WO2016085324A1

WO2016085324A1 - Light weight wall structure

Info

Publication number: WO2016085324A1
Application number: PCT/MY2015/050092
Authority: WO
Inventors: Tee SING HUAT
Original assignee: Ari Utara Sdn. Bhd.
Priority date: 2014-11-28
Filing date: 2015-08-24
Publication date: 2016-06-02
Also published as: MY160852A; PH12017500947B1; PH12017500947A1; ZA201703606B

Abstract

The present invention related to a wall structure for a buildings, comprising; a framework consisting of rectangular sections formed by four inter-engaging flat-sided channel members (101,102,103) having elongate slots extending lengthwise along their base and surrounding a concrete slab; and an expanded metal sheet (104) attached to the sides of the channel members (101,102,103) on each side of the framework and partial embedded in the concrete slab on each side thereof and rendered surface on at least one side of the concrete slab.

Description

LIGHT WEIGHT WALL STRUCTURE

FIELD OF INVENTION The present invention relates to a to solid and rigid wall structure for buildings by using a lightweight steel structure.

BACKGROUND ART In Malaysia, lightweight steel structure had been widely used on trusses for commercial and residential buildings, but not for wall system. Currently lightweight steel structure on wall system are mainly focus on dry wall system where still some skill worker to install. It is an objective to overcome the weakness of the existing lightweight steel structure building and solve the technical problems by providing the novel lightweight steel structure having the double layer of structural mesh which is convenient install on site, more reasonable design and more stable wall structure so as to more suitable for practical applications.

It is another objective to solve the technical problem by providing novel lightweight steel structure to connect a various components and eliminate accumulated errors during the installation work.

SUMMARY OF INVENTION

One aspect of the present invention provides a wall structure for a buildings, comprising; a framework consisting of rectangular sections formed by four inter-engaging flat-sided channel members having elongate slots extending lengthwise along their base and surrounding a concrete slab; and an expanded metal sheet attached to the sides of the channel members on each side of the framework and partial embedded in the concrete slab on each side thereof and rendered surface on at least one side of the concrete slab.

Preferably, the wall structure further includes a plastering means to rendered surface on at least one side of the concrete slab.

Preferably, the channel members are a light-weight steel.

Preferably, the channel members have holes for positioning and connection the expanded metal sheet.

Further, the expanded metal sheet comprising at least one stiffened rib running along the expanded metal sheet.

Preferably, the channel member having pluralities of aperture for positioning and connection with the other channel member. Another aspect of the present invention provides a method for forming a wall structure, comprising steps of: assembling a framework consisting of rectangular sections formed by four inter-engaging flat-sided channel members having elongate slots extending lengthwise along their base; attaching expanded metal sheet to the sides of the channel members on each side of the framework; filling the cavity bounded by the bases of four channel members and the expanded metal sheet with a concrete fluid of consistency such that it can be introduced into the cavity through the slots on a side of a section of the framework without flowing freely through the apertures of the expanded metal sheet; and allowing the concrete to set and rendering at least one surface of the concrete structure thus formed.

Preferably, the method for forming a wall structure, further comprising steps of rendering the surface of the concrete structure using a plastering means.

Further, the method for forming a wall structure, comprising steps of interconnecting the concrete structure with another concrete structure using at least one connection means.

A further aspect of the present invention provides method for erecting a building using the wall-forming method, comprising steps of: assembling a framework consisting of rectangular sections formed by four inter-engaging flat-sided channel members having elongate slots extending lengthwise along their base; attaching expanded metal sheet to the sides of the channel members on each side of the framework; filling the cavity bounded by the bases of four channel members and the expanded metal sheet with a concrete fluid of consistency such that it can be introduced into the cavity through the slots on a side of a section of the framework without flowing freely through the apertures of the expanded metal sheet; and allowing the concrete to set and rendering at least one surface of the concrete structure thus formed.

The present invention consists of features and a combination of parts hereinafter fully described and illustrated in the accompanying drawings, it being understood that various changes in the details may be made without departing from the scope of the invention or sacrificing any of the advantages of the present invention. BRIEF DESCRIPTION OF PREFERRED EMBODIMENT

To further clarify various aspects of some embodiments of the present invention, a more particular description of the invention will be rendered by references to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the accompanying drawings in which:

Figure 1 illustrates the architecture of the lightweight steel structure.

Figure 2 illustrates the interconnection of wall structure using the wall-forming method for a building.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to concrete-steel structure specifically related to wall structure for buildings using stiffened metal mesh supported by a framework of steel channel members.

The use the lightweight steel structure with concrete wall to replace convention walls such as dry wall. The configuration and assembly method of lightweight steel for buildings has great effects on the quality and construction work, especially for wall. The main support components of the wall frame/structure system; such as cold rolling steel having the thickness of 0.55mm -1 .5mm with pre-punch holes and structural mesh (rib lath) of 0.35mm - 0.50mm The pre-punch holes of C section or purlins will allow the concrete or mortar flow better to both sides and provides better performance on strength of wall.

The lightweight wall system is build to be user friendly installation. Furthermore, the wall construction will be systematic, eco friendly, it does not contain any timber products, therefore it's easy to handle in terms of delivery or logistic, and requires less manpower. The wall system has a solid & rigid wall with security feature as both side cover by structural mesh and in between had c-section. The wall system has less hair crack line as rib lath is the best materials for wall surface.

The design of lightweight steel structure with maximum 600mm spacing able to act as a load bearing wall. This present wall system is designed based on maximum 300mm width to apply with structural mesh having plurality of stiffened steel along the structural mesh (rib mesh) and fill in with concrete or mortar to perform better performance compare with conventional brick work or dry wall. Furthermore, the wall system does not need the use mobile crane for building the wall system. The lightweight steel structure having the double layer of structural mesh makes it convenient to be installed on site, able to have more reasonable design and more stable wall structure for practical applications. It further able to connect a various components and eliminate accumulated errors that accrued during the installation work.

The cold formed light gauge steel comprises of C shape, U shape & rib mesh cold formed light gauge steels. The C & U shape comes with holes positioning and connection are provided therein through the fixing components.

As illustrated in Figure 1 , the lightweight wall structure is made from plurality of lightweight steel structure (101 , 102,103) connected to a structural mesh member (104) using a plug, screw, nail, bolt or any other means of connection (105) to a wall or another steel structure. The C-section channel member (101 ) is connected or secured to another C-section channel member (102) to form one horizontal beam and vertical beam, in which a structural mesh (104) or steel encasement stiffened by rigid ribs is attached or secured to at least one part of the C-section channel (101 , 102). Another vertical C-section channel member could be added or secured in parallel spaced apart to the first C-section channel member (101 ) along the horizontal beam (102) sandwiched between the structural mesh (104) to form a wall structure. The lightweight steel structure made of C-section channel members and structural mesh (104) are assembled in such a way that the structure able to receive a concrete or cement mixture. The concrete is poured into the sandwiched structural mesh, in which the mesh would attach to the concrete to form a rigid wall. The structural mesh has mesh opening of sized 3/4", 1/2", 1 ", 1/4", 3/8" inch or sized 2mm - 10mm so that the poured concrete can be contained within the sandwiched wall structure. The outer layer of the structural mesh will be the plastered or applied with a plasterwork which it would attach to the concrete and structural mesh to form a layer of plaster on an exterior wall structure. As illustrated in Figure 2, the lightweight steel structure wall system comprise as beam and column, wherein the bracing and rib mesh is provided for reinforce the stability. The wall system further comprises with wall studs (204), one end of the wall (205) is connected with the other wall (206) by using fitting components. The fitting components or the studs fitting components are selected from bolts and self tapping screws. The structural wall is well positioning through the fitting components at pre-punch hole on C shape & U shape or two L-shapes, has an advantageous structure and the stability of structure is increased, the connecting work of the members of the lightweight steel structure is simplified, the accumulated errors during the installation are eliminated, and the strength of the structure is reinforced. The wall joint 1 (201 ) illustrates "T" junction connection using one channel member for one wall and another channel member from another wall to form a "T" junction wall. The wall joint 2 (202) illustrates another alternative "T" junction connection which includes one channel member from one wall (206) intersecting another two channel member of different walls (205,208). The wall joint 3 (203) illustrates the "L" shaped wall connection using one channel member for one wall and another channel member from another wall. Therefore, the problem of accumulated errors during the installation of walling is eliminated, better strength, solid and even surface wall and less cracking line of the wall. The lightweight steel structure wall system with rib mesh hold high density and solid wall so that the structure wall as to be more suitable for practical application. In additional to building, the lightweight steel structure walling system can be used in all kind of housing, fencing and security wall.

The present invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore indicated by the appended claims rather than by the foregoing description. All changes, which come within the meaning and range of equivalency of the claims, are to be embraced within their scope.

Claims

1 . A wall structure for a buildings, comprising;

a framework consisting of rectangular sections formed by four inter- engaging flat-sided channel members (101 ,102,103) having elongate slots extending lengthwise along their base and surrounding a concrete slab; and an expanded metal sheet (104) attached to the sides of the channel members (101 ,102,103) on each side of the framework and partial embedded in the concrete slab on each side thereof and rendered surface on at least one side of the concrete slab.

2. A wall structure according to claim 1 , further includes a plastering means to rendered surface on at least one side of the concrete slab.

3. A wall structure according to any one of the preceding claims, wherein the channel members (101 ,102,103) are a light-weight steel.

4. A wall structure according to any one of the preceding claims, wherein the channel members (101 ,102, 103) have holes for positioning and connection the expanded metal sheet.

5. A wall structure according to according to any one of the preceding claims, wherein the expanded metal sheet further comprising at least one stiffened rib running along the expanded metal sheet.

6. A wall structure according to any one of the preceding claims, wherein the channel members (101 ,102,103) having pluralities of aperture for positioning and connection with the other channel member.

7. A method for forming a wall structure, comprising steps of: assembling a framework consisting of rectangular sections formed by four inter-engaging flat-sided channel members (101 ,102,103) having elongate slots extending lengthwise along their base;

attaching expanded metal sheet (104) to the sides of the channel members on each side of the framework;

filling the cavity bounded by the bases of four channel members (101 ,102,103) and the expanded metal sheet (104) with a concrete fluid of consistency such that it can be introduced into the cavity through the slots on a side of a section of the framework without flowing freely through the apertures of the expanded metal sheet (104); and

allowing the concrete to set and rendering at least one surface of the concrete structure thus formed.

8. A method for forming a wall according to claim 7, further comprising steps of rendering the surface of the concrete structure using a plastering means.

9. A method for forming a wall according to any one of the preceding claims, further comprising steps of interconnecting the concrete structure with another the concrete structure using at least one connection means.

10. A method for erecting a building using the wall-forming method according to claim 7.