WO2000014356A1

WO2000014356A1 - Reinforced building elements

Info

Publication number: WO2000014356A1
Application number: PCT/AU1999/000743
Authority: WO
Inventors: Dickory Rudduck
Original assignee: Dickory Rudduck
Priority date: 1998-09-08
Filing date: 1999-09-08
Publication date: 2000-03-16
Also published as: AUPP575598A0

Abstract

The invention provides a reinforced building element which has a component, such as a panel which has a first surface reinforced by a mesh reinforcing means. The mesh reinforcing means may be metal mesh or woven mesh, such as fibreglass. The mesh reinforcing means may extend substantially over all the first surface or over only part of that surface. The reinforced building element of the invention may be used to construct walls, including cavity walls for external use. The invention also includes a wall made from the reinforced building element of the invention and methods of making the reinforced building element and the wall.

Description

REINFORCED BUILDING ELEMENTS

Technical Field

This invention relates to reinforced building elements. In one form, this invention relates to building elements being reinforced solid core walls or columns. In another form, this invention relates to reinforced building elements which can be used in facades, for internal walls, in roofing and similar applications, where solid fill is not required. In yet another form, this invention relates to reinforced building elements which can provide flooring. In a further form, this invention relates to reinforced building elements which can be used in other applications, such as staircases and balustrades.

Background Art

There are many applications in which it is necessary or desirable to reinforce panels. For example, supporting walls, floors, roofs and facades often require the use of reinforcement. This invention is predicated upon the substantial advantages which can be achieved by integrating reinforcement with boards or panels or other components.

Disclosure of the Invention

Accordingly, this invention provides a reinforced building element which includes a component having a first surface reinforced by a mesh reinforcing means.

The invention also provides a wall which includes the reinforced building element of the invention. The invention further provides a method of making the reinforced building element of the invention, including the steps of providing a component having a first surface and annexing to the first surface a mesh reinforcing means. The invention further provides a method of constructing a wall, including the steps of making a reinforced building element according to the invention and joining the reinforced building element to one or more studs. The invention further provides a method of constructing a wall, including the steps of making a reinforced building element according to the invention, and providing a further reinforced building element spaced from the reinforced building element by a cavity. Preferably, the further reinforced building element is a reinforced building element according to the invention.

The component in the element of the invention may be a panel, which can be made from any suitable material. By way of example, the following are mentioned: fibre reinforced cement, metal, wood, plastic, other polymeric materials, gypsum and ceramic. The invention is not limited to these materials and other suitable materials will be apparent to one skilled in the art. The panel may be in sheet form or in strip form, for example, weatherboards.

The component may have a single surface reinforced by the mesh reinforcing means, or more than one such surface, for example, two opposing surfaces.

The component may take the form of a part for a staircase or a balustrade, for example. The component may be flat or shaped, including curved.

The reinforcing means can also comprise any suitable means but is preferably a metal reinforcing mesh. Although it is preferred that the reinforcing means is a metal mesh, which has a relatively open configuration, it is within the scope of this invention that the reinforcing means can comprise, for example, a more closely woven mesh, such as those made from fibreglass, polyester, Kevlar (trade mark) or metal.

In some embodiments, the reinforcing means extends substantially over one surface of the component. In another embodiment, the reinforcing means extends over part only of the surface of the component. The reinforcing means may form an overlap between one component and an annexed component. It is within the scope of this invention that the reinforcing means is integrated on more than one, even all surfaces of the component.

The reinforcing means may be integrated with the component by any suitable method, some of which will now be described. A component being a panel may incorporate channels or upstanding ribs adapted to receive or be bonded to the reinforcing means. The reinforcing means may simply be bonded to the panel by adhesive or other suitable bonding material. The reinforcing means may be tied to the panel, for example by the use of staples, cable ties, tape or luggage straps. Other methods of integration may also be suitable.

Especially when the reinforcing means is a metal mesh, it may lie relatively flatly against the component or it may have a different configuration. For example, the metal mesh may be shaped or folded so that some portions are spaced from the surface of a panel with which it is integrated. This can be particularly useful in the construction of floors, for example, with the panel forming the base of the floor and concrete or other fluid material being poured over the reinforcing means, as will be explained in more detail below in connection with the attached drawings.

Folding of the reinforcing means at the edges of the building elements of the invention may also strengthen the edges of the building elements. Alternately, the edges of the reinforcing means may form hooks, which can be used to join one element to another.

The reinforced building elements of the invention may be joined to studs by conventional methods. Preferably, however, the elements of the invention are joined to studs by hidden fixing means, or by remote fixing. Examples of hidden fixing means can be found in International patent application No. PCT/AU99/00490. Examples of remote fixing may be found in International patent application No. PCT/AU99/00185. The content of each of these is imported herein by reference.

The reinforced building elements of the invention lend themselves to a large range of varied uses. By way of example, elements of the invention may be tied together, for example by use of a fin tie connecting the reinforcing means of each component, or a swing tie or a stud tie. Where it is desired to form a solid core building element, two parallel building elements of the invention, tied together in a suitable manner, such as those described above, form a cavity between them which can be filled with concrete or other desired material.

The building elements of the invention may be used to form walls with corners when the component being a panel and reinforcing means are made of suitable material. This may be achieved, for example, by scoring the panel as required and snapping it to form a right angle or other desired angle, having the panel on the outside and the reinforcing means on the inside.

Roof tiles may be fixed to the building elements of the invention.

As will be appreciated by one skilled in the art, the reinforced building elements of the invention can be regarded as having permanent integrated formwork. They may require no external bracing. They can hook or attach to one another without the need for holes or apertures in the components.

Brief Description of the Drawings

The invention will now be described in connection with the accompanying drawings, in which:

Figure 1 is a perspective view of a first embodiment of a reinforced building element according to the invention, being a panel and showing the reinforcing means spaced from the panel;

Figure 2 is a perspective view of part of the panel of Figure 1 , being a magnified detail of the area marked 2 in Figure 1 ;

Figure 3 is an end elevation of the panel of Figure 2;

Figure 4 is a magnified perspective view of a variation of part of the panel of Figure 1 , which variation can be substituted for the panel of Figure 2;

Figure 5 is an end elevation of the panel of Figure 4;

Figure 6 is a magnified perspective view of a further variation of part of the panel of Figure 1 , which further variation can be substituted for the panel of Figure 2;

Figure 7 is an end elevation of the panel of Figure 6;

Figure 8 is a perspective view, reduced in size, of the panel of Figure 1 , used to construct a facade; Figure 9 a perspective view of part of a stud to which an element of the invention may be joined;

Figure 10 is a side view of a second embodiment of the element of the invention, useful to construct a roof;

Figure 11 is a side view of a third embodiment of the element of the invention and shows two panels joined with reinforcing;

Figure 12 is a perspective view of part of a fourth embodiment, suitable for use as a floor base;

Figure 13 shows the embodiment of Figure 12 formed to make a floor;

Figure 14 is a perspective view of part of a fifth embodiment, useful in joining elements to studs;

Figure 15 is a perspective view of part of a sixth embodiment, showing how two panels of the invention may be joined on site to form a corner;

Figure 16 is a perspective view of a seventh embodiment;

Figure 17 is a side elevation of the panel of Figure 16;

Figure 18 is the same view as in Figure 17, after the panel has been snapped to form a corner;

Figure 19 is a magnified detail of the panel of Figure 18, with a corner clip added;

Figure 20 is a perspective view of part of an eighth embodiment, suitable for use as an external wall;

Figure 21 is a magnified view, in plan, of a swing tie included in Figure 20;

Figure 22 is a magnified view of part of Figure 20, showing the swing tie of Figure 21;

Figure 23 is a perspective view of part of a fin tie included in Figure 20; Figure 24 shows in sectional view the fin tie of Figure 23 in situ in the embodiment of Figure 20;

Figure 25 is a perspective view of part of an edge trim which can be used with the embodiment of Figure 1 , for example;

Figure 26 is a side elevation of part of the edge trim of Figure 25;

Figure 27 is a cross-sectional view of part of the embodiment of Figure 1 , with the edge trim of Figures 25 and 26 in place;

Figure 28 shows in perspective view a ninth embodiment of part of a reinforced building element of the invention;

Figure 29 shows the same embodiment as in Figure 28, with its orientation changed through 90°;

Figure 30 shows in magnified cross-sectional view the embodiment in Figures 28 and 29;

Figure 31 shows a complete panel view of the embodiment in Figures 28 to 30;

Figure 32 illustrates in perspective view the use of the embodiment in Figure 31 in construction;

Figure 33 shows in enlarged perspective view a cable tie and disc, useful for integrating the reinforcing means with the panel in the building element of the invention;

Figure 34 is a cross-sectional view of the cable tie and disc of Figure 33 in use;

Figure 35 is a perspective view of the cable tie and disc of Figure 33 in use;

Figure 36 shows another method of integrating the reinforcing means with a panel in the building element of the invention;

Figure 37 illustrates yet another method of integrating the reinforcing means with a panel in the element of the invention; Figure 38 shows an embodiment of the element of the invention where the reinforcing means does not extend over the whole panel;

Figure 39 shows an example of fixing an element of the invention to a stud using "on board technology";

Figure 40 shows a method of fixing an element of the invention to a stud using remote fixing;

Figure 41 is a perspective exploded view of a further embodiment of the building element of the invention, in which the reinforcing means is a more closely woven mesh than in the previously described embodiments;

Figure 42 is a magnified detail of the area of the woven mesh marked 3 in Figure 41 ;

Figure 43 is a cross-sectional view of the embodiment in Figure 41 and illustrates a method of fixing the element to a stud;

Figure 44 details the stud of Figure 43;

Figure 45 shows a cross-sectional view of a variation of the embodiment in Figures 41 to 43, in which the reinforcing means overlaps two panels;

Figure 46 is a perspective view of the embodiment of Figure 45;

Figures 47 and 48 illustrate the construction of an interior wall using the element of the invention;

Figure 49 is a cross-sectional detail of the area marked 4 in Figure 48;

Figure 50 illustrates a step in the construction of an external wall using elements of the invention;

Figure 51 shows in perspective view detail of the area marked 5 in Figure 50 with a second panel in place;

Figure 52 is a perspective view of the dual walled structure of Figure 51 ; and Figure 53 is a cross-sectional view of the structure of Figure 52 after filling with concrete to form an external.

Best Modes of Carrying out the Invention

Referring first to Figure 1 , reinforced building element 10 has panel 12 made of 5 fibre reinforced cement, for example. Panel 12 has, by way of "on board technology" integration means 13 and/or 14.

The reinforcing means is represented by a rectangular metal mesh 16 which is illustrated spaced from panel 12 in element 10. Mesh 16 has horizontal bars 16A and vertical bars 16B. To integrate mesh 16 with panel 12, mesh 16 may be ιo fixed to panel 12 by the use of suitable adhesive, the vertical bars 16B of mesh 16 fitting into integration means 14 of panel 12. The fit between the vertical bars 16B of mesh 16 and integration means 14 may be such that only a small amount of adhesive is needed in order to integrate mesh 16 with panel 12.

Integration means 14 takes the form of rib pairs 15 (refer Figures 2 and 3). is Alternately, integration means 14 may take the form of channels 16 (refer Figures 4 and 5) or elevated ribs 17 (refer Figures 6 and 7).

Integration means 13 may take similar forms.

Turning now to Figure 8, the reinforced building element 10 may be used, for example, to construct facades 18 by attaching elements 10 to studs 20. Elements 20 10 may be attached horizontally as illustrated or vertically or in any other desired configuration.

With reference to Figures 9 and 10, elements 10 may also be used in the construction of roofs. In this embodiment, element 10 has bonded to each side of panel 12 rectangular metal mesh 16 having horizontal bars 16A and vertical bars 25 16B. A vertical bar 16B of mesh 16 can hook into stud 20 via hook 24, as shown by arrow 22 or as explained in connection with Figure 39, for example. Element 10 then provides an inexpensive and sufficiently strong base for fixing of tiles (not shown) which can be linked to mesh 16 on the upper side of element 10. Referring now to Figure 11 , mesh 16 may be shaped at the end of each panel 12, to provide reinforcement in the region of panel joins. In Figure 11 , two panels 12 are joined at clip 28, mesh 16 being bent to form triangular portions 30. Triangular portions 30 provide strength to the edges of panels 12.

5 Turning now to Figure 12, mesh 16 may also be bent at regular intervals to form folded mesh 32. When integrated with panel 12, reinforced building element 34 is formed. This can provide a base for construction of a floor, for example by pouring concrete or other fluid material 36 to cover folded mesh 32 (refer Figure 13).

o Figure 14 shows how mesh 16 may be folded to form folded mesh 38, the configuration of which can be useful in joining reinforced building element 40 to studs (not shown). It will be noted that folded mesh 38 includes more vertical bars than does folded mesh 32 in Figures 12 and 13.

A number of reinforced building elements 10 may be supplied in a flat pack for s ease of transport and assembled to form corners on site. For this purpose, and with reference to Figure 15, mesh 16 may be provided with end loops 42 which can be joined to end loops 42 of a nearby panel to form a corner of the required angle.

With reference to Figures 16, 17 and 18, provided panel 12 is made of 0 appropriate material, it may be scored and snapped, as shown by building element 44, in which panel 12 may be snapped at score line 45 and integrated mesh 16 bent so that element 44 forms the required corner 26. The exposed ends of panel 12 may be neatened by the application of a corner clip 46, shown in Figure 19.

5 With reference now to Figure 20, two panels 12 may be joined to studs 20 by hooking mesh 16 to hooks 24 on studs 20. Refer Figure 9 for detail of hooks 24. In Figure 20, only one panel 12 is shown, in the interests of clarity. A cavity 47 is formed and in Figure 20 this is shown filled with concrete 36.

As well as or instead of studs 20, swing tie 48 (refer Figures 21 and 22) or fin tie 30 49 (refer Figures 23 and 24) may be used to link mesh 16 of one panel 12 to another. An example of use of swing tie 48 is shown in Figure 20, where two swing ties 48 bridge cavity 47 obliquely. In Figure 22, a single swing tie 48 bridges meshes 16 in a perpendicular manner. Arrow 23 shows how swing tie 48 in Figure 22 swings down to grip mesh 16.

5 As to fin tie 49 in Figures 23 and 24, this has apertures 25 and slots 27 into which mesh 16 may fit. Figure 24 shows fin tie 49 connecting two elements 10.

When swing ties 48 or fin ties 49 are used in conjunction with studs 20, the number of studs required may be minimised and extra strength and stability can be provided to the structure.

o Figures 25 to 27 show how the element of the invention, for example, the embodiment in Figure 1 , may be finished with a suitable edge trim or mesh cap 51. Edge trim or mesh cap 51 includes lift spring 29 to retain edge trim 51 in position. Especially where element 10 is to be used on an internal wall, finish 52 may be applied to panel 12 and sheet 53 may be used to cover mesh 16.

s Turning now to Figures 28 and 29, these show on a magnified scale a building element 54 having a panel 12 and three dimensional mesh 55. Element 54 may be fixed to a stud (not shown) in the region of the locations indicated by arrows 56 in Figure 28 or arrows 57 in Figure 29. Thus, in the case of Figure 28, the stud will be attached to folded bars 59, while in the case of element 54 in Figure 29, o the stud will be attached to straight bars 58.

Folded bars 59 are attached to panel 12 by adhesive 60, as shown in Figure 30. Element 54 is illustrated in its entirety in Figure 31. In Figure 32, a number of elements 54 is attached vertically to studs 20 while a further number is attached horizontally to studs 20, in each case to form a wall.

5 Figure 33 shows a cable tie 61 including a disc 62 and a loop 63. Cable tie 61 may be made of nylon or plastic or any other suitable material. As shown in Figures 34 and 35, mesh 16 may pass through loop 63 and in that way be integrated with panel 12. Cable tie 61 includes tail 64 which may be cut away from cable tie 61 once mesh 16 is in place. Figure 36 shows a different way to integrate mesh 16 with panel 12, namely by using a staple 65.

Another method of integrating mesh 16 with panel 12, especially when mesh 16 is folded and not flat, is shown in Figure 37, where a strap or non-stretch tape 66 holds mesh 16 to panel 12.

For some applications, it may be sufficient to have relatively small areas of reinforcing means such as metal mesh integrated with panel 12. One version of this is illustrated in Figure 38, where three strips, 67, 68 and 69 of metal mesh are adhered to panel 12.

Figure 39 is a detailed view of stud 20 in, for example, Figure 10, showing hook 24. As illustrated, horizontal bars 16A of mesh 16 integrated with panel 12 fit into hook 24 to join element 10 with stud 20.

In Figure 40 the same element 10 is fixed to stud 70 by inserting horizontal bar 16A of mesh 16 into cavity 71. There may be a clip fit between bar 16A and cavity 71 or the fixing may be remote, for example by activating slot 72 to enlarge cavity 71 in order to accept bar 16A.

With reference to Figures 41 to 44, woven mesh 73, which may be of fibreglass, for example, can be applied in sheet form to panel 12 to form element 74. Element 74 can be attached to stud 75 when stud spikes 76 penetrate mesh 73.

In Figure 45, mesh 73 is shown overlapping adjoining panels 12, showing how mesh 73 can assist in strengthening elements 74 at joins.

In Figure 46, mesh 73 is applied in strips 77 to panel 12, for cases where overall coverage of panel 12 by mesh 73 is not required. This Figure also illustrates the use of mesh 73 in an overlapping manner, as shown in Figure 45.

The construction steps shown in Figures 47 to 49 show studs 20 erected and joined to a base 78. Element 10 is attached to studs 20 by hanging horizontal bars 16A of mesh 16 on hooks 24. The wall so constructed is useful as an internal wall. Turning now to Figure 50, one element 10 is shown attached to studs 20 with a second element 10 (portion only illustrated in Figure 50) attached to the opposite side of studs 20. As can be seen from Figure 51 , on one side, element 10 includes panel 12 while on the other side, element 10 takes the form of weatherboard panel 79. Element 10 is tied to elements 79 by swing ties 48 which close in the direction of arrow 80.

As shown in Figures 52 and 53, the resulting structure has a cavity 47 which can be filled with concrete 81 to form a solid core panel, especially suitable for use as an external wall.

The building elements of the invention may be finished or treated in any suitable way. For example, an element of the invention may be coated by spraying with a concrete substrate.

Although the specific embodiments described above do not illustrate all the applications of the invention, it will be appreciated by one skilled in the art that other elements, such as columns, staircases and balustrades, may be readily constructed.

Industrial Applicability

It will be readily appreciated by one skilled in the art that the reinforced building elements, walls and methods of the present invention represent a significant advance in the art and have numerous advantages over known systems. It will further be appreciated that, at least in some embodiments, the reinforced building elements of the present invention enable the construction of solid core walls and columns, using ordinary concrete rather than the more expensive and less strong light weight concrete.

Claims

1. A reinforced building element, which includes a component having a first surface reinforced by a mesh reinforcing means.

2. The element of claim 1 , wherein the reinforcing means extends over 5 substantially all the first surface.

3. The element of claim 1 , wherein the reinforcing means extends over part of the first surface.

4. The element of any one of claims 1 to 3, wherein the component is a panel and the first surface incorporates means adapted to receive or be bonded to the ╬╣o reinforcing means.

5. The element of claim 4, wherein the means adapted to receive or be bonded to the reinforcing means is chosen from the group consisting of channels and ribs.

6. The element of any one of claims 1 to 3, wherein the component is a panel is tied to the reinforcing means by use of staples, cable ties, tapes or straps.

7. The element of any one of claims 1 to 6, wherein the reinforcing means lies substantially flat against the first surface.

8. The element of any one of claims 1 to 6, wherein the reinforcing means is shaped so that at least part of the reinforcing means is spaced from the

20 component.

9. The element of any one of claims 1 to 6, wherein the reinforcing means is folded at one or more edges of the component.

10. The element of any one of claims 1 to 6, wherein the reinforcing means forms one or more hooks at one or more edges of the component.

25 11. The element of any one of claims 1 to 10, wherein the component is a panel having a second surface which is also reinforced by a mesh reinforcing means.

12. The element of any one of claims 1 to 11 , wherein the component is a panel made from a material chosen from the group comprising: fibre reinforced cement, metal, wood, plastic, other polymeric material, gypsum and ceramic.

13. The element of any one of claims 1 to 12, wherein the reinforcing means has 5 a closely woven configuration and is chosen from the group comprising metal mesh, fibreglass mesh, polyester mesh and KEVLAR (trade mark) mesh.

14. The element of any one of claims 1 to 12, wherein the reinforcing means is a metal mesh of open configuration.

15. A wall including a building element as claimed in any one of claims 1 to 14, ╬╣o wherein the element is joined to one or more studs.

16. The wall of claim 15, wherein the element is joined to the one or more studs by hidden fixing means.

17. The wall of claim 15, wherein the element is joined to the one or more studs by remotely activated fixing means.

is 18. A wall including a reinforced building element as claimed in claim 2.

19. The wall of claim 18, wherein the reinforced building element is spaced from a further reinforced building element by a cavity.

20. The wall of claim 19, wherein a connection means in the cavity joins the reinforced building element to the further reinforced building element.

20 21. The wall of claim 20, wherein the connection means is chosen from the group comprising a stud, a fin tie, a swing tie and one or more of the foregoing.

22. The wall of claim 21, wherein the connection means is a stud having first and second opposing sides, the reinforced building element is joined to the first opposing side and the further reinforced building element is joined to the second

25 opposing side.

23. The wall of any one of claims 19 to 22, wherein the cavity is filled with concrete.

24. The wall of any one of claims 18 to 23, wherein the further reinforced building element is an element as claimed in claim 2.

25. A method of making a reinforced building element, including the steps of providing a component having a first surface and annexing to the first surface a

5 mesh reinforcing means.

26. The method of claim 25, wherein the annexing step includes bonding the mesh reinforcing means to the component.

27. The method of claim 25 or 26, wherein the component is a panel and the annexing step includes receiving the mesh reinforcing means in channels or ribs ╬╣o formed on a first surface of the panel.

28. The method of claim 25, wherein the component is a panel and the annexing step includes tying the panel to the reinforcing means by use of staples, cable ties, tapes or straps.

29. A method of constructing a wall, including the steps of making a reinforced is building element using the method of any one of claims 25 to 28 and joining the reinforced building element to one or more studs.

30. The method of claim 29, wherein the element is joined to the one or more studs by hidden fixing means.

31. The method of claim 30, wherein the element is joined to the one or more 20 studs by remotely activated fixing means.

32. A method of constructing a wall, including the steps of making a reinforced building element using the method of any one of claims 25 to 28, and providing a further reinforced building element spaced from the reinforced building element by a cavity.

25 33. The method of claim 32, which includes the further step of providing a connection means in the cavity to join the reinforced building element to the further reinforced building element.

34. The method of claim 33, wherein the connection means is chosen from the group comprising a stud, a fin tie, a swing tie and one or more of the foregoing.

35. The method of claim 21 , wherein the connection means is a stud having first and second opposing sides, the reinforced building element is joined to the first opposing side and the further reinforced building element is joined to the second opposing side.

36. The method of any one of claims 32 to 35, which includes the further step of filling the cavity with concrete.

37. The method of any one of claims 32 to 36, wherein the further reinforced building element is an element as claimed in claim 2.

38. A reinforced building element substantially as herein described with reference to Figures 1 or 2 and 3 or4 and 5 or 6 and 7 or 10 or 11 or 12 and 13 or 14 or 15 or 16, 17 and 18 or 19 or 28 or 29 or 30 or 33, 34 and 36 or 36 or 37 or 38 or 41 or 45 or 46 of the accompanying drawings.

39. A wall substantially as herein described with reference to Figures 20 or 21 and 22 or 23 and 24 or 31 or 32 or 39 or 40 or 43 or 47 to 49 or 50 to 53 of the accompanying drawings.