WO2006105580A1

WO2006105580A1 - Wall panel

Info

Publication number: WO2006105580A1
Application number: PCT/AU2005/001594
Authority: WO
Inventors: Owen Lloyd; David Lloyd; Mike Barry
Original assignee: Go Crete Pty Ltd
Priority date: 2004-10-15
Filing date: 2005-10-14
Publication date: 2006-10-12

Abstract

A wall panel comprises a body (22) having first and second major faces; and a plurality of elongate structural members (24, 26) which extend from the first face. A number of the elongate structural members are arranged to extend generally vertically across the first face, and at least one of the elongate structural elements is arranged to extend generally horizontally across the first face, when the wall panel is in position.

Description

WALL PANEL

FIELD OF THE INVENTION

The present invention relates to a wall panel and building systems which use wall panels.

BACKGROUND ^'

- Prefabricated wall panels are often used in many buildings, such as office buildings, high-rise car parks, shopping centres, apartments and other low-rise residential dwellings. In the construction industry, aesthetics, cost and speed of installation are key factors which often determine the selection of materials used in a building. The use of prefabricated wall panels can offer increased design flexibility, time saving during construction and/or increased profitability. For these^ reasons, prefabricated panels are often used in preference to more traditional building products, such as wopd, brick, cast-in-place ^' concrete and concrete masonry products .

Generally, this type of panel is produced off site and delivered to the building site on a just-in-time basis.

To facilitate ease of assembly, connection hardware are ^" cast into the concrete during fabrication. A common connection system involves providing reinforcing bars which extend out from one wall panel. The panel to be joined is provided with holes into which the reinforcing bars are received as the two panels are brought into position. The holes can be filled with an building adhesion product prior to connection such that the reinforcing bars are adhered within the holes once the adhesion product has set. One disadvantage of this connection system is the time taken to prepare the holes/reinforcing bars and line up the panels at the s ite .

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided a wall panel comprising: a body having first and second major faces; and a plurality of elongate structural members which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged to extend generally vertically across the first face, and at least one of the elongate structural elements is arranged to extend generally horizontally across the first face.

Preferably, there are at least two elongate structural members arranged to extend horizontally across the first face, such that a first horizontal elongate structural member is adjacent a lower edge of the first face and a second horizontal elongate structural member is adjacent an upper edge of the first face.

Preferably, the wall panel can^' be joined to at least one" other building element by fastening means which extend through either the elongate structural members or the body of the wall panel into the at least one other building element.

Thus, the wall panel can be joined to any one or more of slabs, floor panels, footings, like wall panels, cast-in-place wall panels and roof trusses.

Additionally, cosmetic walls may be attached to the elongate structural elements. Such cosmetic walls include walls made of plaster board and fibre cement sheet . Preferably, the body is made of a concrete material.

Preferably, the plurality of elongate structural members are cast into the body such that a portion of each of the plurality of elongate structural members protrude from the first face of the body.

Preferably, the elongate structural members have two flanges separated by a web, one flange and part of the web protrude from the first face of the panel. In a preferred embodiment the elongate structural members are channel sections.

in some embodiments, the wall panel is provided with openings for windows or doors. In these embodiments an architrave may be attached to the body within the opening. The wall panel may additionally be provided with -a sill which covers the attachment of the architrave to the body.

In -some embodiments, the second face may have a finish to achieve a desired appearance. Such finishes include renders, exposed aggregate, acid etch and applied patterns .

According to a second first aspect of the present invention, there is provided a wall panel comprising: . a body having first and second major faces; and a plurality of elongate structural members • which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged to extend generally vertically across the first face, and at least one of the elongate structural elements is arranged to be positioned adjacent a vertical edge of the body for securing the panel to a building element. According to a third aspect of the invention there is provided a building comprising at least one wall panel having: 5 a body having first and second major faces; and, a body having a plurality of elongate structural members which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged ° to extend generally vertically across the first face, and at least one of the elongate structural , elements is arranged to extend generally horizontally across the first face.

5 According to a fourth aspect of the inventio^'n there is provided a method for assembling a building comprising the steps of: providing a footing member; providing an at least one wall panel having: 0 a body having, first and second major faces; and, a plurality of elongate structural members which extend from the first face, ^' wherein, when the wall panel is in position, 5 a number of the elongate structural members are arranged to extend generally vertically across .the first face, and at least one of the^' elongate structural elements is arranged to extend generally horizontally across the first face; 0 locating each of the at least one wall panels in the desired position on the footing; and, fastening each of the at least one wall panels to the footing member by fastening at least one of the structural members to the footing. 5

In one embodiment the two panels are fastened together by fastening adjacent vertical structural members to one another by a joint member.

Typically, a roof truss will be fastened to each panel by fastening the roof truss to at least one of the structural members .

Preferably, one or more cosmetic walls are attached to at least one of the elongate structural members of the at least one wall panel.

Throughout this specification, except where -the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that ^' the invention may be more easily understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a plan view of a wall panel according to a first embodiment of the invention;

Figure 2 is an end view of a cross section of the wall panel of figure 1, illustrating attachment of a roof truss to the wall panel;

Figure 3 is an end view of a cross section of the wall panel of figure 1, illustrating attachment of the wall panel to a footing and slab; Figure 4 is a plan view of a cross section of two wall panels, of figure 1, illustrating a join between an external wall panel and an internal wall panel; Figure 5 is a plan view of a cross section of two wall assemblies of figure 1, illustrating a join between two external wall panels;

Figure 6 is a plan view of a cross section of two wall panels of figure 1, illustrating a join between two internal wall panels; and,

Figure 7 is a plan view of a cross section -of a wall panel according to a second embodiment of the invention in which the wall panel is provided with a window opening.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Figure 1 is a plan view of a wall panel 10 according to a first embodiment of the invention in which the wall panel 10 has an upper edge 12, a lower edge 14 and ^'a two side edges^' 16, 18. The wall panel 10 has a structural skeletal frame 20 made of elongate structural members which are cast into a concrete body 22. The body 22 has two major faces.

In this embodiment, the elongate structural members are horizontal channel sections 24 and vertical channel sections 26 which are cast into the body 22 such that part of each channel section 24, 26 protrudes from the body 22. Thus, one flange and a majority of the web of each channel section 24, 26 is exposed. In this embodiment, the channel sections 24, 26 in the wall panel 10 are channel sections. However, it will be appreciated that any elongate structural section may be used.

In preferred embodiments, the channel sections 24, 26 are made of structural steel. As shown in Figure 1, there are two horizontal channel sections 24, one disposed adjacent the upper edge 12 and the other disposed adjacent the lower edge 14. There are a number of vertical channel sections 26: one of which is disposed adjacent each of the side edges 16, 18, with^' the remainder dispersed therebetween. The exact location of the vertical channel sections 26 is, in part, determined by the need to connect the wall panel 10 to other like wall panels 10. Where such attachments to other wall panels 10 are not required the vertical channel sections 26 are. preferably disposed at a maximum of 600 mm centres.

The wall panel 10 also has a number of reinforcing bars ^■28 (shown in broken lines) which extend through the body 22 in one of two mutually orthogonal directions, which are aligned with the edges 12, 14, 16, 18 of the wall panel 10. For illustrative purposes, only two reinforcing bars 28 are shown. The reinforcing bars 28 parallel to the horizontal channel sections 24 are preferably disposed • at 250 mm centres, however it will be appreciated that other centres may be used depending on expected loading conditions during the life of the structure within which the wall panel 10 will be used.

The reinforcing bars 28 parallel to the vertical channel sections 26 are disposed such that one reinforcing bar 28 is disposed within the body 22 between each pair of vertical channel sections 26. Alternative layouts of the reinforcing bars 28 are envisaged depending on the loading conditions of the wall panel 10 or any window/door openings in the wall panel 10. ^■ . .

Figure 2 is an end view of a cross section of the wall panel 10 at the point indicated by arrow A in figure 1.

A roof truss 30 is attached to the wall panel 10 via a bracket 32 which is bolted to the roof truss 30 and attached to the web of the horizontal channel section

24. Tek screws 34 are used to attach the bracket 32 to the horizontal channel section 24, however it will be appreciated that any fastening means may be used.

An inner cosmetic wall 36 and ceiling 38 is attached to the exposed flange of the channel sections 24, 26. Plasterboard, fibre-cement sheet or any similar thin, non-structural wall material may be used for the inner cosmetic wall 26 and/or ceiling 38. Between the body 22 and the inner cosmetic wall 36, thermal/sound insulation material (not shown) can be provided. ^•• ■

It is envisaged that the inner .cosmetic wall 36, and any insulation material, would be provided after the wall panel 10 has been installed.

Figure 3 is an end view of a cross section of the wall panel 10 at the point indicated by arrow B in figure 1. The wall assembly 10 is attached to a top surface of a slab 40 such that the horizontal channel section 24 adjacent the lower edge 14 supports the wall panel 10. Fastening means, such as a dynabolt 42, fasten the wall panel 10 to the . slab 40. Between the web of the horizontal channel section 24 and the top surface of the slab 40, a joint 44 is ^' provided to seal the gap between the web and the slab 40.

The lower edge 14 extends beyond the top surface of the slab 40 such that the lower edge 14 of the body 22 almost contacts the footing 46 beneath the slab 40. A joint 48 is provided between the body 22 and the footing 46. Both joints 44, 48 can be made of any appropriate gap sealing building material, including grout, silicone, mortar and/or foam.

Figure 4 is a plan view of a cross section of a join between two wall panels 10. Wall panel 10, along the

Tine indicated by arrow C in figure 1, is attached to a side edge 16 of a like wall panel 10' . Thus, the connection of the wall panels 10, 10' form two internal corners. To join the wall panels 10, 10^f and provide a mounting surface for an inner cosmetic walls 36, the wall panel 10 is provided -w.ith three vertical channel sections 26. Tek screws 34 are used to- fasten one of the vertical channel sections 26 to the vertical channel section 26 on the side edge 16 of the like wall panel 10'. As shown in figure 4, the other two vertical channel sections 26 provide mounting surfaces for inner cosmetic walls 3&.

Figure 5 is a plan view of a cross section of a join between the wall panel 10, along the line indicated by arrow D, and a like wall panel 10'' to form an external corner. Tek screws 34 are used to fasten vertical channel sections 26 together. A joint 50 is provided between the two wall^' panels 10, 10'' to seal a gap between the wall panels 10, 10''. Inner cosmetic walls 36 are attached to the flanges of vertical channel sections 26.

Figure 6 is a plan view of a cross section of a join between two wall panels 10 along the side edge 16 to form an internal corner. Tek screws 34 are used to fasten the web of a vertical channel section 26 of the first wall panel 10 to the concrete of the body 22 of the second wall panel 10. Again, a joint 50 is provided between the two wall panels 10 to seal a gap between the wall panels 10. Inner cosmetic walls 36 are attached to the flanges of vertical channel sections 26.

Figure 7 is a plan view of a cross section of a wall panels 10'-'' according to a second embodiment. The wall panel 10''' has a vertical channel section 26 which is disposed against a window opening. The window opening is defined by an architrave 52 which is disposed in the^' wall panel- 10'''. An outer window sill 54 is provided on the outside surface 56 of the wall panel 10'" such that a joint 58 between the architrave 5.2 and the body 22 is covered. The joint 58 is also filled with a gap sealing building material. An inner cosmetic wall 36 extends around the vertical channel section 26 to abut the architrave 52.

It will be appreciated that a similar arrangement for door openings in wall panels 10 can be provided.

In addition, it will be appreciated that I-beam section may be used instead of channel sections. The cross section of the elongate structural members 24, 26 can be selected depending on a number of factors, including the building standards which govern the building must abide, the loading requirements of the wall. For example, in low-rise residential dwellings the elongate structural elements 24, 26 used in an external wall panel may have a larger cross section than those used in an internal wall panel. Alternative building materials which set to form a stone-like mass may be used in the body 22 instead of concrete.

Modifications and variations described above, together with others that would ^' be obvious to a person of ordinary skill in the art, are deemed to be within the scope of the present invention, the nature of which is to be determined from the above description.

Claims

1. A wall panel comprising: a body having first and second major faces; and 5 a plurality of elongate structural members which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged to extend generally vertically across the first face,

10 and at least one of the elongate structural elements is arranged to extend generally horizontally across the

^' first face .

2. A wall panel according to claim 1, wherein there 15 are at least two elongate structural members arranged to extend horizontally across the first face, such that a first horizontal elongate structural member is adjacent a lower edge of the first face and a second horizontal elongate structural member is adjacent an 20 upper edge of the first face.

3. A wall panel according to claim 1, wherein the wall panel can be joined to at least one other building element by fastening means which extend through either

25 the elongate structural members or the body of the wall panel into the at least one other building element.

4. A wall panel according to claims 1 to 3, wherein the body is made of a concrete material.

30.

5. A wall panel according to claims 1 to 4, wherein the plurality of elongate structural members are cast into the body such that a portion of each of the plurality of elongate structural members protrude from the first

35 face of the body.

6. A wall panel according to claims 1 to 5, wherein the elongate structural members have two flanges separated by a web, one flange and part of the web protrude from the first face of the panel.

5 7. A wall panel according to claim 6, wherein the elongate structural members are channel sections..

8. A wall panel according to claims 1 to 7, wherein the wall panel is provided with openings for windows or

10 doors .

9. A wall panel according to claim 8 , wherein an architrave is attached to the body within the opening.

15. io. A wall panel according to claim 9, wherein the wall panel is additionally provided with a sill which covers the attachment of the architrave to the body.

11. A wall panel according to claims 1 to 10, wherein 20 the second face may have a finish to achieve a desired appearance .

12. A wall panel comprising: a body having first and second major faces;^' and 25 a plurality of elongate structural members which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged to extend generally vertically across the first face, 30 and at least one of the elongate structural elements is arranged to be positioned adjacent a vertical edge of the body for securing the panel to a building element.

13. A building comprising at least one wall panel 5 having: a body having first and second major faces; and, a body having a plurality of elongate structural members which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged to extend generally vertically across the first face, and at least one of the elongate structural elements is arranged to extend generally horizontally across the first face.

14. A method for assembling a building comprising the steps of: providing a footing member; providing an at least one wall panel having: a body having first and second major faces; and, ^' a plurality of elongate structural members which extend from the first face, wherein, when the wall panel is in position, a number of the elongate structural members are arranged to extend generally vertically across the first face, and at ^• least one of the elongate structural elements is arranged to extend generally horizontally across the first face;^' locating each of the at least one wall panels in the desired position on the footing; and, fastening each of the at least one wall panels to the footing member by fastening at least one of the structural members to the footing.

15. A method according to claim 14, wherein the two panels are fastened together by fastening adjacent vertical structural members to one another by a joint member .

16. A method according to claim 1"5, wherein a roof. truss is fastened to each panel by fastening the roof truss to at least one of the structural members.

17. A method according to claims 14 to 16, wherein one or more cosmetic walls are attached to at least one of the elongate structural members of the at least one wall panel.