WO2017100835A1 - Système de construction - Google Patents

Système de construction Download PDF

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Publication number
WO2017100835A1
WO2017100835A1 PCT/AU2016/051224 AU2016051224W WO2017100835A1 WO 2017100835 A1 WO2017100835 A1 WO 2017100835A1 AU 2016051224 W AU2016051224 W AU 2016051224W WO 2017100835 A1 WO2017100835 A1 WO 2017100835A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
floor
panels
ceiling
wall
Prior art date
Application number
PCT/AU2016/051224
Other languages
English (en)
Inventor
Epaminondas Katsalidis
Original Assignee
Unitised Building 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
Priority claimed from AU2015905235A external-priority patent/AU2015905235A0/en
Application filed by Unitised Building Limited filed Critical Unitised Building Limited
Priority to AU2016374492A priority Critical patent/AU2016374492A1/en
Publication of WO2017100835A1 publication Critical patent/WO2017100835A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • 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
    • E04B1/08—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of metal
    • 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
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815—Elements not integrated in a skeleton
    • E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal
    • 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/28—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups combinations of materials fully covered by groups E04C2/04 and E04C2/08
    • 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

Definitions

  • the present invention relates to building panels and methods of assembly.
  • the present invention also relates to building unit assemblies that are assembled to be structurally self-supporting box frame structures to form a building.
  • prefabricated modules are mostly or fully assembled in a factory and transported to site, where they are lifted into position by a crane. In many situations, a crane large enough to lift a prefabricated module is not available.
  • the present invention provides the option to construct a building using fully box framed structures transported as finished units or alternatively using individual floor and wall panels to assemble a building on site. Equally, partially complete box structures could be utilised.
  • the present invention allows the use of the same panel and column arrangements to be used in either methodology.
  • a system which utilises various light gauge roll-formed steel to form a construction system that allows walls, floors and columns to be easily and accurately connected to form stable medium rise and high rise building structures.
  • a connection system has been developed that allows wall panels to be fixed and supported only at structural column positions, so that they are separated horizontally. This channels gravity loads through these structural columns so that the walls act as deep beams to support localised floor loads and provide lateral stability.
  • connection system provides the lateral connection linking adjoining floor panels to create a continuous diaphragm to transmit lateral loads to shear walls, cores and facades to form a stable building structure.
  • connection system allows for columns, studs, bracing elements of various configurations of materials (such as steel and timber) at intervals and dimensions that may be required to accommodate the various loads of a medium to high rise structure. All these elements are accommodated within approximately 100mm structural wall zone regardless of the building height or the internal configurations.
  • the entire light gauge steel structure complete with columns, studs and bracing elements is then filled with settable infill, as required, when it is in panel form and prior to being combined into box frame structures or erected on site as panels.
  • the system of wall and floor panels can be preassembled off site, prefabricated modules or alternatively transported to site and erected as individual panels. Either way this structure eliminates the need to pour concrete onsite for structural or for fire proofing purposes.
  • connection system for connecting two building elements located one above the other, the building elements including at least one structural column
  • the system including: a bearing plate located at or adjacent an upper end of the structural column and extending between walls of the column; a tie rod having a head on an upper end, the tie rod extending through the bearing plate, such that the head sits above the bearing plate, to a lower end of the column; a coupler for connection to the lower end of the tie rod and to the upper end of an underlying column to connect the two building elements together; wherein as the tie rod is tightened into the coupler, the head bears down on the bearing plate, whereby gravity loads pass through the bearing plate to the walls of the structural column.
  • a wall panel for use in the construction of a building, the panel including: a settable infill and a rigid structural frame at least partially or fully embedded in the settable infill; load-bearing columns located at least adjacent either end of the panel; and upper and lower continuous rails extending the length of the panel, whereby the rails are profiled to at least partially receive the ends of corresponding floor/ceiling panels used to construct the building and the rails are provided with a plurality of apertures registered with apertures in the floor/ceiling panel.
  • the settable material referred to throughout may be foamed concrete or other suitable material.
  • the rigid structural frame may be made of steel, wood or other load-bearing material.
  • the load-bearing columns and other vertical structural members may be free to be positioned, and their quantity determined, to meet the needs of an individual building's structural requirements.
  • the wall panel may include end channels located at either end of the panel; the upper and lower continuous rails preferably extend between the ends channels, whereby the end channels and the upper and lower rails form a portion of the formwork containing the settable material during construction of the panel.
  • the load-bearing columns are preferably spaced inwardly from the end channels such that a gap is provided there between.
  • this allows the settable material to encase the load-bearing columns thereby providing fire and corrosion protection.
  • the rigid structural frame may include a plurality of studs or these can be substituted for cross bracing between columns to provide greater lateral load resistance and act as major shear structures.
  • a number of wall panels may be layered together to create a wall panel assembly to increase rigidity.
  • the invention provides a floor/ceiling panel for use in the construction of a building, the panel including: a settable material layer and a series of horizontal structural members spaced across the panel and at least partially or fully embedded in the settable material; and at least one side rail running along at least one side of the panel, wherein the side rail includes apertures located to align with corresponding apertures in a wall panel for connection to the wall panel, such that the side rail is used to locate and fasten the floor/ceiling panel.
  • the floor/ceiling panel according to the third embodiment may have a side rail that includes a projecting flange running along its length.
  • the projecting flange may be dimensioned to extend between two vertically aligned wall panels for connection to the wall panels.
  • the floor/ceiling panel of the third aspect includes two side rails, one running along each longitudinal side of the panel.
  • the side rails form part of the formwork for casting of the settable material.
  • the side rail may be constructed from two or more profiles mechanically fixed together to form a sub-assembly.
  • the mechanical fixing may involve the profiles being mechanically fixed by riveting, clinching, spot welding, screwing, bolting, etc.
  • the horizontal structural members may be floor joists, which may be made of various materials including steel or timber.
  • the floor/ceiling panel may include an additional upper layer of a trafficable surface, for example a hard concrete screed. This concrete screed may fully embed the purlins within the panel.
  • a method of connecting building elements including: providing a lower wall panel having an upper rail extending the length of the panel; providing two floor/ceiling panels each having at least one side rail projecting out from and running along at least one side of the panel, the rail having a projecting portion projecting from a point on the side offset from the top surface of the floor/ceiling panel; positioning the two floor/ceiling panels such that the respective side rails rest adjacent one another; fixing the side rails to the upper rail, wherein a channel is created above the lower wall panel upper rail and between the floor/ceiling panel edges; receiving a lower portion of an upper wall panel in the channel; fastening the upper wall panel to the lower wall panel through the side rails and upper rail.
  • the adjacent side rails may rest side by side or one above the other.
  • the floor/ceiling panels preferably include side rails that include apertures that align with the apertures in the wall panel's rails and load-bearing columns.
  • a connector is inserted into the corresponding apertures between the floor/ceiling panels and the wall panels at the column locations.
  • Housed in the column may be a tie rod.
  • the tie rod preferably affixes to connectors received in the end or ends of aligned columns and through aligned apertures in the rails of the wall panels and apertures in side rails of the floor/ceiling panels.
  • the wall panels are constructed such that, the upper wall panel has the capacity to be installed in the channel and with its column tie rods engaged be freestanding under normal construction conditions such that it does not require, or has reduced requirement for, temporary support from third party propping element to prevent it from falling over compared to conventional precast panels.
  • the floor/ceiling panel side flange is received onto the lower wall's upper rail with two adjacent side rails resting one above the other to then be fixed to the upper rail below.
  • a prefabricated building unit constructed from at least a floor panel and a ceiling panel according to the third aspect and two wall panels according to the second aspect.
  • Construction of the building units can be done off-site prior to delivery to site, or alternatively the panels may be delivered to site and the units constructed on site.
  • a prefabricated building unit constructed from at least a floor panel, a ceiling panel and two wall panels, whereby the longitudinal sides of the ceiling and floor panels are aligned with the inner surface of the wall panels and wherein the wall panels terminate at a point intermediate the sides of the ceiling and floor panels, respectively.
  • a unit when units are positioned on a first level in a spaced apart configuration and a void is created therebetween, a unit is positioned on a second level above the first level and located above the created void.
  • the walls of the units on the second level vertically align with the walls of the units on the first level and the floor of the unit on the second level forms the ceiling on the created void on the first level.
  • the floors of the units on the second level are horizontally aligned with the ceiling of the units on the first level.
  • Figure 1 is a building according to a first embodiment of the present invention
  • Figure 1A is a diagrammatic representation of the construction elements used in Figure
  • Figure 2 is a perspective view of a wall panel according to a first embodiment before pouring of the foamed concrete
  • Figure 2A is a close up view of the corner of the wall panel of Figure 2
  • Figure 3 is a perspective view of the wall panel of Figure 2 with the foamed concrete poured;
  • Figure 4 is a perspective view of a floor/ceiling panel according to a first embodiment
  • Figure 4A is a close up view of the front and side of the floor/ceiling panel
  • Figure 4B is a close up view of the side of the floor/ceiling panel
  • Figure 5 is a perspective view of a partially constructed building according to the first embodiment of the present invention
  • Figure 5A is a close up view of the upper front corner of the building
  • Figure 5B is a close up view of the lower front corner of the building
  • Figure 6 is a cross-sectional view through two vertically stacked fagade panels
  • Figure 7 is an exploded cross-sectional front view through the centre of a load-bearing column showing the connection of two vertically adjacent wall panels and two horizontally adjacent floor/ceiling panels as represented diagrammatically in Figure 7A;
  • Figure 8 is a cross-sectional front view of the connection shown in Figure 7;
  • Figure 9 is a cross-sectional front view through the line 9-9 in Figure 3 of a wall panel showing the connection represented diagrammatically in Figure 7A;
  • Figure 9A is a top cross-section view of the wall panel at the line 9-9;
  • Figure 10 is a cross-sectional front view through line 10-10 in Figure 3 of a wall panel showing the connection of two vertically adjacent wall panels and two horizontally adjacent floor/ceiling panels through a wall void;
  • Figure 1 1 is a building according to a second embodiment of the present invention.
  • Figure 1 1A is a diagrammatic representation of the construction elements used in Figure 1 1 ;
  • Figure 12 is a cross-sectional front view through the length of a wall panel showing the connection of four building units as represented diagrammatically in Figure 12A;
  • Figure 13 is a building according to a third embodiment of the present invention.
  • Figure 13A is a diagrammatic representation of the construction elements used in Figure 13;
  • Figure 14 is a cross-sectional front view through the length of a wall panel showing the connection of two vertically adjacent building units and a floor/ceiling panel as represented diagrammatically in Figure 14A;
  • Figure 15 is a building according to a fourth embodiment of the present invention.
  • Figure 15A is a diagrammatic representation of the construction elements used in Figure 15;
  • Figure 16 is a cross-sectional front view through the length of a wall panel showing the connection of two diagonally aligned building units as represented diagrammatically in Figure 16A;
  • Figure 17 is a perspective view of a wall panel according to an alternative embodiment.
  • Figure 1 shows a building 10 according to a first embodiment.
  • the building 10 illustrated comprises a series of box-like arrangements surrounding room voids 16 across three levels.
  • the building is constructed from a plurality of individual wall panels 12 and floor/ceiling panels 14 that join together to make the building 10.
  • Construction of the building shown in Figure 1 may be accomplished by the following general assembly method.
  • a series of floor/ceiling panels 14a are positioned on a foundation.
  • a series of upright wall panels 12a are positioned and connected to the floor/ceiling panels 14a along their length (the connection is described below).
  • a second level of floor/ceiling panels 14b are then lifted into place and connected to the upper edges of the ground level wall panels 12a.
  • the second level of floor/ceiling panels 14b create the ceiling for the first level room voids 16a and the floor for the second level room voids 16b.
  • a second series of wall panels 12b is then positioned and connected to the first series of wall panels 12a and potentially the second level of floor/ceiling panels 14b.
  • a third level of floor/ceiling panels 14c is then positioned to enclose the second level of room voids 16b from above, creating their ceilings.
  • the third level of floor/ceiling panels 14c creates the floor for the third level of room voids 16c.
  • Another level of wall panels 12c and floor/ceiling panels 14d is positioned to enclose the third level of room voids 16c.
  • the building may be constructed from one bottom corner and built vertically and horizontally simultaneously until it is completed at the opposite upper corner. As can be seen from Figure 1A, the building is constructed from a series of panels. Each internally positioned wall panel 12 is shared between horizontally adjacent room voids 16.
  • FIG 2 shows an embodiment of a wall panel 12 under construction.
  • the wall panel 12 has an upper rail 18 and a lower rail 20.
  • the rails extend the full length of the wall panel 12.
  • the upper and lower rails 18, 20 include a main plate 42 with two side plates 44 extending generally perpendicularly from the main plate 42. Extending outwardly from the side plates are flanges 45.
  • the shape of the rails 18, 20 defines indented corners 46 running the length of the panel 12. In the embodiment illustrated four indented corners 46 are defined, however it will be appreciated that one, two or three indented corners may be provided, with the other corners remaining non-indented.
  • load-bearing end columns 22 Extending between the upper rail 18 and the lower rail 20 are load-bearing end columns 22.
  • the load-bearing columns 22 are positioned adjacent the ends of the panel.
  • the load-bearing columns 22 are bolted to the upper and lower rails 18, 20 using bolts 48.
  • a doorway 24 has been created in the centre of the span.
  • two additional load-bearing columns 22a On either side of the doorway 24 are positioned two additional load-bearing columns 22a.
  • a top beam 26 and a base beam 28 extend between the additional load-bearing columns 22a creating a rigid structure around the doorway 24. These beams 26, 28 are fixed to the respective upper and lower rails 18, 20.
  • steel studs 30 extending between the upper rail 18 and the lower rail 20 are steel studs 30 forming a rigid structural frame.
  • the studs 30 are spaced across the panel between the load-bearing columns 22, 22a.
  • the studs 30 are spaced more closely together towards the ends of the panels and the doorway 24.
  • End channels 32 are provided at the respective ends of the panel 12 and also at the doorway 24.
  • the end channels 32 (see Figure 2A) include a plate section 34 and side flanges 36 extending generally perpendicular to the plate section 34 in an inward direction.
  • the end channels 32 are spaced off the columns 22 by a small distance leaving a gap.
  • the end channels 32 and the studs 30 are mechanically connected to the rails eg, by clinching.
  • the load-bearing columns 22 illustrated are hollow steel sections.
  • the upper and lower rails 18, 20 include apertures 50, 51 located at the columns 22, such that channels 52 can run from the upper side of the wall panel 12 to the lower side of the wall panel through the columns 22. These channels 52 are utilised in the connection of panels, to be described below.
  • Figure 3 shows the wall panel 12 of Figure 2 in an orientation when a settable material is being cast.
  • the structural components of the wall panel 12 shown in Figure 2 are laid upon a base formwork member (not shown).
  • the base formwork member together with the upper and lower rails 18, 20 and the end channels 32 form the formwork for the pouring of the settable material.
  • a suitable settable material may be foamed concrete 38, commonly referred to as "foamcrete". Foamed concrete is significantly lighter in weight than standard concrete.
  • the foamed concrete 38 As the foamed concrete 38 is poured it spreads about the studs 30 and the load-bearing columns 22.
  • the foamed concrete 38 can flow around and cover all surfaces of the columns 22, as the end channels 32 are spaced off the columns 22. This fully embeds the columns 22 and studs 30 in the foamed concrete 38.
  • the studs 30 in conjunction with the upper and lower rails and the settable material form a truss-like system that both supports the load of the floor/ceiling panels that bear onto them and resist lateral loads, distributing the load forces to the embedded columns 22, 22a within the wall.
  • the studs 30 are load-bearing in that they take the loads from the floor above (the wall acts as a beam) and transfers the loads to the columns.
  • the settable material provides additional lateral stiffness.
  • the foamed concrete 38 also provides thermal and acoustic insulative properties and fire and corrosion resistance to the wall panels 12. When the foamed concrete 38 has suitably set, the wall panel 12 is lifted off the base formwork. The side formwork of the end channels 32 and upper and lower rails 18, 20 remains integral to the wall panel 12.
  • a floor/ceiling panel 14 is show in Figure 4.
  • the panel 14 includes side rails 64 running the length of the panel.
  • the side rails 64 include a projecting flange 66.
  • the side rails 64 are composed of two profiles 68, 70 clinched together (see Figure 7 for more detail).
  • the first profile 68 has an upright portion 69 that extends from a top surface 72 of the panel downwards.
  • the upright portion 69 folds inward to create an inward lip 74.
  • the second profile 70 has an upright portion 71 that extends from the bottom surface 76 upwards and then folds outwardly to form the projecting flange 66.
  • the two profiles 68, 70 are clinched together at their upright portions 69, 71 .
  • the projecting flange 66 projects from a point on the side offset from the top surface 72 of the panel 14.
  • the projecting flange 66 includes a plurality of apertures 67 registered with apertures in the wall panels (to be described further below).
  • the purlins 78 are C-shaped and run perpendicular to the side rails 64.
  • the cross-section of the purlins 78 is illustrated in the drawings (for example Figure 7) by representative cross-sectional outline 78'.
  • the ends of the purlins 78 are clinched at their base 80 to the inward lip 74 of the side rails 64.
  • the top of the ends 82 of the purlins 78 are welded to the upright portion 69 of the first profile 68.
  • the process for constructing the floor/ceiling panel 14 is similar to that used for the wall panel 12.
  • the floor/ceiling panel 14, the side rails 64 and purlins 78 are positioned on top of a base formwork (not shown), which includes end wall formwork (not shown).
  • the side rails 64 form the edge formwork.
  • a layer of reinforcement mesh 84 is laid on top of the purlins 78.
  • a foamed concrete layer 40 is then poured within the formwork. This partially embeds the purlins 78 in the foamed concrete 40.
  • the height of the purlin 78 is 150mm.
  • the purlin 78 is positioned 70mm above the base formwork, aligning with the inward lip 74.
  • the foamed concrete 40 is poured from the base formwork to a depth of 200mm.
  • FIG. 1 shows a building mid construction.
  • Two floor/ceiling panels 14 have been laid on a foundation.
  • Three wall panels 12, two bracing end wall panels 90 and two fagade panels 54 (to be described below) have been positioned.
  • Figure 5A illustrates the upper-most corner of the junction between the fagade panel 54 and wall panel 12 and shows apertures 50 in the upper rail 18 before the second layer of floor/ceiling panels are positioned on top.
  • Figure 5B shows the lowermost corner of the junction between the fagade panel 54 and the wall panel 12.
  • the fagade panel 54 is an alternative wall panel and is constructed from stud framing (not shown), with outwardly facing side channels 58. Cast on the outer surface of the stud framing is a layer of foamed concrete 38a. An opening 62 can be provided for a window or a door. A cantilevered balcony (not shown) could also be incorporated into the fagade panel design.
  • Welded into the side channels 58 at the lower end is a stabilising bracket 60.
  • Welded into the upper end of the side channel 58 is a bearing plate 69 that includes an aperture to receive the upper end of a tie rod 100.
  • the stabilising bracket 60 includes an aperture to receive and stabilise the base of the tie rod 100 (see Figure 5B). The upper end of the tie rod 100 is constrained from downward movement by head 65, which is larger than the aperture in the bearing plate 69.
  • connection of two vertically adjacent fagade panels and connection of those fagade panels to two vertically adjacent wall panels is shown in side view in Figure 6.
  • No settable material e.g. concrete
  • the two fagade panels are identical, as are the two wall panels.
  • an open gap 63 is provided above the bearing plate 69 and head 65.
  • Another gap 71 is provided below the stabilising bracket 60.
  • a guide plate 73 closes the gap 71 from below.
  • Located on the lower end of the tie rod 100, in the gap 71 is a coupler 96.
  • the coupler 96 has a generally cylindrical body 108 and a lower threaded stem 106.
  • the lower threaded stem 106 has a smaller diameter than the body 108.
  • a spacer plate 94 is positioned between the upper and lower wall panels 12 and fagade panels 54.
  • a tool is inserted into upper gap 63 to engage head 65.
  • Turning of head 65 rotates the tie rod 100 and the associated coupler 96.
  • the threaded stem 106 screws into a corresponding threaded aperture 95 in the spacer plate 94.
  • the head 65 bears down on bearing plate 69, which transfers the load to the side channel 58.
  • the upper fagade panel is bolted or otherwise mechanically fixed to the wall panel via the spacer plate projecting from the top of the wall column adjacent the fagade panel.
  • Figure 7 shows the connection between two wall panels 12a, 12b and two floor/ceiling panels 14a, 14b, as diagrammatically illustrated in Figure 7A.
  • the cross-sectional view shown is through the load-bearing columns 22.
  • the indented corners 46 are created by the side plates being inset by a distance inwards from the panel wall surfaces. This inset creates a seat 102 onto which is placed a sealing strip 104.
  • the sealing strip 104 is preferably intumescent, such that it swells when heated, thus protecting the material underneath or sealing the gap in the event of a fire.
  • the lower wall panel 12 is shown as having the hollow load-bearing column 22, with an upper aperture 50 in the upper rail 18 and a lower aperture 51 in the lower rail 20.
  • the aligned apertures 50, 51 and column 22 create a channel 52 through the wall panel 12.
  • a bearing plate 69 with a gap 63 above it.
  • a stabilising bracket 60 with a gap 71 underneath.
  • a tie rod 100 that extends between bearing plate 69 and the lower end of the column 22.
  • a coupler 96 is positioned into the upper aperture 50 in the wall panel 12.
  • the coupler 96 is shaped to have a threaded lower stem 106 that screws into the aperture 50.
  • Above the lower stem 106 is a cylindrical body 108 of larger diameter than the lower stem 106.
  • the lip 1 10 created between the lower stem 106 and central portion 108 seats the coupler 96 on top of the upper rail 18.
  • Above the central portion 108 is a tapered portion 1 12.
  • the tapered portion 1 12 includes a blind hole 1 14 that has an internal screw thread.
  • a first floor/ceiling panel 14a is then lowered into position.
  • the base 76 of the floor/ceiling panel 14a rests on the seat 102a, on top of the first sealing strip 104a.
  • the rails 18, 20 are dimensioned such that the flange 66a extends over the lower wall panel 12a, with the apertures 67 in the flange 66a registering with aperture 50 and slotting over the coupler 96.
  • the second floor/ceiling panel 14b is then lowered into position.
  • the base 76 of the floor/ceiling panel 14b rests on the seat 102b, on top of the second sealing strip 104b.
  • the apertures 67 in the flange 66b register with aperture 50 and slot over the coupler 96.
  • the flange 66b sits over the top of the flange 66a of the first floor/ceiling panel 14a. It can be seen in Figure 8 that the first sealing strip 104a is compressed more than the second sealing strip 104b resulting in the first and second floor/ceiling panels 14a, 14b having an aligned upper floor surface 72 and lower ceiling surface 76.
  • a spacer plate 94 On top of the flange 66b of the second floor/ceiling panel 14b is a spacer plate 94 with central aperture 95.
  • the spacer plate 94 provides a gap between the top and bottom of wall panels for accommodating the fixing of columns and floor/ceiling panels to the upper and lower rails.
  • the upper wall panel 12b is lowered into the gap 120 (see Figure 8) created between the first and second floor/ceiling panels 14a, 14b. As the second wall panel 12b is lowered, the lower aperture 51 slots over coupler 96. The upper wall panel 12b sits on top of the spacer plate 94. As shown in Figure 7 the profile of the lower rail 20 differs to the upper rail 18.
  • the lower rail 20 includes a step 122 in the side plates 44, which align with a corresponding step 124 in the uprights of the side rails 64. The step creates a taper that makes it easier to locate the top wall panel between floor/ceiling panels and provides a tight fit between panels.
  • the wall panels are constructing such that, before fastening, the upper wall panel has the capacity to be installed in the gap 120 and be freestanding under normal construction conditions such that it does not require temporary support from third party propping element to prevent it from falling over. This significantly reduces labour time and therefore cost.
  • FIG. 9 illustrates connection of the same panels, with the cross-section showing through line 9-9 of Figure 3 of the wall panel 12 i.e. through the body of the panels, not through the load-bearing columns 22.
  • a series of connection assemblies 101 may be embedded in the foamed concrete 38 towards the lower surface of the wall panel.
  • connection assemblies include an S-shaped plate 126 that is clinched to the lower rail 20 (see Figure 9A, which is a top view through the wall panel). They also include a cylindrical tubular section 128 that includes a slit that sits over the top of the S-shaped plate 126. Diagonally extending channels 130 are formed from the two sides of the wall panel 12. Screws 132 can be drilled in place onsite to extend through the tubular section 128 and through the lower rail 20 into the floor/ceiling panels 14. The screws draw the tubular section 128 down over the S- shaped plate and connect the lower end of the wall panel 12 to the first and second floor/ceiling panels 14.
  • Figure 10 shows another cross-sectional view through line 10-10 in Figure 3 of the wall panel 12 i.e. through the doorway 24.
  • the doorways 24 in the upper level and the lower level are aligned.
  • the top beam 26 of the lower level sits within the wall panel 12 underneath the upper rail 18, generally above the seats 102.
  • a closing channel 134 is provided to contain the foamed concrete 38 that surrounds the top beam 26.
  • the base beam 28 sits within the gap between the floor/ceiling panels 14 and is covered in foamed concrete 38.
  • the flooring 88 may be laid continuously across the doorway 24 between the two floor/ceiling panels 14.
  • the side rails 64 of the floor/ceiling panels 14 have a projecting flange 66 that is dimensioned to extend between two vertically aligned wall panels 12a, 12b for connection to the wall panels 12.
  • the projecting flanges 66 are clamped between an upper 12b and a lower 12a wall panel.
  • alignment between the side rails 64 of the floor/ceiling panels 14 and the upper and lower rails 18, 20 of the wall panels allows for easy and quick placement of the various panels.
  • Figures 1 1 through 15A show various alternative building constructions utilising elements from the embodiments shown in Figures 1 through 10.
  • Figures 1 1 and 12A show a representative building 200 constructed from a series of prefabricated building units 299.
  • the building units are typically assembled off-site and may be at least partially fitted out internally. Alternatively the panels could be transported to site and the units could be assembled on-site, or near to site, to minimise transportation and fabrication facility costs.
  • the building units may be constructed from wall panels and floor/ceiling panels that are the same or similar in construction to the panels described in relation to Figures 1 to 10. However, in the embodiment illustrated in Figures 1 1 to 12A, different panels are used and similar components will use the earlier reference numeral preceded by a '2'.
  • wall panels 212 are connected to floor panels 214' and ceiling panels 214".
  • the wall panels 212 illustrated include a steel layer 213 including a plurality of stiffening ribs 230 spaced apart by sheet sections 231 .
  • the stiffening ribs 230 provide a similar function to the studs 30 in the first illustrated embodiment.
  • the wall panels 212 include upper and lower rails 218, 220 having an L- shaped construction, with the upright portion being clinched to the sheet section 231.
  • the steel layer 213, together with the upper and lower rails 218, 220 and end channels (not shown) are used as the formwork for the pouring of a foamed concrete layer 238.
  • the foamed concrete layer 238 locks about the ribs 230 when set.
  • the ribs 230 are only embedded on the foamed concrete side of the sheet, not fully encased.
  • the floor panels 214' are of a generally similar construction to the earlier described floor/ceiling panels 14. They include side rails 264a, having two profiles 268a, 270a clinched together.
  • the first profile 268a extends from a top surface 272a downwards and folds to form an inward lip 274a.
  • the second profile 270a has an upright portion that is clinched to the upright portion of the first profile 269a and fold to form an outwardly projecting flange 266a.
  • Purlins 278a, reinforcing mesh 284a, foamed concrete 240a and hard concrete 286a are similarly used to construct the floor panel 214'.
  • the ceiling panel 214" also includes side rails 264b, having two profiles 268b, 270b clinched together.
  • the first profile 268b extends from the bottom surface 276b upwards and folds to form an inward lip 274b.
  • the second profile 270b has an upright portion that is clinched to the upright portion of the first profile 268b and fold to form an outwardly projecting flange 266b.
  • Purlins 278b and foamed concrete 240 are used in a similar way to construct the ceiling panel 214". As the ceiling panel 214" in this particular unit is not being used as a floor for the level above, the ceiling panel 214" does not include reinforcing mesh or hard concrete.
  • FIGS. 13 and 14A show a representative building 300 constructed from a series of prefabricated building units 399 and floor/ceiling panels 14. In the embodiment illustrated in Figures 13 to 14A, similar components will use the earlier reference numeral preceded by a '3'. However, the floor/ceiling panel 14 illustrated is identical to that shown in the embodiment illustrated in Figures 1 through 10 and therefore the same reference numerals will be used.
  • the units 399 used in this construction differ to those shown in Figures 1 1 to 12A, as they are required to receive a floor/ceiling panel 14 that forms both the floor and ceiling (see Figure 14). Therefore the lower rail 320 includes indented corners 346 and receives the floor panel 314' of the unit 399 on one side.
  • the upper rail 318 also includes indented corners 346, with the height of the indents differing to accommodate the full thickness of the ceiling panel 314" on one side.
  • the indented corners 346 on the other side cooperate to form a groove for receiving the floor/ceiling panel 14.
  • a similar connection is accomplished by the projecting flanges 366 extending between two vertically aligned wall panels 312 for connection to the wall panels 312.
  • Figures 15 to 16A show another embodiment, where a building 400 is constructed from a series of prefabricated building units 499, floor/ceiling panels 14 and wall panels 12.
  • a building 400 is constructed from a series of prefabricated building units 499, floor/ceiling panels 14 and wall panels 12.
  • similar components will use the earlier reference numeral preceded by a '4'.
  • the floor/ceiling panel 14 and wall panels 12 illustrated are identical to those shown in the embodiment illustrated in Figures 1 through 10 and therefore the same reference numerals will be used.
  • units 499a are positioned in a spaced apart array on a first layer of a building.
  • the units 499a define voids 416a between them.
  • a second set of units 499b are positioned above the voids 416a of the first layer to form a second layer of the building.
  • This construction can be referred to as a "checkerboard" pattern.
  • Third and subsequent layers may be added, where the third set of units 499c is positioned above the voids 416b of the second layer, vertically aligned with the units 499a of the first layer.
  • the wall panels 412 of the units create the walls for the voids 416.
  • the floor/ceiling panel 414 of the unit above creates the ceiling for the void and the ceiling panel of the unit below creates the floor for the void.
  • Additional wall panels 12 are positioned at the edges of the building to enclose the edge voids.
  • Additional floor/ceiling panels 14 are positioned in the first level and uppermost level to enclose the voids. This construction almost halves the number of units required to construct the same sized building, such as building 299 shown in Figure 1 1 , where twenty one units are utilised. This compares to eleven units 499 in Figure 15, with six floor/ceiling panels 14 and two wall panels 12.
  • the floor/ceiling panels 414 are offset with respect to the wall panels 412. As shown in Figure 16, the wall panels 412 terminate at a point intermediate the sides of the floor/ceiling panels 414. This also allows the wall panels 412a, 412b to align.
  • FIG 17 shows a bracing wall panel 512 according to an alternative embodiment.
  • the bracing wall panel 512 is utilised when a building design requires bracing beyond that which can be provided by a standard wall panel 12. Typically the application would be to act as shear walls in taller structures with higher lateral loads and structural cores.
  • the bracing wall panel 512 has a similar construction to the standard wall panel 12 and consists of columns 530 with upper rail 518 and the lower rail 520.
  • the bracing wall panels 512 differ by including adjustable angled bracing members 519 tied diagonally between the columns 530 and upper rail 518 and the lower rail 520. All members are encased in a settable material 538.
  • bracing wall panels 530 can be layered together to create a thicker wall panel assembly to increase the rigidity as required.
  • the system allows for the lower half of a high rise building to have two or three wall panels layered adjacent each other, with the upper half of the building utilising double or single wall panels, with at least one of the upper wall panels aligning with a wall panel below.
  • the system provides significant flexibility in the way a building is assembled. The ability to utilise panels either alone or in combination with prefabricated modules increases the flexibility of the building system. Panels can be transported in a stacked array, minimising costs.
  • the system allows the incorporation of wider panning floors than existing modular units, as the floors can be subdivided into transport friendly segments. For example a modular unit with a floor width span of 6 metres is not road transportable.
  • the present invention allows floor panels in 3 metre segments to be transported in a 3 metre side/high cargo load and assembled with another 3 metre floor panel onsite to create a 6 metre floor span.
  • foamed concrete reduces weight and therefore handling costs and also increases insulative properties and fire resistance.
  • Light weight panels allow for a smaller/lower capacity crane to be used.
  • the use of panels allows more flexibility in terms of logistics, both during transport (via rail, road or ship) and onsite.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

L'invention concerne un procédé de raccordement d'éléments de construction, qui consiste à fournir un panneau de paroi inférieur ayant un rail supérieur s'étendant sur la longueur du panneau ; à fournir deux panneaux de plancher/plafond présentant chacun au moins un rail latéral faisant saillie et s'étendant le long d'au moins un côté du panneau, le rail ayant une partie saillante faisant saillie depuis un point sur le côté décalé par rapport à la surface supérieure du panneau de plancher/plafond ; à positionner les deux panneaux de plancher/plafond de telle sorte que les rails latéraux respectifs reposent l'un contre l'autre ; à fixer les rails latéraux au rail supérieur, un canal étant créé au-dessus du rail supérieur de panneau de paroi inférieur et entre les bords du panneau de plancher/plafond ; à recevoir une partie inférieure d'un panneau de paroi supérieur dans le canal ; à fixer le panneau de paroi supérieur au panneau de paroi inférieur par le biais des rails latéraux et du rail supérieur.
PCT/AU2016/051224 2015-12-17 2016-12-13 Système de construction WO2017100835A1 (fr)

Priority Applications (1)

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AU2016374492A AU2016374492A1 (en) 2015-12-17 2016-12-13 A building system

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AU2015905235 2015-12-17

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019219286A1 (fr) * 2018-05-17 2019-11-21 Spanminx Limited Module structurel à liaisons verticales

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4567705A (en) * 1982-11-22 1986-02-04 Avco Corporation Fire protection arrangement and method of positioning same
CA2197032A1 (fr) * 1997-02-07 1998-08-07 Descon Building Systems Ltd. Ossature de raccordement de panneaux de batiment de construction legere
US6260320B1 (en) * 1998-06-09 2001-07-17 Nick Di Lorenzo Concrete panel construction system
US20060059808A1 (en) * 2004-09-23 2006-03-23 Nguyen Hung T Prefabricated universal structural steel panel and panel system

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4567705A (en) * 1982-11-22 1986-02-04 Avco Corporation Fire protection arrangement and method of positioning same
CA2197032A1 (fr) * 1997-02-07 1998-08-07 Descon Building Systems Ltd. Ossature de raccordement de panneaux de batiment de construction legere
US6260320B1 (en) * 1998-06-09 2001-07-17 Nick Di Lorenzo Concrete panel construction system
US20060059808A1 (en) * 2004-09-23 2006-03-23 Nguyen Hung T Prefabricated universal structural steel panel and panel system

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019219286A1 (fr) * 2018-05-17 2019-11-21 Spanminx Limited Module structurel à liaisons verticales
GB2587543A (en) * 2018-05-17 2021-03-31 Spanminx Ltd A structural module with vertical ties
US11225789B2 (en) 2018-05-17 2022-01-18 Spanminx Limited Structural module with vertical ties
GB2587543B (en) * 2018-05-17 2022-06-01 Spanminx Ltd A structural module with vertical ties
EP4209639A1 (fr) * 2018-05-17 2023-07-12 Spanminx Limited Traverse verticale pour une colonne porteuse d'un module structurel de bâtiment

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