WO1984001402A1 - Organes structuraux - Google Patents

Organes structuraux Download PDF

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Publication number
WO1984001402A1
WO1984001402A1 PCT/AU1983/000142 AU8300142W WO8401402A1 WO 1984001402 A1 WO1984001402 A1 WO 1984001402A1 AU 8300142 W AU8300142 W AU 8300142W WO 8401402 A1 WO8401402 A1 WO 8401402A1
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WO
WIPO (PCT)
Prior art keywords
structural member
layer
panels
structural
members
Prior art date
Application number
PCT/AU1983/000142
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English (en)
Inventor
Michael James Durack
Original Assignee
Pool Fabrications Singapore Pt
Durack M J
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Filing date
Publication date
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Application filed by Pool Fabrications Singapore Pt, Durack M J filed Critical Pool Fabrications Singapore Pt
Publication of WO1984001402A1 publication Critical patent/WO1984001402A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/045—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
    • E04B7/22—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building 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
    • E04C2/049—Building 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 completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building 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
    • E04C2/06—Building 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 reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/20—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of concrete or other stone-like material, e.g. with reinforcements or tensioning members
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • E04C5/073—Discrete reinforcing elements, e.g. fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/103—Metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/06—Concrete

Definitions

  • This invention is concerned with an improved structural member and a construction method incorporating such a member and structures embodying same.
  • a trend towards the construction of buildings from prefabricated components There are certain cost advantages in the prefabrication of say structural panels at a remote site and then transporting these to a building site for rapid assembly and erection.
  • both weight and dimensions are the most important and often limiting factors.
  • Foam cored panels may comprise a sheet of foamed .plastics material such as polystyrene foam.
  • the slab of foam is encapsulated within a concrete structural panel. If the panel has no structural requirements, the concrete "skins" on either side of the panel may be unreinforced or include only a light reinforcing mesh.
  • load bearing panels of this type may include one or more layers of a substantial reinforcing mesh or even internal stiffening ribs of metal where a high flexural strength is required.
  • Any imperfection in the outer skin of a roof panel will allow water to enter the cavity occupied by the foam insert. The trapped water can then find an imperfection in the inner skin and enter the interior of a building.
  • foam cored structural panels may be made with fibrous cement, plastics, metal or timber skins or combinations thereof but in the main these are used as non-load bearing structural members due to their inherent weaknesses.
  • solid plastics foam cores contribute little if any physical properties to such: structural panels and .in the main, the core is provided only as a physical means for separation of the skins during manufacture.
  • Various proposals for structural panels have been made in respect of concrete skinned, low density cored panels. Those incorporating a slab or core of foamed plastics materials have been • found to be quite unsuitable for the reasons outlined above.
  • the initial portion of the pour has an excessively high bead concentration while the latter part comprises substantially entirely a cementitious slurry. Having poured the initial polystyrene bead rich mix into a mould or the like, the latter portion, comprising a substantially bead free slurry, when poured over the top of the initial layer migrates to the bottom of the mould leaving the upper layer rich in polystyrene beads and consequently lacking in physical strength.
  • sand means particulate silicious material such as an e.g. river or beach sand.
  • the sand comprises a mixture of particle sizes from a maximum of say 3 mesh (Tyler) down to a fine dust e.g. 200 mesh (Tyler) or less.
  • Tyler fine dust e.g. 200 mesh
  • the sand gives the effect of a miniature mixed aggregate similar to conventional concrete mixes but on a substantially smaller scale.
  • a structural member comprising:- an outer surface of fibre reinforced concrete; and an inner core of cementitious material including low density particulate material.
  • the outer surface is reinforced with enlarged end fibres.
  • the enlarged end fibres comprise glass fibres.
  • the enlarged end fibres comprise steel fibres.
  • the low density particulate material comprises a foamed plastics material.
  • the low density particulate material comprises foamed polystyrene beads.
  • the inner core comprises a foamed cementitious material.
  • the inner core has a density of from 250kg/m 3 - 800kg/m 3 .
  • the cementitious material is formed •from a slurry of cement and water.
  • the cementitious material is formed from a slurry of cement, sand and water.
  • said structural member includes reinforcing means selected from steel mesh, or elongate steel members.
  • said structural member includes one or more conduits to receive pre-stressing tensile members.
  • a method of constructing a structural member comprising:- forming a first layer of fibre reinforced concrete against a shaping surface; forming on said first layer a second layer of cementitious material containing low density particulate material; and forming on said second layer a further layer of fibre reinforced concrete.
  • said first layer and said further layer are joined at least at the peripheral edges of said member.
  • said shaping surface comprises a male or female mould.
  • said first, second and further layers are formed by a spraying method.
  • FIGS. 1-3 illustrate a preferred method of constructing a structural panel according to the invention.
  • FIG. 4 illustrates a structural panel with conduits to receive pre-stressing tensile members.
  • FIG. 5 illustrates a composite structure
  • FIG. 6 illustrates a structural beam member according to the invention.
  • FIGS. 7-8 illustrate alternative methods for connection of opposed skins of a layered structure.
  • FIG. 9 illustrates a partial cross section of a modular building construction illustrating aunitary roof member.
  • the bottom or base layer 1 is formed on any suitable surface such as a sheet plastics, steel or concrete surface 3aor the like. This surface may be smooth or decoratively textured and, if required, coated with a mould release agent to facilitate release of the finished panel from the mould surface.
  • the mould frame suitably
  • OMP1 comprises lengths of angle section steel, aluminium—or plastics material 2 or the like movably secured to the mould surface 1 to define the perimeter of the mould and/or to define apertures such as window apertures in a structural wall.
  • the inwardly directed face of the angle iron 2 is lined with a spacer 3 of timber, foam plastics or the like to form a predetermined space of width x the purpose of which will be described later.
  • a cementitious skin mix is then prepared in a suitable mixer according to the ratio: cement 800kg water l ⁇ Olitres sand 1500kg steel fibres 160kg
  • the cement is preferably grey portland cement and the steel fibres are preferably enlarged end .rectangular end fibres made by A.W.I. Fibresteel having dimensions 14mm long x 0.4mm thick x 0.6mm wide. If required, a quantity of conventional plasticizing agent may be employed to improve workability of the mix.
  • the skin material 4 is poured into mould to a required skin thickness and levelled, at least roughly by trowelling, screeding or the like.
  • a core mix is then prepared as follows according to the ratio : water 200 litres cement 400kg foamed " polystyrene beads: _. 3
  • the cement is preferably grey portland cement and the foamed polystyrene beads have a diameter range of from 3-6mm with a density of approximately 15kg/m .
  • the water and cement are added to a mixer such as a concrete mixer to form an homogenous slurry. Once the slurry is formed, the beads are then added and mixed thoroughly to form an homogenous slurry/bead mix.
  • OMPI viscosity of the slurry is such that the tendency of the beads to migrate to the surface during mixing is effectively negated.
  • the mix is then poured into the mould to form a second layer 5 on top of the first "wet" or uncured layer 4.
  • the surface of the cement/bead mix 5 is levelled in a manner similar to the first layer 4.
  • the thixotropic nature of the cementitious mix 5 is such that there is no tendency for the beads to migrate to the surface of the second layer after pouring and levelling.
  • first layer 4 is roughened by a suitable roughening tool.
  • a final layer 7 substantially similar to that of layer 4 is then poured over the top of layer 5 and allowed to flow down the cavity between the edges of layers 4 and 5 and the mould wall formed by angle member 2.
  • the resultant panel is formed with a peripheral edge skin 8 integral with and similar to upper skin 7 and lower skin 4 respectively.
  • the uppermost surface of skin 7 is screeded, trowelled or otherwise levelled and finished as desired.
  • the panel may measure 2.5mm x 4m x 100mm thick.
  • the panel may comprise an 80mm core with 10mm skins on either side.
  • the cementitious slurry for the core may include a foaming or aerating agent to further reduce the density of the composite core material.
  • a foaming or aerating agent to further reduce the density of the composite core material.
  • Such a slurry composition may comprise the slurry mix as described above with the addition of 2 litres of FRO.B (Trade Mark) - an organic foaming agent manufactured by Sika.
  • the water is placed in a conventional concrete mixer with the FRO.B foaming agent and with the mixer rotating, the aqueous mix is aerated by the introduction of compressed air at the rate of about 10. cu.ft./min. for about 3min. Two thirds of the cement is then added and during the mixing cycle, aeration is conducted for a further 3 mins. The remaining portion of the cement is then added and when mixed thoroughly, the foamed polystyrene beads are added.
  • the resultant mix has a "wet" density of
  • FIG. 4 illustrates a modification of the invention in which a panel 8 includes a plurality of pre- stressing tendons 9 such as wire rods cast within the core of the panel. Preferably the ends of tendons 9 are anchored at the panel edges by any suitable anchoring means 10 such as collets or the like cast into the panel edges.
  • FIG. 5 illustrates a composite structure comprising a plurality of preformed panels 11 anchored together by post-tensioned tendons 12 passing through aligned conduits 13 cast into the core of the panels.
  • a composite structure may comprise a suspended floor or roof structure comprising panels measuring 4m x 3m and 100mm thick (10mm skins and 80mm core) .
  • the panels are locked together with high tensile steel cables or rods running at right angles at about 2m centres.
  • the tendons are tensioned to approximately 10 tons prior to anchoring by conventional means.
  • a particular advantage of such composite members is that in the event of compressive failure of portion of a panel, the pre-tensioned cables give support to the structure in a manner similar to a safety net. Being .comprised of separate panels, destructive compressive point loads are confined to a single panel or portion thereof and propagation of stress induced cracks is limited. Any damaged area may be readily repaired (at least cosmetically) by a plastering operation.
  • the beam 14 effectively comprises an elongate member constructed substantially in accordance with the panel construction methods described above.
  • the beam comprises an outer skin of fibre reinforced cementitious material 15 and an inner core 16 having a foamed or unfoamed cementitious material incorporating a low density particulate material.
  • the upper and lower skins 17, 18 respectively may include conventional reinforcing elements or pre-tensionable elements 19 engineered for the particular end use.
  • FIGS. 7 and 8 show yet another embodiment of the invention in which the outer skins 2Q, 21 of structural members 22 are tied together at predetermined intervals to enhance overall strength characteristics.
  • FIG. 7 shows columns 23 of integrally formed fibre reinforced cementitious material linking the upper and lower skins. Alternatively these columns may be replaced by ribs or the like.
  • FIG. 8 shows shaped metal ties 24 acting as internal links.
  • the core material may comprise any light weight particulate material such as wood chips and the like.
  • the invention is not limited to planar panel constructions as in conventional laminating techniques utilizing pre-formed cores and skins.
  • a particular advantage of the invention is that the structural members may be formed in a variety of planar or three-dimensional shapes (in male or female moulds) due to the ability to form "integral" members in a plastic state.
  • FIGS. 9-15 An example of the application of the invention to a building structure is examplified with reference to FIGS. 9-15.
  • FIG. 11 illustrates a plan view of the building construction partially illustrated in FIG. 9.
  • FIG. 12 illustrates a cross section through A-A in FIG. 11.
  • FIG. 13 illustrates an end elevation in the direction of arrow B in FIG. 11.
  • FIG. 14 illustrates a partial sectional view of one corner of the roof member of FIG. 9.
  • the structure comprises a floor member 31 suitably of a cast in situ reinforced concrete raft floor or a member comprising a fibre reinforced skin and a low density core.
  • the floor may be formed as shown in FIG. 5.
  • integral reinforcing beams 32 of greater thickness.
  • the sandwich construction suitably comprises outer skins of cementitious material reinforced with FIBRESTEEL (Regd. Trade Mark) enlarged end steel fibres.
  • the inner core comprises a cement/expanded polystyrene bead mixture and if required may also include reinforcing in the form of rods or welded mesh.
  • FIBRESTEEL Registered. Trade Mark
  • fragmented low density plastics material such as pulverized or chopped polystyrene foam, polyurethane foam, wood chips or similar materials. The construction of such cementitious sandwich members is described earlier in this specification.
  • a roof member 34 comprising a substantially pyra idical unitary construction is supported inwardly of its corners by the blade-like support columns 33.
  • the roof member comprises a sandwich construction with an outer skin 35 of steel fibre reinforced concrete, an intermediate core 36 of concrete/expanded polystyrene bead mixture and an inner skin 37 also of steel fibre reinforced concrete.
  • Roof member 34 comprises a main portion 38 and a cantilevered perimetral portion comprising a downwardly
  • OMPI extending portioi ⁇ 39. and a laterally extending portjLon 40.
  • a lip 41 at the outer edge of perimetral portion defines a channel or trough with the outer surfaces of portions 39 and 40.
  • At the junctions of portions 38, 39 and 40 and in the region of lip 41 are substantially continuous pre- stressed reinforcing tendons 42 which serve to restrain the known tendency of the pyramidical structure to spread in a generally radial lateral direction. Such spreading forces are due to the horizontal vector component of forces directed down the sloping walls of a supported pyramid due to its own mass.
  • any tendency of the structure to sag in the large flat sloping areas 38 is overcome by the combined effects of a number of dynamic forces which serve to cancel each other.
  • the four substantially triangular roof faces are supported at their junctions by columns 33 over about half the length of the junctions.
  • the cantilevered suspension of portion 40 about downwardly extending portion 39 exerts an elevating effect on the large flat area of portion 38.
  • Cantilevered portion 40 acts somewhat as a lever about the upper outer corner 43 of column 33 which serves as a fulcrum.
  • the sandwich structure of the roof member resists sagging by stressing of the inner and outer skins in tension and compression respectively.
  • a roof structure as described provides a dynamically stable structure which is largely self-supporting without the need for rafters, bearers etc. or other reinforcement.
  • roof member 34 is formed as a unitary member on a male mould beside the building site by the method described hereinafter.
  • Lifting attachment points such as bolts 44 are provided at say four equidistantly spaced positions during manufacture.
  • the raft floor 31 is prepared_with columns 33 extending upwardly therefrom.
  • a ventilator and skylight structure 45 is suitably provided at the peak of the roof structure.
  • External walls 46 preferably panels of concrete sandwich construction are situated in a channel 47 in the undersurface of cantilevered portion 40 and a channel 48 formed in the floor 31.
  • Internal walls 49 suitably comprise panels of similar size and construction to outer wall panels 46 with an infil 51 of glass, plasterboard or timber.
  • louvred slats or windows 52 are provided at some or most of the corners of the building. None of the external or internal walls are load bearing as the entire roof is supported on columns 33. Accordingly, the structure of the walls is greatly simplified thus giving rise to great cost benefits.
  • FIG. 10 illustrates an arrangement of reinforcing members which may be included in the roof structure of
  • FIG. 9 if circumstances or local authorities require same.
  • Arrangement 38a would be incorporated within roof portion 38 during the manufacture of the roof structure.
  • arrangements 39a and 40a would be incorporated within portions 39 and 40 respectively. These arrangements may be welded from steel rod, bar, tubing etc. or they may be arranged loosely as individual members in the arrays as shown.
  • FIG. 11 illustrates a typical floor plan for a domestic dwelling which may be built in accordance with the invention.
  • FIG. 12 illustrates a crosssection through A-A in FIG. 11.
  • FIG. 13 illustrates an end elevation of the structure of FIG. 11 in the direction of arrow B.
  • FIG. 14 illustrates a sectional view of one corner
  • the gutter or trough .formed between lip 41 and roof portions 39 and 40 provides an excellent integrally formed stormwater gutter.
  • the very large capacity of gutters so formed permit such structures to be used in regions where heavy rainfall is experienced without the necessity for special plumbing.
  • An aperture 53 is formed for connection to a downpipe.
  • FIG. 15 illustrates in plan view portion of the wall and support structure immediately beneath the portion of roof member shown in FIG. 14.
  • the outer and inner walls are preferably constructed from prefabricated concrete sandwich panels. The joins between abutting panels are then grouted with a cementitious or like material to form a substantially continuous wall surface suitable for decorative finishes.
  • a door 54 is suitably provided in the corner position illustrated. Installation of the door is achieved by affixing one of the door jambs 55 directly to support column 33 by any suitable means such as masonry anchors, screws, rivets or the like.
  • An infil panel 56 comprising a glass sidelight is affixed in a frame attached to the outer wall panel in a manner similar to the door jamb.
  • a male mould is constructed of say a timber frame and a plywood or like sheet material covering.
  • a plastics membrane may be
  • OMPI placed over the mould surface to act as a mould release agent otherwise a conventional release agent may be employed.
  • the three layers of cementitious material are built up one upon the other until the desired thickness is achieved.
  • the top or outer surface is then screeded and/or trowelled off to obtain a smooth finish.
  • lifting bolts are located within the sandwich at desired positions. Further, if reinforcing elements are required such as rods, mesh or the arrays as shown in FIG. 10, these may be incorporated in the sandwich by say placing on top of the first layer and then spraying the successive second and third layers thereover. If required, conduits for electrical cables and the like may also be incorporated in the panels or roof structure during construction.
  • ribs may be formed by building up the thickness of portions of the first layer of steel fibre reinforced concrete or tensile members may be incorporated into the member.
  • the present invention has application to virtually all presently employed structurally reinforced members such as floors, structural beam members including "I" beams, box beams and the like as well as piers, columns, foundations etc.
  • pre or post stressing tendons may be incorporated into the structural member.
  • a first layer of steel fibre reinforced cementitious material is formed against a mould surface, the reinforcing tendons are placed in position against the surface of the first layer and additional steel fibre reinforced cementitious material is sprayed over the tendons to substantially encapsulate them.
  • a second layer of cementitious material containing -low density particulate plastics material is then ' formed over the first layer.
  • channel-like depressions may be formed in the second layer in the region where additional reinforcing tendons are to be placed.
  • the channel-like depressions are then at least partially filled with a steel fibre reinforced cementitious material prior to positioning of the additional tendons.
  • a further layer of steel fibre reinforced cementitious material is then formed over the exposed surface to encapsulate the tendons.
  • the tendon reinforced "skins" of the sandwich structure so formed are thus substantially identical in construction.
  • roof panels may suitably be selected from the following range.
  • Roof panels constructed in accordance with the above thickness ranges should be supported safely with span distances of around 6 metres.
  • the main advantage is that structural members prepared with the sandwich construction method offer a significant weight reduction without substantial reduction in mechanical properties when compared with an equivalent member of conventional reinforced concrete or similar construction.
  • incorporating blocks or slabs of foam is that the flexural an compressive characteristics of the core are not greatly different to the skins.
  • the interstices between the foamed plastics beads comprises a substantially continuous rigid cementitious structure.
  • Engineered designs using prefabricated prior art members are generally constrained by predetermined sheet or panel dimensions.
  • a further advantage is the immense flexibility in design of structural components using the method according to the invention. For example, in an "on the job” situation, modifications to skin or core thicknesses may readily be made to suit varying engineering requirements.
  • a still further advantage is that waterproofing, sound, thermal insulating and fire rating properties are all substantially improved over prior art cored concrete members.
  • the surprisingly unexpected superior physical strengths of structural members made in accordance with the invention is believed to arise from the use of relatively thin skins of cementitious materials having high compressive tensile and flexural strengths compared with prior art concrete skins.
  • the fibres are substantially aligned in a two-dimensiona plane thus alleviating shrink cracking normally associated with curing of thin layers of cementitious slurries.
  • roof and wall panels are manufactured to predetermined engineering specifications and dimensional shape requirements.
  • the panels are transported to a building site where a preformed concrete or concrete sandwich foundation has been formed.
  • Abutting walls are erected by a crane and temporarily held in place by angle brackets bolted to adjacent abutting edges of the wall panels.
  • the roof panels are then hoisted into position on th outer and any inner load bearing walls and similarly pinned. Abutting edges of the roof panels may be joined with a waterproof caulking compound and, if required, adjacent edges may be tied by a plate spanning the joint.
  • the pins may comprise a simple steel rod of say 10mm diameter by 200-300mm in length. The pins merely serve to locate the panels relative to each other and do not provide a tensionable joint. The resultant structure is found to be extremely stable with merely the pinned joints.
  • the weight of the roof panels is sufficient to lock the arrangement together and the excellent thermal properties of the panels substantially alleviates thermally induced expansion and contraction at the wall and roof panel joints.
  • the structure may then be finished in a conventional manner with appropriate doors, windows, trim fittings etc. and a suitable decorative finish such as paint applied to the internal and external surfaces.
  • Utility services such as plumbing, electrical wiring etc. are suitably precast into the panels during manufacture. On present day labour and material costs, it can be deomonstrated that an overall cost saving of 20-25% can be achieved in a low cost domestic dwelling of

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)

Abstract

Un organe structural possède un noyau (5) fabriqué à partir d'une boue de ciment moussée ou non moussée et d'eau dans lequel on incorpore de manière homogène des sphères de polystyrène mousse, et une enveloppe mince extérieure (4, 7) fabriquée à partir d'un matériau cémenteux renforcé avec des fibres d'acier et fabriqué à partir de ciment, de sable et d'une boue aqueuse. L'enveloppe extérieure mince (4, 7) présente d'excellentes propriétés de résistance à la flexion et à la rupture par compression, lesquelles combinées au noyau léger (5) permettent d'obtenir des poutres ou des panneaux structuraux appropriés à de nombreuses applications structurales y compris les constructions. Des panneaux individuels (11) peuvent être joints à leurs bords pour former de grands panneaux en faisant passer au travers du noyau de chaque panneau des câbles de post-tension (12).
PCT/AU1983/000142 1982-10-05 1983-10-05 Organes structuraux WO1984001402A1 (fr)

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2236276A (en) * 1989-08-01 1991-04-03 Henry Melville Green Structural members suitable for toxic and hazardous waste containers
DE4019109A1 (de) * 1990-06-15 1991-12-19 Schweers Hans Gerd Dipl Ing Holzkonstruktion, insbesondere fuer das dach eines wintergartens
EP0465163A2 (fr) * 1990-07-06 1992-01-08 Raphael Nicolaidis Elément de construction portatif et procédé pour sa fabrication
WO1992007714A1 (fr) * 1990-10-25 1992-05-14 Erik Arne Kristoffer Westin Composition a plusieurs constituants destinee a un systeme de plancher en solives, et procede de fabrication
GB2268199A (en) * 1992-06-30 1994-01-05 Hsu Cheng Hui Reinforced and prefabricated construction panel
US5372769A (en) * 1990-10-24 1994-12-13 Cbt, Concrete Building Technology Ab Method of producing concrete elements
FR2766753A1 (fr) * 1997-07-29 1999-02-05 Matiere Soc Civ De Brevets Procede de realisation d'un element prefabrique et element de construction ainsi realise
AU723114B2 (en) * 1996-02-05 2000-08-17 Regents Of The University Of California At San Diego, The Modular fiber-reinforced composite structural member
WO2006042345A1 (fr) * 2004-10-20 2006-04-27 Joro System Gesellschaft M.B.H. Element de construction antibruit
GB2482196A (en) * 2010-07-23 2012-01-25 Page Concrete & Steel Ltd A multilayer lightweight concrete slab
WO2014112890A1 (fr) * 2013-01-21 2014-07-24 Civerpro, S.A. Panneau de ciment à structure sandwich pour la construction de bâtiments
IT201600074350A1 (it) * 2016-07-15 2018-01-15 Gennaro Bencivenga Metodo di costruzione in blocchi di cemento armato alleggeriti e prodotto così ottenuto.
CN112555522A (zh) * 2021-01-20 2021-03-26 四川好运通建材有限公司 一种钢承口复合钢筋混凝土内衬玻璃钢排水管及制备方法
JP2021133640A (ja) * 2020-02-28 2021-09-13 東京製綱株式会社 コンクリートパネル用補強材
EP3308917B1 (fr) * 2016-09-28 2023-05-03 Nichiha Corporation Matériau de construction et son procédé de production

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CN108286341B (zh) * 2017-12-11 2020-09-25 新疆苏中建设工程有限公司 一种不同基底材料交接处防裂钢网模板结构及利用其进行施工的方法

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AU7209074A (en) * 1973-08-13 1976-02-12 John Tilly Greaem Structural wall
GB1445787A (en) * 1974-07-11 1976-08-11 Torvale Holdings Ltd Woodwool slab receiver digital detectors and methods of operation of such detectors
GB1546102A (en) * 1976-07-02 1979-05-16 Redpath Dorman Long Ltd Structural units
AU3188777A (en) * 1976-12-27 1979-06-28 Maso Therm Corp Composite module with reinforced shell
AU3881978A (en) * 1977-08-15 1980-02-14 John Tilly Graeme Wall panel
US4335177A (en) * 1979-10-03 1982-06-15 Kurimoto Iron Works, Ltd. Glass fiber-reinforced cement plates

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AU7209074A (en) * 1973-08-13 1976-02-12 John Tilly Greaem Structural wall
GB1445787A (en) * 1974-07-11 1976-08-11 Torvale Holdings Ltd Woodwool slab receiver digital detectors and methods of operation of such detectors
GB1546102A (en) * 1976-07-02 1979-05-16 Redpath Dorman Long Ltd Structural units
AU3188777A (en) * 1976-12-27 1979-06-28 Maso Therm Corp Composite module with reinforced shell
AU3881978A (en) * 1977-08-15 1980-02-14 John Tilly Graeme Wall panel
US4335177A (en) * 1979-10-03 1982-06-15 Kurimoto Iron Works, Ltd. Glass fiber-reinforced cement plates

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2236276A (en) * 1989-08-01 1991-04-03 Henry Melville Green Structural members suitable for toxic and hazardous waste containers
DE4019109A1 (de) * 1990-06-15 1991-12-19 Schweers Hans Gerd Dipl Ing Holzkonstruktion, insbesondere fuer das dach eines wintergartens
EP0465163A2 (fr) * 1990-07-06 1992-01-08 Raphael Nicolaidis Elément de construction portatif et procédé pour sa fabrication
EP0465163A3 (en) * 1990-07-06 1992-04-15 Raphael Nicolaidis A portable constructional element and a process for its production
US5372769A (en) * 1990-10-24 1994-12-13 Cbt, Concrete Building Technology Ab Method of producing concrete elements
WO1992007714A1 (fr) * 1990-10-25 1992-05-14 Erik Arne Kristoffer Westin Composition a plusieurs constituants destinee a un systeme de plancher en solives, et procede de fabrication
GB2268199A (en) * 1992-06-30 1994-01-05 Hsu Cheng Hui Reinforced and prefabricated construction panel
AU723114B2 (en) * 1996-02-05 2000-08-17 Regents Of The University Of California At San Diego, The Modular fiber-reinforced composite structural member
US6189286B1 (en) 1996-02-05 2001-02-20 The Regents Of The University Of California At San Diego Modular fiber-reinforced composite structural member
FR2766753A1 (fr) * 1997-07-29 1999-02-05 Matiere Soc Civ De Brevets Procede de realisation d'un element prefabrique et element de construction ainsi realise
WO2006042345A1 (fr) * 2004-10-20 2006-04-27 Joro System Gesellschaft M.B.H. Element de construction antibruit
GB2482196A (en) * 2010-07-23 2012-01-25 Page Concrete & Steel Ltd A multilayer lightweight concrete slab
GB2482196B (en) * 2010-07-23 2014-12-31 Page Concrete & Steel Ltd A concrete slab
WO2014112890A1 (fr) * 2013-01-21 2014-07-24 Civerpro, S.A. Panneau de ciment à structure sandwich pour la construction de bâtiments
IT201600074350A1 (it) * 2016-07-15 2018-01-15 Gennaro Bencivenga Metodo di costruzione in blocchi di cemento armato alleggeriti e prodotto così ottenuto.
EP3308917B1 (fr) * 2016-09-28 2023-05-03 Nichiha Corporation Matériau de construction et son procédé de production
JP2021133640A (ja) * 2020-02-28 2021-09-13 東京製綱株式会社 コンクリートパネル用補強材
JP7353214B2 (ja) 2020-02-28 2023-09-29 東京製綱株式会社 コンクリートパネル
CN112555522A (zh) * 2021-01-20 2021-03-26 四川好运通建材有限公司 一种钢承口复合钢筋混凝土内衬玻璃钢排水管及制备方法

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EP0122268A1 (fr) 1984-10-24
AU2073983A (en) 1984-04-24
AU565757B2 (en) 1987-09-24
EP0122268A4 (fr) 1985-03-06

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