NZ580649A

NZ580649A - Metal, preferably steel stud and panel system for filling with concrete

Info

Publication number: NZ580649A
Application number: NZ580649A
Authority: NZ
Inventors: Alister Bennett
Original assignee: Csr Building Products Ltd
Priority date: 2007-04-23
Filing date: 2008-04-01
Publication date: 2011-11-25
Also published as: WO2008128275A1; AU2008241350A1; AU2008241350B2

Abstract

A stud system for 1 use in a formwork having two spaced apart outer wall sheets 2a, 2b comprises at least one elongate stud 4, and one or more elongate reinforcing strips 10, where the stud 4 has a longitudinally extending web 5 with two opposite side edges, first and second longitudinally extending side wall s 7a, 7b with each of the side walls having a first side edge 8a and an opposite second side edge 8b. The first side edges 8a of the side walls 7a, 7b are joined to the respective side edges of the web 5, such that the side walls 7a, 7b extend substantially perpendicularly to the web 5 with each side wall having an outer wall surface and an inner wall surface, with the inner wall surfaces of the two side walls 7a, 7b facing each other. Each side wall has a longitudinally extending flange 9. The flange 9 has a first side edge and an opposite second side edge, with the first side edge of the first flange joined to the second side edge of the first side wall 7a and the first side edge of the second flange joined to the second side edge of the second side wall 7b, such that the flanges 9 extend from the side walls towards each other substantially parallel to the web 5, with the second side edges of the flange being spaced from each other. The outer surface of each side wall of the stud 4 is adapted to be joined face-to-face to a respective outer sheet such that the web spans the distance between the outer wall sheets 2a, 2b. The second edges of the stud flanges 9 are adapted to allow securing of the opposite ends of the reinforcing members 10. The stud 4 defines a first and second inner wall with each inner wall having a first side edge and an opposite second side edge. The first side edge of the first inner wall 18a is joined to the second side edge of the first flange 9 and the first side edge of the second inner wall 18b is joined to the second side edge of the second flange 9, such that the inner walls 18a, 18b extend from the flanges 9 towards the web 5 substantially parallel to the side walls, with the second side edges of the inner walls 18a, 18b being spaced from the web 5. The stud system further comprises a first and a second lip 11, joined to, and extending from, the second side edges of the first inner wall and second inner wall respectively, towards the first side wall and second side wall respectively.

Description

WO 2008/128275 PCT/AU2008/000461 1 PERMANENT FORMWORK SYSTEM TECHNICAL FIELD The present invention relates to building panels and building systems for 5 forming building panels. Particularly, the present invention relates to a permanent formwork system for the construction of walls where concrete is placed within the formwork along with reinforcing steel and the outer skin remains in place and forms the finished wall surface.

BACKGROUND ART Building systems involving prefabricated formwork systems having outer skins that define a cavity which is then filled in with concrete are well known. The outer skins are usually fibre cement panels and remain in place to form the finished wall surface. Concrete is placed within the formwork, along with 15 reinforcing steel. In order to allow concrete to be poured into the cavity and to fit the reinforcing steel, there is a need for large openings within and between the studs.

A significant cost element in these prefabricated formwork systems is the studwork, which is bonded to the outer skins. The studs both support and hold 20 the outer skins as well as keeping the opposing outer skins separated, to define the cavity. These studs must be capable of resisting the static head or force of the concrete during the pouring operation.

US 6161361 (Ehrenkrantz) discloses a composite structural member comprising parallel flanges and a plurality of thermally insulative web 25 connectors intermittently disposed between the web connectors. This document describes the spreading apart and the subsequent springing back of the walls of the flanges. However, the planar finish to abutting surfaces of the flanges and ends would not be adequate for use in concrete pouring into the panel. This is because of the considerable pressure that is generated by the 30 flow of wet concrete pouring into the panel and if a web connector released a WO 2008/128275 PCT/AU2008/000461 2 flange, the panel would bow resulting in distortion of the outer wall. This patent is directed towards drywall construction where the loading and strength requirements are not as high as in concrete filled wall production.

US 5609006 (Boyle) discloses a wall stud comprising C-shaped frame 5 members and core elements. The core elements may be located at the top and bottom of the stud and are adapted to accept nails and screws. Additional core elements may be slidably mounted between the top and bottom. The core elements are retained within the frame members by keepers that extend inwards from the frame members. The sliding core members must be secured 10 by punching through side walls of the frame members. The core elements must be slid along the length of the frame members, and in relation to the intermediate core elements, are not self retaining and must be punched into position. This patent is also directed only to drywall construction.

One problem with known wall systems is that the studs deform or deflect 15 under the static force of the wet concrete when it is poured into the cavity formed by the opposed outer skins. This can result in distortion of the outer wall and a loss in the overall strength and integrity of the wall.

The present invention relates to a permanent formwork system for the construction of walls, where concrete is placed within the formwork along with 20 reinforcing steel and the outer skin remains in place and forms the finished wall surface.

Therefore it would be advantageous to provide an improved permanent formwork system. This would overcome at least some of the disadvantages of previously known approaches in this field, or would provide a useful 25 alternative.

DISCLOSURE OF INVENTION According to a first aspect of the present invention there is provided a stud system for use in a formwork. The stud system has two spaced apart outer wall sheets and comprises at least one elongate stud member and one 30 or more elongate reinforcing members.

WO 2008/128275 PCT/AU2008/000461 3 The stud member has a longitudinally extending web portion and first and a second longitudinally extending side wall portions. The longitudinally extending web portion has two opposite side edges and each of the side wall portions have a first side edge and an opposite second side edge. The first side 5 edges of the side wall portions are joined to the respective side edges of the web portion, such that the side wall portions extend substantially perpendicularly to the web portion. Each side wall portion has an outer wall surface and an inner wall surface, with the inner wall surfaces of the two side wall portions facing each other; and a first and a second longitudinally 10 extending flange portion.

Each flange portion has a first side edge and an opposite second side edge. The first side edge of the first flange portion is joined to the second side edge of the first side wall portion and the first side edge of the second flange portion is joined to the second side edge of the second side wall portion. In 15 this way, the flange portions extend from the side wall portions towards each other substantially parallel to the web portion, with the second side edges of the flange portions being spaced from each other.

The stud member is adapted for the outer surface of each side wall portion to be joined face-to-face to a respective the outer sheet, such that the 20 web portion spans the distance between the outer wall sheets; and The reinforcing members have opposite ends and the stud system is adapted for the opposite ends to be secured in relation to the second edges of the flange portions to reinforce the stud member.

Preferably, the stud system comprises a first and a second inner wall 25 portion, each inner wall portion having a first side edge and an opposite second side edge, the first side edge of the first inner wall portion being joined to the second side edge of the first flange portion and the first side edge of the second inner wall portion being joined to the second side edge of the second flange portion, such that the inner wall portions extend from the flange 30 portions towards the web portion substantially parallel to the side wall portions, with the second side edges of the inner wall portions being spaced from the web portion.

WO 2008/128275 PCT/AU2008/000461 4 Preferably the stud system comprises a first and a second lip portion, joined to, and extending from, the second side edges of the first inner wall portion and second inner wall portion, respectively, towards the first side wall portion and second side wall portion, respectively.

Preferably, each of the reinforcing members comprises an elongate central portion having two opposite ends and a hooked formation at each of the ends, the hooked formations being adapted to hook onto the first and second lip portions thereby to secure the lip portions to each other.

Preferably, the stud member and reinforcing members are separate from 10 each other, although in a second embodiment of the present invention, the stud member and reinforcing members are formed integrally with each other.

Preferably, the stud member includes extruded metal and most preferably includes roll formed galvanised steel and each of the reinforcing members is made by an injection moulding process. The stud member and the 15 reinforcing members are made from metal. Preferably there are a plurality of the reinforcing members.

In one preferred embodiment, each of the side wall portions has a plurality of apertures therein to facilitate adhesion between the side wall portions and the outer wall sheets.

The web portion preferably has at least one aperture therein to allow concrete to flow therethrough.

According to a second aspect of the present invention there is provided a formwork comprising two spaced apart outer wall sheets and at least one stud system. The outer surfaces of the side wall portions are joined, face-to-face 25 with the respective outer wall sheets such that the web portion spans the distance between the outer wall sheets. The outer surfaces of the side wall portions are preferably joined with the outer wall sheets by a polyurethane adhesive.

BRIEF DESCRIPTION OF DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: FIG 1 shows a perspective view of the permanent formwork system according to a first embodiment of the present invention; FIG 2 shows an enlarged perspective view of an elongate stud member of the permanent formwork system shown in FIG 1; and FIG 3 shows an enlarged perspective view of an elongate reinforcing 10 member of the permanent formwork system shown in FIG 1.

BEST MODE FOR CARRYING OUT THE INVENTION FIG 1 shows a permanent formwork system 1 in accordance with a first embodiment of the present invention. The permanent formwork system 1 15 includes two spaced apart outer wall sheets 2a, 2b, at least one elongate stud member 4 and one or more reinforcing members 10. The outer wall sheets 2a, 2b are preferably fibre cement panels, although any suitable building panels may be used. The elongate stud members 4 and the reinforcing members are coated with an acrylic finish to improve their corrosion resistance and increase 20 the longevity of their effective use in the insulated permanent formwork system 1.

The elongate stud members 4 include voids 3 therein to allow concrete to flow through the voids to fill the spaces on both sides of the stud members when concrete is poured into the cavity defined by the two outer wall sheets 25 2a, 2b. The distance between the outer wall sheets 2a, 2b is approximately 100-150mm and the distance between each of the stud members is approximately 100mm, although any suitable distances may be used.

WO 2008/128275 PCT/AU2008/000461 6 The wall sheets 2a, 2b are adhered to the stud members 4. The stud members 4 also include a plurality of apertures 15 therein. These apertures 15 improve the adhesion performance between the stud members 4 and the wall sheets 2a, 2b. The apertures 15 are formed by punching holes into the stud 5 members 4.

Where adjacent sections of the wall sheets 2a, 2b need to be joined in order to create a wall surface that is larger than a single wall sheet, a rigid cementitious jointing is utilised. This rigid cementitious jointing is created by using a conventional adhesive product, manufactured and sold by Ardex GmbH 10 in conjunction with fibreglass reinforcing tape. This rigid cementitious jointing provides improved resistance to joint distortion due to thermal cycling and movement of the wall sheets 2a, 2b. The jointing also provides a smooth surface, which is suitable for a variety of coatings and wall treatments to be applied over the wall sheets 2a, 2b.

FIG 2 shows a stud member 4 according to the present invention. The stud member 4 includes a longitudinally extending web portion 5 with two opposite side edges 6a, 6b. The web portion 5 also includes first and second longitudinally extending side wall portions 7a, 7b. Each of the side wall portions 7a, 7b have a first side edge 8a and an opposite second side edge 8b. 20 The first side edge 8a of the side wall portions 7a, 7b is joined to the respective side edges 6a, 6b of the web portion 5. In this way, the side wall portions 7a, 7b are substantially perpendicular to the web portion 5.

Each side wall portion 7a, 7b has an outer wall surface and an inner wall surface. The inner wall surfaces of the two side wall portions 7a, 7b face each 25 other. Each of the side wall portions 7a, 7b also have a longitudinally extending flange portion 9.

The flange portion 9 has a first side edge 16a and an opposite second side edge 16b. The first side edge 16a of one of the flange portions 9 is joined to the second side edge 8b of the first wall portion 7a. The first side edge 16a 30 of the other flange portion 9 is joined to the second side portion 8b of the second wall portion 7b. In this way, the two flanges 9 extend from the side wall portions 7a, 7b, towards each other and are substantially parallel to the WO 2008/128275 PCT/AU2008/000461 7 web portion 5. The second side edges 16b of the flange portions 9 are spaced apart from each other.

The outer surface of each of the side wall portion 7a, 7b of the stud members 4 are adapted to be joined face-to-face to respective outer wall 5 sheets 2a, 2b. In this way, the web portion 5 spans the distance between the two outer wall sheets 2a, 2b, such that the wall sheets 2a, 2b are supported and held in place by the stud members 4. This engagement is shown in FIG 1.

The stud members 4 have first and second inner wall portions 18a, 18b. Each of the inner wall portions 18a, 18b have a first side edge and an opposite 10 second side edge. The first side edge of the first inner wall portion 18a, is joined to the second side edge 16b of the first flange portion 9. The first side edge of the second inner wall portion 18b, is joined to the second side edge 16b of the second flange portion 9. In this way, the inner wall portions 18a, 18b extend from the flange portions 9 towards the web portion 5, although the 15 second side edges of the inner wall portions 18a, 18b are spaced apart from the web portion 5.

Each of the stud members 4 also includes a first and second lip portion 11, which is joined to, and extends from, the respective second side edges of the first and second inner wall portions 18a, 18b. The first and second lip 20 portions 11 extend towards the respective first side wall portion 7a and the second side wall portion 7b.

As shown in FIG 3 the reinforcing members comprise an elongate central portion 12 having two opposite ends 13a, 13b. Located at each of the opposite ends 13a, 13b is a hooked formation 14. The hook formation is adapted to 25 hook onto the first and second lip portions 11 of the stud members 4, thereby securing the opposed lip portions 11 of each stud member to each other.

The stud members 4 and the restraining members 10 are separate from each other. The stud members 4 include extruded aluminium and the reinforcing members 10 are made by an injection moulding process. Both the 30 stud members 4 and the reinforcing members 10 are made from roll formed WO 2008/128275 PCT/AU2008/000461 8 galvanised steel. In other embodiments not shown in the drawings, the stud members 4 and reinforcing members 10 can be integrally formed.

Each stud member 4 has a number of restraining means 10 connected thereto. In the embodiment shown in FIG 1, three restraining means 10 are 5 connected to each of the stud members 4, whilst in the embodiment shown in FIG 2, two restraining means 10 are connected to the stud member 4. It should be understood that any number of restraining means 10 can be connected to each of the studs 4. In certain applications, only a single restraining means 10 may be used on each of the stud members 4.

Whilst the preferred embodiment show the restraining means 10 being substantially strip-like, in other embodiments, that are not shown in the drawings, the restraining means 10 can be any other suitable shape, have any suitable width or may be webbed or perforated to assist in the flow of concrete between spaces adjacent to the stud members 4. Also, the connection 15 between the restraining means 10 and the studs 4 may be altered within the scope of this invention to include other connection facilitations.

Whilst in the preferred embodiment, the stud members 4 and restraining means 10 are manufactured from metal and most preferably galvanised steel, in other embodiments not shown in the drawings other suitable types of 20 material may also be used, such as polymers, plastics, timber and the like.

INDUSTRIAL APPLICABILITY The invention can be utilised in building panels and building systems for forming building panels. Particularly, the present invention can be utilised in a 25 permanent formwork system for the construction of walls where concrete is placed within the formwork along with reinforcing steel and the outer skin remains in place and forms the finished wall surfaces.

The word "comprising", or similar words, is generally intended to be interpreted in an inclusive sense, rather than exclusively, unless specifically WO 2008/128275 PCT/AU2008/000461 9 indicted otherwise, and would normally allow other examples or features to be included.

It will be apparent that obvious variations or modifications may be made in accordance with the spirit of the invention that are intended to be part of 5 the invention, and any such obvious variations or modification are therefore within the scope of the invention.

Received at IPONZ on 30 September 2011

Claims

CLAIMS: 1. A stud system for use in a formwork having two spaced apart outer wall ^hppts, the stud system comprising: h' lr,ist one elor<ga{«- stuct member; and one or more eiongatx ihi toning members, wherein the stud member has a longitudinally extending web portion with two opposite side edges, a first and a second longitudinally extending side wall portion, each of the side wall portions d first side edge and an oppusik- sotond side edge, the first side fjdges of the suit- wail portions bring joined to rht< resp< < tivi' sidf edges of ini' web portion, su< h th.it the side wall portions extend substantially perpendicularly to the web portion; each side wall portion having an outer wail surface and an Inner wall MJtl.ii v, with the inner wall surfaces of the two side wall portions fdi.ing t'di h other; and each side wall portion having a longitudinally eHi'ndinq Mange portion, wherein said flange portion has a first side edge and an opposite set onrj suit: edge, the first side edge of the first: flange portion being joined to the second side edge of the first side wall portion and the first side edge of the second flange portion being joined to the second side edge of the second side wull portion, such ffujl the tldnge portions extern! fmm *he side wall portions towards fat b nllu-r substantially [kifdllH so fssp web portion, '.-Mi, the second suie > does o' the fi aniie portion-, |j!'iri(i paced from each other; wherein the outer surface of each side kv*iii portion of the stud member is adapted to b* joined face-to-faco to <1 respective said outer sheet, such that the web ooiiion spans the distant e bet ween the outer wall *»( ee!', .vne; ,-n the i e i r" i if -1 r 111 in. 'Mtjrc, 'in ,'t •■\a> ' -it" tint;- the stun syst• 111 t mi g adapted fo- snm e;ipontr* etuis n, H'eil rt reL^ri■ h■ to the second edges of the flange portions to reinforce the stud member; and Received at IPONZ on 30 September 2011 11 the stud system defining a first and second inner wall portion, each inner wall portion having <j fust side edge and an opposite secondsuk edge; tlic !nst side edge of fhn fist inner wall p>>t ti.m bemg joined <m the s**t find side edge of the first things portion <tnd 'ne !h st side < dqc of the second inner waif po-tinn u mo joined tn flu- st<i»»nd side t_ouc of the second flange portion, such that the inner wall portions extend from the flange portions towards the web portion substantially parallel to the side wall portions, witfi She second side edges of the inner wall portions beinq spaced from fh* web portion; where,n f he stud system com pi ses a fit st unci a second lip portion, mtined to, and extending from, the ^ninci side edges of the first inner wall portion and second inner wall portion, respectively, towards the first side wall portion and second side wall portion, respectively.
2, The stud system of claim 1 wherein each of said remfornng members comprises an elongate central portion having two opposite en as and a hooked formation at each of said ends, the hooked foimotions being adapted to hook onto the first and second lip portions thereby to secure the lip portions to each other. 3, ih*' stud system of claim 1 wherein said stud member and <» inm^ oc members are separate from enrh other, 4, The stud system of claim 1 wherein said stud member and reinforcing membeis <n» formed integrally with each other. 5, It 'i -ii i h i • ystfir n[ claim 1 wherein 'Hid stud menin iiu kd^'- roll former! gel. .imvo >,'e<-;, 6, The stud system of claim 1 wherein each of said r» nhm me members is made by an injection moulding process. Received at IPONZ on 30 September 2011 12 / "Tl >' stud system of claim 1 v;h<- said stud member and said Manful i my fnemibtrs are madt from met a!, h, flu- stud system of claim 1 compttvina .i plurality of said reinioruny members, 9. The stud system of claim 1 wherein each of the side wall portions has a plurality of apertures therein to fat 11 it dip adhesion between the side wail portions and the outer wall sheets, in. The stud system of claim i wht'ium suid web portion has at least one aperture therein to allow concrete to flow there through. 11. A Uxr'uvri'k comprising, tvvu spaced dpdM uutrr w^l! sheets and at least one stud system as defined tn t id<m !, in the nuUi surfaces of the side watt portions are joined, tdn> tri-td(r with thr> rfspectrve outer wall sheets sin li that the web portion spans the distance between the outer wall sheets. 12. The formwork of claim llwherein the outer surfaces of the side wall portions are joined with the outer wall sheets by a polyuu-th.me adhesive.