Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating

Definitions

• the present invention relates, in general, to improvements in building materials.
• the invention furthermore relates to structures built from such improved building materials, and to a method of construction utilising such materials.
• static materials such as for example brick, timber and/or reinforced (conventional) concrete.
• static materials such as for example brick, timber and/or reinforced (conventional) concrete.
• static materials have been found, in a practical sense, not to afford a truly acceptable degree of flexibility in and for both construction and design.
• static materials when such so-called static materials are employed it has been found to be somewhat difficult to achieve surfaces other than straight, as for example curved, at an acceptable cost.
• static materials have generally relied rather heavily on secondary support elements and the like whereby to satisfy prescribed design parameters, as for example thermal resistantce, strength capability, fire-rating, water ⁇ proofing etc.
• the present invention seeks to provide an improved form of building material, in the form of a laminate, which may be sized and shaped to suit specified building requirements and parameters. More particularly, the invention seeks to provide a building material which will readily allow for the utilisation or formation of surfaces, other than straight in architectural designs for buildings and the like, thereby allowing architects to design structures having greater aesthetic appeal and which, in an environ- mental sense, are perhaps more compatible with the surroundings or environment.
• the invention furthermore seeks to provide a method of construction best suited for the utilisation of such building material.
• the building material or materials in accordance with the present invention provides for greater flexibility of design, more effective use of man-power, better quality control and, in the result, a finished product manufactured at a reduced overall cost.
• a material for use in building said material being in the form of a laminate and including: at least one layer of an insulating material; at least one layer of a damp-proofing material; and at least one layer of a re-inforcing material, preferably expanded metal.
• a method for the construction of the external shell of a building or the like including the steps of: (i) forming a slab of concrete or the like material on-site whereby to afford a flat surface for construction of said building or the like;
• a building material in accordance with the present invention may comprise a laminate constructed from a number of layers of different materials, arranged in a preconceived order dependent upon the proposed usage therefor, and perhaps more particularly dependent upon whether the building material is intended for use in a structure sited (either wholly or in part) above or below ground level.
• the materials involved in such a laminate may include so-called ferro-cement or fibrecrete including a reinforcing steel framework or mesh, a suitable insulating material, a damp-proofing, water-proofing or anti-condensation material, a layer of expanded metal, and a plaster, cementitious material or other suitable finishing material to suit aspects of acoustics and aesthetics.
• Such a laminate may be assembled by manual and/or mechanical means, with the use of clips, ties, adhesive, heat/pressure and/or any other suitable means of and for inter-connection or attachment.
• the laminate may be fabricated off site, as for example in a shop, factory or the like, on site, or a combination thereof.
• Ferro-cement or the like material may best be described as a type of thin-wall concrete construction which has been found to behave quite differently to conventional reinforced concrete. Fabrication of such ferro-cement generally involves the building up of several layers of relatively small diameter mesh, which is then completely impregnated with mortar in such a way as to minimize, if not remove altogether, air gaps or voids.
• the mesh may be constructed of any suitable material, as for example a metallic material, glass or asbestos fibres (or indeed any other suitable organic material), or even a combination thereof.
• Ferro-cement or any equivalent material, such as fibrecrete has been found to be an extremely workable material and to provide for a markedly improved flexibility in design.
• the ferro- cement or the like material may be provided with one or more ribs, either internal or external, or alterna ⁇ tively it may be in the form of a continuous sheet or layer.
• the reinforcing steel framework or mesh making up part of the laminate in accordance with the present invention may take any known form.
• a general requirement for such a reinforcing framework or mesh is flexibility, especially wherein curved or non-straight surfaces, shapes or the like are called for in an overall structure.
• high tensile steel mesh may be employed with additional layers of so-called “chicken-wire" being affixed to the reinforcement mesh in any known manner, as for example by way of steel wire ties or the like.
• the preferred form of laminate in accordance with the present invention should also include at least one layer of a suitable condensation control material.
• An especially preferred embodiment utilizes polyethylene sheeting (one or more sheets) for this purpose.
• the preferred form of laminate in accordance with the present invention should also include at least one layer of a suitable insulating material.
• a suitable insulating material such as styrofoam may be employed for purposes of insulation.
• other materials having insulating properties such as for example fibreglass, may equally well be employed.
• a layer of styrofoam of a thickness of perhaps from 25-30 mm. will exhibit better insulation characteristics than a 75 mm. layer of fibreglass.
• the thickness of the layer (or layers) of insulating material may be varied dependent on intended usage for the laminate. By way of example, if the building on which the laminate is to be employed was to be located in an extremely hot or cold climate, then the thickness of the insulating material would (or could) be increased accordingly.
• the laminate in accordance with the invention should also include at least one layer of a suitable material which acts as a barrier to condensation.
• suitable and/or preferred damp-proofing and/or water-proofing materials include concrete additives, so-called pargeting (coating with a dense cement plaster or a similar material) , a coating of asphalt, a coating of pitch, a layer (or layers) of polyethylene sheeting, or perhaps even a membrane of neoprene or other suitable material.
• a bituminous membrane may be employed.
• the laminate in accordance with the invention furthermore includes a layer of what might be termed expanded metal (or an equivalent material) , formed by the subjection of a thin metal sheet to an expansion process.
• This expanded metal (or equivalent) acts as a reinforcing agent for the application of plaster, cementitious material or other surface-finishing material.
• the expanded metal sheet will have a thickness of from 4.5 to 7.0 mm.
• a building material in accordance with the present invention will also give rise to the need for a specific mode of construction of any desired structure.
• such a mode of construction will involve a number of different steps or stages, as indicated hereunder.
• the relative locations of the various layers of material within the laminate do not constitute an essential part or feature of the invention. Indeed, those relative locations may be varied to satisfy different building requirements.
• the location of the damp-proofing material or condensation barrier may be altered.
• the present invention also involves a method of erecting a shell for a building structure utilising materials of the aforementioned type.
• a preferred method or mode of construction has been devised, as explained hereunder in detail.
• the first step in the method of construction in accordance with the present invention involves the preparation of the site for construction.
• the building or the like is constructed on a concrete slab. Any known method or techinque for levelling of a site and pouring of such a slab may be employed.
• a frame may be erected on the slab, and affixed thereto, as for example by the use of bolts or the like (not shown) appropriately and strategically located within the concrete slab during pouring thereof.
• the frame or the like constructed of any suitable material such as, for example, steel tubing or piping, of a pre-ordained configuration, constitutes means allowing for definition of the basic shape for the structure being erected, and also as a carrier for electrical services and the like.
• the configuration for such a frame may be calculated in any suitable manner.
• such a configuration is arrived at - through the use of appropriate computer means, whereby to provide a configuration best suited for the prescribed load requirements etc. and which meets the desired design shape for the overall structure.
• flat metal plate, rod or angle may be attached to the support frame in any suitable manner, as for example by spot welding, pinning or the like.
• Such flat plate, rod or angle serves to more fully and correctly define the overall basic form for the structure.
• the flat plate, rod or angle will be affixed at right angles to the frame itself, more specifically on the top of and at the outside edge of the individual elements of that frame.
• a framework of high tensile fabric is located over the flat plate or rod on the support frame and is affixed thereto by any suitable means, as for example through the utilisation of steel wire ties.
• at least one layer of such high tensile fabric mesh will be employed. It should be understood, however, that dependent upon design parameters more than one layer of such fabric may be employed.
• at least one, and preferably several, layers of fine wire are tensioned over the structure and affixed thereto, again in accordance with any known technique.
• the wires and mesh fabric may be cut and trimmed at any location where such structures as windows, vents and the like are required.
• a laminar material consisting of at least one layer of poly ⁇ ethylene (preferably in the form of a sheet) , styrofoam and expanded metal will be located on the support structure.
• the laminate of the aforementioned type will preferably be constructed off-site and delivered on-site for installation.
• the laminate will be provided in the form of panels of pre-ordained sizes according to the overall design for the structure.
• the panels thus provided may then be affixed to the frame structure in any known manner, as for example by pinning, tieing etc.
• the laminate, in the form of panels is placed on the underside of the mesh and tied into the reinforcement.
• Such a structure provides the support frame or formwork required to hold the ferro-cement fibrecrete or other cementitious material, and also is responsible for satisfying the other performance characteristics.
• the mesh is completely impregnated with mortar, preferably of a 2:1 sand/cement ratio.
• the cement is densely compacted with the reinforcement using any known means.
• the resulting ferro-cement structure is highly crack resistant and has been found to be capable of with- standing great pressures.
• the ferro-cement structure formed may be cured in any known manner, whereby to prevent excessive drying out. In an especially preferred embodiment such curing will be facilitated by the use of wet hessian and suitable misting sprays.
• the ferro-cement can be, in effect, keyed into the concrete slab, as for example by having the lowermost edge thereof adapted to be located in a step or the like provided in the slab.
• electrical conduits and the like may be pulled through pre-conceived blockout points in the ferro-cement layer.
• an appropriate surface finishing material as for example plaster, lathe or the like, may then be located internally of the struc- ture.
• the internal walls for the structure may be of any known or conventional material, as for example concrete block, brick, timber, stud wall and plaster or the like dependent upon the nature of the internal finish required for the structure, in turn of course dependent on the intended usage for the structure.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Laminated Bodies (AREA)
• Building Environments (AREA)

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Citations (6)

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• 1985
  • 1985-03-05 EP EP19850901297 patent/EP0173719A4/fr not_active Withdrawn
  • 1985-03-05 WO PCT/AU1985/000038 patent/WO1985003967A1/fr not_active Ceased

Patent Citations (6)

Non-Patent Citations (1)

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