 3400C) which in this case extend all the way across the concrete forming void within the frame module and are adapted for use in Figures 34B-34D To load multiple reinforcing bars in the manner shown in . The top edge of the uppermost protrusion 3400D includes slots 3400E and 3400F into which a corresponding downwardly extending flange of each positioning element 3404 and 3406 can be inserted. The bottom edge of the lowermost protrusion 3402A of the upper frame structure 3402 includes a pair of grooves 3402B and 3402C shaped to receive the upwardly extending lead-in portions of the positioning elements 3404 and 3406 .

Figure 34E shows positioning element 3404 in more detail. The positioning elements 3404 and 3406 are designed to be positioned in one of the two modules and provide a tapered lead-in to assist in positioning an adjacent module when they are brought together. In this example, the locating elements are formed of a plastic or metal material and are structurally elongated, and additionally help to form a seal between the vertically adjacent frame modules so that the concrete does not leaks from between the connection points between these adjacent frame modules.

Turning now to FIG. 34B , this figure shows the upper frame module 3402 being lowered down towards the lower frame module 3400 . In this illustration, the frame modules 3400 and 3402 are shown carrying reinforcing steel bars 3402D and 3400G. The positioning elements 3404 and 3406 are inserted into the grooves 3400E and 3400F of the lower frame module 3400 . As shown in Figure 34C, in the case where the frame modules 3402 and 3400 are brought together out of alignment, the lead-in portions 3404A and 3406A of the positioning elements 3404, 3406 abut against the grooves 3402B and 3402B of the upper frame module 3402. 3402C and align the two frame modules 3402 and 3400 when they are brought together. Their final aligned and connected positions are shown in Figure 34D.

Figures 35 to 38 illustrate another example of panel structures usable in a frame module according to an embodiment of the present invention.

Figure 35 shows an alternative profile shape that may be used in a panel according to an embodiment of the invention. The panel 3500 has generally the same construction as the previous embodiment, however the protruding structure has a profile adapted to receive and grip reinforcing steel bars at distances from the panel's border portion. In this regard, the protrusion structure 3502 has a generally sawtooth-shaped profile and includes a plurality of substantially square protrusions with recesses 3508 therebetween. Notches 3504 and 3506 are located at the top ends of these protrusions (eg, 3502 ). These notches are adapted to receive reinforcement bars in the manner described below. The recesses 3508 and the profile between adjacent protrusions (eg 3502) are also adapted to receive reinforcing steel bars at a first spacing from the border portion of the panel.

Figure 36 shows an example of the placement of reinforcing bars using panels of the type described in Figure 35. As can be seen in this example, the upper and lower layers of reinforcement bars 3600 and 3602 are supported by panel 3500 . Laterally extending reinforcing bars 3604 and 3606 may also be attached to the panels and reinforcing bars 3602 to complete the reinforced structure. In this example, the reinforcement bars 3602 and 3604 may be preformed into a grid prior to insertion into the panel structure. However, they could alternatively be placed as individual rods. Likewise, rods 3600 and 3606 may be formed into a grid or placed individually. In one form, the bars 3604 and 3606 are welded to the profile 3500 and serve as retention means to retain the orthogonally extending reinforcement bars 3602 and 3600 within the frame module.

Frame modules formed using the panels described in connection with Figures 35 to 37 may be particularly advantageously used to form beams for concrete buildings. As will be appreciated by those skilled in the art, different depths of beams may be required within a building, and therefore, the height of these protrusions (eg 3502) may be longer than shown in this embodiment. Also, the spacing between the projections may vary, depending on the requirements of the building part to be formed with the frame structure.

It should be noted that the lower reinforcement bars 3600 and 3606 are positioned within the frame module at a location such that they will be at the bottom of the building section formed with the frame module. This means that these reinforcement bars will typically be under tension in the building. Depending on the thickness of the beam being formed, these upper reinforcing bars 3602 and 3604 may also be in tension. Clearly, an additional level of reinforcement can be provided by varying the profile shape to a certain extent.

Figures 37A to 37F illustrate the six stages of manufacturing a frame module using panels of the type shown in Figures 35 and 36 . First, a sheet of material 3700 is shown in FIG. 37A from which two panels may be formed. Next, the flat panel 3700 is cut into complementary shaped blanks 3702 and 3704 in step 37B. Blank 3702 is illustrated in Figure 37C. Next, blank 3702 in FIG. 37D is formed by folding the blank into its desired shape to provide an upstanding protrusion and other structures in the panel 3702. Next, as shown in FIG. 37E , the panels are welded together (in the manner described elsewhere herein) to form a panel structure 3706 . One or more sides of the panel structure 3706 will typically be bounded by side walls in the manner shown elsewhere herein to provide sides for forming concrete. Finally, the panel structure 3706 is loaded with reinforcement bars in the form of upper and lower reinforcement grids 3708 and 3710 in FIG. 37F . These may be attached to the module by welding or other mechanical fastening means.

Figure 38 shows a larger portion of a frame module 3800 made in the manner described in connection with Figures 37A-37F. However, in this example, the reinforcing steel is placed as individual bars. In this regard, the reinforcement bars 3802 are arranged in a lower layer so as to lie in the concrete of the lower layer. Next, provide the reinforcing steel bars of the upper layer, such as 3804. It can be seen that these rest in the notches at the top of the profiles of the extensions of the panels. Finally, a plurality of transverse reinforcing bars 3806 are provided which overlie the upper reinforcing bars 3804 and assist in securing them within the module 3800 . Also as shown, one side of the module is provided with a wall 3808 to form concrete along the side of the module in use.

Figure 39 shows in cross-section an additional panel profile that may be used in embodiments of the present invention. For example, panels having profiles as illustrated in forms of the invention may be used particularly advantageously to form slab sections of buildings. As described in previous embodiments, the panel 3900 includes a border portion 3902 for forming concrete and an overhang 3904 which, in use, extends upwardly into the concrete forming void of the frame module and is used to Fix multiple reinforcement bars. In this example, the extensions 3904 include a support structure 3906, which in this case is a horizontally oriented notch in the upwardly extending web of the extensions 3904, but could be in another formed in one way or another (for example by punching a tab from the web). This structure 3906 is used to retain and support one or more reinforcement bars extending in a direction substantially parallel to the extension 3904 . As in the previous embodiments, these protrusions 3904 will include openings or voids through which concrete may flow in use. The upper flanges of the extensions 3904 include holes 3108 that allow air to escape from under the flanges during pouring of the concrete.

As will be appreciated, the reinforcing rods held by the retaining structure 3906 are positioned in the underlying layer of concrete formed by the frame structure so that in use when the slab is formed the lower portion of the panel structure, and importantly The reinforcing steel bars it holds are under tension. It should be understood that the sub-layer of concrete in question is that part of the concrete forming the part of the building which is located below the centerline in the concrete which conceptually defines the position of the structure in tension or under tension. These parts are under pressure when loaded.

Figure 40 shows a variation on the panel of Figure 39. The panel 4100 is similar in profile to FIG. 39 , except that it includes a stepped border portion 4102 . The border portion 4102 includes a large upward notch 4104 which serves to reduce the amount of concrete used to form a slab when this type of panel is used. FIG. 41 shows a fragment of a frame module made using panels of the type shown in FIG. 40 . As can be seen, the frame module 4300 includes a plurality of panels 4302 , 4304 , 4306 . Each panel includes a corresponding border portion (eg, 4302A) and an extension portion (eg, 4302B). Each extension supports a set of reinforcement bars 4308 that extend across multiple panels. A plurality of transversely extending reinforcing steel bars (eg 4310) are also provided and supported in the retention structure of the webs of these protruding structures. The reinforcing bars may be spot welded to the extensions 4302 or to adjacent contacting reinforcing bars. Placing the rebars 4308 and 4310 before the module can form a grid. Then, a plurality of tie bars (eg 4312 ), also arranged in a grid, can also be installed on top of these reinforcement bars 4308 and 4310 . Where adjacent reinforcing bars and tie bars meet, for example at point 4314, a portion of a tie mesh or similar reinforcing material 4320 may be positioned and tied to the reinforcement. Additionally, the lower layer of the slab (located below the slab centerline) once formed may be reinforced by arranging transversely extending reinforcement bars, as shown at 4322 . In use, the concrete slab will extend upwards to the point indicated at 4324 when the concrete is poured. As in previous embodiments, the top flanges of these extensions 4302A include one or more holes 4106 to allow air to escape during concrete pouring. FIG. 41 shows an example portion of a building section formed using a permanent frame module comprising panels of the type shown in FIG. 40 .

Figure 43 illustrates a cross-section of the frame of a building that may be formed using frame modules according to various aspects and embodiments of the present invention. The fragment shown shows the connection between the slab 4402 and the walls 4404 and 4406 of a two story building. Accordingly, Figure 43 shows the junctions between the three frame modules. The frame modules forming the wall 4404 are substantially the same as those described in connection with FIGS. 30 to 32 , while the slab 4402 is formed using substantially the same frame modules as described in connection with FIG. 42 . The lower wall portion 4406 is formed using frame modules similar to those in FIGS. 30-31 . However, at its top end, an additional reinforcement structure 4408 is provided to support the weight of the slab 4402 . To accommodate the reinforcement structure 4408 , the upper portion of the medial skin 4410 of the lower frame module 4406 includes an outwardly projecting support member 4408 . Continuous reinforcement between the slab 4402 and the lower wall 4406 is provided using a "question mark" reinforcement ring 4412 and a U-shaped reinforcement tie 4414 and transversely extending reinforcement rods 4416 . These are inserted through slots provided in the walls of the corresponding frame modules. As can be seen, the upper frame module 4404 is lowered onto the lower frame module 4406 and positioned in place using positioning elements 4418 and 4420 in a manner similar to the process described in connection with FIGS. 34A-34D . Concrete is poured into the assembled frame modules by pouring the slab and lower wall sections first. The upper wall part is subsequently poured in isolation, or in a similar manner on a slab part while pouring it.

Figures 44 to 46 illustrate the fabrication of an alternative embodiment of a frame module whereby frames for making beams or other structures may be formed from panels of the type described herein. Figures 44 and 45 illustrate a panel 4500 having generally the same shape as the panel of Figure 8A. In this embodiment, the panels are shaped to allow the border to be folded perpendicular to the overhang of the panel. In a preferred form, the protrusions have notches therein. The panels (before or after being attached to an adjacent panel) may be folded through the notches to create a recess, eg a channel-shaped recess, in the panel.

The panel 4500 is formed (eg, roll formed, pressed, or otherwise) to include a flat border portion 4518 and a protruding structure 4516 . The protruding structure 4516 extends along one of the long edge portions of the panel 4500 . Each protrusion 4516 includes a vertical (eg, perpendicular to the boundary portion 4518 ) web 4516A extending from the boundary portion 4518 to a horizontal flange portion 4516B extending away from the boundary portion 4518 . The horizontal flange 4516B terminates in a short downward return segment 4516C. The border portion 4518 may also include stiffeners (not shown) extending along the length of the panel. The panel 4500 also includes a junction region 4522 extending along the length of the panel 4500 and in close proximity to the protrusion 4516 . The joint area 4522 is recessed by about 2mm and is about 50mm wide and is adapted to receive a trailing portion 4524 like an adjacent panel when the frame module is completed.

The panel 4500 additionally includes a pair of notches 4510 and 4512 cut into the protrusion 4516 . The notches 4510 and 4512 are generally triangular in shape and cut at approximately 90 degrees.

The notches allow the panel 4500 to be folded through the apexes of the notches 4510 and 4512 to form a channel shaped frame module in the manner shown in FIG. 46 . The edges of the notches 4510 and 4512 (brought together by the folding operation) may be welded to each other in order to strengthen the channel shaped frame module.

Thus, the final frame module 4600 shown in FIG. 46 is a channel shape surrounded by straight walls with multiple internal projecting reinforcement structures. The module may be arranged to carry the reinforcing steel bars 4602 carried on these protruding structures 4616 in the manner described above, or using a more conventional housing structure.

As can be seen, this embodiment allows individual panels of the type described herein to be formed into channel-shaped frame modules suitable for use in slabs, beams, belt beams, but preferably without the need to attach multiple separate vertical columns. Straight side walls. The resulting structure may also be erected and closed on its open side to define a frame module for a wall or part of a wall.

As will be appreciated, the plurality of panels 4500 may be joined together and then its side walls folded once a panel assembly is formed, or each panel 4500 may be folded before it is joined to the next similar panel 4500. form a channel.

Any number of notches can be cut into the protruding portion 4516 of the panel 4500, allowing shapes other than rectangular channels to be formed. Additionally, the notches can be cut in any shape or angle to allow for different wall angles.

In an alternative form the side walls, similar to the frame modules in Figure 46, could be manufactured separately from the floor. The walls and floors of the module may be welded together along their adjoining longitudinal edges. The connection along the edge can be strengthened (if desired), as in other embodiments by corner portions or braces. As will be appreciated, in this case, instead of notching the protrusions of the panels, the outer ends of the protrusions can be shaped to form a suitable angle so that they are at the correct angle adjacent to its adjacent panel.

It will be appreciated that various aspects of the present invention allow for the prefabrication of various components in an industrial manufacturing environment, which may present significant advantages. For example, safety can be increased because less on-site work is required. Specifically, most work at heights or in the air is eliminated. Costs can also be reduced because automation can be used in the manufacturing process, reducing delays due to wet weather on the job site and increasing the speed of site installation. The arrangement of the installed elements is simplified, since the arrangement of reinforcements, pipes and auxiliary devices can be done by machine or, if done by hand, these can be done by the worker at a comfortable working height and in a safe manner on ground level.

Additionally, for most conventional framing (especially wood framing), the tolerances of the framing can be improved because tolerances in a manufacturing environment can be better controlled than the manual framing process. Ultimately, this could translate to improved build quality.

These prefabricated modules can be quickly and relatively easily transported and placed on the job site. It is expected that one slab of a building can be formed and poured in 2-3 days, and with proper back supports, additional slabs can be added at a similar rate.

For convenience, the term concrete is used herein throughout to refer to a building material that is delivered in a flowable form but then sets to form part of a building. As will be appreciated, aspects of the invention can be used with materials other than conventional concrete and, therefore, "concrete" should be construed broadly to encompass a wide variety of such flowable, settable building materials.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the context or drawings. All of these different combinations constitute different alternative aspects of the invention.

Claims (46)

1. A prefabricated frame module for a building section, the module comprising: two or more panels, each comprising a boundary portion and one or more projecting structures, the panels being arranged such that their boundary portions together define a first substantially continuous boundary for shaped concrete, the protrusions protrude from the boundary into the concrete; and One or more reinforcement bars are fixed in position relative to the boundary for transportation and for strengthening the concrete. 2. A module as claimed in claim 1, wherein each panel is at least predominantly integrally formed of sheet material. 3. The module of any one of claims 1 or 2, wherein the protruding structures include one or more receiving voids that open outwardly from the first boundary to receive one or more reinforcing rebar. 4. The module of claim 3, wherein the portions of the projecting structures defining the receiving voids are shaped to carry a reinforcing steel bar at a predetermined distance from the boundary. 5. The module of claim 3, wherein the portions of the protruding structures defining the receiving voids are shaped to carry at least two Reinforced steel bars. 6. A module as claimed in claim 3, 4 or 5, wherein the module further comprises a retention structure for capturing the reinforcement bars in the receiving spaces. 7. A module as claimed in claim 6, wherein the retaining structure comprises openings which, in use, contact and pass through the protruding structures of the corresponding panel, the retaining structure being held Welded to these protrusions. 8. A module as claimed in claim 6 or 7, wherein the retention structure defines a second substantially continuous boundary for forming concrete spaced from the first boundary. 9. A module as claimed in any one of claims 1 to 7 including further structure defining a second substantially continuous boundary for forming concrete spaced from the first boundary. 10. A module as claimed in any one of claims 3 to 9, wherein the receiving cavities are shaped such that the panels can be formed from blanks cut from a common sheet of material on which the blanks are arranged Instead, at least one projecting feature portion of one blank is offset from a similar projecting feature of an adjacent blank and positioned within the receiving spaces of another blank. 11. A module as claimed in any one of claims 1 to 10, wherein the reinforcement bars are fixed to the projecting structures. 12. A module as claimed in any one of claims 1 to 11, further comprising two or more spaced apart beam members supporting the panels. 13. The module of claim 12, wherein the beam members have a profiled section including a face arranged to shape the concrete. 14. A module as claimed in claim 12 or 13, wherein at least a part of each protrusion spans the space between the beam members. 15. A module as claimed in any one of claims 1 to 14 wherein each protrusion terminates in a hook for keying into concrete. 16. A module as claimed in any one of claims 1 to 15, wherein each protrusion defines a support structure carrying a reinforcing steel bar. 17. The module of claim 16, wherein the support structure includes a channel. 18. A prefabricated frame module for a building section, the module comprising: a feature defining a substantially continuous boundary for forming concrete; and one or more projecting structures; The projecting structures protrude from the boundary into the concrete and define a support structure carrying a reinforcing steel bar. 19. The module of claim 18, wherein the support structure includes a channel. 20. A module as claimed in claim 18 or 19, wherein the support structure and the reinforcing steel bars it carries are positioned to reinforce the concrete sublayer. 21. A prefabricated frame module for a building section, the module comprising: one or more features defining voids for forming concrete; and Positioning structure by which the module can be positioned relative to a vertically adjacent like or analogous module. 22. The module of claim 21, wherein the positioning structure comprises a positioning element comprising: an engagement portion by which the positioning element is secured relative to the features; and A lead-in for locating the vertically adjacent similar or analogous modules. 23. A module as claimed in claim 21 or 22, wherein the features are complementary to those of the like module when mounted atop the like module. 24. The module of any one of claims 21 to 23, comprising an inner feature and an outer feature at least partially surrounding the inner feature so as to define the void around the inner feature. 25. The module of claim 24, wherein each of the features is tubular, whereby the defined void is tubular. 26. A module as claimed in any one of claims 21 to 25 wherein a portion of one of the features protrudes upwards beyond another portion of the features to form an internal edge of a concrete structure over the other feature. 27. A module as claimed in any one of claims 21 to 26 comprising one or more reinforcing steel bars fixed in position relative to the features for transport and for reinforcing the concrete. 28. The module of any one of claims 21 to 27, wherein at least one of the features comprises two or more panels; and each panel: includes a border portion and one or more of these protrusions; and is integrally formed at least predominantly of sheet material; The panels within the or each feature are arranged such that their boundary portions together define a substantially continuous boundary for forming the concrete. 29. A building section comprising a module as claimed in any one of claims 1 to 28 and concrete. 30. A positioning element comprising: an engagement portion configured to engage, in use, with a frame module; and An import that locates a vertically adjacent similar or analogous module in use. 31. The positioning element of claim 30, wherein the engaging portion comprises: insertable to engage a flange of a frame module; and A stop for limiting insertion of the flange. 32. The positioning element of claim 31, wherein the lead-in portion and the stop portion are corresponding sides of a triangular portion. 33. The positioning element of claim 32, wherein the triangular portion is tubular. 34. A panel for a building part; the panel comprising: a boundary section for shaped concrete, and One or more protruding structures protruding from the boundary portion into the concrete and defining one or more receiving voids that open outwardly from the boundary to receive one or more reinforcing rods rebar. 35. A panel as claimed in claim 34 which is at least predominantly integrally formed of sheet material. 36. A panel as claimed in claim 34 or 35, wherein an edge portion of the sheet is deflected relative to the border portion to form the overhanging structure. 37. A panel as claimed in claim 36 comprising: an edge portion opposite the deflected edge portion; a display surface outward from the concrete; A region adjacent the deflected edge portion is recessed relative to the display surface to receive an opposing edge portion of a similar adjacent panel whereby the display surfaces of the adjacent panels are substantially aligned. 38. A panel as claimed in any one of claims 34 to 37, wherein the receiving voids are formed for the panels formed from staggered blanks. 39. A panel as claimed in claims 34 to 38, wherein the portions of the projecting structures defining the receiving voids are shaped to carry a reinforcing steel bar at a predetermined distance from the boundary. 40. A panel as claimed in claims 34 to 39, wherein the portions of the projecting structures defining the receiving voids are shaped to carry at least two Reinforced steel bars. 41. A panel as claimed in claims 34 to 40, wherein each projection defines a support structure carrying a reinforcing steel bar. 42. The panel of claim 41, wherein the support structure includes a channel. 43. A method of constructing a building section comprising: installing one or more modules as claimed in any one of claims 1 to 28 at a building site to create at least part of a concrete frame structure; filling the concrete frame structure with wet concrete; The concrete was allowed to cure. 44. A method of constructing a building section comprising: Installing a module as claimed in any one of claims 21 to 28 at a building site to provide a frame structure for at least part of a building; filling the concrete frame structure with wet concrete; Install a similar module on top of this module. 45. A method as claimed in claim 44, wherein the concrete is allowed to at least partially cure in order to strengthen the building portion prior to installing the like modules. 46. A method as claimed in claim 43, 44 or 45, comprising leaving the module in place to protect the cured concrete during the life of the building.

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