WO2007012863A1 - Panneaux de construction et construction de bâtiments à l’aide de ces panneaux - Google Patents

Panneaux de construction et construction de bâtiments à l’aide de ces panneaux Download PDF

Info

Publication number
WO2007012863A1
WO2007012863A1 PCT/GB2006/002813 GB2006002813W WO2007012863A1 WO 2007012863 A1 WO2007012863 A1 WO 2007012863A1 GB 2006002813 W GB2006002813 W GB 2006002813W WO 2007012863 A1 WO2007012863 A1 WO 2007012863A1
Authority
WO
WIPO (PCT)
Prior art keywords
building
panels
building panel
trusses
panel
Prior art date
Application number
PCT/GB2006/002813
Other languages
English (en)
Inventor
Frank William Layzell
Original Assignee
Frank William Layzell
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
Priority claimed from GB0515474A external-priority patent/GB0515474D0/en
Priority claimed from GB0516393A external-priority patent/GB0516393D0/en
Application filed by Frank William Layzell filed Critical Frank William Layzell
Publication of WO2007012863A1 publication Critical patent/WO2007012863A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
    • E04B2/847—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising an insulating foam panel

Definitions

  • the present invention relates to the construction of buildings from building panels comprising a wire reinforcing cage structure enclosing a low density core, hi particular the invention relates to a novel structure of building panel and a novel method of constructing buildings using such a panel.
  • the width of the cage is typically of the order of 75mm whereas the width of the foam core is typically of the order of 50mm so that the cage extends approximately 10mm or so on either side of the foam core.
  • the finished thickness of the wall, subsequent to the application of the cement/plaster layer, is typically of the order 95 to 100mm.
  • the panels, which are typically of the order of 1.2m high and 2.4m wide, are light and easily handled and may be cut if necessary to any desired shape. The same form of panel is used to construct internal and external walls as well as roofs and multi-storey floors.
  • buildings are constructed by arranging the building panels adjacent one another on a foundation to which the panels are anchored to form walls. Adjacent panels may be tied to one another by clipping each panel to a strip of reinforcing mesh.
  • the external render may typically comprise Portland cement and Sharp sand mixed with a plaster. Alternatives, such as Gypsum plaster, might typically be used, particularly for rendering internal surfaces.
  • the layer of the cement/plaster encases the wire mesh cage on either side of the foam core producing a rigid structure when dry. If desired, various waterproofing, anti-fungal and fibre reinforcing agents may be applied to the cement mixture or the dried surface.
  • UK patent number 2323404 discloses a method of constructing multi-storey buildings by including vertical "I" section columns erected at spaced apart locations around the building perimeter which support horizontal "U” sectioned steel members which span adjacent columns, and which may be supported intermediate adjacent columns by vertical props. This structure provides additional support for second (and subsequent) stories which are erected in the same manner by securing further vertical columns to the ground floor columns, and adding additional horizontal channel members and props if necessary.
  • a building panel comprising blocks of a low density material contained within a surrounding support cage, the cage comprising a plurality of wire trusses extending along a length of the panel, the trusses being spaced apart such that each truss separates adjacent low density blocks, the trasses being held together by strapping wires which cross each truss, such that the width of the trusses defines the thickness of the cage, wherein the trasses have a ladder structure comprising two longitudinal wires extending substantially parallel to one another and connected together by lateral wires which span the longitudinal wires at spaced apart locations along the length of the trass.
  • a method of constructing a building using building panels comprising: i preparing a foundation; ii standing building panels on the foundation to form walls; iii securing a bottom portion of each building panel to a support member which is set into a floor laid onto the foundation.
  • a method of constructing a building having at least two storeys using building panels according to the first aspect of the present invention comprising supporting floor panels of a second or higher storey directly upon wall panels of the storey below without any additional supporting structure.
  • a fourth aspect to of the present invention there is provided a method of constructing walls of a building from building panels according to the first aspect of the present invention, wherein the wall panels are orientated such that the trasses ran vertically.
  • a building constructed from panel according to the first aspect of the invention.
  • Figure 1 is a perspective schematic illustration of part of a building panel in accordance with the present invention.
  • Figure 2 is a side view of a section of the wire mesh cage of the building panel of Figure 1;
  • Figure 3 is a plan view of a section of the panel of Figure 1 subsequent to rendering
  • FIG. 4 is a schematic illustration of one way in which a ground floor wall may be constructed in accordance with the present invention.
  • Figure 5 illustrates one method of constructing a second (and subsequent) storey of a building in accordance with the present invention.
  • FIG. 1 this is a perspective schematic illustration of a portion of a building panel in accordance with the present invention.
  • the panel which is generally indicated by the reference 1, comprises a core of foam blocks 2 supported within a wire mesh cage 3.
  • the foam may be phenolic foam.
  • the cage 3 comprises an array of "ladder" trasses 4 which are strapped together by strapping wires 5.
  • the panels are essentially factory fabricated but may advantageously be fabricated in a mobile factory which can be conveniently located on site.
  • Figures 2 and 3 show side and end views respectively of the cage of the panel of Figure 1 ; in Figure 2 the cage is shown with the foam blocks absent and in Figure 3 the panel is shown subsequent to rendering 6.
  • all wires are 3mm thick zinc electroplated galvanised wire welded together at joint.
  • the ladder trusses 4 are spaced apart at 50mm intervals and are approximately 130mm wide.
  • the strapping wires 5 are spaced apart at 50mm intervals.
  • the overall size of the panel 3 can be varied to suite applications but will typically be of the order of 1.2m by 2.4m for wall s and up to about 5m by 5m for floors.
  • the foam cores 2 are a little under 50mm deep so that they may be sandwiched between adjacent trusses.
  • the cores are not as wide as the width of the trusses 4 to leave a space within the cage 3 on either side of each foam block 2 to receive cement/plaster render 6 which is applied to the panels 1 once they have been erected to complete the structure, and which is then effectively reinforced by the portions of the cage 3 it encases (see Figure 3).
  • the rendering 6 has a thickness of the order of 25mm on each side of the panel 1 so that the overall panel thickness is of the order of 150mm to 160mm. Where the overall panel thickness is 150mm, the U- value of the panel 1 is 0.34 WAn 2 K.
  • the U- value is measured as the amount of heat lost through one square meter of the panel 1 for every degree difference in temperature either side of the panel 1. It is indicated in units of Watts per Meter Squared per Degree Kelvin or W/m 2 K. The lower the U-Value, the less heat escaping through the panel 1.
  • the embodiment described above use blocks 2 made from phenolic foam.
  • the blocks 2 may be manufactured from a composite comprising phenolic foam and a suitable filler.
  • the filler may be gypsum, rice husk or any suitable porous fire retardant filler.
  • the advantage of using a block having a filler is that the filler absorbs water, therefore allowing the render 6 to adhere more strongly to the surface of the block made from composite material.
  • the embodiments described above use blocks made from phenolic foam and from phenolic foam composite.
  • the phenolic foam may be substituted with a suitable fire retardant foam.
  • the blocks 2 may be manufactured from a composite comprising fire retardant foam and the suitable filler.
  • the panel 1 described above has several advantages over the prior art panel mentioned in the introduction to this specification.
  • the use of ladder trusses 4 rather than zig-zag trusses is advantageous both when cutting the cages 3 to size and when loading them into a suitable machine for inserting the foam blocks 2.
  • a problem with the conventional zig-zag truss is that there is a certain amount of spring tension in the truss so that if the zig-zag wire of the truss is cut it can spring outwards effectively extending the dimension of the panel 1 beyond that intended.
  • the ladder trusses 4 of the panel according to the present invention this problem does not exist and the panel can be cut to desired dimensions with greater accuracy.
  • the simple ladder truss structure is easier to manufacture than the zig-zag truss since no bending of the wire is required.
  • a zig-zag trust would have more structural rigidity through the triangular configuration
  • the adoption of a ladder truss in fact enables the use of thicker gauge wire than cannot easily be bent in conventional machinery.
  • the use of a thicker gauge wire can more than compensate for the apparently weaker structure, enabling the construction of trusses with significantly increased structural rigidity.
  • the prior art panels mentioned above have trusses made from 2mm gauge wire. With the present invention an increase in wire gauge up to 3 mm provides significant improvements in strength.
  • the ability to use thicker gauge wire provides a direct increase in the strength of the trusses as mentioned above.
  • the ladder trusses can be made stronger than the conventional zig-zag trasses, they can be made wider whilst still providing the necessary structural rigidity so that there can be an overall increase in the width of the building panel.
  • the completed panel mentioned above is of the order of 150mm wide whereas conventional panels are of the order of 100mm wide. This increase in the overall size of the panel also increases the strength of the finished panel and building once rendered.
  • the panels according to the present invention can be used as wall (both internal and external) and floor panels in the construction of buildings in accordance with conventional methods, such as that disclosed in UK patent number 2323404 mentioned above.
  • the increased load bearing capability of the new panels enables simplification of the building construction, particularly of multi-storey buildings.
  • the load bearing strength of the panels is such that multi-storey buildings can be simply erected by supporting floor panels directly on wall panels of the storey below, without the need for additional supporting structure.
  • a ground floor wall panel 1 may be secured to a concrete foundation 7 by anchoring the panel to an L sectioned wire mesh bracket 8 which is partially set into a concrete floor 9 laid on top of the foundation 7. Prior to rendering of the wall panel and pouring of the floor the panel 1 may easily be attached to the bracket 8 using conventional clips (for instance CLl 5-G STANLEY-HARTCO clips - manufactured from 20 gauge flat cold rolled steel by Hartco Manufacturing Company).
  • the panels are preferably orientated so that the trusses extend vertically.
  • adjacent wall panels 1 will be arranged immediately next to one another and may be tied to one another using a strip of wire mesh (for instance one of the ladder trusses) clipped to each panel along their abutting edges, preferably on both sides of the panels.
  • panels which meet to form a corner may be fixed together with strips of mesh bent to form an appropriate angled bracket located on either or both the inside and outside of the corner.
  • Figure 5 illustrates one way in which the floor and walls of a subsequent storey may be supported on the walls of the storey below.
  • a portion of the tops of the foam blocks 2 of the lower wall panel 1 is removed leaving a void 10 in the top portion of the panel cage 3.
  • a supporting mesh section 11 is clipped to the outward facing side of the lower panel 1 and extends a short distance above the top of the cage 3.
  • An edge of a floor panel 1 is then laid on top of the wall panel cage 3 and secured to it using L section mesh bracket 12 which is clipped to both the floor panel 1 and wall panel 1.
  • a further L section mesh bracket 13 is clipped to the upper surface of the floor panel 1 and second storey wall panel 1 can then be stood on the floor panel 1 between the mesh support 11 and the L shaped bracket 13 and clipped to both.
  • one or more of the foam cores of any given wall panel could be removed leaving a vertical channel which will then be filled with concrete etc as the floor surface is poured, or as the panel is rendered. This will effectively provide a solid column within the panel.
  • end foam blocks of wall panels which meet at corners could be removed to enable the effective formation of a concrete supporting column at each corner of a building without the need to provide any separate supporting structure, and in particular without the need to pre- erect any separate supporting structure.
  • floor and wall panels may be connected to one another, but essentially this aspect of the present invention provides a multi-storey building (i.e. two or more floors) in which floor panels are supported directly on walls constructed from building panels in accordance with the present invention.
  • the floor panels are also panels according to the present invention but other panel structures could be used. Panels of the present invention have been used to provide floors which span walls of up to around 5m apart without the need for any intermediate support.

Abstract

La présente invention concerne un panneau de construction qui comprend des blocs d’un matériau à faible masse volumique contenus dans une cage de support environnante, la cage comprenant une pluralité d’étais métalliques s’étendant le long du panneau, les étais étant espacés de sorte que chaque étai sépare les blocs de faible masse volumique adjacents, les étais étant maintenus ensemble par cerclage des câbles qui traversent chaque étai, de sorte que la largeur des étais définit l’épaisseur de la cage, dans laquelle les étais ont une structure d’échelle comprenant deux câbles longitudinaux s’étendant sensiblement parallèles l’un à l’autre et raccordés ensemble par des câbles latéraux qui passent au-dessus des câbles longitudinaux à des endroits éloignés sur toute la longueur de l’étai.
PCT/GB2006/002813 2005-07-28 2006-07-27 Panneaux de construction et construction de bâtiments à l’aide de ces panneaux WO2007012863A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB0515474A GB0515474D0 (en) 2005-07-28 2005-07-28 Building panels and construction of buildings with such panels
GB0515474.5 2005-07-28
GB0516393A GB0516393D0 (en) 2005-08-10 2005-08-10 Building panels and construction of buildings with such panels
GB0516393.6 2005-08-10

Publications (1)

Publication Number Publication Date
WO2007012863A1 true WO2007012863A1 (fr) 2007-02-01

Family

ID=37056603

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2006/002813 WO2007012863A1 (fr) 2005-07-28 2006-07-27 Panneaux de construction et construction de bâtiments à l’aide de ces panneaux

Country Status (1)

Country Link
WO (1) WO2007012863A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007091088A2 (fr) * 2006-02-09 2007-08-16 Frank William Layzell Systeme et procédé d'assemblage de panneaux de construction
CN105544772A (zh) * 2015-12-03 2016-05-04 文登蓝岛建筑工程有限公司 一种墙板固定件

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0061100A2 (fr) * 1981-03-18 1982-09-29 SISMO INTERNATIONAL personenvennootschap met beperkte aansprakelijkheid Structures préfabriquées, méthode pour leur fabrication et leur utilisation dans le bâtiment industriel
GB2323404A (en) * 1997-03-18 1998-09-23 Mobility Avenue Sdn Bhd Method of constructing multi-storey buildings

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0061100A2 (fr) * 1981-03-18 1982-09-29 SISMO INTERNATIONAL personenvennootschap met beperkte aansprakelijkheid Structures préfabriquées, méthode pour leur fabrication et leur utilisation dans le bâtiment industriel
GB2323404A (en) * 1997-03-18 1998-09-23 Mobility Avenue Sdn Bhd Method of constructing multi-storey buildings

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007091088A2 (fr) * 2006-02-09 2007-08-16 Frank William Layzell Systeme et procédé d'assemblage de panneaux de construction
WO2007091088A3 (fr) * 2006-02-09 2007-10-25 Frank William Layzell Systeme et procédé d'assemblage de panneaux de construction
CN105544772A (zh) * 2015-12-03 2016-05-04 文登蓝岛建筑工程有限公司 一种墙板固定件

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