CN107542190B

CN107542190B - Composite structural wall and method of construction thereof

Info

Publication number: CN107542190B
Application number: CN201710511556.0A
Authority: CN
Inventors: 黄盛�; 廖玉梅
Original assignee: Individual
Current assignee: Huang Sheng; Liao Yumei; Wang Jinfa
Priority date: 2016-06-28
Filing date: 2017-06-28
Publication date: 2020-05-01
Anticipated expiration: 2037-06-28
Also published as: HK1244857B; ES2733309T3; SG10201703972WA; CN111622374B; HK1244858A1; SG10201908614WA; SG10202107902RA; EP3263795A1; CN107542190A; DK3263795T3; CN111622374A; MY190080A; PL3263795T3; PT3263795T; EP3263795B1

Abstract

The present invention relates to precast wall panels and methods of joining wall panels to construct composite structural walls. The wall plate includes a plate body and at least one guide protruding from at least one channel formed in the plate body. The composite wall is formed by: arranging a first wall panel adjacent a second wall panel, wherein at least one guide member of the first and second wall panels overlap to form a channel; inserting a connecting rod into the channel; dispensing grout into the gap between the first and second wall plates; and curing the grout to join the first and second wall panels to form the composite structural wall. The wall panel may be part of a prefabricated construction module.

Description

Composite structural wall and method of construction thereof

Technical Field

The present invention relates to a composite structural wall, a method of constructing a composite structural wall, a prefabricated construction module, such as a prefabricated volume construction (PPVC), and a building structure constructed therefrom.

Background

Building constructions having cast-in-place shear walls are known and widely used in industry. Because it is a cast-in-place process, the form (form) and the framing (resilience) of the shear wall must be erected before pouring with concrete. Curing of concrete in the field is time consuming and depends on environmental conditions (e.g. weather and temperature). After curing the concrete, it is further necessary to remove the formwork. While the cast-in-place method generally provides a monolithic concrete wall that can withstand high loads and is applicable to most, if not all, types of buildings, the method is a time and labor intensive construction activity.

To increase productivity, precast concrete walls and prefabricated construction modules have been developed and used in the construction industry. Prefabricated walls and modules are produced in a factory and transported to the construction site as needed. This allows for better control and reduces environmental factors (e.g., weather and temperature) induced changes in the concrete during curing at the construction site. However, existing methods of joining two parallel precast concrete walls result in a composite wall that acts as a single wall rather than a single or unitary wall. Similarly, precast concrete walls connecting parallel precast construction modules can result in composite walls that act as individual walls rather than single or integral walls.

Thus, to achieve the same vertical load bearing provided by a unitary wall constructed by existing cast-in-place methods, the composite wall (i.e., the combined widths of the individual walls joined by existing cast-in-place methods to form the composite wall) would be thicker than the unitary wall. Alternatively, to ensure that the width of the composite wall (i.e. the combined width of the individual walls) is not more than that of a unitary wall constructed by the cast-in-place method, the vertical load bearing limits of the composite wall, as well as the height limits of the building structure, are reduced. Either approach places constraints on the design and construction of the building and prevents the owner from maximizing the value of the building being constructed.

Disclosure of Invention

In a first aspect of the invention, there is provided a method of constructing a composite structural wall, the method comprising: adjacently disposing a first pair of wall panels, wherein each wall panel of the first pair of wall panels comprises a first panel body and at least one first guide member attached thereto, the first guide member protruding from a first channel formed in the first panel body, wherein adjacently disposing the first pair of wall panels comprises overlapping the first guide members of the first pair of wall panels to form a first channel; inserting a first connecting rod into the first channel; dispensing a first grout into a first gap between the first pair of wall plates, wherein dispensing the first grout into the first gap comprises dispensing the first grout into a first channel; and curing the first grout to join the first pair of wall panels.

In an embodiment of the first aspect of the invention, the method further comprises: vertically stacking a second pair of adjacently disposed wall plates on the first pair of wall plates, wherein each wall plate of the second pair of wall plates comprises a second plate body and at least one second guide member attached thereto, the second guide member protruding from a second channel formed in the second plate body, wherein vertically stacking the second pair of adjacently disposed wall plates on the first pair of wall plates comprises overlapping the second guide members of the second pair of wall plates to form a second channel; inserting a vertical fixation rod into the first and second channels such that the vertical fixation rod has opposing ends at least partially inserted into the first and second channels, respectively; dispensing a second grout into a second gap between the second pair of wall plates, wherein dispensing the second grout into the second gap comprises dispensing the second grout into a second channel; and curing the second grout to join the second pair of wall panels.

In an embodiment of the first aspect of the invention, the method further comprises inserting a second connecting rod into the second channel.

In an embodiment of the first aspect of the invention, the vertical fixation rod is integral with the first and/or second connection rod.

In an embodiment of the first aspect of the invention, the distributing the first grout comprises distributing the first grout at a height below where the vertical fixing rod is to be inserted.

In an embodiment of the first aspect of the invention, each wall panel of the first and second pairs of wall panels is provided by a separate prefabricated construction module, adjacently arranging the wall panels of the first pair comprises adjacently arranging the prefabricated construction modules of the first pair, vertically stacking the wall panels of the second pair on the wall panels of the first pair comprises vertically stacking the prefabricated construction modules of the second pair on the prefabricated construction modules of the first pair.

In an embodiment of the first aspect of the invention, each wall panel of the first and second pairs of wall panels comprises a bottom end attached to a floor slab, the method further comprising: inserting a plurality of support rods between the cement slabs of the first pair of undertaking construction modules and the second pair of prefabrication construction modules to provide a third gap intersecting the first and second channels, wherein dispensing a second grout into the second gap comprises dispensing the second grout into the third gap, wherein curing the second grout to connect the second pair of wall panels comprises curing the second grout to connect the second pair of prefabrication construction modules to the first pair of prefabrication construction modules.

In an embodiment of the first aspect of the invention, each floor slab of the second pair of prefabricated construction modules comprises at least one floor slab guide attached to and protruding from each respective floor slab, wherein overlapping the second guides of the second pair of wall panels to form the second channel comprises overlapping the floor slab guides of the second pair of prefabricated construction modules to provide the second channel.

In an embodiment of the first aspect of the invention, the at least one first guide comprises a wire attached to a reinforcing structure embedded in each wall panel.

In a second aspect of the invention, there is provided a wall panel in a prefabricated construction module, the wall panel comprising: a plate body; and at least one guide member attached to the plate body and protruding from a groove formed in the plate body, wherein the guide member is adapted to overlap an adjacent guide member of an adjacently arranged wall plate to provide a passage for receiving a connecting rod therethrough, wherein the wall plate is adapted to be connected to the adjacently arranged wall plate by grouting a gap (including the passage) between the wall plate and the adjacently arranged wall plate.

In an embodiment of the second aspect of the invention, the wall panel further comprises a reinforcing structure embedded in the panel body, wherein the guide member is attached to the reinforcing structure.

In an embodiment of the second aspect of the invention, the reinforcing structure is any one selected from the group consisting of a plurality of steel rods, a plurality of corrugated tubes (each adapted to receive a steel rod of a vertically stacked wall panel), a mesh of steel rods, a wire mesh, and a plurality of steel rods (each attached to a joint connector adapted to receive a steel rod of a vertically stacked wall panel).

In an embodiment of the second aspect of the present invention, the surface of the plate body (including the groove formed therein) becomes rough.

In a third aspect of the present invention, there is provided a prefabricated construction module comprising: at least one wall panel according to the second aspect of the invention; and a cement board attached to the bottom end of the wall board.

In an embodiment of the third aspect of the invention, the cement panel comprises a cement panel guide attached to and protruding from it, wherein the cement panel guide is adapted to form a channel.

In a fourth aspect of the present invention, there is provided a building structure comprising: at least one first composite structural wall comprising: a first pair of wall panels disposed adjacent to one another, wherein each wall panel of the first pair of wall panels comprises a first panel body and at least one first guide member attached to the first panel body and protruding from a first channel formed in the first panel body, wherein the first guide members of the first pair of wall panels overlap to provide a first channel; a first connecting rod disposed within the first passage; and a first grout disposed in a first gap between the first pair of wall plates including the first channel, wherein the first grout connects the first pair of wall plates.

In an embodiment of the fourth aspect of the invention, the building structure further comprises: at least one second composite structural wall vertically stacked on the first composite structural wall and comprising: a second pair of wall panels disposed adjacent to each other, wherein each wall panel of the second pair of wall panels comprises a second wall and at least one second guide attached to the second wall and protruding from a second channel formed in the second wall panel, wherein the second guide of the second pair of wall panels overlap to provide a second channel; a second connecting rod disposed within the second channel; a vertical fixation rod having opposite ends at least partially inserted into the first and second channels, respectively; a second grout is disposed in a second gap between the second pair of wall plates including the second passage, wherein the second grout connects the second pair of wall plates.

In an embodiment of the fourth aspect of the invention, each wall panel of the first and second pairs of wall panels is provided by a separate prefabricated construction module.

In an embodiment of the fourth aspect of the invention, each wall panel of the first and second pairs of wall panels comprises a top end attached to the ceiling and a bottom end attached to the floor slab, the building structure further comprising: a plurality of support rods interposed between the ceiling panels of the first pair of precast structural modules and the cement panels of the second pair of precast structural modules to provide a third gap, wherein a second grout is also disposed in the third gap and connects the second pair of precast structural modules to the first pair of precast structural modules.

In an embodiment of the fourth aspect of the invention, each floor slab of the second pair of prefabricated building modules comprises at least one floor slab guide attached to and protruding from each respective floor slab, wherein the floor slab guides of the second pair of prefabricated building modules overlap to provide the second channel.

In an embodiment of the fourth aspect of the invention, the vertical fixation rod is integral with the first and/or second connection rod.

In an embodiment of the fourth aspect of the invention, the building structure further comprises a reinforcing structure embedded in each of the first and second wall panels, wherein the first and second guides are attached to the respective reinforcing structures.

In an embodiment of the fourth aspect of the invention, the reinforcing structure is any one selected from the group consisting of a plurality of steel rods, a plurality of corrugated tubes (each adapted to receive a steel rod of a vertically stacked wall panel), a mesh of steel rods, a wire mesh, and a plurality of steel rods (each attached to a joint connector adapted to receive a steel rod of a vertically stacked wall panel).

Composite structural walls joined from individual wall panels act as single or integral walls and retain the advantages of both existing cast-in-place and prefabricated methods. The composite structural wall provides benefits of precast wall panels, including controlled curing of the wall panels and a reduction in the time required to construct the composite structural wall and/or to connect adjacent modules horizontally and vertically. The composite structural wall is smaller in size than the integral wall formed by the existing cast-in-place method, but the composite wall of the present invention is capable of providing similar vertical load bearing as the integral wall formed by the existing cast-in-place method.

Drawings

Embodiments are further described with reference to the accompanying drawings:

FIG. 1A shows a perspective view of a construction site having prefabricated construction modules;

FIG. 1B shows a perspective view of a multi-storey building constructed from prefabricated construction modules;

FIG. 2 illustrates a prefabricated construction module;

3A-3D illustrate a method of constructing a composite structural wall;

FIG. 4A shows a top cross-sectional view of the adjacent wall panels of FIG. 3C;

FIG. 4B is a partial close-up view of FIG. 4A;

FIGS. 5A-5C show perspective views of two pairs of wall panels stacked vertically in a different order of construction;

FIG. 6 shows a top cross-sectional view of a composite structural wall with two rods in each channel;

FIG. 7A shows a perspective view of a composite structural wall having an opening for a door, a floor slab and a beam structure;

FIG. 7B shows an expanded view of the bottom of FIG. 7A;

FIG. 8 shows a side cross-sectional view of joints at four wall panels, such as an interlayer seam between two pairs of wall panels in a vertical stacking arrangement;

FIG. 9 shows a perspective view of a composite structural wall with an example of a reinforcing structure in a wall panel;

FIG. 10 illustrates a top cross-sectional view of the composite structural wall of FIG. 9;

FIG. 11 shows a perspective view of a composite structural wall with an embedded bellows adapted to receive a steel rod into the composite structural wall;

FIG. 12A shows a top cross-sectional view of the composite structural wall of FIG. 11;

FIG. 12B shows a partial close-up view of FIG. 12A;

FIG. 13 shows a perspective view of a composite structural wall with a joint connector adapted to receive and connect to a stiff steel bar;

figure 14 shows an example of a wire rope suitable for use as a guide.

Detailed Description

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the illustrative embodiments of the invention. It will be understood by those skilled in the art, however, that embodiments of the invention may be practiced without some or all of these specific details. It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. In the drawings, like reference numerals designate the same or similar functions or features throughout the several views.

Embodiments described in the context of one of the methods or apparatuses are similarly effective for use with the other method or apparatus. Similarly, embodiments described in the context of a method are similarly effective for use with an apparatus, and vice versa.

Features described in the context of one embodiment may correspondingly be applied to the same or similar features in other embodiments. Features described in the context of one embodiment may correspondingly be applied to other embodiments, even if not explicitly described in those embodiments. Moreover, additions and/or combinations and/or substitutions described for a feature in the context of one embodiment may correspondingly be applied to the same or similar feature in other embodiments.

As used herein, the article "a" or "an" and variations thereof used in relation to a feature or element includes reference to one or more of the feature or element.

As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

As used herein, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

As used herein, the term "each other" means a reciprocal relationship between two or more objects, depending on the number of objects involved.

Embodiments of the present invention provide a mechanism for joining or coupling two (a pair of) adjacently disposed

wall panels

100, 200 to form a composite structural wall 55. In one embodiment, each connecting

wall panel

100, 200 has guides 105, 205 (e.g., wire loops or wire ropes or J-rings, as shown in fig. 14) spaced at a distance or from each other. A portion of each

guide

105, 205 is embedded in the

wall plate

100, 200, while another portion protrudes from the engagement surface. A

groove

110, 210 is formed or provided in the engagement surface of the

wall plate

100, 200 to accommodate the

guide

105, 205. The two connecting

wall panels

100, 200 are brought close to each other (leaving a gap 30 between the wall panels 100, 200) so that the

guides

105, 205 of the

wall panels

100, 200 are arranged or overlapped to form the channel 25. The connecting rod 40 (e.g., a steel bar) is inserted into the channel 25 formed by the

guides

105, 205 connecting the

wall plates

100, 200. The gap 30 between the

wall panels

100, 200 is then filled with concrete or grout and cured to form the composite structural wall 55. The grout should have high strength and be non-shrink type. High strength grout is a fluid form of concrete, typically made of cement, water, gradient filler and chemical additives. The two

wall panels

100, 200 are held in place by the connecting rods 40 coupling the

guide members

105, 205 while grout is dispensed and cured. This makes it easier to construct the composite wall 55 in a faster and more efficient manner.

Embodiments of the present invention provide an inventive connection system that connects or couples two adjacently disposed

wall panels

100, 200 with infill concrete or grout 50 to form a composite structural wall system by using

guides

105, 205, rather than forming cast-in-place concrete shear walls in a conventional manner. This allows the

panels

100, 200 to be connected in both horizontal and vertical directions. The

wall panels

100, 200 may be part of separate prefabricated building modules 5 and provide connecting means to connect a plurality of prefabricated building modules 5 to form a structure. The structure of the construction should be a single or multi-storey building with different compartments or modules. Each prefabricated construction module 5 may be a single habitable unit, such as a room, or may be part of a single habitable unit.

Fig. 1A shows an elevated perspective view of a building site where a building structure is constructed from a plurality of prefabricated construction modules 5, an example of which is shown in fig. 2. Fig. 1B shows a multilayer structure that can be built up by a multilayer stack of prefabricated building blocks 5. At least one wall panel 100 of each prefabricated construction module 5 is connected to another wall panel 200 of an adjacently arranged prefabricated construction module 5 by in situ grouting in an intermediate joint between the

wall panels

100, 200 to form a composite structural wall 55.

Briefly, without being bound by theory, the composite structural wall 55 is designed to be built under the standard number SS EN 1992-1-1:2008 entitled "Eurocode 2: Design of concrete structures, Part 1-1General ruled lines for building" incorporated herein by reference.

At mid-height, the moment of composite wall 55 is designed as follows:

moment of force due to imperfections

Or 20mm, whichever has a greater value, wherein,

l₀plus the fine moment for the fine wall, if necessary, the effective length (vertical length of the wall).

The composite structural wall 55 may also be constructed in other relevant national standards without departing from the methods and

wall panels

100, 200 disclosed herein.

In an embodiment where two composite walls 55 are vertically stacked, an interlaminar seam is formed between the upper and lower composite walls 55. At the interlaminar seam, the composite wall 55 is designed for a hypothetical eccentricity or imperfection of 20 mm. The key or connecting rod is placed along the centerline of the composite wall 55 and is designed to take up a moment due to this eccentricity.

Each composite wall 55 may be a shear wall of a building structure. Each composite wall 55 is designed as an element to take into account the z-direction (N)_Ed) In the axial or vertical force applied, bending moment (M) applied in the x-direction_Ed,xx) And a bending moment (M) applied in the y-direction_Ed,yy) As shown in fig. 3A-3D. The x, y and z directions shown are perpendicular to each other to represent a three-dimensional axis.

In fig. 3A, wall plate 100 is shown. Wall plate 100 includes a plate body 101 having at least one channel 110 (on a surface of plate body 101) and at least one guide 105 protruding from at least one channel 110. The wall plate 100 in fig. 3A is shown with two channels 110, each having three guides 105, but it should be understood that other numbers of channels 110 and/or guides 105 are possible in various embodiments. The location and number of channels 110 and guides 105 depends on the desired load bearing capacity and size of the composite structural wall 55.

In one example, wall plate 100 has two channels 110, with two guides 105 protruding from each channel. The guides 105 may be disposed near the ends of each channel 110 (i.e., the top and bottom of the plate body) or in other suitable locations. In another example, rather than having two guides in each channel, a third guide 105 may be provided near the middle of the plate body. In another example where the composite structural wall may have a smaller size and load bearing capacity, a single groove 110 and guide 105 may suffice.

In various embodiments, the

wall panels

100, 200 may be precast concrete walls, i.e., the

wall panels

100, 200 are manufactured at a location other than the actual location where the building structure (e.g., multi-storey building) is constructed.

In fig. 3B, a pair of

wall panels

100, 200 is shown, and includes the wall panel 100 of fig. 3A and another wall panel 200. The wall plate 200 includes a plate body 201 having at least one groove 210 formed on a surface of the plate body 201 and at least one guide 205 protruding from the at least one groove 210.

Wall panels

100, 200 may have similar or complementary structures and features. When a pair of

wall panels

100, 200 are adjacently disposed as shown in fig. 3B, the

guides

105, 205 of the

wall panels

100, 200 overlap to form a channel 25 that allows for the subsequent insertion of one or more tie rods 40 (see fig. 4A and 4B and 6).

In embodiments where the

guides

105, 205 are disposed at the same height, when the

wall panels

100, 200 are disposed adjacent as shown in fig. 3B, the

guides

105, 205 may have flexibility to allow bending to form the channel 25.

In embodiments where the

guides

105, 205 are disposed at different heights, the

guides

105, 205 may be disposed in overlapping contact when the

wall panels

100, 200 are disposed adjacent as shown in fig. 3B. Alternatively, the overlapping guides 105, 205 have a vertical gap therebetween.

In an embodiment, the

guides

105, 205 are made of flexible high strength steel wire. The

guide

105, 205 is attached to the

wall plate

100, 200 with a portion (e.g., circular, semi-circular, arcuate, annular) protruding from the

wall plate

100, 200. The semi-circular portions of the

guides

105, 205 are adapted to form a channel 25 and receive the first connecting rod 40 and the vertical fixing rod 45. The

guide members

105, 205 may be attached to the

wall panel

100, 200 during manufacture of the wall panel. By way of example, the

guides

105, 205 may be formed by making a ring from steel wire, a portion of which is embedded in the

wall plate

100, 200 and the remaining portion protrudes from the surface of the

wall plate

100, 200, as shown in fig. 4A and 4B. The two ends of the wire may be connected by a connector or clip to form a loop. Alternatively, the ends are tied together or placed adjacent to each other as shown in the J-joint loop of FIG. 14 to embed into the panel, with the annular or circular or elliptical portion of the wire projecting from the panel to form the channel 25. The steel wire may have a tensile strength equal to at least 2.5% of the induced vertical load of the

wall panels

100, 200. The tensile strength of the

wall panels

100, 200 depends at least in part on the number of guides 105, and may vary accordingly.

A method of constructing the composite structural wall 55 and/or building structure is illustrated in fig. 3A-3D and described below.

The method includes providing a wall panel 100 (fig. 3A), adjacently arranging a first pair of wall panels 100, 200 (fig. 3B), with a first gap 30 between the first pair of wall panels. This step includes overlapping the guides 105, 205 (or first guides) of the first pair of

wall panels

100, 200 to form the first channel 25. The first gap 30 includes the space provided by the grooves 110, 210 (or first grooves) facing each other and the first channel 25, as best seen in fig. 4A and 4B. The first gap 30 also includes a space formed between facing non-grooved surfaces of the

wall plates

100, 200.

The method further includes inserting a first connecting rod 40 into each first channel 25 (fig. 3C) to couple to the

wall plates

100, 200. The first connecting rod 40 should have sufficient strength to pass through the

guides

105, 205 of the

wall plates

100, 200. In an embodiment, the length of the first connecting rod 40 is about or at least the entire longitudinal length of the at least one

groove

110, 210.

The method further includes distributing a first grout into the first gap 30 (fig. 3D), while the first connecting rod 40 couples the

wall plates

100, 200.

The method further includes curing and/or hardening the first grout to form a sealant 50 to join the first wall panel 100 and the second wall panel 200 to form the composite structural wall 55 (fig. 3D). The composite structural wall 55 thus constructed represents a unitary structural wall and has increased load bearing capacity compared to a similarly sized composite wall formed from two precast concrete walls using conventional cast in place methods.

Fig. 4A shows a top cross-sectional view of the first pair of

wall panels

100, 200 corresponding to fig. 3C, while fig. 4B shows a close-up view of fig. 4A, in particular the

grooves

110, 210 and the first channel 25, into which the first connecting rod 40 is inserted. The above-described method according to the present invention creates a horizontal connection between

adjacent wall panels

100, 200 to form the composite structural wall 55. The present invention allows horizontally adjacent prefabricated construction modules 5 to be secured or connected horizontally when the

wall panels

100, 200 form part of separate prefabricated construction modules 5.

The present invention also allows for vertical fixing or joining of vertically adjacent composite structure walls 55 or prefabricated construction modules 5. Accordingly, the above-described method of constructing the composite structural wall 55 and/or building structure (as shown in fig. 3A-3D) may be suitably modified as described below and as shown in fig. 5A.

Continuing from the method described above with reference to fig. 3A-3C, the method further includes vertically stacking a second pair of adjacently disposed wall panels on the first pair of wall panels (see fig. 5A). This step includes overlapping the guide members (or second guide members) of the second pair of wall panels to form a second channel. In at least some embodiments, the second pair of wall panels may have a similar or identical construction to the first pair of wall panels, and thus, the details of

wall panels

100, 200 may be applied to the second pair of wall panels accordingly.

The method further includes inserting a vertical fixing rod 45 through the second channel and partially into the first channel 25 such that a lower end of the vertical fixing rod 45 is at least partially inserted into the first channel and overlaps a portion of the first connecting rod 40 (see fig. 5A). The overlap is known as the lap length and allows vertical loads to be transferred between the first connecting rod 40 and the vertical fixing rod 45. The grooves and channels of the first and second pairs of

wall plates

100, 200 should preferably be aligned in a substantially linear manner for maximum structural strength. Fig. 5A shows the vertical fixing bar 45 arranged in the second channel, while the second pair of wall plates is stacked on the first pair of wall plates together with the vertical fixing bar 45. Alternatively, the vertical securing rod 45 may be inserted into the second and first channels after the second pair of wall plates is stacked on the first pair of wall plates.

The method further includes dispensing a second grout into a second gap between a second pair of wall plates, wherein dispensing the second grout into the second gap includes dispensing the second grout into the second channel.

Modifications may be made to the above-described method described with reference to fig. 5A, and possible modifications are described, but are not limited to the following.

In one embodiment, after stacking the second pair of wall plates on the first pair of wall plates, and after the vertical securing rod 45 passes through the second channel and partially into the first channel 25, but before dispensing the second grout into the second gap, the method further comprises inserting a second connecting rod 47 into the second channel. The second connecting bar 47 may have sufficient strength to pass through the second guide of the second pair of wall plates. In an embodiment, the length of the second connecting rod 47 is substantially or at least the entire longitudinal length of the second channel.

In one embodiment, a vertical securing rod 45 is inserted into the first channel 25 prior to dispensing and curing the first grout and also prior to vertically stacking a second pair of adjacently disposed wall plates on the first pair of wall plates. In one example of this embodiment (see fig. 5B), a second connecting bar 47 may be present in the second channel of the second pair of wall plates, while the second pair of wall plates are stacked on the first pair of wall plates together with the second connecting bar 47. In another example of this embodiment (see fig. 5C), second connecting bar 47 may not be present in the second channel of the second pair of wall plates while the second pair of wall plates are stacked on the first pair of wall plates. Thereafter, the second connecting rod 47 may be inserted into the second passage.

In one embodiment, vertical fixation rods 45 may be inserted into the first channel 25 after the first grout is dispensed but before the first grout is fully cured. In yet another embodiment, the first grout is dispensed to a height below the location where the vertical fixation rod 45 is to be inserted, for example below the overlap length. In other words, only the non-overlapping or non-overlapping length portions of the first connecting rods 40 are grouted, the overlapping portions (i.e., the overlapping length) of the first connecting rods 40 and the corresponding portions with respect to the first channel 25 and the first gap 30 remain un-grouted for the time of the run. This has the advantage that the dispensed first grout is allowed to set without the need to quickly or immediately stack the second pair of wall plates and insert the vertical fixing rod 45 into the first channel 25 before the first grout has fully set. Suitably, after the first grout has set, a second pair of adjacently disposed wall plates is stacked on the first pair of wall plates, and the vertical fixing rod 45 is inserted into the second channel into which the second grout is dispensed to the first channel 25 and to the portion of the gap 30 not filled by the first grout. It will be appreciated that the second channel may be partially filled with a second grout, for example to a height below the subsequent overlap length to accommodate a third or subsequent pair of wall panels and their vertical fixing bars.

In one embodiment, the vertical fixing rod 45 may be additionally used as the first 40 and/or second connecting rod 47. In one example, the vertical securing rod 45 is integral with or formed as part of the first connecting rod 40. In another example, the vertical fixing rod 40 is integral with or formed as part of the second connecting rod 47. In yet another example, the vertical fixing rod 45 is integral with or forms part of both the first 40 and second connecting rods 47. While in another embodiment, the vertical fixing rod 45 is only partially inserted into the first and

second channels

25 and 45. In various embodiments, the first connecting rod 40, the second connecting rod 47, and/or the vertical fixing rod 45 may be steel rods.

To further increase the height of the building structure, other pairs of wall panels may be stacked vertically as described above, i.e. a third pair of adjacently disposed wall panels is stacked in a vertical or upward direction on a second pair of connected wall panels, a fourth pair of adjacently disposed wall panels is stacked vertically on a third pair of connected wall panels, and so on.

In some embodiments, the

wall panels

100, 200 form part of separate prefabricated construction modules 5. Accordingly, arranging the

wall panels

100, 200 adjacently and vertically stacking the adjacently arranged wall panels respectively comprises arranging the prefabricated building modules adjacently and vertically stacking the adjacently arranged prefabricated building modules.

In an embodiment, the first channel 25 formed by the

guides

105, 205 should be suitably sized to receive the first connecting rod 40 and the vertical fixing rod 45 to allow the second set of wall panels to be stacked vertically on the first pair of wall panels. Fig. 6 shows a top cross-sectional view of the composite structural wall 55 with the first connecting rod 40 and the vertical securing rod 45 in the first channel 25.

In an embodiment, the at least one

groove

110, 210 may be sized to accommodate at least a protruding portion of the at least one

guide

105, 205. In an embodiment, facing grooves 110, 210 (fig. 6, two w)₂) And the size of the gap 30 (fig. 6, w)₃) May be slightly larger than the protruding portion of the at least one

guide

105, 205. This minimizes the size of the structural composite wall 55 and the amount of thin mud required.

In an embodiment, each

wall panel

100, 200 is attached to a floor slab 15 (fig. 7A and 8). Each cement panel 15 may further include a

panel guide

115 or 215. The panel guides 115, 215 are similar to the

guides

105, 205 in that the panel guides 115, 215 of adjacent cement panels 15 are disposed in an overlapping arrangement to form a channel, such as the first channel 25. A portion of each

panel guide

115, 215 is embedded within a significant length of the cementitious panel to provide continuity of panel reinforcement. Similar to the

guides

105, 205, the panel guides 115, 215 may be high strength steel wire ropes. In an embodiment, the panel guides 115, 215 have a higher tensile strength than the

guides

105, 205 to provide reinforcement to the cement panel 15. In an embodiment, the cement panel 15 is further attached to the beam structure 17 to provide additional structural strength as shown in fig. 7B. Fig. 7B shows a composite structural wall 55 formed with attached cement panels 15 and beam structures 17.

In an embodiment, each

wall panel

100, 200 in the respective prefabricated construction modules 5 is also attached to the ceiling 10. In other words, the opposite ends of each wall panel are attached to the ceiling 10 and the floor slab 15, respectively (fig. 2). Alternatively, the floor 15 of the upper module 5 may serve as a ceiling for the lower module.

In an embodiment, the

support rods

130, 230 are inserted or interposed between the cement panels 15 of the first pair of prefabricated modules (optionally the ceiling 10 thereof) and the second pair of prefabricated modules to provide a third gap (fig. 8) intersecting the first and second channels. Grout is dispensed to fill the third gap to connect the first pair of precast structural modules to the second pair of precast structural modules or to connect the cement panel 15 of the second pair of precast structural modules to the ceiling 10 of the first pair of precast structural modules. The support bars 130, 230 prevent the grout from leaking and, when the grout cures, form an interlaminar seam. The support bars 130, 230, the first pair of prefabricated building modules or the ceiling 10 thereof and the cement panel 15 of the second pair of prefabricated building modules may form an enclosed space for receiving grout.

The

wall panels

100, 200 may further include reinforcing structures to provide structural strength, particularly tensile strength, to the wall panels. The reinforcing structure may also serve as an attachment point or anchor point for the

guides

105, 205 to be attached, for example by welding or tying. The reinforcing structure may be embedded within the

wall panel

100, 200 during the prefabrication process. The reinforcing structure may be provided as a plurality of

steel discs

125, 225, steel rods or wire mesh or a plurality of corrugated tubes, wherein each corrugated tube is adapted to receive a steel rod. Fig. 4A and 4B show a reinforcing structure that is a plurality of

steel bars

125, 225 embedded in the wall panel. Fig. 9 shows a composite wall 55 formed by two

wall panels

100, 200 connected together, each embedded with a reinforcing structure comprising a mesh of steel rods. The mesh comprises an arrangement of intersecting

vertical bars

125, 225 and

horizontal bars

135, 235. Fig. 10 shows a top cross-sectional view of the composite wall 55 of fig. 9. Fig. 11, 12A and 12B show a plurality of non-intersecting

corrugated tubes

140, 240 embedded in a wall plate, wherein each corrugated tube is adapted or sized to receive a steel rod.

In an embodiment, a joint connector 145 (mechanical rebar connector) may be provided to receive the steel bar 125 of the vertically stacked wall panels. Fig. 13 shows a composite structural wall 55 in which in each wall panel a joint connector 145 is attached to each steel bar 125 and is adapted to receive and secure another steel bar of the vertically stacked wall panels. The attachment of the joint connector 145 to the steel bar 125 may be by any suitable means, such as by a tapered thread design, by welding, or by using grout. Fig. 13 shows a splice connector 145 disposed near the upper end of wall plate 100, attached (e.g., welded) to vertical steel bar 125 of wall plate 100, and positioned to receive vertical steel bar 125 of a vertically stacked or upper wall plate (not shown). Because the second (upper) pair of wall plates is stacked on the first (lower) pair of wall plates, each vertical steel bar 125 from the upper wall plate is inserted into the joint connector and may be secured by taper design, welding or grout. A joint connector 145 may alternatively be arranged at the lower end of the wall plate to receive the steel bar of the lower wall plate.

Other types of reinforcing structures may also be used alone or in combination with the non-limiting examples described herein. As can be seen from the top cross-sectional views of the various embodiments, the reinforcing structure does not interfere with the method of joining the panels.

A shear resistance check may be performed to determine the structural integrity of the composite wall 55. Shear resistance is checked at the interface between the

wall panels

100, 200 and the grout fill. The shear resistance may be due to:

(a) induced shear forces from lateral loading in the wall minor direction;

(b) induced shear forces from differential lateral loading in the wall principal direction (wall major direction);

(c) induced shear forces from the action of the frame in the minor direction of the wall.

In an embodiment, the surface of the

wall plate

100, 200 having the at least one

groove

110, 210 may be roughened to provide surface roughness for interface shear transfer.

In an embodiment, wall panel 100 is part of a prefabricated construction module 5, as shown in fig. 2. Prefabricated construction module 5 comprises a cement panel 15, at least one wall panel 100 as described herein, and optionally a roof 10 and/or a beam structure 17. The prefabricated building modules 5 may also comprise at least one end wall 20. The precast structural modules are connected to adjacent precast structural modules using

wall panels

100, 200 and the methods described herein. At least one

wall panel

100, 200 serves as a connecting means between adjacent pre-construction modules 5. Additional precast construction modules 5 may be stacked on top of the lower pair of precast construction modules 5 to stack the modules 5 and extend the building structure vertically upwards according to the vertically added wall panels. For vertically connected pre-fabricated construction modules 5, the channel 25 formed by the

wall panels

100, 200 of adjacent pre-fabricated construction modules should be able to receive a vertical fixing rod 45.

It should be understood that the prefabricated building modules 5 need not be identical, especially for horizontally adjoining prefabricated building modules 5. For example, a pre-fabricated building block 5 placed at the end of a structure typically has one wall panel 100 and two or three end walls 20, while a pre-fabricated building block located in the central portion of the structure has two or three

wall panels

100, 200 and one or two end walls 20. The

wall panels

100, 200 serve as connecting means to connect adjoining prefabricated construction modules 5.

For example, a pre-construction module 5 to be placed in the middle of a structure may have four

wall panels

100, 200 to attach to four other pre-construction modules 5. It should be understood that other shapes of the pre-fabricated construction modules 5 may be similarly designed and applied.

End wall 20 and wall panel 100 may take any shape or size desired and/or have openings for door and/or window fittings as desired. The prefabricated construction modules 5 may also have exposed sides (i.e., no end walls or wall panels) to allow for different design configurations. The plurality of prefabricated construction modules 5 may be joined together to form a structure. The structure may have a single or multi-storey building. The structure may be used as a building for private or commercial use. The structure can be used as a temporary building in events and disaster relief operations, in which case the ease and speed of construction at the site is important.

According to one aspect of the invention, the building structure includes one or more composite structural walls 55 arranged in a single or multi-story arrangement. Each composite structural wall 55 may include

connected wall panels

100, 200 as described above, and thus, corresponding descriptions (including additions, combinations, substitutions, attachments) of

wall panels

100, 200 and features thereof are omitted herein. Each

wall panel

100, 200 may form part of a separate construction module 5 as described above, and therefore, the corresponding description of their features (including additions, combinations, substitutions, attachments) is omitted herein.

Example 1

The first 100 and second 200 wall panels are each configured with a horizontal length (l) of 1200mm₁) 90mm width (w)₁). The grooves have a depth (w) of 25mm₂) And a length (l) of 100mm₃). Wall plate 100 includes a center (800 mm apart (l)₂) Two grooves 110). 20mm (w) between the first 100 and second 200 wall panels₃) Gap 30 is used to describe this example of a composite structural wall 55. The reinforcing structure in the

wall panels

100, 200 is a

steel bar

125, 225 embedded in the

plate body

101, 201 along the longitudinal height of the

wall panels

100, 200.

The composite structural wall of example 1 has a width or thickness of 200mm (assuming a grout width of 20mm) and has a load bearing capacity similar to a conventional cast-in-place wall of similar width or thickness. It should be clear that other grout widths or gap widths are equally possible.

Example 2

In this example of the composite structural wall 55, the reinforcing structure in the

wall panels

100, 200 is a web of horizontal 135, 235 and vertical steel bars 125, 225 (fig. 9 and 10). The

wall panels

100, 200 are constructed with a length (l) of 1000mm₁) 140mm width (w)₁) And a trench similar to example 1. Wall plate 100 includes a central (600mm apart (l)₂) Two grooves 110). The gap 30 between the first 100 and second 200 wall plates is 20 mm. Alternatively, bellows 140, 240 or joint connector 145 may be used in conjunction with steel rod 125.

Example 3

Prefabricated construction module 5 is constructed as in fig. 2 as wall panel 100 of example 1, cement slab 15 of 130mm thickness, end wall 20 of 150mm width and ceiling 10 of 50mm x50mm hollow cross-sectional dimension (600mm centre to centre).

The embodiments of the invention described herein allow horizontally adjacent wall panels or prefabricated construction modules to be supported from each other via connecting rods while grout is dispensed and cured. This reduces construction time and labor requirements, thus reducing construction costs. Embodiments of the present invention allow vertically stacked wall panels or prefabricated construction modules to be supported from each other via vertical fixing rods while dispensing and curing grout.

With the present invention,

precast wall panels

100, 200 and precast construction modules 5 can be assembled into a building structure at a construction site more quickly and efficiently. The

wall panels

100, 200 and the construction modules 5 can be manufactured at a factory while foundation work at the construction site is being performed, thereby reducing construction cycle time resulting in increased productivity. Moreover, the quality of the

wall panels

100, 200 and the construction modules 5 is improved due to the controlled environment in which the wall panels and the construction modules are manufactured. Moreover, composite structural walls 55 constructed using the present invention will act as monolithic walls, thus enabling similar load bearing capacity to monolithic walls constructed from existing cast-in-place methods and having similar width dimensions or thicknesses. Accordingly, it will be appreciated that the present invention will result in reduced construction costs while increasing productivity and economic benefits.

Whilst there has been described in the foregoing description preferred embodiments of the present invention, it will be understood by those skilled in the technology concerned that many variations or modifications in details of design or construction may be made without departing from the present invention.

Claims

1. A method for constructing a composite structural wall, the method comprising:

adjacently arranging a first pair of prefabricated construction modules (5) providing a first pair of wall panels (100, 200), wherein each wall panel (100, 300) of the first pair of wall panels (100, 200) comprises:

a first plate (101, 201) having a first width (w)₁) A first length (l)₁) A first height and a first length (l)₁) And a first surface defined by a first height, wherein the first length (l)₁) And the first height has a greater width (w) than the first width₁) Larger size; and

at least one first guide (105, 205) connected to the first panel body (101, 201), wherein adjacently arranging a first pair of prefabricated modules (5) comprises adjacently arranging a first pair of wall panels (100, 200), distributing a first grout (50) into a first gap (30) between the first pair of wall panels (100, 200); and curing the first grout (50) to join the first pair of precast construction modules(5) Wherein curing the first grout (50) comprises joining first surfaces of the first pair of wall panels (100, 200) to form a first composite structural wall (55) having a width (w) that is the first width (w) of the first panel body (101, 201)₁) At least two times the amount of the first component,

characterized in that at least one first guide (105, 205) protrudes from a first groove (110, 210) formed in the first surface, adjacently arranging a first pair of prefabricated modules (5) comprises overlapping the first guides (105, 205) of the first pair of wall panels (100, 200) to form a first channel (25);

inserting a first connecting rod (40) into the first channel (25);

wherein distributing the first thin slurry (50) into the first gap (30) comprises distributing the first thin slurry (50) into the first channel (25); and

wherein a width of the first grout (50) between ungrooved portions of the first surfaces of the first pair of wall plates (100, 200) is less than the first width (w) of the first plate body (101, 201)₁)。

2. The method of claim 1, further comprising:

vertically stacking a second pair of adjacently arranged pre-construction modules (5), comprising vertically stacking a second pair of adjacently arranged wall panels (100, 200) respectively provided by the second pair of adjacently arranged pre-construction modules (5) on the first pair of wall panels (100, 200), wherein each wall panel (100, 200) of the second pair of wall panels (100, 200) comprises:

a second plate (101, 201) having a second width (w)₁) A second length (l)₁) A second height and a second length (l)₁) And a second surface defined by a second height, wherein the second length (l)₁) And the second height has a greater width (w) than the second width₁) Larger size; and

at least one second guide (105, 205) attached to the second panel body (101, 201) and protruding from a second groove (110, 210) formed in the second surface, wherein vertically stacking a second pair of adjacently disposed wall panels (100, 200) on the first pair of wall panels (100, 200) comprises overlapping the second guide (105, 205) of the second pair of wall panels (100, 200) to form a second channel (25);

inserting a vertical fixation rod (45) into the first and second channels (25) such that the vertical fixation rod (45) has opposite ends at least partially inserted into the first and second channels (25), respectively;

dispensing a second grout into a second gap (30) between the second pair of wall plates (100, 200), wherein dispensing the second grout into the second gap comprises dispensing the second grout into a second channel (25); and

curing a second grout to join the prefabricated construction modules (5), wherein curing the second grout comprises joining second surfaces of a second pair of wall panels (100, 200) to form a second composite structural wall (55) having a width at least twice a second width of the second panel body (101, 201), wherein the width of the second grout between non-grooved portions of the second surfaces of the second pair of wall panels (100, 200) is less than the second width of the second panel body (101, 201).

3. The method of claim 2, further comprising:

a second connecting rod (47) is inserted into the second passage (25).

4. A method as claimed in claim 2 or 3, wherein the first and/or second surface includes an opening therethrough for a door and/or window fitting.

5. The method of claim 4, wherein the first and second light sources are selected from the group consisting of a red light source, a green light source, and a blue light source,

wherein each wall panel (100, 200) of the first and second pairs of wall panels (100, 200) comprises a bottom end attached to the floor slab (15),

the method further comprises the following steps:

inserting a plurality of support rods (130, 230) between the cement sheets (15) of the first pair of pre-construction modules (5) and the second pair of pre-construction modules (5) to provide a third gap intersecting the first and second channels (25),

wherein the dispensing of the second grout into the second gap (30) comprises dispensing the second grout into the third gap,

wherein curing the second grout comprises fixing the second grout to connect the second pair of pre-construction modules (5) to the first pair of pre-construction modules (5).

6. A composite structural wall (55) formed from a first pair of connected prefabricated construction modules (5) comprising:

a first pair of wall panels (100, 200), wherein each panel is provided by one of the precast construction modules (5) of the first pair of precast construction modules (5), each wall panel of the first pair of wall panels (100, 200) comprising:

a first plate (101, 201) having a first width (w)₁) A first length (l)₁) A first height and a first length (l)₁) And a first surface defined by a first height, wherein the first length (l)₁) And the first height has a greater width (w) than the first width₁) Larger size; and a first pair of pre-construction modules (5) arranged adjacent to each other and comprising:

at least one first guide (105, 205) attached to the first plate body (101, 201);

a first grout disposed in the first gap (30) between the first pair of wall panels (100, 200), wherein the first grout connects the first surfaces of the first pair of wall panels (100, 200) to form a composite structural wall having a width at least twice the first width of the first panel body (101, 201),

characterized in that at least one first guide (105, 205) protrudes from a first groove (110) formed in the first surface, wherein the first guides (105, 205) of the first pair of wall panels (100, 200) overlap to provide a first channel (25);

a first connecting rod (40) inserted into the first passage (25);

the first gap (30) comprises a first channel (25);

wherein a width of the first grout between ungrooved portions of the first surfaces of the first pair of wall plates (100, 200) is less than the first width of the first plate body (101, 201).

7. The composite structural wall (55) of claim 6, further comprising:

a reinforcement structure embedded in the first plate body (101, 201), wherein the first guide (105) is attached to the reinforcement structure, wherein the reinforcement structure is any one selected from the group consisting of a plurality of steel bars (125), a plurality of corrugated tubes (140), a steel bar mesh (125, 135), a steel wire mesh, and a plurality of steel bars attached to a joint connector (145), the plurality of corrugated tubes each being adapted to receive a steel bar of a vertically stacked wall panel (100), the joint connector being adapted to receive a steel bar (125) of a vertically stacked wall panel (100).

8. A composite structural wall (55) as claimed in claim 6 or 7, wherein the first surface of the first plate body is roughened.

9. The composite structural wall (55) of claim 6 or 7, further comprising a cement panel attached to the bottom end of the first wall panel (101, 201).

10. The composite structural wall (55) of claim 8, further comprising a cement panel attached to the bottom end of the first wall panel (101, 201).

11. A building structure made up of a plurality of prefabricated construction modules (5), comprising:

a first composite wall (55) being a composite structural wall (55) as claimed in any one of claims 6, 7 or 8;

a second pair of prefabricated construction modules (5) connected together by a second composite structure wall (55) vertically stacked on the first composite structure wall (55), wherein the second composite structure wall (55) comprises:

-a second pair of wall panels (100, 200), respectively provided by a second pair of prefabricated construction modules (5) and arranged adjacent to each other, each wall panel of the second pair of wall panels (100, 200) comprising:

a second plate (101, 201) having a second width (w)₁) A second length (l)₁) A second height and a second length (l)₁) And a second surface defined by a second height, wherein the second length(l₁) And the second height has a greater width (w) than the second width₁) Larger size; and

at least one second guide (105, 205) attached to the second plate body (101, 201) and protruding from a second groove (110) formed in the second surface, wherein a second pair of guides (105, 205) of a second pair of pre-construction modules (5) overlap to provide a second channel (25);

a second connecting rod (47) inserted into the second passage (25);

a vertical fixing rod (45) having opposite ends respectively inserted at least partially in the first channel (25) and the second channel (25); and

a second grout is arranged in a second gap (30) between the second pair of wall plates (100, 200), the second gap comprising a second channel (25), wherein the second grout connects second surfaces of the second pair of wall plates (100, 200) to form a second composite structural wall (55), wherein the second composite structural wall (55) has a width that is at least twice the second width of the second plate body (101, 201), wherein the width of the second grout between non-grooved portions of the second surfaces of the second pair of wall plates (100, 200) is smaller than the second width of the second plate body (101, 201).

12. The building structure of claim 11, wherein the first and/or second surface includes at least one opening therethrough for a door and/or window fitting.

13. The building structure as set forth in claim 12,

wherein each wall panel (100, 200) of the first and second pairs of wall panels (100, 200) comprises a top end attached to the ceiling (10) and a bottom end attached to the floor slab (15),

the building structure further includes:

a plurality of support bars (130, 230) interposed between the ceiling (10) of the first pair of prefabricated modules (5) and the floor slab (15) of the second pair of prefabricated modules (5) to provide a third gap,

wherein a second grout is also arranged in the third gap and connects the second pair of pre-construction modules (5) to the first pair of pre-construction modules (5).

14. The building structure as set forth in claim 13,

wherein each floor slab (15) of the second pair of prefabricated construction modules (5) comprises at least one floor slab guide (115, 215) attached to and protruding from each respective floor slab (15), and

wherein the slab guide (115, 215) of the second pair of prefabricated building modules (5) overlaps the second channel (25).

15. The building structure of claim 11, claim 12, claim 13 or claim 14, wherein the vertical fixing bars (45) are integral with the first connecting bar (40) and/or the second connecting bar (47).