WALL UNIT
A method of manufacturing a wall unit comprises assembling a set of substantially parallel vertical elongated wall ties having opposite edges which are substantially coplanar on each side of the set. Each wall tie has a plurality of triangular openings distributed along its length with the openings of adjacent wall ties substantially aligned in a horizontal direction. A plurality of reinforcing rods are inserted horizontally through respective sets of aligned openings. Due to the triangular configuration of the openings each rod is deflected under gravity towards, and comes to rest adjacent, an edge of the wall tie. One or more formwork panels are secured to the substantially coplanar edges on each side of the wall ties.
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This application related to and claims priority to Irish Patent Application Serial Number S2008/0203, filed Mar. 19, 2008, Irish Patent Application Serial Number S2008/0204, filed Mar. 19, 2008, Irish Patent Application Serial Number S2008/0205, filed Mar. 19, 2008, and Irish Patent Application Serial Number S2008/716, filed Sep. 3, 2008, the entirety of all which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTn/a
FIELD OF INVENTIONThe present invention relates to wall units such as, but not limited to prefabricated wall units.
BACKGROUND OF THE INVENTIONA type of wall construction is known in which formwork panels are mounted vertically upright and parallel to one another on a solid concrete floor, and the gap between the two filled with concrete. When the concrete is set the formwork panels may be removed, or left in place to form an integral part of the wall. In the later case they are known as permanent formwork panels and are typically made of cement—see, for example, WO 2004/091903.
It is therefore desirable to provide an improved wall unit for use in this type of construction, as well as a method of manufacturing such a wall unit and a wall tie for use in the construction of such a unit.
SUMMARY OF THE INVENTIONAccording to the present invention there is provided a wall unit comprising a set of substantially parallel elongated wall ties having opposite edges which are substantially coplanar on each side of the set so as to lie in two substantially parallel planes containing said edges, at least one reinforcing mesh recessed into the wall ties on at least one side of the set by being received in slots in the wall tie edges on that side of the set, and at least one formwork panel secured to the substantially coplanar edges on each side of the set of wall ties.
The invention further provides a method of manufacturing a wall unit comprising assembling a set of substantially parallel elongated wall ties having opposite edges which are substantially coplanar on each side of the set so as to lie in two substantially parallel planes containing said edges, recessing at least one reinforcing mesh into the wall ties on at least one side of the set by inserting the mesh in slots in the wall tie edges on that side of the set, and securing at least one formwork panel to the substantially coplanar edges on each side of the set of wall ties.
The invention further provides a wall tie for spacing opposite substantially parallel formwork panels in a wall unit, the wall tie comprising an elongated member with substantially parallel opposite flat longitudinal edges for retaining a formwork panel, each edge having a plurality of slots which intermittently interrupt the edge to allow a reinforcing mesh to be recessed into the wall tie clear of the edge.
The invention also provides a wall unit made by the above method. According to a further aspect of the present invention there is provided a method of manufacturing a wall unit comprising assembling a set of substantially parallel vertical elongated wall ties having opposite edges which are substantially coplanar on each side of the set, each wall tie having a plurality of openings distributed along its length between its opposite edges with the openings of adjacent wall ties substantially aligned in a horizontal direction, inserting a plurality of reinforcing rods horizontally through respective sets of aligned openings, the openings being configured such that under gravity each rod is deflected towards, and comes to rest adjacent, an edge of the wall tie, and securing at least one formwork panel to the substantially coplanar edges on each side of the set of wall ties.
The invention also provides a wall unit made by the above method.
A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
In the drawings the same reference numerals have been used for the same or equivalent components in the various embodiments.
Referring to
Referring now to
Next,
Then,
Next,
Now,
Now the rectangular section 42 of wall ties 10 and mesh 26 revealed in the panel opening 36 is cut out,
At this point the wall unit is complete except for its concrete filling, and is preferably pre-fabricated off-site and transported as a self-supporting unit to the construction site.
At the construction site the unit is located on a pair of parallel floor-mounted support rails of the kind described in the above U.S. patent application Ser. No. 12/366,157, the short tabs 20 at the bottom edge of the unit locating between the rails. When the unit is in its final position, a concrete filling is poured into the gap between the formwork panels 34 and allowed to set. To avoid the concrete escaping, the vertical gap between the panels 34 at the ends of the unit are closed off either by the unit abutting edge-to-edge against another such unit, with the gap between the two being permanently bridged by further cement board permanent formwork, or by the unit joining another wall at a T shaped junction, for example as shown in
In
Barcodes (or other machine-readable identifiers) are applied to the pre-fabricated wall units as they are produced and the units are shipped with their associated support rails and formwork panels 52 which are also bar-coded.
When a rail is scanned on site with a handheld scanner attached to a PDA on which a model of the building is either stored or accessible across a network, the PDA can display where the rail is to be fixed on the ground. Similarly, before being placed in position, the wall unit and formwork panels 52 can be scanned to ensure they are properly located and also to update the progress of the construction through the PDA.
The number of parallel side-by-side wall ties 10 in a particular wall unit, as well as their length and the distance between their opposite edges, may be varied according to the required dimensions of the wall unit.
A second embodiment of the invention will now be described with reference to
Referring to
The first stage in manufacturing the wall unit is to assemble a set of substantially vertical wall ties 110 side-by-side and substantially parallel to one another, in the manner shown in
Next,
Next, vertical steel reinforcing rods (not shown) are inserted between adjacent wall ties 110 so as to extend substantially parallel to the wall ties, and are secured by twisted wire.
Now,
At this point the wall unit is complete except for its concrete filling, and is preferably pre-fabricated off-site and transported as a self-supporting unit to the construction site.
At the construction site the unit is located on a pair of parallel floor-mounted support rails of the kind described in the above U.S. patent application Ser. No. 12/366,157, the short tabs at the bottom edge of the unit locating between the rails. When the unit is in its final position, a concrete filling is poured into the gap between the formwork panels 134 and allowed to set. To avoid the concrete escaping, the vertical gap between the panels 134 at the ends of the unit are closed off either by the unit abutting edge-to-edge against another such unit, with the gap between the two being permanently bridged by further cement board permanent formwork, or by the unit joining another wall at a T shaped junction.
Barcodes (or other machine-readable identifiers) are applied to the pre-fabricated wall units as they are produced and the units are shipped with their associated support rails and bridging formwork panels which are also bar-coded.
When a rail is scanned on site with a handheld scanner attached to a PDA on which a model of the building is either stored or accessible across a network, the PDA can display where the rail is to be fixed on the ground. Similarly before being placed in position, the wall unit and bridging formwork panels can be scanned to ensure they are properly located and also to update the progress of the construction through the PDA.
The number of parallel side-by-side wall ties 110 in a particular wall unit, as well as their length and the distance between their opposite edges, may be varied according to the required dimensions of the wall unit.
The invention is not limited to the embodiments described herein which may be modified or varied without departing from the scope of the invention.
Claims
1. A wall unit comprising:
- a set of substantially parallel elongated wall ties having opposite edges which are substantially coplanar on each side of the set so as to lie in two substantially parallel planes containing said edges,
- at least one reinforcing mesh recessed into the wall ties on at least one side of the set by being received in slots in the wall tie edges on that side of the set, and
- at least one formwork panel secured to the substantially coplanar edges on each side of the set of wall ties.
2. The wall unit as claimed in claim 1, further including apertures in the wall ties which are aligned in a direction substantially normal to the longitudinal direction of the wall ties, and at least one reinforcing rod extending through the apertures along an edge of a rectangular opening in the set of wall ties.
3. The wall unit as claimed in claim 1, further including at least one reinforcing rod extending substantially parallel to and between adjacent wall ties along an edge of a rectangular opening in the set of wall ties
4. The wall unit as claimed in claim 1, wherein each wall tie has a generally I-shaped cross-section.
5. The wall unit as claimed in claim 1, having a concrete filling in the gap between the formwork panels.
6. A wall tie for spacing opposite substantially parallel formwork panels in a wall unit, the wall tie comprising:
- an elongated member with substantially parallel opposite flat longitudinal edges for retaining a formwork panel, each edge having a plurality of slots which intermittently interrupt the edge to allow a reinforcing mesh to be recessed into the wall tie clear of the edge.
7. The wall tie as claimed in claim 6, wherein the wall tie has a plurality of apertures distributed along its length between the opposite edges.
8. The wall tie as claimed in claim 6, having a generally I-shaped cross-section.
9. The wall tie as claimed in claim 6 formed from one of a metal, polymer or composite material.
10. The wall tie as claimed in claim 6 wherein said flat longitudinal edges are arranged to adhesively and/or mechanically retain a formwork panel.
11. A method of manufacturing a wall unit comprising:
- assembling a set of substantially parallel elongated wall ties having opposite edges which are substantially coplanar on each side of the set so as to lie in two substantially parallel planes containing said edges,
- recessing at least one reinforcing mesh into the wall ties on at least one side of the set by inserting the mesh in slots in the wall tie edges on that side of the set, and
- securing at least one formwork panel to the substantially coplanar edges on each side of the set of wall ties.
12. The method as claimed in claim 11, wherein the wall ties include apertures which are aligned in a direction substantially normal to the longitudinal direction of the wall ties, the method further includes inserting at least one reinforcing rod through the apertures to lie along an edge of a rectangular opening in the set of wall ties.
13. The method as claimed in claim 11, further including inserting at least one reinforcing rod substantially parallel to and between adjacent wall ties to lie along an edge of a rectangular opening in the set of wall ties.
14. The method as claimed in claim 11, wherein each wall tie has a generally I-shaped cross-section.
15. The method as claimed in claim 11, further including filling the gap between the formwork panels with concrete.
16. A method of manufacturing a wall unit comprising:
- assembling a set of substantially parallel vertical elongated wall ties having opposite edges which are substantially coplanar on each side of the set, each wall tie having a plurality of openings distributed along its length between its opposite edges with the openings of adjacent wall ties substantially aligned in a horizontal direction,
- inserting a plurality of reinforcing rods horizontally through respective sets of aligned openings, the openings being configured such that under gravity each rod is deflected towards, and comes to rest adjacent, an edge of the wall tie, and
- securing at least one formwork panel to the substantially coplanar edges on each side of the set of wall ties.
17. The method claimed in claim 16, wherein the openings are triangular and each rod comes to rest at the lowermost angles of the respective set of aligned triangular openings.
18. The method claimed in claim 16, wherein vertically consecutive rods come to rest adjacent alternate edges of the wall ties.
19. The method claimed in claim 16, further including filling the gap between the formwork panels with concrete.
20. A wall unit made by the method of claim 16.
Type: Application
Filed: Mar 19, 2009
Publication Date: Sep 24, 2009
Applicant: OFF SITE CONSTRUCTION R&D LIMITED (Dublin)
Inventor: Eoghan MELLETT (Dublin)
Application Number: 12/407,288
International Classification: E04B 2/28 (20060101); E04B 1/00 (20060101);