AU2008202281B1

AU2008202281B1 - Spacing member for a building panel

Info

Publication number: AU2008202281B1
Application number: AU2008202281A
Authority: AU
Inventors: Peter David Arkcoll; Ronald James Arkcoll
Original assignee: CSR Structural Systems Pty Ltd
Current assignee: CSR Structural Systems Pty Ltd
Priority date: 2008-05-22
Filing date: 2008-05-22
Publication date: 2009-07-23
Anticipated expiration: 2028-05-22
Also published as: NZ577139A

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATiON FOR A STANDARD PATENT ORIGINAL Applicant(s): RONALD JAMES ARKCOLL and PETER DAVID ARKCOLL Actual Inventor(): Ronald James Arkeoll Peter David Ark coll Address for Serv ce: PATENT ATTORNEY SERVICES 26 Ellingworth Parade Box Ilill Victoria 3128 Australia Title: SPACING MEMBER FOR A BUILDING PANEL Associated Provi ional Applications: No(s).: The following s ttement is a full description of this invention, including the best method of performing it 1nown to me/us: 1 $PACING MEMBER FOR A BUILDING PANEL Field of the Invention The pre ent application relates to building panels for use in building construction, and in particular, to spacing members for a hollow building panel that can be filled with a fller such as etnrete. Background if the Invention Prefabricated building components, which are manufactured at one site and then transported to i construction site to be assembled, have proven useful to the building and construction ir dustry. 10 Prefabrcated building components, in the form of prefabricated, reinforced concrete pane s made to specific sizes and dimensions, provide relatively quick and simple assernly and construction, thereby contributing to earlier building project completion. 'Ihe use of prefabricated building components can also provide a substantial reduction in labour costs in both the manufacturing and assembly processes, as the panels 15 are typically nass produced at a manufacturing site and transported to the construction site where theY are assembled. In this regard, there is no requirement for a large number of tradesmen md labourers to assemble individual blocks or bicks to form the walls of the building. One issue with using prefabricated reinforced concrete panels is that, due to their 20 typical large size and weight, they are relatively difficult to handle and transport. In this regard, dedicated lifting equipment in the form of cranes and the like, is often required to handle the panels, which can significantly add to transport and handling costs. There are also safety issues associated with handling such panels at both the manufacturing and the construction site, which require adherence to stringent safety requirements and 25 procedures in order to ensure a safe work environment. For tlts reason, building components that are not completely prefabricated but which are finished at the construction site upon, or immediately prior to, assembly have been proposed. Such components are typically assembled off-site in a form that is more easily handled and transported to the construction site where they can be readily erected 30 and filled wi concrete, without the need for cranes and other such dedicated equipment. One such b ilding component is described in Australian Innovation Patent Nos. 2 2004100393 and 2007100210, the contents of which are incorporated herein by reference for further back round technical information. The pan described in the above referenced patent applications comprises a pair of facing sheets, such as fibre cement sheets, spaced apart and connected by a plurality of 5 studs or spacer members. The studs or spacer members are in the form of steel stud frames extend g longitudinally between the facing sheets in a spaced array, Following assembly of the facing sheets and the studs, each panel can be easily stacked for transportation t the construction site, where they can be relatively quickly and easily hand erected ii to position. The panels are then reinforced as required, typically by 1o feeding steel ba s through the aligned holes in the studs separating the facing sheets, and then the panels are core-filled with concrete by pouring concrete into the internal cavity or space provi ed between the facing sheets to achieve the desired structural strength of the panel. Du to the simplicity of the design of the panels, panels can be made in a variety of size- and thicknesses to suit a variety of architectural and engineering design 15 requirements. Further, the panels are able to meet structural strength, thermal-barrier and acoustic-b trier standards. Depend g upon the particular application of the panel and the structural requirements f the construction to which it is used, the reinforcement requirements of the panel may differ between applications. Typically, the studs of the panel have holes 20 formed there to facilitate the flow of concrete between the studs of the panel to ensure that the poure concrete is evenly distributed throughout the internal space of the panel. The ho. es formed in the studs also typically function to accommodate and locate the reinforcin bars. In this regard, upon erecting the panels and prior to pouring the concrete, rein arcing bars are inserted through the holes fanned in the studs to provide 25 horizontal rei forcement. Typically, the holes are round or oval in shape and readily accommodate a single reinforcing bar. However, in instances where greater horizontal reinforcemen is required, it is not possible to readily insert two or more reinforcing bars through the h les in the studs such that the bars are separated from one another and are securely local in position. In such instances it is necessary for alternative means such 30 as wire ties to be provided to locate and separate the bars, requiring additional labour and tools. Thus, bere is a need to provide a building panel of the type that is core-filled with concrete whi h provides for a variety of horizontal reinforcement options. 3 The above references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art in Australia. Summary of the Invention 5 According to a first aspect, the present invention provides a spacing member for a building panel comprising: an elongate web configured to extend at least partially between a pair of spaced facing members; the web having longitudinal edges each being attachable to a respective one of the 10 pair of spaced facing members, the web including a plurality of holes spaced along its length, each hole having a conformation to receive extending therethrough and to locate in position at least two elongated reinforcement bars for providing reinforcement to the building panel, the conformation of each hole comprising a peripheral shape of the hole which provides: 15 e in a first upright orientation of the spacing member two concavities in a lower edge of the peripheral shape of the hole which are arranged to receive, locate and support respective reinforcement bars so that they are maintained separated from each other, and e in a second upright orientation of the spacing member which is an inversion of 20 the first upright orientation a single concavity in a lower edge of the peripheral shape of the hole which is arranged to receive, locate and support a single reinforcement bar so that it is maintained in a desired position between the facing members. 25 In the preferred spacing member, when it is in its first upright orientation, the conformation is operative to locate and maintain the reinforcement bars separated horizontally from each other. Also preferably when the spacing member is in its first upright orientation, the 30 reinforcement bars are received, located, supported and maintained spaced inwardly from the facing members of the building panel by predetermined distances to receive filler material between each reinforcement bar and the respective facing member. 4 Preferably when the spacing member is in its first upright orientation, the two concavities in the lower edge of each hole are spaced apart by a raised convex region of the peripheral shape of the hole, the convex region functioning to assist in locating and maintaining the reinforcement bars in their respective concavities. 5 Each hole in peripheral shape may comprise an arcuate portion which defines the single concavity for receiving the single reinforcement bar and a laterally extending linking portion which provides the two concavities for receiving the two reinforcement bars. Preferably the two concavities in the laterally extending linking portion are 10 separated by a convex region which is operative to assist in locating and maintaining the two reinforcement bars in the respective concavities. Preferably the single reinforcement bar received and located in the hole when the spacing member is in the second upright orientation is maintained centred between the 15 spaced facing members of the panel. Each hole may be formed by cutting or punching the hole in the web between its longitudinal edges. The peripheral shape of each hole preferably includes a stiffening flange formed by bending a portion of the web around the peripheral edge of the hole out 20 of the plane of the web. In this embodiment, part of the conformation of the hole may comprise an upwardly extending convexity between the two spaced concavities for receiving respective reinforcement bars and the convexity may include a differently profiled stiffening flange compared to the flange at the two concavities. 25 According to a second aspect, the present invention provides a building panel comprising: a pair of spaced facing members so as to define a cavity therebetween; a plurality of spacing members, each of the spacing members comprising an elongate web extending at least partially between the pair of spaced facing members the 30 web having longitudinal edges attached to respective ones of the pair of spaced facing members, the web including a plurality of holes spaced along its length, each hole having 5 a conformation to receive extending therethrough and to locate in position at least two elongated reinforcement bars for providing reinforcement to the building panel, the conformation including a peripheral shape of the hole which provides: * in a first upright orientation of the building panel two concavities in a lower edge of 5 the peripheral shape of the hole which are arranged to receive, locate and support respective reinforcement bars so that they are maintained separated from each other, and e in a second upright orientation of the building panel which is an inversion of the first upright orientation a single concavity in a lower edge of the peripheral shape of the 10 hole which is arranged to receive, locate and support a single reinforcement bar so that it is maintained in a desired position between the facing members; and a filler of concrete or other filler material substantially filling the cavity between the facing members including continuously extending through the holes and encapsulating the reinforcement bars. 15 In a third aspect, the present invention provides a method of erecting and installing a building panel in a building structure, the method comprising the steps of: providing a building panel comprising a plurality of spacing members, each spacing member being according to any one of claims 1 to 11, and arranging the spacing 20 members in parallel spaced relationship to each other so that the holes of each spacing member are substantially aligned with corresponding holes in all of the other spacing members, providing a pair of spaced facing members attached to all of the plurality of spacing members at the respective longitudinal edges of each spacing member so as to define a 25 cavity between the spaced facing members, erecting the building panel in a selected one of first upright and second upright orientations depending upon whether two spaced reinforcement bars are to be provided extending through aligned holes in the plurality of spacing members or whether a single reinforcing bar is to be provided extending through aligned holes in the plurality of 30 spacing members, inserting reinforcing bars through the aligned holes in the plurality of spacing members so that they are located and supported by the concavities in the lower edges of 5a the peripheral shapes of the aligned holes in the plurality of spacing members with the reinforcing bars having the desired spacing from the spaced facing members of the building panel, and substantially filling with concrete or other filler material the cavity between the 5 facing members including continuously extending through the holes in the spacing members and encapsulating the reinforcement bars. 10 15 20 25 5b Brief Description of the Drawings Possible and preferred features of the present invention will now be described with particular reference to the accompanying drawings. However it is to be understood 5 that the feature illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. In the drawings: FIG. I shows a perspective view of a first embodiment of a building panel in accordance with the present invention; FJG. 2 5hows a front view of the stud of the building panel of FIG. I in a first 10 orientation; FIG. 3 shows a front view of the stud of the building panel of FIG. I in a second orientation; FIG. 4 shows a front view of an alternative configuration of hole in the stud; and FIG. 5 shows a fragmentary, part sectional view of a further configuration of hole 15 in the stud. Detailed Des ription of an Exemplary Embodiment of the Invention Whilst the panels of the present invention will be described in relation to their application as a permanent formwork structural walling system, it will be appreciated that 20 the present invention could be employed in relation to a variety of structural elements, such as flooring systems and the like. Referri ng to FIG. 1, a building panel 10 in accordance with an embodiment of the present inven ion is shown. The panel 10 comprises a pair of facing members shown as sheets 12 spa ed apart by a plurality of spacer members shown as studs 14 to define an 25 internal space 13 therebetween. The facing sheets 12 are generally rigid, and may be in the form of f bre cement sheets, plasterboard sheets, or sheets made from any suitable material. The facing sheets 12 form the external surfaces of the panel 10 and may be configured to have one or more skins attached thereto, where required. The stads 14 are arranged to extend in a substantially vertical and parallel array 30 within the sp cc 13 so as to define a plurality of chambers 15 therein. Each stud 14 is in the form of an elongate frame member having a U-channel shaped cross section and being made f om a galvanised sheet steel or any other suitable material. Each stud 14 comprises a web 16 that has along its longitudinal edges a pair of flanges 18. The 6 flanges 18 exte d substantially perpendicular from the web 16 and provide a means for attachment of t e facing sheets 12 to the stud 14. Such attachment may be achieved by applying a suita le adhesive to the outer surfaces of the flanges 18, which adheres to the inner surface of the corresponding facing sheet 12. It will be appreciated that in addition 5 to, or instead of, such an adhesive attachment, one or more screws or similar mechanical fasteners may te provided to secure the facing sheets 12 to the flanges 18 of the studs. As shovn, a plurality of holes 20 are provided in the web 16 of each stud 14 at regular intervals along the length thereof. Each of the holes 20 is preferably formed by punching the desired shape of the hole from the web 16 in a known manner, although 10 other means f4or forming the holes 20 are also envisaged. The holes 20 enable communication between the adjacent individual chambers 15, such that when concrete is poured into the space 13, the concrete is able to flow between the individual chambers 15 facilitating even distribution of the concrete throughout the space 13 of the panel 10. The ho es 20 formed in the web 16 of the studs 14 also function to receive and is locate horizon 1 reinforcing bars 22, as shown in FIG. J - In this regard, as the assembly of studs 14 an(l facing sheets 12 is formed, the studs are positioned such that the holes 20 formed in adj' cent studs substantially align. This enables the reinforcing bars 22 to be inserted through the boles 20 from one end of the panel 10, prior to pouring the concrete, such that they are supported in position by the studs 14. In the embodiment as shown in 20 FIG. 1, two reinforcement bars 22 are inserted through a series of aligned holes 20, however it wi 1 be appreciated that the number of bars 22 may vary depending upon the structural loa requirements of the panel The manner in which the studs 14 function to receive and locate the reinforcing bars 22 can be seen more clearly in FIGS. 2 and 3. 25 Each Iole 20 has a peripheral shape that is generally semi-oval, comprising an arcuate portion 24 connected by a laterally extending linking portion 26 that extends in the direction across the web 16. As is shown in FIG. 2, the linking portion 26 forms a base or lower portion of the hole 20, whilst in FIG. 3, the laterally extending portion 26 forms the upper portion of the hole 20. 30 Referr ng to FIG. 2, the laterally extending linking portion 26 comprises a pair of concavities o troughs 25 with an intermediate a peaked or convex region 27. As is shown, the t-oughs 25 are located at opposing ends of the linking portion 26. The troughs 25 pr video a means for locating two reinforcing bars 22 such that the bars 22 are 7 spaced apart from each other. In this arrangement, two bars 22 can be inserted from an open end of th panel 10 through aligned holes 20 in the studs 14 of the panel 10 to provide horizontal reinforcement of the panel 10 when filled with concrete- The two bars 22 are retained separated by the function of the shape of the holes as the bars naturally 5 locate themsel es in the troughs 25 provided in the linking portion 26. By spacing apart the reinforcing bars 22, concrete flow within the space 13 of the panel 10 and around the bars 22 is imp oved, thereby achieving the desired structural characteristics of the panel 10. The spacit g between the troughs 25 and the depth of the troughs within the panel 10, i.e. the spacing of each trough 25 from its nearest facing sheet 12, can be chosen so that 10 the panel 10 od final concrete filled structural element can comply with the relevant building stand yards. It will also be appreciated that the automatic locating function of the shape of the holes 20, in particular, the provision of the spaced apart troughs 25 for receiving the bars 22, does not require significant manual manipulation to position the bars 22 within the 15 panel 10. As the bars 22 are naturally received and located in the troughs 25, the bars can be relatively simply inserted into position, on site. There is also no need for wire tiles to main in the bars 22 at their required spacing as is a shown practice at present. Referring to FIG. 3, an alternative arrangement of the stud 14 is shown. In this arrangement, the stud 14 is provided for use with a panel 10 that requires only a single 20 horizontal reinforcing bar 22. In this arrangement, the studs 14 of the panel 10 are attached to t-e facing sheets 20 in an inverted orientation, with respect the arrangement of FIG. 2. As can be seen, te laterally extending linking portion 26 forms the upper portion of the hole 20. Therefore, the single reinforcing bar 22 is received and supported on the arcuate portion 24 of the hole 20, resting at the lowest point thereof. As the lowest 25 point of the arcuate region 24 is located laterally in the centre of the hole 16, the single reinforcing bars is located substantially in the centre of the panel 10 when inserted. Similrly, with such an arrangement as shown in FIG. 3, the process of inserting the reinforci g rods 22 into the panel 10 is relatively simple. The rods 22 are merely inserted front an open end of the panel 10 through aligned holes in the studs 14 of the 30 panel and t-cy naturally locate in positions at the centre of the arcuate portions 24, namely the lowest points of the holes 20. The concrete can then be poured into the space 13 encapsul ting the rods 22 therein and providing the desired horizontal reinforcement to the panel 0. 8 It will appreciated that the studs 14 of the present invention provide a means for facilitating the flow of concrete within the space 13 of the panel 10, as well as provide a unique means for receiving and locating reinforcing bars 22 within the panel to achieve the desired strength of the panel 10. The studs 14 can be simply adapted to allow 5 for a variety of structural specifications of the panel 10 to be satisfied, in particular, whether single or dual horizontal reinforcement bars are required, by merely changing the orientation of the studs by inversion during assembly. As such, there is no need to supply two diferent types of studs 14 such different construction needs or use wire ties where two horizontally spaced rods are required. 10 It will be appreciated that whilst the embodiment of the studs 14 as shown is able to cater for single and double horizontal reinforcement, the shape of the holes can be adapted to cter for other multiple reinforcement needs. In this regard, the arcuate portion 24 ard/or the laterally extending linking portion 26 may comprise additional troughs 25 fo med therein to provide additional reinforcement options for the panel 10. 15 Referr ng to Fig. 4, one variation of the spacing member construction is illustrated. It this embodiment, a further concavity or trough 35 and/or 36 is formed in the peripheral edge of the hole 20 so that a further reinforcement bar can be received and located therein. This trough 35 may be above the dual concavities 25 or, when inverted, may be at 36 above the single concavity 24. This configuration is probably not preferred 20 because a ba: can more readily be dislodged from the trough 35 or 36 and fall to the lower portion of the hole 20 where it may not be located spaced from the bar or bars located in the troughs 25 or 24. Nevertheless this embodiment falls within the scope of the present invention. In Fig. 5 there is shown a portion of a web sectioned longitudinally at 16A to 25 show the cor formation at trough 25 and at 16B to show the conformation of the edge of the hole 20 where it extends up into the arcuate portion 24. In this embodiment, the edges of the tole 20 are bent out of the plane of the web 16 to form stiffening flanges 21. In the conve portion 27 the material of the web is not bent, or is not bent to the same extent, out cf the plane of the web 16 so that this differing shaping of the hole edges 30 helps to define convex region 27 separating the troughs 25 which receive the reinforceme t bars. 9 It is tc be understood that various alterations, modifications and/or additions may be made to the features of the possible and preferred embodiment(s) of the invention as herein described without departing from the spirit and scope of the invention. 10

Claims

1. A spacing member for a building panel comprising: an elongate web configured to extend at least partially between a pair of spaced 5 facing members; the web having longitudinal edges each being attachable to a respective one of the pair of spaced facing members, the web including a plurality of holes spaced along its length, each hole having a conformation to receive extending therethrough and to locate in position at least two 10 elongated reinforcement bars for providing reinforcement to the building panel, the conformation of each hole comprising a peripheral shape of the hole which provides: 0 in a first upright orientation of the spacing member two concavities in a lower edge of the peripheral shape of the hole which are arranged to receive, locate and support respective reinforcement bars so that they are maintained separated 15 from each other, and e in a second upright orientation of the spacing member which is an inversion of the first upright orientation a single concavity in a lower edge of the peripheral shape of the hole which is arranged to receive, locate and support a single reinforcement bar so that it is maintained in a desired position between the 20 facing members.

2. A spacing member according to claim 1 wherein, when the spacing member is in its first upright orientation, the conformation is operative to locate and maintain the reinforcement bars separated horizontally from each other. 25

3. A spacing member according to claim 1 or 2 wherein, when the spacing member is in its first upright orientation, the reinforcement bars are received, located, supported and maintained spaced inwardly from the facing members of the building panel by predetermined distances to receive filler material between each reinforcement bar and the 30 respective facing member. 11

4. A spacing member according to any one of the preceding claims wherein when the spacing member is in its first upright orientation, the two concavities in the lower edge of each hole are spaced apart by a raised convex region of the peripheral shape of the hole, the convex region functioning to assist in locating and maintaining the reinforcement 5 bars in their respective concavities.

5. A spacing member according to any one of claims 1 to 3 wherein each hole in peripheral shape comprises an arcuate portion which defines the single concavity for receiving the single reinforcement bar and a laterally extending linking portion which 10 provides the two concavities for receiving the two reinforcement bars.

6. A spacing member according to claim 5 wherein the two concavities in the laterally extending linking portion are separated by a convex region which is operative to assist in locating and maintaining the two reinforcement bars in the respective concavities. 15

7. A spacing member according to any one of the preceding claims wherein the single reinforcement bar received and located in the hole when the spacing member is in the second upright orientation is maintained centred between the spaced facing members of the panel. 20

8. A spacing member according to any one of the preceding claims wherein each hole has been formed by cutting or punching the hole in the web between its longitudinal edges. 25

9. A spacing member according to claim 8 wherein the peripheral shape of the hole includes a stiffening flange formed by bending a portion of the web around the peripheral edge of the hole out of the plane of the web.

10. A spacing member according to claim 9 wherein part of the conformation of the 30 hole comprises an upwardly extending convexity between the two spaced concavities for receiving respective reinforcement bars and wherein the convexity includes a differently profiled stiffening flange compared to the flange at the two concavities. 12

11. A spacing member for a building panel substantially as herein before described with particular reference to the accompanying drawings. 5

12. A building panel comprising: a pair of spaced facing members so as to define a cavity therebetween; a plurality of spacing members, each of the spacing members comprising an elongate web extending at least partially between the pair of spaced facing members the web having longitudinal edges attached to respective ones of the pair of spaced facing 10 members, the web including a plurality of holes spaced along its length, each hole having a conformation to receive extending therethrough and to locate in position at least two elongated reinforcement bars for providing reinforcement to the building panel, the conformation including a peripheral shape of the hole which provides: * in a first upright orientation of the building panel two concavities in a lower edge of 15 the peripheral shape of the hole which are arranged to receive, locate and support respective reinforcement bars so that they are maintained separated from each other, and e in a second upright orientation of the building panel which is an inversion of the first upright orientation a single concavity in a lower edge of the peripheral shape of the 20 hole which is arranged to receive, locate and support a single reinforcement bar so that it is maintained in a desired position between the facing members; and a filler of concrete or other filler material substantially filling the cavity between the facing members including continuously extending through the holes and encapsulating the reinforcement bars. 25

13. A method of erecting and installing a building panel in a building structure, the method comprising the steps of: providing a building panel comprising a plurality of spacing members, each spacing member being according to any one of claims 1 to 11, and arranging the spacing 30 members in parallel spaced relationship to each other so that the holes of each spacing member are substantially aligned with corresponding holes in all of the other spacing members, 13 providing a pair of spaced facing members attached to all of the plurality of spacing members at the respective longitudinal edges of each spacing member so as to define a cavity between the spaced facing members, erecting the building panel in a selected one of first upright and second upright 5 orientations depending upon whether two spaced reinforcement bars are to be provided extending through aligned holes in the plurality of spacing members or whether a single reinforcing bar is to be provided extending through aligned holes in the plurality of spacing members, inserting reinforcing bars through the aligned holes in the plurality of spacing 10 members so that they are located and supported by the concavities in the lower edges of the peripheral shapes of the aligned holes in the plurality of spacing members with the reinforcing bars having the desired spacing from the spaced facing members of the building panel, and substantially filling with concrete or other filler material the cavity between the 15 facing members including continuously extending through the holes in the spacing members and encapsulating the reinforcement bars. 20 25 30 13a