AU2011250644A1

AU2011250644A1 - Elongate building panel improvement

Info

Publication number: AU2011250644A1
Application number: AU2011250644A
Authority: AU
Inventors: George Milatos
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-05-05
Filing date: 2011-04-15
Publication date: 2014-02-20
Also published as: WO2011137478A1

Abstract

A panel and structure for buildings where a plurality of elongate panels of sheet metal are joined together side by side providing on one side a finished face and on an opposite side support for cladding. Such structure is useful for walls, floors and ceilings and provides for economic construction. There are inter engaging shapes between the sides which assists alignment between joined panels and assists resistance to water transfer between an outer and inner side of the structure.

Description

WO 2011/137478 PCT/AU2011/000440 1 ELONGATE BUILDING PANEL IMPROVEMENT FIELD OF THE INVENTION This invention relates to a building improvement and in particular to a panel, a construction using lightweight panels and a method of construction. 5 BACKGROUND OF THE INVENTION It is known to construct buildings with timber or steel frame walls where typically a builder will purchase lengths of material required, cut this to size and then build the framed wall in sections, either on site or in factory using a jig table. Each frame section can be anything from 3 metres to 6 metres or longer and 10 between 2 to 3 metres high and they are implicitly therefore quite heavy. Such construction therefore will require a number of persons to assist in erecting such frames or otherwise hire of a crane which is expensive. After wall frames have been built, balanced and levelled, one then needs to construct the roof, often this being built with timber rafters or steel trusses 15 following on with steel bracing, roof battens and ceiling battens, metal facias which become very complicated, require people who will be acrobatic almost in their physical abilities, and this means that this can be quite time consuming, possibly dangerous and equivalently expensive. Typically, a team of least 4 men to build a three bedroom domestic house which 20 can withstand a cyclone, will take as much as 15 or more days simply erecting the framework and not including external cladding. OBJECT OF THIS INVENTION It is an object of this invention to provide both a panel in one case, a building construction method in another as well as a building so constructed that will WO 2011/137478 PCT/AU2011/000440 2 result in efficiencies both in terms of components as well as a reduction in the number of people that might be required to construct the building and at the least, it will provide the public with a useful alternative. BRIEF DESCRIPTION OF THE INVENTION 5 The invention can be said to reside in the provision of an elongate panel formed from sheet metal which has a face portion on one side, side walls extending from each side of the face portion with each of the side walls ending at a common distance from the face portion with an inwardly extending portion. The depth of each side portion is chosen for the application so that a wall can 10 be constructed using a plurality of such panels skewered side by side with therefore adjoining side portions secured together. Further however, the width of the face portion can be also chosen to be appropriate for its application but in the case of a wall, it can be a width that is appropriate for matching or conventional unit sizes for instance the width of a 15 conventional door in a building, the width of a window pane, bench in'a building and the like. To this end, a width of approximately 450mm is found to be very convenient. The invention then could be said to reside in an assembly of a plurality of such panels held together in side by side adjoining relationship and having secured 20 to a rear side of such structure, appropriate cladding for the application. For an external wall then, the panel would provide the metal external surface providing a decorative outer protective surface, and inside or at the rearward side of the respective joined panels then, appropriate cladding such as plasterboard can be secured by appropriate fixing to the inwardly extending 25 rearward portions of each respective panel. The advantage of this arrangement is that each assembly is constituted by a plurality of relatively lightweight but nonetheless relatively strong panels which WO 2011/137478 PCT/AU2011/000440 3 can be then joined in situ by conventional fixing means which could be as an example well known tek screws. It would be appropriate then to have the assembly with each of the panels of elongate dimensions and having a consistent and constant size and shape 5 substantially along its full length so that it could be made from pressed metal or it could be roll formed which is known to be an economic and efficient system for forming such panels. If each of the panels is then aligned vertically, this would then provide for an assembly constituting the side wall of a building. 10 In a further instance however, a panel of like kind can be used for a floor. Again, the advantage is relatively lightweight in respect of each individual panel being able to be handled in most cases by a single person and that they can be assembled and joined together in adjoining relationships in situ makes it a very attractive arrangement. 15 In this case, in preference there is provided that each panel has its face lower most so that a flooring material is secured to the rearward inwardly directed portions of each respective panel. The advantage of this arrangement is that apart from its construction providing for a very strong wall and the ability to provide utility services by passing pipes 20 or wires either along each panel or through the respective sides of respective panels by having appropriate apertures therein, is that there is presented a lower most face which of itself can be appropriate for totally sealing the floor from influence from the underneath side but it- can also provide a ceiling in the event that the floor structure is used as an elevated floor where a further 25 building or room or structure can be erected beneath the floor. In a further application, a panel of like kind can be used for a ceiling. This can be achieved by having the front face of each panel lower most and roofing WO 2011/137478 PCT/AU2011/000440 4 materials attached to the rearward side in other words the inwardly directed portions of the respective joined together panels. One of the issues that could be of concern using panels in such a way is that .respective adjoining sides for instance where they form portion of a- wall, would 5 attract and allow water seepage there between. To this end there is provided in preference an interrupting space. This can be provided by different shapes in each respective side wall but in preference, there is provided an interlocking shape where one portion provides a female shape and the other portion provides a male shape which assists in 10 maintaining alignment of the respective panels in side by side positions and by, in at least one preferred case, not having such interlocking shapes closely nesting, this allows for a water break which assists in maintaining a water seal between respective sides of an assembly formed by these panels. It is generally known to provide corrugations or other deforming shapes in a 15 metal face for purposes of strengthening and stiffening such metal surfaces and to the extent that is appropriate, it is anticipated that each of these panels also will have some form of further shaping to assist in the strength and stiffness of the respective face. In one form of the 'invention then although this need not necessarily be the only 20 or indeed the -broadest form of this, there is proposed a building panel comprised of a sheet of metal, formed to be of elongate dimensions and having at least a substantially constant cross-sectional shape and size along its elongate length, the panel having a front portion, side portions extending rearwardly from each respective side edge of the front portion, the rear portion 25 from each respective side portion extending inwardly from a read edge of the respective side portions, the respective side portions each being the same distance from the front face.

WO 2011/137478 PCT/AU2011/000440 5 In preference, a first of the side portions has at least one outwardly projecting portion, and the second of the side parts has at least one end of the projecting portion, the position and size and shape of the at least one outwardly projecting portion or portions being such that the respective side portion will nest co 5 operatively with the inwardly projecting portion of a second building panel which is the same as this first said building panel when positioned to be in a joining relationship with the said first building panel with a front face that is substantially coplanar with the front face of said first building panel. In a further form of this invention it could be said to reside in a combination of a 10 first building panel as above and a second building panel as above joined together in side by side relationship with respective male and female portions inter-engaging and being held together by respective fastenings through the respective adjoining side portions. In a further-form the invention could be said to reside in a wall for a building 15 including a plurality of elongate panels as above, each having a substantially planarface on one side, side portions extending rearwardly a common distance from the front fact, and each having an inwardly directed portion to which there is secured an appropriate cladding material. In a further form, the invention could be said to reside in a floor of a building 20 constituted by a plurality of panels adjoined in side by side relationship as in any one of the above statements where there is provided that the front facing in each case is lowermost and there is a flooring material positioned and secured with a respective inwardly directed portions. In another form, the invention could be said to reside in a ceiling constituted by 25 a plurality of elongate panels as in any one of the above statements where the front face portion is lowermost and defines a substantially planar ceiling where each of the panels is joined with like panels by having side portions adjoining one another and affixed together and appropriate insulation and roofing material being affixed above the panels thus joined.

WO 2011/137478 PCT/AU2011/000440 6 The invention could be also said to reside in a method of constructing building which comprises joining together a plurality of elongate panels each of a common width and depth each having a front face, two rearwardly extending portions and at a rearward edge, inwardly extending portions which provide a 5 fixing surface substantially parallel to a front face respective panel, the method including joining such respective panels together to form a structure appropriate for a selected one of the aspects of the building namely floor, a wall or a ceiling. The invention could also be said to reside in a combination of a building having at least one of its walls, floor or ceiling constructed in accordance with the said 10 method or using panels joined together and being of a shape as previously described. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of this invention it will now be described with reference to embodiments which shall be described with the assistance of i5 drawings wherein; Figure 1 is a perspective view of the end Of a panel according to- a first embodiment, Figure 2 illustrates the same embodiment as in Figure 1 this being a perspective view where there are a plurality of such panels joined together form 20 an assembly, Figure 3 is a perspective view of an end of a further panel according to a second embodiment, Figure 4 is a perspective view of the same panel providing an assemblage, WO 2011/137478 PCT/AU2011/000440 7 Figure 5 shows a side elevation of a detail of a building using in one case the panels of the first embodiment for a side wall and the panels of the first embodiment to provide support for a floor, Figure 6 is now a detail of a building using the panels of the first embodiment for 5 a wall, and the panels of the first embodiment for a ceiling supporting roofing, Figure 7 is another detail of a building incorporating in this case a wall using panels of the first embodiment, and a roofing support structure resting on the panels providing the wall in a load bearing arrangement providing a ceiling and providing support for insulation and roofing, 10 Figure 8 is another detail showing a verandah assemblage where the flooring and support structure is provided by a panel according to the first embodiment there is provided support for a barricade, Figure 9 shows in some detail regarding the use of the roof and supported structure using the first embodiment, 15 Figure 10 is further detail showing the roof structure supported by panels of the first embodiment, Figure 11 is the further detail showing the ridge structure where panels according to the first embodiment are brought together end to end protected by a ridge cap, 20 Figure 12 is further detail showing how a window can be fitted between adjoining vertically aligned panels providing a wall for a building in this case there being provided the panels according to the second embodiment, Figure 13 is the further detail showing flooring structure using the panels of the first embodiment, WO 2011/137478 PCT/AU2011/000440 8 Figure 14 is an elevation of a completed building constructed in accordance with the described method using panels appropriate for the floor, walls and ceiling, Figure 15 is a view from above of the completed structure as in Figure 14 with 5 part cut away illustrating some of the detail of the respective panels joined in side by side relationship, and Figure 16 is a detail cross sectional view of the interengaging shape of a respective embodiment shown. An advantage of the invention is that it can provide for substantially all or most 10 of the structure of a building using relatively lightweight individual panels which when collectively joined together can nonetheless provide a very strong structure in fact suitable for a cyclonic circumstance where both the erection costs and the complication of the construction are kept relatively simple. Also each panel is relatively light in weight so that construction will not normally 15 require more that several people or even a crane. Tests conducted thus far have shown that the structure indeed is very strong and flexible indeed and would provide a very appropriate and economic structure suitable for consideration for cyclonic areas. It is intended that the application would be appropriate for merely two people 20 with relatively basic experience to.build their own house to a point of lock-up by following relatively straightforward instructions. While the concept is to provide a simple elongate panel and structure, the general concept can be varied. In this particular application, the panels in each case are intended to be roll 25 formed which is to say cold rolled from 1.2mm thick 5OOg sheet metal in either plain zinc alum or using another coating protective such as that sold under the WO 2011/137478 PCT/AU2011/000440 9 trade mark Colourbond. In order to match conventional measurements, each panel is chosen to be 100mm deep, 450mm width and the length can be chosen appropriate to the application. Because of the implicit strength of such a construction, significant lengths can 5 be used and provide a self-supporting structure. Because some applications involve exposure to the outside elements, one issue is that joint to joint surfaces will attract moisture and could in fact induce water seeping through the joints through another side and to some extent contaminate vulnerable coating surfaces. 10 To that end then, we have provided a water trap and this also provides assistance in alignment and joining especially for those who might be less skilled. DETAILED DESCRIPTION OF THE INVENTION Referring specifically to Figures 1 and 2 therefore, the panel (1) front face (2) 15 with rearwardly extending side portions (3) and (4) which each have a common distance away from the front (2) wherein they have inwardly extending portions (5) and (6). These inwardly extending portions (5) and (6) provide a parallel face to generally the general planar alignment of the front face (2). Also, these inwardly extending portions (5) and (6) are of a width that will allow 20 for use to secure other materials thereto such as flooring in the one case or plasterboard in another as in example using appropriate attachment that uses such things as tek screws. Alignment and water trap aspect is provided by conventionally interlocking shapes at (7) and (8). 25 One of these (7) is a mate ended to protrude into:a cavity defined by female shape as shown at (8) in a like panel.

WO 2011/137478 PCT/AU2011/000440 10 It will be noticeable that the size of the male shape is slightly less than the available cavity with the female shape (8) which is to allow for the water retaining gap. A central trough (9) front face (2) provides some stiffening as does a rounding 5 of corners at (7) again provide for further stiffening. When reference is made therefore to a planar surface in relation to a front face, it assumes that this is defined by a major portion of the material and incidental strengthening shapes may be disregarded in this sense. Figure 2 shows how the panel in (1) can be fitted one with respect to the other 1o in adjoining relationships so that the front face .(2) in each case are held together to have and define a common co-planar alignment. An aperture will extend through a side wall which tends to be typical of the apertures that- can be cut through the walls from time to time either in general manufacture or subsequently allow utilities to cross across panels. 15 Figure, 3is a second embodiment which can provide the same function as the first embodiment with the exception now that the panel has three troughs (13), (14) and (15) between these ridges (16) and (17). The ridges in this case provide a relatively planar surface and the overall shape here can be selected as an alternative shape to that shown in Figure 1. 20 The troughs and ridges again form the purpose of providing stiffening and here again we have side portions (18) extending rearwardly from front face each a common distance away from the face defined in this case by the ridges. Once again there is a protruding shape set within the side wall (19) protruding from the side wall (18).

WO 2011/137478 PCT/AU2011/000440 11 The example now is showing co-operative alignment with like panels in Figure 4. We now look at actual ways in which the panel has been used in actual examples in relation to a building. 5 Figure 5 shows for instance side wall (30) which is comprised of a plurality of panels according to the first embodiment each joined one to the other as shown in Figure 2 aligned to extend vertically on a elongate bracket (31). This bracket (31) acts as a flashing passing from portion (32), (33) across beneath the panel to close an end at (34). 10 The flooring (36) is comprised of a plurality of joined together side by side panels as in Figure 1 which rest on joist (37) which in turn is supported by a stud (38) which is supported by a concrete foundation (39). The panels in the flooring (36) have their planar surface lower most at (40) but the flooring which comprises manufactured chipboard (41) is attached at 15 appropriate locations through metal engaging screws such as tek-screws. A skirting board (42) is used to cover a joint of the wall (30). Figure 6 shows a wall (30) comprised of vertically aligned panels according to the first embodiment with the inner plasterboard cladding at (32) supporting at its upper end a bracket (3) which is joined again by simple joining techniques to 20 a ceiling construction which also provides a structural support for both the ceiling and a roofing structure at (44). Incidentally, appropriate insulation such as aircell sarking insulation (45) this is also used in the ceiling roof assemblage at (46). The assemblage providing the ceiling and roof support is- shown at (47) 25 comprises a plurality of the panels as in Figure 1 joined together by side by side WO 2011/137478 PCT/AU2011/000440 12 joining means above this where the base is lower most, the inwardly projecting portions used to secure the port (48) with corrugated steel roofing in this case. An alternative view of the arrangement as in Figure 6 is shown in Figure 7 where we now have an end on view particularly of the roofing ceiling structure. 5 Figure 8 shows veranda and flooring detail this being generally shown at (49). Appropriate structural members at (52) attach to structural member (53) for a barricade at (50). An end detail on the roof is shown in Figure 9 and 10 with corrugated roofing (60) supported over insulation- (61) structurally supported by panels (62) shown. 1o Further capping (65) provides cover of male edging side portion (8) further detail in the roofing (10) is a further end cap (66). With a pitched roof, the arrangement can include a ridge the detail of which is shown in Figure 11 Where two sets of assembly of panels are shown in this case at (70) in one case and (7-1) in the other which are joined to support 15 bracket (72), a ridge capping (73) being positioned above ridge alignments of the corrugated roofing material at (74) and (75) butting together panels (70) and (71) and (76). Figure 12, there is some window-detailing showing a window frame at (80) glass at (81) at each side edge capping to (83), with panel (84) on one side and 20 (85) on the other. In this case, the panel 83 and 84 are the second embodiment. One of the aspects of this arrangement is that the width of each panel is chosen to be of modular width which means that it will fit without modification and generally other elements, such as doors and windows that have generally 25 standard shapes and sizes.

WO 2011/137478 PCT/AU2011/000440 13 In this case, a width of 450mm has been selected and has shown itself to be a good size for this application. The invention is not intended to be limited to a single unitary size but an aspect of the invention is that it can provide as a single panel a unit that can be 5 comfortably lifted by a single person or at most two people and it can be fixed relatively easily to provide many deep legs which is to say the adjoining sides which provide significant strength and rigidity. We would envisage therefore that one would not wish to have widths less than say 250mm and one would generally not wish to have wider than 600mm as 1o desirable constraints and in preference the size range would be between 400mm to 500mm and of course preferably lie within the close to 450mm range. The depth of the side portions is determined by the desirable depth of the wall between an outer face and an inner face and this has been chosen to be 100mm in this case but again it is not intended that this should be limited and it 15 could of course be made deeper or narrower it could in one case be as much as 150mm or more or as little as 75mm or less. In preference then it lies within the range of 75mm to 150mm, preference is 100mm. An advantage of the arrangement is that relatively lightweight steel can be used 20 and to this extent, 1.5mm has been chosen but it could lie with the range of 0.8mm to 2.00mm thickness although in preference it should lie within the range of 1.0mm to 2.00mm but 1.5mm of course in preference. Figure 13 is a further illustration of how assemblage of panels flooring as supported by a structure such as at (91) used in conjunction with steps at (92) 25 and flooring at (93).

WO 2011/137478 PCT/AU2011/000440 14 In Figure 14 there is a side view of a house constructed using the techniques described from which it will be seen that very appropriate construction can be achieved using the techniques described. As can be seen there are many vertically aligned faces at (6) of side walls and in this case there is a lower 5 structure at (97) and a floor with a lower face (98). Looking from above at Figure 15 there is a conventional corrugated roofing at (100) which is schematically removed to show the roof and ceiling structure (101) and showing some detail of side walls (102). Figure 16 illustrates in slightly larger detail cross sectional view of the 10 iiterengaging shape with the addition in this case of a resilient seal (103).

Claims

1. A building panel comprised of a sheet of metal, formed to be of elongate dimensions and having at least a substantially constant cross-sectional shape and size along its elongate length, the panel having a front portion, side portions 5 extending rearwardly from each respective side edge of the front portion, the rear portion from each respective side portion extending inwardly from a rear edge of the respective side portions, the respective side portions each being the same distance from the front face.

2. A building panel as in the immediately preceding claim further comprised 10 in that a first of the side portions has at least one outwardly projecting portion, and the second of the side parts has at least one end of the projecting portion, the position and size and shape of the at least one outwardly projecting portion or portions being such that the respective side portion will nest co-operatively with the inwardly projecting portion of a second building panel which is the 15 same as this first said building panel when positioned to be in a joining relationship with the said first building panel with a front face that is substantially coplanar with the-front face of said first building panel.

3. A structure having in combination a first building panel as in claim 2 of the preceding claims and a second building panel as in claim 2 of the preceding 20 claims joined together in side by side relationship with respective male and female portions inter-engaging and being held together by respective fastenings through the respective adjoining side portions.

4. A wall for a building including a structure as in preceding claim 3, each panel having a substantially planar face on one side, side portions extending 25 rearwardly a common distance from the front fact, and each having an inwardly directed portion to which there is secured an appropriate sheet of cladding material. WO 2011/137478 PCT/AU2011/000440 16

5. A floor of a building including a structure as in preceding claim 3 where there is provided that the front facing of each panel of the structure is lowermost and there is a flooring material positioned and secured to respective inwardly directed portions. 5

6. A ceiling of a building including a structure as in preceding claim 3 where there is provided for each panel a panel where the front face portion is lowermost and defines a substantially planar ceiling where each of the panels is joined with like panels by having side portions adjoining one another and affixed together and appropriate insulation and roofing material being affixed above the 10 panels thus joined.

7. A method of constructing a building which comprises joining together a plurality of elongate panels each of the same width and depth each having a front face, two rearwardly extending portions and at a rearward edge, inwardly extending portions which provide a fixing surface substantially parallel to a-front 15 face respective panel, there method including joining such respective panels together to form a structure appropriate for a selected one of the aspects of the building namely floor, a wall or a ceiling.

8. A combination of a building having at least one of its walls, floor or ceiling constructed in accordance-with the said method or using panels joined together 20 and being of a shape as previously described.

9. A panel as in either one of claims 1 or 2 having a width within the range of 250mm to 600mm, a depth of the side portions within the range of 150mm to 75mm and each panel being comprised of sheet metal having a thickness within the range of 0.8mm to 2.00mm. 25

10. A building structure including an assembly of at least two panels each of the panels being comnprised of sheet metal of substantially the same cross sectional shape along its length, each panel having a face portion, side walls extending from each side of the face portion and each of the side walls ending WO 2011/137478 PCT/AU2011/000440 17 at the same distance from the face portion with an inwardly extending portion, the panels being held together in side by side adjoining relationship by fasteners between the two sides, with respective face portions defining and being coincident with a common plane, and having secured to a rear side of 5 such structure, appropriate cladding for the application.

11. A building structure as in the immediately preceding claim where the respective panels have matching interengaging portions in their sides with a sealing material between the interengaging portions.