GB2051177A

GB2051177A - Building Component and Moulding Method

Info

Publication number: GB2051177A
Application number: GB7921241A
Authority: GB
Original assignee: Individual
Current assignee: Individual
Priority date: 1979-06-19
Filing date: 1979-06-19
Publication date: 1981-01-14
Also published as: IN154538B; GB2051177B

Abstract

A prefabricated building component comprises a core 28 of reinforced concrete housed within a sheath 22, 23 made of non-corrosive material e.g. aluminium. The component may be a slab or column and incorporate polyurethane insulation 26. The component may be cast onto a facing sheet forming the mould bed which may be inclined to form a tapered column. The mould bed may also serve as a transporter base. <IMAGE>

Description

SPECIFICATION Building Component This invention relates to a building component, such as a column or panel, for use in constructing multi-storey buildings, and to methods of making and erecting such building components.

The columns of multi-storey buildings, such as blocks of flats, are usually made of reinforced concrete and are construdted in situ or prefabricated in a factory. For cost reasons, prefabricated columns are preferable. However, prefabricated columns are difficult to handle and erect, particularly when they are long. Similarly, although prefabricated panels are the cheapest way of constructing the walls of such a building, they too suffer from handling and erection problems.

The present invention provides a prefabricated building component comprising a core of reinforced concrete housed within a sheath made of non-corrosive material, wherein the sheath constitutes a mould for casting the core and a permanent protective covering for the core when the concrete has been cured. Preferably, the sheath is made of aluminium.

In one preferred embodiment, the building component is a column, in which case the sheath is constituted by two elongate side plates and a base plate.

Advantageously, the side plates are provided with mutually overlapping flanges which are rivetted together or clip-pressed joints.

In another preferred embodiment, the building component is a panel, in which case the sheath is constituted by two side plates, two end plates and a base plate. Advantageously, these side plates and the base plate have flanges which are rivetted to the end plates to form a rigid sheath. Preferably, a plurality of spacer plates are provided between the two side plates.

In both preferred embodiments, the external surface of one of the side plates may have a stucco stove enamelled baked-on finish and the external surface of the other side plate may have a plain mill finish. Also, a sheet of insulating material may be provided between the core and one of the side plates. Preferably, said sheet is made of rigid polyurethane foam.

The invention also provides a method of making a prefabricated building component comprising the steps of constructing a sheath-like mould of non-corrosive material, and of casting a core of reinforced concrete within the mould, wherein the mould is left in place round the core after the concrete has been cured, thereby constituting a permanent protective sheath for the building component.

The invention further provides a method of making a plurality of prefabricated building components comprising the steps of constructing a plurality of sheath-like moulds of non-corrosive material on a frame, and of casting a core of reinforced concrete within each mould, wherein the moulds are left in place round the cores after the concrete has been cured, thereby constituting permanent protective sheaths for the building components.

In one preferred embodiment, the frame has a base which is pivotable, and the building components are columns, and wherein the moulds are costructed on the frame with the base horizontal, and the concrete is cast with the base at a small angle to the horizontal, the open ends of the sheath-moulds being higher than their other, closed ends during the casting process.

Preferably, said small angle is 15 .

Alternatively, the building components are panels, the sheath-like moulds being positioned substantially vertically on the frame with their open ends uppermost, and wherein the sheathlike moulds are secured to the frame.

The invention further provides a method of making and erecting prefabricated building components, the method comprising the steps of making prefabricated building components as defined above, and further comprising the step of removing the building components from the frame using a crane.

Where this method is used to make and erect columns, advantageously, prior to the removal of the building components by the crane, the base of the frame is pivoted, together with the building components, into the vertical position.

The invention will now be described in greater detail, by way of example, with reference to the accompanying drawings, in which: Fig. 1 is an exploded perspective view of part of a column constructed in accordance with the invention; Fig. 2 is a schematic side elevation of an assembly-transporting-erection frame for making, transporting and erecting columns of the type shown in Fig. 1 and Fig. 3 is an exploded perspective view of a panel constructed in accordance with the invention.

Referring to the drawings, Fig. 1 shows a column 1 having first and second half-moulds 2 and 3 respectively. The half-mould 2, which is intended to form part of the external wall of a building, is made of aluminium and has a stucco stove enamelled baked-on finish in any one of twelve colours. Such a finish not only results in a pleasing appearance, but is also substantially vandal proof. The half-mould 3, which is intended to form part of the internal wall of a building, is also made of aluminium but has a plain mill finish which can be suitably decorated when the building is finished. The two half-moulds 2 and 3 are joined together at their overlapping longitudinal edges 2' and 3' by means of rivets (not shown).

A 25 millimetre thick sheet of rigid polyurethane foam is positioned within the halfmould 2, this sheet 4 acting, in use, as a heatinsulation layer. The remainder of the core of the mould is filled with concrete 5 which surrounds a reinforced steel cage 6. The top of the reinforced steel cage 6 is provided with a threaded lifting insert 7 by means of which the column can be lifted. The top portion of the cage 6 is shown exposed to illustrate the form of the cage. As shown, the column 1 has a central rectangular portion 1 a having dimensions of 1 50 millimetres by 180 millimetres, and two ears 1 b which, in use, mate with grooves in panels which are positioned between adjacent pairs of columns, and which form the external walls of the building.

the column 1 has a length of 12.25 metres.

Fig. 2 shows an assembly-transportingerection (A.T.E.) frame 10 upon which twentyfour columns of the type shown in Fig. 1 can be made, transported and erected. The frame 10 has a base 10' one end of which is pivoted at 11 to a support 12. The base 10' is pivotable between the horizontal position (shown in dotted lines) and the vertical position (shown in dash-dot lines) by means of a hydraulic ram 13.

In order to make the columns 1, the twenty four half-moulds 2 are laid on the base 10' of the A.T.E. frame 10, with the base in its horizontal position, and with the external faces of the halfmoulds facing down. Each half-mould 2 is then provided with its sheet 4 of rigid polyurethane foam which is adhered to the inside of its external face. The steel reinforcement edges 5 are then positioned on the sheets 4, followed by the positioning of the other half-moulds 3. The overlapping edges 2' and 3' of the half-moulds 2 and 3 are then rivetted together, and the base of each mould is closed off by means of a respective base plate (not shown). The purpose of the base plates is merely to prevent concrete escaping from the columns during the subsequent filling process.

The twenty-four completed moulds are then secured to the base 10' of the A.T.E. frame 10, which is then pivoted by means of the ram 13, through about 1 50 (to the position shown in full lines in Fig. 2). The base 11 is held in this position by means of a prop 14. The moulds are then filled with concrete, a continuous vibration being carried out during the filling process. Obviously, the moulds are positioned on the base 10' so that their base plates are adjacent to the pivoted end 11 of the A.T.E. base. The columns are then left to cure for at least 21 days.

When the columns are required for erection, the A.T.E. frame 10 (complete with the columns) is loaded onto a vehicle and transported to the building site. Upon arrival at the site, the base 10' of the A.T.E. frame 10 is pivoted to the vertical position. The columns are, therefore, completely supported at all times until they are in the vertical position. The columns can then be removed, one by one, from the A.T.E. frame 10 using a crane (not shown) and the threaded lifting inserts 7.

Fig. 3 shows a panel 21 having first and second mould side plates 22 and 23 respectively, two mould end plates 24 and a mould base plate 25. All the mould plates 22 to 25 are made of aluminium. The side plate 22, which is intended to form part of an external wall of a building, has a stucco enamelled baked-on finish in any one of twelve colours. Such a finish not only results in a pleasing appearance, but is also substantially vandal proof. The side plate 23, which is intended to form part of the internal wall of the building, has a plain mill finish which can be suitably decorated when the building is finished. The end plates 24 are shaped to mate with the "ears" 1 b of the columns 1 described above.The plates 22, 23 and 25 are provided with flanges 22', 23' and 25' respectively which are rivetted to the end plates 24 to form a mould whose dimensions are 150x 1350x2900 millimetres.

A 25 millimetre thick sheet 26 of rigid polyurethane foam is positioned in the mould against the inside surface of the side plate 22.

This sheet 26 acts, in use, as a heat-insulation layer. Three aluminium spacer plates 27 are positioned within the mould together with the usual steel reinforcement (not shown). The remainder of the mould is filled with concrete 28.

The top edge of the concrete core is provided with a pair of threaded lifting inserts 29 by means of which the panel 21 can be lifted.

The panels 21 are made, in batches of twentyfour on an A.T.E. frame (not shown, but similar to the frame 10 of Fig. 2). Each panel mould is made by first assembling the side plate 22, the end plates 24 and the spacer plates 27. The sheet 26 is then adhered to the inside face of the side plate 22, and the steel reinforcement is placed through the spacer plates 27. The side plate 23 and the base plate 25, are positioned, and the plates are then rivetted together to form the complete, rigid mould. The complete moulds are then placed vertically open end upwards, in the A.T.E. frame and secured to prevent any hydraulic bulge. The moulds are then filled with concrete, a continuous vibration being carried out during the filling process. The panels are then left to cure for at least 21 days.

When the panels are required for erection, the A.T.E. frame (complete with the panels) is loaded onto a vehicle and transported to the building site.

As and when required, the panels are released from the A.T.E. frame so that they can be lifted away (still in the vertical position) by means of a crane and the threaded lifting inserts 29. As indicated above, the panels 21 mate with the columns 1 so that these components can be put together to form a building having continuous, generally smooth internal and external walls.

The columns and panels described above, and their methods of construction and erection, are intended primarily for use in the building method described in the specification of my copending patent application No.

However, they can also be used with other building processes.

It will be apparent that the columns and panels described above have a number of advantages over known types of prefabricated building components. Thus, the permanent aluminium mould increases the strength of the columns and panels and so enables them to be transported, handled and erected more easily. This added strength also means that longer and more slender prefabricated columns can be so handled.

Moreover, the erection method utilising the A.T.E.

frame, enables the columns to be positioned vertically whilst being completely supported by the frame. Once positioned vertically, any forces acting on the the columns due to handling, are taken up by their steel reinforcement cages, and so not present any problems.

Although the column 1 described above has a generally rectangular body portion 1 a and two "co-linear" ears 1 b, it will be appreciated that other column configurations are also possible.

Thus, where a column is to form a corner of a building, the ears will be positioned at "rightangles" to one another on adjacent sides of the central body portion. In another case, the column would be generally T-shaped, having three ears on three sides of the central body portion of the column. Similarly, although panel 21 described above is solid, it will be appreciated that panels incorporating doorways and window apertures could be made by the positioning of appropriate shuttering within the panel mould prior to the introduction of the reinforcement and concrete. It is also possible to clip-press joint the overlapping edges 2' and 3' together instead of using rivets.

Similarly, the flanges 22', 23' and 25' could be clippressed jointed to the end plates 24. Also, a crane could be used to pivot the base 10' of the A.T.E.

frame 10 instead of using the hydraulic ram 1 3.

Moreover, the dimensions of the various parts are not critical. Thus, the insulation sheets 4 and 26 could be 30 millimetres thick, and the columns 1 can have a length of up to 1 5.3 metres.

Claims

1. A prefabricated building component comprising a core of reinforced concrete housed within a sheath made of non-corrosive material, wherein the sheath constitutes a mould for casting the core and a permanent protective - covering for the core when the concrete has been cured.

2. A building component as claimed in Claim 1, wherein the sheath is made of aluminium.

3. A building component as claimed in Claim 1 or Claim 2, wherein the building component is a column.

4. A building component as claimed in Claim 3, wherein the sheath is constituted by two elongate side plates and a base plate.

5. A building component as claimed in Claim 4, wherein the side plates are provided with mutually overlapping flanges which are rivetted together.

6. A building component as claimed in Claim 1 or Claim 2, wherein the building component is a panel.

7. A building component as claimed in Claim 6, wherein the sheath is constituted by two side plates, two end plates and a base plate.

8. A building component as claimed in Claim 7, wherein the side plates and the base plate have flanges which are rivetted or clip-pressed jointed to the end plates form a rigid sheath.

9. A building component as claimed in Claim 7 or Claim 8, wherein a plurality of spacer plates are provided between the two side plates.

10. A building component as claimed in any one of Claims 4 to 9 when appendant to Claim 2, wherein the external surface of one of the side plates has a stucco stove enamelled baked-on finish, and the external surface of the other side plate has a plain mill finish.

11. A building component as claimed in any one of Claims 4 to 10, wherein a sheet of insulating material is provided between the core and one of the side plates.

12. A building component as claimed in Claim 11, wherein said sheet is made of rigid polyurethane foam.

13. A prefabricated building component substantially has hereinbefore described with reference to, and as illustrated by, Figure 1 or Figure 3 of the accompanying drawings.

14. A method of making a prefabricated building component comprising the steps of constructing a sheath-like mould of non-corrosive material, and of casting a core of reinforced concrete within the mould, wherein the mould is left in place round the core after the concrete has been cured, thereby constituting a permanent protective sheath for the building component.

1 5. A method of making a plurality of prefabricated building components comprising the steps of constructing a plurality of sheathmoulds of non-corrosive material on a frame, and of casting a core of reinforced concrete within each mould, wherein the moulds are left in place round the cores after the concrete has been cured, thereby constituting permanent protective sheaths for the building components.

16. A method as claimed in Claim 15, wherein the frame has a base which is pivotable, and the building components are columns, and wherein the moulds are constructed on the frame with the base horizontal, and the concrete is cast with the base at a small angle to the horizontal, the open ends of the sheath-moulds being higher than their other, closed ends during the casting process.

1 7. A method as claimed in Claim 16, wherein said small angle is 150.

18. A method as claimed in Claim 15, wherein the building components are panels, the sheathlike moulds being positioned substantially vertically on the frame with their open ends uppermost, and wherein the sheath-like moulds are secured to the frame.

1 9. A method of making prefabricated building components substantially as hereinbefore described with reference to the accompanying drawings.

20. A method of making and erecting prefabricated building components, the method comprising the steps of making prefabricated building components as claimed in any one of Claims 1 5 to 19, and further comprising the step of removing the building components from the frame using a crane.

21. A method as claimed in Claim 20 when appendant to Claim 16 or Claim 17, wherein, prior to the removal of the building components by the crane, the base of the frame is pivoted, together with the building components, into the vertical position.

22. A method of making and erecting prefabricated building components substantially as hereinbefore described with reference to the accompanying drawings.