WO2009087593A2 - Procédé de construction d'un agencement de paroi, agencement de paroi, et système de paroi modulaire - Google Patents

Procédé de construction d'un agencement de paroi, agencement de paroi, et système de paroi modulaire Download PDF

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Publication number
WO2009087593A2
WO2009087593A2 PCT/IB2009/050031 IB2009050031W WO2009087593A2 WO 2009087593 A2 WO2009087593 A2 WO 2009087593A2 IB 2009050031 W IB2009050031 W IB 2009050031W WO 2009087593 A2 WO2009087593 A2 WO 2009087593A2
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WO
WIPO (PCT)
Prior art keywords
wall
wall system
core
post
panel
Prior art date
Application number
PCT/IB2009/050031
Other languages
English (en)
Other versions
WO2009087593A3 (fr
Inventor
Johan Leonard Human
Original Assignee
Imison (Proprietary) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Imison (Proprietary) Limited filed Critical Imison (Proprietary) Limited
Publication of WO2009087593A2 publication Critical patent/WO2009087593A2/fr
Publication of WO2009087593A3 publication Critical patent/WO2009087593A3/fr

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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
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • 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
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/165—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with elongated load-supporting parts, cast in situ
    • 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

  • THIS INVENTION relates to a method of constructing a wall arrangement, to a modular wall system suitable for use in the method, and to a wall arrangement.
  • a method of constructing a wall arrangement including: constructing, in situ, a core of a wall arrangement from a modular wall system comprising a plurality of prefabricated core elements, the core elements including at least one wall panel including a substantially rectangular body defining two operatively vertically disposed opposite side edges, an operative top edge, an operative bottom edge, and two opposite faces, these faces forming part of a plurality of vertical faces of the core; and spray-applying to at least some of the faces of the core, including at least one of the faces of the wall panel, a cementitious material base slurry to form a base rendering layer.
  • the spray-applying may be performed using a spray applicator apparatus of a known type.
  • a spray applicator apparatus of a known type.
  • One such applicator is disclosed in Republic of South Africa Patent No. 2003/5932.
  • the base slurry may have a cement:sand ratio of not below 1 :4.
  • the base slurry may have a cement:sand ratio of between 1 :3 and 1 :4.
  • the base slurry may have a watercement ratio of less than 0.45.
  • the base slurry may include an admixture for enhancing sprayability.
  • the admixture may be one of a polymer and a plasticizer.
  • the weight of the admixture may be between 0.5% and 2% of the weight of the cement.
  • the base rendering layer may have a thickness of between 4mm and 10mm.
  • the base slurry may include aggregate.
  • the method may include partially penetrating some of the aggregate into the core by the spray-applying to enhance bonding between the base rendering layer and the core. This will clearly only apply in the case of the core defining a face made of a material, e.g. expanded polystyrene, permitting penetration into it of sand or aggregate in the slurry for the base rendering layer.
  • the combination of the sand e.g. an angular grained sand such as one sometimes referred to as "sharp sand”
  • aggregate type e.g. an angular grained sand
  • the spray velocity is selected so as to ensure penetration of some of the sand or aggregate into a face of the core during spray- application. Such penetration causes mechanical bonding between the base rendering layer and the core, in addition to chemical bonding by the cement in the layer.
  • the method may include applying over the base rendering layer cementitious material cover slurry to define at least one cover rendering layer.
  • the cover slurry may have a cement:sand ratio of between 1 :4 and 1 :5.
  • the cover slurry may be applied by means of a suitable spray applicator apparatus.
  • the cover slurry may include a water retentive agent.
  • the water retentive agent may be between 4Og and 15Og polypropylene fibres per 50kg cement.
  • the method may include providing a reinforcement mesh in the cover rendering layer.
  • the reinforcement mesh may be one of a steel mesh, a woven polypropolene mesh, and a woven glassfibre strand mesh.
  • the at least one cover rendering layer may include a final rendering layer having a cement:sand ratio of between 1 :5 and 1 :7.
  • the at least some of the faces of the core may include two such faces on opposite sides of the core so that the spray-applying defines two opposite base rendering layers.
  • the method may include providing an arrangement of tie means, each extending through the core, to bind the opposite base rendering layers together.
  • the method may include defining two opposite grooves in the respective opposite faces and filling the grooves with rendering to define opposite reinforcing bands in the respective grooves.
  • the grooves may be dovetail grooves.
  • the method may include encapsulating reinforcement in the rendering in each groove.
  • the reinforcement may be one of a steel mesh strip and a woven alkali resistant glass fibre mesh strip.
  • the method may include installing a ring beam, supported on the core.
  • the body of the wall panel may be made of a material having a density of below 500kg/m 3 .
  • the body of the wall panel may be made of a synthetic polymeric material.
  • the synthetic polymeric material may be one of expanded polystyrene and extruded polystyrene.
  • the body of the wall panel may be factory cut into a required shape using suitable cutting equipment.
  • the body of the wall panel may include a lower body part and an upper body part, the two body parts defining between them an operatively horizontally disposed joint.
  • the body may be a single piece unit.
  • the body of the wall panel may define along at least a part of the length of each of its opposite side edges an interlock formation for operatively providing interlock of the edge with an adjacent core element.
  • Each interlock formation may define a laterally open groove, the wall system including an elongate jointing member of which one side is receivable in the groove in a configuration in which the other side projects from the groove and is receivable in such a groove defined by the adjacent core element.
  • the body of the wall panel may define, in at least one of its faces, two opposite recesses, each extending along at least a part of the length of one of its opposite side edges, for receiving a side half of a reinforcement strip for operatively bridging a joint with an adjacent core element.
  • the wall panel may include at least one column member, which is received within a passage defined in the body of the panel, which is disposed parallel to and spaced apart from both side edges, and which extends at least substantially between the operative top and operative bottom edges of the body.
  • the column member may be a concrete element.
  • the column member may be a steel element.
  • the passage may be between and spaced apart from the opposite faces of the body of the wall panel.
  • the column member, where provided, of the wall panel may define at its operative top securing means for securing to another structural member.
  • the column member may, alternatively or additionally, define at its operative bottom securing means for securing to another structural member.
  • the at least one column member of the wall panel may include two spaced apart column members.
  • the wall panel may define along its operative top edge a recess or groove for accommodating a length of ring beam.
  • the core elements may include a first type post, the first type post including a body defining a side edge extending along a height of the first type post and the side edge defining an interlock formation for operatively providing interlock with an adjacent core element.
  • the first type post may include at least one column member received in a groove defined along an opposite side edge of the body of the first type post.
  • the column member of the first type post may be one of a concrete element and a steel element.
  • the body of the first type post may be made of a synthetic polymeric material.
  • the core elements may include a T-post including a body defining a generally T-shaped cross-section and three side edges, each extending along an operative height of the body and defining along its length an interlock formation for operatively providing interlock with an adjacent core element.
  • the T-post may include at least one column member received within a passage defined in its body.
  • the column member of the T- post may be one of a concrete element and a steel element.
  • the body of the T-post may be made of a synthetic polymeric material.
  • the core elements may include an L-post including a body defining a generally L- shaped cross-section and two side edges, each extending along a height of the body and defining along its length an interlock formation for operatively providing interlock with an adjacent core element.
  • the L-post may include at least one column member received within a passage defined in its body.
  • the column member of the L-post may be one of a concrete element and a steel element.
  • the body of the L-post may be made of a synthetic polymeric material.
  • the core elements may include an upper infill panel for spanning over an opening, the upper infill panel including a generally rectangular body defining an operative bottom edge for operatively defining an upper boundary of an opening.
  • the upper infill panel may include a lintel in its operative bottom edge.
  • the core elements may include a window infill panel for underlying a window, the window infill panel including a generally rectangular body defining an operative top edge, for operatively defining a lower boundary of a window opening, and an operative bottom edge.
  • the window infill panel may include a sill element in the operative top edge.
  • a wall arrangement constructed in accordance with the method of the first aspect of the invention.
  • the wall system including a plurality of prefabricated core elements, the core elements including at least one wall panel including: a core comprising a plurality of prefabricated core elements, the core elements including at least one wall panel including a substantially rectangular body defining two operatively vertically disposed opposite side edges, an operative top edge, an operative bottom edge, and two opposite faces; and at least one column member, which is received within a passage defined in the body, which is disposed parallel to and spaced apart from both side edges, and which extends at least substantially between the operative top and operative bottom edges.
  • the core elements of the wall system of the third aspect of the invention may include, in addition to the wall panel, also other core elements such as at least one of a first type post, a T-post, an L-post, an upper infill panel, and a window infill panel, essentially as defined above in relation to the method of the first aspect of the invention.
  • core elements may be as defined above in relation to the method of the first aspect of the invention and such definition does not warrant repetition here.
  • a wall arrangement including: a core constructed from a modular wall system, in accordance with the third aspect of the invention; and a cementitious material base rendering layer applied to each of a plurality of vertical faces of the core.
  • the wall arrangement may include at least one cementitious material base rendering layer applied to the base rendering layer.
  • Figures 1 a, 1 b, and 1 c show three axonometric views of an embodiment of a wall panel, which is a core element of a modular wall system, in accordance with the third aspect of the invention, suitable for use in a method of constructing a wall arrangement, in accordance with the first aspect of the invention;
  • Figures 2a, 2b, and 2c show, respectively, an axonometric view, a side view, and a top view of a lower body part of the wall panel of Figure 1 ;
  • Figures 3a, 3b, and 3c show, respectively, an axonometric view, a side view, and a top view of an upper body part of the wall panel of Figure 1 ;
  • Figures 4a and 4b show, respectively, an axonometric view and a cross-section of a column member of the wall panel of Figure 1 ;
  • Figures 5a and 5b show, respectively, an axonometric view and a cross-section of a column member, which is an alternative to that of Figures 4;
  • Figures 6a, 6b, and 6c show three axonometric views of a wall panel, which is an alternative to that of Figures 1 ;
  • Figures 7a and 7b show two exploded axonometric views of a window panel including core elements of the wall system, the core elements including two first type posts, a window infill panel, and an upper infill panel;
  • Figure 8 shows an assembled axonometric view of the window panel of Figures 7;
  • Figure 9 shows an assembled axonometric view of a door panel including core elements similar to those of the window panel of Figure 8, except the window infill panel;
  • FIG. 10 shows an axonometric view of a T-post, which is a core element of the wall system
  • Figures 1 1 a and 1 1 b show an axonometric view and a top view, respectively, of a lower body part of the body of Figure 10;
  • Figures 12a and 12b show an axonometric view and a top view, respectively, of an upper body part of the body of Figure 10;
  • Figure 13 shows an axonometric view of an L-post, which is a core element of the wall system;
  • Figures 14a and 14b show an axonometric view and a top view, respectively, of a lower body part of the body of Figure 13;
  • Figures 15a and 15b show an axonometric view and a top view, respectively, of an upper body part of the body of Figure 13;
  • Figure 16 shows an exploded axonometric view of an arrangement including core elements of the wall system, including three wall panels, as shown in Figure 1 , and a T- post, as shown in Figure 10, the arrangement including also a floor slab (partially shown) and ring beam elements;
  • Figure 17 shows an axonometric assembled view of the wall system of Figure 16;
  • Figures 18, 19, and 20 show construction steps in a method, in accordance with the first aspect of the invention, of constructing a wall arrangement, in accordance with both the second aspect and fourth aspect of the invention, the method including the use of core elements of the wall system and applying rendering;
  • Figure 21 shows a partial section at XXI-XXI in Figure 20
  • Figure 22 shows a partial section at XXII-XXII in Figure 20;
  • Figure 23 shows a partial section at XXI N-XXI 11 in Figure 20;
  • Figure 24 shows an axonometric assembled view of an arrangement including a floor slab (partially shown), ring beam elements, and a wall system, in accordance with the third aspect of the invention, the system including two wall panels, as shown in Figure 1 , a T-post as shown in Figure 10, and a first type post as shown in Figures 7;
  • Figure 25 shows a detail of fixing of a column member of the wall panel of Figure 1 to the floor slab of Figure 16;
  • Figure 26 shows an axonometric view of a further embodiment of a wall panel, which is a core element of a wall system, in accordance with the third aspect of the invention, suitable for use in a method of constructing a wall arrangement, in accordance with the first aspect of the invention;
  • Figure 27 shows an axonometric exploded view of the wall panel of Figure 26;
  • Figure 28 shows a top view of the wall panel of Figure 27;
  • Figure 29 shows an axonometric view of a T-post, which is a core element of the last-mentioned wall system
  • Figure 30 shows a top view of the T-post of Figure 29
  • Figure 31 shows an axonometric view of an L-post, which is a core element of the last-mentioned wall system
  • Figure 32 shows a top view of the L-post of Figure 31 ;
  • Figure 33 shows an exploded axonometric view of an arrangement including core elements of the last-mentioned wall system, including three wall panels, as shown in Figure 26, and a T-post as shown in Figure 29, the arrangement including also a floor slab (partially shown) and reinforcement bars for a ring beam;
  • Figure 34 shows an axonometric assembled view of the arrangement of Figure
  • Figure 35 shows an exploded axonometric view of an arrangement including another wall system, in accordance with the third aspect of the invention, including three core elements in the form of wall panels, and a matching T-post, the arrangement including also a floor slab (partially shown) and reinforcement bars for a reinforced concrete ring beam;
  • Figure 36 shows an axonometric assembled view of the arrangement of Figure 35;
  • Figures 37a and 37b show an operative side view and an operative top view, respectively, of another embodiment of a wall panel, which is a core element of a wall system, in accordance with the third aspect of the invention
  • Figure 38 shows an axonometric view of an arrangement including another embodiment of a wall system, in accordance with the third aspect of the invention, including three wall panels, as shown in Figures 37a and 37b, a matching T-post, and a cast concrete ring beam, the arrangement including also a floor slab (partially shown) and ring beam elements;
  • Figures 39a and 39b show two axonometric views of another embodiment of a wall panel, which is an embodiment of a wall system, in accordance with the third aspect of the invention
  • Figures 40a and 40b show two axonometric views of yet another embodiment of a wall panel, which is a core element of a wall system, in accordance with the third aspect of the invention
  • Figures 41 a and 41 b show two axonometric views of a T-post, which is a core element of a wall system, in accordance with the third aspect of the invention
  • Figures 42a and 42b show two axonometric views of an L-post, which is a core element of a wall system, in accordance with the third aspect of the invention
  • Figure 43a and 43b show an exploded axonometric view and an assembled axonometric view, respectively, of a door panel comprised of core elements of a wall system, in accordance with the third aspect of the invention, the door panel including a steel lintel;
  • Figures 44a and 44b show an exploded axonometric view and an assembled axonometric view, respectively, of a door panel which is an alternative to that of Figures 43;
  • Figures 45a and 45b show an exploded and an assembled bottom axonometric view of a window panel which is comprised of core elements of a wall system, in accordance with the third aspect of the invention.
  • Figure 46 shows a partial section of a wall of a wall arrangement constructed in accordance with the method of the first aspect of the invention, showing partial penetration of aggregate in a rendering layer into a face of a core element of the wall arrangement.
  • a wall panel which is a core element of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 10.
  • the wall panel 10 includes a substantially rectangular body 12, comprising a lower body part 14.1 , an upper body part 14.2, and a column member 16.
  • the body 12 is made of a synthetic polymeric material, say expanded polystyrene. It has a density of, say, 200kg/m 3 .
  • a body similar in shape to the body 12 may be a single piece body instead of a two-piece body.
  • size limitations of expanded polystyrene cutting equipment may induce opting for a two-piece body.
  • Expanded polystyrene was selected for the lower body part 14.1 and the upper body part 14.2 inter alia for its light weight, good thermal insulation properties, ease of cutting, and low cost.
  • the bodies may be made of any other suitable material, e.g. extruded polystyrene, but typically a material having a density of less than 500kg/m 3 , inter alia for ease of handling.
  • the wall panel 10 typically is factory assembled, i.e. prefabricated.
  • the body 12 defines two operatively vertically disposed opposite side edges 18, an operative top edge 20, and an operative bottom edge 22.
  • the body 12 defines along each of its side edges 18 a groove 26, thus defining interlock formations providing for interlock with an adjoining core member via a jointing member, as will be described below.
  • the body 12 defines two opposite faces 24.1 and 24.2.
  • face 24.1 it defines the following grooves, of which the purpose will be revealed in the remainder of this description: a shallow central dovetail groove 28, say 10mm deep, parallel to the side edges 18; a shallow central dovetail groove 30, say 10mm deep, perpendicular to the side edges 18; two opposite shallow half dovetail grooves or recesses 32 along the respective edges 18; and a deep central groove 34 along the operative top edge 20.
  • the body 12 defines an arrangement of grooves mirroring that defined in the face 24.1 , as described above.
  • the body 12 also defines therethrough an operatively vertically disposed central passage (see reference numeral 36 in Figures 2c and 3c), accommodating the column member 16 in a snug sliding fit.
  • the lower body part 14.1 defines along an operative top edge thereof an interlock formation in the form of a tongue 38.
  • the cross- section of a passage 36 defined through the lower body part 14.1 is clearly visible in Figure 2c.
  • the upper body part 14.2 defines, along an operative bottom edge thereof, a tapered groove 40, complementary to the tongue 38 shown in Figure 2a, and, along its operative top edge, the groove 34.
  • the column member 16 is a composite member including two cold rolled steel studs 42, secured to each other by suitable welding, or mechanical fixings, e.g. self drilling self fixing screws or rivets, in a back-to-back arrangement.
  • a column member which can serve as an alternative to the column member 16, is designated generally by the reference numeral 44.
  • the column member 44 comprises a cold rolled steel channel 46 and a cold rolled steel stud 48 secured together by welding or mechanical fixings e.g. self drilling self fixing screws or rivets, to define a boxed section.
  • Such a column member can serve in a wall panel equivalent to the wall panel 10 of Figures 1 , but having a passage defined through its body shaped for receiving the element 44 in a snug sliding fit.
  • a wall panel that can serve as an alternative to the wall panel 10 of Figures 1 is designated generally by the reference numeral 50.
  • the wall panel 50 includes certain features that are similar to those of the wall panel 10 of Figures 1 . A description of similar features will generally not be repeated here and such features, where designated here, are designated again by the same reference numerals as before.
  • the wall panel 50 has dual, spaced apart column members 16, each at approximately a quarter width of the wall panel 50 from a side edge thereof.
  • the number of such column members in a wall panel will be determined by load bearing capacity requirements.
  • the element 16 has secured to its operative top securing means in the form of two steel hoops 52 and to its operative bottom securing means in the form of a foundation fixing bracket 54.
  • a window panel of a wall system in accordance with the third aspect of the invention, is designated generally by the reference numeral 57.
  • the window panel 57 includes two first type posts, each being a core element of the wall system and designated generally by the reference numeral 58.
  • the first type posts 58 are identical and one of them will now be described.
  • the first type post 58 includes an expanded polystyrene body 60, comprised of a lower body part and an upper body part, defining a side edge 61 .
  • the side edge 61 has a groove 26 defined therein, identical to the groove 26 of the wall panel 10 of Figure 1 .
  • the side edge 61 thus defines an interlock formation identical to and compatible with that of the wall panel 10 of Figures 1 .
  • the first type post 58 defines along an opposite edge thereof a dovetail groove into which a column member 64 has been precast.
  • the window panel 57 includes also an upper infill panel, which is a core element of the wall system, designated generally by the reference numeral 66.
  • the upper infill panel 66 is for spanning over an opening, which may be either a window or a door opening.
  • the upper infill panel 66 includes a generally rectangular expanded polystyrene body 68 defining an operative bottom edge 70, operatively defining an upper boundary of an opening. Within edge 70, the body 68 defines a dovetail groove within which a reinforced concrete lintel 71 has been precast.
  • the infill panel 66 includes certain further features that are similar to those of the wall panel 10 of Figures 1 . A description of similar features will generally not be repeated here and such features, where designated here, are designated again by the same reference numerals as before.
  • the window panel 57 includes also a window infill panel, which is a core element of the wall system, designated generally by the reference numeral 72.
  • the window infill panel 72 includes an expanded polystyrene body 73 defining an operative top edge 74 which has a dovetail groove defined along its length and which has a concrete sill element 76 precast into the groove.
  • Figures 7 also show certain jointing members 78, made of expanded polystyrene, which fit into the respective grooves 26, as will be shown subsequently.
  • an assembled arrangement of the core elements shown in Figures 7 defines the window panel 57.
  • the window panel 57 defines a window 82 and is interchangeable with the wall panel 10 of Figure 1 .
  • an assembled arrangement of core elements defines a door panel, designated generally by the reference numeral 84.
  • the door panel 84 includes an upper infill panel 66 and two first type posts 58.
  • the upper infill panel 66 and the first type posts 58 are identical to those of the window panel 57 of Figure 8, as described above, and are not described again.
  • the door panel 84 defines a door opening 86.
  • the door panel 84 is also interchangeable with the wall panel 10 of Figure 1 .
  • a T-post which is a core element of the wall system, is designated generally by the reference numeral 87. It includes a body 88, comprising a lower body part 90.1 and an upper body part 90.2, both made of expanded polystyrene.
  • the body 88 defines three side edges 18 identical to the side edges 18 of the wall panel 10 of Figure 1 . It defines also at its operative top two grooves 34, in a T-arrangement, each corresponding to the groove 34 of the wall panel 10 of Figure 1 .
  • the lower body part 90.1 defines at its top a T- shaped tongue arrangement 92, which fits snugly into a complementary groove arrangement (not clearly shown) defined at the operative bottom end of the upper body part 90.2 to make up the body 88.
  • the lower body part 90.1 defines therethrough also two passages 36, each identical in cross-section to the passage 36 of the wall panel 10 of Figure 1 .
  • the upper body part 90.2 defines therethrough two passages 36 corresponding to those of the lower body part 90.1 of Figures 1 1 .
  • the T-post 87 includes also two column members such as the column member 16 (see Figures 4) that have been slid into the respective two passages 36 (see Figures 1 1 b and 12b) defined through the body 88.
  • an L-post which is a core element of a wall system in accordance with the third aspect of the invention, is designated generally by the reference numeral 94. It includes a body 96, comprising a lower body part 98.1 and an upper body part 98.2, both made of expanded polystyrene.
  • the lower body part 98.1 is shown in more detail in Figures 14a and 14b and the upper body part 98.2 in Figures 15a and 15b.
  • L-post 94 Further features of the L-post 94 are analogous to those of the T-post 87 of Figure 10 and, as such, are not described in detail herein. Suffice it to say that, in the L-post 94, two column members such as the column member 16 (see Figures 4) are received the respective passages 36 (see Figures 14b and 15b) to define the L-post.
  • a wall system in accordance with the third aspect of the invention, is designated generally by the reference numeral 100 and includes: three wall panels 10; the T-post 87 of Figure 10, including two column members 16; expanded polystyrene jointing members 78; ring beam elements in the form of steel channel elements104; and ring beam connectors 106.
  • steel channel elements 104 may be used, e.g. I-beam elements.
  • the wall system 100 is to be assembled on a floor slab 108, which is partially shown. It is particularly to be assembled as a part of a bigger wall arrangement, the remainder of which is not shown. Such an arrangement typically will include also L-posts 94, as shown in Figure 13, and two column members 16 as shown in Figures 4.
  • each of the jointing members 78 is received within a passage (see Figure 24) defined at a joint defined between an edge of a wall panel 10 and an adjoining edge of the T-post 87, thus interlocking the two edges (see Figure 22).
  • the respective channel elements 104 have been interconnected via the ring beam connectors 106 via rivets or self drilling self fixing screws 1 10, of which only some are shown. As such, the channel elements 104 and the connectors 106 now define a ring beam arrangement 1 12.
  • the ring beam arrangement 1 12 has been sunk into the arrangement of grooves 34 defined along the operative top edges of the wall panels 10 and the T-post 87.
  • the ring beam arrangement 1 12 is tied to the respective column members 16 of the panels 10 via the hoops 52. Some hoops 52 are still standing upright and are reserved for securing roof elements to the column members 16.
  • the column members 16 are secured to the floor slab 108 via their brackets 54 (see Figure 1 b).
  • the wall system 100 clearly now defines, between each two adjacent core elements, a vertical dovetail groove 1 14 comprised of two half dovetail grooves of the abutting core elements.
  • a suitable rendering material in this example a fibre reinforced cementitious rendering material having a fibre length of 19mm, but this length may be varied.
  • a grid of reinforced cementitious material bands is formed on each face defined by the wall arrangement, including: horizontal bands 122 in the grooves 30, at mid-height of the wall panels; vertical bands 124 in the grooves 28 centrally in the wall panels 10; and vertical bands 126 in the grooves 1 14 across the joints between adjoining core elements.
  • Each of the bands 122, 124, and 126 has a mirror image counterpart on the opposite face of the core element concerned. These serve as reinforcing bands resisting bending of the respective walls, as will become apparent below.
  • reinforcing bands 122, 124, and 126 may significantly increase the bending resistance of walls including the wall system 100, including its resistance to lateral forces. Such reinforcing bands may as well be used with other types of wall systems including lightweight core elements.
  • a reinforcement mesh 129 made of woven polypropolene or of woven glassfibre strand mesh with an alkali-resistant coating, is placed against the base rendering layer 128.
  • a cover rendering layer 130 made of a cover slurry in the form of a cementitious fibre reinforced material, is applied to the layer 128 and encapsulates the mesh 129.
  • a cover rendering layer which is a final rendering layer, 132, made of a cover slurry in the form of a cementitious fibre reinforced material, is applied to the layer 130.
  • the base rendering layer 128 is applied as a slurry using a suitable spray applicator apparatus, the slurry preferably having a cement:sand ratio of between 1 :3 and 1 :4.
  • the spray applicator apparatus may be of a known type, e.g. that disclosed in Republic of South Africa Patent No. 2003/5932.
  • the slurry may have a watercement ratio of less than 0.45.
  • coarse sand is used, e.g. sand sometimes referred to as "sharp sand".
  • the combination of the sand type or aggregate type and the spray velocity is selected so as to ensure partial penetration of some of the sand or aggregate into the face during spray- application. Such penetration of the sand or aggregate into the face causes mechanical bonding between the base rendering layer and the core, in addition to chemical bonding by the cement in the layer.
  • the base rendering layer 128 in this example has a thickness of between 6mm and 8mm.
  • Such partial penetration of aggregate or sand is shown in Figure 46, by way of example of a part of the face 24.1 of the body 12 of the wall panel 10. Some granules of aggregate or sand 131 in the rendering layer 128 are partially penetrated into the body 12 through the face 24.1 to yield the mechanical bonding.
  • the cover rendering layers 130 and 132 also are applied as cover slurry using a suitable spray applicator apparatus.
  • the cementitious material for the layer 130 may have a cement:sand ratio of between 1 :4 and 1 :5, although it is not limited to this range.
  • the cementitious material for the layer 132 may have a cement:sand ratio of between 1 :5 and 1 :7, although it is not limited to this range.
  • the cementitious material of at least one of the rendering layers 128, 130, and 132 may include a water retentive agent.
  • the Applicant proposes the use of about 45g polypropylene fibres per 50kg cement, although alternatives exist.
  • the cementitious material of at least one of the rendering layers 128, 130, and 132 may, alternatively or additionally, include at least one admixture, such as a polymer or a plasticizer, for enhancing sprayability.
  • the final rendering layer 132 may be skimmed using a suitable trowel, straight edge, or the like.
  • Each rendering layer or layer may have a fibre length of about 6mm, but this length may be varied.
  • a wall arrangement 134 (shown semi-completed in Figure 20), in accordance with both the second and fourth aspects of the invention, is defined by the combination of the wall system, comprising mainly core elements, and the rendering layers.
  • the wall system 100 now defines a core of the wall arrangement 134.
  • FIG 21 shows how the mesh reinforcement strips 1 16 are secured to the column member 16 via the screws 1 19.
  • the bands 124 are reinforced by the mesh reinforcement strips 1 16.
  • the bands 124 being interconnected via the screws 1 19 and the column member 16, act similarly to the flanges of an I-beam to resist bending of the wall about a horizontal axis parallel to the wall, with such bending inducing tension in the one band and compression in the other.
  • the bands 124 therefore have a significant stiffening and strengthening effect on the wall.
  • Figure 22 shows a joint defined between the upper and lower bodies 14.1 and 14.2 of a wall panel 10. Due to the shape of the joint, passage of water through the joint is inhibited. Figure 22 shows also how the mesh reinforcement strips 1 16 on opposite sides of the joint are tied together via the wire ties 1 18. The bands 122 are reinforced by the mesh reinforcement strips 1 16. The bands 122, being interconnected via the ties
  • Figure 23 shows a joint defined between two wall panels 10, the joint including jointing members 78. It shows also how the mesh reinforcement strips 1 16 on opposite sides of the joint are tied together via the wire ties 1 18.
  • the bands 126 are reinforced by the mesh reinforcement strips 1 16.
  • the bands 126 being interconnected via the ties 1 18, act similarly to the flanges of an I-beam to resist bending of the wall about a horizontal axis parallel to the wall, with such bending inducing tension in the one band and compression in the other.
  • the bands 126 therefore have a significant stiffening and strengthening effect on the wall.
  • Figure 24 merely shows how a buttress may be defined in a wall 140 using a T-post 87 (see Figure 16) and a first type post 58 (see Figure 7a).
  • Figure 25 shows how the column member 16 of the wall panel 10 may be fixed to the floor slab 108 via a bracket 54 (see Figure 1 b) and two fasteners 141 . The same may apply to the column members of other core elements.
  • a wall panel which is a core member of another embodiment of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 142.
  • the wall panel 142 includes many features that are identical or similar to features of the wall panel 10 of Figure 1 . Similar features generally are not described again and some of them are designated by the same reference numerals as before.
  • each of the lower body part 14.1 and the upper body part 14.2 has a dovetail groove 144 defined into its one face along the operative height of the body, midway between opposite side edges of the body.
  • a reinforcement member 146 in the form of a reinforcement bar, is placed in the continuous dovetail groove 144 defined by fitting the upper body part 14.2 on top of the lower body part 14.1 .
  • the reinforcement bar 146 has a bracket 148 secured to its operative underside for securing the reinforcement bar to a floor slab.
  • a threaded end 154 of the reinforcement bar 146 protrudes from the upper body part 14.2 within a groove 34 defined in its top. This threaded end will, in the installed configuration of the wall panel 142 as a part of a wall arrangement, in accordance with the second aspect of the invention, serve to secure a ring beam to the column member 152.
  • An alternative type wall panel (not shown) of the wall system may include more than one operatively vertically disposed reinforced concrete element, all spaced apart from the side edges of the panel.
  • Figures 29 and 30 show, respectively, an axonometric view and a top view of a T-post 156 matched to the wall panel 142 of Figure 26.
  • the T-post 156 includes a reinforced concrete column member 152 identical to that of the wall panel 142.
  • Figures 31 and 32 show, respectively, an axonometric view and a top view of an L-post 158 matched to the wall panel 142 of Figure 26.
  • the L-post 158 includes a reinforced concrete column member 152 identical to that of the wall panel 142.
  • Figure 33 shows an exploded view of a wall system 160, in accordance with the third aspect of the invention, including three wall panels 142, a T-post 156, and jointing members 78.
  • a reinforced concrete ring beam arrangement will be formed in the grooves 34 defined in the operative top edges.
  • reinforcement bars 162 will be placed in the grooves 34.
  • Figure 34 shows the wall system 160 assembled and a concrete ring beam arrangement 164 cast into the grooves 34 (see Figure 33) and the operative top edges of the wall panels 142 and the T-post 156.
  • a steel ring beam arrangement may be used with the wall system 160.
  • FIG 35 shows yet another embodiment of a wall system, in accordance with the third aspect of the invention, designated by the reference numeral 166.
  • the wall system 166 includes wall panels 167 that are similar to, but thinner than, the wall panel 142 of Figure 26.
  • the wall panels 167 include reinforced concrete column members 168 that are of smaller cross-sectional area than the reinforced concrete column member 152 of the wall panel 142. As such, the load bearing capacity of these column members 168 is lower than that of the column members 152.
  • Jointing members 78 in the form of MASONITE strips are used with the wall panels 142.
  • the wall panels 167 define lateral recesses 170 along their operative top edges, each recess exposed across the width of one face of the body of the panel concerned, for accommodating a length of ring beam element 172.
  • the reinforcement bar of each column member 168 defines a threaded end for securing a ring beam element to it using a matching nut.
  • Figure 36 shows a steel ring beam arrangement 174, assembled from steel ring beam elements 172, secured to the concrete elements 168 via nuts 176.
  • the wall system 166 includes many features that are similar to those of the wall system 160 of Figures 33 and 34. A description of similar features will generally not be repeated here and such features, where designated here, are designated again by the same reference numerals as before.
  • a concrete ring beam arrangement may have been cast on the wall system 166, using shuttering suitable for the purpose.
  • FIG. 37a and 37b another embodiment of a wall panel, which is a core element of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 170.
  • the wall panel 170 includes certain features that are similar to those of the wall panel 142 of Figures 26 to 28. A description of similar features will generally not be repeated here and such features, where designated here, are designated again by the same reference numerals as before.
  • the body of the wall panel 170 defines therethrough two operatively vertically disposed, spaced apart, square cross-section passages 172, centred between opposite faces of the wall panel 170.
  • a concrete column member 174 has been factory cast after positioning centrally in the passage a reinforcement member 176, similar to the reinforcement member 146 of Figure 27 but having an end length that is bent at a right angle to the remainder of the member to define a lap/bond length 177. Centring of each reinforcement member 176 in the corresponding passage 172 may be ensured using suitable spacers (not shown) in the passage.
  • the concrete column members 174 may be cast with the body of the panel 170 in a vertical orientation. As an alternative to casting the concrete column members 174 in the body of the panel 170, they could be cast separately in moulds and then inserted, particularly slid, into the respective passages 172.
  • FIG 38 a partially completed wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 178.
  • the wall system 178 includes many features that are similar to those of the wall system 160 of Figures 33 and 34. A description of similar features will generally not be repeated here and such features, where designated here, are designated again by the same reference numerals as before.
  • the wall system 178 includes three wall panels 170 such as that of Figures 37 and a matching T-post 180.
  • a reinforced concrete ring beam arrangement 164 has been cast into the grooves 34 defined in the operative tops of the panels 170 and corresponding grooves defined in the top of the T-post 180.
  • Each lap/bond length 177 of a reinforcement member 176 of a column member 174 of each panel 170 inside the groove 34 of the panel provides a bond between the column member and the ring beam arrangement 164, the length 177 particularly being lapped or spliced with a horizontal reinforcement member 162 in the beam arrangement.
  • Loading to be imposed on the reinforced concrete ring beam arrangement 164, including roof loading, will be transferred via the reinforced column members 174 and the brackets 148 of these members to the floor 108 or foundations under the wall system.
  • FIGs 39a and 39b another embodiment of a wall panel, which is a core element of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 200.
  • the wall panel 200 is an equivalent of the wall panel 10 of Figures 1 .
  • the wall panel 200 includes features that are similar or identical to features of the wall panel 10 and already described above. A description of these features is not repeated here and some such features are again designated by the same reference numerals as before.
  • the wall panel 200 includes a body 201 which is made of a single piece of expanded polystyrene, as opposed to the two piece body 12 of the panel 10.
  • FIGS 40a and 40b another embodiment of a wall panel, which is a core element of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 202.
  • the wall panel 202 is an equivalent of the wall panel 50 of Figures 6.
  • the wall panel 202 includes features that are similar or identical to features of the wall panel 10 and already described above. A description of these features is not repeated here and some such features are again designated by the same reference numerals as before.
  • the wall panel 202 includes a body 203 which is made of a single piece of expanded polystyrene, as opposed to the two piece body of the panel 50.
  • FIGs 41 a and 41 b another embodiment of a T-post, which is a core element of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 204.
  • the T-post 204 is an equivalent of the T-post 87 of Figure 10.
  • the T-post 204 includes features that are similar or identical to features of the T-post 87 of Figure 10 already described above. A description of these features is not repeated here and some such features are again designated by the same reference numerals as before.
  • the T-post 204 includes a body 205 which is made of a single piece of expanded polystyrene, as opposed to the two piece body 88 of the T-post 87.
  • FIG. 42a and 42b another embodiment of an L-post, which is a core element of a wall system, in accordance with the third aspect of the invention, is designated generally by the reference numeral 208.
  • the L-post 208 is an equivalent of the L-post 94 shown in Figure 13.
  • the L-post 208 includes features that are similar or identical to features of the L-post 94 and already described above. A description of these features is not repeated here and some such features are again designated by the same reference numerals as before.
  • the L-post 208 includes a body 209 which is made of a single piece of expanded polystyrene, as opposed to the two piece body 96 of the L-post 94.
  • FIGS 43a and 43b show an embodiment of a door panel, designated generally by the reference numeral 210, which is an alternative to the door panel 84 of Figure 9.
  • the door panel 210 includes features that are similar or identical to features of the core elements already described above. A description of these features is not repeated here and some such features are again designated by the same reference numerals as before.
  • the door panel 210 includes two first type posts 58, each including a steel column member 212 received within a passage defined in the post. It includes also a steel lintel 214 received within a groove defined in an operative bottom edge of the panel 66 and secured to the column members 212 via riveted brackets 216.
  • Figures 44a and 44b show a door panel, designated by the reference numeral 218, which is similar to the door panel 210 of Figures 43, but it includes no lintel 214.
  • the requirement of a lintel is determined by a required load bearing capacity of the infill panel 66.
  • the column members 212 fit through respective passages 213 defined through the upper infill panel 66.
  • Figures 45a and 45b show a window panel 220.
  • the window panel 220 includes features that are similar or identical to features of the door panel 210 and core elements already described above. A description of these features is not repeated here and some such features are again designated by the same reference numerals as before.
  • the window panel 220 includes also a window infill panel 222 defining slots 224 for receiving respective bottom end portions of the column members 212.

Abstract

L'invention concerne un procédé de construction d'un agencement de paroi, le procédé comportant les étapes consistant à construire, in situ, l'âme d'un agencement de paroi à partir d'un système de paroi modulaire comprenant une pluralité d'éléments d'âme préfabriqués puis à appliquer par pulvérisation un enduit aux faces verticales définies par l'âme. Les éléments d'âme comprennent au moins un panneau de paroi et éventuellement des piliers, entre autres. Chaque élément d'âme comprend un corps constitué d'un matériau léger, par ex. du polystyrène expansé. Le panneau de paroi comprend un corps sensiblement rectangulaire définissant deux bords latéraux opposés, disposés verticalement en utilisation, et au moins un élément de colonne s'étendant au moins sensiblement entre des bords fonctionnels supérieur et inférieur du corps dans un passage défini à l'intérieur du corps. L'invention concerne également un système de paroi comprenant des éléments d'âme susmentionnés destinés à former l'âme d'un agencement de paroi, ainsi qu'un agencement de paroi construit en accord avec le procédé de l'invention.
PCT/IB2009/050031 2008-01-07 2009-01-07 Procédé de construction d'un agencement de paroi, agencement de paroi, et système de paroi modulaire WO2009087593A2 (fr)

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ZA2008/00204 2008-01-07
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FR2950910A1 (fr) * 2009-10-01 2011-04-08 Const Composites Bois Panneau pour la realisation d'une construction et procede d'assemblage d'au moins deux panneaux
WO2016025987A3 (fr) * 2014-08-19 2016-04-14 Bfre Pty Ltd As Trustee Panneau mural isolé et préfabriqué et ensemble de revêtement mural
FR3134402A1 (fr) * 2022-04-11 2023-10-13 Isolfrance Bloc de construction sous forme de profilé d’angle, et son utilisation pour l’assemblage d’une structure résidentielle

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US20050066587A1 (en) * 2003-09-29 2005-03-31 Dale Brisson Modular homes
WO2006095266A1 (fr) * 2005-03-11 2006-09-14 Sandwich Panel Construction Sdn. Bhd. Procede de construction de structures au moyen de materiaux prefabriques
US20070245640A1 (en) * 2003-10-03 2007-10-25 Euretech International Pty Ltd, An Australian Corporation Building Structure and Modular Construction

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GB2062057A (en) * 1979-10-09 1981-05-20 Vidal P B Building panel
US5231813A (en) * 1991-09-16 1993-08-03 Drawdy Curtis P Insulated panel apparatus
US6519904B1 (en) * 2000-12-01 2003-02-18 Charles N. Phillips Method of forming concrete walls for buildings
DE10300024A1 (de) * 2003-01-03 2004-07-22 Neu, Jörg Bauelement für den Wohnungs- und Gesellschaftsbau
US20050066587A1 (en) * 2003-09-29 2005-03-31 Dale Brisson Modular homes
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FR2950910A1 (fr) * 2009-10-01 2011-04-08 Const Composites Bois Panneau pour la realisation d'une construction et procede d'assemblage d'au moins deux panneaux
WO2016025987A3 (fr) * 2014-08-19 2016-04-14 Bfre Pty Ltd As Trustee Panneau mural isolé et préfabriqué et ensemble de revêtement mural
FR3134402A1 (fr) * 2022-04-11 2023-10-13 Isolfrance Bloc de construction sous forme de profilé d’angle, et son utilisation pour l’assemblage d’une structure résidentielle
WO2023198975A1 (fr) 2022-04-11 2023-10-19 Isolfrance Bloc de construction sous forme de profilé d'angle, et son utilisation pour l'assemblage d'une structure résidentielle

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