WO2009033224A1 - Panneau de construction et procédé de formation d'un panneau de construction - Google Patents

Panneau de construction et procédé de formation d'un panneau de construction Download PDF

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Publication number
WO2009033224A1
WO2009033224A1 PCT/AU2008/001354 AU2008001354W WO2009033224A1 WO 2009033224 A1 WO2009033224 A1 WO 2009033224A1 AU 2008001354 W AU2008001354 W AU 2008001354W WO 2009033224 A1 WO2009033224 A1 WO 2009033224A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
building panel
frame
forming
building
Prior art date
Application number
PCT/AU2008/001354
Other languages
English (en)
Inventor
David John O'donnell
Original Assignee
Cilc International Pty Ltd
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 AU2007904930A external-priority patent/AU2007904930A0/en
Application filed by Cilc International Pty Ltd filed Critical Cilc International Pty Ltd
Publication of WO2009033224A1 publication Critical patent/WO2009033224A1/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
    • E04C2/30—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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/0428—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like having a closed frame around the periphery
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/0457—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like having closed internal cavities

Definitions

  • This relates to lightweight building panels which can be used as the floor and/or wall and/or roof and/or ceiling panels of a building.
  • Such panels have generally comprised monolithic elements which can incorporate within their body a frame support structure which is encased within a matrix such as conventional concrete, lightweight concrete, expanded or foamed plastics material.
  • a difficulty with such panels relates to the deterioration that can occur to the frame structure encased within the concrete over a period of time as a result of moisture entering and seeping into the matrix.
  • the panels can also be heavy and thus difficult to handle
  • Alternative arrangements have utilised lightweight expanded or foamed plastics material which is sandwiched between a pair of hard board panels or the like and which in some cases is associated with a supporting frame located between the hardboard panels.
  • Such panels can present a fire risk or at least can present a danger in the event of fire.
  • the present invention resides in a building panel comprising a building frame which has sufficient structural integrity to withstand the anticipated loadings for the panel, the frame having one face overlaid by an outer layer formed of a lightweight concrete which is fixed to the frame, the outer layer being separated from the frame panel by a separation layer, the outer layer being fixed to the frame through fixings which are received through the separation layer.
  • the other face of the panel is adapted to receive a finishing cladding.
  • the separation layer is formed of metal sheeting.
  • the separation panel is formed of a thermal insulating material. According to a preferred feature of the invention the separation panel is formed from an expanded or foamed plastics material.
  • the separation layer is formed from a membrane formed of a plastics material.
  • the plastics membrane is formed with a plurality of closely adjacent closed spaced, fluid filled cells.
  • the separation layer comprises at least two membranes separated by a plurality of closely adjacent, closed spaced, fluid filled cells.
  • the outer layer incorporates reinforcing.
  • the reinforcing comprises a mesh.
  • the reinforcing is fixed to the frame by said fixings.
  • the outer layer comprises a cellular panel which is fixed to the frame said cellular panel being formed of an open cellular matrix which is filled with said lightweight concrete.
  • the open cellular matrix is formed of a plastics material.
  • the open cellular matrix is formed with closely adjacent cells which are open to at least the outer face of the cellular panel.
  • the open cellular matrix is formed with closely adjacent cells which are open to each other.
  • the panel is intended in use to be used as a wall and/or ceiling panel.
  • the panel is intended to be used as a floor panel.
  • the frame includes a truss like structure.
  • the invention resides in a method of forming a building panel comprising forming a substantially planar frame which has sufficient structural integrity to withstand the anticipated loadings for the panel; locating the frame substantially horizontal, defining a mould space above the upper face of the frame which has a perimeter substantially corresponding to the perimeter of the frame, locating a separation panel across the base of the moulding space to cover the upper face, introducing a lightweight concrete into the mould, screeding the lightweight concrete to form an outer layer and allowing the concrete to harden, the method including applying fixings between the outer layer and the frame, said fixings being received through the separation layer.
  • a finishing cladding is applied to the other face of the.
  • the separation layer is formed of metal sheeting. According to a preferred feature of the invention the separation layer is formed from a membrane formed of a plastics material. According to a preferred feature of the invention the separation panel is formed of a thermal insulating material. According to a preferred feature of the invention the separation panel is formed from an expanded or foamed plastics material. According to a preferred feature of the invention the plastics membrane is formed with a plurality of closely adjacent closed closely spaced fluid filled cells. According to a preferred feature of the invention the separation layer comprises at least two membranes separated by a plurality of closely adjacent, closed spaced, fluid filled cells.
  • reinforcing is introduced into the moulding space prior to the introduction of the lightweight concrete.
  • the reinforcing comprises a mesh. According to a preferred feature of the invention the reinforcing which is fixed to the frame prior to the introduction of the lightweight concrete by said fixings.
  • the reinforcing is supported in spaced relation from the separation layer within the moulding space.
  • the separation layer is covered by at least one cellular panel which is fixed to the frame prior to the introduction of the lightweight concrete by said fixings, said cellular panel being formed of an open cellular matrix which is to be filled with said lightweight concrete.
  • the open cellular matrix is formed of a plastics material.
  • the open cellular matrix is formed with closely adjacent cells which are open to at least the outer face of the cellular panel.
  • in the open cellular matrix is formed with closely adjacent cells which are open to each other.
  • the frame includes a truss-like structure.
  • Figure 1 is a schematic side elevation of a mould accommodating a frame according to the first embodiment with the separation panel in position;
  • Figure 2 is a schematic section elevation of the mould of Figure 1 with the open cellular matrix material in position;
  • Figure 3 is a schematic section elevation of the mould of Figure 2 with the open cellular matrix panel in position;
  • Figure 4 is a schematic sectional elevation of a panel according to the first embodiment formed from the mould of figures 1 , 2 and 3;
  • Figure 5 is a part sectional isometric view of the panel according to the first embodiment.
  • Figure 6 is a schematic sectional elevation of a panel according to the second embodiment formed from the mould.
  • Each of the embodiments relates to building panels which can be utilised in the construction of a building which can be used as a floor panel or a wall panel, or a ceiling panel.
  • the panel according to the first embodiment as shown in Figures 4 and 5 is intended as a wall or ceiling panel and comprises a frame 11 which comprises a stud frame similar to those used in frame building constructions and which is formed of an appropriate channel section formed of steel sheet.
  • a frame 11 which comprises a stud frame similar to those used in frame building constructions and which is formed of an appropriate channel section formed of steel sheet.
  • One face of the frame 11 supports separation panel 13 which is formed of an expanded polystyrene foam.
  • the separation panel is overlaid by a layer 15 of lightweight concrete which accommodates an open cellular plastic matrix panel 17 which is fixed to the frame 11 by fixings 19 which extend between open cellular plastic matrix panel 17 and the frame 11.
  • the open cellular panel which is formed of a suitable plastics material is one which is used conventionally in water drainage and is formed with an apertured upper and lower face which are held in spaced relation by a set of spaced apertured webs to form a set of cells whereby communication is also open across the panel and between the cells.
  • a suitable plastics material is one which is used conventionally in water drainage and is formed with an apertured upper and lower face which are held in spaced relation by a set of spaced apertured webs to form a set of cells whereby communication is also open across the panel and between the cells.
  • VERSICELL VERSICELL
  • the lightweight concrete which is utilised with the invention comprises concrete intermixed with expanded polystyrene granules and/or beads.
  • the method of forming the panel comprises initially forming the frame 11 , positioning the frame such that it is horizontal creating a moulding space above a the upper face of the frame by a set of side boards 21 such that the frame defines the base of the moulding space and the sides of the moulding space extend above the frame.
  • the frame is then overlaid by a separation panel 13 as shown at Figure 1.
  • the separation panel comprising a panel formed of an expanded polystyrene foam.
  • the separation panel is then overlaid by a panel or plurality of panels 17 formed of the open cellular matrix which are located in position over the separation panel 13 to fully cover the separation panel 13.
  • the cellular matrix panels 17 are fixed to the frame 11 by suitable fixings 19 whereby the fixings 19 pass through the separation panel as shown at Figure 2.
  • a lightweight concrete mixture incorporating expanded polystyrene granules is then poured into the mould cover the open cellular matrix and to fill the cells within the open cellular matrix 17.
  • the upper face of the concrete can then be screeded and/or textured as desired provide the desired external finish and to define the outer later 15 over the separation layer as shown at Figure 3.
  • the concrete is then allowed to harden and when satisfactorily hardened the composite panel is removed from the mould.
  • the other face of the building panel can have a cladding 27 of the form marketed under the trade mark GYPROCK applied to it subsequent to the moulding of the other layer or prior to the moulding of the other layer.
  • the embodiment provides a building panel with the structural capacity of conventional building frame but one which also has the high thermal insulating carrying capacities as a result of the lightweight concrete panel which is fixed to the frame.
  • the presence of the separation panel serves to provide for relative expansion and contraction of the frame relative to the overlying concrete panel without causing cracking and/or the creation of zones of weakness between the frame and the outer layer.
  • the second embodiment as shown at Figure 5 is intended for use as a floor panel and corresponding components to those of the first embodiment are given the same reference numerals in Figure 5.
  • the frame 11 incorporates a truss-like structure to be able to take the additional loadings anticipated for a floor panel.
  • the separation panel is formed of metal sheeting which has a similar a profile to that form of sheeting which is used as roof cladding.
  • the layer of light weight concrete 15 incorporates a reinforcing mesh 23 which is supported from the separation panel by suitable chairs 25 before the lightweight concrete is introduced into the mould.
  • the formation of the panel is similar to that of the first embodiment.
  • the third embodiment of the invention is a variation of the first and second embodiments and involves the replacement of the panel of expanded polystyrene foam as the separation layer by a material in the form of a plastics membrane which incorporates a separated by a plurality of closely adjacent, closed spaced, fluid filled cells.
  • a material in the form of a plastics membrane which incorporates a separated by a plurality of closely adjacent, closed spaced, fluid filled cells.
  • An example of such a material comprises one in which at least two layers of a plastics membrane are separated by a plurality of closely adjacent, closed spaced, fluid filled cells.
  • One such material is marketed under the trade mark AIR-CELL.
  • the panels In forming the panels they can be preformed to accommodate access ways such as doorways windows ventilation ducts and the like.
  • the panels according to the embodiments can be formed of materials which have been recycled and which are mainly recyclable in that steel frame can be formed of a recycled steel, the open cellular matrix material can be formed of a recycled plastics, and the lightweight expanded polystyrene granules and/or beads can be provided by recycling expanded polystyrene materials which have been granulated.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Panels For Use In Building Construction (AREA)
  • Building Environments (AREA)

Abstract

L'invention porte sur un panneau de construction comprenant un bâti de construction (11) qui présente une intégrité structurale suffisante pour résister aux changements anticipés du panneau, le bâti comportant une face recouverte par une couche externe (15) formée d'un béton léger qui est fixé au bâti, la couche externe étant séparée du panneau de bâti par une couche de séparation (13), la couche externe étant fixée au bâti par des dispositifs de fixation qui sont reçus à travers la couche de séparation.
PCT/AU2008/001354 2007-09-11 2008-09-11 Panneau de construction et procédé de formation d'un panneau de construction WO2009033224A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2007904930A AU2007904930A0 (en) 2007-09-11 Building Panel and Method of Formation
AU2007904930 2007-09-11

Publications (1)

Publication Number Publication Date
WO2009033224A1 true WO2009033224A1 (fr) 2009-03-19

Family

ID=40451482

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2008/001354 WO2009033224A1 (fr) 2007-09-11 2008-09-11 Panneau de construction et procédé de formation d'un panneau de construction

Country Status (1)

Country Link
WO (1) WO2009033224A1 (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1330351A (fr) * 1962-05-17 1963-06-21 H H Robertson Holdings Ltd Perfectionnement à la construction des planchers
GB1173769A (en) * 1965-12-27 1969-12-10 Hoechst Ag Walls Comprising Building Slabs Clad with Cover Sheets
GB1377201A (en) * 1972-02-24 1974-12-11 Williams F Wall panel for use in building construction
US3956864A (en) * 1974-12-30 1976-05-18 Westeel-Rosco Limited Composite structural assembly
US4525965A (en) * 1982-02-10 1985-07-02 Artcraft Panels, Inc. Prefabricated building panels
EP0102120B1 (fr) * 1982-08-23 1988-03-30 Beheermaatschappij H.D. Groeneveld B.V. Plancher pour l'utilisation dans la technique marine et la construction navale
US20060144005A1 (en) * 2004-12-30 2006-07-06 United States Gypsum Company Non-combustible reinforced cementitious lightweight panels and metal frame system for flooring

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1330351A (fr) * 1962-05-17 1963-06-21 H H Robertson Holdings Ltd Perfectionnement à la construction des planchers
GB1173769A (en) * 1965-12-27 1969-12-10 Hoechst Ag Walls Comprising Building Slabs Clad with Cover Sheets
GB1377201A (en) * 1972-02-24 1974-12-11 Williams F Wall panel for use in building construction
US3956864A (en) * 1974-12-30 1976-05-18 Westeel-Rosco Limited Composite structural assembly
US4525965A (en) * 1982-02-10 1985-07-02 Artcraft Panels, Inc. Prefabricated building panels
EP0102120B1 (fr) * 1982-08-23 1988-03-30 Beheermaatschappij H.D. Groeneveld B.V. Plancher pour l'utilisation dans la technique marine et la construction navale
US20060144005A1 (en) * 2004-12-30 2006-07-06 United States Gypsum Company Non-combustible reinforced cementitious lightweight panels and metal frame system for flooring

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