NZ555414A - Composite panel with flanged forms embedded in a settable material - Google Patents

Abstract

A composite panel with complementary reinforcing forms embedded in a settable material is disclosed. A first form (1) has a part (14) which extends from a region near a first side of the panel to a flange (8, 9) embedded within the panel nearer to a second side of the panel. A complementary second form has a part which extends from a region near the second side of the panel to a flange embedded nearer to the first side. There may be a set of first and/or second forms. The flanges of the first and second forms have parallel longitudinal axes. The flanges interact via the settable material to confer a structural or load bearing advantage to the panel.

Description

555414 NEW ZEALAND PATENTS ACT, 1953 No: 555414/560655 Date: 25 May 2007 and 15 August 2007 COMPLETE SPECIFICATION PANELS We, NEW ZEALAND HEAVY ENGINEERING RESEARCH ASSOCIATION INCORPORATED, a company duly incorporated under the laws of New Zealand of 17-19 Gladding Place, Manukau City, Auckland, New Zealand, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: 555414 The present invention relates to composite building elements, composite panels or unitised panels, methods for forming such composite and/or unitised elements or panels, elements or panels so made, uses of such composite and/or unitised elements or panels and related methodologies including methods of construction, componentry of such elements or panels, and the like.

Alternative construction techniques are always being sought to best take advantage of characteristics of available materials or materials being developed, as well as combinations of materials.

An interest to the construction industry is the provision of factory made components for making composite building elements or panels and elements or panels that are factory made in whole or in part.

Prior art building elements tend to have short comings and disadvantages eg, in height, in length, in thickness of facing plates, etc as well as in make up, performance, manufacturing complexity, cost etc.

NZ patent specification 282881 (British Steel pic) discloses double skin composite panels are known. These comprise two steel facing plates positioned one on either side of a layer of concrete and connected thereto by transverse cross members which extend generally normally to and are attached at their ends to both facing plates.

That specification in addition states that hitherto, such double skin composite panels have been produced in situ. They state that the panels usually require relatively thick facing plates, internal ties and facing plate stiffness. They mention also that there is a requirement for external support and/or internal stiffeners to the facing plates during pouring of concrete to avoid structural distortion caused by the high hydrostatic pressures produced during pouring. They state it has usually been found necessary to limit the height from which or the rate at which concrete is poured to reduce such pressures.

New Zealand patent specification 282881 itself is directed to double skin composite panels intended to be factory produced and delivered to site as integral structures. Nevertheless facing plates are secured together by transverse connecting members.

We see an advantage in avoidance of such ties connecting from each side eg; no metal conductive pathway from one side to the other.

We also see a prospect for metal clad lightweight concrete panel systems that are load bearing that do not have the cladding faces tied directly to each other and/or have an improved ability to anchor fixings.

We envisage such panels as being useful as at least walls, floors and ceilings. The Off,(6 invention envisages the provision of a lined panel which includes as part of its composft^tructure [ 2 3 DEC 2008 555414 an outer metal (preferably steel) part and a set settable material part bound in some way to the metal part. The set settable material is preferably a filler that is a pourable, pumpable, flowable material which has the ability to convert or set to a stiff mass in a controlled manner. When "set" the core filler or settable material provides support to the steel elements to resist compressive loads.

Such settable materials can be cementitious in their nature and can include such aggregate and/or other materials as might be appropriate to render the overall panel construction more light weight for almost the same, the same or improved load bearing purposes than hitherto has been the case with conventional construction panels.

By way of example, but in no way limiting of the invention hereafter described, a preferred settable material is a cementitious material preferably including light weight aggregate materials. In other forms however a foam plastics or other set settable material may be utilised in total, or in part, as the settable material hereinafter described.

The material may include foamed inorganic and/or organic polymers or foamed inorganic and/or organic polymers in combination with cementitious setting materials.

The invention also envisages composite building elements where sheet metal is partly or wholly embedded in a set material.

It is an object of the present invention to provide components, methods and panels that are able to be factory manufactured, preferably to some modular requirement, and to be used as a load bearing panel when installed in a constructional sense.

It is preferred that the panels are lined on at least one side or on both. Irrespective of whether or not the lining is the same or different on each side, preferably at least one side is of a metal (preferably steel). Preferably there is provision for fixing from at least one or that side's lining into the set material of the composite or unitised panel.

It is a further or alternative object of the present invention to provide a composite and/or unitised panel lined on both sides with a metal (whether the same or different) yet containing therein a set settable material embedding part of the lining of one side (preferably each side) without providing any substantial or direct metal to metal link from one side to the other thereby to reduce thermal and/or acoustic conductivity from one side to the other.

It is a further or alternative object of the present invention to provide a composite and/or unitised panel having metal liners on each side, or on at least one side, yet providing with a plurality of fitted together pressed or long run formed, sheet metal sections at least one panel liner or facing and providing one or more zones where several thicknesses of metal, some embedded \ :'1 1 panel, are available for securement of fittings to the panel. 555414 It is a further or alternative object of the present invention to provide a method or methods of manufacture of a composite and/or unitised panel comprising or including at least one exterior liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, and a matrix of a set settable material (i) moulded to the sheet metal and/or any interposed materials) and (ii) embedding and retaining at least the distal regions of each said inwardly extendable form, wherein, otherwise than from being matrix embedded and retained, the inwardly extending embeddable forms do not tie directly or indirecdy to any exterior sheet beyond said matrix except preferably at the sides of the panel and do not tie direcdy or indirecdy to that surface of the matrix opposite that moulded to the sheet metal and/or any interposed material(s).

It is a further or alternative object of the present invention to provide panels made by such a method.

It is a further or alternative object of the present invention to provide uses and/or assemblies of such panels.

It is a further or alternative object to provide metal clad panels with a core of set settable material(s) as if metal sandwiched where there is no, or no substantial, through panel metal to metal contact and/or where embedded and retained projections of each preferably fabricated metal liner interpose and/or are behind those of the other preferably fabricated metal liner.

In an aspect the invention is a composite panel having first and second sides as its faces and being a panel of at least one settable material and having, partially and/or substantially wholly embedded in said settable material(s) complementary arrays of sheet metal forms; wherein one array extends from beyond one side, extends from one side, or extends from adjacent or nearer one side but within the panel, to embedded flanges at least substantially adjacent or nearer the second side but within the panel, and a second array extends from beyond the second side, extends from the second side, or extends from adjacent or nearer the second side but within the panel, to embedded flanges adjacent or nearer the first side but within the panel; and (A) there is lapping in part of individual flanges of one array with individual flanges of the other array when one notionally considers the panel normally to a said face, and/or (B) there has been perforation and/or expanding of some part of at least one of wherein forms to better mechanically tie to said settable material(s), and/or 555414 (C) there has been, for at least one array, some mechanical linking of the sheet metal forms, one to another, prior to any at least partial embedding thereof.

In an aspect the invention consists in a composite panel having first and second sides as its faces and being a panel of at least one settable material and having at least partially embedded in said settable material(s) complementary arrays of sheet metal forms; wherein one array extends from, or one array from adjacent one side but within the panel, to embedded flanges at least substantially adjacent the second side but within the panel, and a second array extends from, or a second array extends from adjacent the second side but within the panel to embedded flanges adjacent the first side but within the panel; and wherein there is lapping in part of individual flanges of one array with individual flanges of the other array when one notionally considers the panel normally to a said face.

In an aspect the invention is a composite panel having first and second sides (eg, as its faces), the panel having complementary reinforcement forms at least partially embedded in set settable material or settable materials ("settable material(s)"); wherein one form or set of forms ("first form(s)"), each form having at least one flange and having part or parts which i) extend(s) from beyond one side, ii) extend(s) from one side, and/or iii) extend(s) from adjacent or nearer one side but within the panel, laterally to said flange(s) embedded at least substantially adjacent or nearer the second side but within the panel, and another form or set of forms ("second form(s)"), each form having at least one flange and having part or parts which i) extend from beyond the second side, ii) extends from the second side, and/or iii) extends from adjacent or nearer the second side but within the panel, laterally to flanges embedded adjacent or nearer the first side but within the panel; wherein flanges of the first form(s) and flanges of the second form(s) have longitudinal axes substantially parallel; and wherein the flanges of the first form(s) and flanges of the second form(s) interact, first form flange to second form flange, via the set settable material(s) interposed therebetween, thereby to confer a structural or load bearing advantage to the composite panel.

Preferably the interaction via the interposed material(s) is as a consequence of flange lapping (ie, overlapping in part) or near lapping (ie, nearly overlapping in part) within the when one notionally considers the panel normally to a said side. 2 3 DEC 2008 555414 Preferably said interaction is without a flange of a first form touching a flange of a second form.

Preferably each form is elongate and the flange longitudinal axis is, or flange longitudinal axes are, parallel to the longitudinal axis of the form(s).

Preferably at least one of said first and second form(s) is, or are, metal form(s).

Preferably both of said first and second form(s), is or are, metal form(s).

Preferably at least one of said forms is a, or arc, sheet metal form(s).

Preferably there is at least one set of elongate forms as an array, each form of an array having a said flange from a said longitudinal part thereof extending to the flange.

Preferably said elongate from or forms has or have the flanges as longitudinal Hps to a lipped channel section elongate form.

Preferably there is lapping in part of individual flanges of one array with individual flanges of the other array when one notionally considers the panel normally to a said side.

Preferably one array extends from one side or extends from adjacent or nearer one side but within the panel.

Preferably wherein both arrays extend from one side or extends from adjacent or nearer one side but within the panel.

Optionally there has been perforation and/or expanding of some part of at least one of the forms, or the material of the forms, to better mechanically tie to said settable material(s).

Preferably there has been, for at least one set as an array, some mechanical linking of the forms, one to another, prior to any at least partial embedding thereof.

Optionally said settable material(s) is or includes at least one cementitious material and/or at least one polymeric material (eg, PUR).

Optionally said panel includes a mix of different settable material(s) and one of said settable materials provides a surface over one of said sides.

Preferably there is said lapping of the flanges.

The composite panel defined may be externally lined.

Preferably said forms are sheet metal forms that are elongate and said flanges extend along parallel to the longitudinal axis thereof.

Preferably at least one of the sets is an array of mutually parallel elongate sheet metal forms.

A panel claim 21 wherein each elongate form has two flanges and each is in-turned to constrict the opening of a channel of a channel like section.

In any aspect optionally additional forms have been introduced to increase strength ' some areas. 2 3 DEC 2008 555414 -7 — Preferably at least some of the embedded flanges are substantially flat and extend parallel to a face of said panel.

Preferably at least two individual sheet metal forms of a set, as an array are mechanically linked prior to the set of the settable material.

Preferably there is flange lapping and the lapping of individual flanges is such that along a face of a said panel (when notionally moving transversely to the preferred aligned longitudinal axis of roll or pressed elongate sheet metal forms), there is an alternating (as a consequence of an offset of the arrays) of which flange laps with which.

Optionally conduit forms pass between said arrays.

Preferably said conduit forms are embedded in said settable material.

Preferably conduit forms extend between said arrays substantially perpendicularly and/or obliquely to the elongate axis of the sheet metal forms.

In another aspect the invention is a structure or an envelope or wall which includes at least one composite panel of any one of the preceding claims.

In another aspect the invention is formwork of a composite panel as previously set forth. In another aspect the invention is formwork or a panel as previously set forth.

In another aspect the invention is a composite panel having first and second sides as its faces and being a panel of at least one settable material and having, partially and/or substantially wholly embedded in said settable material(s) complementary arrays of sheet metal forms; wherein one array extends from beyond one side, one array extends from one side, or one array extends from adjacent or nearer one side but within the panel, to embedded flanges at least substantially adjacent or nearer the second side but within the panel, and a second array extends from beyond the second side, a second array extends from the second side, or a second array extends from adjacent or nearer the second side but within the panel, to embedded flanges adjacent or nearer the second side but within the panel to embedded flanges adjacent or nearer the first side but within the panel; and wherein there is lapping in part of individual flanges of one array with individual flanges of the other array when one notionally considers the panel normally to a said face.

In an aspect the invention consists in a composite panel having first and second sides as its faces and being a panel of at least one settable material and having, partially and/or substantially wholly embedded in said settable material(s) complementary arrays of sheet metal forms; wherein one array extends from beyond one side, one array extends from one side, or one array extends from adjacent or nearer one side but within the panel, to embedded flanges at least substantially adjacent or nearer the second side but within the panel, and ^^^loperty /W /# [ 2 3 DEC 2M 555414 8 a second array extends from beyond the second side, a second array extends from the second side, or a second array extends from adjacent or nearer the second side but within the panel, to embedded flanges adjacent or nearer the first side but within the panel; and wherein there is perforate expanding of some part of at least one of the metal forms to better mechanically tie to said settable material(s).

In an aspect the invention consists in a composite panel having first and second sides as its faces and being a panel of at least one settable material and having, partially and/or substantially wholly embedded in said settable materials), complementary arrays of elongate sheet metal forms, the longitudinal axes of the elongate forms being parallel, wherein one array extends from beyond one side, one array extends from one side, or one array extends from adjacent or nearer one side but within the panel, to embedded flanges at least substantially adjacent or nearer the second side but within the panel, and a second array extends from beyond the second side, a second array extends from the second side, or a second array extends from adjacent or nearer the second side but within the panel, to embedded flanges adjacent or nearer the first side but within the panel; and wherein there has been, for at least one array, some mechanical linking of the sheet metal forms, one to another, prior to any at least partial embedding thereof.

Preferably there is lapping in part of individual flanges of one array with individual flanges of the other array when one notionally considers the panel normally to a said face.

Preferably any of the embodiments hereinafter described and shown in the drawings or variations thereof, can satisfy such a statement of invention. At least two different settable materials can be used.

Preferably said sheet metal forms are elongate and said flanges extend along a longitudinal axis thereof.

Preferably at least one of the arrays (optionally both arrays) has said sheet metal forms as members of a channel like section.

Preferably each channel like section has two flanges and each is in turned to constrict the opening of such a channel of the channel like section.

Optionally the flanges have a flanged lip that preferably extends back into the channel of said channel section.

Preferably said embedded flanges are substantially flat and preferably extend parallel to a face of said panel.

Preferably individual sheet metal forms are mechanically linked prior to the set of the settable material. 555414 Preferably the lapping of the individual flanges is such that along a face of a said panel (when notionally moving transversely to the preferred aligned longitudinal axis of roll or pressed elongate sheet metal forms), there is an alternating (as a consequence of an offset of the arrays) of which flange laps with which, eg, preferably substantially as hereinafter described with reference to any one or more of the accompanying drawings.

In some preferred forms of the present invention conduit or solid reinforcing bars (eg, tubing, rods, solid rods, reinforcing rods or solid bars) pass between said arrays.

Preferably said conduit or solid reinforcing bars (eg, tubing, rods, solid rods, reinforcing rods or solid bars) are embedded in said settable material.

Where said sheet metal forms are elongate, preferably the elongate axis of the sheet metal forms of each said array is, or both arrays are, substantially parallel and said conduit forms preferably extend between said arrays substantially perpendicularly and/or obliquely.

In some preferred forms of the present invention the composite panel is a wall panel or a wall. It m&y be curved, cornered or the like.

In other forms the panel can be for any constructional or free standing or other purpose (eg; acoustic, security, etc.).

In some forms of the present invention, quite apart from a preferred off-set to ensure lapping of flanges, alternately there can be a greater degree of asymmetry from one side of the other. Such asymmetry can arise from the adoption of sheet metal forms for each array or a mixture of sheet metal forms for one or each array.

In a further aspect the invention consists in a composite panel comprising sheet metal elongate members, arranged substantially with their elongate axes parallel and with at least part of each embedded in one or more settable materials irrespective of whether or not one or other side conccals and/or presents any part of any such elongate member.

Preferably said composite panel has some degree of lapping of such metal forms when considered transversely of the panel axis.

In a further aspect the invention consists in a building structure or a building envelope which includes at least one composite panel as aforesaid.

In some preferred forms of the present invention both arrays are fully embedded. In other embodiments, however, at least the base of a preferred sheet metal form has its outer metal surface exposed or not embedded (irrespective of whether subsequently coated, clad or otherwise treated). In some forms the sheet metal forms include locating recesses for fixtures which will ensure passage of a said fixture into a said embedded flange of a sheet metal form of the other at and /or its own embedded flange. 555414 In another aspect the invention is a composite and/or unitised panel comprising or including at least one exterior liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, and a matrix of a set settable material (i) moulded to and/or contacting the sheet metal and/or any interposed materials) and (ii) embedding and retaining at least the distal regions of each said inwardly extendable form, wherein, otherwise than from being matrix embedded and retained, the inwardly extending embeddable forms do not tie directly or indirectly to any exterior sheet beyond said matrix and do not tie direcdy or indirectly to that surface of the matrix opposite that moulded to the sheet metal and/or any interposed material(s).

In another aspect of the present invention, there can be provided a composite building element where sheet metal is profiled and is embedded in a matrix of a set settable material moulded to and/or contacting the sheet metal and/or any interposed material(s), wherein, for each sheet of metal, there are regions thereof spaced apart through the matrix when considered (eg, if a panel) perpendicularly of at least some regions of the panel.

The composite instructions of the present invention demonstrate high stiffness and vertical load carrying capacity prior to any visible buckling of light gauge skin (if for example the sheet metal forms part of the skin).

In an aspect the invention is a composite and/or unitised panel comprising or including a first sheet or panel liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, a second sheet or panel liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, and a matrix of set settable material (i) moulded to the sheet metal and/or any interposed materials) and (ii) embedding and retaining at the least the distal regions of each set of said extendable forms, wherein, otherwise than from being matrix embedded and retained, the inwardly extending embeddable forms of one sheet or panel liner do not tie direcdy or indirecdy to the other sheet or panel liner nor to the inwardly extending embeddable forms thereof.

Preferably said sheet or panel liner is of a metal (preferably sheet metal). 555414 - ii - Preferably said metal is a steel. Optionally that steel is coated eg, galvanised or otherwise protected.

Preferably the metal is profiled preferably by a long run procedure (optionally pressing).

Preferably the panel liner is fabricated from at least two, and preferably more than two, preformed sheet metal components pressed or long run formed (or some hybrid of the two).

Preferably at least some of the metal components are fabricated to a channel form. Preferably said channel form has a profiled exterior face.

Preferably said channel form metal components include at least one flange to direct inwardly of its (optionally profiled) lining region of the section and that flange provides distally thereof a fold in flange which laps over the exterior lining region.

Preferably there is such a flange sequence flanking either side of said exterior lining region.

Preferably said panel liner is fabricated form a plurality of metal components of an elongate character where transverse sections thereof are serially fixed one to another.

In a further aspect the invention is a composite and/or unitised panel comprising or including a panel liner fabricated from at least two components of sheet metal, and a matrix of a set settable material keyed to the fabricated panel liner, wherein each of the at least two components has at least one flange or flange sequence embedded and retained in the set settable material.

Preferably the arrangement is as detailed hereinafter (preferably by reference to a double lined composite or unitised panel).

The invention is also a panel where a filler is interposed between two such fabricated panel liners as aforesaid or at least two liners, one of which is a fabricated panel liner as aforesaid.

Preferably where there are the sandwiching fabricated panel liners, preferably one or more of the flange or flange sequences of each sheet metal component of one fabricated panel liner extends into the set settable material (ie, filler) beyond the distal region of flange or flange sequences of the each sheet metal component other fabricated liner.

Preferably said extension into the set settable material is such that there is some interposing of flanges or flange sequences from one side with those of the other.

Preferably lapping of the final flange of each flange sequence allows fixing into the panel through at least two metal thicknesses.

In a further aspect the invention is a composite and/or unitised panel comprising or including a fabricated panel liner, of sheet metal, and a cementitious and/or biopolymer matrix keyed to the fabricated panel line: 555414 wherein, the keying is to flanges and/or flange sequences of juxtaposed sheet metal channel forms where the base of each channel presents on its underside the liner surface.

In another aspect the invention is a construction provided by a series of prefabricated panels, wherein, each panel comprises or includes a first sheet or panel liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, a second sheet or panel liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, and a matrix of set settable material (i) moulded to the sheet metal and/or any interposed material(s) and (ii) embedding and retaining at the least the distal regions of each set of said extendable forms, wherein, otherwise than from being matrix embedded and retained, the inwardly extending embeddable forms of one sheet or panel liner do not tie direcdy or indirecdy to the other sheet or panel liner nor to the inwardly extending embeddable forms thereof.

Optionally at least some panels mate panel to panel (eg, index) via an interposed lesser panel that includes a utilities cavity (eg, by virtue of only a partial fill).

In another aspect the invention is a load and/or non-load bearing panel comprising or including a first sheet or panel liner, whether fabricated or non-fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, a second sheet or panel liner, whether fabricated or non- fabricated and whether profiled or non-profiled in whole or in part, of sheet metal defining or having been provided with inwardly extending embeddable forms, and a matrix of set settable material selected from a cementitious composition and/or a polymeric composition (i) moulded to the sheet metal and/or any interposed materials) and (ii) embedding and retaining at the least the distal regions of each set of said extendable forms, wherein, otherwise than from being matrix embedded and retained, the inwardly extending embeddable forms of one sheet or panel liner do not tie directly or indirectly to the other sheet or panel liner nor to the inwardly extending embeddable forms thereof.

In another aspect the invention is a metal faced panel. 555414 -13 Having fabricated long run metal forms or elongate pressings, or a hybrid of both, providing a metal facing on either side of filling, wherein, over some extent(s) of the panel, in the plane(s) of the panel, metal sheet spaced normally to such faces is such that, if the forms of one side are "A" and the other side are "B", there is in the transverse direction, for such extent(s), a metal thickness progress as follows: A to B to A to B.

In another aspect the invention is a method of forming a load and/or non-load beating panel comprising or including the steps of: laying up a panel liner of a plurality of elongate roll formed or pressed metal sheet forms; each of a scction having a panel exterior zone and a flange or flange sequence on one side of the zone, and, optionally for some forms, a flange of flange sequence on the other side of the zone, before, during and/or after such laying up attaching each metal sheet form to its neighbour(s); and laying a settable material on the panel liner so as to embed the flanges and/or flange sequences, and to conform to the sheet metal defining the panel exterior zone and/or to material inside that zone; and optionally laying down a similar or dissimilar panel liner, or a sheet metal liner with embeddable features, into said settable material so as to fix, with or without further provision of settable material, only, or primarily only, via the settable material(s) when set to said first mentioned panel line.

The method of attachment is not critical. It may involve popriveting, "flanged hole" attachment, welding, adhesion, or other. Flanged hole attachment is favoured for pre-pain ted/pre-coated metal forms and involves punching a hole, pressing an upstand around a hole in an adjacent element and then rolling the upstand back over the first hole to lock the two members together. The method provides a panel of any of the kinds previously mentioned.

The invention is also any such panel when so formed.

In still another aspect the invention is a self supporting load-bearing or non-load- bearing wall or floor panel including two structural skins interlocked indirecdy through, and held apart by, settable filler.

Preferably the structural skins are profiled to have stiffening formations to resist local and/or overall buckling.

Optionally die structural skins have lateral members either attached mechanically to or formed integrally with the skin to extend into the filler to resist loads.

Preferably one or more structural skin is manufactured of (preferably light ga components which are mechanically connected to each other, but not to the opposir 555414 Optionally a partial inner skin is placed between the main structural skin and the filler as required to carry additional loading.

In use, a preferred method of connection to the footing includes a steel channel extending substantially from one edge of a structural skin to an opposite end of the skin and attached to the structure, into which the panel is lowered.

Panels may have peripheral features (eg, rebates, grooves, channels, tongues, etc) to facilitate panel to panel indexing, panel to footing placement, support of applied loads, etc.

Some panels can be of small expanse (eg, to accommodate utilities) or of lesser length (eg, to accommodate openings such as windows or doorways).

To provide peripheral features metal forms of a different section to these forms used elsewhere are envisaged.

In still another aspect the invention is a load-bearing and/or non-load-bearing building element comprising formed elements typically of metals based products such as steel or aluminium sheet, coil, strip, or plate and a typically settable compound or compounds such as concrete and/or polymeric material (preferably bio-polymers) wherein the principal composite interaction between the formed elements is by interlocking mechanical means.

In still another aspect the invention is a load-bearing and/or non-load-bearing building component comprising elements formed from metal based sheet, strip or plate materials, and a space filler composition, where the principal composite interaction between the formed elements is through mechanical connection.

The space filler is a performance enhanced settable compound such as lightweight concrete or foamed polyurethane which may form a chemical bond with the formed elements.

In another aspect the invention is a load-bearing and/or non-load-bearing filled (or at least substantially filled) building component, wherein each of a number of elements , as a set, are serially mechanically connected (eg, to adjacent elements on each side) but those of one side are unconnected to those elements, as a set, on an opposing side of the component.

Preferably formed elements as a set on one side are offset from those on the other side, with no direct connection other than through the filler, which give an integral load resisting component.

The formed elements may include lateral extensions either formed integrally or attached mechanically to act in a composite manner with the settable compound to resist loads.

Formed elements are strategically placed alongside the principal elements as required to carry additional loading.

A preferred footing for panels of the invention includes a steel channel, into which^r panel is lowered, I 2 3 DEC 2D08 555414 Optionally at least some panel(s) in elude (s) at least one formed hollow and/or local indentations into which screws and other fastenings may be attached.

In another aspect the invention is a wall or other like structure where panels (howsoever formed) dock on a part filled exoskeleton post that provides for utilities.

Preferably said panels are metal sheet faced set material filled panels (eg, as previously defined).

Preferably said docking is by a tongue and groove engagement. Preferably the post presents the tongue(s).

As used herein the terms "composite" in respect of a panel refers to any suitable mixture of materials.

As used herein the term "unitised" in respect of a panel refers to a panel formed from at least two multiple preformed components and in some way they are held relative to each other (preferably by said matrix in addition to any optional prefixing).

As used herein the term "module" or "modular" refers to any chosen characteristic of a dimensional nature that allows the mating or use together of such panels and/or components of such panels.

As used herein "settable material" refers to any suitable material or distinct suitable materials that has a flowable characteristic notwithstanding any solids or foaming agent that may be present therein and which thereafter can set to provide the matrix. Examples include, but are in no way limited to cementitous material(s), foamed plastics material(s) [eg, polyurethane] etc, and mixtures thereof. Similarly the term "matrix" refers the overall set settable material rather than any adhesive or binding ingredient thereof.

In some embodiments the settable material may be set or cured otherwise than in situ.

An applied layer of adhesive can be used to achieve any formwork to settable material(s) bond instead of the bond being generated during a curing process eg, between the outer and inner filler (eg outer geopolymer and inner foam. In this way we may adhere an outer material such as plywood, gib board or even a plastic. In some circumstances this possibly may do away with floating ribs.

As used herein the term "embedded and retained" refers to a relationship between the sheet or panel liner and the matrix whereby separation in a direction normal to the general plane of a substantially or notionally flat composite and/or unitised panel can be resisted. A corresponding meaning attaches to shaped panels (ie, which might have some intentional curving or the like).

"Embedded" has the further meaning that the sheet or sheets are surrounded by the settable material on sheet-to-matrix interfaces. 555414 As used herein the term "reinforcing bar" refers to any elongate member used for reinforcement and may encompass any of the following terms "tubing", "rod", "solid rod", "reinforcing rod" or "solid bar".

As used herein "and/or" includes "and" or "or", or where the context allows, both.

As used herein the term "s" following a noun means, as might be appropriate, the singular or plural form of the noun, or both.

As used herein the term "sheet" refers to a material of a sheet like form whether flat or not and whether of a constant thickness or not.

As used herein the term "panel" refers to any component able to provide by itself or in conjunction with any other component structure or the like some panel like characteristic whether as part of or all of a wall, a ceiling, a roof, a floor or the like in preferably a building. Such panels however, are not restricted to use in the building or the construction industry and could have uses elsewhere (eg, as freestanding walls for display purposes, security purposes and the like). Preferably the sheet metal "keys" to the set settable material and thus is "retained" by part of the sheet metal (eg, a flange of a flange sequence or holes or profiled flanges) having set material blocking withdrawal.

As used herein the term "inward" or "inwardly" refers to a direction into a panel from the sheet or panel liner. "Outward" and "outwardly" have the corresponding meaning. Such directions are independent of whether or not the panel or components thereof are substantially As used herein "flange" can include a configured sheet metal flange where or not part of a "flange sequence".

As used herein the term "key" or "keyed" or "keying" preferably refers to the outcome of the set of settable material on the sheet and/or panel liner to provide a mechanical attachment (eg, embedded and retained) irrespective of whether or not there is any adherence.

As used herein "load bearing" means able to bear a load at least in one direction along the panel.

Preferred forms of the present invention will now be described with reference with the accompanying drawings in which: Figure 1 shows a perspective end view of a part width of an assembly of sheet metal forms adapted to interact with each other such that the two shown on the lower side and the three shown on the upper side interact so as to provide embeddable forms in the fill material (the fill not being shown) and overlapping sheet metal (when viewed normal to the panel) as a result of flanges flat. and/or flange sequences, Figure 2 is an end view of the arrangement as shown in Figure 1, o,K I 3 DEC 2M 555414 - 17 Figure 3 is a perspective view of a panel (but omitting the fill material for clarity) showing a channel form at the right hand end able to receive the panel, Figure 4 shows how components of a system such as depicted in Figures 1 -3 and described in more detail by reference to at least Figures 5-7 can co-act to form a panel liner or face with embeddable forms as a result of flanges and/or flange sequences and an out of register similar arrangement is possible on the other side or face so that the embeddable forms, as a result of the panel liner fabrications on each side or face, result in the interposed arrangement as shown and the overlapping as depicted, (Figure 4 also showing how modifications of the main profiled forms can be used to provide each side periphery of the lined panel form), Figure 5 is an end view or a section of a main sheet metal form of a kind used in Figure 4, Figure 6 shows a sheet metal form as is appropriate for forming part of the side peripheries of the panel of Figure 4, Figure 7 shows a sheet metal form or component to co-act with the component of Figure 6 (that of Figure 7 preferably being for the interior of the panel whilst that of Figure 6 is for the exterior of the panel) where the two components may or may not overlap at the sides of the panel.

Figure 8 shows holes that can be formed in the sides of the components as depicted in the preceding figures, Figure 9 shows rivet hole placement for the components such as in Figures 5-7, Figure 10 shows a cross connection that can be used between adjacent panels (generally of the form shown in Figure 4) so as to provide a partially filled panel or post that may leave a services cavity, Figure 11 shows a front view of the assembly of Figure 10 showing side openings to the sendees cavity in order to run services, Figure 12 is a view of the form work of a panel in accordance with a further embodiment of the present invention, (eg, one having a steel face on each exterior side), Figure 12 showing the assembly of three different types of elongate sheet metal element looking longitudinally of such elongate members, and forming a complete unitised part.

Figure 13 is an end view or sectional view of a preferred main elongate element of the assembly as shown in Figure 12, Figure 13A is an isometric view of part of the length of such a main elongate element as shown in Figure 13, Figure 14 is an end view or sectional view of an exterior elongate element of an assembly as shown in Figure 12, Figure 14A is a short length isometric view of the exterior elongate element of Fi 555414 Figure 15 is an end or cross-sectional view of an interior elongate element incorporated in an assembly as shown in Figure 12, Figure 15A is a short length isometric view of the interior elongate element of Figure 15, Figure 16 is a viewT such as in the direction AA of Figure 13 showing openings in the inward extending sheet region of the inwardly extending embeddable forms of the elongate element of Figure 13, Figure 17, analogously to Figure 16, is the view BB of either or both of the elongate elements of Figures 14 and 15, Figure 18 is a perspective view of the assembly shown in Figure 12, Figure 19 is a view of the panel in accordance with a further embodiment of the present invention, (eg, one face being concrete and the other face being steel and with preferably a two filler mix with two different types of elongate sheet metal element forming a "floating rib" looking longitudinally of such elongate members).

Figure 20 is an end view or sectional view of a preferred main elongate element of the assembly as shown in Figure 19, Figure 20A is an isometric view of part of the length of such a main elongate element as shown in Figure 20, Figure 21 is an exterior elongate element of an assembly as shown in Figure 19, Figure 21A is a short length isometric view of the exterior elongate element of Figure 22, Figure 22 is an end or cross-sectional view of an interior elongate element incorporated in an assembly as shown in Figure 19, Figure 22A is a short length isometric view of the interior elongate element of Figure 22, Figure 23 is a view of the panel in accordance with a further embodiment of the present invention, (eg, concrete on each face, preferably using fillers of different mixes), Figure 24 is an end view or sectional view of a preferred main elongate element of the assembly as shown in Figure 23, Figure 24A is an isometric view of part of the length of such a main elongate element as shown in Figure 23, Figure 25 is an end view or sectional view of a pairing of elongate elements (mirror imaged preferably) of an assembly as shown in Figure 23, the pairing providing a combination or subassembly as a "floating rib", Figure 25A is a short length isometric view of the floating rib of Figure 25, Figure 26 is an end or cross-sectional view of an interior elongate element incorpc an assembly as shown in Figure 23, Figure 26A is a short length isometric view of the interior elongate element of Figi/re"26, 555414 Figure 27 is a diagrammatic view showing reinforcing bar which may or may not be incorporated to act as a rigidifying influence transversely of the longitudinal run of the elongate sheet metal forms of any one or more of the embodiments of the present invention, such reinforcing bar acting not only as a rigidifying feature for the form work and/or the completed panel, (ie, with the cementitious or other filling material in place), but also providing access for utilities, Figure 27 for simplicity not showing the make up, insofar as the elongate metal forms are concerned, of the whole panel, Figure 28 shows with aggregate fill a variation of the wall as shown in Figure 4, Figure 29 shows two elements used in the wall of 28 being used on a wall where the form work elements, of a different kind, are embedded behind one face of the wall but not the other, Figure 30 shows a wall where all of the form work is embedded Figure 31 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 32 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 33 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 34 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 35 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 36 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 37 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 38 shows a sheet metal form of a kind that may be used in the panels of Figures 28 to 30, Figure 39 shows a graph of the design axial ultimate strength of concentric and eccentrically loaded 100mm panels (i.e the panel of Figure 28) with a light weight cementious filler and a foam filler, Figure 40 shows a graph of the design axial ultimate strength of concentric and eccentrically loaded 125mm panels (i.e the panel of Figure 28) with a light weight cementious filler and a foam filler, 555414 Figure 41 shows a graph of the design axial ultimate strength of concentric and eccentrically loaded 100mm panels (i.e the panel of Figure 28) with a medium weight cementious filler and a normal weight cementious filler, Figure 42 shows a graph of the design axial ultimate strength of concentric and eccentrically loaded 125mm panels (i.e the panel of Figure 28) with a medium weight cementious filler and normal weight cementious filler, and Figure 43 is a table showing the mechanical properties of possible filler materials.

Preferred forms of the present invention will now be described with reference first to a preferred embodiment where both faces of a panel are lined with a fabrication of sheet metal forms and which have such forms attached, one to another, by any suitable fixing arrangement, eg, riveting, welding, clinching, seam lining, or the like.

Some drawings show reasonably symmetric panel forms but it should be appreciated that asymmetric panel forms can also be used (ie, asymmetric in the sense that there can be a fabricated face provided by at least two shaped forms of long run and/or pressed sheet metal and, on the other face, any appropriate facing material, if any at all).

Preferably however there is a sandwiching effect by the panel liners thereby to present an exterior metal face.

In the preferred embodiments depicted a fill is provided between the panel liners. Any acceptable fill material that is a settable material and which confers the appropriate characteristics to the panel can be used.

For example, James Hardie WO 00/14354 discloses a panel filling cemetitious material 17, preferably producing a core density of between 200kg/m3 and around 1200kg/m3, and ideally around 550kg/m\ Their preferred cementitious formulation comprises a mixture of sand, cement and water, together with suitable additives adapted to achieve the desired density and to facilitate mixed performance and bonding. One particularly preferred formulation they disclose includes, within a tolerance of around i 10%, approximately: 45% by weight of cement; 19% by weight of sand, 29.5% by weight of water; 4% by weight of expanded polystyrene beads, and 0.5% by weight of concrete additives.

Whilst such a composition can be used, a preferred filler for use with the present invention is a foamed Portland cement concrete with a dry density of about 650kg/m/v3 and comprisini approximately: 57% by weight of cement, 555414 12% by weight of sand or flyash, 29% by weight of water, 2% by weight of specialist additives and foaming agent.

In other forms of the present invention, a non-cementitious fill can be used, eg, of a biopolymer or a polymeric foam eg, a polyurethane foam alone or in conjunction with other material(s).

As can be seen in the drawings there are provided on each face as a sheathing assembly there is a main long run form, rolled form and/or pressed form as one of the elements. Each such element (see particularly Figure 5) includes a channel form with a restricted entrance. The channel base 3 is to contact, preferably directly, the filling material. In some embodiments the filling material can include or the tillable space can be packed with an insulating material or left, in part, protected against filling by some appropriate inclusion (eg, a void former or foam material).

Preferably visible on the outer face of the main panel/facing region which has been profiled, preferably by longitudinal forming of exterior grooves 4, there are localised hollows or indentations, to facilitate fixing to the resulting panel at positions underlying part of a flap sequence. The visible outer face has also been stiffened by the longitudinal forming of exterior indentations 5. All such profiling assists in suppressing visible deformation of the outer face under normal in-service conditions.

The arrangement as shown in Figure 5 and carried through in Figures 1-4 includes on one side a flap sequence 6, 8 and 10 and on the other side a flap sequence 7, 9 and 11.

In other forms a flap 6 and/or 7 alone could be used with openings and/or kinking to render it retainable in the set embedding fill.

The inwardly directed flanges 6 and 7 are preferably provided with openings as shown in the figures to allow migration of unset fill along the panel and to key through the mated flanges 6, 7 and vice versa.

The face (substantially parallel) flanges 8 and 9 (which may or may not be strengthened by inturned flanges 10 and 11 respectively) are positioned to He inwardly of the base 3 of the channel forms of the other side. They ate also positioned to ensure fixings, (eg, screws, bolts, etc) using grooves 4, or any of them, if at sufficient length will pass not only through the metal thickness on the face of the panel but also through a flange 8 or 9, or both, for more secure fixing without reaching to the other face of the panel and thereby providing any metal to metal conductive pathway through the panel.

As can be seen in the figures, the stagger of one face relative to the other results in the pairings 14 of flange sequences of the proximate forms being interposed between mirror o\ fit V arrangements from the other face. This ensures, if desired, a fixing from a groove 4 canpSgage V I 2 3 DEC MB 555414 into a flange 9 or 8 of a form of the facing/panel liner from the other side, if it is not to extend to a flange 8 or 9 from the form of same side. There is the prospect of fixing through both without reaching to the other side. The grooves 4 are slightly offset from a symmetrical position so that a screw from one side which is longer than half the panel width does not interfere with a screw that is also longer then half the panel width which is installed from the other side.

Preferably other forms, such as those depicted in Figures 6 and 7 which are variations of the form as shown in Figure 5, are provided with rebates 12 and 13 respectively that co-act in the manor as shown in each of the side peripheries of the panel of Figure 4 to define locating sockets/grooves 22.

The modularity of the system allows any appropriate side periphery to side periphery distance to be used. Variations of the form substantially as shown in Figures 10 and 11 can be used to provide abbreviated panels or post forms able to index with a fabricated tongue 21 into a groove 22 provided by the paired rebates 12 and 13 of the forms as shown in Figures 6 and 7.

Figure 10 shows a roll formed or other formed member (of any suitable material whether metal, plastics or otherwise) 19 (eg, a plastic extrusion) which has the effect of leaving clear a utilities conduit 23 accessible via openings 20. The optional member 19 keeps the fill 24 against the metal surfaces other than those of the region 23.

As can be seen in Figure 1, paired members 6 and 7, from Figure 5, or vice versa, of proximate forms 1 provide an attached intrusion 14 topped by the top part of a T-form defined respectively by a flange 8 or 9, or vice versa. The forms 14 can be provided with the through openings 15 depicted (either circular or square cross section) and previously described to allow fill migration and/or keying.

It is envisaged that the preferred method of manufacture in accordance with the present invention comprises a layout jig or formwork into which the forms of one side are positioned (post fabrication, prior to fabrication or during fabrication, or any hybrid thereof). There can then be a laying up of the fabricated form of the other side into such a jigging arrangement. Thereafter there can then be the filling with the appropriate mix by any appropriate feed in method to ensures a complete fill.

It should be appreciated that the forms shown in juxtaposition or subassembly in Figures 1-4 are not necessarily the full side periphery to side periphery expanse. Side peripheries are preferably each formed with components as shown in Figures 4-7 but need not be necessarily be so.

The dimensions of the panel or modular panels of a panel system in accordance present invention will depend on the end usage. Likewise the nature of the fill. Likewi thickness(es) and surface treatment(s) of the metal forms. 555414 By way of example, a panel sub-assembly as shown in Figure 2 could be of half a metre in side periphery to side periphery with each channel base being about 250mm across (can be of any length). Its inwardly directed flanges 6 and 7 can be of about 75mm. The flanges 8 and 9 can be of about 89mm whilst the inturned hp can be of about 5mm.

Do appreciate that such dimensions are in no way fixed at these values.

Mating of such forms in the manner aforementioned will provide a filled panel of thickness of about 100mm.

As far as the rebates are concerned, these can be of any suitable co-acting kind. By way of example, the dimensions of the panel forming sheet metal of Figure 6 can be much the same as that of Figure 5 but with a rebate of about 45mm by about 27.7mm. The panel of, for example, Figure 7 could be 125mm across (with similar dimensions otherwise as far as intrusion is concerned) but with a flange of say 50mm and a rebate of, for example, about 45mm by about 28.9mm. Again these are examples only.

A preferred metal is sheet steel (eg, G300 or G550coated sheet steel) and can be as little as about 0.4mm thick (preferably at least 0.5mm thick up to, say, 2mm thick) depending on the loading outcomes required.

The preferred sheet steel grades and thicknesses are either Grade 300 at 0.75mm thick or Grade 550 at 0.55mm thick. While sheet thickness can range from the about 0.4mm thickness stated upwards, examples of appropriate steel thicknesses are 0.55mm, 0.75mm and 1.2mm thickness.

The position of holes can be as is appropriate but preferably as such as to maintain modularity of the system. Preferred hole shape is circular.

A preferred filler for use with the present invention is a foamed Portland cement concrete with a dried density of about 650kg/m3. The preferred recipe for such a material is: 57% by weight of cement, 12% by weight of sand or flyash, 29% by weight of water, and 2% by weight of specialist additives and foaming agent.

Preferred load carrying capacity in terms of length is 10 tonnes/metre width for a panel of around 6 metres in length. Including self-weight.

It should be appreciated that thinner sheet will be more difficult to handle during manufacture and more prone to local damage and surface. Thicker sheet is less difficult to handle and less prone to such damage and will provide a greater capacity for the fasteners that mighj^^oP®''/' -used. 2 3 DEC 2008 555414 Prefcrrcd form to form fabrication preferably takes place on a supporting surface and/or in a jig and is by riveting and/or line clinching and/or other connecting mechanisms.

Panel edges, where they occur, can be joined by blind steel rivets through holes drilled as appropriate. Alternatively the join can be achieved using clinching of the two sheets at the edges through the pre-formed holes.

Figures 12 through 18 show a further form of the present invention where complementary arrays capped, at each end of the array progressions, by elongate members (the inner and exterior members) respectively of Figures 15 and 14 to provide ends (laterally of the arrays) of components as in Figure 13. Such figures correspond more or less with those previously disclosed.

Figures 16 and 17 however show how preferred openings might be provided therein so that, if desired, tubes as shown in Figure 27 or reinforcing bar can pass through such openings 26.

The panel construction sequence for the steel face on each side option shown in Figures 12 through 18 is as follows: (i) Punch the holes into the steel sheet. (ii) Cut and fold (either roll form or fold press) the steel sheets into the elements. (iii) Assemble and connect the elements together (either through clinching, mechanical lock, seaming etc). (iv) Insert the panel face into the slanted or level formwork. (v) Install the service pipes and/or reinforcing bars if required. (vi) Connect the panel edge elements together (either through riveting, clinching, etc). (vii) Seal edges as required and prepare panel for filler. (viii) Prepare filler material and pour into panel once ready. (ix) Remove panel after a suitable amount of time for filler set. (x) Panel ready to be used on site after filler obtained required strength.

Figures 19 through 22A shows an embodiment where, in a manner substantially as previously described there is the metal array and end capping reliant upon members as depicted in Figures 20 through 22, the arrangement being substantially as previously defined. In this situation however, preferably a light concrete core as the settable material can be used to provide the embedding core 27 and one side can be provided with identical or different more rupture resistant settable material 28, ie, for example, a durable, high modulus of rupture concrete mix.

An arrangement even as shown in Figure 19 can make provision for transverse service pipes or reinforcing bar as depicted in Figure 27.

By way of example, if one considers the panel of Figure 19 as having a panel thickp^s^@^jfy~^>s say 100mm, the outer zonal material could be a concrete mix of, for example, 35mm dajbgS. Even 0/^\ so, there is still provision with openings of the kinds depicted in Figures 16 and 17, bijt nnal^gpy|^- \ 555414 for the sections of Figures 20 to 22, to accommodate, by way of example, a 28mm diameter steel service pipe at, for example, spacings of, say, 2 metre intervals up through the panel or a reinforcing bat at spacings of 1 metre intervals for example.

The panel construction sequence for the steel face/concrete face and with a two filler mix as described in connection with Figures 19 through 22A is as follows: (i) Punch the holes into the steel sheet. (ii) Cut and fold (either roll form or fold press) the steel sheets into the elements, this process also includes expanding the element flanges if required. (iii) Assemble and connect the elements together (either through clinching, mechanical lock, seaming etc). (iv) Insert the panel face into the pouring box. (v) Install the service pipe and/or reinforcing bar if required. (vi) Seal and prepare panel for fillers. (vii) Prepare both filler materials and pour into panel once ready, the lighter filler first followed by the more durable filler. (viii) Level the durable filler and set patterns if required. (ix) Remove panel after a suitable amount of time for filler set.

(*) Panel ready to be used on site after fillers obtained required strength.

In Figure 19 the floating rib assembly 30 is shown. This can be two mirroring sections mechanically or adhesively, or both, held together.

Figure 19 shows, by way of example, a fully embedded floating rib 30 to the left hand side of Figure 19. The right hand side of Figure 19 shows parts of the floating rib 30 A outwardly of the settable material 28.

The settable material can be the same or different from the settable material on the other side, ie, 27 (for example, a durable surface providing mix when the floating rib is fully embedded and a light-weight mix when the floating rib extends outwardly of the settable material).

The left hand side of Figure 19 shows the floating rib 30 flanges 29 embedded but not in an overlapping arrangement as previously defined. Nonetheless there remains the lapping of, for example, 30 with flange 31.

By way of example all of the elongate members could be manufactured from, for example, 1.2mm fixed steel sheets although thicknesses of, for example, 1.2mm to 0.55mm thick G300 (or G500) galvanised steel are also preferred.

The panel construction sequence for the embodiment with a concrete double face as^^jrty Q/j? shown in Figures 23 through 26A is as follows: (i) Punch the holes into the steel sheet. i „ „ ~tvia U I 2 3 0eC 2MB 555414 (ii) Cut and fold (either roll form or fold press) the steel sheets into the elements, this process also includes expanding the element if required. (iii) Assemble and connect the elements together (either through clinching, mechanical lock, seaming etc). (iv) Insert the panel face into the pouring box. (v) Install the service pipe and/or reinforcing bar if required. (vi) Connect the panel edge elements together (either through riveting, clinching, etc). (vii) Prepare both filler materials and pour the durable filler first up to a certain height. (viii) Insert the steel panel up to a certain depth, then pour the lighter filler to a certain height to be followed by the durable filler. (is) Level the durable filler and set patterns if required. (x) Remove panel after a suitable amount of time for filler set. (xi) Panel ready to be used on site after fillers obtained required strength.

In other embodiments surface coating (eg, with plaster, Gibraltar board, fibre board, etc.) can be considered.

It is believed that a panel in accordance with the present invention provides a worthwhile alternative to existing panel forms. Such elements and panels as described demonstrate high stiffness and vertical load carrying capacity prior to visible buckling of the light gauge sheet metal skin. Such capacity is surprising.

Optionally in the arrangement as shown in Figures 23 through 26A the regions 39, 40 and 41 of the sectional forms of Figures 24 through 26 respectively can be of perforately expanded metal so as to increase mechanical concrete bonding. Preferably the flange regions 33, 34 and 35 are not perforately expanded so as to ensure good and adequate fixing.

Figures 28, 29 and 30 show further embodiments of the present invention.

Figure 28 shows a panel with a cementious filler. The panel is not lined on its periphery. The performance characteristics of such a panel are shown in the graphs of Figures 39 to 42 Figure 29 shows a panel with a cementious filler, but further having form work elements 28 embedded behind on one face of the wall but not the other. The form work liner may for example be a high density settable material.

Figure 30 shows a panel with a cementious filler, but with form work elements 28 embedded on both of its sides. The form work liners may be a high density settable material 28.

Figures 31 to 38 show various sheet metal forms of kinds used in the panels of Figures 28 to 30.

Figures 39 to 42 show the design ultimate axial strength to the effective panel heiep^»for different fillers for a 100mm thick panel and a 125mm thick panel. Figures 39 and 40 shop the 2 3 DEC 2000 555414 results using a foam filler and a light weight concrete filler. Figures 41 and 42 show the results using a medium weight concrete filler and a normal weight concrete filler.

Figure 43 summarises the mechanical properties of the different fillers used for the panels shown in Figures 39 to 42.

The design axial strength is that associated with the ultimate limit state loads, i.e. it must be compared with the strength limit state applied loads from a suitable loading standard such as AS/NZS 1170.

The figures 39 to 42 show curves for concentric and eccentric loading. Under concentric loading the axial load is applied to the panel centre at the top, (i.e. as a roof or a floor placed on top of the panel which is continuous on both sides of the panel).

Under eccentric loading the axial load is applied at the face of the panel (i.e. as a floor connected to the panel face by an angle connection).

The x-axis of figures 39 to 42 show the effective panel length for design. This is the length of an effective pin ended column and can be taken as the clear distance from the top of the floor to the bottom of the floor above or roof. Hence, for a 6 metre panel with a floor attached at 3 metres and a rood at 6 metres, the effective length (or height) is conservatively taken as 4 metres.

As shown in Figure 39 there is little difference between die curves of foam filler and the light weight cementious filler. Therefore, the foam filler is providing a similar performance to the light cementious filler.

Similar results were obtained for the 125mm panel as shown in Figure 40.

As shown in Figure 41, the medium and normal weight cementious fillers do have increased strength compared with the lighter fillers shown in Figure 39. However, there is a major difference between the normal weight cementious filler and the medium weight cementious filler.

Similar results were obtained for the 125mm panel as shown in Figure 42 What is common between all the graphs shown on Figures 39 to 42, is that at 5 metres effective height both concentric and eccentric loading starts to become the same due to the elastic limit being reached. The light weight fillers have such low compressive strength, density and modulus of elasticity that they do not contribute much tot the panel overall strength. As such, the steel is carrying most of the load, while the filler is just preventing it from buckling.

When medium and normal cementious fillers are used the filler contributes to the overall strength. Such embodiments may be suitable for use in heavy load bearing applications. Such a panel may be used as a shear wall, for blast resistance, or any other suitable heavy duty uses.In this specification where reference has been made to patent specifications, other external documents, or othe of information, this is generally for the purpose of providing a context for discussing thi of the invention. Unless specifically stated otherwise, reference to such external docume 555414 to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art. ■5s®" 2 3 DEC 2008 555414 29-

Claims (33)

WHAT WE CLAIM IS:

1. A composite panel having first and second sides, the panel having complementary reinforcement forms at least partially embedded in set settable material or settable materials ("settable material(s)"); wherein one form or set of forms ("first form(s)"), each form having at least one flange and having part or parts which laterally to said flange(s) embedded at least substantially adjacent or nearer the second side but within the panel, and another form or set of forms ("second form(s)"), each form having at least one flange and having part or parts which laterally to flanges embedded adjacent or nearer the first side but within the panel; wherein flanges of the first form(s) and flanges of the second form(s) have longitudinal axes substantially parallel; and wherein the flanges of the first form(s) and flanges of the second fomi(s) interact, first form flange to second form flange, via the set settable materials) interposed therebetween, thereby to confer a structural or load bearing advantage to the composite panel.

2. A composite panel of claim 1 wherein the interaction via the interposed material(s) is as a consequence of flange lapping (ie, overlapping in part) or near lapping (ie, nearly overlapping in part) within the panel when one notionally considers the panel normally to a said side.

3. A composite panel of claim 1 or 2 wherein said interaction is without a flange of a first form touching a flange of a second form.

4. A composite panel of claim 1, 2 or 3 wherein each form is elongate and the flange longitudinal axis is, or flange longitudinal axes are, parallel to the longitudinal axis of the form(s).

5. A composite panel as claimed in any one of the preceding claims wherein at least one of said first and second form(s) is, or are, metal form(s).

6. A composite panel as claimed in claim 5 wherein both of said first and second form(s), is or are, metal form(s). i) extend(s) from beyond one side, ii) extend(s) from one side, and/or iii) extend(s) from adjacent or nearer one side but within the panel, i) extend from beyond the second side, ii) extends from the second side, and/or iii) extends from adjacent or nearer the second side but within the panel, 555414 -30-

7. A composite panel as claimed in any one of the preceding claims wherein at least one of said foms is a, or are, sheet metal form(s).

8. A composite panel of any one of the preceding claims wherein there is at least one set of elongate forms as an array, each form of the array having a said flange from a said longitudinal part thereof.

9. A composite panel of claim 8 wherein said elongate for or forms has or have the flanges as longitudinal lips to a lipped channel section elongate form.

10. A composite panel as claimed in claim 8 or 9 wherein there is lapping in part of individual flanges of one array with individual flanges of the other array when one notionally considers the panel normally to a said side.

11. A composite panel as claimed in any one of claims 8, 9 and 10 wherein one array extends from one side or extends from adjacent or nearer one side but within the panel.

12. A composite panel as claimed in any one of claims 8, 9 and 10 wherein both arrays extend from one side or extends from adjacent or nearer one side but within the panel.

13. A composite panel as claimed in any one of the preceding claims wherein there has been perforation and/or expanding of some part of at least one of the forms, or the material of the forms, to better mechanically tie to said settable matcrial(s).

14. A composite panel as claimed in any one of the preceding claims wherein there has been, for at least one set as an array, some mechanical linking of the forms, one to another, prior to any at least partial embedding thereof.

15. A composite panel as claimed in any one of the preceding claims wherein said settable material(s) is or includes at least one cementitious material.

16. A composite panel as claimed in any one of claims 1 to 14 wherein the settable materials) is or includes a polymeric material.

17. A composite panel as claimed in any of the preceding claims wherein said panel includes a mix of different settable materials) and one of said settable materials provides a surface over one of said sides.

18. A composite panel of any one of the preceding claims wherein there is said lapping of the flanges.

19. A composite panel as claimed in any one of the preceding claims that is lined.

20. A composite panel of claim 7 wherein said sheet metal forms are elongate and said flanges extend along parallel to the longitudinal axis thereof.

21. A panel of any one of the preceding claims wherein at least one of the sets is an array of mutually parallel elongate sheet metal forms. 555414 -31 -

22. A panel claim 21 wherein each elongate form has two flanges and each is in-turned to constrict the opening of a channel of a channel like section.

23. A panel of any one of the preceding claims where additional forms have been introduced to increase strength in some areas.

24. A panel of any one of the preceding claims wherein at least some of the embedded flanges are substantially flat and extend parallel to a face of said panel.

25. A panel of any one of the preceding claims wherein at least two individual sheet metal forms of a set, as an array are mechanically linked prior to the set of the settable material.

26. A panel of any one of the preceding claims wherein there is flange lapping and the lapping of individual flanges is such that along a face of a said panel (when notionally moving transversely to the preferred aligned longitudinal axis of roll or pressed elongate sheet metal forms), there is an alternating (as a consequence of an offset of the arrays) of which flange laps with which.

27. A panel of any one of the preceding claims wherein conduit forms pass between said arrays.

28. A panel of claim 27 wherein said conduit forms are embedded in said settable material.

29. A panel of claim 27 or 28 wherein conduit forms extend between said arrays substantially perpendicularly and/or obliquely to the elongate axis of the sheet metal forms.

30. A structure ot an envelope or wall which includes at least one composite panel of any one of the preceding claims.

31. Formwork of a composite panel of any one of claims 1 to 28.

32. Fotmwork or a panel substantially as herein described with reference to any one or more of the accompanying drawings.

33. A sheet metal formwork item substantially as hereinbefore described with reference to any one or more of the accompanying drawings.