AU2004203553B2 - Wall panel installation apparatus and method - Google Patents

Description

Title Wall Panel Installation Apparatus and Method Field of the Invention The invention relates to a method and apparatus for installing wall panels. This invention particularly although not exclusively relates to a method and apparatus for installing external wall panels in multistorey buildings, and for illustrative purposes this invention will be described with reference to this application. However, it is envisaged that this invention will find other applications where relatively large and/or heavy panels are to be erected from a horizontal to a vertical position, such as bulkheads and flat-assembled building framework.

Background Art Fagade wall panels have been used in the building industry for a number of years. The panels provide for rapid construction of the fagade of a building by installing fagade wall panels with the assistance of a crane. Traditionally the fagade wall panels are installed by overhead crane lifting the panel from outside the building, the fagade wall panel being produced on the preinstalled floor and lifted from its upper edge. In order to bring the panel from the horizontal floor to its vertical, installed position, it is usual for a large number of labourers to guide the panel outward while supporting the lower edge of the panel. As the panels are large and heavy, the task of installing the panels is fraught occupational health and safety issues relevant to the well-being of labourers and the public.

These issues include the fact that current practice for installing the panelling requires the removal of safety handrails. Before the rails are removed the installers must put in place a series of safety lines, which are attached to harnesses worn by labourers. This process is time consuming and causes delays in installation. Once the lines are in place, the installers can remove the safety rails and commence installation. The panels are typically manually moved into a lifting position where the lifting crane can take up the load at the top edge of the panel. This is usually done either by physically lifting and carrying the panel or using rollers (such as a skate boards) placed under the -2edges of the panel which then can be wheeled to the lifting position where the rollers are then removed.

Once in the lifting position the leading end of the panel is then attached to a lifting mechanism such as a crane, jib, hoist or the like. The panel is then mechanically lifted from floor level into a vertical position. One problem with this form of lifting is that the lines or chains used to attach the panel to the lifting mechanism can snag or catch on the overhanging ledge created by the flooring of the next story. Furthermore, once the panel is vertical its entire weight is supported by the hoist alone; this makes the panels difficult to manoeuvre, as they are prone to environmental effects such as wind shear, which causes the panel to sway which may result in damage or injury.

The panel is then secured into position and the time consuming process of installing safety lines and removing the handrails is repeated for each panel to be installed.

Accordingly it would be advantageous to provide a method and apparatus which ameliorates at least one of the foregoing disadvantages and provides a safe and convenient way of installing wall facade panels into position in a building.

Summary of the Invention In one aspect of the present invention there is provided panel installation apparatus including: an undercarriage; a substantially horizontal panel support spaced above and having a leading portion extending beyond the plan of said undercarriage; a movable support adapted to engage the lower edge of a panel supported on said panel support and movable thereon from a trailing position on said panel support to said leading portion.

In another aspect of the present invention there is provided a method for installing wall panels including the steps of: supporting a wall panel on a panel installation apparatus including an undercarriage, a substantially horizontal panel support spaced above and having a leading portion extending beyond the plan of said undercarriage; -3locating the lower edge of said panel on a movable support movable on said panel support from a trailing position to said leading portion; manoeuvring the panel installation apparatus whereby the top edge of said panel is engageable by a lifting device and said leading portion extends beyond the plan installed position of said panel; lifting the panel top edge with said lifting device whereby the panel lower edge moves on said movable support towards said leading portion until the panel is vertical and the panel lower edge lifts clear of the movable support; and removing the installation apparatus, and securing panel into the required position.

The panel installation apparatus may be constructed substantially from steel or aluminium, but may also be constructed from any other material, which will support the weight of a wall panel. The supporting surfaces may comprise a material selected to minimize damage to the panels. The carriage may be constructed from a material and to a design that provides sufficient weight distributed to counteract the bending moments and shear forces involved in the lifting operation. Alternatively, the carriage may be constructed to allow the use of counter weights to counteract the bending moments and shear forces which may act on the apparatus.

The panel installation apparatus may be designed such that it can be readily dismantled into constituent parts or it may be a collapsible unit designed to be folded away for easy storage and transportation.

The undercarriage may include a transport means such as, a set of wheels. Alternatively the transport means may include a set of castors, roller, sleds, slides, tracks or the like such that it provides sufficient manoeuvrability for the panel installation apparatus. The undercarriage may optionally be fitted with a braking mechanism to prevent unwanted movement of the undercarriage as might occur through slippage of the transport means during the lifting operation.

The panel support may be a composed of a singular body, such as a solid plate or one or more rail like members. Alternatively, the support may be defined by one or more latterly opposed members, such as a pair of laterally spaced rails or beams. Furthermore, the support may include a coating for one or more of the following, reducing friction between the support portion, the -4movable support and the panel, protecting the support portion and/or panels from damage.

The movable support may take any suitable form. For example, the movable support may include a trolley or cart, which runs along one or more rails, groves, kerfs, tracks or channels provided on the panel support. The movable support may finish substantially flush with the panel support's effective surface, but may alternatively be movable to sit proud of the panel support during the lifting operation. A stop may optionally be mounted on the panel support in order to prevent the movable support form travelling beyond a critical point. Alternatively, the trolley or cart may be tethered to the trailing end of the carriage to prevent movement of the cart beyond a critical point.

Preferably, the support portion is elevated to a predetermined height by a fixed frame. Alternatively, the support portion could be mounted on an adjustable frame allowing the level of elevation to be selectively varied. The frame may be a series of rails, braces webs or the like.

The lifting device may be a forklift, walky reach, monorail, floor crane, jib, hoist or any other such device capable of hoisting the wall panel.

Brief Details of the Drawings In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings illustrate preferred embodiments of the invention, and wherein: FIG. 1 is an illustration of one embodiment of the carriage; FIG. 2 illustrates one embodiment of the edge support member; FIG. 3a depicts one embodiment of the assembled installing apparatus; FIG. 3b illustrates another possible arrangement of installing the edge support in the assembled apparatus; FIG. 3c illustrates yet another embodiment arrangement of installing the edge support in the assembled apparatus; FIG. 4 is an illustration of the assembled embodiment of FIG. 3 showing the positioning of the panel; and FIGs. 5a to 5e depict the method of installing a wall panel in accordance with the present invention.

FIG. 6 is a detailed view of the panel undergoing the lifting operation Description of the Preferred Embodiments In reference to figure 1, there is illustrated the main portion of a panel installation apparatus The apparatus having a panel support which is elevated in this embodiment by an undercarriage composed of four vertical members (14) and bracing The undercarriage is mounted on a transport means, in this instance a set of wheels The panel support (11) is shown in this embodiment, as two parallel beams each having a channel The beams extend beyond the transport means (12) and the undercarriage (13) to form leading portion The apparatus may also employ a counter weight(s) (18) of suitable mass to counteract the bending moments and shear forces which may act on the apparatus. The counter weight (18) is fitted to the trailing portion of the under carriage In this instance the weight (18) is shown as a singular weight spanning the length of and suspended from the rear bracing strut via brackets However it is to be appreciated that the weight required to counteract the bending moments and shear forces may equally be provided as a series of weight mounted along or suspended from the trailing portion of the apparatus Figure 2 shows the movable support in the form of a rudimentary cart with rear lip rollers (22) and bed (23).

The rollers (22) permit the cart (20) along the channels (17) in response to a driving force. The driving force is created by frictional engagement between the panel and the cart bed during the lifting operation. This driving force urges the cart towards the leading portion The rear lip (21) is designed to prevent the panel from sliding off the rear of the cart, as the panel's angle of inclination of increases during the lifting process. The lip also assists in manoeuvring the panel into an upright position. As the panel and the cart near a critical point on the leading portion, the lip exserts a small force on the bottom edge of the panel (40) forcing the panel rest upon its bottom edge.

Figure 3a shows the fully assembled installation apparatus, cart (20) is positioned within the channels (17) of the panel support members The bed of the cart (23) is shown to sit proud of the panel support However, it is to be noted that in some instances the cart bed may indeed sit flush with the -6support portion. Alternatively the cart may be adjustable between flush and proud seated positions. This for example may be achieved by providing the cart with a jacking mechanism. Alternatively, a ramp may be used, the ramp being so designed that at the trailing edge of the apparatus the cart sits flush with the panel support. As the cart gradually moves along the ramp during the lifting process towards the leading portion it is forced to sit proud of the panel support.

In the particular embodiment shown in figure 3a, the cart runs between two channels but other various configurations are possible. Figure 3b illustrates one such alternative, in this instance the cart (20) runs on one or more rails The carts rollers (22) are arranged to actively grip the rail(s) Another possible alternative is depicted in figure 3c, in this instance a solid surface is used as the support portion. The cart is arranged to run along one or more groves whereby rollers (22) actively engage the under side of the solid support surface (33).

In the embodiment represented by figure 3a, the beams (11) may optionally be fitted with removable end caps. While the apparatus is in operation the caps prevent the cart from leaving the channels During storage of the apparatus, the caps are detached allowing the cart to be removed from the channels. In addition to their main function, the caps also provide a safety feature as they cover any sharp edges, which may be present on the ends of the beams.

In reference to figure 4, a wall panel is depicted positioned on the installation apparatus. The bottom edge (40) is positioned on the cart The top edge (41) and a substantial portion of the panel rest upon the panel support Once the panel is positioned on the apparatus, any additional work required to be done on the panel prior to installation, such as fixing sun hoods etc, may be performed.

Figures 5a to 5e depict one possible method of installing the wall panel in accordance with the present invention. Once the panel is positioned on the installation apparatus as shown in figure 4, it may then be moved to the installation area The top edge of the panel (41) is attached to a lifting device (52) such as a forklift, via lines The installation apparatus is then positioned such that the leading portion (16) of the panel support (11) extends -7over the safety rail (53) and beyond the panels installation point (54) as shown in figure Figure Sc depicts the first stage of the lifting operation. The top edge of the panel (41) is lifted off the panel support (11) by the lifting device As the panel's angle of inclination (55) increases, the cart (20) is force to move towards the leading portion A more detailed view of this stage of the lifting operation is illustrated in figure 6.

Once the cart (20) reaches the critical position on the leading portion, above the installation point (56) the panel is lifted clear, shown in figure 5d. The installation apparatus is then removed and the panel placed into position and secured, as shown in figure Se.

During the placement of the panel into its final position, the leading portion (16) may be used as a brace to steady the panel and reduce the effects of wind shear.

Figure 6 is depicts a detailed view of the lifting operation. As the lifting force p is applied by the lifting device via lines (51) to the top edge of the panel the angle of inclination 6 (55) increase. This results in a reactive force which acts as a driving force upon the cart This inturn causes the cart to move towards the leading portion Once the cart reaches the critical point on the leading portion the panel is forced to rest upon its bottom edge (41) by the carts rear lip At this instance, the weight of the panel momentarily rests upon the leading portion of the panel support At this point, the resultant force Ap form the weight of the panel creates the maximum amount of shear force which act upon the apparatus. Subsequently the apparatus must be sufficiently designed to counter balance this force. The force required to counter balance the apparatus A, is easily calculated using standard engineering principles and the following standard equations: 0 (1) SM" 0 (2) Where a is an arbitrary point on apparatus, F the forces about point a and M the resultant bending moment about a. In the drawn example, the shear force created by weight of the panel will force the trailing edge of the apparatus -8upward. Analysing the forces acting on the apparatus about the front leg reduces the calculation to a simple lever problem: F =0 0 -A, M, =0 0 A Pd1 Ad 2 A, d A d2 Where dl is the distance from the front leg of the carriage to the critical point and d2 is the distance front leg to the rear of the carriage. In general, the counter force Ac will be equal to the shear force of the panel Ap thus the required counter balancing force is proportional to the weight of the panel to be lifted.

It is to be understood that the above embodiments have been provided only by way of exemplification of this invention, and that further modifications and improvements thereto, as would be apparent to persons skilled in the relevant art, are deemed to fall within the broad scope and ambit of the present invention described herein.

Claims (24)

1. A wall panel installation apparatus said apparatus including: an undercarriage; Sa substantially horizontal panel support spaced above and having a leading portion extending beyond the plan of said undercarriage; and Sa movable support adapted to engage the lower edge of a panel supported on said panel support and movable thereon from a trailing position on said panel support c 10 to said leading portion.

2. The panel installation apparatus according to claim 1 wherein said undercarriage further includes a transport means.

3. The panel installation apparatus according to claim 2 wherein said transport means is selected form at least one of a set of castors, wheels, rollers, sleds, tracks, slides.

4. The panel installation apparatus according to claims 2 or 3 wherein said under carriage is fitted with a braking mechanism.

The panel installation apparatus according to any one of claims 1 to 4 wherein said movable support is either a trolley or cart.

6. The panel installation apparatus according claim 5 wherein said movable support runs along at least one rail, groove, kerf, track or channel provided on said panel support.

7. The panel installation apparatus according to any one of the preceding claims wherein the movable support sits proud of said panel support.

8. The panel installation apparatus according to any one of the preceding wherein said movable support is tethered to said installation apparatus at said trailing 00 O position so as to prevent the movement of said movable support beyond a critical point.

9. The panel installation apparatus according to any of claims 1 to 7 wherein said panel support is fitted with at least one stop to prevent movement of the movable support beyond a critical point.

The panel installation apparatus according to claim 9 wherein the at least one stop is position on the leading portion of said panel support.

11. The panel installation apparatus according to any one of the preceding wherein said panel support is defined by one or more laterally opposed members.

12. The panel installation apparatus according to claim 11 wherein said laterally opposed members are a pair of laterally spaced rails or beams.

13. The panel installation apparatus according any one of the preceding wherein said panel support is elevated above said undercarriage by a frame.

14. The panel installation apparatus according claim 13 wherein said frame is a series of rails, braces or webs.

The panel installation apparatus according 13 or 14 wherein said frame is adjustable allowing the level of elevation of said panel support above the undercarriage to be selectively varied.

16. The panel installation apparatus according to any one of the preceding claims wherein the panel support further includes a coating for either reducing the friction between the support portion, movable support and the panel, or protecting the support portion and/or panels from damage. 00 11 S

17. The panel installation apparatus according to any one of the preceding claims wherein the apparatus is substantially constructed from either steel, aluminium, timber or plastic composites.

18. The panel installation apparatus according to any one of the preceding claims Swherein said apparatus is constructed to allow the use of counter weights to counteract the bending moments and shear forces which act on the apparatus during 0installation of said panel. c 10

19. The panel installation apparatus according one of the preceding wherein said apparatus can be readily dismantled into constituent parts.

The panel installation apparatus according one of claims 1 to 18 wherein said apparatus is a collapsible unit.

21. A method for installing wall panels said method including the steps of: supporting a wall panel on the panel installation apparatus of any one of claims 1 to manoeuvring the panel installation apparatus whereby the top edge of said panel is engageable by a lifting device and said leading portion extends beyond the plan installed position of said panel; lifting the panel top edge with said lifting device whereby the panel lower edge moves on said movable support towards said leading portion until the panel is vertical and the panel lower edge lifts clear of the movable support; and removing the installation apparatus, and securing panel into the required position.

22. The method of installing wall panels according to claim 21 wherein the lifting device is selected from at least one of a forklift, a walky reach, a monorail, a floor crane or jib. 00 12 0 0

23. The method of installing wall panels according to claim 21 or 22 wherein the step of securing the panel further including the step of bracing said panel with the leading portion of said apparatus.

24. A wall panel installation apparatus substantially as hereinbefore described Swith reference to the accompanying drawings. A method of installing wall panels substantially as hereinbefore described with reference to the accompanying drawings.