WO2009015433A1 - A building panel and locking device therefor - Google Patents
A building panel and locking device therefor Download PDFInfo
- Publication number
- WO2009015433A1 WO2009015433A1 PCT/AU2008/001105 AU2008001105W WO2009015433A1 WO 2009015433 A1 WO2009015433 A1 WO 2009015433A1 AU 2008001105 W AU2008001105 W AU 2008001105W WO 2009015433 A1 WO2009015433 A1 WO 2009015433A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- core
- building panel
- building
- locking
- locking member
- Prior art date
Links
- 239000000463 material Substances 0.000 claims abstract description 75
- 239000004567 concrete Substances 0.000 claims abstract description 53
- 239000011178 precast concrete Substances 0.000 claims abstract description 17
- 230000007246 mechanism Effects 0.000 claims abstract description 15
- 230000000694 effects Effects 0.000 claims abstract description 9
- 238000005266 casting Methods 0.000 claims description 17
- 238000000034 method Methods 0.000 claims description 16
- 239000011800 void material Substances 0.000 claims description 12
- 238000007689 inspection Methods 0.000 claims description 11
- 239000012779 reinforcing material Substances 0.000 claims description 11
- 239000004033 plastic Substances 0.000 claims description 10
- 229920003023 plastic Polymers 0.000 claims description 10
- -1 polypropylene Polymers 0.000 claims description 8
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 239000004794 expanded polystyrene Substances 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 230000001413 cellular effect Effects 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- 125000006850 spacer group Chemical group 0.000 claims description 3
- 239000011162 core material Substances 0.000 description 95
- 238000010438 heat treatment Methods 0.000 description 22
- 229910000831 Steel Inorganic materials 0.000 description 13
- 239000010959 steel Substances 0.000 description 13
- 239000012530 fluid Substances 0.000 description 7
- 230000003014 reinforcing effect Effects 0.000 description 7
- 230000013011 mating Effects 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 241000995070 Nirvana Species 0.000 description 4
- 239000004793 Polystyrene Substances 0.000 description 4
- 239000011152 fibreglass Substances 0.000 description 4
- 229920002223 polystyrene Polymers 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 238000010276 construction Methods 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000006260 foam Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 230000000295 complement effect Effects 0.000 description 2
- 238000009415 formwork Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
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- 239000002803 fossil fuel Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
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- 238000011065 in-situ storage Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B21/00—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings
- F16B21/02—Releasable fastening devices locking by rotation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B21/00—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings
- F16B21/09—Releasable fastening devices with a stud engaging a keyhole slot
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B21/00—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings
- F16B21/10—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings by separate parts
- F16B21/16—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings by separate parts with grooves or notches in the pin or shaft
Definitions
- the present invention relates to a building panel.
- the invention relates to a precast concrete building panel.
- the invention also relates to a method of casting a building panel. While the building panel is commonly described herein in terms of a wall panel, the invention may have application to other types of precast panels including ceiling, roof and floor panels.
- the present invention also relates to a connecting system for precast cementitious components.
- the invention relates to a connecting system which is used to secure precast concrete wall panels into edgewise abutting relationship with each other. Thus, it may be used to secure two panels side by side or one panel atop another.
- the invention may also have application to connecting a wall panel to a slab.
- the invention also relates to a locking device for concrete components.
- precast concrete panels are formed as substantially solid bodies of concrete, albeit with reinforcing material.
- the thicker the concrete panel the greater its insulative properties.
- Thermal insulative properties are measured in terms of R value and an R value of 1.5 is desirable for building walls.
- solid concrete panels would need to have a theoretical thickness of 375mm millimetres in order to exhibit an R value of 1.5 and therefore achieve satisfactory thermal insulative properties.
- the locking devices comprise pins and keepers.
- the pins are connected to one concrete component and are received in a keeper connected to another concrete component.
- the pin and associated keeper are disposed upon respective mating edges of the two concrete components.
- a building panel being generally planar in form and having a core which is substantially planar in form with opposite sides, the core being substantially aligned with the plane of the building panel, with cementitious material disposed on both sides of the core, the core being formed with a series of substantially parallel open channels which are arranged with the openings on alternate sides of the core, some of the channels being filled with the cementitious material.
- the channels in the core may extend from top to bottom of the core and be generally aligned with the height dimension of the finished building panel. Thus the channels are arranged to alternate from one side to the other across the width of the core.
- the core may have a uniform cross-section over its height. Consequently, the form of the core could be described as corrugated, undulating, sinusoidal or crenellated.
- the corrugations are of a regular formation.
- the term corrugated includes a zig-zag formation, preferably a regular zig-zag formation.
- a preferred profile is one which reduces waste.
- the core may be of uniform thickness so that the crests on the first side of the core define the openings on the second side of the core and the openings on the first side of the core define the troughs on the second side of the core.
- each of the channels has a necked region at or adjacent the opening and a main void, wherein the necked region is of narrower dimension(s) than the main void.
- the cross-section of the channels may be described as dovetailed.
- the cementitious material will be provided on both sides of the core, extending into some or most of the channels thereby creating alternating "columns" of cementitious material on either side of the core, with columns on the same side of the core being joined by a common plane of cementitious material.
- the cementitious material on each side of the core is interlocked with the core by virtue of the necked regions.
- the building panels according to the present invention may be precast building panels.
- the precast building panels may be part of a building system where the building panels are shaped so as to mesh with each other and also a building slab.
- a building system is described in Australian patent no 785414 in the name of MACH Systems Pty Ltd. While the specification describes the invention in the context of precast building panels, the invention is not limited thereto and the present invention may also be applied to a building panel which is poured in situ.
- the core of the building panel may comprise insulative material.
- the core may also be moisture impervious to minimise the penetration of water or moisture from the outside of a building to the inside.
- the core may be moulded or extruded to shape.
- the core is formed of rigid cellular plastics material, for example, expanded polystyrene, expanded polypropylene or expanded polyethylene.
- the core may be cut from a solid block of cellular plastics material, for example by a hot wire.
- the core may have a smooth outer skin. Alternatively, the outer surface of the core could be shaped or roughened or deformed to enhance bonding with the cementitious material.
- the building panel may also include reinforcing material.
- reinforcing material For example, traditional steel reinforcing mesh may be employed. However, alternative reinforcing materials may be used. These include steel mesh or fabric such as expanded metal, fibreglass fabric or carbon fibres.
- the core may incorporate holding means for the reinforcing material.
- the core may include integral protrusions to create a seat for the reinforcing material.
- reinforcing sheet material such as fibreglass fabric may be permanently bonded to the outermost surfaces of one or both sides of the core.
- the core may extend from edge to edge and top to bottom. However, preferably the core does not extend all the way to the top and the bottom so that the two concrete sides of the panel may be joined to create concrete 'beams' at the top and bottom of the panel.
- the core size may instead be a standard width (and height), with the building panels being of a width to accommodate a single core or multiple cores arranged side by side.
- the cementitious material is preferably concrete, which is usually a composition of gravel, sand, cement and water. It is possible that different grades of cementitious material may be used on either side of the core. For example, a different density of concrete may be used on one side of the panel compared to the other side. This may be to reduce the overall weight of the panel while balancing strength and thermal performance characteristics.
- the building panel has a higher density cementitious material e.g. 50MPa concrete on one side of the core and relatively lower density cementitious material on the other side of the core, such as HySSIL or other forms of lightweight concrete (the units MPa refer to compressive strength).
- a building so constructed constitutes a second aspect of the present invention.
- the building panel may also employ void formers.
- the void formers may be in the form of inserts which fit with or into the channels in the core to preclude one or some of the channels from being filled with cementitious material. This facilitates the creation of service ducting for cabling, water pipes, air ducts for space heating or ducts for thermal heating pipes. These void formers are suitably attached to the core prior to pouring of the cementitious material.
- the panel may also include a lifting bracket.
- the lifting bracket may comprise one or more lifting rods which extend into the channels to become embedded in the cementitious material.
- the lifting rod(s) extends the full length of the panel.
- the lower ends of the lifting rods may have flanged ends.
- a method of casting a building panel including:
- cementitious material of at least two different densities including a relatively higher density material and a relatively lower density material
- the mould may be vibrated and allowed to set.
- the core assembly may include any of the features described above in connection with the first aspect of the invention such as reinforcing material, void formers, lifting brackets, cabling, water pipes, heating conduits etc.
- a connecting system for precast cementitious components including:
- first and second precast cementitious components adapted to be arranged in abutting relationship in an assembled configuration, the first and second precast components having respective edges which face each other in the assembled configuration;
- a locking mechanism including mutually engageable components disposed at the facing edges, the locking mechanism including a remote actuating means to effect locking of the mutually engageable components at or beyond a third edge of one of the first and second precast components, to secure the first and second precast components together.
- the third edge may be on top of one of the components. Where the precast components are arranged one atop the other then the third edge may also be atop the upper component. This renders the remote actuating means most accessible when the components are being assembled.
- at least one of the components is substantially planar in form having a length, width and thickness. Side edges will be therefore defined across the thickness dimension at the sides. Also, top and bottom edges will be defined across the thickness dimension at the top and bottom.
- the present invention provides a connecting system including:
- first and second precast cementitious components adapted to be arranged in abutting relationship, the first and second precast components having respective first and second edges which face one another in the assembled configuration;
- a locking device including a locking member which is disposed at the second edge of the second component, the locking member being moveable between an unlocked configuration and a locked configuration whereby it is adapted to receive the head of the pin, the locking device further including an elongate member connected to the locking member and extending to a third edge of the second component, wherein operation of the locking member may be effected from the third edge by the elongate member.
- the precast cementitious components may comprise wall panels which may be secured side by side to each other (in edgewise abutting relationship or alternatively may be secured one atop the other.
- the connecting system might also be used to join a wall panel to a slab or a concrete footing.
- precast cementitious roof panels could be interconnected using the system.
- the system could also be used to join and fasten precast ccementitious floor panels together.
- the pin may dually serve as a lifting pin to move the panels into position.
- lifting pins are supplied by Reid Construction Systems Pty Ltd of Australia. These pins are cast into the component. Additionally, a semicircular recess is formed about the pins such that they do not protrude beyond the main surface of the associated edge but access to the pins can still be obtained.
- the first and second facing edges of the precast cementitious components may have a complimentary profile as described in my Australian patent no 785414.
- the elongate member forming part of the locking device may be movable linearly by the actuating means to effect operation of the locking member.
- the elongate member may comprise a rigid member such as a rod or a bar or alternatively may comprise a flexible member such as a cable.
- the rod may be threaded at the upper end. By screwing a nut onto the upper end of the elongate threaded rod, this will serve to draw the rod out of the concrete component once the nut abuts against the third edge.
- other means of moving the elongate member may also be employed.
- a cable actuating device may be used.
- the elongate member may also be a combination of a cable and a rigid member such as a rod.
- a plurality of locking members may be operated simultaneously.
- the threaded rod may extend upwards through the height of the wall panel and be connected to a roofing component. This effectively ties the roofing component to the floor slab which may be a requirement in some cyclone areas.
- the locking member may comprise any suitable member which is adapted to engage with the pin.
- the locking member is an arcuate member with a recess formed to receive the head of the pin.
- the locking member may be arcuate member which is forked.
- the locking member may be a part- cylindrical shell.
- the locking member is preferably one-half to two-thirds of a cylinder with the missing part defining a gap to receive the head of the pin.
- the locking member may be pivotally mounted to the second component.
- An axial spigot may be incorporated into the locking member for this purpose.
- the two ends of the spigot are received into a shaped plastic spacer which is cast into the concrete component.
- the locking member is pivotally connected to the elongate member.
- the interconnection in the unlocked configuration is at a point further from the third edge than the pivot axis to effect rotation of the locking member.
- a locking device for use with a precast concrete component to lock the component to another precast concrete component, the device including a locking member adapted to receive the head of a pin extending from the edge of the other component; and an elongate member connected to the locking member, the elongate member being adapted for remote operation of the locking member.
- the locking device may be cast into the concrete component.
- the locking device may include any of the features described above in accordance with the fifth aspect of the present invention.
- This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
- Figure 1 is a horizontal cross-sectional view through a portion of a building panel according to a preferred embodiment of the present invention
- Figure 2 is a horizontal cross-sectional view through a portion of a building panel slightly modified from that shown in Figure 1 ;
- Figure 3 is a schematic longitudinal cross-section showing a lower detail of the building panel of Figure 2;
- Figure 4 is a schematic longitudinal cross-section showing an upper detail of the building panel of Figure 1 ;
- Figure 5 is a horizontal cross-sectional view showing a corner junction between two building panels of the type illustrated in Figure 1 or 2;
- Figure 6 is a perspective view of a core assembly, further illustrating a lifting bracket assembled with the core assembly
- Figure 7 is a perspective view showing the lifting bracket in isolation
- Figure 8 is a perspective view showing an upper frame forming part of the lifting bracket of Figure 7;
- Figure 9 is a schematic top view of a building panel illustrating the lifting bracket in position
- Figure 10 is a vertical cross-section aligned with the general plane of the building panel showing the inclusion of heating conduits;
- Figure 11 is a vertical section through B-B of Figure 16, illustrating the airflow through the building panel;
- Figure 12 is an exploded perspective view of an insert assembly for a service conduit for the building panel
- Figure 13 is a perspective view of a heating conduit for the building panel
- Figure 14 is an exploded view of a space heating conduit for the building panel
- Figure 15 is a cross-sectional view through a building panel showing the arrangement of service conduits and heating conduits of Figures 12-14 assembled with the core assembly;
- Figure 16 is a partial perspective view of a connecting system in accordance with a preferred embodiment of the present invention.
- Figure 17 is a partial perspective view showing the connecting system of Figure 16 with the two concrete components in assembled configuration
- Figure 18 is a diagrammatic view illustrating the locking mechanism for use in the connecting system shown in Figure 16 prior to interconnection;
- Figure 19 is a view of the components of Figure 18 just prior to engagement
- Figure 20 is a perspective view of the components of Figure 18 in full engagement
- Figure 21 is a sectional view through the connecting system of Figure 18;
- Figure 22 is a front view of concrete components connected using the connecting system of Figures 16 to 21 ;
- Figure 23 is a front view of a connecting system according to another preferred embodiment of the present invention.
- Figure 24 is a front view of a connecting system according to Figure 23, except shown in the locked configuration;
- Figure 25 is a diagram illustrating the mating profile of the two concrete components
- Figure 26 is a schematic perspective view showing the mating profile of the two concrete components
- Figure 27 is a detail of the connecting system of Figure 23 shown in the unlocked configuration
- Figure 28 is a detail of the connecting system of Figure 23 shown in the locked configuration
- Figure 29 is a detailed view of two positions of the locking member.
- FIG. 1 is a horizontal cross-section through a core assembly 10 incorporated into a building panel 12.
- the core assembly 10 includes a core 14 which is constructed of high density expanded polystyrene. A suitable material is sold under the brand name lsolite VH.
- the core has a substantially uniform cross-section throughout its height.
- the cross-section is in the shape of a regular zig-zag of uniform thickness.
- the cross- section defines channels 16, albeit rather shallow channels which extend substantially parallel to each other in the height direction of the finished panel.
- the channels open towards alternating sides of the core 10.
- the resulting shape of the core 14 is zig-zag as shown.
- the zig-zag core is cut by hot wire from a solid block of polystyrene having dimensions of 5.5m long x 1220mm wide and 600mm thick.
- the cross-section selected is easy to cut and reduces waste.
- the core has dimensions of length (which may equate to height in a wall panel), width (the other major dimension besides length/height) and thickness.
- the width of the core 14 may be substantially commensurate with the width of the building panel 12.
- the zig-zag core 14 defines external points 22.
- steel reinforcing mesh 24 is bonded/secured to the external points 22 to extend across the opening 17 of each of the channels 16.
- the reinforcing mesh 24 extends on both sides of the core 14 and is substantially commensurate with the length (i.e. height) and width dimensions of the core 14.
- fibreglass reinforcing mesh may be used.
- the core assembly 10 may be formed of sheets 14a, 14b of a standard width which may be joined to make up the required width in the building panel 12.
- Figure 2 illustrates a join 30 between two polystyrene core sheets 14a and 14b having complementary edge profiles.
- the core assembly 10 is disposed essentially within the building panel so as to be substantially aligned with the general plane of the building panel 12.
- the core assembly 10 is inserted into a mould so that cementitious material extends on both sides of the core assembly 10 and in most cases extends into the channels 16. As will be appreciated, this creates parallel spaced columns of cementitious material within the boundary defined by the channels 16. These columns are joined by the concrete which extends along the outside of the building panel.
- the cementitious material conforms to the shape of the dovetail channels 16.
- the cementitious material used in the building panel 12 may be concrete.
- a preferred material is aerated cementitious material such as HySSIL developed by CSIRO in Australia.
- HySSIL developed by CSIRO in Australia.
- the current Australian government guidelines for home insulation provide that in temperate zones, the insulation value for building walls should be R-1.5 or preferably R- 2. It is believed that the present invention can achieve an R value of 1.74 by adopting the following design guidelines:
- HySSIL cementitious material of 115mm in thickness is believed to give an R value of 0.46.
- HySSIL cementitious material of 1500kg/cm 3 was used for one side of the building panel and HySSIL cementitious material of 900kg/cm 3 was used for the other side of the building panel 12.
- FIG. 12 also shows an insert assembly comprised of a conduit 88 having a lower port 90 and a guide insert 92 for guiding cables or heating conduits 82. See also the discussion below in connection with Figures 12 to 15.
- Cabling (not shown) may also be inserted into the core assembly 10, prior to being placed into the mould.
- the left hand panel of Figure 5 shows one embodiment where the width of the core 14 is substantially commensurate with the width of the building panel 12.
- Figures 3 and 4 illustrate the vertical extent of the core 14 relative to the building panel 12.
- the core 14 does not extend to the bottom of the building panel 12 but falls short by about 80mm to provide a lower 'beam' of concrete or cementitious material.
- the core 14 provides an upper beam height of approximately 100mm.
- the concrete building panels 12 of the present invention may be compatible with known precast concrete building systems.
- the building panels 12 of the present invention may be constructed in accordance with the principles set down in Australian patent no 785414 in the name of MACH Systems Pty Ltd, the details of which are incorporated herein by reference.
- the building panel 12 may be mounted on a slab 40 provided with a rebate 42 to accommodate the building panel 12.
- the profile of the rebate 42 and the bottom edge of the panel 12 may be complementary or meshing to maintain the building panel 12 relative to the slab 40.
- locking means (not shown) may be provided to secure the building panel 12 to the slab 40 and the panels to each other. Details of the edge profiles and the locking mechanism are disclosed in the abovementioned Australian patent and the reader is directed to that earlier specification for further information. Further, the reader is also directed to the locking device for precast concrete components, discussed further below in Figures 16 to 19.
- Figure 5 shows the engagement between two building panels 12 arranged at 90° to define a corner of a building.
- the two panels 12 may be locked together by means of any suitable locking mechanism as mentioned above.
- Figures 6 to 9 illustrate the form of a lifting bracket which may be used to lift the building panel 12 once it has been cast.
- Figure 6 simply illustrates the lifting bracket 44 relative to the core assembly 10.
- Figure 7 illustrates the form of the lifting bracket 44 by itself.
- the lifting bracket 44 comprises three elongated rods 46.
- the rods may be threaded or the ends of the rods may be threaded.
- the rods are coupled to nuts with winged flanges 48.
- the rods 46 are coupled to an upper lifting frame 50 which includes three triangularly spaced nuts 52 which engage with the upper ends of respective rods 46.
- the lifting frame 50 further includes a lifting eye 54.
- the three rods 46 extend into three adjacent concrete columns 17, two on one side of the building panel 12, and one on the other.
- the rods 46 may extend the full height of the building panel 12 or may extend partially into the building panel 12 as depicted in Figure 6.
- the lifting bracket 44 may be preassembled as part of the core assembly 10, prior to insertion of the core assembly 10 into the casting mould.
- the elongate rods 46 may be attached to the reinforcing material 24 in the core assembly 10.
- the mould used to cast the building panel comprises a casting bed of conventional form.
- the building panel 12 is cast on the casting bed with its general plane being horizontally disposed on the casting bed.
- the outside perimeter of the building panel 12 will be defined by formwork attached to the casting bed.
- the casting bed 62 will thereby define one side of the finished building panel 12.
- HySSIL (or other lightweight concrete) is placed in the base of the mould.
- the HySSIL is screeded to a predetermined depth that will allow for expansion of the material due to the contained gas producing additives (assume expansion of about 30%).
- the core assembly 10 is positioned within the mould so as to allow a desired amount of cementitious material to form on both sides of the core 14.
- the desired position of the core assembly is achieved through the used of Nirvana Connectors 32
- the Nirvana Connectors pierce through the polystyrene core 14 and protrude beyond either side of the core 14 to act as spacers to hold the core at a predetermined spacing from the casting bed.
- the Nirvana Connectors may also be adapted to hold the steel reinforcing in place.
- a layer of high density concrete (50 MPa) is then placed on top of the foam core and the casting bed is vibrated in the conventional fashion to enable the cementitious material to settle in the mould. This will also enable the cementitious material to be worked into the channels 16 of the core 14, on the lower side of the core 14 within the mould 60.
- Pascals Principal provides: where a body is wholly or partly immersed in a fluid it is acted upon by an upthrust equal to the weight of fluid displaced. In this configuration with the high density concrete disposed above the lower density HySSIL, Pascal's Principal is exploited to maintain the core in position.
- upthrust 1 ,500 kg/cm (weight of HySSiI) whereas the weight of the concrete on top of the foam core is 2,500 kg/cm.
- the depth of the layer of HySSiI concrete will be screeded to a predetermined level to allow for the expansion of the material as the chemicals produce the hydrogen bubbles, allowing for a 30% expansion rate.
- the angular ribs of the foam core will tend to sink into the HySSiI to the point where the core 14 is supported by the Nirvana connectors.
- FIG. 12 illustrates a heating assembly 80 that may be incorporated into the building panel 12 in accordance with the present invention.
- the heating assembly 80 may incorporate the features described in our earlier International application no
- the heating assembly 80 includes a conduit 82 formed from black polypropylene pipe arranged in a U-shape having upper ends, the first of which forms an inlet for the heating fluid and the second of which forms the outlet for the heating fluid.
- the heating fluid may be heated by any conventional means such as a gas or oil boiler or solar heating. Particular reference is made to our earlier application PCT/AU2006/000737 which teaches methods and apparatus for solar heating.
- the conduit 82 extends through two adjacent channels 16 of the core 14, the two channels 16 being arranged on the same side of the core 14.
- the conduit 82 extends through the higher density concrete layer.
- the U-shaped conduits 82 extend from the top of the building panel 12 down through the higher density concrete layer created in channel 16, through the concrete 'beam' at the bottom of the building panel 12 and then up the higher density concrete layer defined by adjacent channel 16.
- the two links of the conduits 82 may be arranged to extend within the same channel 16 as depicted in Figure 15.
- conduits 82 may be arranged within a space heating conduit 88 of the type depicted in Figure 12.
- the heating fluid e.g. water carried by the conduit 82 may be heated by any known means such as a fossil fuel boiler or a solar collector unit.
- the heating fluid passes through the conduit 82 to heat the panel 12.
- the heat retained within the building panel 12 is given off as radiated heat over a period of time. Additionally, the heat may be distributed by means of a convection current which flows through the space heating conduit 88 as depicted in Figure 11.
- the space heating conduit includes a lower air inlet port 90 and an upper outlet port 91.
- Figure 14 illustrates the form of the space heating conduit 88 which is inserted into one of the channels 16 of the core, prior to casting.
- Figures 16 to 22 illustrate a connecting system which may be used to connect the building panels 12 together.
- the concrete component connecting system has application beyond this and may be used on any suitable precast cementitious components.
- the connecting system 110 in Figure 16 includes a first concrete slab 112, only a portion of which is illustrated in Figure 16.
- Figure 16 depicts an outer periphery 114 of the slab 112. Along the upper edge of the outer periphery 114 is formed a first edge 116 of the slab 112.
- Figure 16 also illustrates a portion of a precast concrete wall component in the form of a panel 118 which defines a second edge 120.
- the second edge 120 is located on the lower periphery of the precast concrete panel 118.
- the second mating edge 120 faces the first edge 116 in the assembled configuration which is illustrated in Figure 17.
- These facing edges 116, 120 are substantially complimentary in profile as described in my Australian patent no 785414, the details of which are incorporated herein by reference.
- the panel 118 incorporates a locking device which includes a locking member 126 disposed at the second edge 120 of the panel 118 and a threaded rod 128 which extends from the locking member 126 at the second edge 120 to a third edge 130 of the slab 118.
- the third edge 130 is opposite the second edge 120.
- the locking member 126 is received in a void former 132 comprised of plastic so that the locking member 126 may be secured relative to the concrete panel 18.
- the locking member 126 is shown in greater detail in Figures 18 to 21 .
- the locking member 126 is in the form of a partly cylindrical shell 134 which is formed with spigots 136 which are rotatable within the plastic void former 132 ( Figure 16).
- the threaded rod 128 is connected to the part-cylindrical shell 134 through a connecting pin 138.
- the connecting pin 138 is disposed further away from the third surface 130 than the spigots 136 so that when the threaded rod 128 is pulled in the upward direction, the part-cylindrical shell 134 will be caused to rotate in a clock-wise direction around the spigots 136.
- the part-cylindrical shell 134 is only one-half or two thirds of a full cylinder, defining a gap 140 in the cylindrical wall which can be most clearly seen in Figure 20. However, in the disposition of Figures 18 and 19, the gap 140 is disposed downwardly so that when the locking member 126 approaches the pin 122, the head of the pin 24 can be received in the gap 140.
- part-cylindrical shell 134 is split, with the opening of this split 142 defined at the edge of the part-cylindrical shell. This enables the two parts of the cylindrical shell on either side of the pin head 124 to engage underneath the head 124 as the shell 134 is rotated. When the connecting pin 138 reaches its uppermost position shown in Figure 20, the part-cylindrical shell 134 will be fully engaged with the head of the pin 124, forming a secure connection.
- a truss support bracket 144 is mounted on the third edge 130 with the threaded rod 128 extending through an aperture 146 in the bracket 144.
- a nut (not shown) is attached to the threaded rod 128 and engages against the support bracket 144, continued turning of the nut will draw the threaded rod 128 in a direction out of the panel 118 to rotate the locking member 126 to the engaged configuration illustrated in Figure 17.
- Figure 22 illustrates a front view of a precast concrete wall panel 118 mounted on a slab 112.
- the precast concrete wall panel 118 is cast with openings defining the windows and doors. Additionally, the panel 118 may be cast so as to simulate overlapping wallboards as shown. Additionally, other joinery elements such as architraves, window sills and doorsills may be simulated in concrete by being precast into the concrete panel 118. The timber joinery such as window frames, windows, door frames and doors may be later installed.
- the wall panel 118 is shown with four locking members 126 which engage with respective pins 122 cast into the slab 112. While the above describes the locking of a wall panel 118 onto a slab 112, this embodiment may also have application to lock two slabs together.
- Figures 23 to 28 illustrated another embodiment of the concrete component connecting system 110' whereby two wall panels 118' and 118" may be connected to each other. However, it could also have application to a wall-slab connection or to the connection of other types of concrete components.
- This embodiment utilises similar components to the first embodiment and like numerals are used to represent like parts. Prime symbols (') are used to indicate where the parts have been modified to adapt to this embodiment.
- the first wall panel 118' is provided with two pins 122 which are located in spaced disposition at intermediate locations along a first edge 116' of the panel 118'.
- the first edge 116' faces a second edge 120' on the other wall panel 118" and the two edges have a complimentary profile as illustrated in Figure 25.
- two locking members 126' At corresponding heights along the second edge 120' are located two locking members 126' which are adapted to receive respective heads 124 of the pins 122 in a similar manner as described in the first embodiment.
- Each of the locking members 126 is connected to the threaded rod 128' by means of two short portions of cable 150 and 152 as shown most clearly in Figures 27 and 28.
- Figures 27 and 28 illustrate the detail of the modified concrete component connecting system 110'.
- the locking members 126' still comprise a part-cylindrical shell 134'.
- the part-cylindrical shell 134' is connected by means of two short cable portions 150 and 152.
- the first cable portion 150 is connected to the perimeter of the cylindrical shell 134' at one edge of the gap 140' formed in the part-cylindrical shell 134' by a swaged connection 154.
- the first cable portion 150 then passes around an upper side of a cable guiding pin 156.
- the first cable portion 150 then passes downwardly to be connected to the threaded rod 128' at a first forged steel sleeve 158.
- the second cable portion 152 is connected to the perimeter of the part-cylindrical shell 134' at the upper edge of the gap 140', where the second cable portion 152 is swaged at 160 as shown.
- the second cable portion 152 then passes under the cable guiding pin 156 and then passes upwardly to be connected to the threaded rod 128' by a second forged steel sleeve 162.
- the second forged steel sleeve 162 is above the first forged steel sleeve 158.
- the threaded rod 128' may be housed in a PVC conduit 164.
- Figure 27 also illustrates the location of the threaded nut 166 at the top of the threaded rod 128'.
- the threaded nut 166 is received within a recess 168 formed in the third edge 130' of the wall panel 118".
- the threaded rod 128' may be drawn upwardly.
- the threaded rod 128' is drawn upwardly, so to are the forged steel sleeves 162 and 158.
- the raising of the second forged steel sleeve 162 will draw the second cable portion 152 to pass underneath the cabling guiding pin 156 and draw the swaged end 160 towards the cable guiding pin 156. This will urge the part-cylindrical shell 134' to rotate about the spigot 136' in the clockwise direction.
- the swaged end 154 of the first cable portion 150 will be drawn in a clockwise direction and the cable 150 will pass over the cable guiding pin 156.
- This passage of the first cable portion 150 is facilitated by the upward movement of the forged steel sleeve 158.
- the part-cylindrical shell 134' will thus adopt the position illustrated in Figure 28.
- the threaded rod 128 may extend through a roofing truss 170 which is placed on top of the third edge 130'.
- the threaded rod 128' may pass through the roofing truss 170 where it is received by another threaded nut 172.
- the threaded nut may be rotated by the use of a hollow tube spanner 174.
- the existence of the threaded rod 128' above the nut 172 can provide evidence of the relative position of the rod 128' and that will provide some indication as to whether or not the part- cylindrical shell 134' has engaged with the locking pin 122.
- the locking member 126' may include an indicator to indicate whether or not the part-cylindrical shell 134' has moved to the locked configuration (See Figure 29).
- the part-cylindrical shell 134' may include a pair of diametrically aligned grooves 180.
- the locking member 126' may include a non- moveable part which is provided with a second pair of diametrically aligned grooves
- the non-moveable part may be provided as part of the plastic void former 132'.
- the part-cylindrical shell 134' is rotated from the unlocked configuration to the locked configuration as shown in the right-hand side of Figure 29, it will be understood that the grooves 180 will align with the grooves 182.
- the alignment of the two pairs of grooves 180, 182 can be visually inspected when an inspection shaft (not shown) is provided in the panel 118", the inspection shaft having a longitudinal axis which aligns with the axis of rotation of the part-cylindrical shell 134'.
- the inspection shaft may comprise simply a cylindrical void extending through the side wall panel 118" to check the position of the part-cylindrical shell 134' and thus verify that engagement with the pin 122 has taken place.
- the inspection shaft may be formed by a PVC conduit which is put in place prior to casting.
- the inspection shaft may also be put to use when one of the locking members
- the locking member 126' fails to engage.
- the locking member 126' may be provided with a hexagonal spigot 184 which may be manually rotated to rotate the part-cylindrical shell 134', in the event that it fails to rotate, due to some malfunction of the concrete component connecting system 110'.
- the inspection shaft may facilitate visual inspection of the locking mechanism or give a tactile indication.
- the inspection shaft may receive an insert (not shown).
- the insert may have a key which engages with the pairs of grooves 180, 182 if and only if they are correctly aligned.
- the insert may be in the form of a plastic plug which remains in the inspection shaft to seal the inspection shaft once the inspection is complete.
- a locking mechanism is also provided at a fourth lower edge 186 of the panel 118".
- the locking mechanism includes a locking member 126".
- This locking member 126" is similar to the locking member 126' in that it uses two cable portions. However, the location of the cable guiding pin 156 is different.
- the locking member 126" engages with a pin 122 provided in slab 112. The locking member 126" can be locked and unlocked as described above in connection with Figures 27 and 28.
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Joining Of Building Structures In Genera (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2008281325A AU2008281325A1 (en) | 2007-08-02 | 2008-07-30 | A building panel and locking device therefor |
US12/671,855 US20110192107A1 (en) | 2007-08-02 | 2008-07-30 | Building panel and locking device therefor |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2007904163 | 2007-08-02 | ||
AU2007904163A AU2007904163A0 (en) | 2007-08-02 | A building panel | |
AU2007904338 | 2007-08-13 | ||
AU2007904338A AU2007904338A0 (en) | 2007-08-13 | Locking device for precast concrete components |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2009015433A1 true WO2009015433A1 (en) | 2009-02-05 |
Family
ID=40303810
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2008/001105 WO2009015433A1 (en) | 2007-08-02 | 2008-07-30 | A building panel and locking device therefor |
Country Status (3)
Country | Link |
---|---|
US (1) | US20110192107A1 (en) |
AU (1) | AU2008281325A1 (en) |
WO (1) | WO2009015433A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA2898002A1 (en) * | 2015-07-22 | 2017-01-22 | James Foley | Trench box and method of assembly |
CA3037062A1 (en) | 2016-09-16 | 2018-03-22 | Osblock Inc. | Structural panel assembly for mounting building walls and method for mounting building walls using same |
US10150138B1 (en) * | 2017-05-16 | 2018-12-11 | Roger Thomas Haag | Interface for inserting bonding material between the joins of two interlocking members |
CA182140S (en) | 2018-06-29 | 2019-04-15 | Osblock Inc | Wall panel |
USD1018901S1 (en) | 2022-04-13 | 2024-03-19 | Osblock Inc. | Block for construction |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2494788A1 (en) * | 1980-11-25 | 1982-05-28 | Mauri Flli Snc | CLAMP FOR ASSEMBLING FLAT RIGHT ANGLE ELEMENTS |
FR2568956A1 (en) * | 1984-08-13 | 1986-02-14 | Fauconnier Michel | Method and its device for assembling panels |
JPH04350232A (en) * | 1990-11-22 | 1992-12-04 | Misawa Homes Co Ltd | Connecting structure for wall panel |
JP2000087436A (en) * | 1998-09-14 | 2000-03-28 | Goto Concrete Kk | Coupling method and separating method for member |
-
2008
- 2008-07-30 AU AU2008281325A patent/AU2008281325A1/en not_active Abandoned
- 2008-07-30 WO PCT/AU2008/001105 patent/WO2009015433A1/en active Application Filing
- 2008-07-30 US US12/671,855 patent/US20110192107A1/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2494788A1 (en) * | 1980-11-25 | 1982-05-28 | Mauri Flli Snc | CLAMP FOR ASSEMBLING FLAT RIGHT ANGLE ELEMENTS |
FR2568956A1 (en) * | 1984-08-13 | 1986-02-14 | Fauconnier Michel | Method and its device for assembling panels |
JPH04350232A (en) * | 1990-11-22 | 1992-12-04 | Misawa Homes Co Ltd | Connecting structure for wall panel |
JP2000087436A (en) * | 1998-09-14 | 2000-03-28 | Goto Concrete Kk | Coupling method and separating method for member |
Also Published As
Publication number | Publication date |
---|---|
AU2008281325A1 (en) | 2009-02-05 |
US20110192107A1 (en) | 2011-08-11 |
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