AU2014200646B2

AU2014200646B2 - Flooring panel

Info

Publication number: AU2014200646B2
Application number: AU2014200646A
Authority: AU
Inventors: Salim Dalla
Original assignee: CSR Building Products Ltd
Current assignee: CSR Building Products Ltd
Priority date: 2013-02-11
Filing date: 2014-02-06
Publication date: 2018-05-10
Anticipated expiration: 2034-02-06
Also published as: AU2014200646A1; NZ620883A

Abstract

A lightweight building panel, typically made from autoclaved aerated concrete, is provided with at least a s pair of rebates or grooves extending lengthwise along each of the longitudinal sides of the panel at the corner edges of the upper face and sides of the panel to assist in transporting the panels by a grab lift. Each rebate or groove has a double profile including an upper part and a io lower part angularly inclined to one another to assist in guiding the jaws of the grab lift into contact with the rebate at the correct lifting location and to form a waist at the junction of the two profiles to assist in positive engagement of the jaws of the grab lift to securely hold is the panel when lifting. The panels having the double profile rebate are used in lightweight flooring applications. The advantage of the panels is that multiple panels can be lifted simultaneously and placed one at a time in desired locations to form the lightweight 20 flooring thereby reducing handling of the panels to achieve cost savings. eifDJi14 508720_1 (GHMaIIers) P91877 AU 2 51b 48b 58 48a 'la 64b --'' -- 64a 50b- 56 59 2 766a 62b B 68b 66a 66b-- - - - FIGURE 7 44 48b 48a 50 59 --46 50a 68b DD 68a 64 br-- 56 62 bs----62 -- 60a 60b 78 66a 66b 74

Description

FIELD OF THE INVENTION

The present invention relates to building panels.

In one form, the present invention relates to lightweight building panels which are useful in constructing a flooring system of a building, particularly a multistorey io building.

In one form, the present invention relates to a building panel in the form of a lightweight flooring panel which has been modified to enable the building panel to be lifted by a suitable lifting apparatus or device, and lowered into a required location with little or no additional manhandling.

In one form, the present invention relates to a lightweight flooring panel having an arrangement for cooperating with a suitable lifting apparatus or device for moving the panels from one location to another location, such as for use in constructing the flooring of a building which arrangement is also useful for fixing the flooring panel in position to form part of the floor of the building.

The present invention finds particular application as part of a method of constructing lightweight flooring systems using lightweight flooring panels that can be lifted into place in a stacked array of multiple substantially identical lightweight flooring panels and deposited one at a time at convenient locations.

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In one form, the present invention relates to a lifting apparatus that is suitable for use in cooperating with the modified lightweight flooring panels to lift, transport and lower individual flooring panels of a stacked array of panels .

Although the present invention will be described with particular reference to one form of a lifting apparatus io and to one form of a lightweight flooring panel, it is to be noted that the scope of the present invention is not restricted to the described embodiments, but rather the scope of the invention is more extensive so as to include other forms and arrangements of the building panels and other forms and arrangement of the lifting apparatus or device, and the use of the panels and lifting device in applications other than described.

BACKGROUND OF INVENTION

It is desirable to reduce costs when building a building construction, particularly a multistorey building having a number of different floors. Generally, multistorey buildings have a framework and concrete infill in which the floor and ceiling of each storey is made either partially or entirely from concrete. In an effort to reduce costs, particularly relating to the construction of the upper storeys of multistorey buildings, it has been suggested to use a steel framework of individual interconnected steel framework members, for support and to fill the space between the steel framework members with a suitable flooring system. One suggested flooring system is to use panels spanning between the individual framework

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2014200646 11 Apr 2018 members for forming the floor. Although flooring panels have been used in the past, and in some cases the performance of the flooring panels has been acceptable, there is always a need for improvement so as to reduce time and therefore costs further, either in the manufacture of the components used in the building, such as for example, the flooring panels themselves or in the methods or techniques of installing the panels, including the devices and methods used to lift and/or transport the io panels, and for locating the panels in the correct position to form the flooring.

One of the significant costs associated with using flooring panels is the installation of such panels.

Currently, when using flooring panels, it is necessary to correctly orient the panels before installing the panels since the panels have different parts performing different functions which require that the panels can only be positioned in the one orientation for installation.

Therefore, in the past, it was necessary to not only transport the panel, usually singly, but to correctly orient the panel before installation to ensure the panel was installed in the correct manner so that the different parts matched up to corresponding parts of other panels to form the flooring which increased the cost of the building by slowing down the rate of installation of individual panels. Therefore, one way to reduce costs of a building could be to provide a flooring panel which does not need to be oriented uniquely before installation so that the rate of installation of panels can be increased.

Another contributing factor to the current cost of installation of the flooring panels currently in use, is

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2014200646 11 Apr 2018 that owing to the way in which the panels are transported, a single panel only can be transported or lifted safely. Having to lift each panel in turn, one by one, increases the time taken to install the panels and hence contributes to the cost of building by the lifting apparatus having to return to the store of flooring panels each time a new panel is to be selected. Therefore, there is a need to provide a flooring panel which can be lifted in multiples so as to save time of installation.

Another contributing factor to the cost of building constructions is that often the panels when installed, are not completely level with respect to the framework, which makes it difficult to fasten the individual panels to the floor substrate to form a perfectly flat floor so that adjustment of the panel is required in order for the fastener to engage with the panel. Often it is necessary to relocate the panel in order for the position of the fastener to be adjusted to allow the flooring panel to be correctly positioned, which also takes extra time reducing the rate of installation of the flooring. Therefore, there is a need to be able to adjust the position of the relevant fastener whilst the building panel is in place.

Accordingly, it is an aim of the present invention to provide a flooring panel which does not need to be uniquely oriented before installation.

Accordingly, it is an aim of the present invention to provide a modified flooring panel which makes it easier and faster to form a floor.

Accordingly, it is an aim of the present invention to

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2014200646 11 Apr 2018 provide a building panel which can be arranged in a stacked array of substantially identical building panels so that the stacked array can be lifted as a single unit.

Accordingly, it is an aim of the present invention to provide a lifting apparatus or device capable of lifting a stacked array of a multitude of building panels as a single unit and each building panel deposited one at a time at the required location.

Accordingly, it is an aim of the present invention to provide a flooring panel capable of being secured in place using a suitable fastener in which the position of the fastener can be adjusted while the panel is in place.

Accordingly, it is an aim of the present invention to provide a method of lifting building panels, which is cost effective, by allowing multiple panels to be lifted simultaneously.

Accordingly, it is an aim of the present invention to provide a method of constructing a lightweight flooring system using modified building panels that have been modified to assist lifting of the panels.

SUMMARY OF INVENTION

According to one form of the invention, there is provided a lightweight building panel adapted to form a lightweight flooring system of a building construction, the panel comprising a body having a pair of faces being a top face and an underneath face, and a pair of

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2014200646 11 Apr 2018 longitudinally extending sides located on opposite sides of the body intermediate the top face and the underneath face, the edge between the top face and the longitudinal extending side being an upper side edge of the panel, the panel being substantially symmetrical about a longitudinally extending central axis, each of the pair of longitudinally extending sides having io a rebate in the form of a double profile groove extending along the length of the longitudinal side, the double profile groove of the rebate having a waist line located intermediate an upper inclined surface and a lower inclined surface the upper inclined surface and the lower inclined surface being oppositely angularly inclined to one another at an angle greater than about 90° to form the waist line located there between, the upper inclined surface of the rebate being located along the upper side edge of the panel formed between the longitudinal side and the top face of the panel in use, and the lower inclined surface extending away from the waist line in a direction towards the underneath face of the panel, the upper inclined surface of the rebate having a first height and the lower inclined surface of the rebate having a second width, the first height being less than the second width,

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2014200646 11 Apr 2018 wherein the upper inclined surface is an undercut surface 5 extending from the top face inboard of the panel at a first angle in a generally downwards direction away from the top face to the waist line and the lower inclined surface extending from the waist line to the side surface of the longitudinal side of the panel at a downwardly io directed angle in a direction away from the top surface.

BRIEF DESCRIPTION OF EMBODIMENTS

In one form, the building panel is a lightweight flooring panel. Typically, the flooring panel is a flooring panel of aerated material, preferably an Autoclaved Aerated Concrete (AAC) material.

Preferably, the building panel is an AAC building panel manufactured and sold under the name Hebei®.

In one form, the building panel is provided with two rebates, preferably one rebate being located along one side or edge and another rebate being located along another side or edge, more preferably on opposed sides or edges, such as on the two longitudinal edges.

In one form, the building panel is provided with a rebate along one or both of the transverse edges or sides of the building panels .

In one form, the building panel is provided with a

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2014200646 11 Apr 2018 symmetrical pair of rebates along the two longitudinal sides and a pair of rebates along the two transverse sides so that the building panel has four rebates along the upper side edges of the panel.

In one form, the rebate has a profile which is complementary to the profile of the clamping members of the lifting apparatus, preferably to the gripping elements of the clamping members.

Forms of the rebates include the following.

In one form, the rebate has two parts, an upper part and a lower part. Typically, the length of the upper part, closer to the top face of the panel is shorter in length than is the lower part which is closer to the bottom face of the panel. More typically, the upper and lower parts are angularly inclined to one another. Typically, the upper and lower parts are angularly inclined to each other at opposite directions to form a waist immediate the two parts, typically at the junction of the two parts. More typically, the upper part is inclined at an angle of between about 100° and about 135° to the top face and the lower part is inclined at an angle between about 10° and

45° to a plane parallel to the upper face.

Typically, the gripping elements are friction grips. In one form, the friction grips are plates, typically elongate or rectangular plates or square plates.

Preferably the friction grips are provided with surface irregularities, such as for example, combinations of troughs and crests. In one form, the troughs and crests are arranged as regularly repeating concentric rings of

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2014200646 11 Apr 2018 alternating troughs and crests. However, other forms and arrangements are possible.

In one form, the lifting apparatus is a scissors lift, typically a scissors grab lift and more preferably a scissors clamp lift having a pair of opposed clamping members. Preferably, the clamping members are jaws or similar arranged in face-to-face opposed relationship and capable of movement towards each other and movement away io from each other.

More preferably, the jaws or similar are arranged to move between a closed configuration in which the panel or panels are held securely between the jaws for transporting and/or lifting the panel and an open configuration in which the jaws are released from the panel, such that the grab lift can be removed from the panel after the panel has been deposited in the required location and released from the jaws.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the panel and of the lifting apparatus will now be described to illustrate forms of the invention by way of example only with reference to the accompanying drawings in which:

Figure 1 is an isometric view from one end of one form of a lightweight flooring panel having a first thickness.

Figure 2 is an end elevation view of the panel of Figure 1.

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Figure 3 is a side elevation view from one side of the panel of Figure 1.

Figure 4 is an isometric view from one end of another form 5 of a flooring panel having a second thickness in which the second thickness is greater than the first thickness.

Figure 5 is an end elevation view of the panel of Figure 4.

Figure 6 is a side elevation view from one side of the panel of Figure 4.

Figure 7 is a schematic side elevation view of one form of a lifting apparatus in an open configuration in which a stack of four panels are released from the jaws of the lifting apparatus .

Figure 8 is a schematic side view of the form of the lifting apparatus of Figure 7 in a closed configuration in which the jaws of the lifting apparatus engage the lowermost panel of the stack of four panels in preparation for lifting the stack of panels.

Figure 9 is a schematic side elevation view of the form of the lifting apparatus of Figure 7 lifting a stacked array of four panels of the first thickness.

Figure 10 is a schematic side elevation view of the lifting apparatus of Figure 7 lifting a stacked array of two panels of the second thickness.

Figure 11 is a schematic side elevation view of one form

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2014200646 11 Apr 2018 of a panel showing the angular relationship of one part of the rebate to another part of the rebate at the upper side edges of the panel.

Figures 12(a) to 12(e) are end views of different thicknesses of panels showing the dimensions and relationships of the upper and lower part of the respective rebates in which Figure (a) corresponds to a thickness of 150mm, Figure (b) to 175mm, Figure (c) to

200mm, Figure (d) to 225mm and Figure (e) to 250mm.

Figures 13(a) to 13(f) are partial side views of the end profile of grooves located along the ends of panels of various thicknesses in which Figure (a) corresponds to a thickness of 100mm, Figure (b) to 150mm, Figure (c) to

175mm, Figure (d) to 200mm, Figure (e) to 225mm and Figure (f) to 250mm.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

One embodiment of a building panel, in the form of a light weight flooring panel will now be described in detail. A lightweight flooring panel, generally denoted as 10 is typically made from a lightweight structural building material, typically in the form of a reinforced concrete containing product, more typically, an autoclaved aerated concrete (AAC) flooring panel with a form of internal reinforcing, such as for example, of the type made by CSR Hebei®. However, it is to be noted that any suitable material may be used to form the flooring panel and the panel may be any suitable type of panel.

Panel 10 is of a solid generally rectangular prism shape,

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2014200646 11 Apr 2018 such as a general parallelepiped shape or similar having a top face 12, a bottom face 14, two longitudinal sides 16, 18 and two transverse ends 20, 22 generally arranged to extend perpendicularly to one another to form a slab or similar shape having a length of typically up to about 6 meters, a width of typically up to about 600mm and a height of typically up to about 300mm or more. However, flooring panel 10 can be made in any suitable length, width or height combination as required depending upon the ¹⁰ hype of flooring required and the construction method of the building having the flooring system.

A discontinuity in the form of a rebate, such as a groove or similar is provided along the upper side edge of panel

10 on both sides of panel 10. The discontinuity can take any suitable or convenient form. One preferred form of the rebate is a double profile (DP) groove, notch, or similar 24, 26, extending lengthwise along the upper side edges or corners in use of panel 10, as shown more particularly in Figures 1 and 2 for panel 10 having a relatively smaller height or thickness such as for example, about 150mm or 175mm, and in Figures 4 and 5 for panel 10 having a relatively larger thickness, such as for example, a thickness of about 225mm or 250mm. In one form, each of grooves 24, 26 at either side of panel 10 is provided with two surfaces angularly inclined to one another to form an angulated groove or groove of an angulated profile. As grooves 24, 26 are substantially identical to one another, only one of the grooves will be described in detail. It is to be noted that groove 24, 26 can take any suitable profile. One preferred profile is a DP notch.

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The two inclined surfaces forming groove 24, are an upper surface 28 which is an undercut surface extending from top face 12 inboard of panel 10 at an angle, in a generally downwards direction away from top face 12, and a lower surface 30 which extends from the inboard lower edge of upper surface 28 to side surface 16 at a downwardly directed angle, also in a direction away from top surface

12. In one form, the junction between the upper surface and the lower surface is a waist line. In one form, the angle of inclination θι upper surface 28 can vary from about 100° to about 135° with respect to top face 12, and the angle of inclination Θ2 of lower surface 30 with respect to a plane parallel to the plane of top face 12, can vary from about 10° to about 45°.

It is to be noted that grooves 24, 26 provide lifting slots, reaction surfaces, bearing surfaces or similar for engagement by suitable clamping members of a suitable lifting assembly to lift the panels as will be described in more detail later in this specification. Additionally, it is to be noted that grooves 24, 26 are shaped to receive elongate reinforcing bars, tie down bars or other fasteners therein to assist in fastening the flooring panels to the solid substrate of a floor to maintain the flooring panels in position after installation, such as for example, the reinforcing bars forming part of a ring anchor system which is anchored by steel cleats located external to the floor substrate or steel framework members, to resist upward movement of the panels from the floor when installed in the building, also to be described in more detail later in this specification.

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Although ends 20, 22 of panel 10 of Figures 1 to 3 and of the panel of Figures 4 to 6 are shown as being smooth, straight or the like in the drawings, i.e. perpendicular to the top, bottom and side surfaces of the panel and are not provided with any discontinuities, other forms of panel 10 (not shown) have grooves similar to grooves 24, located along the upper edges of one or both ends of the panel, such as at the end edges of top surface 12. If transversely extending grooves are provided, their size, shape, profile or similar is the same as, or similar to grooves 24, 26 so as to be able to receive corresponding elongate reinforcement bars or tie down bars therein to assist in keying the floor panels to the building, such as for example, forming part of the ring anchor system. It is to be noted that the transverse ends of floor panels adjacent to the edge of the flooring are usually provided with rebates or grooves around the perimeter of the floor to receive the reinforcing bars or tie down bars of the ring anchors which in one embodiment, extend around almost the entire perimeter of the floor at each level in the multi storied building.

One form of a lifting apparatus for lifting building panels 10, generally denoted as 40, is in the form of a grab lift or similar which will now be described.

Grab lift 40 is provided with an attachment point for allowing the lift to be connected to a suitable lift assembly such as for example, the lifting hook located at the end of a cable of a crane lift (not shown). In one form, the attachment point is an eyelet 42 provided in an eyelet member 44 for receiving a lifting hook (not shown) at the end of a cable (not shown). Eyelet member 44 is

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2014200646 11 Apr 2018 pivotally connected to a suitable scissor assembly 46 by pivot pin 45. Scissor assembly 46 forms the operating mechanism of lift 40. In use, lift 40 is raised and lowered by the crane.

In one form, scissors assembly 46 includes a pair of upper scissor members 48a, 48b pivotally connected together at one respective end and pivotally connected to eyelet member 44 by pivot pin 45. Upper scissor member 48a is io pivotally connected to lower scissor member 50a at the other end thereof by pivot pin 51a, whilst upper scissor member 48b is pivotally connected to lower scissor member 50b at the other end thereof by pivot pin 51b. Lower scissor members 50a, 50b are pivotally connected to one another about an intermediate pivot, such as a pivot pin 52 or similar located at or about the midpoint of the two members 50a, 50b. The interconnection of the upper and lower scissors members by the various pivot pins allows the scissors members to move relative to one another when the grab lift is moving between the open and closed configurations such that upper scissors members 48a, 48b pivotally move in the direction of arrows A respectively when lift 40 is moving from the open configuration of Figure 7 to the closed configuration of Figure 8 and lower scissors members 50a, 50b move in the direction of arrows B when lift 40 is moving from the closed position of Figure 8 to the open position of Figure 7, the upper members move in the direction of arrows C and the lower members move in the direction of arrows D.

A locking arrangement in the form of a movable locking hook 54 is pivotally connected to pivot pin 52 so as to be capable of pivoting movement between a locking

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2014200646 11 Apr 2018 configuration as shown in Figure 7 in which locking hook 54 engages pivot pin 45 to maintain lift 40 in the open configuration, such as for example, to allow lift 40 to be placed over a stacked array of panels, and an unlocked position as shown in Figures 8, 9 and 10 in which lift 40 is able to be maintained into a closed configuration. In one form, locking hook 54 is provided with an elongate shank 56 having one end pivotally connected to pivot pin 52, and a substantially curved or arcuate engaging portion io 58 for cooperatively engaging with pivot pin 45 to maintain grab lift 40 in the open configuration as shown more particularly in Figure 7. A stop, in the form of a stop, rest, pin or similar 59, is provided on lower scissor member 50b to retain hook 54 in the unlocked configuration thereby allowing lift 40 to remain in the closed configuration, as shown in Figures 8, 9 and 10.

A pair of clamping members in the form of jaws 60a, 60b, are pivotally connected to the respective lower ends in use of lower scissor members 50a, 50b, respectively by respective pivot pins 62a, 62b on either side of grab lift 40. Each jaw 60a, 60b is provided with a respective handle portion 64a, 64b located at or towards the upper end in use of jaws 60, for manually moving grab lift 40, and converting grab lift 40 between the open and closed configurations. Handle portions 62a, 64b are each provided with a reaction or bearing surface in which the pair of reaction surfaces face inwardly towards one another. Gripping elements in the form of a friction grips 66a, 66b or similar, are located at the distal end of jaws 60a, 60b respectively for cooperatively engaging against the inclined surfaces 28, 30 of grooves 24, 26 on opposite sides of panel 10. It is to be noted that the

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2014200646 11 Apr 2018 shape, profile, size and inclination of friction grips 66a, 66b are complementary to the shape, profile, size, inclination of groves 24, 26 so that friction grips 66 are received within grooves 24, 26 to bear against respective upper surfaces 28 and lower surface 30 of grooves 24, 26 to enable grab lift 40 to securely hold panel 10 prior to and during lifting of panel 10. It is to be noted that owing to the location of lower inclined surface 30 and the angle of the slope of lower surface 30, friction grip 66 is guided into position by lower surface 30 to adopt a position in alignment with upper surface 28 to enable friction grips 66 to apply sufficient force to upper surface 28 to lift panel 10. Further it is to be noted that the slope of lower surface 30 is such so as to provide support for the distal end of friction grip 64 as well as acting as a guide for the friction grips.

In one form, the friction grips are in the form of a gripping surface located on one face of a rectangular plate (not shown) having a multitude of concentric rings of different diameters in which each ring comprises a trough and crest providing a gripping surface. Other arrangements are possible.

A movably adjustable restraint strut 68a is pivotally attached to lower scissor member 50a and a separate movably adjustable restraint strut 68b is pivotally attached to lower scissor member 50b to assist in operation of grab lift 40, particularly to maintain lift

40 in the closed configuration.

Restraint struts 68a, 68b are movable between an unrestrained configuration, allowing grab lift 40 to open

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2014200646 11 Apr 2018 and close, in which each strut 68a, 68b is aligned along the lengthwise extending axis of the corresponding lower scissor member 50a, 50b as shown in Figure 7, and to a restrained configuration in which grab lift 40 is maintained in the closed configuration by being prevented from opening by struts 68a, 68b extending outwardly from the longitudinal axis of lower scissor members 50a, 50b respectively to bear against the inboard reaction or bearing surfaces of handle portions 64a, 64b of jaws 60a, io 60b respectively, which face one another, as shown more particularly in Figures 8, 9 and 10. It is to be noted that whilst struts 68a, 68b are in contact with handles 64a, 64b, scissors assembly 46 remains immovable so that grab lift 40 remains in the closed configuration. Grab lift 40 can move to the open configuration only after restraining struts 68a, 68b are released from contact with handles 64a, 64b.

In the restraint configuration, the distal ends of struts

68a, 68b extend outwardly from members 50a, 50b to contact and bear against the inwardly facing surfaces of handle portion 64a, 64b of jaws 60a, 60b respectively, to prevent grab lift 40 moving from the closed configuration to the open configuration by preventing pivoting movement of jaws

60a, 60b to release the gripping ends of the jaws from moving in a direction away from each other.

One end of safety chain 70 is connected to jaw 60a and the other end of safety chain 70 is connected to jaw 60b to extend underneath panel 10 when held by grab lift 40 as shown more particularly in Figures 7 to 10 as a safeguard in case panels 10 dislodge from grab lift 40.

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In operation of grab lift 40 to lift panels 10, firstly panels 10 are placed in a stacked array of from about two individual panels as shown in Figure 10 to about four individual panels as shown in Figures 8 to 10, in top face to bottom face relationship, depending upon the thickness of the panels which can vary from about 150mm to about 250mm. It is to be noted that the panels are all stacked with the top face 12 uppermost so that grooves 24, 26 are located at or towards the top face of each panel 10 as shown in Figures 7 to 10 for efficient lifting and positioning of the panels.

Grab lift 40 is operated so as to be in an open configuration so that the opposed spaced apart jaws 60a,

60b can be lowered along either side of the stacked array of panels 10. Grab lift 40 is manoeuvred so that friction grips 64a, 64b are aligned with grooves 24, 26 of the lowermost panel 76 of the stacked array of panels 74, whereupon grab lift 40 is operated to move from the open configuration to the closed configuration by the upper scissors members moving in the direction of arrows A and the lower scissors members moving in the direction of arrows B, so that friction grips 64a, 64b engage grooves 24, 26 with the distal end of friction grips 64a, 64b received against respective upper surface 28 to squeeze or clamp panel 10 between the two opposed jaws 60a, 60b. Safety chain 70 can be then connected underneath lowermost panel 76 and the panels lifted as a single unit in unison supported upon lowermost panel 76.

When the individual panels are to be installed in the floor, grab lift 40 is positioned above the required location and lowered so that lowermost panel 76 is in

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2014200646 11 Apr 2018 position, whereupon restraining struts 68 are moved from the restraining position to the unrestrained position to allow grab lift 40 to be operated by being moved to the open configuration, in which the upper and lower scissors members move in the direction of arrows C and D respectively, thereby allowing release of the panels.

After release of the panels, grab lift 40 is raised slightly so that friction grips 64a, 64b are free to align with the grooves of the next lowermost panel 78, so that io grab lift 40 can be operated to engage with the grooves of this panel. With grab lift 40 in the closed configuration securely holding next panel 78, grab lift 40 is raised to lift the array of remaining panels in the stacked array as a single unit to a new location whilst leaving behind the first lowermost panel 76 in the correct location to form the floor.

Grab lift 40 is moved to the required location of the next panel, now the new lowermost panel 78, provided there are more than two such panels, whereupon operation of grab lift 40 as described above, is repeated to lower the stacked array to the position required of the then lowermost panel 78. Grab lift 40 is then operated to move to the open configuration to release lowermost panel 78 and the other stacked panels to deposit the panel where required. After grab lift 40 is raised slightly so that friction grips 64a, 64b can engage with grooves 24, 26 of the next panel to lift the now depleted array of panels to a new location, and so on until all the individual panels are deposited one at a time in sequence in the respective locations to form the floor of the building without the lifting apparatus having to return to the store of panels.

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In one form, the individual panels are located in side-byside abutting relationship with lengthwise extending grooves 24, 26 on either side in face-to-face or side-byside relationship to each other to form an elongate open channel having a width corresponding to about twice the width of the groove in which both sides are mirror images of each other formed by the upper surface 28 and lower surface 30 on each side edge of the channel. In one form, a suitable fastener is provided on the solid substrate of io the floor, such as for example, a bracket having an aperture, typically a steel cleat having a slot or similar. A reinforcing bar or tie bar is received in the open channel and passed through the aperture of the bracket or cleat in order to tie the flooring panels to the floor substrate using one or other forms of a ring anchor system. In one form, typically the ring anchor system consists of N12 reinforcement bars located in the channel formed by the two side-by-side grooves at the joint between consecutive panels and continuous around the perimeter of the group of floor panels. The reinforcement bars are anchored at corners and the intersection of the grooves and perimeter.

After the panels are laid, reinforcing bars (N12) are placed between the panels in the grooves and around the perimeter of the floor to form the ring anchor system.

In one form, the bars should be supported on chairs or equivalent to allow proper placing of grout. Panels may require propping before placing the ring anchor system when subject to dead and live load variations. Owing to the increased width of the gap or channel between adjacent parallel grooves, access to the chairs located within the grooves or channels is possible to adjust the position of

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2014200646 11 Apr 2018 the chairs and hence the position of the N12 bar or similar.

The reinforcement is to be encased in a weak mix concrete 5 grout or similar. The joints and perimeter sections should be wetted, filled with minimum characteristic compressive strength concrete of 15MPa (maximum aggregate size 6mm and maximum slump 200mm). The grout should be compacted (rodded) to ensure the grout encases the reinforcement and is worked into the groove.

A suitable material, such as for example, an adhesive, a grout, or similar filler type material, in the form of a slurry, paste, gel, viscous liquid or similar, is inserted into the open channel and packed down around the reinforcing rod to cement the rod to the flooring panels to form a floor of the building.

ADVANTAGES OF FORM OF THE INVENTION

Advantages of one or more form of the invention include one or more of the following.

As the panel is provided with a groove on either side and/or along either end, when two panels are located in side-by-side relationship and/or in end-to-end relationship, the channel formed by the grooves is about twice the width of the groove so grout can be inserted into the open channel in sufficient quantity to retain the reinforcing rod in position within the channel and accordingly hold the flooring panel in position on the floor with little or no chance of the flooring panel accidentally or inadvertently lifting, thereby making a

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2014200646 11 Apr 2018 more robust, durable floor that is level.

The increased width of the open channel formed from the two rebates allows for adjustment of the position of the bar within the channel to a greater extent, such as for example, provides a larger space into which support chairs and shims are locatable to adjust the height of the bar in the channel thereby making a floor which is level.

io As the panels can be readily lifted by the grab lift and placed accurately in position by lowering the grab lift and releasing the lift from the panel, there is little or no adjustment of the final position of the panel required, such as by workmen having to push the panel into position once it is on the floor substrate, thereby saving time and effort in not having to manhandle the panel into its final position after its initial placement.

Multiple panels can be lifted and positioned using the grab lift since the panels can be lifted as a single stacked array of individual panels thereby saving time in not having to return to the store of panels each time a new panel is selected.

After lifting multiple panels in a single stacked array, individual panels of the stacked array can be deposited at desired locations one at a time in sequence by lifting the array using the lowermost panel of the array and moving up in turn to the next lowermost panel as each panel, being the then lowermost panel, is deposited in the correct location to form the flooring.

After manufacture, individual panels are tilted 90° to

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2014200646 11 Apr 2018 allow for more efficient storage occupying less space without the chance that sides or edges of the panels will be damaged. Tilting the panels 90° allows easier lifting and installation. However, in some embodiments, the panels can be stored horizontally in stacked relationship to form an array of panels in top face to bottom face relationship one above the other to provide for easier lifting.

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Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A lightweight building panel adapted to form a lightweight flooring system of a building construction, the panel comprising a body having a pair of faces being a top face and an underneath face, and a pair of longitudinally extending sides located on opposite sides of the body intermediate the top face and the underneath io face, an edge located between the top face and the longitudinal extending side being an upper side edge of the panel, the panel being substantially symmetrical about a

15 longitudinally extending central axis, each of the pair of longitudinally extending sides having a rebate in the form of a double profile groove extending along the length of the longitudinal side, the double profile groove of the rebate having a waist line located intermediate an upper inclined surface and a lower inclined surface

25 the upper inclined surface and the lower inclined surface being oppositely angularly inclined to one another at an angle greater than about 90° to form the waist line located there between,

30 the upper inclined surface of the rebate being located along the upper side edge of the panel formed between the longitudinal side and the top face of the panel in use, and the lower inclined surface extending away from

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2014200646 11 Apr 2018 the waist line in a direction towards the underneath face of the panel, the upper inclined surface of the rebate having a first 5 height and the lower inclined surface of the rebate having a second width, the first height being less than the second width,

10 wherein the upper inclined surface is an undercut surface extends from the top face inboard of the panel at a first angle in a generally downwards direction away from

15 the top face to the waist line and the lower inclined surface extends at a second angle from the waist line to the side surface of the longitudinal side of the panel at a downwardly directed angle in a direction away from the top surface.
2. A building panel according to claim 1 in which the panel is made from autoclaved aerated concrete.
3. A building panel according to claim 1 or 2 in

25 which the panel is a reinforced autoclaved aerated concrete panel.
4. A building panel according to any preceding claim in which the building panel is a substantially

30 rectangular prism or parallelepiped.
5. A building panel according to any preceding claim in which the building panel is provided with a

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2014200646 11 Apr 2018 further rebate located along a first transversely extending end and a further rebate located along a second transversely extending end, wherein the two transversely extending further rebates are at opposite

5 ends of the building panel.
6. A building panel according to claim 5 in which the further rebate located along the first transversely extending end is located along the upper edge of the

10 first transversely extending end and the further rebate located along the second transversely extending end is located along the upper edge of the second transversely extending end.

15 7. A building panel according to claim 6 in which the building panel comprises the pair of substantially identical rebates extending along the two longitudinal extending upper edges of the longitudinal sides of the panel and the pair of transversely extending further

20 rebates extending along the two transversely extending upper edges of the transversely extending ends of the panel so that the building panel has four rebates along the upper side edges and the upper end edges of the top face of the panel.

8. A building panel according to any one of claims 5 to 7 in which the profile of the pair of substantially identical rebates is the same as or similar to the profile of the pair of transversely

30 extending further rebates.

9. A building panel according to any preceding claim in which the angle of inclination between the

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2014200646 11 Apr 2018 upper inclined surface and lower inclined surface of the rebate is in the range of from about 100° to about 135° .

5 10. A building panel according to any preceding claim in which the upper inclined surface of the double profile groove of the rebate and the lower inclined surface of the double profile groove of the rebate are angularly inclined to one another such that the first io angle of the upper inclined surface is an angle of between about 100° to about 135° to the top face of the panel and the second angle of the lower inclined surface is an angle between about 10° and about 45° to a plane parallel to the top face of the panel.

11. A building panel according to any preceding claim in which the first angle of inclination θι between the upper inclined surface and the lower inclined surface of the rebate is such that the angle of

20 inclination Θ1 varies from about 100° to about 135° with respect to the top face and the second angle of inclination Θ2 of the lower inclined surface with respect to a plane parallel to the plane of the top face varies from about 10° to about 45°.

12. A building panel according to any preceding claim in which the lower inclined surface of the rebate provides support for a lifting apparatus for use in lifting the building panel.

13. A building panel according to any preceding claim in which the waist line of the rebate aligns friction grips of a lifting apparatus to engage the upper

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2014200646 11 Apr 2018 inclined surface of the rebate to facilitate lifting of the panel by the lifting apparatus.

14. A building panel according to any preceding claim

5 in which the panel has a thickness of from about 150 mm to about 250 mm.

15. A building panel according to claim 14 in which the panel has a thickness of about 150 mm, about 175

10 mm, about 225 mm, or about 250 mm.

16. A lightweight flooring system comprising a multitude of building panels located in side by side abutting relationship to one another in which the

15 rebate along one longitudinal side of one panel is adjacent the rebate along one longitudinal side of an adjacent panel to form a channel for receiving therein a fastener to form the flooring system wherein each building panel is in accordance with any preceding

20 claim.

17. A lightweight flooring system according to claim 16 in which each panel of the multitude of building panels has a further rebate at the first end and a

25 further rebate at a second end, so that when two panels are located in end-to-end abutting relationship to one another, one of the further rebates of one panel is located adjacent one of the further rebates of the other panel to form a channel intermediate the one

30 panel and the other panel for receiving therein a fastener to secure the panels to form the flooring system.

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18. A lightweight flooring system according to claim 16 or 17 in which the fastener includes a reinforcing bar, a tie down bar, a steel cleat, or other part of a ring anchor system.

19. A stacked array of substantially similar lightweight building panels for use in constructing a lightweight flooring system of a building construction wherein each of the panels is in accordance with any io one of the claims 1 to 15, the panels of the stacked array being stacked such that the respective top faces of each panel are uppermost and the rebates of one panel are aligned with the rebates of another panel to form a substantially identical repeating unit in which

15 the rebates are oriented in the same orientation in spaced apart relationship to one another.

20. A method of lifting a stacked array of substantially identical building panels using a lifting

20 apparatus in which the panels are in accordance with any one of claims 1 to 15.

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