IES20050674A2 - Construction of a concrete panel - Google Patents

Abstract

A process for preparing a concrete panel for use in building construction is described, the concrete panels comprising a concrete outer leaf and a concrete base leaf which are connected together by connector keying bars, lifting hooks and edge banding. Use of the concrete panels produced by the invention enable buildings to be erected with the minimum of labour whilst at the same time ensuring the buildings produced have sufficient structural integrity. <Figure 1>

Description

Introduction The present invention relates to a process for preparing a concrete panel for use in building construction. It also relates to a method of constructing a building using such a panel.

Because of increased labour and other costs, the use of prefabricated building units has been increasing rapidly. Ideally, what is required is to be able to erect a building using prefabricated units with the minimum of labour, while at the same time having sufficient structural integrity. One of the problems of most prefabricated building systems is how the various prefabricated units are tied together. Thus, for example, it is known to have the four exterior walls of a building prefabricated or tied together at the corners and subsequently a floor or roof placed on the four walls. There are quite satisfactory methods and constructions available for relatively low rise buildings but do have considerable problems when used for more high rise constructions. If a prefabricated building requires elaborate fixing for structural integrity between floors or between sections of wall, then many of the advantages of using the prefabricated panels for constructing walls, ceilings and floors are lost.

A further problem is the need to produce such wall panels efficiently. The present invention is directed towards achieving this. ............ —.

IHT fl/ Statements of Invention l/3z According to the invention, there is provided a process for preparing a concrete panel for use in building construction comprising; (a) preparing a base leaf mould defining at least the perimeter of a base leaf by placing upstanding magnetised wall members on a metal base plate; (a) (b)placing and tying reinforcing bars in the mould with free portions of ΙΕ ο 5 0 6 7 4 -2the reinforcing bars projecting proud of the mould wall members to form keying bars, which keying bars are provided by forming and placing a composite reinforcing mesh comprising a pair of spaced-apart parallel base keying bars for sitting on the base mould, a spaced-apart upper keying bar and a connector keying bar rising and failing between each base bar and the upper bar to form a plurality of triangular openings on each side of the reinforcing mesh, the upper bar and portion of the connector bars forming the keying bars. (c) pouring concrete into the mould; (d) vibrating the concrete; (e) curing the base leaf in the mould; (f) repeating step (a) to form an outer leaf mould; (g) placing and tying reinforcing bars in the outer leaf mould; (h) repeating steps (c) and (d) for the outer leaf mould; (i) inverting the base leaf in its mould; (j) placing the base leaf and mould over the outer leaf mould with the exposed surfaces spaced-apart and the keying bars projecting into the concrete in the outer leaf mould; (k) curing the concrete in the base leaf mould in a final curing step; and (l) removing the wall panel from the moulds.

In one embodiment of the invention the outer leaf is configured to extend in one direction beyond the base leaf to form a ledge on the panel for support in use of a floor panel.

IE 05067 4 -3Preferably, step (e) comprises curing the concrete for sufficient time to allow the base leaf mould be inverted without movement of the concrete.

In another embodiment of the invention additional magnetised wall members are placed within the mould to provide an ope for the wall panel.

In one embodiment of the invention there is provided a process comprising placing at least two spaced-apart lifting hooks, provided by U-shaped bars, in the base leaf mould adjacent one edge thereof, which edge forms a top edge of the panel when forming part of a building thereof with one leg of the U-shaped bar lying within the mould and the other leg lying above the mould substantially at the same height as the keying bars so as to project into the outer leaf.

Preferably, the free ends of the U-shaped bar are cranked and tied to the reinforcing bars in the base leaf mould.

In a further embodiment the reinforcing bars are placed proud of the mould to provide additional reinforcing along the top edge of the panel in use.

In another embodiment of the invention the concrete is cured in a heated enclosure.

Preferably, the curing temperature is between 25°C and 30°C.

Preferably, the final curing is for between 8 and 12 hours.

Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of one construction of concrete panel according to the invention, IE 0 5 0 6 7 4 -4Fig. 2 is an end view of the panel of Fig. 1, Fig. 3 is a perspective view of another panel according to the invention, Figs. 4 to 10 inclusive are perspective views showing progressively the formation of a base leaf for forming the concrete panel in a mould, Fig. 11 is a perspective view of an outer leaf formed to prepare the panel, Fig. 12 is a perspective view of a different layout of mould, Figs. 13 to 20 inclusive are largely diagrammatic views of the plant showing the process for making the panel, and Figs. 21 to 23 show how the panels are used to construct a building.

Referring to the drawings and initially to Figs. 1 and 2 thereof, there is illustrated a concrete panel, indicated generally by the reference numeral 1, comprising an outer leaf 2 and a base leaf 3 of concrete connected together by connector keying bars 4, lifting hooks 5 and edge banding 6. The keying bars 4, lifting hooks 5 and edge banding 6 are all formed from reinforcing bars and the outer leaf 2 and base leaf 3 are of concrete with further reinforcing, not shown but described below. It will be noted that the outer leaf 2 projects beyond the base leaf 3.

Fig. 3 illustrates an alternative construction of panel, indicated generally by the reference numeral 7, in which parts similar to those described with reference to the previous drawings are identified by the same reference numerals. However, it will be noted that in this embodiment, the outer leaf 2 is the same size as the base leaf 3.

( » Before describing in detail the construction of the wall panel 1, reference is now made to Figs. 4 to 10 inclusive to show the reinforcing arrangements for the panels. In Fig. 4, there is illustrated a base leaf mould 10 having conventional reinforcing spacers 11 mounted therein. Fig. 5 illustrates reinforcing bar 12 laid on the spacers 11. Fig. 6 IC ο50674 -5illustrates the construction of connector keying bars 4 which effectively forms part of a composite reinforcing mesh, identified generally by the reference numeral 15. The composite mesh 15 comprises a pair of spaced-apart parallel base keying bars 16 and an upper keying bar 17. The upper keying bar 17 and the base keying bars 16 are connected together by connector keying bars 4. These are placed in the mould, together with further reinforcing bars 19 projecting through lifting eye connectors 20. These lifting eye connectors 20 are downwardly directed to allow the use of lifting hooks (not shown) on the bottom (i.e. exterior in use) of the leaf and hence on the outside of the panel. The additional reinforcing bar 19 projects through each lifting eye connector 20 serve to anchor them. Lifting hooks 25 are illustrated in Fig. 8 and are shown placed in the base leaf mould 10 in Fig. 9, as are the edge banding bars 6. Each lifting hook 25 is a U-shaped bar and comprises a pair of legs 26. It will be noted that each leg 26 is cranked at 27. It will also be noted that each lifting hook 25 projects above the mould. Then, when concrete is poured in the mould, all that is exposed is one leg 26 and portion of the lifting hook 25, together with some of the edge banding 6. Also exposed are the connector keying bar 4 and the upper keying bar 17. This is illustrated clearly in Fig. 10. The surface of the concrete is identified in Fig. 10 by the reference numeral 30. This is now the full formation of the base leaf 3.

Fig. 11 illustrates, in the same way as Fig. 10, the completed outer leaf in its outer leaf mould 11. The outer leaf 2 does not have any of the composite reinforcing mesh 15 exposed.

Just to complete briefly the process which will be described in more detail, when the base leaf 3 in its mould 10 has been at least partially cured so that the concrete is set, the concrete is poured to form the outer leaf 2 into its respective outer leaf mould 11 and the base leaf 3 in its mould 10 is inverted above the outer leaf mould 11 and kept in spaced-apart relationship with it so that portion of the composite reinforcing mesh 15 projects into the concrete in the outer leaf mould. Then the composite panel is allowed to set.

Fig. 12 illustrates an alternative construction of mould, indicated generally by the reference numeral 40, having provision for two opes 41 and 42. This can be used for « 05067 4 -6each type of leaf.

Referring now to Fig. 13, there is illustrated in broad outline the plant for carrying out the invention, indicated generally by the reference numeral 50 comprising a mould cleaning station 51, plotting station 52, mould forming station 53, reinforcing bar fixing station 54, concrete pouring station 55, panel forming station 56 and curing station 57. Detailed descriptions, where necessary, of these stations and the processes carried out on them are illustrated in Figs. 14 to 20 inclusive.

Referring now to Fig. 14, there is illustrated the intake station 51 in which there is an intake conveyor 101 mounting cleaning brushes 102 and 103 which clean base plates for moulds, one of which is identified by the reference numeral 201 in the plotting station 52. The base plate 201 has marked on it by lines 203 the position for placing removable side walls to form the mould. Then, in the mould forming station 53, as illustrated in Fig. 13, magnetised wall members 300 are placed in position on the base plate 201. This mould has provision for opes 301 and 302. The mould sides 300 are magnetised and thus can be securely fixed to the base plates 201.

Referring to Figs. 16 and 17, the reinforcing bars, as illustrated in Figs. 4 to 9 inclusive are placed in position to form the base leaf 3 in the reinforcing bar fixing station 54. The station includes reels 401 for a reinforcing bar including a reinforcing bar cutter 402. There is further provided a storage area 403 for the composite reinforcing mesh 15. It should be repeated that these are only used in forming the base leaf 3. When the reinforcing bar has been fully placed in position, the mould is then transferred to the concrete pouring station 55 (see Fig. 18) which includes a concrete plant 500 connected to a movable trolley 501. The mould with the concrete is then transferred to the panel forming station 56 where it is vibrated.

A base leaf mould 10 is illustrated in Fig. 13 at the panel forming station 56 where it is vibrated and then transferred to the curing station 57. When a base leaf 3 has been sufficiently cured that it can be inverted, it is sent back to the panel forming station 56 where it is illustrated in Figs. 13 and 19 as having been inverted. Fig. 13 does not illustrate the next step as two base leaf moulds 10 are illustrated. Reference must now be made to Fig. 20. Then, as illustrated in Fig. 20, there is an outer leaf mould ΙΕ ο 5 Ο 6 7 4 -7οη the panel forming station 56 and the inverted base leaf 13 in its mould 10 is placed over the outer leaf mould 11 and into the outer leaf 2 to form the composite panel 1. Then the necessary vibration takes place and the composite panel is sent for curing to the curing station 57. Subsequently, after sufficient curing, it is delivered out the plant 50.

Generally speaking, the curing is carried out for between 8 and 12 hours at a temperature of between 25°C and 30°C. It will be appreciated that the base leaf 3 does not have to be cured for as long as that initially since the base leaf 3 only needs to be cured sufficiently to ensure that the concrete in the mould will remain set, since it will have subsequent curing with the outer leaf.

Referring now specifically to Figs. 21 to 23, there is illustrated diagrammatically how, for example, a panel 1 may be used to form portion of a building. Firstly, the panel is placed in position as illustrated in Fig. 1. Then, in this case, a floor slab 8 having projecting reinforcing bars 9 is placed over two of the panels 1. Then a further panel 1 is placed on top, as shown in Fig. 23, and concrete is then poured down in the direction of the arrow A. The concrete is identified by the reference letter C and is usually allowed rise above the floor slab 8.

This provides continuous concrete at the joint, together with anchorage by reinforcement. Additionally, the slab 8 is supported on the panel 1.

In the specification the terms “comprise, comprises, comprised and comprising” or any variation thereof and the terms “include, includes, included and including” or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa.

The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detail within the scope of the claims.

Claims (5)

1. A process for preparing a concrete panel for use in building construction comprising: (a) preparing a base leaf mould defining at least the perimeter of a base leaf by placing upstanding magnetised wall members on a metal base plate; (b) placing and tying reinforcing bars in the mould with free portions of the reinforcing bars projecting proud of the mould wall members to form keying bars, which keying bars are provided by forming and placing a composite reinforcing mesh comprising a pair of spaced-apart parallel base keying bars for sitting on the base mould, a spaced-apart upper keying bar and a connector keying bar rising and falling between each base bar and the upper bar to form a plurality of triangular openings on each side of the reinforcing mesh, the upper bar and portion of the connector bars forming the keying bars. (c) pouring concrete into the mould; (d) vibrating the concrete; (e) curing the base leaf in the mould; (f) repeating step (a) to form an outer leaf mould; (g) placing and tying reinforcing bars in the outer leaf mould; (h) repeating steps (c) and (d) for the outer leaf mould; (i) inverting the base leaf in its mould; (j) placing the base leaf and mould over the outer leaf mould with the exposed surfaces spaced-apart and the keying bars projecting into the BE 0 5 Ο 6 7 4 -9concrete in the outer leaf mould; (k) curing the concrete in the base leaf mould in a final curing step; and (l) removing the wall panel from the moulds.

2. A process as claimed in claim 1, in which the outer leaf is configured to extend in one direction beyond the base leaf to form a ledge on the panel for support in use of a floor panel.

3. A process as claimed in any preceding claim, in which additional magnetised wall members are placed within the mould to provide an ope for the wall panel.

4. A process as claimed in any preceding claim, further comprising the step of placing at least two spaced-apart lifting hooks, provided by U-shaped bars, in the base leaf mould adjacent one edge thereof, which edge forms a top edge of the panel when forming part of a building thereof with one leg of the Ushaped bar lying within the mould and the other leg lying above the mould substantially at the same height as the keying bars so as to project into the outer leaf.

5. A process for producing a composite wall panel substantially as described herein with reference to the accompanying drawings.