Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/84—Walls made by casting, pouring, or tamping in situ
  • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
  • E04B2/8658—Walls made by casting, pouring, or tamping in situ made in permanent forms using wire netting, a lattice or the like as form leaves

Definitions

• the invention relates to building elements for use as cladding panels, partition walls, loadbearing walls, floor and roofs in the construction of buildings generally.
• the object of the present invention is to provide elements whereby the ease and simplicity of construction can be improved over existing systems.
• a system is known from French Utility Model 2 566 818 which uses corrugated panels of foam polystyrene in conjunction with steel lattices as a basis for a structural system where the concrete is applied on to the foam for various structural purposes.
• the steel lattices act as shuttering and further reinforcement is then installed at the site.
• the present invention aims to provide a system where units can be produced in a factory and then can be brought to a site and be erected without the need for extra reinforcement. This allows for a more closely controlled and cost effective operation.
• the present invention provides a structural building element for use in conjunction with concrete in the construction of a building panel comprising a pair of spaced outer meshes of wires defining a cavity therebetween and including between said outer meshes insulation and a cavity to receive concrete in a quantity defined by the spacing of said outer meshes said cavity including a plurality of reinforcing wires in a sufficient quantity to provide structural reinforcement to the defined quantity of concrete without the need for further reinforcement of said panel.
• the invention is arranged for use in forming a floor or roof panel, said reinforcing wires being of steel and occupying an area which in a vertical cross-section of the assembled panel is at least 0.13% of the area for concrete within that said cross-section.
• the invention is arranged for use in forming a wall panel, said reinforcing wires being of steel and occupying within any horizontal cross-section of the assembled wall an area which is at least 0.4% of the area occupied by concrete within said cross-section.
• the cellular insulation is in the form of polystyrene foam sheets or slabs but other known thermal insulation materials can be used provided they have sufficient rigidity, lightness and insulating properties.
• the mesh outer panels may be interwoven wires or a composite net material or a lattice and have the added benefit that outer cladding, plastering, tiling or other surface finishes can be applied to these outer mesh panels.
• the other function of the outer mesh panels is to define the dimensions and hence the amount of concrete subsequently used.
• the inner reinforcing wires which are usually in the form of steel wires of between 3.5mm and 6mm in diameter, can also be in the form of one or more meshes and these may be interwoven or otherwise joined as lattices or nets. Their disposition should be such that they can be fully enclosed and encapsulated in the concrete.
• the main advantage of the invention is that the building elements can be fabricated at a remote site such as a factory with the ensuing advantages in cost and consistency. Moreover control of specification at the site is improved.
• the outer meshes may be joined by transverse wires and these in turn facilitate factory manufacture and can improve the cross-loading characteristics of the structure.
• the space between outer meshes should include a pair of sheets of cellular thermal insulation material with a cavity therebetween including one or more meshes of wires and suitable to receive the concrete.
• the cavity is approximately 50mm wide, 17 vertical steel wires of 6mm diameter per metre length provide sufficient reinforcement.
• Another example is the use of 24 vertical wires of 3.5mm diameter within a 56mm wide cavity per metre length.
• a pair of outer meshes can be connected by tie wires of 3.5mm, diameter so that there are a minimum of 17 number connecting wires per m 2 with a cavity between the two elements which can be filled with a specially formulated concrete mix.
• Such composite panels can then when the cavity is filled with concrete be capable of taking limited structural loads (up to two storeys height for example) and can be capable of resisting wind loads up to 150 mph when properly restrained.
• the wall element of the invention there is a single wire mesh in the cavity and placed centrally and the connecting wires now act as the ties and the wind braces and there shall be a minimum of 34N 3.5mm ⁇ connecting wires per m 2 .
• the specially formulated concrete when placed in the cavity it encapsulates the central mesh thus providing a composite panel which can be capable of taking structural loads up to two storeys height in areas of seismic activity according to the design calculations which determine the area of primary reinforcement in the central cavity.
• two meshes within the cavity are spaced from a pair of respective insulating slab surfaces whereby when the cavity is filled with concrete the mesh panels are fully encapsulated.
• the mesh will include sufficient reinforcing wires at the prefabrication stage to achieve the purpose of full reinforcement of the panel itself only requiring joint connecting reinforcement at site. The specification of wires necessary for this purpose will be described later with reference to the described example.
• a composite structural unit is capable of taking high structural loads such as would be encountered in a multi-storey building.
• the spacing of the mesh is preferably achieved by the assembly facilities of the proprietory machine MMS1 (Patent applied for GB 9115040.9 Machine for forming Building Elements) or where transportation circumstances dictate alternative methods can be employed such as plastic spacers and wire combs.
• MMS1 Patent applied for GB 9115040.9 Machine for forming Building Elements
• alternative methods can be employed such as plastic spacers and wire combs.
• the use of a plain surface to the slab and the distancing of the net from this face enables the whole of the net panel to be equidistant from its slab surface and so to be fully encapsulated in concrete. This contrasts with the prior art system previously referred to where the corrugations preclude this possibility.
• a basic element for use as a floor or roof element a basic element is now factory assembled so that there is a mesh on one side (lower) and three meshes on the other (upper) side spaced off the upper side and spaced apart and this is combined with rigid blocks of cellular plastics material to form troughs into which concrete can be placed to fill the troughs and encapsulate the three meshes, the three upper meshes can provide the full primary reinforcement for floors and roofs and the lower mesh a key for a plaster finish.
• Such an element can be laid flat to form a floor and flat or pitched to form a roof.
• an element is formed which performs in all respects as in the previous form except that the cellular plastics part is now manufactured as one profiled unit with voids to reduce the handling weight.
• the elements in the various forms of the invention will be tied together, and concrete and other materials will be applied after which a monolithic structure is achieved complete with surface finishes.
• the materials employed in the invention can include:
• the elements of the invention employing the above materials can be:
• An element comprising two panels of type A pre ⁇ fabricated to provide a cavity of 50mm or more between the inner faces of the panels for use in conjunction with a specially formulated concrete mix as load bearing walls in buildings up to two storeys high and also including reinforcement. (Fig 2, both alternatives) .
• C. An element comprising two panels AA which are a variation of panel type A having the meshes within the cavity spaced off their respective faces and embodying the primary reinforcement and prefabricated to provide cavities of various widths between the inner faces of the panels for use in conjunction with concrete as load bearing walls in complex structures and multi-storey structures (Fig 3) .
• D An element comprising a panel of polystyrene 40mm or more thick with a mesh (2) on one face only and spaced off the other face three assemblies of reinforcement of various centres for use in conjunction with concrete for floors and roofs of reinforced concrete construction.
• E An element the same as D above except that the polystyrene is in one preferred profiled unit.
• the invention enables standard materials to be brought together in a specific manner and under factory controlled conditions, which can then be employed in construction in their prefabricated form to achieve performance results not previously available in this simple form.
• the elements can be light and easy to manhandle, obviating the need for mechanical handling plant except for lifting to level of use in multi-storey constructions. They are easy to cut to facilitate the formation of openings (such as doors and windows).
• the elements can provide thermal and acoustic insulation as an integral feature.
• the thermal insulation qualities can be utilised to avoid surface condensation.
• a homogenous nature can be achieved in the finished surfaces which obviates shrinkage and surface cracking particularly at internal angles of walls with floors which is the most common incidence of cracking in most structures.
• the finished structure employing the elements can have a monolithic nature which is effective in areas of seismic activity and even the partition walls can add to the stability of the structure in this respect.
• the whole structure can be proof against progressive collapse.
• the design enables the compressive strength of concrete to be achieved in seven days instead of twenty-eight days as with traditional methods and work can be carried out in extreme climates without the need for traditional protective methods against cold and heat, provided only that the ambient temperatures encountered allow the operation of the pump for placing the concrete.
• the enveloping panels of element C can provide the insulation whereby the concrete which is poured into the cavity between these panels achieves its design strength more quickly than in the un- insulated cavity provided by traditional shuttering, and consequently floors and upper storey walls can proceed far sooner.
• the concrete can be of a specially formulated mix with a small aggregate which obviates the need for vibration necessary with traditional methods.
• walls and ceilings can be finished by plastering or rendering and in particular other forms of sheet material finishes can be applied to walls by hooking directly to the horizontal carrier bars.
• factory made units according to the invention can incorporate all the necessary functions of the elements of construction in one piece, so that one site operation provides permanent shuttering, thermal and acoustic insulation, integral reinforce ⁇ ment, integral key or support system for facing integral protection of concrete whilst curing, all of which lead to greatly reduced time and cost on site.
• Factory production of the elements provides accuracy and highly economic use of materials leading to lightweight, speed of erection, and eventual construction costs far below those of traditional methods.
• the design further enables full shuttering qualities to be achieved from polystyrene instead of the expensive materials used traditionally, namely timber or steel and in the case of timber the inherent waste of a valuable raw material.
• Figure 1 shows a vertical cross-section of the single panel A (for cladding, partitions etc) .
• Figure 2 shows a vertical cross-section of the double panel B employing two single panels A (for two storeys etc) and the alternative Bl for seismic areas.
• Figure 3 shows a vertical cross-section of a double panel C employing two single panels AA (for multi-storey work) .
• Figure 4 shows the form of mesh (2) attached to the surfaces of each of the elements A and B and the outer surfaces of element C.
• Figure 5 shows an isometric projection part broken away of two elements tied together for the pouring in of concrete where combs and spacers are employed.
• Figure 6 shows a horizontal cross-section of the Figure 5 arrangement where combs and spacers are employed.
• Figure 7 shows a horizontal cross-section of the Figure 2 arrangement.
• Figure 8 shows an isometric projection of element D for use in floors and roofs.
• Figures 9 shows horizontal cross-sections of finished floor or roof elements D and E.
• an element A comprises a rigid slab of CFC free, water repellant, flame retardant expanded polystyrene of a density of 26Kg per cubic metre, a thickness of 40mm or more and having opposing parallel plain faces (1), net works of electrically welded zinc coated steel wire or stainless steel (2) on and in contact with each face of the polystyrene slab to provide a key for plaster and/or rendering.
• the two networks or meshes are connected through the polystyrene by stainless steel ties (8) which are electrically welded to the opposing lattices.
• Such a panel is combined with others to define a cavity and form an element in accordance with the invention.
• a double panel B for load bearing walls of concrete for use in structures up to two storeys in height employs two of the same elements A which are tied together and spaced apart by zinc coated or stainless steel wires (2b) which are electrically welded to each of the opposing nets.
• An alternative in the top part of the Figure is shown where there is only one central mesh in the cavity.
• a double panel C for reinforced concrete walls employs the same polystyrene panels (1) and two of the same meshes (2) on each outer face as used in element A together with meshes of varying size vertical bars (2a) which are spaced off mechanically or by plastic cradles (3) but parallel to the inner faces of the polystyrene slabs.
• the meshes (2a) are spaced off the face of the polystyrene by mechanical means or by plastic spacer cradles (3) (see Figure 5) 25mm thick which permit full encasement of the steel by concrete when it is subsequently poured in. These cradles (3) have grooves to receive the horizontal and vertical steel bars to ensure perfect alignment. - 18 - Meshes (2a) are tied together and spaced apart by zinc coated or stainless steel wires or combs (2c) thus connecting the panels AA.
• the primary steel reinforcement (6) ⁇ the vertical bars (6) of meshes (2a) ⁇ are selected by manufacturing software (a computer programme to perform structural calculations) according to the structural duty to be performed by the panel.
• An unusual and beneficial aspect of the design is the small diameter wires which can be used for primary reinforcement because of the invention.
• the maximum diameter of wire used is 6mm whether as nominal reinforcement in accordance with the requirements of the British Standard Code of Practice for the design of reinforced concrete structures or in cases where the reinforcement has to be designed for specific applications.
• nominal primary reinforcement that is reinforcement of the panel itself
• the area of reinforcement must be equal to at least 0.4% of the area of concrete per metre length of wall in a given horizontal cross-section.
• nominal reinforcement as small as 3.5mm ⁇ is employed. In all cases nominal primary reinforcement used in the panels exceeds the minimum requirement of the British Standard.
• the width of the cavity "x" in Figure 5 between the internal faces of the opposing panels of polystyrene is selected by the manufacturing software according (i) to the structural duty to be performed by the wall and, (ii) by the acoustic performance required of the wall.
• the net work of zinc coated or stainless steel wires (2) to form the cladding or plaster support should consist of vertical wires of 2.5mm min diameter spaced so that 25 wires occur in a 1.2 metre span; while the horizontal wires are of 3.5mm diameter and 15 wires occur in a 2.7 metre span; giving a minimum pitch of 50mm in the vertical wires and a general pitch of 200mm in the horizontal wires.
• the specification of the wires depends on the load to be carried, the elevation of the wall and the aspect.
• connecting wires 2b there should be at least 17 wires of 3.5mm diameter in any given 1 square metre area, approximately uniformly located across the area.
• element D is manufactured comprising a single panel of polystyrene 40mm or more thick having a mesh (2) over the whole of one face only and over lesser areas of the other face three meshes (4) spaced apart.
• Each mesh (4) is supported by wires passing through the polystyrene slab so that it is spaced off the upper face of that slab and includes a number of parallel reinforcement bars (11) in accordance with the required span and load. This then provides the permanent shuttering and reinforcement for floors and roofs.
• the amount of reinforcement (11) in the meshes (4) is selected by the manufacturing software to meet with the load span criteria given by the user.
• Element D is designed for economy in long distance transportation and the units are delivered to site numbered according to location which is identified on a placement plan.
• Blocks of dense polystyrene (5) for use as formers to create the voids to be filled with concrete are included in the delivery.
• the element is manufactured in accordance with the general description as element D except that the polystyrene is now one preformed profiled unit and is the preferred element for floors and roofs.
• the composite units D or E are propped in position at the desired elevation, using any proprietary propping system. Because of the eventual light weight of the finished floor, fewer props are needed than with traditional reinforced concrete floors. Projecting reinforcing rods (11) of the meshes (4) are interlaced with vertical wires of the respective meshes in the walls.
• Loose connecting bars at joints are placed into position to tie the roof or floor and wall steel structure together. This process is also adopted for tying the walls to the floors and roofs when employing elements B and Bl and C for walls. Starter bars for the next level of reinforced walls are also incorporated at this stage.
• each outer mesh determines the parameters of the inner cavities for concrete taking into account the volume occupied by insulation material, e.g polystyrene sheets or slabs, and inner meshes of reinforcing wires are provided to a sufficient degree to provide full structural reinforcement of the ultimate wall or floor panel.
• insulation material e.g polystyrene sheets or slabs
• inner meshes of reinforcing wires are provided to a sufficient degree to provide full structural reinforcement of the ultimate wall or floor panel.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Building Environments (AREA)
• Buildings Adapted To Withstand Abnormal External Influences (AREA)
• Panels For Use In Building Construction (AREA)
• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
• Glass Compositions (AREA)
• Vending Machines For Individual Products (AREA)
• Reinforcement Elements For Buildings (AREA)

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Publications (1)

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Family Applications (1)

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Cited By (3)

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Citations (5)

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• 1991
  • 1991-04-16 GB GB9107988A patent/GB2254863B/en not_active Expired - Fee Related
• 1992
  • 1992-04-16 WO PCT/GB1992/000712 patent/WO1992018718A1/en active IP Right Grant
  • 1992-04-16 ES ES92908352T patent/ES2114935T3/es not_active Expired - Lifetime
  • 1992-04-16 AT AT92908352T patent/ATE162872T1/de not_active IP Right Cessation
  • 1992-04-16 EP EP92908352A patent/EP0584093B1/de not_active Expired - Lifetime
  • 1992-04-16 AU AU15520/92A patent/AU1552092A/en not_active Abandoned
  • 1992-04-16 DE DE69224288T patent/DE69224288T2/de not_active Expired - Fee Related

Patent Citations (5)

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