WO2001033006A1 - Panneau de construction - Google Patents

Panneau de construction Download PDF

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Publication number
WO2001033006A1
WO2001033006A1 PCT/CA2000/001257 CA0001257W WO0133006A1 WO 2001033006 A1 WO2001033006 A1 WO 2001033006A1 CA 0001257 W CA0001257 W CA 0001257W WO 0133006 A1 WO0133006 A1 WO 0133006A1
Authority
WO
WIPO (PCT)
Prior art keywords
cementimous
light
panel
weight
wall
Prior art date
Application number
PCT/CA2000/001257
Other languages
English (en)
Inventor
Norman Wood Campbell
David L. Costford
Original Assignee
Herculete Canada Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Herculete Canada Limited filed Critical Herculete Canada Limited
Priority to NZ518988A priority Critical patent/NZ518988A/en
Priority to AU10140/01A priority patent/AU1014001A/en
Priority to MXPA02004265A priority patent/MXPA02004265A/es
Publication of WO2001033006A1 publication Critical patent/WO2001033006A1/fr

Links

Classifications

    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame

Definitions

  • This invention relates to precast building panels and in particular to a building panel formed of a light-weight cementimous material having light- weight metal channel members embedded therein.
  • U.S. Patent 5,178,941 discloses a composite material of a weight lighter than concrete.
  • U.S. Patent 4,774,794 discloses the embedding of members in a foam cement slab.
  • U.S. Patent 4,910,076 discloses a cement matrix reinforced with a fibre network.
  • the present invention is the result of a need to create a viable, light-weight panel system that would succeed in the broad use of the commercial market place.
  • One of the objectives of the present invention was to use readily obtainable construction materials and methods to produce a lightweight cementimous material with a higher tensile strength then regular concrete. This was accomplished by creating a reinforced building panel with two uniquely different elements for the required strength and lightness of the product.
  • a fibre-reinforced cellular concrete mixture sold under the trade name Herculete.
  • Herculete This material is the result of a composition of portland cement, water, synthetic fibres and an expanding agent. A full description of this material may be found in United States Patent 5,397,516 of 14 March 1995.
  • the resulting weight of the product is approximately 26% of the weight of regular concrete.
  • This cementimous material is tough and light. Unlike ordinary concrete, it has a light-weight closed cell structure that is micro-reinforced with uniformly distributed synthetic fibres. It can be used in virtually any precast concrete application.
  • ordinary concrete is made with cement and aggregates, typically crushed stone used as fillers.
  • the Herculete material eliminates the fillers, reinforces the cement with fibres and expands it with uniformly dispersed air cells.
  • the air cells give it superb insulating properties, convenient lightness and easy usability.
  • the material is made from commonly used time-proven building materials such as aluminum, calcium, magnesium and silica and the expanding agent is made from commonly used materials.
  • the cementimous material is easy to mix and can be handled and molded like ordinary concrete, it can be used in place of ordinary concrete in most precast applications and the resulting products are tough, light-weight and easy to cut and shape.
  • the composition of the cementimous material is portland cement, water, synthetic fibres and the expansion agent.
  • the plain cement is the main component and different types of cement can be used to achieve desired aesthetic and physical characteristics.
  • Plain water is used to hydrate the cement and prepare the slurry paste that subsequently expands to twice its initial volume.
  • a special blend of synthetic fibres are added to the slurry. These have been used for years to reinforce ordinary cement but the Herculete cementimous material uses ten times as much fibre as commonly used to reinforce concrete slabs. The manufacturing process results in approximately two thousand reinforcing strands per cubic inch of material. This is one of the factors which gives the material its characteristic toughness and resilience. Synthetic fibres, for example, polypropylene fibres, are inert and harmless.
  • the expansion agent is mixed into the water/cement slurry at high speeds. Following a short dormant period the cement slurry begins to rise, much like bread dough rises when the yeast is added. The composition of the expanding agent creates a controlled and sustainable rise in the slurry until it hardens.
  • the fibre reinforced cellular concrete used in this invention has a homogenous nature so that the thermal resistance of the material is consistent throughout. This means that the R-value of the material is constant and the R- value used in calculations for thermal transmissions are not reduced to thermal bridging as would be found in most common wall construction. Because the material is composed mainly of concrete, its heat capacity allows it to store energy for later release similar to more massive wall assemblies. This translates to higher effective R-value per inch (R-2, ASHRAE 90.1 ) then would be determined using typical steady-state test methods.
  • the material may be clad with a regular or coloured face mix or alternatively may remain exposed, utilizing just about any form liner, shape/design desired, then coated with an elastomeric paint which offers unlimited colour choice and control, various textures and with durability and ease of maintenance in mind.
  • the present invention provides a reinforced concrete panel with two uniquely different systems for the required strength and lightness of the product.
  • the first system is the approximately 2000 micro-fibre per cubic inch in a matrix of cement and water which forms a microscopic enclosed cell structure that is capable of resisting the movements of the second element.
  • the second element consists of a light-weight galvanized channel that has been altered to provide slots or perforations along its web section to accommodate the passage of the liquid cementimous material in the manufacturing process then later to provide for the passage of electrical, mechanical and/or plumbing components in the field.
  • the two elements of the invention are weak and flexible on their own, in comparison to a regular concrete assembly, but when brought together and in combination, one element restraining the movement of the other, a very strong light-weight panel is the result.
  • the components are economic and are ideal for mass production for use in general construction of all types.
  • the vertical wall panel (plain exterior finish by example) is simply rotated to the horizontal plane and becomes an ideal lintel or floor system.
  • This system provides for a squeak proof, sound deadening, flooring system that is attached to both the lower exterior and upper exterior wall by a unique system that has been created for the specific purpose. Through testing, this floor system has been proven to carry the necessary residential loads over typical spans with acceptable deflections.
  • a channel system of varying lengths is used and anchored in the top of the lower exterior walls at varying stages along that surface. They are unique, in that by design, the channel will accept a "T" bolt that when rotated 90 degrees will restrain that bolt from the vertical forces but allow (until tightened) movement along its length for proper alignment with the other (floor and upper exterior wall) components that, by design, are held together to meet the most stringent codes with one effort.
  • the uniqueness of this device is that when molded into the Herculete and "C" channel panel during the manufacturing process it can be used as a lifting point for the efficient handling of the panel assembly in the manufacturing plant, during transportation, and as part of the erection on side process. Further, by design, this connection system allows for the safety of the lower exterior walls and the floor system to be connected
  • the invention relates to a building panel for use in a wall structure, said panel comprising a body of hardenable cementimous material with a plurality of light-weight metal members partially embedded therein, said cementimous material comprising a fibre-reinforced cellular concrete having a weight substantially less than that of regular concrete, said light-weight metal members projecting from said body of cementimous material to provide studs ready for reception of finishing wall board or the like and to provide a recessed wall to facilitate the installation of electrical systems and the like.
  • the invention relates to a precast, light-weight building panel comprising, in combination, a body of cementimous material consisting of portland cement, water, synthetic fibres in a density of approximately two thousand fibrous strands per cubic inch of cementimous material and an expanding agent, and a plurality of light-weight galvanized metal studs of generally "C"-shape laid parallel to one another and partially embedded in said cementimous material so that they project outwardly of the material after it has set, said studs having slots therein to allow passage therethrough of selected building services.
  • FIGURE 1 is a plan view of a building panel according to the invention
  • FIGURE 2 is a side view of the panel in Figure 1 ;
  • FIGURE 3 is a sectional view of the panel in Figure 1;
  • FIGURE 4 is a wall section of a building structure utilizing the present invention;
  • FIGURE 5 is a fragmentary view in cross-section as shown at location "5' in Figure 4;
  • FIGURE 6 is a view similar to Figure 4.
  • FIGURE 7 is a plan view of a panel reinforcing grid and the weld points therefore;
  • FIGURE 8 is a detail of vertical joints between panels;
  • FIGURE 9 is a sectional view of a permanent forming arrangement;
  • FIGURE 10 is an elevation view of a junction between an interior wall and floor
  • FIGURE 11 is a sectional view of an alternate flooring system
  • FIGURE 12 is a junction detail of an exterior wall with a floor panel
  • FIGURE 13 illustrates a joint at an exterior wall and a footing
  • FIGURE 14 is a schematic elevation view of a residential structure;
  • FIGURE 15 illustrates a wall/roof connection;
  • FIGURE 16 illustrates a residential wall in section;
  • FIGURE 17 is another residential wall in section but of an upper level;
  • FIGURE 18 is a cross-sectional view of a residential wall/floor panel connection;
  • FIGURE 19 is a perspective view thereof;
  • FIGURE 20 is a graph showing the expansion process of the cementimous material;
  • FIGURE 21 is a partial elevation view of a sound attenuation walls; and
  • FIGURES 22 and 23 are plan and sectional views thereof.
  • FIGS 1 -3 illustrate a building panel 10 according to the invention for use in a wall structure of a dwelling, commercial building or the like.
  • the panel 10 has a body 12 of the cementimous material Herculete in accordance with the invention and a plurality of light-weight metal studs 14 are embedded into the cementimous material during the processing steps and those members 14 have an exposed flange 16 which, collectively, are ready for reception of finishing wall board or the like.
  • the panel has an 8 inch depth of cementimous Herculete and a 2 !/-. inch face mix 18.
  • Figure 4 is a wall section of the building panel 10, a twist and lock plate 20 being used in an embedded anchor socket 22 for the connection between a panel 10 and a beam 24.
  • Figure 5 shows a section through the line 5-5 of Figure 4 and illustrates the drywall 26 secured to the projected portion of stud 14.
  • Figure 6 shows the relationship between an upper wall panel 28, a beam 30 and roof panels 32.
  • Figure 7 shows a panel reinforcing grid of metal studs 14 which are equally spaced at 16 inch centres across the panel. Anchors 34 are embedded 6 inches into the cementimous material 12. Studs 14 are suitably secured to upper and lower tracks 36, 38 respectively.
  • Figure 8 provides a detail of a vertical joint between two panels 10a and 10b.
  • Panel 10a has a channel 40 along one of its marginal edges and that channel receives a tongue 42 on the marginal side edge of the adjacent panel 10b.
  • the joint is roped and caulked as indicated at 44 on the outside of the joint.
  • Figure 9 shows a permanent forming arrangement where precast concrete joists 46 have Herculete panels 48 extending between pairs of the joists 46.
  • the joists 46 are placed in position and the Herculete light-weight precast panels 48 are placed in position therebetwen the concrete joists and a normal weight structural, reinforced concrete topping 50 is installed on the upper surface of the joist 46 and Herculete 48.
  • the Herculete "forming” remains in position and provides a concrete appearance.
  • Figure 10 shows a junction between an interior wall panel 10 connected to a Herculete floor panel 52. This connection is made by way of the welding together of two joining plates, one of which 54 is embedded in the Herculete floor panel 52 and the other member 56 being anchored in the upper end of the wall panel 10. Temporary access pockets 58 are provided for welding of the facing plates 60a and 60b of the members 54 and 56 and these access pockets are subsequently filled with plaster following inspection.
  • Figure 1 1 shows an alternate flooring system where an upper floor is formed by a Herculete panel 62 and the embedded metal studs 64 have projecting portions 66 to which drywall ceiling 68 is secured.
  • the projected portions 66 creates a space between the drywall ceiling and the lower surface of panel 62 through which conduits and the like may be run.
  • Figure 12 shows a connection or junction between an exterior wall 70 and a floor panel 72.
  • Weld plates 74, 76. 78 and 80 are embedded in their respective locations to provide welding sites such as 82 and 84.
  • FIG. 13 A joint between an exterior wall 86 and a footing 88 is shown in Figure 13. Again, weld plates are embedded in the exterior wall at 90 and 92 for welding to adjacent, embedded weld plates 94, 96 in the footing.
  • Figure 14 is a schematic of a residence which comprises a plurality of Herculete panels 10.
  • Figure 15 shows a wall/roof connection where the wall panel 100 is connected to a steel uplift strap 102 by way of a unit strut 104 embedded in the upper end of panel 100.
  • An alignment and locking plate 106 is located between the joints in the panels.
  • Figure 16 is a cross-section through a residential wall showing the panel 110 having the exposed metal studs 114 embedded in the Herculete cementimous material 112. The wall 110 is channelled to received a floor panel 116 which also has exposed metal studs 114 embedded in the cementimous material of the floor panel.
  • FIG. 17 is an upper extension of the Figure 16 illustration and shows the uplift strap 102 previously illustrated in Figure 15 used here to locate the upper part of wall panel 1 10 to its proper location with a wooden truss 122. The lower end of the strap 102 is received in the anchor box 124 embedded in the upper end of wall panel 110.
  • Figure 18 is a cross-section through a residential wall/floor panel, the upper wall 111 being joined to the lower wall 110 through the combination of an anchor sleeve 126 embedded in the upper end of the lower wall 1 10 which receives one end of an anchor bolt 128 having a twist-and-lock head 130 thereon, that head being received in the anchor sleeve 126.
  • the anchor bolt 128 passes through a slot 132 provided in the floor panel, as shown in Figure 19, and a pocket 134 is provided in the floor panel to receive a spreader plate 136.
  • FIGS 21, 22 and 23 illustrate a highway sound attenuation barrier made from panels in accordance with the material disclosed by the present invention.
  • a plurality of panels 150, 152 and 154 are located on top of one another with their marginal edges engaging one another.
  • the end portions of each of the panels are formed to slideably engage a steel post 156 and a cap portion 158 engages the upper end of the post and is large enough in area to also cover small face panels 160 that overlie the connections between the aligned ends of the panels and the post itself. This provides for a light-weight, affective sound attenuation wall.
  • Figure 20 is a graph showing the expansion process of the cementimous material Herculete used in the present invention. Due to the composition of the cementimous material, its heat capacity allows it to store energy for subsequent release. This translates to an insulation value of R2 per inch whereas normal concrete has an insulation value of R.017 per inch. This insulation characteristic makes the substance ideally suited as an energy efficient material for residential and commercial construction.
  • the panels utilizing the cementimous material of the invention permits removal of the finished product from its form work within a six hour period whereas normal concrete requires twenty-four hours. This greatly enhances productivity. It will be appreciated that form liners can be used in the process to provide a variety of finishes such as stucco, brick, fluted block, etc. Colours can also be added to the mix.
  • a number of products can be made utilizing the cementimous material. These include residential floor systems to replace existing wood joist and plywood sheeting and by means of which the flooring is fire resistive and provides sound attenuation.

Abstract

L'invention concerne un panneau de construction léger, un système de construction comportant des panneaux de ce type et le procédé de fabrication de ces panneaux. Ce procédé consiste à utiliser une matière à base de ciment sous forme de béton cellulaire renforcé par des fibres, son poids correspondant à environ 26 % du poids du béton ordinaire. Des éléments métalliques légers, partiellement incorporés dans la matière à base de ciment au cours de la fabrication du panneau, sont en saillie par rapport à ce panneau. Dans un mode de réalisation, des éléments canaux superficiels en forme de «C» fournissent, dans un panneau de mur ou de plancher, des tiges mises en place, destinées à recevoir des gypsoplaqués ou des feuilles de plâtre. Ce mode de réalisation concerne également une paroi à évidement destinée à l'installation de boîtes électriques et analogues.
PCT/CA2000/001257 1999-10-29 2000-10-24 Panneau de construction WO2001033006A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
NZ518988A NZ518988A (en) 1999-10-29 2000-10-24 Building panel
AU10140/01A AU1014001A (en) 1999-10-29 2000-10-24 Building panel
MXPA02004265A MXPA02004265A (es) 1999-10-29 2000-10-24 Panel de construccion.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA 2287909 CA2287909C (fr) 1999-10-29 1999-10-29 Panneau de construction
CA2,287,909 1999-10-29

Publications (1)

Publication Number Publication Date
WO2001033006A1 true WO2001033006A1 (fr) 2001-05-10

Family

ID=4164530

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA2000/001257 WO2001033006A1 (fr) 1999-10-29 2000-10-24 Panneau de construction

Country Status (5)

Country Link
AU (1) AU1014001A (fr)
CA (1) CA2287909C (fr)
MX (1) MXPA02004265A (fr)
NZ (1) NZ518988A (fr)
WO (1) WO2001033006A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10364185B2 (en) 2017-04-03 2019-07-30 Michael John Mabey Light-weight, fire-resistant composition and assembly
US11299886B2 (en) * 2019-04-24 2022-04-12 Protectiflex, LLC Composite stud wall panel assembly

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2443344A1 (fr) 2001-04-03 2002-10-17 James Hardie Research Pty Limited Bordages lateraux de fibrociment, procede de fabrication et d'installation
US8297018B2 (en) 2002-07-16 2012-10-30 James Hardie Technology Limited Packaging prefinished fiber cement products
US8281535B2 (en) 2002-07-16 2012-10-09 James Hardie Technology Limited Packaging prefinished fiber cement articles
MXPA05003691A (es) 2002-10-07 2005-11-17 James Hardie Int Finance Bv Material mixto de fibrocemento de densidad media durable.
US7998571B2 (en) 2004-07-09 2011-08-16 James Hardie Technology Limited Composite cement article incorporating a powder coating and methods of making same
MX2008013202A (es) 2006-04-12 2009-01-09 James Hardie Int Finance Bv Elemento de construcción de refozado y sellado en superficies.

Citations (12)

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Publication number Priority date Publication date Assignee Title
US4124669A (en) 1973-05-08 1978-11-07 Urmston Charles W B Aerated concrete process
US4132555A (en) * 1975-01-02 1979-01-02 Cape Boards & Panels Ltd. Building board
US4774794A (en) 1984-03-12 1988-10-04 Grieb Donald J Energy efficient building system
US4910076A (en) 1986-03-11 1990-03-20 Mitsubishi Kasei Corporation Fiber reinforced cement mortar product
US5178941A (en) 1991-09-06 1993-01-12 Pao-Sou Lin Precast concrete slab and method of making same
US5248549A (en) 1992-05-18 1993-09-28 Felipe Silva Concrete panels with continuous elongated members
EP0434869B1 (fr) 1987-03-19 1993-12-15 International Building Systems Inc. Montant en acier en panneau préfabriqué
WO1994029542A1 (fr) * 1993-06-09 1994-12-22 Cavaness Investment Corporation Panneau de construction composite
US5397516A (en) 1993-03-25 1995-03-14 Thermo Cement Engineering Corp. Process for making building panels
US5473849A (en) 1992-05-28 1995-12-12 Materials Technology, Limited Building wall and method of constructing same
US5520729A (en) 1993-06-08 1996-05-28 Sicowa Verfahrenstechnik Fur Baustoffe Gmbh & Co. Kg Process for producing heat-insulating material
WO1999010607A2 (fr) * 1997-08-22 1999-03-04 Dennis Leblang Panneau de construction moule monobloc et procede de realisation

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4124669A (en) 1973-05-08 1978-11-07 Urmston Charles W B Aerated concrete process
US4132555A (en) * 1975-01-02 1979-01-02 Cape Boards & Panels Ltd. Building board
US4774794A (en) 1984-03-12 1988-10-04 Grieb Donald J Energy efficient building system
US4910076A (en) 1986-03-11 1990-03-20 Mitsubishi Kasei Corporation Fiber reinforced cement mortar product
EP0434869B1 (fr) 1987-03-19 1993-12-15 International Building Systems Inc. Montant en acier en panneau préfabriqué
US5178941A (en) 1991-09-06 1993-01-12 Pao-Sou Lin Precast concrete slab and method of making same
US5248549A (en) 1992-05-18 1993-09-28 Felipe Silva Concrete panels with continuous elongated members
US5473849A (en) 1992-05-28 1995-12-12 Materials Technology, Limited Building wall and method of constructing same
US5397516A (en) 1993-03-25 1995-03-14 Thermo Cement Engineering Corp. Process for making building panels
US5520729A (en) 1993-06-08 1996-05-28 Sicowa Verfahrenstechnik Fur Baustoffe Gmbh & Co. Kg Process for producing heat-insulating material
WO1994029542A1 (fr) * 1993-06-09 1994-12-22 Cavaness Investment Corporation Panneau de construction composite
WO1999010607A2 (fr) * 1997-08-22 1999-03-04 Dennis Leblang Panneau de construction moule monobloc et procede de realisation

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10364185B2 (en) 2017-04-03 2019-07-30 Michael John Mabey Light-weight, fire-resistant composition and assembly
US11299886B2 (en) * 2019-04-24 2022-04-12 Protectiflex, LLC Composite stud wall panel assembly

Also Published As

Publication number Publication date
MXPA02004265A (es) 2004-03-31
CA2287909A1 (fr) 2001-04-29
CA2287909C (fr) 2003-02-18
AU1014001A (en) 2001-05-14
NZ518988A (en) 2003-10-31

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