NZ759893A - Stud for wall construction - Google Patents
Stud for wall constructionInfo
- Publication number
- NZ759893A NZ759893A NZ759893A NZ75989319A NZ759893A NZ 759893 A NZ759893 A NZ 759893A NZ 759893 A NZ759893 A NZ 759893A NZ 75989319 A NZ75989319 A NZ 75989319A NZ 759893 A NZ759893 A NZ 759893A
- Authority
- NZ
- New Zealand
- Prior art keywords
- rails
- spacer
- wall
- flanges
- stud
- Prior art date
Links
- 238000010276 construction Methods 0.000 title description 12
- 210000000088 Lip Anatomy 0.000 claims abstract description 42
- 210000002832 Shoulder Anatomy 0.000 claims abstract description 30
- 238000009415 formwork Methods 0.000 claims abstract description 6
- 239000007787 solid Substances 0.000 claims abstract description 4
- 230000000717 retained Effects 0.000 claims description 4
- 210000001624 Hip Anatomy 0.000 claims description 3
- 239000000463 material Substances 0.000 description 16
- 229920000915 polyvinyl chloride Polymers 0.000 description 16
- 239000004800 polyvinyl chloride Substances 0.000 description 16
- 238000000034 method Methods 0.000 description 10
- 239000000853 adhesive Substances 0.000 description 8
- 230000001070 adhesive Effects 0.000 description 8
- 230000003014 reinforcing Effects 0.000 description 8
- 239000011518 fibre cement Substances 0.000 description 6
- 239000004700 high-density polyethylene Substances 0.000 description 5
- 229920001903 high density polyethylene Polymers 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 229920002689 polyvinyl acetate Polymers 0.000 description 3
- 239000011118 polyvinyl acetate Substances 0.000 description 3
- 229920001651 Cyanoacrylate Polymers 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- NLCKLZIHJQEMCU-UHFFFAOYSA-N cyano prop-2-enoate Chemical class C=CC(=O)OC#N NLCKLZIHJQEMCU-UHFFFAOYSA-N 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000006011 modification reaction Methods 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000004698 Polyethylene (PE) Substances 0.000 description 1
- RTQYOYLLVABCGS-UHFFFAOYSA-N [SiH4].CC(O)=O Chemical compound [SiH4].CC(O)=O RTQYOYLLVABCGS-UHFFFAOYSA-N 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000001808 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000001419 dependent Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000789 fastener Substances 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 239000003673 groundwater Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 230000000284 resting Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
Abstract
A stud for use in panel formwork for solid filled walls, the stud comprising a pair of rails, each rail including, a rail body configured to be attached to an inner face of a respective wall sheet and a pair of spaced apart opposed flanges extending away from the rail body, each flange including a lip, and a plurality of spacer elements extending between the rails to hold the rails and respective wall sheets in a spaced apart arrangement, each spacer element including a spacer body and a connector provided at each end of the spacer body, each connector including shoulders that engage respective lips of the flanges to thereby fasten the connectors to the rails. ip, and a plurality of spacer elements extending between the rails to hold the rails and respective wall sheets in a spaced apart arrangement, each spacer element including a spacer body and a connector provided at each end of the spacer body, each connector including shoulders that engage respective lips of the flanges to thereby fasten the connectors to the rails.
Description
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STUD FOR WALL CONSTRUCTION
Background of the Invention
The present invention relates to a stud for use in wall construction, a wall including the
stud and a method of constructing a wall using the stud.
Description of the Prior Art
The reference in this specification to any prior publication (or information derived from
it), or to any matter which is known, is not, and should not be taken as an acknowledgment or
admission or any form of suggestion that the prior publication (or information derived from it) or
known matter forms part of the common general knowledge in the field of endeavour to which
this specification relates.
It is known to provide techniques for constructing walls using wall sheets as concrete
formwork, which then form part of the completed wall structure.
WO2005/019552 describes a system comprising paired studs for attachment to inside
surfaces of facing sheets to provide panel formwork for concrete walls. The studs comprise a
head and outwardly extending spaced flanges with inwardly directed teeth and lips. Spacer
elements are engaged with the recess between the flanges and may be formed from off-cuts of
sheet material or as specifically formed elements. The latter are formed from hard plastic and in a
preferred embodiment are formed as a rectangular box which can be orientated in alternate
directions. The system may include end elements, internal top and bottom plates, internal
corners, external corners and a shadow line junction between panels. The invention extends to
panels formed with the above system and buildings formed from the panels.
WO2009/070830 describes a method of constructing a wall, the method including
providing first and second spaced apart wall portions for receiving a filling material. Each wall
portion includes at least one track on a support, at least two support members, each support
member being aligned with the track and extending from the support, a wall panel supported by
the at least one track and the at least two support members and at least one joining member
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coupled to the wall panel and the support members. Spacers are also coupled to and extend
between the wall portions.
Summary of the Present Invention
In one broad form, an aspect of the present invention seeks to provide a stud for use in
panel formwork for solid filled walls, the stud comprising: a pair of rails, each rail including: a
rail body configured to be attached to an inner face of a respective wall sheet; a pair of spaced
apart opposed flanges extending away from the rail body, each flange including a lip; a plurality
of spacer elements extending between the rails to hold the rails and respective wall sheets in a
spaced apart arrangement, each spacer element including: a spacer body; and, a connector
provided at each end of the spacer body, each connector including shoulders that engage
respective lips of the flanges to thereby fasten the connectors to the rails.
In one embodiment the rail body is a substantially planar elongate body.
In one embodiment the flanges extend from edges of the rail body.
In one embodiment the flanges extend substantially perpendicularly from the rail body.
In one embodiment the spacer body includes a pair of substantially parallel spaced webs
extending between the connectors.
In one embodiment the connectors include plates extending between ends of the webs.
In one embodiment each web includes a structural ridge extending along a surface of the
web.
In one embodiment each web includes a narrow waist.
In one embodiment the lips extend inwardly from the flanges and the shoulders extend
outwardly from the connectors so that the connector is retained between the flanges.
In one embodiment the connectors are fastened to the rails using at least one of: snap fit
engagement; and, cantilevered snap fit engagement.
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In one embodiment the lips are configured to engage the shoulders to thereby fasten the
connector to the rail.
In one embodiment the flanges deform outwardly to allow the connector to pass between
the lips.
In one embodiment the lips include a sloped outer lip surface that engages the shoulders
to urge the flanges laterally to allow passage of the shoulders past the lips.
In one embodiment the sloped outer lip surface has a convex curved profile.
In one embodiment the shoulders include a sloped outer shoulder surface that engages the
lips to urge the flanges laterally to allow passage of the shoulders past the lips.
In one embodiment the sloped outer shoulder surface has a convex curved profile.
In one embodiment the lips and shoulders include sloped outer surfaces having convex
curved profiles to progressively increase the lateral mechanical force applied to the flanges as the
shoulders move past the lips.
In one embodiment: at least one rail includes a plurality of holes spaced along an inner
surface of the rail body; and, at least one of the connectors of each spacer includes a peg that
projects from an outer surface of the connector, and wherein the peg is configured to engage one
of the plurality of holes to thereby locate the spacer along the rail.
In one embodiment the hole extends at least part way through the rail body.
In one embodiment: each rail includes a plurality of holes spaced along in the inner
surface of the rail body; and, each connector of each spacer includes a peg that projects from an
outer surface of the connector to engage a respective hole.
In one embodiment the plurality of holes are spaced apart by a set distance to thereby
maintain a set spacing between spacers.
In one embodiment the set distance is at least one of: greater than 200mm; greater than
250mm; greater than 280mm; less than 400mm; less than 350mm; less than 320mm; less than
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eight times a height of the spacer; less than seven times a height of the spacer; more than four
times a height of the spacer; more than five times a height of the spacer; approximately six times
a height of the spacer; and, approximately 300mm.
In one embodiment the spacers have a height that is at least one of: greater than 25mm;
greater than 40mm; less than 75mm; less than 60mm; and, approximately 50mm
In one embodiment the spacer body has at least one of: a length of at least one of: greater
than 90mm; greater than 100mm; less than 300mm; less than 255mm; approximately 123mm,
approximately 138mm, approximately 153mm, approximately 188mm, approximately 253mm,
and, approximately 103mm; and, a width of at least one of: greater than 40mm; greater than
42.5mm; less than 50mm; less than 47.5mm; and, approximately 45mm.
In one embodiment the rail has at least one of: a length of up to 3000mm; and, a width
that is at least one of: greater than 40mm; less than 60mm; and approximately 50mm.
In one embodiment the rails are made of at least one of: a thermoplastic polymer;
polyvinyl chloride; rigid polyvinyl chloride; and, recycled rigid polyvinyl chloride.
In one embodiment the spacers are made of at least one of: a thermoplastic polymer;
polyethylene; high density polyethylene; and, recycled high density polyethylene.
In one embodiment the rail body is attached to a wall sheet using at least one of: adhesive
bonding; mechanical bonding; polyvinyl acetate copolymer adhesive; polyvinyl acetate silane
copolymer adhesive; solvent based polyvinyl chloride cements cyanoacrylates; 2-part epoxy
adhesives; and, structural acrylic adhesives.
In one embodiment the wall sheet is at least one of: a fibre cement wall sheet; and, a
polyvinyl chloride wall sheet.
In one broad form, an aspect of the present invention seeks to provide a wall structure
including multiple wall sections, and each wall section including: a pair of wall sheets; a plurality
of studs, each stud being attached to each of the pair of wall sheets to hold the wall sheets in a
substantially parallel spaced apart configuration, each stud including: a pair of rails, each rail
including: a rail body adapted to be coupled to an inner face of a respective wall sheet; a pair of
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spaced apart opposed flanges extending away from the rail body, each flange including a lip; a
plurality of spacer elements extending between the rails to hold the rails and respective wall
sheets in a spaced apart arrangement, each spacer element including: a spacer body; and, a
connector provided at each end of the spacer body, each connector including shoulders that
engage respective lips of the flanges to thereby fasten the connectors to the rails.
In one embodiment the wall includes multiple wall sections arranged in end-to-end
abutment and wherein at least one rail body spans a join between adjacent wall sheets of adjacent
wall sections.
In one embodiment a space between the wall sheets is filled with a filling material.
In one embodiment the wall sheet is at least one of: a fibre cement wall sheet; and, a
polyvinyl chloride wall sheet.
In one broad form, an aspect of the present invention seeks to provide a method of
constructing a wall, the method including: providing at least one track on a support; attaching a
number of wall sections to the track, each wall section including: pair of wall sheets to the at
least one track; a plurality of studs, each stud being attached to each of the pair of wall sheets to
hold the wall sheets in a substantially parallel spaced apart configuration, each rail including: a
rail body adapted to be coupled to an inner face of a respective wall sheet; a pair of spaced apart
opposed flanges extending away from the rail body, each flange including a lip; a plurality of
spacer elements extending between the rails to hold the rails and respective wall sheets in a
spaced apart arrangement, each spacer element including: a spacer body; and, a connector
provided at each end of the spacer body, each connector including shoulders that engage
respective lips of the flanges to thereby fasten the connectors to the rails; and, providing a filling
material between wall sheets of the wall sections.
In one embodiment the method includes positioning reinforcing members between the
wall sheets so that the reinforcing members are at least partially supported by the spacers, prior to
providing the filling material.
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It will be appreciated that the broad forms of the invention and their respective features
can be used in conjunction and/or independently, and reference to separate broad forms is not
intended to be limiting.
Brief Description of the Drawings
Various examples and embodiments of the present invention will now be described with
reference to the accompanying drawings, in which: -
Figure 1A is a schematic side view of an example of a wall;
Figure 1B is a schematic plan view of the wall of Figure 1A;
Figure 1C is a schematic end view of the wall of Figure 1A;
Figure 2A is a schematic plan view of an example of a rail;
Figure 2B is a schematic end view of the rail of Figure 2A;
Figure 2C is a schematic perspective view of a part of the rail of Figure 2A;
Figure 3A is a schematic plan view of a spacer;
Figure 3B is a schematic side view of the spacer of Figure 3A;
Figure 3C is a schematic end view of the spacer of Figure 3A;
Figure 3D is a schematic perspective view of the spacer of Figure 3A;
Figure 4 is a schematic end view of a stud including rails of Figure 2A and a spacer of
Figure 3A;
Figures 5A to 5C are schematic end views showing attachment of a spacer of Figure 3A
to a rail of Figure 2A;
Figure 6A is a schematic perspective view of wall section components;
Figure 6B is a schematic perspective view of a partially constructed wall section;
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Figure 7A is a schematic perspective view of a wall corner section;
Figure 7B is a schematic perspective view of an example of a wall end cap;
Figure 7C is a schematic perspective view of a portion of a wall;
Figure 8A is a schematic perspective view showing a wall during construction;
Figure 8B is a schematic close-up view of the tracks of Figure 8A; and,
Figure 8C is a schematic diagram of an example of a partially constructed wall.
Detailed Description of the Preferred Embodiments
An example of a wall construction will now be described with reference to Figures 1A to
In this example, a wall is constructed on a support 101 such as a slab, footing, building
foundation, or the like. The wall 100 includes a number of wall sections 110, which in this
example are provided in an end-to-end arrangement to construct a straight wall 100. Each wall
section 110 includes wall sheets 111, 112, such as fibre cement sheets, which are held in a
parallel spaced apart arrangement by studs 113. The studs 113 typically extend substantially
vertically for most of a height of the wall sheet, with multiple studs being spaced apart
horizontally along the wall sheets 111, 112, so that each wall section includes multiple studs.
The studs 113 are attached to the wall sheets to hold the wall sheets in a spaced apart position,
allowing a filling material, such as concrete, or the like, to be provided therebetween, as will be
described in more detail below.
An example of a stud arrangement for such a wall construction technique will now be
described in more detail with reference to Figures 2 to 4.
In particular, in the example, the stud is formed from a pair of rails 230, shown in Figures
2A to 2C, and a plurality of spacer elements 340, shown in Figures 3A to 3D, which extend
between the rails 230 to hold the rails in a spaced apart arrangement, as shown in Figure 4.
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Each rail 230 includes a rail body 231 configured to be attached to an inner face of a
respective wall sheet 111, 112. Each rail 230 also includes a pair of spaced apart opposed
flanges 232, which extend away from the rail body 231 with each flange including a lip 233.
In this particular example, the rail body 231 is substantially planar and has a generally
elongated rectangular shape, with the flanges 232 extending substantially perpendicularly away
from opposing long edges of the rail body 231. However, it will be appreciated that this is not
essential and other configurations could be provided. For example, the rail body could have an
alternative shape, the flanges 232 could be spaced from the edges, or the flanges 232 could be
provided at angles offset to perpendicular. Nevertheless, the above described arrangement is
particularly advantageous as it can be easily created during an extrusion process, whilst using
minimal amounts of material, thereby reducing environmental impacts and cost, but maintaining
sufficient structural integrity.
In the current example, the stud 340 includes a spacer body that extends between
connectors 342 provided at each end of the spacer body. Each connector includes shoulders 343
that engage the respective lips 233 of the flanges 232 to thereby fasten the connectors 342 to the
rails 230. An example of this is shown in Figure 4, in which the connectors 342 are retained in
position by the lips 233 of the rail flanges 232.
In one particular example, the spacer body includes a pair of substantially parallel spaced
webs 341 extending between the connectors 342, which in this example are in the form of plates
that extend between and beyond ends of the webs 341, to thereby form the shoulders 343. The
webs 341 and connectors 342 can be separate components, although more typically these are
integrally formed, for example as part of an extrusion process. Again it will be appreciated that
the particular configuration of the spacer, and in particular the spacer body and connectors 342
could vary. For example, the spacer could include a single solid body, instead of the webs 341.
However, it will be noted that the webs provide could structural strength under compression or
tension, whilst using minimal material, thereby reducing environmental impacts and cost.
Additionally, as will be described in more detail below, the use of webs provides an opening,
which can received reinforcement members, such as rebar, and which also allows for flow of
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filling material therethrough, which can assist in ensuring complete filling of the cavity between
the wall sheets 111, 112.
Accordingly, the above described arrangement provides a pair of rails that can be
attached to respective wall sheets, with a plurality of space elements being used to hold the rails
and hence wall sheets in a substantially parallel spaced apart arrangement.
A number of features will now be described.
In the current example, the lips 233 extend inwardly from the flanges 232 with the
shoulders 343 extending outwardly from the connector 342 so that the connector is retained
between the flanges 232 as shown in Figure 4. In this regard, the term inwardly refers to the lip
extending from one flange towards the opposing flange, so that the lips are provided between the
flanges, whilst outwardly refers to the shoulders projecting beyond sides of the body. It will be
appreciated, however, that this arrangement is not necessarily essential and alternative
configurations could be employed. For example, the lips 233 could extend outwardly from the
flanges 232 and be accommodated between inwardly projecting shoulders 343 on the connectors
342.
Nevertheless, the arrangement shown in Figure 4 is particularly advantageous as this
provides for a significant degree of coupling strength whilst minimising the amount of material
employed in construction of the rails and spacers, which in turn reduces material wastage and
saves costs.
The connectors are typically fastened to the rails using snap-fit engagement and, in
particular, a cantilevered snap-fit arrangement. In this configuration, the flanges 232 are
resiliently deformable to allow passage of the connectors 342 and shoulders 343 between the lips
233. Once past the lips 231, the flanges 232 returning to their original position so that the lips
233 engage a rear of the shoulders 343, to thereby fasten the connector 342 and hence the spacer
340 to the rail 230. An example of this process is shown in more detail in Figures 5A to 5C.
In this example, as shown, the spacer 340 and rail 230 are urged towards each other to
cause the flanges 232 to deform progressively outwardly so that the connector 342 passes
between the lips 233.
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To facilitate this process, the lips 233 include a sloped outer lip surface 234 that engages
the shoulders 343 to urge the flanges laterally outwardly to allow passage of the shoulders
therebetween. Similarly, the shoulders 233 include a sloped outer surface 344 that engages the
lips 233 to urge the flanges laterally outwardly to allow passage of the shoulders past the lips. In
both cases, the sloped outer lip surface 234 and sloped outer shoulder surface 344 typically have
a convex curved profile, which can facilitate the deformation of the flanges 232. In particular,
the sloped surface allows movement of the spacer 340 and rail 230 towards each other to be
translated into a lateral force which is applied to the flanges, thereby urging the flanges 231
apart. Furthermore, the use of the convex curved profile employs mechanical advantage to
progressively increase the lateral force applied to the flanges 232 as the shoulders 343 move past
the lips 233. An example of this is shown by the dotted lines in Figures 5A and 5B which show
that as the flanges 232 deform outwardly, and the curved surfaces 234, 344 pass each other, the
angle of contact changes to thereby increase the level of mechanical advantage and hence
increase the magnitude of the lateral force applied to the flanges 232, thereby facilitating passage
of the connector 342 between the lips 233.
The rail 230 and spacers 340 can be configured so that the spacers lock into defined
positions on the rail 230, thereby maintaining a spacing between the spacers 340. In one
example, this is achieved using a locking peg 345 provided on the spacer.
In this example, as shown in Figure 2A, the rail 230 includes a plurality of holes 235
spaced along an inner surface of the rail body 231, with the holes 235 being either recesses
formed in a surface of the rail body 231, or could be apertures that pass through the rail body
231.
At least one of the connectors 342 of the spacer 340 includes a peg 345 that projects from
an outer surface of the connector 342. In use, the peg 345 is configured to engage one of the
plurality of holes 235 to thereby locate the spacer along the rail and, in particular, lock the spacer
in a defined position relative to the rail 230. This prevents spacers inadvertently sliding relative
to the rail 230 during wall construction, whilst maintaining a vertical spacing between the spacers
340.
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It will be appreciated that the holes 235 provided in only one of the rail bodies 230 and/or
that pegs 345 may be provided in only one connector 342. In this instance, this can allow free
movement of the spacers 340 relative to one of the rails 230 of each pair of rails, which can assist
in the wall construction process, for example, to accommodate different levels of a support.
More typically, however, holes are provided in both rails, thereby locking a respective vertical
positioning of the rails 230.
As previously mentioned, the holes are spaced by a set distance to thereby maintain a set
spacing and in particular set vertical separation, between spacers 340. Part of the purpose of this
is to ensure that there is sufficient open space within the stud to allow filling material to flow
through the stud during the process of filling a wall section. This in turn helps ensure the wall
cavity between the wall sheets 111, 112 is completely filled, avoiding the presence of voids,
which can in turn affect the structural integrity of the wall. However, this must be balanced by
ensuring a sufficient number of spacers 340 are provided, to adequately support spacing of the
wall sheets 111, 112 during construction and filling of the wall.
To achieve this, the set distance is typically at least one of greater than 200mm, greater
than 250mm, greater than 280mm, less than 400mm, less than 350mm, less than 320mm, less
than eight times a height of the spacer, less than seven times a height of the spacer, more than
four times a height of the spacer, or more than five times a height of the spacer. More typically,
the set distance is approximately six times a height of the spacer or approximately 300mm.
The spacers typically have a height that is greater than 25mm, greater than 40mm, less
than 75mm, less than 60mm, or more typically approximately 50mm, a length that is greater than
90mm, greater than 100mm; less than 300mm; less than 255mm; approximately 123mm,
approximately 138mm, approximately 153mm, approximately 188mm, approximately 253mm,
or more typically approximately 103mm, and a width that is greater than 40mm, greater than
42.5mm, less than 50mm, less than 47.5mm or more typically approximately 45mm.
The rail typically has a length dependent on the required wall height, but typically up to
3000mm and a width that is greater than 40mm, less than 60mm, or more typically
approximately 50mm.
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Additionally, the webs 341 may include cut-outs 346, 347, defining a narrowing waist.
This reduces the amount of material required to manufacture the spacer which in turn reduces the
spacer cost and environmental impact. Additionally, this can reduce the cross-sectional area of
the spacer which can result in enhanced flow of filling material through the stud. Finally, this
can also act as a mechanism to locate reinforcing members which can rest in a recess 347 so that
these are centrally located within the wall section.
The spacer 340 may also include a structural rib 348 extending around an inner mid-point
of the spacer, and in particular along the webs 341 and across the connectors 342, to provide
additional structural strength.
Typically the rails are made of a thermoplastic polymer, such as polyvinylchloride (PVC)
and, in particular, a rigid PVC. In one preferred example, the rails are manufactured from a
recycled rigid PVC thereby significantly reducing the environmental impact of constructing the
wall.
Similarly, the spacers are typically made of a thermoplastic polymer and, in particular,
polyethyelene. In one example, this is high-density polyethylene (HDPE) and in a preferred
example, recycled HDPE. The use of HDPE is particularly beneficial as this provides suitable
strength and rigidity.
The rail bodies can be attached to the wall using a variety of techniques, such as adhesive
or mechanical bonding. In one preferred example, a polyvinyl acetate copolymer adhesive, such
as polyvinyl acetate-silane copolymer, is used to attach the rail body 231 to the wall sheets 111,
112, which are typically fibre cement sheets or similar. However, it will be appreciated that
other wall sheet materials could be used. For example, one or more of the wall sheets could be
made of a polyvinyl chloride (PVC) material, or similar, in which case alternative adhesives
might be used, such as solvent based polyvinyl chloride cements, cyanoacrylates, 2-part epoxy
adhesives, structural acrylic adhesives, or the like.
In this regard, permanent formwork for a below ground applications typically uses an
extruded PVC unit, whilst fibre cement sheets are generally not preferred for below ground
application due to the difficulty of preventing ground water movement into /through the
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completed wall structure. However, in one example, one or both of the wall sheets could be
made from PVC, allowing this to be used in a range of different applications. For example, for
use in underground construction, such as basement walls or similar, the wall could include an
outer PVC wall sheet which could be used to prevent ingress of moisture. Alternatively, for
above ground applications, an inner PVC wall sheet could be used to provide a wall surface that
is smoother than a traditional fibre cement wall sheet, which could facilitate painting or other
finishing. It will also be appreciated that PVC wall sheets could be used both externally and
internally, depending on the intended application.
As previously mentioned, the studs can be used to construct wall sections having a pair of
wall sheets held in a spaced apart arrangement by a plurality of studs 113. To construct such a
wall section, a number of rails 230 are initially laid on a pair of wall sheets 111, 112, and
attached thereto using adhesive, as shown in Figure 6A. Spacers 340 are then attached to the
rails on one of the wall sheets, before the other wall sheet is brought into engagement with the
spacers, as shown in Figure 6B.
In the example shown in Figures 6A and 6B, one of the studs is provided projecting
outwardly from an end of the wall to form a male wall section end, which in turn can be attached
to a female end of an adjacent wall section, allowing the stud to span the wall sections 110, and
hence physically attach the wall sections 110.
Typically, when constructing a wall, wall sections may be interconnected in direct
abutment, but may also use additional components. For example, a wall corner section is shown
in Figure 7A. The wall corner section 750 includes first and second wall sheets 751, 752, joined
by a right-angled connector body 753 and an external reinforced webbing 754. A wall end
section is shown in Figure 7B. In this example, the wall end section 760 includes a wall sheet
761 connected to two right-angled corner members 763, 762. As shown in Figure 7C, two wall
sections can be interconnected at right angles using a corner section 750 with an end cap 760
being used to seal an end of a wall.
It will be appreciated that the studs 113 and other components can be used in a wall
construction process, and example of which will now be described with reference to Figures 8A
to 8C.
C:\Users\JZT\AppData\Local\Temp\7f54-c61e-9a93-0c7a.DOCX-24/10/2011
In this example, the wall is constructed by initially mounting a pair of tracks 871 on a
support 881, such as a slab, foundation or similar. Wall sections 110 are then mounted to the
tracks, for example, by fastening the wall sheets to the tracks using fasteners, such as screws, or
the like, and supported in place by bracing 875.
Vertical reinforcing bars 872 are typically positioned between the webs 341 of the spacers
340, to thereby hold the reinforcing bar 872 in a vertical orientation, allowing the reinforcing
bars 872 to be attached to starter rebars 873 extending out of the substrate. Horizontal
reinforcing bars 874 are provided resting on the spacers 340, and attached to the vertical
reinforcing bars 872. Additional reinforcement may also be provided in corner or other sections,
as per the building structural design.
It will be appreciated that corner 750 and end caps 760 can be used as appropriate, to
form a substantially enclosed internal wall cavity. Examples of this are shown in Figure 8C,
which also shows how windows 880 can be provided utilising end caps 760 to define a window
perimeter.
Once the completed wall sections are constructed, they can be filled with concrete or
other similar building materials 876. This is typically achieved via filling holes provided in the
wall sheets, which are spaced apart by 600mm, in order to ensure filling of the entire cavity,
preventing the formation of voids, which can in turn affect structural integrity.
Throughout this specification and claims which follow, unless the context requires
otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be
understood to imply the inclusion of a stated integer or group of integers or steps but not the
exclusion of any other integer or group of integers. As used herein and unless otherwise stated,
the term "approximately" means ±20%.
Persons skilled in the art will appreciate that numerous variations and modifications will
become apparent. All such variations and modifications which become apparent to persons
skilled in the art, should be considered to fall within the spirit and scope that the invention
broadly appearing before described.
C:\Users\JZT\AppData\Local\Temp\7f54-c61e-9a93-0c7a.DOCX-24/10/2011
Claims (10)
1) A stud for use in panel formwork for solid filled walls, the stud comprising: a) a pair of rails, each rail including: i) a rail body configured to be attached to an inner face of a respective wall sheet; ii) a pair of spaced apart opposed flanges extending away from the rail body, each flange including a lip; b) a plurality of spacer elements extending between the rails to hold the rails and respective wall sheets in a spaced apart arrangement, each spacer element including: i) a spacer body; and, ii) a connector provided at each end of the spacer body, each connector including shoulders that engage respective lips of the flanges to thereby fasten the connectors to the rails.
2) A stud according to claim 1, wherein the rail body is a substantially planar elongate body.
3) A stud according to claim 1 or claim 2, wherein the flanges extend from edges of the rail body.
4) A stud according to any one of the claims 1 to 3, wherein the flanges extend substantially perpendicularly from the rail body.
5) A stud according to any one of the claims 1 to 4, wherein the spacer body includes a pair of substantially parallel spaced webs extending between the connectors.
6) A stud according to claim 5, wherein the connectors include plates extending between ends of the webs.
7) A stud according to any one of the claims 1 to 6, wherein each web includes a structural ridge extending along a surface of the web.
8) A stud according to any one of the claims 1 to 7, wherein each web includes a narrow waist.
9) A stud according to any one of the claims 1 to 8, wherein the lips extend inwardly from the flanges and the shoulders extend outwardly from the connectors so that the connector is retained between the flanges.
10) A stud according to any one of the claims 1 to 9, wherein the connectors are fastened to the rails using at least one of: a) snap fit engagement; and, b) cantilevered snap fit engagement. C:\Users\JZT\AppData\Local\Temp\7f54-c61e-9a93-0c7a.DOCX-24/
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2018904634 | 2018-12-06 |
Publications (1)
Publication Number | Publication Date |
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NZ759893A true NZ759893A (en) |
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