ASPECTS OF CONSTRUCTION

The present invention provides a composite wall construction including a first wall element extending in a first general plan, a second wall element extending in a second general plan parallel to the first plane and spaced from the first wall element. The first and second wall elements define a space between them and the second wall element has an inner sheet defining one side of the space. A plurality of elongate reinforcing members extend longitudinally vertically within the space and are attached to each of the first and second wall elements. Each reinforcing member is formed of sheet material and has keying formations to facilitate adhesion between the reinforcing member and a settable substance poured into the space. The first wall element has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends.

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Description
TECHNICAL FIELD

The present invention relates to aspects of construction. In particular, the invention relates to a composite wall construction, a partition wall construction, and a combined beam-and-slab construction.

BACKGROUND TO THE INVENTION

In the construction industry, when designing parts of structures such as walls, beams, slabs, reinforcement, etc, there are various primary objectives sought to be achieved depending on the needs of the particular application. Sometimes, when a particular feature is given preference in a design, this can be to the detriment of other features.

Features that are often taken into account include capacity for bearing load, potential modes of failure, thermal and acoustic insulation, cost, and ease and convenience of construction.

Many existing parts of structures have been designed in the interest of some of these features, but this has often been at the expense of other such features or even without regard to such other features.

It is an object of the present invention to overcome or ameliorate disadvantages of the prior art or to provide a desirable alternative thereto.

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a composite wall construction including:

    • a first wall element extending in a first general plane;
    • an insulating second wall element extending in a second general plane parallel to the first plane and spaced from the first wall element, whereby the first and second wall elements define a space between them, the second wall element having an inner sheet defining one side of said space and an insulating layer of thermally insulating material superposed on the inner sheet on an opposite side thereof to said space; and
    • a plurality of elongate reinforcing members extending longitudinally vertically within the space and being attached to each of the first and second wall elements, each reinforcing member being formed of sheet material and having keying formations to facilitate adhesion between the reinforcing member and a settable substance poured into the space.

In a preferred embodiment, the first wall element has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends.

In a preferred embodiment, the composite wall construction includes a plurality of horizontally extending elongate bracing members attached to the first wall element on an opposite side thereof to the space.

Then, preferably, the composite wall construction includes a facade extending over, and mounted on, the bracing members so as to be spaced from the first wall element.

In a preferred embodiment, each reinforcing member is substantially Z-shaped in cross-section viewed longitudinally.

In a preferred embodiment, the composite wall construction includes a plurality of horizontally extending reinforcing bars, and wherein each reinforcing member defines a plurality of bar apertures, each reinforcing bar passing through aligned bar apertures of the plurality of reinforcing members.

In a preferred embodiment, each keying formation is constituted by a keying aperture in the respective reinforcing member.

In a preferred embodiment, the second wall element includes an outer sheet disposed on an opposite side of the insulating layer to the inner sheet.

Then, preferably, the outer sheet is of elastomeric material.

In a preferred embodiment, the composite wall construction includes a lower end cover for at least partly covering a lower open end of the space.

Then, preferably, the end cap defines plurality of starter apertures for enabling the passage therethrough of a plurality of starter bars on which the composite wall construction is placed.

In a preferred embodiment, the composite wall construction includes insulating foam material substantially filling the space.

According to a second aspect of the invention there is provided a partition wall construction including:

    • a first wall element extending in a first general plane;
    • a second wall element extending in a second general plane parallel to the first plane and spaced from the first wall element, whereby the first and second wall elements define a space between them, wherein at least one of said wall elements has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends; and
    • thermally insulating foam material substantially filling the space.

In a preferred embodiment, each of the wall elements has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends.

In a preferred embodiment, the partition wall construction includes insulating foam material substantially filling the space.

According to a third aspect of the invention there is provided a combined beam and slab construction including:

    • integral shuttering defining a slab zone for accommodating concrete poured for a slab and an elongate beam zone for accommodating concrete poured for a beam, the beam zone being integral with, and extending below, the slab zone and the slab zone extending beyond at least one of the left side and right side of the beam zone when it is viewed longitudinally.

In a preferred embodiment, the combined beam and slab construction includes:

    • a plurality of horizontal elongate beam reinforcing members which are disposed in a first beam reinforcement layer on the shuttering in the beam zone and which extend substantially parallel to each other;
    • at least one successive additional beam reinforcement layer above the first beam reinforcement layer, of horizontal elongate beam reinforcing members which are disposed in the beam zone and which extend substantially parallel to each other,
    • such that the beam reinforcing members of each additional beam reinforcement layer are supported on the beam reinforcing members of the beam reinforcement layer immediately below and such that the beam reinforcing members of each beam reinforcement layer extend substantially at right angles to any beam reinforcement layer immediately above or below that layer;
    • a plurality of horizontal elongate slab reinforcing members which are disposed in a first slab reinforcement layer in the slab zone and which extend substantially parallel to each other, and substantially at right angles to, and in contact with, the beam reinforcing members of the uppermost beam reinforcement layer;
    • at least one successive additional slab reinforcement layer above the first slab reinforcement layer, of horizontal elongate slab reinforcing members which are disposed in the slab zone and which extend substantially parallel to each other,
    • such that the slab reinforcing members of each additional slab reinforcement layer are supported on the slab reinforcing members of the slab reinforcement layer immediately below, and such that the slab reinforcing members of each slab reinforcement layer extend substantially at right angles to any slab reinforcement layer immediately above or below that layer.

In a preferred embodiment, each reinforcing member includes keying formations to facilitate adhesion between the reinforcing member and a settable substance poured into said zone in which that reinforcing member is disposed.

In a preferred embodiment, each reinforcing member includes a web and each keying formation includes an aperture in the web.

Preferably, each beam reinforcing member is in the form of an I-beam having upper and lower horizontally extending flanges and a central vertical interconnecting web.

Then, preferably, each slab reinforcing member, except for such members disposed in the uppermost slab reinforcement layer, is in the form of an I-beam having upper and lower horizontally extending flanges and a central vertical interconnecting web, and wherein each slab reinforcing member in said uppermost slab reinforcement layer is in the form of an inverted T-beam having a lower horizontally extending flange and a central vertical web.

Also preferably, the web of each I-beam defines a plurality of bar apertures, the construction including a plurality of elongate reinforcing bars, each reinforcing bar passing through the bar aperture of a reinforcing member in a particular respective reinforcement layer.

Preferably, the web of each slab reinforcing member in said uppermost slab reinforcement layer has an uppermost edge with a series of longitudinally spaced notches therein, the construction including a plurality of upper reinforcing bars each extending substantially at right angles to those slab reinforcing members and being accommodated in aligned notches of a plurality of those slab reinforcing members.

In a preferred embodiment, the combined beam and slab construction includes a mesh disposed immediately above said upper reinforcing bars.

In a preferred embodiment, the combined beam and slab construction includes insulating foam material substantially filling the beam zone and slab zone.

According to a fourth aspect of the invention there is provided a complex wall construction including a pair of composite wall constructions according to the first aspect of the invention, the composite wall constructions being arranged as mirror images with respect to each other and sharing a common single insulating second wall element, wherein the second wall element includes:

    • a first insulating wall element extending in a first general insulating wall plane;
    • a second insulating wall element extending in a second insulating wall plane parallel to the first insulating wall plane and spaced from the first insulating wall element, whereby the first and second insulating wall elements define an insulating space between them, wherein each of said insulating wall elements has a plurality of spaced-apart vertically extending corrugations forming recesses into which the insulating space extends.

In this specification, where reference is made to features being horizontally or vertically orientated, then this is intended to mean substantially horizontally or vertically orientated (and therefore encompasses these features being a few degrees from the horizontal and vertical orientations, respectively) as would be understood by a person skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 is a schematic front view of a composite wall construction according to an embodiment of the invention;

FIG. 2 is a schematic rear view of the composite wall construction of FIG. 1;

FIG. 3 is a schematic plan view of the composite wall construction of FIG. 1;

FIG. 4 is an enlarged view of the encircled detail in FIG. 3;

FIG. 5 is a schematic side view of the composite wall construction of FIG. 1;

FIG. 6 is an enlarged view of the encircled detail in FIG. 5;

FIG. 7 is a schematic perspective view of a corrugated wall panel of the wall construction of FIG. 1;

FIG. 8 is a schematic perspective view of a reinforcing member of the wall construction of FIG. 1;

FIG. 9 is a schematic perspective view of a bracing member of the wall construction of FIG. 1;

FIG. 10 is a schematic perspective view of an end cover of the wall construction of FIG. 1;

FIG. 11 is a schematic front view of a partition wall construction according to an embodiment of the invention;

FIG. 12 is a schematic plan view of the partition wall construction of FIG. 11;

FIG. 13 is an enlarged view of the encircled detail in FIG. 12;

FIG. 14 is a schematic perspective view of a part of a composite wall construction according to another embodiment of the invention;

FIG. 15 is a schematic plan view along the line XV-XV in FIG. 14;

FIG. 16 is a schematic side view of part of the composite wall construction of FIG. 14;

FIG. 17 is a schematic perspective view of a part of a combined beam and slab construction according to an embodiment of the invention;

FIG. 18 is an enlarged view of the demarcated detail in FIG. 17;

FIG. 19 is a schematic perspective view of an I-beam of the combined beam and slab construction of FIG. 17;

FIG. 20 is a schematic perspective view of an inverted T-beam of the combined beam and slab construction of FIG. 17;

FIG. 21 is a schematic exploded view of the composite wall construction of FIG. 1;

FIG. 22 is a schematic perspective view of a portion of the composite wall construction of FIG. 23;

FIG. 23 is a schematic perspective view of the composite wall construction of FIG. 23;

FIG. 24 is a schematic exploded view of a portion of the composite wall construction of FIG. 23;

FIG. 25 is a schematic exploded view of the partition wall construction of FIG. 11;

FIG. 26 is a schematic exploded view of a portion of the partition wall construction of FIG. 25;

FIG. 27 is a schematic perspective view of the partition wall construction of FIG. 25;

FIG. 28 is a schematic perspective view of a portion of the partition wall construction of FIG. 25;

FIG. 29 is a schematic exploded view of a part of a combined beam and slab construction of FIG. 17;

FIG. 30 is a schematic exploded view of a window assembly for use in the constructions according to an embodiment of the invention;

FIG. 31 is a schematic perspective view of a window assembly of FIG. 30;

FIG. 32 is a schematic exploded view of a portion of a frame of the window assembly of FIG. 30;

FIG. 33 is a schematic perspective view of a portion of a frame of the window assembly of FIG. 30;

FIG. 34 is a schematic exploded view of the composite wall construction of FIG. 1;

FIG. 35 is a schematic perspective view of the composite wall construction of FIG. 23;

FIG. 36 is a schematic exploded view of a portion of the composite wall construction of FIG. 23;

FIG. 37 is a schematic exploded view of the partition wall construction of FIG. 11;

FIG. 38 is a schematic perspective view of a portion of the composite wall construction of FIG. 23;

FIG. 39 is a schematic exploded view of the partition wall construction of FIG. 11;

FIG. 40 is a schematic exploded view of a portion of the partition wall construction of FIG. 25;

FIG. 41 is a schematic perspective view of the partition wall construction of FIG. 25;

FIG. 42 is a schematic exploded view of a portion of the partition wall construction of FIG. 25;

FIG. 43 is a schematic perspective view of a portion of the partition wall construction of FIG. 25;

FIG. 43 is a schematic front plane view of a part of the combined beam and slab construction of FIG. 17;

FIG. 44 is a schematic exploded view of the combined beam and slab construction of FIG. 17;

FIG. 45 is a schematic perspective view of a part of a combined beam and slab construction of FIG. 17;

FIG. 46 is a schematic exploded view of a window assembly for use in the constructions according to an embodiment of the invention;

FIG. 47 is a schematic perspective view of a window assembly of FIG. 30;

FIG. 48 is a schematic exploded view of a portion of a frame of the window assembly of FIG. 30;

FIG. 49 is a schematic perspective view of a portion of a frame of the window assembly of FIG. 30.

 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS External Wall Construction

Referring to FIGS. 1 to 6, 21-24, and 34-37, there are shown details of a composite wall construction 10 according to an embodiment of the invention.

The wall construction 10 includes a first wall element in the form of a corrugated wall panel 12 extending in a general wall plane, which is parallel to the plane of the wall construction as a whole. The corrugated wall panel 12 is of steel or aluminium.

A second wall element in the form of an insulating wall panel 14 is provided, and extends in its own general plane which is also parallel to the plane of the wall construction 10 as a whole. The insulating wall panel 14 is spaced from the corrugated wall panel 12, so that the two wall panels define a space 16 between them.

The wall panel 12 has spaced-apart, vertically extending corrugations 18 which form recesses 20 into which the space 16 extends.

The insulating wall panel 14 has an inner sheet 22 of steel or aluminium which defines the side of the space 16 opposite the corrugated wall panel 12, a layer of thermally insulating material 24 superposed on the inner sheet, and a layer of elastomeric material 26 on the opposite side of the layer of thermally insulating material. In one embodiment, the insulating wall panel 14 is a rigid Polyisocyanurate (PIR) foam with sheet shell, as shown in FIG. 21. The sheet shell comprises an inner sheet and an outer sheet. The inner sheet and out sheet is made of steel or aluminium. The elastometic matter, such as plastic board, is disposed on one side of the insulating wall panel. In one embodiment, a rending panel 60 is placed to the outer side of the wall panel.

Within the space 16 are a number of elongate reinforcing members 28 extending vertically within the space. The reinforcing members 28 are formed of steel or aluminium sheets which are folded so as to be substantially Z-shaped in cross-section when viewed longitudinally, as best seen in FIG. 4.

As a result of the Z-shaped cross-section, each reinforcing member 28 has two end webs 30 and 32 joined by an interconnecting web 34. One of the end webs 30 is connected to the corrugated wall panel 12 and the other end web 32 is connected to the insulating wall panel 14.

According to one preferred embodiment, the reinforcing members 28 are connected to the wall panels 12 and 14 by a suitable adhesive, although other forms of connection may be used instead, such as welding or rivets.

Each reinforcing member 28, along the length of its interconnecting web 34, is provided with a series of spaced keying apertures 36, and a series of spaced bar apertures 38 which are positioned alternately with respect to the keying apertures. The keying apertures 36 of each reinforcing member 28 are substantially aligned with the keying apertures of the other reinforcing members. Similarly, the bar apertures 38 of each reinforcing member 28 are substantially aligned with the bar apertures of the other reinforcing members.

A number of reinforcing bars 40 are provided and extend horizontally through, and are supported by, the respective bar apertures 38.

Attached to the corrugated wall panel 12 are a number of bracing members 42. These bracing members 42 extend horizontally along the corrugated wall panel 12, below one another as seen in FIG. 1. Each bracing member 42 has a central raised portion 42.1 and two flanges 42.2 extending laterally from the raised portion.

In another embodiment, the brace members 42 extend horizontally along the reinforcing members 28, as seen in FIG. 21. A wall panel 50 is directly attached to the brace members 42. Typically this wall panel comprises an inner sheet 52 and a layer of acoustic barrier and/or a layer of fire resistant panel 54. In another preferred embodiment, each side of the wall construction 10 is provided with a side C section bar 54.

As will be described in further detail below, the bracing members 42 constitute an attachment region for a wall facade.

At the lower end of the wall construction 10, there is provided a lower end cover 44 which partly covers the lower end, and hence the space 16, of the wall construction 10. The end cover 44 has a number of holes 46 in it which are for accommodating starter bars protruding from a concrete footing (the starter bars and footing not being shown) on which the wall construction 10 is placed during erection thereof, as described in more detail below.

The wall construction 10 can be used to form an external wall of a building (not shown). It is envisaged that a number of wall constructions 10 will be used together to form the external wall.

To erect the wall, it is preferable first to have a cast concrete footing (not shown) with starter bars protruding upward from it. Each of the pre-fabricated wall construction 10 is placed on the footing so that the starter bars extend through the holes in the end cap and through the space, so as to extend above the upper end of the wall construction.

It will be appreciated that the spacing and positioning of the starter bars must be such that they do not interfere with, and are not obstructed by, the components of the wall construction 10 in the space 16, in particular, the reinforcing members 28 and the reinforcing bars 40.

Once the wall constructions 10 are erected in this manner, they are propped in place by suitable temporary propping means (not shown). These may, for example, include bars supported on the adjacent ground surface which extend upwards at an inclined angle to engage the wall construction.

Then, concrete (not shown) is poured into the space 16 via the open top of the wall construction 10.

As the concrete is poured, it flows not only downwards to fill the space 16, but also through the keying apertures 36 of the reinforcing members 28, and though any spaces in the bar apertures 38 that are not taken up by the reinforcing bars 40 themselves. The concrete also fills the recesses 20 formed by the corrugations 18 of the corrugated wall panels 12.

The bracing members 42 serve to brace the corrugated wall panels 12 to prevent them from blowing out due to the pressure of the concrete as it is poured.

The upper ends of the starter bars, such as a C section bar, (not shown) can then be suitably tied to a suspended concrete slab above (not shown) to fully secure the wall constructions 10, and hence the building wall as a whole.

Once the concrete has set and been allowed to cure properly, the propping means can be removed.

It will be appreciated that the concrete, by flowing through the keying apertures 34 (and possibly parts of the bar apertures) of the reinforcing members 28, serves to positively key itself to the reinforcing members. Thus, if surrounding parts of the concrete were to break off, for example due to impact or an earthquake, the remainder of the concrete would still be joined fast to the reinforcing members 28.

Although the reinforcing members 28 may by themselves have a low resistance to buckling due to their thin profiles, it is the combination of the reinforcing members and the surrounding concrete which not only compensates for this, but results in significant resistance to buckling and crumbling. In particular, unlike in the case of conventional reinforcing bars of round cross-section, the fact that the reinforcing members 28 according to the present invention are formed of plate material, results in there being a relatively, and significantly, large area of the reinforcing members in contact with the concrete. Thus, the interaction between the reinforcing members and the concrete takes place over a significantly larger area than would be the case with conventional round-section reinforcing bars. The interaction and interconnection is further enhanced by the keying of the concrete to the reinforcing members 28 as described above.

The concrete also sets around the horizontal reinforcing bars 40, which serve to further strengthen the wall constructions 10 and effectively to interconnect the reinforcing members 28 with one another via the concrete.

As a result of the combination of different types of materials involved and their relative position, the wall construction 10 may, in suitable embodiment, also have superior acoustic insulation properties.

As mentioned above, the bracing members 42 constitute attachments for another wall panel 50 or a building facade (not shown). In particular a facade having a desired appearance may be attached to the raised portions 42.1 of the bracing members 42 by suitable attachment means such as hooks, brackets, or the like. Each bracing member 42 is attached to the corrugated wall panel 12 by way of the two flanges 42.2, and the raised portion 42.1 stands proud of the flanges. Therefore, the facade will be spaced from the corrugated wall panel 12. The space between the facade and corrugated wall panel 12 may be used as a space to accommodate utilities such as electric cables, thin ducting, and the like, which extend along the wall. This provides a useful manner of concealing such utilities.

Internal Partition Wall Construction

Referring to FIGS. 11 to 13, 25-28 and 38-42, there is shown a partition wall construction 200. The partition wall construction 200 includes a first wall panel 202 and a second wall panel 204, each of these wall panels extending in a general plane parallel to that of the partition wall construction as a whole. The wall panels 202, 204 are spaced apart from each other to define a space 206 between them.

Each of the wall panels 202, 204 has a number of spaced-apart vertically extending corrugations 208. The corrugations 208 form recesses 210 into which the space 206 extends.

The space 206 is filled with a thermally insulating material (not shown). In one preferred embodiment, this material is a foam material which is sprayed into the space 206 before the foam sets. According to a preferred embodiment, the foam is Polyisocyanurate (PIR) foam.

As the foam material is sprayed into the space 206, it fills the space. However, it is a material which does not readily flow. Therefore, to facilitate complete filling of the space 206 including in the recesses 210, it is necessary, according to one preferred embodiment, to have nozzles (not shown) that are provided for spraying the foam into the space 206 positioned in a multi-linear or staggered configuration so that there are nozzles substantially aligned with the centre of the space 206 between the wall panels 202, 204 and nozzles substantially aligned with the recesses 210.

The corrugations 208 assist in providing the partition wall construction 200 with an enhanced resistance to buckling when compared with an otherwise comparable, but planar, wall panel. Thus, the partition wall construction 200 may, in particular embodiments, be suitable for providing a degree of load bearing capacity. Simply by way of example, they may be suitable to serve as load-bearing structures for two-storey buildings, but not for buildings which are of a greater number of levels.

In one embodiment, further finishing wall panels 220 and inner sheet 222 may be affixed to both sides of the partition wall construction 200

The combination of the corrugated wall panels 202, 204 and the insulating material can result in the partition wall construction 200 being useful not only for a certain level of load-bearing capacity and thermal insulation, but also acoustic insulation. Therefore, the partition wall construction 200 may constitute an effective internal partition wall between, for example, two adjacent rooms of a home, office, or the like.

Internal/External Wall Construction

Referring now to FIGS. 14 and 15, there is shown part of a composite wall construction 250 according to a different embodiment to that shown in FIG. 1. Components in these figures corresponding to components described above are indicated by the corresponding reference numerals.

It will be noted that only a portion of all of the components of the wall construction are shown, except for the reinforcing bars 40 which are fully shown (and which are therefore shown extending beyond the other components).

The composite wall construction 250 essentially includes a pair of the wall constructions, corresponding substantially to the wall construction 10, superposed on each other, substantially as mirror images. However, instead of each such wall construction having the insulating wall panel 14, the wall construction 250 is provided with a common, central partition wall construction 200.

The wall construction 250 can therefore be used for any of the purposes to which the wall construction 10 can be used. In addition, it can provide a suitable wall to serve as a dividing wall between two independent spaces, such as two adjacent apartments.

Indeed, the greater number of layers when compared with the wall construction 10 assists in providing the wall construction 250 with a greater level of acoustic insulation, which is important in acoustically isolating such separate dwellings. In addition, the central partition wall construction 200 can provide comparable heat insulation to the insulating wall panel 14 of the wall construction 10.

In addition, the overall load-bearing capability of the wall construction 250 can be higher than that of the wall construction 10, due to the effective doubling up of the load-bearing components in the wall construction 250 than in the wall construction 10.

Beam and Slab Combination

Referring to FIGS. 17 to 19, 29 and 43-45, there is shown a combined beam and slab construction 300. The construction 300 includes integral shuttering 302 defining a beam zone 304 and a slab zone 306. The bottom and sides of the beam zone 304 are defined, respectively, by a base portion 302.1 of the shuttering and side portions 302.2 of the shuttering. The bottom of the slab zone 306 is defined partly by the beam zone 304 and partly by floor portions 302.3 of the shuttering 302.

It will be noted that the beam zone 304 is integral with, and extends below, the slab zone 306, and that the floor portions 302.3 of the shuttering 302, and hence the slab zone 306, extend beyond the left side and right sides 308 and 310, respectively, of the beam zone when it is viewed longitudinally.

As discussed further below, the beam zone 304 is for accommodating concrete poured to form a beam and the slab zone 306 is for accommodating concrete poured to form a slab which is integral with the beam.

The construction 300 includes layers of horizontal elongate reinforcing members, generally designated 312, in the form of I-beams. Such an I-beam 312 is shown in more detail in FIG. 19. There are three layers of such reinforcing members 312 in the beam zone (as discussed further below) which are called beam reinforcing members, and a single layer in the slab zone (also discussed further below) which are called slab reinforcing members.

In particular, a first layer of the beam reinforcing members 312, specifically designated 312.1, are disposed on the base portion 302.1 of the shuttering so as to extend parallel to one another.

Above the first layer of beam reinforcement members 312.1, there is an additional, middle layer of the beam reinforcing members, specifically designated 312.2, which also extend parallel to each other. The beam reinforcing members 312.2 are supported on the first layer of beam reinforcement members 312.1 and extend at right angles to them.

Above the middle layer of beam reinforcement members 312.2, there is a further, upper layer of the beam reinforcing members, specifically designated 312.3, which also extend parallel to each other. The beam reinforcing members 312.3 are supported on the middle layer of beam reinforcement members 312.2 and extend at right angles to them (and hence parallel to the first layer of beam reinforcement members 312.1).

Each I-beam 312 has upper and lower horizontally extending flanges 314 and 316, respectively, and a central vertical interconnecting web 318.

Each web has a series of keying formations each in the form of a keying aperture 320. Arranged alternately with respect to the keying apertures 320 are a series of bar apertures 322. The keying apertures 320 and bar apertures 322 are discussed further, below.

The upper surfaces of the upper flanges 314 of the upper layer of beam reinforcing members 312.3 is co-planar with the upper surfaces of the floor portions 302.3 of the shuttering 302. These upper surfaces of the upper flanges 314 essentially define the uppermost extremity of the beam zone 304.

Above the upper layer of beam reinforcement members 312.3 (and hence above the beam zone 304), there is a single layer of the reinforcing members 312, being slab reinforcing members, which are specifically designated 312.4, which also extend parallel to each other. The slab reinforcing members 312.4 are supported partly on the floor portions 302.3 of the shuttering 302 and partly on the upper layer of beam reinforcement members 312.3 and extend at right angles to those beam reinforcement members.

Above the layer of slab reinforcement members 312.4, there is a further layer of elongate slab reinforcing members 326. However these differ from the previously mentioned, I-beam reinforcing members 312 as each is in the form of an inverted T-beam having a lower horizontally extending flange 328 and a central vertical web 330. Each web has a series of keying formations in the form of keying apertures 332. The slab reinforcing members 326, unlike the reinforcing members 312, do not have bar apertures.

The slab reinforcing members 326 rest on the reinforcement members 312.4 and extend at right angles to them.

As best seen in FIG. 18, there are provided reinforcing bars 334 which extend through the bar apertures 322 of the middle layer of beam reinforcing members 312.2. In other embodiments (not shown), similar reinforcing bars are provided in each of the three layers of reinforcement members 312.

Each slab reinforcing member 326 has a series of semi-circular notches 336 in the upper edge of its web 330. Reinforcing bars 368 (only one being shown) are provided and extend across the top of the reinforcing members 326 at right angles to them, and are accommodated in the notches 336.

A mesh (not shown) can be placed immediately above, and rested upon, the reinforcing bars 368.

A number of juxtaposed combined beam and slab constructions 300 can be used in the construction of a building where separate beams and slabs might otherwise have been used, for example a car park.

Prior to the installation of the combined beam and slab constructions 300, suitable pillars (not shown) could be constructed, and the constructions 300 could then be installed above the pillars so as to be supported on them.

After the installation of the combined beam and slab constructions 300, concrete could be poured into them. As a result of the constructions 300 being juxtaposed in relation to one another, the adjacent floor portions 302.3 of each pair of adjacent constructions 300 would effectively be continuous with each other. Thus, the poured concrete would flow evenly through the various constructions 300.

As the concrete is poured, it first fills the beam zone 304 of each construction 300, and then fills the slab zones 306. It flows so as to encapsulate the various reinforcement members 312, 326 and bars 334, 368 and the above-mentioned mesh. It also flows through the keying apertures 320, 332 and open bar apertures 334 or open portions thereof.

Thus, as the concrete sets, it keys itself to the reinforcing members. The concrete is poured to a desired level above the mesh so as to leave a suitable thickness of unreinforced concrete.

Window Assembly

Referring to FIGS. 30-33 and 46-49, there is shown a window assembly for use in the above constructions. The window assembly 400 comprises a window jam component 402, window frame component 404 and an architrave component 406 superposed with each other. Each of these components is made of a roll form sheet metal. Any of the wall constructions above may include one or more window assembly disposed thereon.

Although the invention is described above with reference to specific embodiments, it will be appreciated by those skilled in the art that it is not limited to those embodiments, but may be embodied in many other forms.

Claims

1-38. (canceled)

39. A composite wall construction including:

a first wall element extending in a first general plane;
a second wall element extending in a second general plane parallel to the first plane and spaced from the first wall element, whereby the first and second wall elements define a space between them, the second wall element having an inner sheet defining one side of said space; and
a plurality of elongate reinforcing members extending longitudinally vertically within the space and being attached to each of the first and second wall elements, each reinforcing member being formed of sheet material and having keying formations to facilitate adhesion between the reinforcing member and a settable substance poured into the space;
wherein the first wall element has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends.

40. A composite wall construction according to claim 39, wherein the second wall element has an insulating layer of thermally insulating material superposed on the inner sheet on an opposite side thereof to said space.

41. A composite wall construction according to claim 39, including a plurality of horizontally extending elongate bracing members attached to the first wall element on an opposite side thereof to the space.

42. A composite wall construction according to claim 41, including a facade extending over, and mounted on, the bracing members so as to be spaced from the first wall element.

43. A composite wall construction according to claim 39, wherein each reinforcing member is substantially Z-shaped in cross-section viewed longitudinally.

44. A composite wall construction according to claim 39, including a plurality of horizontally extending reinforcing bars, and wherein each reinforcing member defines a plurality of bar apertures, each reinforcing bar passing through aligned bar apertures of the plurality of reinforcing members.

45. A composite wall construction according to claim 39, wherein each keying formation is constituted by a keying aperture in the respective reinforcing member.

46. A composite wall construction according to claim 39, wherein the second wall element includes an outer sheet disposed on an opposite side of the insulating layer to the inner sheet.

47. A composite wall construction according to claim 46, wherein the outer sheet is of elastomeric material.

48. A composite wall construction according to claim 39, including a lower end cover for at least partly covering a lower open end of the space.

49. A composite wall construction according to claim 48, wherein the end cap defines plurality of starter apertures for enabling the passage therethrough of a plurality of starter bars on which the composite wall construction is placed.

50. A composite wall construction according to claim 39, including insulating foam material substantially filling the space.

51. A partition wall construction including:

a first wall element extending in a first general plane;
a second wall element extending in a second general plane parallel to the first plane and spaced from the first wall element, whereby the first and second wall elements define a space between them, wherein at least one of said wall elements has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends; and
thermally insulating foam material substantially filling the space.

52. A partition wall construction according to claim 51, including insulating foam material substantially filling the space.

53. A complex wall construction including a pair of composite wall constructions according to claim 39, the composite wall constructions being arranged as mirror images with respect to each other and sharing a common single second wall element, wherein the second wall element includes:

a first wall element extending in a first general wall plane;
a second wall element extending in a second wall plane parallel to the first wall plane and spaced from the first insulating wall element, whereby the first and second wall elements define a space between them, wherein each of said wall elements has a plurality of spaced-apart vertically extending corrugations forming recesses into which the space extends.

54. A composite wall construction according to claim 39 wherein the second wall element has an insulating layer of thermally insulating material superposed on the inner sheet on an opposite side thereof to said space.

55. A composite wall construction comprising:

a first wall panel component;
a second wall panel component; and
a corrugated structure component;
wherein the corrugated structure component has the first wall panel component disposed on one side and the second wall panel component disposed on another side, and
the corrugated structure has a plurality of spaced-apart vertically extending corrugations forming recesses;
such that the corrugated structure defines empty space between the first wall panel component and the second panel component for a settable substance poured therein.

56. A composite wall construction according to claim 55, wherein the first wall panel has an insulating layer.

57. A composite wall construction according to claim 56, wherein the insulating layer comprises a sheet shell having an insulating element therein.

58. A composite wall construction according to claim 57, wherein the insulating element comprises rigid Polyisocyanurate (PIR) foam.

59. A composite wall construction according to claim 55, wherein the insulating layer has a elastomeric panel disposed on one side.

Patent History
Publication number: 20120073227
Type: Application
Filed: Jun 4, 2010
Publication Date: Mar 29, 2012
Applicant: HSEM MANAGEMENT PTY LTD (Ryde, NSW)
Inventor: Mahir Urusoglu (Auburn NSW)
Application Number: 13/376,032
Classifications
Current U.S. Class: Foam (52/309.4); With Vertical Support (e.g., Stud) Between Facers (52/481.1); With Transverse Tie (52/426)
International Classification: E04B 2/34 (20060101); E04C 2/20 (20060101); E04C 2/34 (20060101);