COMPOSITE WALL PANEL, WALL SYSTEM AND COMPONENTS THEREOF, AND A METHOD OF CONSTRUCTION THEREOF

Abstract

A composite wall, ceiling or floor panel (10), system and method, including a sheet (14) having a first face (18) including at least one first mounting portion (16), and at least one formwork member (20) with at least one second mounting portion (30) arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. Structural support comes from piers (for a wall) or beams (ceiling or floor) formed in the spacing between adjacent formwork members. The formwork members act as the core of a wall, ceiling or floor panel. An external coating (123) is applied to the formwork members, such as spray shotcrete or render. Channels (28) formed by the formwork members defines integrated ducting for services to be run.

Claims

1. A composite wall, ceiling or floor panel including a sheet having a first face and a second face, the first face including at least one first mounting portion, the panel further including at least one formwork member having at least one second mounting portion arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together.

2. A composite panel according to claim 1, the sheet including an insulation layer and a lining layer.

3. A composite panel according to claim 2, the insulation layer also providing the first face of the sheet and the lining layer providing the second face of the sheet.

4. A composite panel according to any one of claims 1 to 3, the first and second mounting portions including respective projections and recesses arranged such that the projections are received into the recesses.

5. A composite panel according to claim 4, the arrangement of projections and recesses providing a keyway arrangement whereby the projections and recesses have an inter-cooperating keyway projection and keyway channel locking one to the other.

6. A composite panel according to any one of the preceding claims, the formwork member acting as a column section of the panel may have at least one leg projecting from a main body portion.

7. A composite panel according to any one of the preceding claims, the body portion of the formwork member including an exterior surface profile configured to receive and assist retention of a coating.

8. A composite panel according to any one of the preceding claims, including a coating of concrete applied to at least one of the faces.

9. A composite panel according to any one of the preceding claims, the at least one formwork member including a complex exterior profile or a textured surface or combinations thereof to increase surface area for adhesion of the coating.

10. A composite panel according to any one of the preceding claims, the sheet further including a moisture barrier material.

11. A composite panel according to any one of the preceding claims, the at least one formwork member including at least one core channel running along a longitudinal direction of the formwork member(s).

12. A composite panel according to claim 11, the core channel(s) providing one or more voids as service/utility conduits.

13. A composite panel according to any one of the preceding claims, the panel provided as a wall panel.

14. A composite panel according to any one of claims 1 to 12, the panel provided as a floor panel.

15. A composite panel according to claim 8, wherein the concrete is spray applied concrete.

16. A method of constructing a structural composite wall, ceiling or floor, the method including connecting at least one formwork member to a first face of a panel sheet, erecting and supporting the panel sheet and connected formwork member(s), and coating at least a portion of the first face of the panel sheet and the formwork member(s) with concrete, and allowing the concrete to harden to form a wall section.

17. A method according to claim 16, the at least one formwork member including projections inserted into respective channels in the first face of the panel.

18. A method according to claim 16 or 17, including connecting adjacent erected panels with a metal or non-ferrous locking member spanning adjoining wall panels.

19. A method according to any one of claims 16 to 18, including placing one or more reinforcing bars in at least one void or space formed between two adjacent said formwork members.

20. A method according to any one of claims 16 to 19, including forming a floor panel by placing the panel horizontally to create a reinforced floor slab using voids or spaces formed between two adjacent said formwork members to form a vault structure onto which concrete is poured and leveled.

21. A method according to claim 20, including placing one or more reinforcing bars in at least one void or space formed between two adjacent said formwork members.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIGS. 1 and 2 show a section through a wall/floor panel with the panel sheet and formwork member (e.g. column section) connected together according to an embodiment of the present invention.

[0044] FIG. 3 shows a wall/floor panel according to an alternative embodiment of the present invention.

[0045] FIG. 4 shows a number of connected panels according to an embodiment of the present invention.

[0046] FIG. 5 shows a section through a panel where a window or door opening is to be formed, according to an embodiment of the present invention.

[0047] FIGS. 6a and 6b show sectional views of an alternative form of creating openings in a wall under construction, such as window and door openings, using panels and a system according to an embodiment of the present invention.

[0048] FIG. 7 shows a sectional view of an alternative embodiment of the present invention with formwork members defining gaps to create concrete piers, and a separate coating applied.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0049] One or more embodiments of the present invention will hereinafter be described with reference to the accompanying drawings.

[0050] FIGS. 1 and 2 show sections through a panel 10. An interior lining board 12 is bonded, such as by gluing, to a 50 mm thick sheet 14 of insulation material (such as EPS) in a manufacturing facility. The sheet 14 has a uniform series of receiving recesses 16 (such as formwork slots or channels) pre-cut into the first face 18 (forming the exterior face in this embodiment) to receive two core sections 20,22 or 24,26. Embodiments of the present invention may utilise one or more core sections. The required number will vary with the technical specification for a wall or wall panel arrangement. For example, one core section may be used, which may have multiple “legs” 30, or alternatively several narrower core channels may be used having fewer legs. A range of channels 28 in the core sections formed by legs 30 of the core sections allowing the body portion 32 to stand away from the first face 18 of the panel 10 to create “voids” i.e. the channels 28 for services and utilities. These voids also reduce the overall amount of material needed to form the wall panel with minimal or no reduction, if any, in overall strength once coated with concrete. Horizontal channels can be ‘pre-cut’ or pre-formed in the formwork member (core) sections to form (reinforced concrete) head, sill and/or bond beams. The core section may provide no final strength to the concreted panel as the core creates the shape of the concrete which provides the structural element i.e. the panel provides the “formwork” for the concrete wall.

[0051] Legs 16 of the formwork members may include means for retaining the formwork member to the sheet. In the embodiment shown in FIGS. 1 and 2, a ‘keyway’ arrangement is used. This includes a cooperating projection and channel arrangement, with a leg 16 incorporating a projection 34 and recess 36 each inter-engaging with a respective recess 38 and projection 40 in the sheet face 18. The formwork members are inserted e.g. by sliding, into the channels 16 and the inter-engaging projections and recesses act as a locking ‘keyway’ to prevent the formwork members from coming back out. Friction between the materials of the sheet and the formwork members (cores) aids retaining these components together.

[0052] Overall width W of the formwork column members 20,22,24,26 can be varied to suit particular applications. Likewise, their thickness T can be varied to suit as desired application. Thus, overall strength of the wall/floor panels, particularly when the concrete coating is dried, can be varied to suit structural loading specifications.

[0053] The exterior surface of the formwork column members 20,22,24,26 can have a profile or shape to increase surface area in order to improve initial concrete adhesion when spraying the concrete onto the panels. Angular profile sections of peaks 42 and troughs 44, or undulations, or a textured surface, or other shapes may be utilised.

[0054] Preferably the lining layer 12 may be a finishing layer of cement based board or plasterboard. The cement based board may be a 2.0-10.0 mm thick sheet, preferably between 4.5 and 6.0 mm, and the plasterboard may be 8.0 mm-12 mm thick, preferably around 10 mm thick sheet.

[0055] An alternative form of the panel 60 is shown in FIG. 3. The panel 60 has a sheet material 62 providing a substrate to which is attached a formwork column member 64 (all shown in cross section). Other features are as shown in FIGS. 1 and 2. However, the ‘keyway’ arrangement has chamfered faces 66 and 68. The sheet 62 has chamfered faces 66 in the channels 70. The formwork column member has chamfered faces 68 on the projections 72 projecting into those channels. It will be appreciated that the projections 72 and the recesses or channels 70 could be reversed such that the formwork column members 64 have the recesses or channels and the sheet has the projections. The projections are preferably slid into the channels. The substrate can be a single material or can be a combination or lamination of materials, such as an insulation material/moisture barrier material with a layer of a finishing material, such as in FIGS. 1 and 2. Preferably the overall width of the panel W.sub.p is a standard trade size, such as 1200 mm or a multiple or fraction thereof, such as 600 mm, 900 mm, 1200 mm, 1500 mm, 2400 mm or 3000 mm etc. The formwork member may preferably be formed of or include expanded polystyrene (EPS) or any material that retains its form as the member. For example, plastic, plant fibre, recycled plastic or rubber waste, metal, plastic coated timber or combinations thereof.

[0056] Construction of the panel(s) and use for constructing a building wall will hereinafter be described. The formwork member core sections 20,22,24,26 slide into the pre-cut slots 16 in the first face of the panel, with the completed panels then placed upright on the perimeter of the concrete floor slab/foundation (not shown). A metal locking member, such as a steel or non-ferrous locking plate (not shown) spans adjoining wall panels 10 for alignment. Once the wall panels 10 have been erected, reinforcing bars are placed between the core sections 20,22,24,26 in accordance with the site engineering specification. Horizontal beams can be formed by the pre-cut channels in the core, with head and sill beams framing window and door openings, and a continuous bond beam or beams formed at the top and/or at a specified height in the wall panels. Shotcrete (sprayed concrete) is applied to the exterior of the panels in a continuous process, thereby forming the vertical columns, the horizontal beams and the exterior finished surface creating a reinforced concrete structure.

[0057] The composite panel (lined flat sheet plus sized cores) may be placed horizontally to create a reinforced floor slab using the voids between cores and the pre-cut slots (transverse) to form a “honeycomb” or “vault” structure onto which reinforcing is placed and concrete is poured and leveled. This floor slab can then support another set of wall panels to create an extra storey/level.

[0058] FIG. 4 shows a series of panels 100A-D of the present invention.

[0059] Adjacent ones of the panels 100A-D are connected together by respective locking members 102A-C. Each locking member can be metallic, such as a formed steel, non-ferrous, alloy or plastics fastener shaped or arranged, with or without other components, to connect into the adjacent panel sheets and/or into the formwork members attached to those sheets and thereby hold the panel sheets together until the concrete has been applied and sufficiently set to give structural rigidity and strength. Put simply, the locking members serve the purpose of holding adjacent panels together until the concrete has sufficiently set. Formwork members 104A-H, the same as or similar to the formwork members shown in FIGS. 1 to 3, are engaged in respective channels 106A . . . n of the panels as previously described. These engaged formwork members provide stability and some rigidity to the respective panel until the panel is coated with concrete and the concrete is sufficiently set. Thereafter, the concrete provides structural strength to specification for the wall.

[0060] Door openings 111 and window openings 112 can either be formed in the panels after the formwork members are applied but before the concrete is applied (i.e. the openings may be cut through the panel sheet) or, alternatively, the formwork members are applied in shorter sections to suit the specific panel after the openings have been cut in the panel sheet. Door and window openings may be formed on site (i.e. in situ when the panels are erected) or offsite, (such as at a factory producing the blank panel sheet).

[0061] Openings at the top of the formwork(s) at the base of the window opening(s) may be provided with a further locking member 114 that may also block those openings to prevent concrete entering the voids below. This further locking member 114 also connects together adjacent formworks 104B,104C to add strength where the window opening is created. This further locking member may be the same as one of the locking members 102A . . . n.

[0062] A corner or junction locking member may be provided to connect panels at that are not directly in a straight line. For example, at a corner, which may be 90 degrees, 45 degrees or other angle, or the panels may be joined to form a generally curved wall approximated by multiple flat panels, or the panels may be pre-curved and connected by curved locking members prior to spraying with concrete.

[0063] In use, the required number of panels 100A . . . n are connected together with locking members 102A,B,C . . . etc, as required.

[0064] The formwork members provide initial rigidity to the panel but also provide an underlying former such that when the concrete is applied and sets, the concrete forms piers providing structural rigidity and strength to meet a required specification.

[0065] It will be appreciated that both faces of the wall may include the formwork member(s) engaged in respective channels on each face of the panel. The formworks may be directly opposite one another or may be staggered. The finished face of each panel may be faced outwards such that the formwork member mounted face of each panel are towards one another. Thus, a cavity is formed between the first faces of each panel having the respective formwork members mounted thereto. Concrete is applied to the cavity to form a solid structure providing sound and thermal insulation, such as for an internal wall between buildings or rooms. Services, such as utilities can be run through the voids formed by the formwork members connected to the respective panel sheet.

[0066] In FIG. 5 there is shown a section through a panel under construction. A window opening or doorway is to be formed in the panel. A subsidiary panel 120, such as a 50 mm thick EPS sheet, is overlaid on selected ones of the formwork members 122A-D. In this example, the subsidiary panel 120 is applied to the central two formwork members 122B and 122C. However, the subsidiary panel, or further subsidiary panel(s), may span further/other formwork members.

[0067] Alternatively, the subsidiary panel may be integral with the formwork member(s) e.g. one piece of EPS foam that, optionally has no internal voids, but retains the projections for inter-engaging with the channels/slots in the panel sheet. Looking at the drawing FIG. 5, this would entail the subsidiary panel 120, and formwork panels 122B and 122C being manufactured or formed as one piece or being single thicker pieces having the same thickness of the subsidiary panel and formwork panel, as shown in FIGS. 6a and 6b. Such a one-piece component may simplify constructing the panel prior to coating with concrete and avoid potential positioning errors in placing a separate subsidiary panel over separate formwork member(s).

[0068] When the concrete coating 123 is applied to the first face 124, the subsidiary panel 120 prevents concrete from coating the covered formwork members, but also provides an edge to coat up to, thereby giving a straight edge and clean window/door reveal 126. The, subsidiary panel, the overlaid formwork members, and the section of panel sheet(s) 127,128 between the formed reveal(s) 126 may be cut away once the concrete has sufficiently set to create the opening. The panel sheets may include a finishing layer 129 on an outer face of each panel, and an inner facing sheet of material 130, such as EPS, to which the formwork members are attached via an interlocking arrangement as shown in FIGS. 1 and 2.

[0069] Each formwork member may be an elongate member (e.g. 104A, 104D, 104H) or may be a relatively short member compared to its width (e.g. 110A, 110B, 110C . . . ), or may be an intermediate length member (e.g. 104B, 104C), or may be formed of multiple shorter member sections connected to form an elongate formwork member. These sections may be bonded together, such as by an adhesive, or may be mechanically joined by one or more connectors or fasteners.

[0070] FIGS. 6a and 6b show a sectional view of two stages of an alternative form of the invention for creating a window or door opening compared to that shown in FIG. 5. Essentially, the formwork members 122B,122C and the subsidiary panel 120 of FIG. 5 are combined into one or more thick formwork members 132A,132B,132C. It will be appreciated that a single formwork member 132 of suitable dimensions to define the required opening measurements (width and height) could be used. As previously described, the formwork panel(s) ‘keys’ into the inner facing material or other facing sheet or coating, and a final finishing layer 129 may be applied. FIG. 6a shows three formwork members keyed into the inner first face 124 of the inner facing material. These formwork members are 150 mm thick (compares with 100 mm thickness of the formwork members 122A-D). The additional thickness helps to support the edges of a coating when applied to the formwork members 122a,122D adjacent to the opening to be formed, and makes the door or window reveal the same thickness as the adjacent formwork members plus their coating. These thicker formwork members can thereafter be readily removed with the unneeded out facing over the window or door section to form the opening. FIG. 6b shows a concrete coating (such as shotcrete) covering the formwork members 122A and 122D and forming the 150 mm reveal 136 of the window opening. The thicker formwork members 132A,132B and 132C have been removed along with the unneeded facing section 134. Window frame members 138 are shown against the reveal 136 to finish the opening.

[0071] In FIG. 7, formwork members 122A-D are keyed into a first face 124 of a facing material, such as by a tongue and groove arrangement previously described. The formwork members are laterally spaced relative to one another and thereby define gaps, 140A,140b, 140C and so on. Those gaps provide spaces to form supporting piers 142, such as by using concrete. FIG. 7 makes clear that the coating material 144 is separate to the piers. The coating material can be an applied concrete mixture (such as shotcrete), a render coating with or without a pre applied support mesh, metal or plastic sheeting (such as corrugated sheeting), or a series of panel (e.g. gypsum, cement or wood based sheets) which may be fastened directly or indirectly to the formwork members and/or to the concrete piers, or combinations thereof.