WO2018204984A1

WO2018204984A1 - Panel having curved reinforcement

Info

Publication number: WO2018204984A1
Application number: PCT/AU2018/050440
Authority: WO
Inventors: Timothy Mark GRABHAM
Original assignee: Csr Building Products Limited
Priority date: 2017-05-12
Filing date: 2018-05-11
Publication date: 2018-11-15
Also published as: AU2018265763A1

Abstract

A reinforced building product and a method of manufacturing such a reinforced building product is described in which the building product comprises a generally solid rectilinear body of a lightweight cementitious material in the form of a panel of a regular parallelepiped shape having a generally curvilinear reinforcement embedded wholly within the rectilinear body in which part of the curved reinforcement is closer to one face of the building product and another part of the curved reinforcement is closer to another part of the building product thereby providing enhanced strength to the panel. A method of forming the curved reinforcement mesh is also described in which a generally planar mesh is deformed into a generally curved shape for being embedded within the rectilinear body during moulding of the panel. The curvilinear reinforcement imparts greater strength and rigidity to the building product to enable the panel to resist damage due to flexing or bending during manufacturing, handling and installation of the panel which is the advantage of such an arrangement.

Description

PANEL HAVING CURVED REINFORCEMENT

FIELD The present description relates generally to manufacturing processes for

manufacturing reinforced products, to handling processes for components used in the manufacturing processes for manufacturing the reinforced products, and to reinforced products made by such manufacturing processes. In one form the present description relates to manufacturing processes for the manufacture of reinforced building products, including structural and non-structural building products which have reinforcement embedded within the building products for enhancing the strength and rigidity of the building products, and to methods of handling the reinforcement during the manufacturing process for embedding the reinforcement into the product during the manufacturing processes for making the reinforced building product, and to the reinforced building products when made by the manufacturing process.

In one form the present description relates to manufacturing processes for making reinforced autoclaved aerated concrete building products, to methods of handling the reinforcements for embedding within the reinforced autoclaved aerated concrete building products during the manufacturing processes, and to reinforced products made using such manufacturing processes. One form of embodiments of the present description find particular application in manufacturing reinforced autoclaved aerated concrete panels having reduced thicknesses, to methods of handling the reinforcement which is to be embedded within the reduced thickness AAC building products during the manufacturing process of such products, and to reduced thickness reinforced AAC panels when manufactured by the manufacturing processes.

Although the present description describes manufacturing processes, handling of components used in the manufacturing processes, and products produced by the manufacturing processes for making reinforced autoclaved aerated concrete building products having reduced thickness, it is to be noted that the scope of protection is not restricted to the described embodiments, but rather the scope of protection is more extensive to include other forms and variations of the manufacturing processes, the handling of components during the manufacturing processes and of the building products having reduced thickness made by the manufacturing processes. BACKGROUND

The construction industry, particularly relating to the construction of residential housing and buildings having multiple units or multiple dwellings, such as multi-level apartment buildings, is under intense pressure to provide housing at an affordable cost, especially during times of rapidly escalating house prices, more particularly in high cost cities. One way to reduce costs is to provide new and innovative building products at a lower cost than the cost of more traditional building products. However, the production of new and innovative building products is not without problems and/or disadvantages. One way of reducing costs is to reduce the amount of material in a building product. However, attendant with the reduction in the amount of material used in a building product, is a deterioration in the durability and/or performance of the product including key performance and durability properties and characteristics of the product, such as for example, making a product thinner results in the product being more flexible and susceptible to damage due to flexing, cracking, twisting or similar both during manufacture and subsequent handling and installation of the product. Accordingly, reducing the thickness of a panel of AAC results in the panel being less robust, and more susceptible to damage by cracking due to excessive flexibility or flexure of the panel. In some cases, a reduction in the thickness of the panel results in the inability of the panel to be self-supporting. Often, reinforcing the panel is not sufficient to counteract the unwanted flexing of the panel. Accordingly, there is a need to be able to make a building panel with less material, but which has sufficient strength and/or rigidity and/or structural strength so as to be sufficiently robust for commercial acceptability. SUMMARY

According to one form of the present invention there is provided a building product comprising a body formed from a mouldable material and a reinforcement, the body having a generally rectilinear shape, the reinforcement being generally curvilinear, wherein the reinforcement is located within the body of the product, the curvilinear reinforcement enhancing the strength and/or rigidity of the building product to increase robustness of the building product.

According to one form of the present invention there is provided a method of making a reinforced building product

comprising a generally rectilinear body made from a mouldable material, the body having a first face and a second face, and a generally curvilinear reinforcement, the reinforcement being curved in a direction from the first face of the body to the second face of the body, the method comprising the steps of locating the reinforcement in a first orientation, imparting a curvilinear shape to the reinforcement, introducing the mouldable material into a mould, simultaneously or subsequently locating the reinforcement in the generally curvilinear shape in the mould, forming the body of the building product around the curvilinear reinforcement when in the mould, wherein the mouldable material surrounds the curvilinear reinforcement to embed the curvilinear reinforcement within the body of the generally rectilinear building product.

According to one form of the present invention there is provided a method of making a generally curvilinear reinforcement for use in forming a reinforced building product, the method comprising the steps of locating a first set of linear reinforcing elements in a first orientation in a first location, locating a second set of linear reinforcing elements in a second orientation in a second location, joining the first set of linear reinforcing elements to the second set of linear reinforcing elements to form a generally rectilinear array of reinforcing elements, and applying a deflecting force to the interconnected array of the first set of linear reinforcing elements and the second set of reinforcing elements to impart a curvilinear shape collectively to the reinforcing elements, and maintaining the curvilinear shape.

According to one form of the present invention, there is provided an apparatus for handling a generally curvilinear reinforcement for embedding within a building product made from a mouldable material, comprising a holder for locating the reinforcement in a first orientation in a first location, a force applying device for applying a deflecting force to the rectilinear reinforcement to deflect the reinforcement from a generally rectilinear shape to a generally curvilinear shape, and a shape maintaining device for maintaining the generally curvilinear shape of the reinforcement during the manufacturing process for forming a generally rectilinear building product from the mouldable material within which the generally curvilinear reinforcement is embedded.

BRIEF DESCRIPTION OF EMBODIMENTS In one form, the curvilinear reinforcement is curved, arcuate, arched, elliptical, rounded, serpentine, twisted, sigmoid, sinuous, arced, arciform, circular, ovoid, crescent, sickle-shaped, bow-shaped, bowed, concave, convex, falcate, semicircular, crescentic, or is provided with a radius of curvature in one direction or in one plane, or the like.

Forms of the reinforcement include rods, bars, wires, shafts, mesh, screens, perforated sheets, sieves, or the like.

Forms of the mesh reinforcement are formed, made or manufactured from a generally rectilinear arrangement of individual linear reinforcing elements, typically

interconnected to one another to form a generally rectilinear interconnected array or arrangement of the linear reinforcing members. Typically, the curvilinear

interconnected array or arrangement is in the form of a grid or array of linear reinforcing elements, more typically longitudinally extending and transversely extending elements, which have been subjected to bending, deflection, deformation, distortion, or similar disrupting forces or the like. Typically, the reinforcing elements include linear rods, bars, wires, or similar.

In one form of the curved reinforcing mesh both the longitudinal wires and transverse wires are curved whereas in other forms only the longitudinal wires or only the transverse wires are curved. Preferably, the transverse wires are curved and the longitudinal wires are linear.

Although the rods or wires can be of any form, type or similar, preferred forms of the elements include the following:

The reinforcing elements in the form of rods or wires can be manufactured from any suitable or convenient material. Typically, the rods or wires are made from metal, alloys, stainless steel, coated steel, high tensile steel, or the like, including being made from any suitable or convenient material having properties conducive to forming and maintaining the generally curvilinear shape of the reinforcement when embedded in the generally rectilinear panel, block or slab. One form of wire is high tensile wire. One form of rod or bar is Rebar.

In one form the material from which the wires or rods forming the mesh are manufactured is such so that after the mesh has been curved, the mesh retains the curved shape before, during and after installation within the mould at the moulding station.

Forms of the wire have a diameter from about 2 mm to about 16 mm, typically from about 2.5 mm to about 14 mm, more typically from about 3 mm to 10 mm, preferably about 3 mm to 6 mm, more preferably about 3 mm to 5 mm inclusive.

In one form the mesh reinforcement includes a multitude of longitudinally extending linear wires and a multitude of transversely extending linear wires interconnected to one another to form a generally rectilinear grid pattern or arrangement in which the longitudinal wires and transverse wires extend substantially perpendicularly to one another to form gaps, spaces, voids or similar therebetween, typically, rectangular or square gaps or spaces. In forms of the mesh, the dimensions of the gaps or spaces are sufficient to receive therethrough a handling element for securing the mesh during handling operations of the mesh and during manufacturing steps of the manufacturing process.

Other patterns or arrangements of the reinforcing elements are possible, such as the longitudinal wires and transverse wires being inclined to one another to form diamond shaped or rhomboid shaped patterns or arrangements. The spacing apart of the longitudinal wires of forms of the mesh are any suitable or convenient spacing, size or dimension. In forms of the mesh, the spacing apart of the longitudinal wires is uniform or constant whereas in other forms the spacing apart of the longitudinal wires is variable.

Although the reinforcement mesh can be of any type, form or style and have any suitable or convenient curvature, shape, size, dimensions or the like, typical forms of mesh include mesh having any suitable number of longitudinal wires and any suitable number of transverse wires. Typically, the number of longitudinal wires is from about 3 to about 12, more typically from about 4 to about 10, even more typically about 5 to about 8 individual wires.

Typically, the number of transverse wires is from about 2 to about 30, typically from about 3 to about 20, more typically from about 4 to about 10, even more typically about 5 to about 8.

Forms of the mesh are 5 x 4, 5 x 3, 5 x 5 or the like in which there are five longitudinal wires and three, four or five transverse wires, respectively. Forms of the panel in which the curved reinforcement mesh is embedded include panels having ends of the mesh closer to the longitudinal sides of the panel. In one form the reinforcement has typical values of 14 ± 3 mm or from 19 ± 3 mm.

Forms of the panel have embedded curved mesh at or towards the centre of the panel, typically about the central axis or midpoint of the panel. Typical values are 26 ± 3 mm,

25 ± 3 mm or the like.

Forms of the mesh reinforcement include perforated sheets having a plurality of apertures, openings, holes, voids, gaps or similar in which the plane of the sheet is curved to form the generally curvilinear reinforcement.

Forms of the building product include panels, blocks, slabs, tiles, or the like. Typically, the building product is made from a lightweight material, typically the lightweight material has a density of less than about 1800 kg/m². Forms of the lightweight material include lightweight cementitious materials, such as for example, aerated concrete, autoclaved aerated concrete or the like. Preferably, the material is autoclaved aerated concrete (AAC) made by CSR Building Products Limited and marketed under the name HEBEL.

Although the panel can have any suitable length or any suitable width, typically the length is greater than about 2.4 m, greater than about 2.75 m, greater than about 3.0 m, up to about 3.3 m, up to about 3.6 m, or even longer of up to about 4.2 m. However, the length can be less than about 2.4 m.

Typical widths are in the range from about 200 mm to about 1.2 m, typically from about 250 mm to about 900 mm, more typically from about 270 mm to about 800 mm, more typically from about 300 mm to about 750 mm, and even more typically from about 400 mm to about 600 mm.

Although the panel can have any reasonable thickness from about 30 mm up to about 200 mm, typically from about 40 mm up to about 150 mm, it is preferred that the panel have a thickness of about 45 mm nominally to about 80 mm nominally, with typical thicknesses being about 50 mm nominally, about 75 mm nominally, or about 100 mm nominally. Forms of the panel include shapes such as parallelepipeds, rectangular prisms, or other regular shapes having substantially rectangular faces, sides, edges, ends or the like. Forms of the rectangular prism have two opposed faces, being a top, upper, front or obverse face and a bottom, lower, rear or reverse face in spaced apart relationship to each other. Sides, edges, and ends of the rectangular prism are formed around the perimeter of the panel intermediate the obverse face and reverse face.

Forms of the panel are straight edged or straight ended whereas other forms of the panel are provided with interlocking elements, such as for example projecting elements and receiving elements, typically, the shape of the projections and receivers are complementary to one another, such as for example a tongue and groove arrangement or similar complementary arrangement for interlockingly connecting two panels to one another.

It is to be noted that in forms of the panel, the long edges are provided with one of a pair of interlocking elements such that a projection is located along one long side and a receiver located along the opposite long side. Forms of the panel have interlocking elements located along the end edges or short edges in which one of the pair of complementary interlocking elements is located along one end or short edge and the other of the complementary pair of interlocking element is located along the other of the short edge or end of the panel.

Forms of the panel can include the curvilinear reinforcement located in any suitable or convenient orientation or position or configuration with respect to the body of the panel. In one form the curvilinear mesh has a simple shape, being of a single curve only, or part of a single curve only, or a complex shape, having more than a single curve, such as an "S"-shape, a double curved shape or a regularly repeating curved shape, such as for example, a sine curve or other regularly repeating curved shape. In one form the reinforcement is a concave mesh, or a convex mesh, or similar.

In one form the concave shape is in an upwardly facing orientation, such as facing towards the obverse or upper face, whereas in another form the concave shape is in a downwardly facing orientation, such as facing towards the reverse or lower face.

In one form the curvilinear reinforcing mesh is formed with the transversely extending curved cross wires located on the outside of the longitudinally extending straight rods, which arrangement is referred to as the cross wire being an outside cross wire or similar description.

In one form the curvilinear reinforcing mesh is formed with the transversely extending curved cross wires located on the inside of the longitudinally extending straight wires, which arrangement is referred to as the cross wires being an inside cross wire or similar description.

In forms of the panel, the curved reinforcing mesh is located centrally or substantially centrally within the panel which is sometimes referred to as the reinforcement having a "centralised mesh location".

In forms of the panel the curved reinforcing mesh is located to one side of the panel, which is sometimes referred to as the reinforcement having a "shifted mesh location". In one form the amount of displacement of the curved reinforcement mesh in the shifted mesh location is in the range of from about 2 mm to about 12 mm, typically in the range from about 4 mm to about 10 mm, more typically in the range of from about 6 mm to about 8 mm, to position the two middle longitudinal rods in the centre of the thickness of the panel.

In one form of the manufacturing process, the reinforcing mesh is curved prior to installation within the mould for forming the reinforced building product.

In one form of the manufacturing process, the reinforcing mesh is curved after installation within the mould for forming the reinforced building product. In one form of the manufacturing process, preferably the curved reinforcing mesh is introduced into the moulding station post the pouring process for introducing the flowable material into the mould so that the flowable material in the mould flows around the mesh as it is being introduced into the mould to fully embed the curved mesh within the panel formed from the block being moulded in the mould when the flowable material sets or cures to form a solid substrate.

In one form of the manufacturing process, the curved reinforcing mesh is introduced into the moulding station prior to or substantially simultaneously with the pouring process for introducing the flowable material into the mould.

In one form, the equipment for manufacturing the building product includes a maintainer for maintaining the reinforcing mesh in the curved configurations prior to and during introduction of the flowable material into the mould. One form of the maintainer is a holder. Preferably, the holder includes the base of the mould, typically the holder is in the form of a plate, preferably a steel plate, and more preferably a steel plate that spans the full width of the mould station, preferably having a width of 1 .5m.

Forms of the holder include a body or body portion. Typically, the body or body portion of the holder is a retaining comb. More typically, the retaining comb includes a multitude of individual retaining elements, typically in the form of teeth extending from the base or base plate in a generally upwards direction. Preferably, the retaining elements of the retaining comb are collectively in the shape of a sawtooth or have a sawtooth profile or similar, or are in the form of a regularly repeating curve, such as a sine curve or similar. Forms of the individual teeth of the retaining comb have curved distal ends. More typically, the distal ends are curved on both sides to form a rounded end. More preferably, the collective shape or profile of the ends of the teeth in the sawtooth or sine curve profile extend along the full width of the mould.

Forms of the retaining comb include individual teeth. Preferably, the individual teeth each have an inclined surface and are substantially triangular in cross-section or shape.

In forms of the holder, the retaining combs are connected to the base through a bracket. The bracket can have any suitable or convenient form. In forms of the holder, the base moves with respect to the fixed part of the mould, preferably moves in a lateral or side to side movement to and from either side of the mould. Preferably, the base moves reciprocally to the full extent of the width of the mould. Forms of the holder include a handling element. Forms of the handling element move to engage/disengage from the reinforcing mesh. Typically, the movement of the handling element is reciprocal in a substantially vertical plane, such as for example, alternatively vertically up and down. Forms of the holder, preferably in the form of rods, shafts or similar rotate about the central axis of the rod, typically rotate through about 90° to move between an engaged position and a released position.

The base of the holder is able to be moved along the width of the mould so that the mesh received within the combs of the holder and the holder itself move in unison with each other as a single unit.

In forms of the handling apparatus, the handling element is lowered vertically through the space or gap between the top or upper most and the next lower or second uppermost longitudinal wire or rod.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of products and components thereof will now be described by way of example with reference to the accompanying drawings in which Figure 1 is a schematic side view of one form of a holder for forming one form of mesh reinforcement.

Figure 2 is a schematic top perspective view of one form of a base plate of the assembly for forming the mesh reinforcement.

Figure 3 is a schematic side elevation view of the holder showing the location of one form of the handling element. Figure 4 is a schematic side elevation view of the assembly apparatus showing the handling element in a lowed position.

Figure 5a is a schematic side view of one form of a reinforced panel having a curved mesh reinforcement in which the curved mesh reinforcement is concavely curved downwardly (concave down).

Figure 5b is a schematic side view of one form of a reinforced panel having a curved mesh reinforcement in which the curved mesh reinforcement is concavely curved upwardly (concave up).

Figure 6a is a schematic side view of one form of a reinforced panel in which the position of the curved reinforcing mesh is located at a centralised mesh location.

Figure 6b is a schematic side view of one form of a reinforced panel in which the position of the curved reinforcing mesh is at a shifted mesh location.

Figure 7a is a schematic side view of one form of the building product in which the curved reinforcement mesh has the transverse wires on the outside of the curve (cross rod outside).

Figure 7b is a schematic side view of one form of the building product in which the curved reinforcement mesh has the transverse wires on the inside of the curve (cross rod inside).

Figure 8 is a schematic sectional plan view of one form of a reinforced panel showing the configuration of longitudinal wires and transverse wires forming one form of curved mesh reinforcement located within the panel.

Figure 9 is a schematic and cross section view of one form of a reinforced panel having one form of curved mesh showing typical dimensions of and position of the 5 longitudinal wires and cross wires with respect to the body of the panel.

Figure 10 is a schematic part perspective view and part sectional view of one form of reinforced panel showing the relationship between the curved mesh and the body of the panel.

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Figure 1 1 is a schematic cross section view of the reinforced panel of figure 10.

SPECIFIC EMBODIMENT 5 Handling of one form of reinforcement, in the form of a mesh reinforcement, will now be described as part of the manufacturing process for making a panel having curved reinforcement.

One form of apparatus or assembly for handling reinforcement mesh is generally in the o form of a jig 30 or similar. Jig 30 includes a support base, generally denoted as 1 to provide support for jig 30. Support base 1 is generally rectangular and is fixed in position and arranged in a substantially horizontal configuration at the lower end of jig 30. Support base 1 has a pair of long sides and a pair of shorts sides. A base assembly 3 is mounted on base 1 , and is able to move with respect to base 1

5 reciprocally to and from the long sides as shown by arrows "A" of figure 2. Base

assembly 3 includes a base, typically a base plate 6 in the form of a plate, platen or similar planar element, including a generally rectangular or square plate, so that base assembly 3 and baseplate 6 move in unison laterally between the respective long sides of support base 1 . Retaining comb 2 is connected to base assembly 3 by suitable fixing o means, such as for example, a bracket or similar for engaging with mesh 5 to position and retain reinforcement mesh 5 during the handling operation, such as to both curve the reinforcement mesh and to provide for lifting of the mesh 5 from jig 30 (to be described in more detail later). Retaining comb 2 moves laterally between the respective long sides in the direction of arrow "B" in unison with baseplate 6 in5 accordance with corresponding movement of base assembly 3. Although comb 2 can have any suitable or convenient form, one preferred form includes a multitude of individual retaining elements, typically in the form of individual comb teeth 18. One form of each individual comb teeth 18 is such that the multitude of teeth 18 form a substantially sinusoidal or similar curve having alternating peaks 4 and troughs 14 joined by generally curved surfaces 16 for contacting mesh 5. The distal ends of each individual tooth 18 are rounded on both sides. It is to be noted that curve 10 of the side surfaces of teeth 18 of comb 2 is in accordance with the curve required to be imparted to reinforcing mesh 5 for embedding within the AAC panel at the moulding station during the manufacturing process of making the reinforced AAC panel. Comb 5 has a trough 14 located between adjacent peaks 4 formed by the tops of two adjacent teeth 18. An opening is defined between adjacent peaks 4 for receiving there through mesh 5 to rest in trough 14 intermediate two teeth 18 of comb 5.

Mesh 5 is located against curved surface 10 of one of the teeth 18 of comb 2 to adopt an inclined orientation, which orientation is inclined to the left hand side when viewed in figure 1 . Although the mesh can have any suitable or convenient form, one form of mesh 5 comprises multiple longitudinally extending wires 20, more particularly, namely uppermost long wire 20a, second upper long wire 20b, second lower long wire 20c, and lowermost long wire 20d. In figure 1 there is shown 4 such longitudinal wires 20a, 20b, 20c, and 20d in spaced apart parallel relationship to one another with a relatively larger spacing between the lowermost wire 20d and the next lower most wire, being lower wire 20c when in trough 14. Mesh 5 includes multiple transverse wires 22 interconnected to each of the longitudinal wires 20 defining gaps (not shown) there between. It is to be noted that a single transverse wire 22 is shown in the figures of the accompanying drawings for clarity.

Further, it is to be noted that mesh 5 is inserted vertically into comb 2 from above to rest in the position 1 1 shown in figure 1 . Retaining comb 2 is positioned and arranged such that the lowermost part of the opening corresponding to trough 14 secures lowermost long wire 20d in position 1 1 as shown in figure 1 .

In forms of jig 30 the relative positions of retaining combs 2 are adjustable to accommodate mesh 5 being of different dimensions, particularly different lengths, such as for example, for forming the reinforcement of panels having different lengths. With particular reference to figure 2 there is illustrated baseplate 6 having two retaining combs 5 located in substantially parallel spaced apart relationship to one another at or towards either end of baseplate 6. One of the retaining combs is located at position 13 whereas the other of the retaining combs is located at position 12. In this embodiment either or both retaining comb 2 is releasably connected to baseplate 6 and can be selectively detached from baseplate 6 and moved along the length of the baseplate to a new location with respect to the other retaining comb such that their respective separation is in accordance with the length of the mould into which mesh 5 is to be installed, which in turn is determined by the length of the panel being manufactured. The retaining comb is readily secured at the new location to accommodate mesh having the different length. In some embodiments, one of the combs 2 is fixed whereas the other of comb 2 is movable to adjust the relative distance between the two combs whereas in other embodiments the positions of both combs 2 are adjustable.

A handling element in the form of an elongate rod 7 is provided for engaging and releasing mesh 5. Rod 7 is connected to an overhead assembly, such as for example an overhead gantry or similar. Movement of the rod 7 is in accordance with

corresponding movement of the gantry. When in the left hand side inclined position as shown in figure 1 , mesh 5 is in contact with curved surface 10 of one tooth 18 to adopt the inclined orientation as shown in figure 1 . In this orientation, rod 7 is aligned with the gap between the uppermost long wire 20a and the second uppermost long wire or upper wire 20b whereupon rod 7 is lowered through the gap. Simultaneously with being lowered, rod 7 contacts uppermost long wire 20a to form mesh 5 into a generally arcuate shape by bending, deflecting or deforming mesh 5 as rod 7 is being lowered, so that uppermost wire 20a is on the left hand side of rod 7 and the next uppermost wire, upper wire 20b and the third wire, being second lower wire 20c, are both on the right-hand side of rod 7.

Base assembly 3, together with baseplate 6 and comb 2 are moved to the left hand side in the direction of arrow "B" as shown in figure 3 to move the lowermost wire 20d to the left hand side. As the lowermost wire 20d moves to the left hand side, mesh 5 is further deformed or deflected by the continued lowering of rod 7 to adopt the generally arcuate shape required of the mesh for embedding in the panel at the moulding station.

When the lowermost wire 20d is in the extreme left hand side, rod 7 is further lowered through the gap between the lowermost wire 20d and the second lowermost wire 20c until the distal end of rod 7 in the form of wedge 8 contacts the lowermost wire 20d to retain mesh 5 in position in the curved configurations. It is to be noted that when wedge 8 at the distal end of rod 7 is securely fastened to the lowermost wire 20d, mesh 5 is arranged with respect to rod 7 so that the uppermost long wire 20a and the lowermost long wire 20d are on the left hand side of rod 7 whereas the second uppermost long wire 20b and the second lowermost long wire 20c are both on the right-hand side of rod 7 and transverse wire 22 is generally curved into an arcuate shape, such as for example, as shown in figure 4. In this configuration mesh 5 is bent into the generally arcuate shape for installation into the mould. Owing to the material from which the long wires 20 and the transverse wire 22 are manufactured, when mesh 5 is deformed or deflected or subject to a deforming force or similar to alter the generally rectilinear form of mesh 5 to a generally curvilinear configuration, mesh 5 retains the curved configuration.

With mesh 5 securely retained by rod 7 in the curved configuration, rod 7 is raised to withdraw mesh 5 from between teeth 18 of comb 2 to be clear of jig 30. The gantry is moved laterally to convey rod 7 to the moulding station within the manufacturing installation. At the moulding station, a mouldable mixture of flowable material is introduced into the mould for forming the aerated mixture. After the introduction of the flowable material into the mould for moulding into the shape of the panel, the gantry is moved to lower rod 7 with attached curved mesh 5 into the aerating mixture within the mould. The aerating mixture continues to aerate to form a block from which the AAC building product can be obtained. The aerating mixture continues to aerate around curved mesh 5 and rod 7 to fully embed curved mesh 5 within the block of AAC being formed in the mould. At the relevant time during the manufacturing process occurring at the moulding station, the lowermost wire 20d is released from wedge 8 of bar 7, such as for example by axially rotating rod 7 through about 90°, to disengage wedge 8 from the lowermost wire 20d thereby allowing rod 7 to be withdrawn from mesh 5 and to be raised by corresponding movement of the gantry to lift rod 7 from the mixture within the mould at the moulding station so as to be clear of the mould. When rod 7 has been removed entirely from the mould, it is conveyed back to the mesh handling station for reuse with another fresh mesh 5 positioned within jig 30. Now, jig 30 has moved to the right hand side as indicated by arrow "C" of figure 2 ready to receive fresh mesh 5 to recommence another cycle in the bending of mesh into the curved configurations and transporting the curved mesh to the moulding station. ADVANTAGES

Advantages of one or other embodiment as described herein include the following.

One advantage of handling the reinforcement mesh relates to the manner of engaging the mesh which allows numerous mesh pieces or individual sheets of mesh to be connected to the handling element or handling rod simultaneously. In some embodiments up to about 100 individual pieces or sheets of mesh can be connected to a group or set of handling elements in a single operation using the method of handling of embodiments of the description.

Efficiencies gained by using the described embodiments allow more panels to be made.

In forms of the method, the curved mesh is introduced into the moulding station post commencement of the pouring process which assists in retaining the curved mesh in the curved configurations. In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Claims

CLAIMS;

1 . A reinforced building product comprising a body formed from a mouldable material and a reinforcement, the body having a generally rectilinear shape, the reinforcement being generally curvilinear, wherein the reinforcement is located within the body of the product, the curvilinear reinforcement enhancing the strength and/or rigidity of the building product to increase robustness of the building product.

2. A method of making a reinforced building product comprising a generally rectilinear body made from a mouldable material, the body having a first face and a second face, and a generally curvilinear reinforcement, the reinforcement being curved in a direction from the first face of the body to the second face of the body, the method comprising the steps of locating the reinforcement in a first orientation, imparting a curvilinear shape to the reinforcement, introducing the mouldable material into a mould, simultaneously or subsequently locating the reinforcement in the generally curvilinear shape in the mould, forming the body of the building product around the curvilinear reinforcement when in the mould, wherein the mouldable material surrounds the curvilinear reinforcement to embed the curvilinear reinforcement within the body of the building product.

A method of making a generally curvilinear reinforcement for use in forming a reinforced building product, the method comprising the steps of locating a first set of linear reinforcing elements in a first orientation in a first location, locating a second set of linear reinforcing elements in a second orientation in a second location, joining the first set of linear reinforcing elements to the second set of linear reinforcing elements to form a generally rectilinear array of reinforcing elements, and applying a deflecting force to the interconnected array of the first set of linear reinforcing elements and the second set of reinforcing elements to impart a curvilinear shape collectively to the reinforcing elements and maintaining the curvilinear shape.

4. An apparatus for handling a generally curvilinear reinforcement for embedding within a building product made from a mouldable material, comprising a holder for locating the reinforcement in a first orientation in a first location, a force applying device for applying a deflecting force to the rectilinear reinforcement to deflect the reinforcement from a generally rectilinear shape to a generally curvilinear shape, and a shape maintaining device for maintaining the generally curvilinear shape of the reinforcement during the manufacturing process for forming a generally rectilinear building product from the mouldable material within which the generally curvilinear reinforcement is embedded.

A reinforced product according to any preceding claim in which the curvilinear reinforcement is curved, arcuate, arched, elliptical, rounded, serpentine, twisted, sigmoid, sinuous, arced, arciform, circular, ovoid, crescent, sickle- shaped, bow-shaped, bowed, concave, convex, falcate, semicircular, crescentic, or is provided with a radius of curvature in one direction or in one plane.

A reinforced product according to any preceding claim in which the

reinforcement is in the form of rods, bars, wires, shafts, mesh, screens, perforated sheets, or sieves.

A reinforced product according to any preceding claim in which the

reinforcement is in the form of a mesh which is formed, made or manufactured from a generally rectilinear arrangement of individual linear reinforcing elements, typically interconnected to one another to form a generally rectilinear interconnected array or arrangement of the linear reinforcing members.

A reinforced product according to any preceding claim in which the curvilinear interconnected array or arrangement is in the form of a grid or array of linear reinforcing elements including longitudinally extending and transversely extending elements, which have been subjected to bending, deflection, deformation, distortion, or other disrupting forces or the like in order to adopt the curvilinear orientation.

A reinforced product according to any preceding claim in which the reinforcing elements prior to bending include linear rods, bars, wires or shafts.

A reinforced product according to any preceding claim in which both of the longitudinal wires and transverse wires of the curved reinforcing mesh are curved or only the longitudinal wires are curved or only the transverse wires are curved.

A reinforced product according to any preceding claim in which the transverse wires are curved and the longitudinal wires are linear.

A reinforced product according to any preceding claim in which the reinforcing elements in the form of rods or wires are made from metal, alloys, stainless steel, coated steel, high tensile steel, including being made from any suitable or convenient material having properties conducive to forming and maintaining the generally curvilinear shape of the reinforcement when embedded in the generally rectilinear panel, block or slab.

A reinforced product according to any preceding claim in which the material from which the wires or rods forming the mesh are manufactured is such so that after the mesh has been curved, the mesh retains the curved shape before, during and/or after installation within the mould at the moulding station.

A reinforced product according to any preceding claim in which the reinforcing element has a size, including a diameter, of from about 2 mm to about 16 mm, typically from about 2.5 mm to about 14 mm, more typically from about 3 mm to 10 mm, preferably about 3 mm to 6 mm, more preferably about 3 mm to 5 mm inclusive.

A reinforced product according to any preceding claim in which the mesh reinforcement includes a multitude of longitudinally extending linear reinforcing elements and a multitude of transversely extending linear reinforcing elements interconnected to one another to form a generally rectilinear grid, pattern or arrangement in which the longitudinal reinforcing elements and transverse reinforcing elements extend substantially perpendicularly to one another to form gaps, spaces, or voids therebetween, typically, rectangular or square shaped gaps or spaces.

16. A reinforced product according to any preceding claim in which the dimensions of the gaps, spaces or voids are sufficient to receive therethrough a handling element for securing the mesh during handling operations of the mesh and/or during manufacturing steps of the manufacturing process.

17. A reinforced product according to any preceding claim in which the longitudinal elements and transverse elements are inclined to one another to form diamond shaped or rhomboid shaped patterns or arrangements. 18. A reinforced product according to any preceding claim in which the spacing apart of the longitudinal reinforcing elements of the mesh are uniform or constant or the spacing apart of the longitudinal reinforcing elements is variable. 19. A reinforced product according to any preceding claim in which the number of longitudinal wires is from about three to about twelve, more typically from about four to about ten, even more typically about five to about eight individual wires, and the number of transverse wires is from about two to about thirty, typically from about three to about twenty, more typically from about four to about ten, even more typically about five to about eight.

20. A reinforced product according to any preceding claim in which the mesh is a 5 x 4, a 5 x 3, or a 5 x 5 mesh in which there are five longitudinal wires and three, four or five transverse wires, respectively forming each respective mesh.

21 . A reinforced product according to any preceding claim in which the curved reinforcement mesh is embedded within the product so that the ends of the mesh are closer to the longitudinal sides of the panel. 22. A reinforced product according to any preceding claim in which the

reinforcement has typical values of 14 ± 3 mm or from 19 ± 3 mm. A reinforced product according to any preceding claim in which the mesh is embedded at or towards the centre of the panel, typically about the central axis or midpoint of the panel, and in which the values of the mesh are 26 ± 3 mm, or 25 ± 3 mm.

A reinforced product according to any preceding claim in which the mesh reinforcement includes perforated sheets having a plurality of apertures, openings, holes, voids, gaps or similar in which the plane of the sheet is curved to form the generally curvilinear reinforcement.

A reinforced product according to any preceding claim in which the product includes panels, blocks, slabs, or tiles, in which the building product is made from a lightweight material having a density of less than about 1800 kg/m².

A reinforced product according to any preceding claim in which the lightweight material includes lightweight cementitious materials, aerated concrete, autoclaved aerated concrete or similar.

A reinforced product according to any preceding claim in which the length of the product is greater than about 2.4 m, greater than about 2.75 m, greater than about 3.0 m, up to about 3.3 m, up to about 3.6 m, or up to about 3.9 meter, or up to about 4.2 m.

A reinforced product according to any preceding claim in which the width of the product is in the range of from about 200 mm to about 1 .2 m, typically from about 250 mm to about 900 mm, more typically from about 270 mm to about 800 mm, more typically from about 300 mm to about 750 mm, and even more typically from about 400 mm to about 600 mm.

A reinforced product according to any preceding claim in which the thickness of the product is in the range from about 30 mm up to about 200 mm, typically from about 40 mm up to about 150 mm, preferably with about 45 mm nominally to about 80 mm nominally, with typical thicknesses being about 50 mm nominally, about 75 mm nominally, or about 100 mm nominally. A reinforced product according to any preceding claim in which the shape of th product is a parallelepiped, rectangular prism, or other regular shape having substantially rectangular faces, sides, edges, and/or ends having two opposed faces, being a top, upper, front or obverse face and a bottom, lower, rear or reverse face in spaced apart relationship to each other.

A reinforced product according to any preceding claim in which the product is straight edged or straight ended or is provided with interlocking elements, including projecting elements and receiving elements, in which the shape of the projections and receivers are complementary to one another, including a tongue and groove arrangement or similar complementary arrangement for interlockingly connecting two panels to one another.

A reinforced product according to any preceding claim in which the product is a panel having a pair of long sides or edges in which the long sides or edges are provided with one of a pair of interlocking elements in which one of the projection or the receiver is located along one longitudinal side or edge and the other of the projection or the receiver is located along the opposite long side or edge.

A reinforced product according to any preceding claim in which the product has interlocking elements located along the end edges or short sides in which one of the pair of complementary interlocking elements is located along one end edge or short side or short and of the panel and the other of the complementary pair of interlocking elements is located along the other of the short edge or short side or short end of the panel.

A reinforced product according to any preceding claim in which the curvilinear reinforcement has a simple shape, being of a single curve only, or part of a single curve only, or has a complex shape, having more than a single curve, such as an "S"-shape, a double curved shape or a regularly repeating curved shape, such as for example, a sine curve or other regularly repeating curved shape.

A reinforced product according to any preceding claim in which the curvilinear reinforcement is is a concave mesh, or a convex mesh, or similar. A reinforced product according to any preceding claim in which the concave shape is in an upwardly facing orientation, such as facing towards the obverse or upper face of the product, or is in the concave shape which is in a downwardly facing orientation, such as facing towards the reverse or lower face.

A reinforced product according to any preceding claim in which the curvilinear reinforcing mesh is formed with the transversely extending curved cross wires located on the outside of the longitudinally extending straight rods, which arrangement is referred to as the cross wire being an outside cross wire or similar description.

A reinforced product according to any preceding claim in which the curvilinear reinforcing mesh is formed with the transversely extending curved cross wires located on the inside of the longitudinally extending straight wires, which arrangement is referred to as the cross wires being an inside cross wire or similar description.

A reinforced product according to any preceding claim in which the curved reinforcing mesh is located centrally or substantially centrally within the panel which is sometimes referred to as the reinforcement having a "centralised mesh location".

A reinforced product according to any preceding claim in which the curved reinforcing mesh is located to one side of the panel, which is sometimes referred to as the reinforcement having a "shifted mesh location".

A reinforced product according to any preceding claim in which the amount of displacement of the curved reinforcement mesh in the shifted mesh location is in the range of from about 2 mm to about 12 mm, typically in the range from about 4 mm to about 10 mm, more typically in the range of from about 6 mm to about 8 mm, to position the two middle longitudinal rods in the centre of the thickness of the panel.

42. A reinforced product according to any preceding claim in which the reinforcing mesh is curved prior to installation within the mould for forming the reinforced building product.

A reinforced product according to any preceding claim in which the reinforcing mesh is curved after installation within the mould for forming the reinforced building product.

A reinforced product according to any preceding claim in which the curvilinear mesh is introduced into the moulding station post the pouring process for introducing the flowable material into the mould so that the flowable material in the mould flows around the mesh as it is being introduced into the mould to fully embed the curved mesh within the panel formed from the block being moulded in the mould when the flowable material sets or cures to form a solid substrate.

A reinforced product according to any preceding claim in which the curved reinforcing mesh is introduced into the moulding station prior to or substantially simultaneously with the pouring process for introducing the flowable material into the mould.

A reinforced product according to any preceding claim in which equipment used for manufacturing the building product includes a maintainer for maintaining the reinforcing mesh in the curved configuration prior to and during introduction of the flowable material into the mould.

A reinforced product according to any preceding claim in which the maintainer is a holder which includes the base of the mould.

A reinforced product according to any preceding claim in which the base of the holder is a plate, preferably a steel plate, and more preferably a steel plate that spans the full width of the mould station, preferably having a width of about 1 .5m.

A reinforced product according to any preceding claim in which the holder includes a body or body portion in the form of a retaining comb having a multitude of retaining elements for retaining the mesh prior to, during and/or after curving the mesh. A reinforced product according to any preceding claim in which the retaining elements are in the form of teeth extending from the base or base plate in a generally upwards direction wherein the retaining elements of the retaining comb are collectively in the shape of a sawtooth or have a sawtooth profile or similar alternating profile, or are in the form of a regularly repeating curve, such as a sine curve or similar.

A reinforced product according to any preceding claim in which the individual teeth of the retaining comb have curved distal ends and/or curved sides or similar.

A reinforced product according to any preceding claim in which the distal ends of the individual teeth of the retaining comb are curved on both sides to form a rounded end.

A reinforced product according to any preceding claim in which the collective shape or profile of the ends of the teeth in the sawtooth or sine curve profile extend along the full width of the mould.

A reinforced product according to any preceding claim in which the individual teeth of the retaining comb each have an inclined surface and are substantially triangular in cross-section or shape or have two opposed inclined surfaces.

A reinforced product according to any preceding claim in which the holder includes a base wherein the base moves with respect to the fixed part of the mould, preferably in a lateral or side to side movement to and from either side of the mould to assist in curving the mesh.

A reinforced product according to any preceding claim in which the base moves reciprocally to the full extent of the width of the mould.

A reinforced product according to any preceding claim in which the holder further comprises a handling element for movement to engage/disengage from the reinforcing mesh, typically one of the reinforcing elements of the mesh, wherein the movement of the handling element is reciprocal in a substantially vertical plane, such as for example, alternatively vertically up and down or perpendicularly to the plane of movement of the base.

A reinforced product according to any preceding claim in which the holder is in the form of a rod, shaft or similar able to rotate about the central axis of the rod, typically rotate through about 90° to move between an engaged position and a release position.

A reinforced product according to any preceding claim in which the base of the holder is able to be moved along the width of the mould so that the mesh received within the combs of the holder and the holder itself move in unison with each other as a single unit.

A reinforced product according to any preceding claim in which the handling apparatus includes a handling element wherein the handling element is lowered vertically through the space or gap between the top or uppermost reinforcing element and the next lower or second uppermost reinforcing element.

A reinforced building product substantially as herein described with reference to the accompanying drawings.

A method of making a reinforced building product substantially as herein described with reference to the accompanying drawings.

A method of making a generally curvilinear reinforcement for use in forming a reinforced building product substantially as herein described with reference to the accompanying drawings.

64. An apparatus for handling a generally curvilinear reinforcement for embedding within a building product made from a flowable material substantially as herein described with reference to the accompanying drawings.