WO1988001325A1

WO1988001325A1 - Modular building system

Info

Publication number: WO1988001325A1
Application number: PCT/AU1987/000265
Authority: WO
Inventors: Frank Smith
Original assignee: Unan Pty Ltd.
Priority date: 1986-08-14
Filing date: 1987-08-14
Publication date: 1988-02-25
Also published as: GB2207688A; GB8808848D0; BR8707423A

Abstract

A precast building panel (1) for site or factory fabrication and for use as a retaining wall, floor, roofing or wall panel in or on a structure. The panel structure comprises a planar lining member (2), a removable resilient ribbed frame (3) proportioned to approximate the dimensions of the lining member (2) and profiled so as to enable a moulded profile to be formed in the edges of the panel (1). The panel (1) also has a means (4) for maintaining the ribbed frame (3) in spaced apart relationship, reinforcing mesh (16), at least one conduit pipe (10), a filler material for binding and setting the lining member (2), the reinforcing mesh and conduit pipe (10). Setting of the filler material and subsequent removal of the frame results in the panel having at least one finished exterior face and at least on profiled edge.

Description

MODULAR BUILDING SYSTEM

The present invention relates to a building system utilising prefabricated structural panels suitable for use, in particular, though not exclusively, in hospital, laboratory, school, residential, office, factories, warehousing building construction.

A great variety of building panels are known both of the load bearing and cosmetic variety and these panels are generally prefabricated in concrete and finished prior to transportation to the building site.

With the known load bearing panels their weight creates transportation and lifting difficulties.

The excessive weight of the commonly known factory fabricated concrete panels limits the number which can be transported on one vehicle.

Loading and unloading of the panels necessitates heavy duty lifting equipment.

In remote areas, transportation costs of prefabricated and prefinished panels are high as weight limitations imposed on vehicles limit the number of panels per carrier vehicle. The present invention seeks to ameliorate the aforesaid problems by introducing an efficient and economic concept in modular bui/tding construction for use in both local and remot areas. One advantage of the present invention is that the fabrication of the panels combines the economies that exist in factory prefabrication of building panels with the economies that can be achieved by using locally available meterials to complete the panel on site.

In its present form, the present invention comprises an improved method. for building structures utilising modular panels, said panels comprising: a panel lining member; a prefabricated removeable perimetre frame; at least two spacer tubes spacing the long sides of the removeable perimetre frame; at least two bolts passing through the spacer tubes and clamping the long sides of the removeable perimetre frame together; reinforcing mesh or needle type reinforcement disposed within a recess in said frame; said frame generally having within it at least one service conduit; said lining member being fixedly attached to and parallel to the plane of the same frame; said panels being constructed by a method comprising the steps of: laying the said panels on the ground, or the building's floor slab or other prepared area; pouring concrete into the said recess formed within the frame, and finishing of the said concrete. wherein, on completion of said panel, the abovementioned bolts are removed, the removeable perimetre frame is removed and the panel is lifted or rotated into position so that said planar lining member forms nart of an inner wall surface of a structure; said finished concrete forming part of an outer surface or inner surface of a structure.

The panel can be used for construction of retaining walls, walls, roofs, ground floors or suspended floors with the latter having additional structural assistance for support.

In the preferred embodiment, the panel is partially factory prefabricated then completed on the site of the building to be constructed using the panels.

Preferably, the planar lining member is of a fibre cement material.

The removeable perimetre frame is preferably comprised of ribbed members. The spacer tubes are preferably of standard manufactured metal, plastic or other material preferably between 10 mm and 30 mm diameter.

The bolts referred to are preferably of mild steel, or plastic or other threadable material.

The reinforcing mesh is of standard structural reinforcing mesh, or steel or fibreglass "needle" type reinforcing.

The various services pipes and conduits located within the panels are standard manufactured items conforming to the various statutory requirements and Australian Standards.

The invention will now be described in detail with reference to a preferred but non-limiting embodiment wherein:

Fig. 1A shows an exploded view of the essential elements of the panel according to a preferred embodiment, being more than one sheet of fibre cement board wide.

Fig. 1B shows an exploded view of the essential elements of the panel being one sheet of fibre cement board wide.

Fig. 2 shows a cut away view of the panel in its completed form according to the preferred embodiment, one sheet of fibre cement board wide.

Fig. 3 shows a plan view of the preferred method of forming an in situ construction corner with the prefabricated panels. Fig. 4 shows a plan view of the preferred tongue and groove or other interlocking section method of the abutment between adjacent panels.

Fig. 5 shows an elevational section of the preferred method of connecting a panel to a concrete ground floor slab. Fig. 6 shows a top plan view of a portion of a typical panel showing removeable formwork adapted to the peripheral frame.

Fig. 7 shows a typical elevational view indicating the optional tie cables connecting the wall panels. Fig. 8 shows a typical elevation of a variation of the construction from concrete infil to steel frame.

Fig. 9 shows a typical elevation of a variation of the construction from full concrete panel construction to concrete frame construction. Referring to Figures 1A and 1B there is shown an exploded view showing the principal integers of panel 1 according to the apparatus aspect of the present invention.

The panel is shown in the upright position and has a planar lining member 2 which pref erably is a f ibre cement material .

This lining member has two main purposes. Firstly, when the panel is in situ, it forms an inner wall surface of the structure built with the panels. For instance, it could form a wall or ceiling surface. Secondly, the panel acts as formwork when the concrete is poured into the panel framework to complete the method aspect of the present invention.

The lining member 2 is chosen according to the size of the panel to be used for the particular job, but utilises full width and length of generally standard sized sheets of fibre cement board as manufactured. Specifically manufactured sizes of fibre cement board could be envisaged.

A removeable perimetre frame 3 is prefabricated to the required size of the panel. The lining member 2 is fixedly located within frame 3 such that the plane of the frame is parallel to the plane of the lining member 2.

The frame is preferably constructed from a resilient material such as cold rolled steel ribbed members bolted together to define the periphery of the frame.

The ribbed member 3 of the peripheral frame has mainly a three fold purpose.

Firstly, it acts as peripheral removeable structural formwork when the concrete is poured into the frame according to the method aspect of the invention.

Secondly, the ribbed section 3 acts as a resilient edging for the panel imparting a clean line to the periphery of the panel. Thirdly, it acts as a tongue and groove or other interlocking former which allows the panels to fit together.

Within the periphery of the frame 3 is a network of angle sections 7 which are proportionately smaller in comparison to the frame 3. These angle sections 7 are used when the panel size is wider than one sheet of fibre board.

The interstitial network of smaller angle sections 7 forming studs noggings and bracings provide added structural intiegrity to the lining member 2 by bracing and by providing added resistance against lateral loads which may be imposed on the panel either in transit or in situ. The configuration of the interstitial angle sections 7 can be varied considerably according to the anticipated loads which may be imposed on the structure. formed by the panels.

For instance, the angles 7 could be disposed diagonally, laterally or vertically. The structural needs can dictate the configuration of the frame 3.

Spacer tubes 4 and bolts 5 are shown within peripheral frame 3.

The frame 3 is adapted to accommodate service conduits, such as water, gas or electrical conduits.

The service conduits can be located according to the required position of the service outlets inside or outside of the building to be made with the panels.

The conduits preferably enter the wall panel through the top plate 9 with the termination points dictated by need.

Fig. 1 shows one embodiment of the wall panel with water lines 10 and an electrical conduit 11. The service conduits are held in position by holes 12 which are drilled through the angle sections 7 for panels wider than one sheet of fibre board. Where panels are only the width of a single sheet of fibre board then angle sections 7 are not necessary. In this case the services pipes and conduits are fixed to the reinforcing mesh, or spacer tubes if needle reinforcement is used.

The portions of the conduits which are to remain within the wall frame are installed during prefabrication of the frame 3. A connecting means 13 is provided on each conduit on the outside of the top plate to facilitate ease of adaption to the remainder of the service lines to which the conduits are to be attached.

It is envisaged that buildings constructed with the panels will have main or sub-main service conduits running to the roof and thence down within the wall panels.

Reinforcing mesh 16 of a known grade and type (or alternatively needle type reinforcing may be mixed in the concrete) is then placed within the recess 15 such that it abuts the angle members 3. Both single and double layers of mesh would be envisaged dependent upon the structural requirements of the panel.

Once the frame 3 is completed with service conduits and lining member 2 fixedly attached, and reinforcing mesh 16 placed in position and spacer tubes and bolts are placed in position and tightened, the prefabrication part of construction is complete. The panel in its skeletal state is now ready for transportation to the building site.

In this state the panel is a lightweight structure which is easily transportable and easy to handle. Furthermore, its inherent structural resilience despite its incompleteness ensures safety of panels during transportation.

The skeletal panels stack efficiently to achieve space economy on transport vehicles as well. By using 1200 mm and 900 mm wide panels, efficient utilisation of standard cargo containers is achieved.

There are no excessive weights to be considered in calculating costs of transportation as would be the case if concrete panels were to be carried. According to the method aspect of the present invention, the invention envisages pouring concrete into the framework of the panels to complete each panel structure on the site.

When the skeletal frames are on site, each can be positioned to approximate their final in situ position. The panels are completed by the following steps:

The frame is laid on the ground or the building's concrete floor slab or on any other prepared surface. The inner surface 14 of lining member 2 acts as base formwork onto which the concrete is poured. The poured concrete is finished off by trowelling smooth, or by trowelling in a selected finish such as marble or pebble aggregate. Such aggregate would then be exposed by hosing with a light spray or similar treatment. The ribbed members of the peripheral members 3 create a tongue and groove or other interlocking recess whose overall depth will approximate the required thickness of the concrete.

Referring to Fig. 6, there is shown a section of a wall panel showing a part of the peripheral ribbed member which is attached a kinked piece of removeable formwork 37. This formwork acts in shaping the concrete of the wall panel into a tapered corner. The result of the action of the formwork 37 is shown clearly in Fig. 4 wherein the two abutting wall panels 26 and 27 are formed with tapered corners 38 and 39 respectively, shown dotted on Fig. 4.

When the concrete has set, the panel can be lifted or rotated into position.

An advantage of pouring the concrete on site to complete the panel, is that local materials can be used to make the concrete, as most Locations, whether remote or not, can supply constituent materials for concrete. Waking concrete on site is therefore cheaper as transport costs are reduced due to weight reduction of the prefabricated panels.

Fig. 2 shows a cut away view of a completed panel according to a preferred embodiment.

The composite structure of the reinforcing steel 16 and concrete imparts considerable strength to the panels.

Once each panel is rotated into position it is secured either temporarily by stays until it is connected to its adjacent panel or it is connected immediately to an adjacent panel.

When a complete run of panel walling has been stood up and temporarily braced, optional steel cables may be threaded through the spacer tubes. The cables can then be tightened and thus placed in tension. It should be noted that the spacer tubes are located at door head height and chair-rail height so tha the optional steel cables referred to can run the full length of the wall (at door head) or from doorway to doorway or doorway to corner (at chair-rail height). Fig. 8 shows a typical elevation of these optional cables.

Fig. 3 shows a plan view of two abbreviated wall panels forming a corner joint according to a preferred embodiment. The wall panels are joined by means of an optional steel cable 18 in tension. Cable 18 is fixed to the wall panels 21 and 22 by means of cable bolts 24 which are full wall size in length at door head height or are long lengths between doorways at chair-rail height. When the wall panels are positioned, the fibre cement linings 2 form an internal corner which is finished by the known means of taping and setting.

Fig. 4 shows the preferred method of abutment or adjoining walls panels disposed at 180 degrees relative to each other. A tongue and groove or other interlocking joint is formed whereby panels 26 and 27 are located to leave a gap 28 present between them. At the outside of the wall panel a rubberised expansion joint 29 is wedged within the said gap. This expansion joint is overlaid with a mastic sealant 30 to waterproof the join.

A single layer of mastic strip material used between adjacent panels and panels and other constructional elements such as floors could also be envisaged. At the inside of the wall panel, the respective lining members 2 are connected by a taped and set joint, or by a standard manufactured jointing section.

Fig. 5 shows a preferred method of connecting a wall panel to a concrete floor.

Slab 32 is prepared with a tongued steel or concrete former 33 leaving a portion 33 protruding upwardly from the slab. The male tongue acts as a key to hold the wall panel in position, fitting into a female groove at the base of the wall section. Other interlocking sections may be envisaged in lieu of tongue and groove.

The abovementioned method of construction using panels which are partially shop fabricated and then completed on site, results in an economic, robust durable and structurally sound building.

The method is of great advantage in remote or local areas particularly in building structures such as hospitals, schools and laboratories which require extensive services supplied in conduits. The positioning of these conduits can be factory prepared and specified prior to construction.

It is envisaged that multi-storey structures can be constructed using this method. Where this is, done, the panels would be adapted with shoulders or other connecting devices on the inside surfaces to act as bearing supports for floor panels. Alternatively the panels could be bolted to the structural frame of the building.

It will be recognised by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein, such as but not limite to altering the dimensions of the panels, varying stress grades of materials using the panels in construction of retaining walls, walls, ground floors and suspended floors without departing from the overall spirit and scope of the invention as broadly described herein.

The panels can be built out of concrete or steel framing and fibre cement (i.e. with partial concrete infil) for internal walls. Such panels would still be integrated into the overall building system, and Fig. 8 shows details of these variations in steel framing, Fig. 9 shows them in concrete framing.

The panels can also be completed in the factory using lightweight or aerated concrete to allow for economical transport from factory to building site. In this application the skeletal panel would be made in the factory, and aerated or lightweight concrete poured into the said skeletal frames. The exposed aggregate finish would then be applied as a waterproof coat to the panel while it is "green". Alternatively the said lightweight panels could be sheeted both sides with fibre cement lining boards. Refer to Figures 10 and 11.

Claims

THE CLAIMS

1. A precast building panel for site or factory fabrication for as a retaining wall or as a floor, wall or roofing panel in or on a structure; said panel comprising: a substantially planar lining member, a resilient ribbed frame proportioned to approximate the size and shape of said lining member, a means for maintaining the spaced apart distance of opposing members of said frame, reinforcing mesh or rod reinforcement at least one conduit pipe or opening, a filler material for binding and setting the said lining member, said frame, said reinforcement mesh or rod reinforcement and said at least one conduit pipe, wherein when the filler material is introduced onto the panel, setting of the filler material results in a reinforced panel having a finished exterior face or faces.

2. A precast building panel according to claim 1, wherein at least one element of said ribbed frame is adapted to mate with a complimentary element of an adjacent frame.

3. A precast building panel according to claim 2 , wherein the planar lining member is formed from a fibre cement material.

4. A precast building panel according to claim 3 further comprising a second planar lining member overlying the filler materials.

5. A precast building panel according to claim 4, wherein the filler materials comprise concrete.

6. A building panel according to claim 5, wherein the thickness of the finished panel falls within the range of 100 mm to 200 mm.

7. A building panel according to claim 6, wherein the length of the panel falls within the range of 1200 mm to 10 000 mm and the width of the panel falls within the range of 900 mm to 2400 mm.

8. A building panel according to claim 7 wherein the said frame is adapted to engage and link with doors, windows eaves facias, awnings and verandahs of buildings.

9. A building panel according to claim 8 characterised in that the filler materials comprises a lightweight aerated concrete and fills a void space between the first and second planar lining member.

10. A building panel according to claim 10 further comprising a conduit passage for electric and water service lines.

11. A building panel according to claim 11 wherein the means for maintaining the spaced apart distance of the said frame elements comprises a tie rod threadably engaging said frame elements.

12. A method of constructing a precast building panel comprising the steps of: a) laying a planar lining member on a flat surface; b) assembling a ribbed frame around or near the periphery of said planar lining member, to define a space; c) overlaying at least one conduit at a predetermined distance above said lining member; d) laying at least one layer of reinforcing mesh either above or below said conduit at a predetermined distance from said lining member; e) pouring a filling material in said space to set the reinforcing mesh said conduits in position; and f) allowing said filler material to dry.

13. A method according to claim 12. comprising the additional step of overlaying the filler material with a planar lining member prior to setting of the filler material.