GB2315785A - Wall panel - Google Patents

Abstract

A wall panel for use in constructing a dwelling comprises opposite skins of resin polymer concrete material and an inner core of insulating material. The panel may be provided with door or window openings and is located at ground level by a prefabricated locating plate which engages a groove in the lower edge of the panel.

Description

APPLICATION TO THE PATENT OFFICE 1. pp0icant.

MARK CHRISTOPHE COURTNEY Z. Subiect The patent will relate to the Mr. M.C. COURTNEYS product. The product comprises a series of prefabricated panels to form internal and external walls for both single Storey and two storey dwellings. These panels are constructed from a resin polymer concrete formed in precision moulds to give a total minimum thickness of 95mm. All internal cavities within the panel thickness are fulty filled with preformed insulation slabs, either of dense Rockwool quilt or foamed polyisocyanurate depending on sound deadening properties required.

The external faces can be self finished or have various decorative treatments applied after erection. Internal faces can again be self finished or receive varying finishes according to location and specification. Party walls comprise two thicknesses of standard panels spaced apart and filled between, if necessary, to achieve the required density for the 1 local requirement for sound reduction properties.

The whole series of panels rest onto preformed sole plates which are bolted down to concrete foundations suitably designed for the locally existing site conditions.

The roofs generally comprise conventional timber, gangnail, roof trusses with coverings of felt, battens and s7ate/tile. Other roof construction can be supplied if specified.

All buildings can be supplied to any stage of completion from roofed over shell for self finishing or to a luxury "turn-key" specification including fully concealed electrical wiring and plumbing/heating.

Introduction Two full panels, a window panel and a door panel together with wooden lintels and bases were supplied. These were tested according to instructions from Future Building Systems [International] Ltd under the prescribed loading system. The loading requirement was that four equal loads should be applied at 600mm centres to the wooden lintel at the top and that stiff support should be supplied to the panel through the base. A 3000kN Amsler Testing Machine, which wqs calibrated by Testwell Ltd. immediately prior to the tests, was used to apply the loads.

A preliminary test was carried out own a full panel in order to observe its behavious and that of the loading and recording systems. Minor modifications were made to the support and recording systems and instructions for the loading sequence were received.

Deflections of the panels were measured musing dial gauges.

Loading and Recordinz Svstems The loading system, designed to apply 200kN, is shown in Figure 1 and Plate 1. It distributes the applied load by means of simply supported beams and rollers to the required positions on the lintel.

The test on Full Panel 1, as shown in Plate 1, was carried out with no lateral support at the top.

This allowed lateral movement of the top of the panel during the test so that the load was not truly in the plane of the panel. Lateral restraint without rotational retraint, Plate 2 was introduced at the top of the panel giving satisfactory testing conditions. The Door Panel was bedded in Kaffir D and screwed to its base.

The loading sequence for full Panel 2 was:1. Load to 20tS and hold for 5 minutes 2. Unload to 5N 3. Load in 7 equal steps to 47kN 4. Hold at 47kN for 1 Hour 5. Load in 4 equal steps to 68kN 6. Hold at 68kN for 1 hour 7. Unload to 5kN 8. Load to 68kN 9. Remove dial gauges 10. Load until serious cracking observed It was considered that unloading from 47kN was more indicative than from 68kN and the sequence for the Window and Door Panels was as above but with steps 5 and 6 deleted.

Lateral displacements were recorded at the centre of each of the panels on the upright members and vertical displacements were recorded at the base of the panel. Dial gauge positions for Full Panel 1 are seen in Plate 1 and for Full Panel 2 in Plate 2.

Results and Discussion Full Panel 2 withstood a load of 130kN before cracking was observed and plates 2 to 8 illustrate the loading sequence and show the final failure cracks at maximum load. The material failed in tension where the tensile stress due to lateral bending exceeded the axial compressive stress by an amount sufficient to cause failure. As is clear from plate 8, the main members of the Panel had not failed at this load.

In all cases although signifiant cracking was observed at the loads indicted in Figures 17 to 19 thre was no tendency for the panels to collapse or buckle.

The prescribed loading pattern for the tests, that is equal loads at 600mm centres, is far more severe than is experienced by the panels in situ. Working panels are always attached to adjacent panels and combined lateral stiffness is ensured by using a tongue and groove type fixing. The loads at the ends of working panels are therefore distributed between adjacent panels. The lateral bending and lateral displacements of the test panels are therefore much greater than would be experienced in practise. A further factor increasing test displacements is the bending due to an interaction between in plane loads and lateral displacements.

Conclusions 1. Vertical displacements were sensibly linear up to a total load of about 40kN.

2. Lateral displacements were significant from the commencement of loading as would be expected from the design of the panel.

3. Little evidence of creep was apparent below a total load of about 30kN.

4. Significant creep took place above 30kN.

5. Complex displacement patterns were observed due to the method of construction and material of the panels.

6. Despite large lateral displacements, cracking of the panels did not take place below about 130kN for the Full panel, 90kN for the Window panel and llDkN for the Door panel.

7. The prescribed loading pattern was far more stringent than would be experienced by the panels in situ.

8. The panels did not collapse even after significant cracking.

9. There was no evidence of buckling of the panels.

10. The panels are able to withtand at least four times the maximum working load [7.5kN on each loading point, that is 22.5kN per panel] without noticeable separation or cracking.

N.J. Woodman, M.Sc Ph.D, MICE. C.Eng.

Each panel is capable of withstanding sustained wind loading from 65 m/sec wind speed and the total structure is braced and connected to achieve the same integrity.

Two storey buildings have to be designed by a Structural Engineer to ensure that sufficient stiffness can be achieved at both first floor and roof levels to comply with this loading.

Panels can be used as a cladding when fixed to suitably designed structural frameworks.

7. Thermal Performance Heat loss/heat gain values of completed buildings are variable depending on the full specification of insulation, glazing and external finishes.

The panels themselves, are highly insulated and can achieve an average "U" value of better than 0.4 W/sqm.K.

The insulation properties of the panels are illustrated by the figures from the Loss Prevention Council test where the temperature inside the furnace was 700or but the thermocouples on the outside surface of the panel registered temperatures of 320C or less after 30 mins exposure.

8. Durability The make up of the panels comprises a mixture of polyester resin, silicon sand, clay aggregate and styrene. The resins and styrene are to comply to Lloyds 100A + standard, whilst all other materials are inert.

Due to the ultra violet protection afforded by the fillers and applied external finish a life in excess of 80 years can be expected. With continued maintenance such life would be greatly extended.

All fixings are plated or galvanised and there is no embedded reinforcement to cause problems due to induced corrosion stresses.

9. Acoustic Performance Acoustic resistance is achieved by ensuring that walls of a certain mass per sq.m. are placed between adjoining separate habitable units.

Such party walls are constructed from two separate skins of panels and filled between with insitu concrete to give a minimum total mass of 4t5Kg/sq.m with all gaps sealed with sand/cement mortar to prevent airborne transmissions.

10. Condensation All window frames are provided with built in trickle vents with insect screening. All areas of high vapour production e.g. kitchens and bathrooms/showers are supplied with electrical extract vent fans connected to the lighting but with a separate overide switch for use without the lights.

11. Rodents and Boring Insects The matrix material can be compared with concrete and is therefore proof against boring insects and gnawing animals.

Patent Application No. 9616031.2 List of attached drawing.

FIGURE:01. Window instalation diagram.

FIGURE:02. Door instalation diagram.

FIGURE:03. Miscellaneous fixing down details.

FIGURE:04. Internal wall details.

FIGURE:05. Typical section thro. party wall.

FIGURE:06. Typical junction internal and external walls.

FIGURE:07. Sole plate joint details.

FIGURE:08. Alternative wall panel joint system.

Claims (7)

1) A wall panel for use in constructing a building, the panel comprising opposite skins of resin polymer concrete material and an inner core of insulating material.

2) A wall panel as claimed in claim 1, in which the resin polymer concrete material extends along a lower edge of the panel and is formed with a groove for seating the panel over the complementary rib of a sole plate.

3) A wall panel as claimed in claim 1 or 2, in which the resin polymer concrete material extends over opposite vertical edges of the panel, one vertical edge being formed with a groove and the other vertical edge being formed with a complementary rib to enable two such panels to be interfitted edge-to-edge.

4) A wall panel as claimed in any preceding claim, formed with an opening to receive a window or door frame, the resin polymer concrete material extending over the edges of the opening.

5) A wall panel as claimed in claim 4, in which one of the skins thereof is formed with a cheek extending around the edge of the opening, for the window or door frame to abut against.

6) A wall panel as claimed in claim 4 or 5, in which a capillary groove is formed in the edge of and extends around the opening.

7) A wall panel as claimed in any preceding claim, in which the inner core comprises a preformed panel of insulating material.