AU635233B2

AU635233B2 - Prefabricated building construction

Info

Publication number: AU635233B2
Application number: AU47112/89A
Authority: AU
Inventors: Robert Barkshire; John O'connor Mccabe
Original assignee: Lancord Pty Ltd
Current assignee: Lancord Pty Ltd
Priority date: 1988-12-21
Filing date: 1989-12-21
Publication date: 1993-03-18
Anticipated expiration: 2009-12-21
Also published as: AU4711289A

Description

AUSTRALI A PATENTS ACT 6 3 5 2 COMPLETE SPECIFICATION

ORIGINAL

(FOR OFFICE USE) Class Int Class Application Number: Lodged: Complete Specification Lodged: Accepted: Published: Priority: Related Art: Name of App 1 i cant(s): .BAR.R I E.R..ENG.I.NEER.I.NG.&..CD.NS.TRU.CT.I.ON..C.O.... P.TY..LTD Address of App i cant 0..Wo.o.a.r o.ng.a.P.ar.,..Vi.ct .ri a 1. 5 Actual Inventor(s) JO.qHN 0' CONNOR McCABE and ROBERT BARKSHI RE 6 '*Address for Service: PATENT ATTORNEY SERVICES 26 Ellingworth Parade, Box Hill, Victoria 3128 Complete specification for the invention entitled: PREFABRICATED BUILDING CONSTRUCTION The following statement is a full description of this invention, including the best method of performing it known to PREFABRICATED BUILDING CONSTRUCTION This invention relates to prefabricated building construction and particularly to methods for manufacturing prefabricated building panels or structural components. The invention also relates to prefabricated building panels or structural components. Fafdt In the past it has been known to construct prefabricated building panels of reinforced concrete. For standard sizes reusable formwork can be designed and constructed for enabling the panels to be cast. When particular panels of non-standard shape are required, special formwork must be constructed and this is quite expensive.

The erection and use cf specially designed formwork is well known on building sites such as for the construction of reinforced concrete columns, stairways, stair wells, lift wells, wall sections as well as floor slabs. The construction and use and later disassembly of special formwork whether on site or off site is time consuming and expensive. The advantages of prefabricated building sections are well known, particularly the speed with which building sections can oo be erected compared to fabrication on site.

S"One particular problem with concrete structures whether made of 20 2 prefabricated sections assembled on site or of building sections .fabricated on site is that the concrete lacks aesthetic appeal both in colour and texture, Frequently also concrete needs external Soo* covering for protection against weathering and to prevent unsightly finishes both upon completion and well as over periods of time when unsightly staining develops.

0S e The use of building blocks or bricks is known. The laying of the blocks or bricks at a building site can be time consuming thus being a significant factor in the total construction time for a particular project. Also the laying of blocks or bricks on site can 30 b: e interrupted by inclement weather leading to significant disruptions to project schedules, r. It is an object of the present invention to provide a method of manufacturing prefabricated panels or structures using building blocks which are assembled orior to erection and which can be transported to and erected at the final desired location, It is a further object of the present invention to provide a prefabricated building panel or structural component composed of blocks or bricks and which is capable of manufacture off site and transport to and erection at a desired final location.

According to the present invention there is provided a method of manufacturing a prefabricated structural component including the steps of: laying a course of construction blocks, the blocks having upright holes arranged to at least partially align with corresponding holes in the construction blocks in an adjacent course of similar construction blocks; laying at least one reinforcing piece along the first course of blocks so as not to substantially obstruct the holes; laying a second course of similar blocks along the first course so that holes in the blocks of the second course substantially align with holes in the blocks of the first course and locating grout between the first and second courses whereby the grout located between the first and second courses together with said at least one reinforcing piece form a reinforced beam between the first and second courses; laying further courses of similar blocks with grout between adjacent courses, the blocks being positioned so that holes in the blocks of the further courses align with aligned holes in the preceding courses; locating an anchor member so that an externally accessible portion of the anchor member is accessible from externally of the finished structural component to enable mounting of the finished structural component to a building structure, the anchor member including said externally accessible portion and an anchoring portion which is located between two adjacent courses of blocks, the anchoring portion having an aperture therethrough and the anchor member being located so that the aperture is aligned with the aligned holes in the adjacent courses of blocks; locating a reinforcing rod in aligned holes in the courses so that the reinforcing rod extends through the aligned holes and also passes through the aperture in the anchoring portion of the anchor member; and filling the cavity formed by the aligned holes and containing the reinforcing rod with grout so as to form a reinforced column extending through the courses of 35 blocks and through the aperture in the anchoring portion.

In one possible embodiment the blocks in the first course are each provided with a channel extending longitudinally so that as the blocks of the first course are laid, a longitudinal channel along 3 4 S S S *5

S

N.)

substantially the length of the course is formed, the reinforcing piece being located within the channel so that the grout between tlhie first and second courses enters said channel and forms said reinforced beam. Alternatively the reinforcing piece may be laid on top of the first course of blocks so as not to substantially obstruct the holes within the blocks of the first course, the grout surrounding the reinforcing piece thereby forming said reinforced beam extending along the first course and between the blocks of the first and second courses.

During manufacture, preferably at least one of the holes provided in the blocks of the first course is plugged by a plug member during the laying of the first course, the plug member including a handle extending generally in the direction of the second course, the method including the step of drawing the plug member upwardly from the hole in the first course when the second course has been laid so the plug member is drawn into the aligned hole in the second course thereby maintaining the cavity formed by the aligned holes in the first and second courses substantially clear of grout during the process of laying courses, The structural component may include courses which extend around an angle, at least one of the reinforcing pieces which are laid along the first course conforminf Lo the general shape of the line of the course so as to extend continuously through the angle.

With some structural components it is possible for each course to extend through at least two angles so that the structural component has two coucave corners in plan view, the structural component forming in use at least three walls of an at least partially enclosed space within a building structure. The angles through which the courses are laid can be right angles so that the structural component 30 is generally C shaped in plan view and forms three walls of a substantially enclosed space within the building structure.

Alternatively, the structural component can extend through three right angles and form in plan view a closed box structure having four walls and an access opening in one wall, the reinforcing pieces between adjacent courses of blocks extending around through each of the three right angled corners, any reinforcing pieces terminating along one wall btieing overlapped with continuation reinforcing pieces so as to splice the reinforcing pieces together within the grout and 4 1r Si I Sr a ,,r 0.41 S S~d form a substantially continuous reinforced beam between adjacent courses.

The anchoring portion may comprise an anchoring plate which is laid between adjacent courses of blocks, the anchoring plate having said aperture therethrough which is aligned with aligned holes in the adjacent courses of blocks, the reinforcing rod which is located through the aligned holes also passing through the aperture in the anchoring plate. The anchor member may comprise a suspension anchor member for enabling mounting of the structural component so as to be suspended from the building structure, said externally accessible portion of the suspension anchor member comprising a face plate which in use lies substantially along the outer faces of at least two adjacent courses of blocks, and a support plate projecting laterally from the face plate and away from the courses of blocks, the support plate being arranged to be secured to the building structure so that the structural component extends downwardly from the face plate and support plate, said anchoring plate projecting inwardly from the face plate so as to be located between adjacent courses of blocks.

The method may further include the step of embedding a lifter within the reinforced column formed by the grout in the aligned holes in which the reinforcing rod is located, the lifter having a head portion which is exposed so as to be engagable by lifting apparatus to enable lifting of the structural component.

A substantially clear passage may be left through adjacent courses of blocks whereby a tension rod may be passed through the clear passage from the top to the bottom of the structural component and the rod then being tensioned so as to post tension the structural component, The present invention also provides a prefabricated structural 30 component comprising a plurality of courses of building blocks, at least one reinforcing piece being located so as to extend generally between adjacent courses of blocks, the reinforcing piece being embedded within grout so as to form a reinforced beam extending between the adjacent courses, the structural component further including a transverse reinforcing rod extending transverse to the lines of the courses of blocks and through aligned holes in the blocks of the courses, the transverse reinforcing rod being contained within a passage defined by the aligned holes, the passage being

S

S.

I.

S

S SS

S

S~a i-A -i Ij 7

'I,

filled with grout so as to form a transveise reinforced column, the building component further including an anchor member comprising an externally accessible portion which is accessible from externally of the structual component to enable mounting of the structural component to a building structure, the anchor member also including an anchoring portion which is located between two adjacent courses of blocks, the anchoring portion having an aperture therethrough which is aligned with the aligned holes in the courses of blocks, the reinforcing rod which extends through the aligned holes also passing through the aperture in the anchoring portion whereby the transverse reinforced column passes through the aperture in the anchoring portion.

Preferably the courses are laid substantially horizontally so that the transverse reinforcing rod extends substantially upright throughout substantially the entire height of the structural component, the structural component further including a lifter coupled to the upright reinforcing rod so that lifting forces can be applied to the lifter and the lifting force transmitted to the reinforced column extending through the height of the structural component.

A base plate may be provided at or beneath the bottom course of blocks, the reinforcing rod extending upwardly from the base plate through the passage, a lifter being provided at the upper end of the reinforcing rod so that lifting force applied to the reinforcing rod 25 is transferred to the base plate so that lifting force is applied from the bottom of the structural component. In this embodiment, the reinforcing rod in the passage may be grouted through a lower portion of its length, an upper portion of the length of the reinforcing rod being surrounded by a sleeve allowing movement between the reinforcing rod and the sleeve whereby lifting forces applied to the upper end of the reinforcing rod sufficient to cause stretching of the rod at its upper portion will be taken up by sliding movement between the rod and the sleeve.

The structural component may further include a female coupling 35 for coupling the structural component to a vertically abutting oo structural component; the female coupling having a plate which is generally co-planar with a top or bottom edge of the structural component, reinforcing rods extending from the plate within the structural component, the reinforcing rods being embedded in grout so as to structurally unite the female coupling to the structural component, the plate further including an aperture for receiving a male projecting portion of the vertically abutting structural component. The female coupling may further include a bore which opens outwardly through the aperture in the plate so that in use the male projecting portion of the vertically abutting structural component projects through the aperture in the plate into the bore, the bore being defined by a sleeve having a closed inner end, the sleeve projecting into the structural component from the plate.

The structural component may further include a male coupling for coupling the structural component to a vertically abutting structural component; the male coupling comprising a plate for location at the top or bottom edge of the structural component, reinforcing rods projecting from the plate and extending into the structural component and being embedded in grout so as to structurally unite the male coupling to the structural component, the male coupling further including a projecting rod projecting beyond the top or bottom edge of the structural component for being received within a female aperture within the vertically abutting structural component.

A coupling channel may be provided in a face of the structural component, the coupling channel opening outwardly through the face and having a restricted mouth, the coupling channel being defined by 25 a length of channel having a reinforcing rod welded to the inner base web of the coupling channel section so that the reinforcing rod extends beyond the end of the coupling channel into the structural component, the reinforcing rod being embedded within grout within the structural component so as to structurally unite the coupling channel to the building component, the reinforcing rod being stepped inwardly so as to locate the reinforcing rod generally centrally within the thickness of the structuiral component.

S Possible and preferred features of the present invention will now be described with particular reference to the accompanying drawings.

However it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. In the drawings: Fig. 1 is a schematic perspective view of a portion of first and second courses of blocks, Fig. 2 shows a fragment of a panel made of acoustic blocks and a post tensioning tube extending vertically, Figs. 3, 4 and 5 show three possible lifters for use in the present invention, Fig, 6 shows schematically a lifting frame for structural components such as the lift well section illustrated, Fig. 7 shows the reinforcing rod extending vertically and having a sleeve allowing stretching during lifting, Fig. 8 is a side elevational view of an anchor member for suspension of a panel from a building structure, Fig. 9 is a sectional view showing male and female coupling members for vertically abutting building components, and Fig. 10 shows a coupling channel for mounting in a structural S component.

The method of manufacturing and the features of prefabricated panels or structural components (hereinafter referred to as see* "structural components") will be described with reference to the drawings. The first step involves laying a course 10 of construction blocks or bricks 11 (hereinafter referred to "blocks"), the blocks "having upright holes 12 arranged to align with corresponding holes in S. an adjacent course 15 of similar blocks, The blocks are laid on a flat bed from which they are lifted later. String lines may be run to guide the laying of the blocks as is known in the brick laying 30 trade. The initial course 10 of blocks 11 is preferably provided with a groove or channel 16 in its upper face so that a continuous groove or channel is defined along the upper face of the course The front and back upright faces of the blocks can be generally conventional so that the groove or channel 16 is not visible.

The process further includes the step of laying a reinforcing rod or, if desired, two reinforcing rods along the channel 16 so as not to block the holes. The rod(s) 20 may be generally conventional, e.g. may be 9mm deformed high tensile galvanised reinforcing rod(s) of the general kind used in pipe reinforcement. If two rods 20 are used without a channel 16, 6mm rods may be used.

Preferably, at least one of the holes in the blocks along the length of the initial course 10 is plugged with a member 21 which conforms substantially to the shape of the hole 12 in plan view. The plug 21 has a handle 22 extending upwardly from the plug. The purpose and use of the plug member 21 will be described further below.

A second course of blocks 15 is laid along the first course with mortar or other grout or bonding agent 17 between the courses, the second course 15 having blocks with holes 12 aligned at least with the hole or holes in the first course 10 having the plug members 21. The grout may be a 3 in 1 mix of finely washed coarse sand and A grade cement.

After the second course 15 has been laid, the or each plug member 21 is drawn upwardly from the first course 10 into the respective aligned hole in the second course 15 making a clear bore 18 through the mortar or other bonding agent layer 17 between the first and g 20 second courses, This drawing of the plug member 21 upwardly may be o••oo achieved by grasping the handle 22 at the top of the plug member and Ce drawing the plug member upwardly into the second course.

The steps of laying further courses and drawing the plug e.a.

member(s) 21 up through the intervening mortar or other binding agent layer can be repeated as often as desired so that as the number of courses increases and an upright panel or structural component C *structure is formed, there is also formed a continuous passage 18 o.

extending generally vertically through the entire height of the structural component, 30 If desired, and depending on the height and use of the structural component, further courses beyond the first 10 may be provided with the grooved or channelled blocks into which reinforcing rods are laid along the courses. This provides with the mortar, grout or other bonding agent laid between the courses a continuous lateral reinforced beam. For example, at every 600mm of height there may be provided a lateral reinforced beam defined by the mortar or grout in the grooved blocks.

When the desired height of the structural component has been reached, the plug member(s) 21 may be removed from the top course thereby exposing the vertical passage 18 through the entire nui,ber of courses. Into this passage lS there may be inserted a reinforcing rod 30 and the passage 18 may be filled with grout or bonding cement 31 or the like so that there is formed a continuous reinforced column extending the whole height of the structural component. As mentioned above, there may be several vertical passages 18 created for receiving reinforcing rods 30 and for filling with grout 31 so as to define several reinforced concrete beam'r extending through the height of the component.

With the method described above it is possible to prefabricate not only generally rectangular panels for any desired purpose but it is also possible to prefabricate structures of other shapes, For example, structures having an L shape in plan view may also be erected. In the case of structures having corners, the grooves or channels 16 in the first course 10 and higher courses of blocks may c extend around the corners. In this case, or when the channels 16 are not provided the reinforcing rods 20 are preferably bent at the 20 required angles so as to pass around the corner thereby forming with the grout a reinforced beam of the desired angled shape.

It is also possible to prefabricate generally box shaped structures. In particular it is possible to prefabricate lift. well or stair well sections which can be generally C shaped or closed rings in plan view having continuous back and opposed side walls and a front wall which is interrupted over part or over the full height of the structure by an opening. Such a structure can be prefabricated off site to specifications and assembled on site by

C.

being manoeuvred into position with similar structures being mounted .i 30 one on top of another.

The method according to the preferred aspect of the invention as described above enables ancho- members 40 to be assembled into the structural component and arranged to project externally of the face or faces, the anchor members 40 being usable to anchor the structural component in use, e.g, to a building frame. An anchor member 40 for u-e in the present invention preferably has an embedded portion 41 which is laid between adjacent courses Ila, 12b (Fig. The embedded portion 41 includes an aperture 42 therethrough which is aligned with a hole through which a vertical reinforcing bar 30 is to be inserted so that the anchor member 40 is firmly secured when the vertical reinforcing rod and surrounding grout is inserted and passes through the anchor member 40. The portion 43 of the anchor member projecting externally from the structural component may be provided with anchoring points such as anchoring apertures 44 for co-operation with mating formations provided say on the framework of the building structure.

The anchor member 40 in Fig. 8 is particularly designed for enabling mounting of structural components so as to be suspended from the building structure. The anchor member 40 comprises a face plate which lies along the face of the courses of blocks 11a, 11b, 11c.

The support plate 43 projects laterally to be secured to the building structure so that the structural component or panel extends downwardly from the face plate 45 and the support plate 43. Two anchoring plates 41, 41a are spaced so as to receive a brick course lib between them, the anchoring plates 41, 41a being embedded in the grout between the adjacent courses lla, llb, le and the vertical reinforcing bar 30 passing through the apertures 42 in the anchoring S 20 plates.

•The method of the present invention preferably further includes the step of coupling a lifter 50 to tle vertical reinforcing bar so that after insertion and setting of the grout 31 around the vertical reinforcing bar 30, the lifter 50 is partially embedded in the reinforced column. A portion of the lifter 50 is exposed at the top of the reinforced column and at the top of the panel or structure so that a lifting attachment may be coupled to the lifter 50 and a lifting force applied to the lifter to lift the structural component. The lifting force applied to the lifter will be passed 30 through the vertical reinforcing rod 30 to substantially the entire height of the panel.

5 The coupling of the lifter 50 to the vertical reinforcing rod may be achieved as shown in Figs. 3 and 5 by prcviding a coupling hole 51 or other co-operating formation at the lower end of the lifter, the upper end of the vertical reinforcing rod 30 being provided with, say, an inverted U shape 52 for co-operating with the lower end of the lifter. In another arrangement (Fig. the lower end of the lifter 50 is spliced with the vertical reinforcing rod Tn particular, the lifter 50 is provided with a downward extension portion 53 which is a generally linear rod provided with deformations such as helically arranged thickened ribs or the like of the general kind known to be provided on reinforcing rods, By overlapping the lower extension portion 53 of the lifter with the upper end of the vertical reinforcing rod 30, the grout effectively splices the lifter 50 and reinforcing rod 30 together.

The upper end of the lifter 50 may be provided with a formation such as an eye 54 (Fig. 3) or an enlarged head 55 (Figs. 4 and 5) for co-operation with a crane mounted lifting hook or the like. The upper end of the lifter 50 may be recessed slightly below the upper edge of the upper course of blocks so as not to project substantially above the structural component.

In Fig. 7 the reinforcing rod 30 is grouted along a lower portion of its length 32. An upper portion 33 of the length of the reinforcing rod is surrounded by a sleeve 34 which allows movement between the rod 30 and the sleeve 34. With this arrangement, lifting forces applied to the upper end of the rod 30 sufficient to cause some stretching of the rod at its upper portion 33 will be taken up by the sliding movement between the rod and the sleeve 34.

For some applications of the panel or structure, the method may include the step of providing a generally vertical tube 35 (Fig. 2) extending through the entire height of the structural component. The tube 35 is arranged to extend the full height of the structural component through aligned holes in the blocks so that a clear passage 36 without mortar or grout extends through the entire height of the structural component at the location of the tube. Grout may be placed around the outside of the tube 35 after the completion of the top course of blocks, however, the upper and lower ends of the tube 30 are open so that there remains a clear passage through the entire height of the component. This method of erection enables the insertion through the passage 36 of a rod through the entire height of the component, the rod being tensioned on site by tightening of a nut or the like onto a top plate on the structure so that the structure is effectively post tensioned on site so as to be usable as a free standing wall or structural element without further support.

A L.ie plate (not shown) can be located at the bottom course from which the vertical rod extends.

The method according to the preferred embodiment of the invention as described above can be seen to enable the construction of a structural component having the structural, insulating and aesthetic appeal of solid block. The method can be carried out within a suitable building so that the work of erecting the panels or structural components can continue regardless of weather conditions.

The structures can be erected and allowed to stand so that the mortar, grout and cement can cure to full strength before being lifted in the same general manner as pre-cast concrete panels and transported and erected at the final site. Because the structures are made of blocks using substantially conventional block laying techniques, the structures can be readily made to varying shapes and sizes according to specifications without the need for construction of special formwork or the like. Also surface damage to a prefabricated structure can be readily repaired by cutting out the surface portion of a damaged block and refacing the block with an undamaged block face so that the repair is completely invisible and no structural integrity is jeopardized.

The completed prefabricated panel or structural component 20 comprises multiple courses r building blocks, between some of which a reinforcing rod 20 runs, the rod being embedded in mortar or grout o* *so as to define with the rod a reinforced beam through the structure, Sthe panel or structure also including one or more generally vertical eO reinforced columnsdefined by a reinforcing rod 30 through a passage extending through the entire height of the structure, the passage being filled with mortar or grout so as to define with the vertical rod a reinforced upright column.

At the upper ends of the reinforced concrete columns there are provided lifters 50 coupled to the associated vertical reinforcing 30 rods 30 so that lifting forces applied to the lifters are passed through the lifters to the respective vertical reinforcing rods.

In Fig. 9 the panel 60 includes coupling means 61 for coupling see**: the panel to a vertically abutting buildiig component 62 such as C•1 another panel or a slab or the like of a building structure. The panel 62 includes a female coupling 63 which is structurally united with the panel 62. In particular, the female coupling 63 has a plate 64 which is built into the panel so as to be co-planer with the top edge 65 of the panel 62. Reinforcing rods 66 are welded to and extend from the plate 64 within the panel 62, the reinforcing rods 66 passing through holes in the blocks of the panel 62 and then being embedded in grout. The plqte 64 includes an aperture 67 for receiving a male projecting portion 71 of the vertically abutting building component 60. The aperture 67 opens into a bore which is defined by a sleeve 68 having a closed inner end 69. The sleeve 68 also projects into the holes in the blocks. The male projecting portion passes 71 through the aperture 67 into the sleeve 68 and can b. grouted in that position to join the panel 62 to the vertically iDutting building component The male coupling 61 comprises a plate 70 which is located at the edge 72 of the building component 60. Reinforcing rods 73 are welded to and projected from the plate 70 and are also embedded in grout in the holes in the blocks to structurally unite the male coupling 61 into the building component 60. A projecting rod 71 which can also have an inner end 75 grouted into the building component 60 projects beyond the edge 72 so as to be received and grouted within the female aperture 67, In Fig. 10 there is shown a coupling channel 80 which in use is 20 mounted in a face 81 of the panel 82. The coupling channel 80 opens o S outwardly and has a restricted mouth 83 so that a nut or the like can "be located within the channel and resist being drawn out through the mouth. The channel 80 has a reinforcing rod 84 welded to the base web of the channel section, the reinforcing rod 84 extending beyond the ends of the channel being stepped inwardly at 85 so that the reinforcing rod 84 is located generally centrally within the thickness of the panel 82. The reinforcing rod 84 is imbedded within grout within the panel 85 so that t 1 coupling channel is united structurally to the panel. The channel. may be similar to the known S 30 "Unistruts" used in precast concrete panels, The blocks 11 used in erecting the panels may be generally conventional sized bricks having vertical holes 12 through the entire height, the holes being spaced from the brick ends so that holes in one block in one course align with corresponding holes in the courses above and below, In the Fig. 2 possible embodiment of a panel or structural component 11 is provided with of the block, the having cavities cavities sound insulating properties, 18 having openings 19 in the extending vertically through each block front face the entire height of the block. In plan view such a block 11 may be F shaped with the two cavities 18 having restricted mouths 19 opening to the front face of the block. The cavities 18 align when similar blocks are overlapped and laid in courses in conventional block laying fashion. The mouths 19 to the cavities enable sound impinging on the front face to penetrate the cavities 18 and be dispersed.

Fig. 6 shows an apparatus for handling prefabricated upright panels or structural components having variable shape in plan view.

The apparatus includes a lifting frame 90 for placement over a prefabricated structure 91. The frame includes at least one longitudinal member 92 provided with at least two lifting points 94 for attachment to the upper portion of the structural component 91.

The longitudinal frame member 92 is extendable, preferably telescopically, so as to enable the separation between the lifting points 94 to be varied so that structural components having variable shape can be lifted from points of differing separation. The longitudinal member 92 is substantially rigid against bending transverse to its longitudinal extent.

The frame 90 also includes a transverse member 95 which is also 20 provided with at least two lifting points 94, one of which is a lifting point provided on the longitudinal member 92 at the "intersection of the transverse member 95, the transverse member also being extendable, preferably telescopically, and being rigid against bending transverse to its length.

With this arrangement of frame, both longitudinal and transverse membhrs 92, 95 may be telescopically adjustable so that at least three lifting points can be utilised to lift structures of variable shapr.

In the illustrated embodiment the lifting frame 90 is generally S" 30 rectangular and all four tdges 92, 93 95, 96 are telescopically Sextendable. Lifting points 94 may be provided at the four corners of the rectangular frame. This frame 90 is particularly suitable for lifting a prefabricated structural component having a rectangular plain but of variable dimensions, such .is a prefabricated lift well structure 91.

It will be seen that the present invention enables the prefabr;ication of brick or building block structures having greater ease of manufacture than precast concrete oanels particularly for irregular or small job lots built to specifications. The panels or structures have the insulating and aesthetic character;stics of bricks or blocks while having the required strength for structural purposes and for high rise buildings.

It is to be understood that various alterations, modifications and/or additions may be made to the features of the possible and preferred embodiment(s) of the invention as herein described without departing from the spirit and scope of the invention.

*o 0 0 o

S

S *S

S*

f 5*

S

Claims

1. A method of manufacturing a prefabricated structural component including the step:- of: laying a course of construction blocks, the blocks having upright holes arranged to at least partially align with corresponding holes in the construction blocks in an adjacent course of similar construction blocks; laying at least one reinforcing piece along the first course of blocks so as not to substantially obstruct the holes; laying a second course of similar blocks along the first course so that holes in the blocks of the second course substantially align with holes in the blocks of the first course and locating grout between the first and second courses whereby the grout located between the first and second courses together with said at least one reinforcing piece form a reinforced beam between thp first and second courses; laying further courses of similar blocks with grout between adjacent courses, the blocks being positioned so that holes in the blocks of the further courses align with aligned holes in the preceding courses; locating an anchor member so that an externally accessible portion of the anchor member is accessible from externally of the finished structural component to enable mounting of the finished structural component to a building Etructure, the anchor member including said externally accessible portion and an anchoring portion which is located between two adjacent courses of blocks, the anchoring portion having an aperture therethrough and the anchor °.member being located so that the aperture is aligned with the aligned 25 holes in the adjacent courses of blocks; locating a reinforcing rod in aligned holes in the courses so that the reinforcing rod extends through the aligned holes and also passes through the aperture in the anchoring portion of the anchor member; and filling the cavity formed by the aligned holes and containing the reinforcing rod with grout so 30 as to form a reinforced column extending through the courses of *e 9 blocks and through the aperture in the anchoring portion.

2. A method as claimed in Claim 1 wherein the blocks in the first course are each provided with a channel extending longitudinally so that as the blocks of the first course are laid, a longitudinal 35 channel along substantially the length of the course is formed, the e reinforcing piece being located within the channel so that the grout between the first and second courses enters said channel and forms said reinforced beam. 4 17

3. A method as claimed in Claim 1 wherein the reinforcing piece is laid on top of the first course of blocks so as not to substantially obstruct the holes within the blocks of the first course, the grout surrounding the reinforcing piece thereby forming said reinforced beam extending along the first course and between the blocks of the first and second courses.

4. A method as claimed in any one of the preceding claims wherein at least one of the holes provided in the blocks of the first course is plugged by a plug member during the laying of the first course, the plug member including a handle extending generally in the direction of the second course, the method including the step of drawing the plug member upwardly from the hole in the first course when the second course has been laid so the plug member is drawn into the aligned hole in the second course thereby maintaining the cavity formed by the aligned holes in the first and second courses substantially clear of grout during the process of laying courses. A method as claimed in any one of the preceding claims wherein the structural component includes courses which extend around an angle, at least one of the reinforcing pieces which are laid along the first course conforming to the general shape of the line of the course so as to extend continuously through the angle.

6. A method as claimed in Claim 5 wherein each course extends through at least two angles so that the structural component has two concave corners in plan view, the structural component forming in use 25 at least three walls of an at least partially enclosed space within a 4 building structure.

7. A method as claimed in Claim 6 wherein the angles through which 4 the courses are laid are right angles so that the structural o •w component is generally C shaped in plan view and forms three walls of 30 a substantially enclosed space within the building structure.

8. A method as claimed in Claim 6 wherein the structural component extends through three right angles and forms in plan view a closed box structure having four walls and an access opening in one wall, the reinforcing pieces between adjacent courses of blocks extending 35 around through each of the three right angled corners, any •ego reinforcing pieces terminating along one wall being overlapped with continuation reinforcing pieces so as to splice the reinforcing pieces together within the grout and form a substantially continuous 18 reinforced beam between adjacent courses.

9. A method as claimed in any one of the preceding claims wherein said anchoring portion comprises an anchoring plate which is laid between adjacent courses of blocks, the anchoring plate having said aperture therethrough which Is aligned with aligned holes in the adjacent courses of blocks, the reinforcing rod which is located through the aligned holes also passing through the aperture in the anchoring plate, A method as claimed in Claim 9 wherein the anchor member comprises a suspension anchor member for enabling mounting of the structural component so as to be suspended from the building structure, said externally accessible portion of the suspension ar hor member comprising a face plate which in use lies substantially along the outer faces of at least two adjacent courses of blocks, and a support plate projecting laterally from the face plate and away from the courses of blocks, the support plate being arranged to be secured to the building structure so that the structural component extends downwardly from the face plate and support plate, said anchoring plate projecting inwardly from the face plate so as to be located between adjacent courses of blocks.

11. A method as claimed in any one of the preceding claims and further including the step of embedding a lifter within the reinforced column formed by the grout in the aligned holes in which the reinforcing rod is located, the lifter having a head portion ooeoe which is exposed so as to be engagable by lifting apparatus to enable 25 lifting of the structural component.

12. A method as claimed in any one of the preceding claims and :'"further including the step of leaving a substantially clear passage through adjacent courses of blocks whereby a tension rod may be passed through the clear passage from the top to the bottom of the structural component and the rod then being tensioned so as to post tension the structural component.

13. A prefabricated structure component when manufactured by a method as claimed in any one of the preceding claims.

14. A prefabricated structural component comprising a plurality of 35 courses of building blocks, at least one reinforcing piece being located so as to extend generally between adjacent courses of blocks, the reinforcing piece being embedded within grout so as to form a 19 5 l I r reinforced beam extending between the adjacent courses, the structural component further including a transverse reinforcing rod extending transverse to the lines of the courses of blocks and through aligned holes in the blocks of the courses, the transverse reinforcing rod being contained within a passage defined by the aligned holes, the passage being filled with grout so as to form a transverse reinforced column, the building component further including an anchor member comprising an externally accessible portion which is accessible from externally of the structual component to enable mounting of the structural component to a building structure, the anchor member also including an anchoring portion which is located between two adjacent courses of blocks, the anchoring portion having an aperture therethrough which is aligned with the aligned holes in the courses of blocks, the reinforcing rod which extends through the aligned holes also passing through the aperture in the anchoring portion whereby the transverse reinforced column passes through the aperture in the anchoring portion. A structural component as claimed in Claim 14 wherein the courses are laid substantially hori::ontally so that the transverse reinforcing rod extends substantially upright throughout substantially the entire height of the structural component, the structural component further including a lifter coupled to the upright reinforcing rod so that lifting forces can be applied to the lifter and the lifting force transmitted to the reinforced column ooooo extending through the height of the structural component. 25 2 16. A structural component as claimed in Claim 14 wherein a base plate is provided at or beneath the bottom course of blocks, the reinforcing rod extending upwardly from the base plate through the oooo passage, a lifter being provided at the upper end of the reinforcing rod so that lifting force applied to the reinforcing rod is transferred to the base plate so that lifting force is applied from the bottom of the structural component.

17. A structural component as claimed in Claim 16 wherein the reinforcing rod in the passage is grouted through a lower portion of its length, an upper portion of the length of the reinforcing rod being surrounded by a sleeve allowing movement between the reinforcing rod and the sleeve whereby lifting forces applied to the upper end of the reinforcing rod sufficient to cause stretching of the rod at its upper portion will be taken up by sliding movement between the rod and the sleeve.

18. A structural component as claimed in any one of Claims 14 to 16 and further including a female coupling for coupling the structural component to a vertically abutting structural component; the female coupling having a plate which is generally co-planar with a top or bottom edge of the structural component, reinforcing rods extending from the plate within the structural component, the reinforcing rods being embedded in grout so as to structurally unite the female coupling to the structural component, the plate further including an aperture for receiving a male projecting portion of the vertically abutting structural component.

19. A structural component as claimed in any one of Claims 14 to 16 and further including a male coupling for coupling the structural component to a vertically abutting structural component; the male coupling comprising a plate for location at the top or bottom edge of the structural component, reinforcing rods projecting from the plate and extending into the structural component and being embedded in grout so as to structurally unite the male coupling to the structural component, the male coupling further including a projecting rod projecting beyond the top or bottom edge of the structural component for being received within a female aperture within the vertically abutting structural component.

20. A structural component as claimed in Claim 18 wherein the female S"coupling further includes a bore which opens outwardly through the 25 S* aperture in the plate so that in use the male projecting portion of the vertically abutting structural component projects through the aperture in the plate into the bore, the bore being defined by a sleeve having a closed inner end, the sleeve projecting into the structural component from the plate.

21. A structural component as claimed in any one of Claims 14 to and further including a coupling channel in a face of the structural component, the coupling channel opening outwardly through the face and having a restricted mouth, the coupling channel being defined by length of channel having a reinforcing rod welded to the inner base 35 web of the coupling channel section so that the reinforcing rod extends beyond the end of the coupling channel into the structural component, the reinforcing rod being embedded within grout within the structural component so as to structurally unite the coupling channel to the building component, the reinforcing rod being stepped inwardly so as to locate the reinforcing rod generally centrally within the thickness of the structural component.

22. A method of manufacturing a structural component as claimed in Claim 1 and substantially as herein before described with particular reference to the accompanying drawings.

23. A prefabricated structural component as claimed in Claim 14 and substantially as herein before described with particular reference to the accompanying drawings. Dated this 13th day of January, 1993 PATENT ATTORNEY SERVICES Attorneys for BARRIER ENGINEERING CONSTRUCTION CO PTY LTD -Si z nIV 0