GB2407828A - Prefabricated structural masonry wall panel - Google Patents

Prefabricated structural masonry wall panel Download PDF

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Publication number
GB2407828A
GB2407828A GB0325779A GB0325779A GB2407828A GB 2407828 A GB2407828 A GB 2407828A GB 0325779 A GB0325779 A GB 0325779A GB 0325779 A GB0325779 A GB 0325779A GB 2407828 A GB2407828 A GB 2407828A
Authority
GB
United Kingdom
Prior art keywords
bricks
array
panel
reinforcing bar
grout
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB0325779A
Other versions
GB0325779D0 (en
GB2407828B (en
Inventor
Donald Gudgeon
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB0325779A priority Critical patent/GB2407828B/en
Publication of GB0325779D0 publication Critical patent/GB0325779D0/en
Priority to AU2004218615A priority patent/AU2004218615B2/en
Priority to CNB2004100901146A priority patent/CN100432347C/en
Publication of GB2407828A publication Critical patent/GB2407828A/en
Priority to HK05104772A priority patent/HK1071780A1/en
Application granted granted Critical
Publication of GB2407828B publication Critical patent/GB2407828B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/041Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres composed of a number of smaller elements, e.g. bricks, also combined with a slab of hardenable material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0053Machines or methods for applying the material to surfaces to form a permanent layer thereon to tiles, bricks or the like
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001Mechanical features of panels
    • E04C2002/002Panels with integrated lifting means, e.g. with hoisting lugs

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Finishing Walls (AREA)
  • Financial Or Insurance-Related Operations Such As Payment And Settlement (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

A prefabricated structural masonry wall panel includes an array of bricks, each brick having an aperture through it. A reinforcing bar extends across the array and passes through aligned apertures of adjacent bricks. A lifting attachment extends from the reinforcing bar and projects from an edge of the array. Grout is located between adjacent bricks of the array and extends into the apertures. An internal finish is applied to one face of the array.

Description

Prefabricated Structural Masonry Wall Panel
Background of the Invention
The present invention relates to prefabricated wall panels. More particularly, although not exclusively, the invention relates to prefabricated structural masonry wall panels for use in the building industry.
It is known to provide tilt-up cladding panels for use in the building industry. These comprise reinforced concrete panels that are cast at the building site in a horizontal plane and then tilted up after curing for attachment to an existing framework. Such panels provide no structural support.
Brick veneer and double brick domestic buildings are known. In brick veneer houses for example, a timber or steel framework is first erected say on a concrete slab and then bricks are laid individually to form a weather- resistant veneer at the frame exterior. This is a time- consuming and labour intensive procedure requiring skilled framers and bricklayers at the building site.
Double brick buildings are also time-consuming and labour intensive to build, requiring significantly more on-site bricklaying labour than is required in brick veneer construction.
In addition to the on-site labour mentioned above, further tradesmen are needed for the purpose of installing internal cladding such as plasterboard or cement rendering for example.
Object of the Invention
-
It is an object of the present invention to overcome or substantially ameliorate the above disadvantages and/or more generally to provide a masonry prefabricated structural panel having the external appearance of brickwork for example, and the internal appearance of a finished wall, whilst providing structural support for a building incorporating a plurality of such panels.
Disclosure of the Invention
There is disclosed herein a prefabricated structural masonry wall panel, comprising: an array of bricks, each brick having an aperture therethrough, a reinforcing bar extending across the array and passing through aligned apertures of adjacent said bricks, a lifting attachment extending from the reinforcing bar and projecting from an edge of the array, grout located between adjacent said bricks and extending into said apertures, and an internal finish applied to one face of the array.
Preferably the bricks and grout are treated to be water- impermeable and damp-proof.
Preferably the reinforcing bar extends beyond an edge of the array opposite to said edge at which the lifting attachment projects.
Preferably edge bricks of said array comprise a recess for receiving a seal.
Preferably electrical wiring is encased by the internal finish.
There is further disclosed here in a wall comprising a plurality of prefabricated masonry wall panels as disclosed above, the wall further comprising: an epoxy-type sealant at edges of each panel.
There is still further disclosed herein a wall comprising a plurality of prefabricated masonry wall panels as disclosed above, the wall further comprising: an epoxy-type sealant extending into said recess of =eighbouring edge bricks of each panel.
There is yet further disclosed herein a method of prefabricating a structural masonry wall panel, comprising: placing an array of apertured bricks in intended positions in a form with apertures of adjacent bricks aligned with one another and an intended outer face of each brick facing downward, passing a reinforcing bar through the aligned apertures of at least some of the bricks such that the rod extends across the array, applying grout to spaces between the bricks such that the grout flows into the apertures, and applying an internal finish with installation as required to the upper facing surface of the bricks.
Preferably the method further comprises attaching a lifting attachment to the reinforcing bar.
Preferably the method further comprises laying electrical wiring upon the array of bricks prior to applying the internal finish.
Preferably the method further comprises applying a water- impermeable and damp-proof treatment to the bricks and grout.
Definition As used herein, the term "brick" is intended to encompass full bricks, half bricks and irregularly shaped and/or sized bricks. Half bricks would not have an aperture, but would have a half-aperture at one end. Half bricks would generally be end bricks.
Brief Description of the Drawings
A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings, wherein: Figure 1 is a schematic illustration showing bricks being laid out in a form, Figure 2 is a schematic plan view of a pair of bricks with each brick custom- made to include a central aperture and a pair of end recesses which co- operate with one another to define an aperture, Figure 3 is a schematic cross-sectional elevation of an uppermost brick having a lifting attachment connected to the end of a reinforcing bar passing through a brick aperture, Figure 4 is a schematic cross-sectional elevation of the base of one prefabricated masonry panel supported by another prefabricated panel, Figure 5 is a schematic cross-sectional illustration of a detachable mould base serving as a temporary support for a prefabricated wall panel as it is transferred to storage, Figure 6 is a schematic elevational view of a prefabricated panel in situ alongside, above and below other such prefabricated panels, Figure 7 is a schematic cross-sectional plan view showing a joint between the endmost bricks of a pair of neighbouring prefabricated panels, Figure 8 is a schematic elevation showing the construction of a multi-storey building with a prefabricated wall panel at each floor, and Figure 9 is a schematic crosssectional end elevation of adjoining prefabricated panels at a building structure finished floor level, showing a structural socket at the top of the panel to receive a dowel from the bottom of a panel thereabove.
Description of the Preferred Embodiment
In Figure l of the accompanying drawings there is depicted schematically a worker W placing exterior bricks 1 in a form or mould table 2. The bricks 1 are placed facing side-down in the form. A space is left between each brick sufficient to receive grout or mortar of the desired thickness. Each brick 1 as shown in Figure 2 has a central aperture 3 and a pair of end recesses 4. The aperture 3 is sized to receive a length of reinforcing bar together with surrounding grout/mortar. Recesses 4 are slightly less than half the size of aperture 3 such that when two bricks are placed at desired spacing, the mutually facing recesses approximate the size and shape of the central aperture thereby allowing a length of reinforcing bar to pass between the bricks at that location with mortar/grout surrounding the reinforcing bar.
The bricks are positioned in a standard brick pattern such that the recesses 4 of one course of bricks is aligned with the apertures 3 in the adjacent course of bricks. Once all of the bricks 1 are so placed in an array defining the desired panel shape, reinforcing bar 5 is passed through the aligned recesses and apertures from one edge of the array to the other. In the finished wall, the reinforcing bar will be vertical.
The grout or mortar mixture is poured into the spaces between the bricks so as to adequately fill the apertures 3 and recesses 4 and thereby encase the reinforcing bar.
It should be noted in this regard that there may be several reinforcing bars extending throughout the array at spaced positions. The reinforcing bars will be both vertical through the apertures and horizontal through the brick coursing. Some or all of the apertures will contain reinforcing bars, and some or all of the brick courses will contain reinforcing bars for structural or shrinkage purposes. A lifting eyelet 6 can be attached to an end of one or more reinforcing bars 5 and one such eyelet is shown in Figure 3 to project beyond an upper edge 7 of the panel. It should be noted in this regard that the reinforcing bar provides a recess to socket from which the eyelet projects.
At the bottom edge of the panel, the reinforcing bar 5 might project slightly as shown at 8 in Figure 4 for receipt within a recess 9 at the top of an uppermost aperture 3 of a lower panel in the mould in the multistorey high-rise construction. An epoxy-type-type seal surrounds the projection 8 in the recess 9. The dry gaps between panels are to be suitably insulated.
There is a steel seat plate 11 positioned between vertically adjacent panels to define the width of a dry joint 12.
An interior wall finish 13 is applied to the upper surface of the array of bricks on the mould table 2.
Finish 13 might be a plaster or a cement-rendered finish for example or might alternatively be a tiled finish or any other finish suitable for the interior of a building.
Such finish might be in the form of an insulating layer.
Electrical wiring 14 might be placed upon the array of bricks prior to application of the interior wall finish.
The bottom projecting extremity of the reinforcing bar 5 - 9 - might be threaded to receive a nut 15 and washer 16 as shown in Figure 5. This may be useful in case the grip between apertures 3 and the reinforcing bar 5 is provided by the grout is insufficient for lifting purposes.
As shown in Figure 7 the endmost bricks of each panel might be provided with a longitudinal recess 16. These recesses face one another to define a space into which a seal strip 17 can fit. A tap-in joint gap seal strip 18 is inserted into the vertical joint at the interior face of the brick panel. There is also integral water/damp proofing in the mortar.
Once the grout or mortar of the array of bricks has set, and the interior finish has also set, the array can be lifted from the mould table by application of hoisting force to the eyelets 6. The face of the brickwork to be presented to the exterior of a building is the face that was presented downwardly to the mould table. The mortar/grout and external face surface of the panel can be treated with a waterproof material such as a silicon- based spray to a form a water-impermeable and damp-proof barrier. The treatment might be absorbed somewhat into the brick work and mortar, or might remain as a surface coating.
A building constructed using the above-disclosed panels can rely on the panels for structural load support.
Moreover, the building need not comprise a separate framework and panels of single brick thickness can provide significant load-bearing capability and resistance to bowing by virtue of the vertically extending reinforcing bars and horizontally placed brick coursing reinforcing bars.
The panels can be delivered to site and tilted up by crane or hoist and lifted/delivered to desired positions.
An epoxy-type cement can be used at the edges of the panels to improve weatherproofing between adjacent panels or where edges of panels meet other structure. Such might be applied to set plates at the building periphery upon which the panels are to be mounted for example.
Further, horizontal gap seals might be provided between the interior finished surface of each panel and structural flooring.
It should be appreciated that modifications and alterations obvious to those skilled in the art are not to be considered as beyond the scope of the present invention. For example, structural brick columns, right angled corner segments, double or triple-thickness brick wall panels or single thickness brick panels having columnar brickwork strengtheners (i. e. internal garage wall brick columns for example) might be fabricated in accordance with the disclosed method. Furthermore, panels having windows or doors therein might also be prefabricated in accordance with the described method. /

Claims (11)

  1. CLAIMS: 1. A prefabricated structural masonry wall panel, comprising: an
    array of bricks, each brick having an aperture therethrough, a reinforcing bar extending across the array and passing through aligned apertures of adjacent said bricks, a lifting attachment extending from the reinforcing bar and projecting from an edge of the array, grout located between adjacent said bricks and extending into said apertures, and an internal finish applied to one face of the array.
  2. 2. The panel of Claim 1 wherein the bricks and grout are treated to be water-impermeable and damp-proof.
  3. 3. The panel of Claim 1 wherein the reinforcing bar extends beyond an edge of the array opposite to said edge at which the lifting attachment projects.
  4. 4. The panel of Claim 1 wherein edge bricks of said array comprise a recess for receiving a seal.
  5. 5. The panel of Claim 1 wherein electrical wiring is encased by the internal finish.
  6. 6. A wall comprising a plurality of prefabricated masonry wall panels as claimed in Claim 1, the wall further comprising: an epoxy-type sealant at edges of each panel.
  7. 7. A wall comprising a plurality of prefabricated masonry wall panels as claimed in Claim 4, the wall further comprising: an epo-type sealant extending into said recess of neighbouring edge bricks of each panel.
  8. 8. A method of prefabricating a structural masonry wall panel, comprising: placing an array of apertured bricks in intended positions in a form with apertures of adjacent bricks aligned with one another and an intended outer face of each brick facing downward, passing a reinforcing bar through the aligned apertures at least some of the bricks such that the rod extends across the array, applying grout to spaces between the bricks such that the grout flows into the apertures, and applying an internal finish to the upper facing surface of the bricks.
  9. 9. The method of Claim 8 further comprising attaching a lifting attachment to the reinforcing bar.
  10. 10. The method of Claim 8 further comprising laying electrical wiring upon the array of bricks prior to applying the internal finish.
  11. 11. The method of Claim 8 further comprising applying a water-impermeable and damp-proof treatment to the bricks and grout.
GB0325779A 2003-11-05 2003-11-05 Prefabricated structural masonry wall panel Expired - Fee Related GB2407828B (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
GB0325779A GB2407828B (en) 2003-11-05 2003-11-05 Prefabricated structural masonry wall panel
AU2004218615A AU2004218615B2 (en) 2003-11-05 2004-10-07 Prefabricated structural masonry wall panel - UK APP.NO. 0325779.7 (05 NOV 03)
CNB2004100901146A CN100432347C (en) 2003-11-05 2004-11-03 Prefabricated structural masonry wall panel
HK05104772A HK1071780A1 (en) 2003-11-05 2005-06-08 Prefabricated structural masonry wall panel

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0325779A GB2407828B (en) 2003-11-05 2003-11-05 Prefabricated structural masonry wall panel

Publications (3)

Publication Number Publication Date
GB0325779D0 GB0325779D0 (en) 2003-12-10
GB2407828A true GB2407828A (en) 2005-05-11
GB2407828B GB2407828B (en) 2007-05-16

Family

ID=29725959

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0325779A Expired - Fee Related GB2407828B (en) 2003-11-05 2003-11-05 Prefabricated structural masonry wall panel

Country Status (4)

Country Link
CN (1) CN100432347C (en)
AU (1) AU2004218615B2 (en)
GB (1) GB2407828B (en)
HK (1) HK1071780A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2443806A (en) * 2006-11-15 2008-05-21 Poundfield Products Ltd Method of forming a prefabricated block
GB2449336A (en) * 2007-05-01 2008-11-19 Adrian Galvin Masonry Wall Panel
CN103628690A (en) * 2013-10-20 2014-03-12 曹新中 Brick or block wall and painting operation method thereof
CN103711319A (en) * 2012-10-01 2014-04-09 凌怀宇 Flat laying and vertical mounting wall building process

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103056966B (en) * 2013-01-22 2015-10-14 陈振基 The method of prefabricated panel is made of building block finished product
CN108661204A (en) * 2016-08-12 2018-10-16 陈迎春 A kind of engineering prefabricated component connection method
CN111424844A (en) * 2019-05-23 2020-07-17 曹新中 Beam column and block wall integral or independent lying work

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2159552A (en) * 1984-06-01 1985-12-04 William Hunter Millar Building structure of blocks having apertures and locating rods
US4957685A (en) * 1986-04-23 1990-09-18 Panelbrick Industries Pty. Limited Method of making a transportable brick panel
EP0756047A2 (en) * 1995-07-26 1997-01-29 Ziegelmontagebau Winklmann GmbH & Co KG Method of making prefabricated plastered masonry walls, and formwork table for executing such a method
FR2743585A1 (en) * 1996-01-15 1997-07-18 Macchi Construction Panel construction manufacturing method
GB2333534A (en) * 1998-01-21 1999-07-28 Molatex Limited Portable building structure comprising connected blocks
US20010045551A1 (en) * 2000-03-17 2001-11-29 Sutter Michael J. Prefabricated masonry fence system and method for constructing same
WO2003104577A1 (en) * 2002-06-10 2003-12-18 U-H Rakennus Oy A building element arrangement

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4429499A (en) * 1980-06-30 1984-02-07 Kunishiro Co., Ltd. Reinforced brick assembly

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2159552A (en) * 1984-06-01 1985-12-04 William Hunter Millar Building structure of blocks having apertures and locating rods
US4957685A (en) * 1986-04-23 1990-09-18 Panelbrick Industries Pty. Limited Method of making a transportable brick panel
EP0756047A2 (en) * 1995-07-26 1997-01-29 Ziegelmontagebau Winklmann GmbH & Co KG Method of making prefabricated plastered masonry walls, and formwork table for executing such a method
FR2743585A1 (en) * 1996-01-15 1997-07-18 Macchi Construction Panel construction manufacturing method
GB2333534A (en) * 1998-01-21 1999-07-28 Molatex Limited Portable building structure comprising connected blocks
US20010045551A1 (en) * 2000-03-17 2001-11-29 Sutter Michael J. Prefabricated masonry fence system and method for constructing same
WO2003104577A1 (en) * 2002-06-10 2003-12-18 U-H Rakennus Oy A building element arrangement

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2443806A (en) * 2006-11-15 2008-05-21 Poundfield Products Ltd Method of forming a prefabricated block
GB2449336A (en) * 2007-05-01 2008-11-19 Adrian Galvin Masonry Wall Panel
CN103711319A (en) * 2012-10-01 2014-04-09 凌怀宇 Flat laying and vertical mounting wall building process
CN103628690A (en) * 2013-10-20 2014-03-12 曹新中 Brick or block wall and painting operation method thereof

Also Published As

Publication number Publication date
CN100432347C (en) 2008-11-12
CN1614175A (en) 2005-05-11
HK1071780A1 (en) 2005-07-29
AU2004218615A1 (en) 2005-05-19
GB0325779D0 (en) 2003-12-10
GB2407828B (en) 2007-05-16
AU2004218615B2 (en) 2009-01-08

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