GB2365456A

GB2365456A - Construction panel

Info

Publication number: GB2365456A
Application number: GB0112396A
Authority: GB
Inventors: Roger Alfred Bullivant
Original assignee: Roxbury Ltd
Current assignee: Roxbury Ltd
Priority date: 2000-05-22
Filing date: 2001-05-22
Publication date: 2002-02-20
Also published as: GB0012277D0; GB0112396D0

Abstract

A construction panel includes a body 10 of lightweight material, such as foamed polystyrene, forming a sheet generally in the plane of the panel and several elongate reinforcing members 18 aligned with the plane of the panel and embedded within the body 10 of lightweight material. At least some of the reinforcing members each have an edge 20 along their length which projects out of the body, and the panel further includes a layer of settable material 26, which may be cementitious, covering a face of the body and the projecting edges 20 of the reinforcing members.

Description

<Desc/Clms Page number 1> Panels The present invention relates to panels, and in particular, but not exclusively, to panels for use in the construction of buildings. The invention also relates to the construction, connection and support of such panels. According to the invention, there is provided a construction panel comprising a body of a lightweight material forming a sheet generally in the plane of the panel, a plurality of elongate reinforcing members aligned with the plane of the panel and embedded within the body to be supported by the body on both of their sides to resist flexing of the reinforcing members when under load, at least some of the reinforcing members each having an edge along their length and which projects out of the body, the panel further comprising a layer of settable material covering a face of the body and the said projecting edges of the reinforcing members. Preferably the projecting edges are formed to provide enhanced keying with the settable material. The enhanced keying may be provided by perforation or ribbing or by a bar member of the reinforcing member. The body is preferably recessed along the line of each projecting edge, to form a depression within which settable material covers the corresponding edge. Preferably the body has a plurality of slots formed therein, and corresponding in section to the cross-section of that part of the corresponding member lying within the body, so that the members can be located therein by sliding them longitudinally into the slot. Preferably the slot terminates at a depression. Alternatively, the body may be formed around the reinforcing member. The reinforcing members may each have an edge which is embedded within the body along substantially the whole of the length of the member. In one form, the embedded edge may be formed to be non-planar. Preferably the

embedded edge is provided with a flange projecting laterally, or is barbed. Preferably, the reinforcing members are made of flexible material, such as thin sheet material, such as steel or aluminium. In another form, the reinforcing members may each include first and second bar members which are spaced generally parallel to each other and spaced apart by spacer means. The spacer means may include at least one further bar member. The further bar member may be arranged between the first and second bar members in a saw-tooth or zigzag configuration and secured to the first and second bar members. Preferably the body has first and second faces generally parallel with the plane of the panel, there being at least some first reinforcing members arranged to have an edge projecting as aforesaid out of the first face, and at least some second reinforcing members arranged to have an edge projecting as aforesaid out of the second face. Preferably the first and second reinforcing members are arranged in an alternating arrangement across the panel. Preferably the body comprises a lightweight material, preferably foamed, such as a foamed synthetic plastics material, preferably foamed polystyrene, or a foamed cementitious material. The settable material may be cementitious. The settable material may be cast with a decorative form to the exposed face thereof. The decorative form may provide the appearance of a conventional roof covering, such a roof tiles. The panel may be connected at an edge to another like panel by means of a connection member having first formations embedded in the settable material of the first of the panels, and second formations embedded in the settable material of the second of the panels. The connection member may comprise a substrate to which the first and second formations are attached. The substrate may be elongate, having a plurality of first and second formations formed therealong. The formations may provide a closed outline such as a hoop for

embedding in the settable material. Preferably a beam is provided along at least one edge of the panel, the beam being formed of settable material which is continuous with the settable material of the said settable material layer. Preferably the beam is formed within shuttering means which define the shape of the beam. The shuttering is preferably retained to form part of the beam. The shuttering is preferably formed of metal. The shuttering is preferably in the form of a trough within which settable material is contained as it sets. The shuttering is preferably provided with openings in the base thereof, for receiving upwardly extending continuations of reinforcing bars of piles on which the beam is supported, thereby providing attachment between the piles and the settable material of the beam and panel. Preferably the openings are slots, whereby the shuttering and piles may be brought together in a range of relative positions. The invention also provides a building comprising at least one panel as defined above. The invention also provides a building panel arrangement comprising a panel which incorporates a body of settable material, and a beam arranged to support the panel and formed of settable material, the settable material of the beam being continuous with the settable material of the body. Preferably the panel is a panel as defined above. The invention also provides a support beam arrangement comprising a body of settable material, and shuttering which defines the shape of the beam, the shuttering being provided with openings in the base thereof, for receiving upwardly extending continuations of reinforcing bars of piles on which the beam is supported, thereby providing attachment between the piles and the settable material of the beam.

Preferably the openings are slots, whereby the shuttering and piles may be brought together in a range of relative positions. Preferably the shuttering is

retained to form part of the beam. The shuttering may be formed of metal. The shuttering may be in the form of a trough within which settable material is contained as it sets.

The invention also provides a connection member for connecting panels of settable material, the connection member having first formations for embedding in settable material of a first panel, and second formations for embedding in settable material of a second panel.

The connection member may comprise a substrate to which the first and second formations are attached. The substrate may be elongate, having a plurality of first and second formations formed therealong. The formations may provide a closed outline such a loop embedded in the settable material.

Examples of the present invention will now be described in more detail, by way of example only, and with reference to the accompanying drawings, in which:- Fig. 1 is a transverse cross-section through a building panel according to a first embodiment of the present invention including reinforcing members of a first form; Fig. 2 shows a portion of a first form of a reinforcing member of the panel; Figs. 3, 4 and 5 show portions of modified reinforcing members of a first form; Fig. 6 is a transverse cross-section through a building panel according to a second embodiment of the present invention including reinforcing members of a second form; Fig. 7 shows a portion of a second form of a reinforcing member of the panel; Fig. 8 is a transverse cross-section through a further modified panel; Fig. 9 is a partial vertical section through a building construction formed in accordance with the invention; Fig. 10 is a second vertical section through the building of Fig. 9, viewed

in a perpendicular direction; Fig. 11 is a vertical section through a beam and supporting pile; Fig. 12 is a schematic perspective view of a connecting member for use in the construction of a building; and Fig. 13 is a vertical section through part of a building constructed in accordance with the invention.

Fig. 1 shows a partial cross-section through a first example of a construction panel which is primarily intended for use as a floor panel, but has other applications as will become apparent. The panel is formed from a body 10 which is a sheet of lightweight material such as foamed polystyrene, lying generally in the plane of the panel. The polystyrene sheet may be, for example, substantially rectangular or square, having a length and width of around 1.5m and a depth of around 200 mm. Foamed polyurethane or any other suitable lightweight inert insulating material can also be used. In particular, the body 10 can be formed of foamed pourable material, such as concrete.

In the case of foamed polystyrene or other material which can be cut in this manner, hot wire cutting techniques are used to form thin slots 12 of L-shaped configuration, the slots being parallel and spaced regularly across the panel, running substantially across the whole extent of the panel. Each slot 12 terminates in an open top V cross-section recess 14 at the outer face 16 of the body 10. When the panel is used as a floor panel, the face 16 is the uppermost face of the body 10.

A reinforcing member 18, to be described in more detail below, occupies each slot 12, with the upper edge 20 of the member 18 projecting out of the slot 12, to be exposed within the recess 14, by virtue of the slots 12 terminating at the depressions 14.

Each reinforcing member 18 is formed from a flexible material such as thin sheet metal. For example, sheet aluminium or sheet steel having a thickness of less than 1 mm may be used. Each member 18 has a transversely

extending flange 22 at its lowest extremity, which is embedded within the body 10 in the example shown in Fig. 1. The dimensions of the slots 12 are substantially equal to the dimensions of the reinforcing member 18, so that each reinforcing member may be located within the corresponding slot by threading from one end of the slot to the other. This leaves the reinforcing members 18 in intimate contact with the body 10 along the whole of their length, with the exception of the exposed upper edge 20 within the recesses 14. Consequently, the body LO supports the members 18 against deflection, buckling or other deformation, thereby improving their load bearing capacity well beyond that of the reinforcing members 18 in the absence of this support. It has been found that reinforcing members 18 which are unable to support their own weight without deflection are nevertheless improved in strength in this manner to such a degree as to provide adequate structural performance of the panel formed. A sheet 24 of appropriate material, such as plasterboard, may be attached to the lower face of the body 10, to protect the body 1() against damage during use. The upper face 1G of the body LO is covered by a layer 26 of settable material, to complete the building panel. The settable material 26 is preferably cementitious material poured across the face 16 to form an upper layer to the panel. It will be realised that the settable material will also run into the recesses 14, thereby allowing the members 18 to be keyed to the layer 26, enhancing the unitary construction of the complete panel. The result of this construction is a lightweight building panel which provides considerable structural strength, even though it uses much less concrete and steel than conventional building panels. In addition, the panel provides good thermal insulation by virtue of the thermal properties of the body 10.

Figs. 2, 3, 4 and 7 show short lengths of the reinforcing members 18 in

more detail, by way of example. The member 18 in Fig. 2 is a simple L-shape as illustrated in Fig. 1. Holes 28 are provided along the upper edge, by punching, rolling or another manufacturing technique. These holes 28 are located within that portion of the upper edge 20 which is exposed within the recess 14 when the members 18 are introduced into the body 10. In consequence, the settable material 26 can flow through the holes 28, thereby improving the continuity of the layer 26, and improving the keying of the members 18 to the layer 26. Fig. 3 shows a further alternative reinforcing member in which flanges 22, 22A project from both sides of the member, giving the member an inverted T-shape. Holes 28 are not illustrated in Fig. 3, but could be provided. The holes 28 shown in Fig. 2 could alternatively be omitted, if desired. Fig. 4 shows a further optional modification in which the keying between the members 18 and the layer 26 is improved by the formation of corrugations or castellations 30, formed during manufacture, such as by a rolling operation. Fig. 4 also shows a further optional modification in which a longitudinally extending strengthening rib 32 is formed in the member 18. Fig. 5 shows a further modification, in which barb-like flanges 34 are provided to enhance the security in which the members 1.8 are retained within the body 10. It will be readily apparent that the various features of the members shown in Figs. 2 - 5 could be used in many different forms and combinations. Corresponding modifications will be required to the shape of the slots 12, to ensure that intimate contact is retained between the body 10 and the members 18, once they have been introduced into the slots 12. In a second embodiment, as illustrated in Figs. 6 and 7, a second form of reinforcing member 18A is embedded within a body 10A, which may be polystyrene, as described above. In the case of a body 10A of foamed polystyrene, the reinforcing member 18A may be held in shuttering, and the

polystyrene blown around it, the body 10A thus being formed around the reinforcing member 18A. Each reinforcing member 18A is formed from an upper bar 17A and a lower bar 17B, which are spaced apart and arranged parallel to each other, and a intermediate bar 17C which is arranged between, and secured to, the upper and lower bars 17A and 17B, in a saw-tooth or zigzag configuration. The bars 17A, B, C may be made of lengths of conventional reinforcing bar. A brace bar (not shown) may be provided between the exposed upper bars 17A of adjacent reinforcing members to securely join them together and maintain their spacing. This example thus again incorporates reinforcing members which are embedded within the body 10A to be supported against flexing, but which provide improved structural performance to the panel. However, it will be realised that because the member 18A is not formed of sheet material, it may not be possible to slide the members 18A into pre-formed slots. It is for this reason that the body 10A is described as being blown around the member 18A. Fig. 8 shows a modified panel generally similar to the panel shown in Figs. 1 and 6 and having many corresponding features, for which the same reference numerals have been used again. The panel shown in Fig. 8 is intended for use as a wall panel, therefore being required to resist flexing under load applied within the plane of the panel, and to resist load applied in either direction perpendicular to the plane of the panel. The principal difference between the panel of Fig. 8 and the panels of Figs. 1 and 6 is the addition of further reinforcing members 18B in the panel of Fig. 8. The members 18B are like the members 18, but are introduced from the opposite face of the body 10. In Fig. 8, the members 18B are illustrated as being the same as the reinforcing members of Fig. 1, but it will be understood that members like those of Fig. 7 could alternatively be used. The members 18,

18B are all aligned parallel with each other but they alternate, so that between each pair of members 18, there is located a member 18B. In addition, a second layer 26A of settable material is provided on the other face of the body 10, and is keyed to the members 18B by the formation of recesses 14A to receive exposed edges 20A of the members 18B, as has been described. Consequently, the performance of the floor panel of Fig. 1 to support loads applied from above when the panel is arranged horizontally, is now replicated on the opposite face of the panel of Fig. 8, providing for support against loads applied in either direction perpendicular to the plane of the panel, and also against buckling under forces applied in the plane of the panel. This makes the panel of Fig. 8 particularly appropriate for use in forming a wall. Figs. 9 and 10 show a detail of a building construction which incorporates a panel of the type shown in Fig. 1. Alternatively, panels of the type shown in Fig. 6 could be used. Fig. 9 is a view in a direction corresponding with the view of Fig. 1, i.e. along the length of the members 18. Fig. 10 is a view in the perpendicular direction, i.e. perpendicular to the members 1.8. Figs. 9 and 10 show additional arrangements provided at the edges of the floor panel 40. A supporting beam illustrated generally at 42 is provided to support the edge of the panel 40. The beam 42 has a ledge 44 at the outer side of the building, to support brick or blockwork 46. An inner skin of brickwork or blockwork 48 may be supported directly on the panel 40. The beam 42 is formed of settable material, such as cementitious material. In particular, the beam 42 is formed of the same settable material as the layer 26 of the panel 40. Shuttering in the form of a trough 50 and an upstand 52 are provided as required to define the shape of the beam 42. Shuttering 54 may be polyurethane for example, to provide thermal properties in addition to shuttering functions. A cage 56 of reinforcement can be embedded in the beam 42, as required.

It is an important aspect of the arrangements shown in Figs. 9 and 10 that the settable material of the layer 26 is the same as the settable material of the beam 42 and is poured in the same operation, so that the material forms a continuous body including the beam 42 and the upper layer 26. Thus, the beam 42 can be seen as permanently connected to the panel 40, or alternatively, the beam 42 can be seen as an integral part of the panel 40. It will be readily apparent that by use of appropriate shuttering, many different beam shapes and sizes can be formed in this manner. It will also be apparent that the beam could be formed integrally with a panel extending away in one direction, or could also be formed integrally with a second panel extending away in an opposite direction and either at the same height or at a different height as the panel 40. In many situations, it will be appropriate to support the beam 42, for instance by means of piles. One arrangement for doing this is illustrated in Fig. 11. A pile 60 is shown in section, and consists of a body 62 of material such as concrete, through which reinforcing bars (or "rebars") extend. In Fig. 11, the rebar 64 projects upwardly above the upper face of the body 62. This can be achieved either during manufacture, or by cutting away some material of the body 62, to leave the rebar 64 exposed. In order to receive the rebar 64, the trough 50 is provided with a slot 66. Alternatively, an aperture of appropriate size to receive the rebar 64 could be provided, but it is envisaged that through the provision of a slot or oversized aperture, realignment of the trough 50 on the pile 60 can be provided conveniently, as may be required in practice. Once the pile 60 has been installed, and the trough 50 has been placed over the rebar 64, which projects through the slot 66, the remaining structures shown in Figs. 9 and 10 are assembled, and finally, the settable material of the beam 42 and layer 26 are poured. This leaves the rebar 64 deeply embedded within the material of the beam 42, thereby providing a strong tie between the

beam 42 and the pile 60. Panels of the type described above can be used for many building applications. In many of these, it will be necessary to connect panels together at their edges. Fig. 12 illustrates a connection member which may be used for this purpose. The member 70 has a substrate 72 from which projects a line of hoops 74 formed, for instance, of round bar bent over to form closed outlines. A similar line of hoops 74 is provided on the other face of the substrate 72, but is not visible in Fig. 12. Fig. 13 illustrates members 70 used to connect panels. In this case, a building 10 is formed from a vertical wall panel 82 formed in accordance with Fig. 8, and a roof panel 84 formed generally in accordance with Fig. 1 or Fig. 6. These meet at the building eaves 86. At that position, a member 70 is provided, having hoops 74 which project into the wall panel 82 and other hoops 74 which project into the roof panel 84. These hoops are positioned to project into settable material of the panels 82, 84, for instance by forming appropriate cut- aways along the edges of the panels, for receiving the hoops 74 and settable material when the layers 26, 26A are formed. The member 70 provides a good tie between the settable material of the various panels. In the building 80 shown in Fig. 13 a similar member 70 is used along the lower edge of the wall panel 82, to tie the wall panel 82 to a concrete counterfort base slab 88. This may be pinned to the ground at 90 or otherwise supported on good or stabilised ground. Alternatively, the counterfort slab 88 could be replaced by a floor panel and footing arrangement of the type shown in Figs. 9 and 10.

It will be apparent from the above description that many variations and modifications can be made to the apparatus described above, without departing from the scope of the present invention. In particular, many different materials

and many different shapes and forms of individual components can be used, in order to modify the shape, size and performance of the panel, as required for a variety of tasks. It is envisaged that panels formed in accordance with the invention will exhibit good structural properties in addition to good thermal insulation properties, but with low weight relative to alternative conventional panel constructions. Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

Claims 1. A construction panel comprising a body of a lightweight material forming a sheet generally in the plane of the panel, a plurality of elongate reinforcing members aligned with the plane of the panel and embedded within the body to be supported by the body on both of their sides to resist flexing of the reinforcing members when under load, at least some of the reinforcing members each having an edge along their length and which projects out of the body, the panel further comprising a layer of settable material covering a face of the body and the said projecting edges of the reinforcing members. 2. A panel according to claim 1, wherein the projecting edges are formed to provide enhanced keying with the settable material. 3. A panel according to claim 2, wherein the enhanced keying is provided by perforation or ribbing or by a bar member of the reinforcing member. 4. A panel according to any preceding claim, wherein the body is recessed along the line of each projecting edge, to form a depression within which settable material covers the corresponding edge. S. A panel according to any preceding claim, wherein the body has a plurality of slots formed therein, and corresponding in section to the cross- section of that part of the corresponding member lying within the body, so that the members can be located therein by sliding them longitudinally into the slot. 6. A panel according to claim S, wherein the slot terminates at a depression. 7. A panel according to any of claims 1 to 4, wherein the body is formed around the reinforcing member. 8. A panel according to any preceding claim, wherein the reinforcing members each have an edge which is embedded within the body along

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substantially the whole of the length of the member. 9. A panel according to claim 8, wherein the embedded edge is formed to be non-planar. 10. A panel according to claim 8 or claim 9, wherein the embedded edge is provided with a flange projecting laterally, or is barbed. 11. A panel according to any preceding claim, wherein the reinforcing members are made of flexible material. 12. A panel according to any preceding claim, wherein the reinforcing members are made of thin sheet material. 13. A panel according to any preceding claim, wherein the reinforcing members are made of steel or aluminium. 14. A panel according to any of claims 1 to 4, 7, 8 or 13, wherein the reinforcing members each comprise first and second bar members which are spaced generally parallel to each other and spaced apart by spacer means. 15. A panel according to claim 14, wherein the spacer means includes at least one further bar member. 16. A panel according to claim 15), wherein the further bar member is arranged between the first and second bar members in a saw-tooth or zigzag configuration and is secured to the first and second bar members. 17. A panel according to any preceding claim, wherein the body has first and second faces generally parallel with the plane of the panel, there being at least some first reinforcing members arranged to have an edge projecting as aforesaid out of the first face, and at least some second reinforcing members arranged to have an edge projecting as aforesaid out of the second face.

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18. A panel according to claim 17, wherein the first and second reinforcing members are arranged in an alternating arrangement across the panel. 19. A panel according to any preceding claim, wherein the body comprises a lightweight material. 20. A panel according to claim 19, wherein the lightweight material is foamed. 21. A panel according to claim 19, wherein the lightweight material is a foamed synthetic plastics material, 22. A panel according to claim 19, wherein the lightweight material is a foamed polystyrene. 23. A panel according to claim 19, wherein the lightweight material is a foamed cementitious material. 24. A panel according to any preceding claim, wherein the settable material is cementitious. 25. A panel according to any preceding claim, wherein the settable material is cast with a decorative form to the exposed face thereof. 26. A panel according to claim 25, wherein the decorative form provides the appearance of a conventional roof covering, such a roof tiles. 27. A panel according to any preceding claim, wherein the panel is connected at an edge to another like panel by means of a connection member having first formations embedded in the settable material of the first of the panels, and second formations embedded in the settable material of the second of the panels.

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28. A panel according to claim 27, wherein the connection member comprises a substrate to which the first and second formations are attached. 29. A panel according to claim 28, wherein the substrate is elongate, having a plurality of first and second formations formed therealong. 30. A panel according to any of claims 27 to 29, wherein the formations provide a closed outline such as a hoop for embedding in the settable material. 31. A panel according to any preceding claim, wherein a beam is provided along at least one edge of the panel, the beam being formed of settable material which is continuous with the settable material of the said settable material 32. A panel according to claim 31, wherein the beam is formed within shuttering means which define the shape of the beam. 33. A panel according to claim 32, wherein the shuttering is retained to form part of the beam. 34. A panel according to either claim 32 or claim 33, wherein the shuttering is formed of metal. 35. A panel according to any of claims 32 to 34, wherein the shuttering is in the form of a trough within which settable material is contained as it sets. 36. A panel according to any of claims 32 to 35, wherein the shuttering is provided with openings in the base thereof, for receiving upwardly extending continuations of reinforcing bars of piles on which the beam is supported, thereby providing attachment between the piles and the settable material of the beam and panel. 37. A panel according to claim 36, wherein the openings are slots, whereby

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the shuttering and piles may be brought together in a range of relative positions. 38. A building comprising at least one panel as defined in any of the preceding claims. 39. A building panel arrangement comprising a panel which incorporates a body of settable material, and a beam arranged to support the panel and formed of settable material, the settable material of the beam being continuous with the settable material of the body. 40. A building panel arrangement according to claim 39, wherein the panel is a panel as defined in any of claims 1 to 3 7. 41. A support beam arrangement comprising a body of settable material, and shuttering which defines the shape of the beam, the shuttering being provided with openings in the base thereof, for receiving upwardly extending continuations of reinforcing bars of piles on which the beam is supported, thereby providing attachment between the piles and the settable material of the beam. 42. A support beam arrangement according to claim 41, wherein the openings are slots, whereby the shuttering and piles may be brought together in a range of relative positions. 43. A support beam arrangement according to claim 41 or claim 42, wherein the shuttering is retained to form part of the beam. 44. A support beam arrangement according to any of claims 41 to 43, wherein the shuttering is formed of metal. 45. A support beam arrangement according to any of claims 41 to 44, wherein the shuttering is in the form of a trough within which settable material

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is contained as it sets. 46. A connection member for connecting panels of settable material, the connection member having first formations for embedding in settable material of a first panel, and second formations for embedding in settable material of a second panel. 47. A connection member according to claim 46, wherein the connection member comprises a substrate to which the first and second formations are attached. 48. A connection member according to claim 47, wherein the substrate is elongate, having a plurality of first and second formations formed therealong. 49. A connection member according to any of claims 46 to 48, wherein the formations provide a closed outline such a loop embedded in the settable material. 50. A construction panel substantially as hereinbefore described with reference to Figs. 1 to 8 of the accompanying drawings. 51. A building panel arrangement substantially as hereinbefore described with reference to Figs. 9 and 10 of the accompanying drawings. 52. A support beam arrangement substantially as hereinbefore described with reference to Figs. 9 to 11 of the accompanying drawings. 53. A connection member for connecting panels of settable material substantially as hereinbefore described with reference to Figs. 12 and 13 of the accompanying drawings. 54. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same

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invention as any of the preceding claims.