초록 ▼

A plurality of pre-formed panels are provided. Each panel comprises construction boards held apart from each other by spaced apertured metal strength members (2) to form a sandwich construction. Each strength member is provided with at least one bar (10) extending beyond an edge of the construction

A plurality of pre-formed panels are provided. Each panel comprises construction boards held apart from each other by spaced apertured metal strength members (2) to form a sandwich construction. Each strength member is provided with at least one bar (10) extending beyond an edge of the construction boards. Each strength member has a bar receiving portion (63) associated with its end opposite the at least one bar. To construct a wall, a first such panel is first erected with its strength members (2) extending vertically and with the bars (10) projecting above the remainder of the panel. The void between the construction boards is then filled with a settable material. A second panel is located vertically above the first by slotting the bars of the first panel into bar receiving portions of strength members in the second panel. Thereafter, the void between the construction boards of the second panel is filled with the settable material.

대표청구항 ▼

1. A method for constructing reinforced, filled and set walls, the method comprising the steps of: providing a plurality of unitary pre-formed panel structures, each panel structure comprising two construction boards fixedly held apart from each other by a pre-set distance to form a hollow sandwich

1. A method for constructing reinforced, filled and set walls, the method comprising the steps of: providing a plurality of unitary pre-formed panel structures, each panel structure comprising two construction boards fixedly held apart from each other by a pre-set distance to form a hollow sandwich construction by a plurality of apertured strength members and with a void defined between the construction boards, the strength members being spaced from each other, each strength member comprising a vertically extending web and a pair of flanges, each flange being directly joined to the web along a vertically extending edge of the web, with one said flange being coupled to one construction board, the second said flange being coupled to the other construction board, and the web extending between the construction boards, and at least one bar joined to a first portion of the strength member and extending beyond an edge of the construction boards to form a stabbing bar, and each strength member having a bar receiving portion located adjacent to the end of the strength member opposite the first portion;placing a first said panel structure in an erect position with the first said panel structure's strength members extending vertically and with the stabbing bars projecting above the remainder of the panel structure;filling the void between the construction boards with a settable material;before, during or after said filling step, locating a second said panel structure vertically above the first by lowering the second said panel structure on to the first such panel structure so that respective stabbing bars of the first panel structure slot into bar receiving portions of strength members in the second panel structure; andthereafter filling the void between the construction boards of the second panel structure with said settable material. 2. A method according to claim 1, wherein each strength member comprises a steel stud forming said web and flanges and formed of steel, the stabbing bars also being formed of steel, each stabbing bar being welded to an upper portion of a stud. 3. A method according to claim 1, wherein the construction boards are attached to the strength members by an adhesive including an intumescing additive. 4. A method according to claim 1, including the step of conferring a surface profile to at least one of the stabbing bars and the bar receiving portions by a surface profiling method to thereby key into the settable material such that, when the settable material fills voids in the second panel structure, tension continuity is established between the strength members of the two panels, the surface profiling method being selected from the group consisting of one or more of rolling a profile into the surface of at least one of the stabbing bars and lower end portions of the strength members, providing the edge of the stabbing bars with a serrated or re-entrant shaped edge profile, adhesively bonding aggregate particles to the surface of at least one of the stabbing bars and lower end portions of the strength members, and welding portions of reinforcing rods to surfaces of the stabbing bars. 5. A method according to claim 1, further including the step of providing lateral reinforcement to each panel structure. 6. A method according to claim 5, wherein each strength member includes a plurality of through apertures sized to receive reinforcing rods, and wherein the step of providing lateral reinforcement comprises inserting reinforcing rods through aligned apertures in the strength members of a panel structure in a predetermined reinforcing rod schedule. 7. A method according to claim 1, further comprising the steps, during manufacture of a panel structure, of providing each strength member with an upper reference surface adjacent the strength member' end that is vertically uppermost in use and a lower reference surface adjacent the strength member' an opposite end, controlling the separation of one said surface from the other for each strength member during manufacture of said strength members, and aligning the upper reference surfaces for all the strength members of a panel structure against a straight edge during manufacture of a panel structure; and the method further comprising the step, during the step of location of said second panel structure, of bringing the lower reference surfaces of said second panel structure into contact with upper reference surfaces of said first panel structure before the step of filling the voids of the second panel structure. 8. A method according to claim 7, wherein the construction boards are rebated where they meet, and wherein the method comprises the step of applying a curable sealant to the region of said rebates immediately before location of the second panel, the cure-rate of the sealant being selected so that the sealant remains essentially liquid for a sufficient period to allow location of the second panel, thereafter hardening to provide resistance to pressure of the settable material during filling of the voids in the second panel. 9. A method according to claim 1, wherein the construction boards consist of cement particle board, and the settable material comprises a self-compacting concrete, the method comprising the step of allowing the concrete to self compact. 10. A strength member for use in the manufacture of unitary pre-formed hollow panel structures having two construction boards fixedly held apart from each other by a pre-set distance by strength members to form a hollow sandwich construction with a void defined between the construction boards for use in a method for constructing reinforced, filled and set walls by placing a first said panel structure having strength members extending vertically and with stabbing bars joined to and forming part of the strength members projecting above the remainder of the panel structure, by filling the void between the construction boards with a settable material, by locating, before, during or after said filling step, a second said panel structure vertically above the first by lowering the second said panel structure on to the first such panel structure so that respective stabbing bars of the first panel structure slot into stabbing bar receiving portions of the lower ends of strength members in the second panel structure, and by thereafter filling the void between the construction boards of the second panel structure with said settable material; a said strength member being provided with a plurality of apertures therethrough to allow flow of settable material through and around the strength member, and having a first end and a second end, and comprising: a vertically extending web and a pair of flanges, each flange being directly joined to the web along a vertically extending edge of the web, one said flange being arranged to be coupled to one construction board and the second said flange being arranged to be coupled to the other construction board in said panel structure to hold the two construction boards apart from each other by said pre-set distance, with the web extending between the construction boards, andat least one projecting stabbing bar joined to a first portion of the strength member at said first end and arranged to extend beyond an edge of the construction boards in said panel structure, andthe strength member defining at least one stabbing bar receiving portion at said second end. 11. A strength member according to claim 10, comprising a steel stud forming said web and flanges, said at least one projecting stabbing bar also being formed of steel and being welded to the stud adjacent the at least one projecting stabbing bar's said first end. 12. A strength member according to claim 11, provided with a single stabbing bar projecting substantially along the centreline of the stud, and formed from a profiled plate having a first surface on one side and a second surface on its other side, a looped portion of reinforcing rod being welded to at least one of said first and second surfaces to provide enhanced keying between the stabbing bar and the settable material. 13. A strength member according to claim 12, wherein the bar receiving portion comprises a cage formed at said second end by welding an inverted insert to said stud adjacent said second end, a said single stabbing bar of said first panel structure being adapted to be received longitudinally in a central space defined within a said cage of a said single stabling bar of a said second panel structure as a said second panel structure is located vertically above a said first panel structure. 14. A strength member according to claim 10, further including a plurality of through apertures sized to receive reinforcing rods to provide lateral reinforcement to a said panel. 15. A strength member according to claim 10, comprising an upper reference surface adjacent said first end and a lower reference surface adjacent said second end, the upper and lower reference surfaces being related to each other such that when a said second panel structure is located vertically above a said first panel structure and the stabbing bars of strength members of the first panel structure slotted into bar receiving portions of strength members of the second panel structure, the respective upper reference surfaces of the strength members of the first panel structure make facial contact with the respective lower reference surfaces of aligned strength members of the second panel structure. 16. A unitary pre-formed hollow panel structure for use in a method for constructing reinforced, filled and set walls, the panel structure comprising two construction boards fixedly held apart from each other by a pre-set distance to form a hollow sandwich structure by a plurality of apertured strength members and with a void defined between the construction boards, the strength members being spaced from each other, each strength member comprising a vertically extending web and a pair of flanges, each flange being directly joined to the web along a vertically extending edge of the web, with one said flange being coupled to one construction board, the second said flange being coupled to the other construction board, and the web extending between the construction boards, and at least one bar joined to a first portion of the strength member and extending beyond an edge of the construction boards to form a stabbing bar, and each strength member having a stabbing bar receiving portion located adjacent to the end of the strength member opposite the first portion; whereby a structural wall may be erected by the steps of placing a first said panel structure in an erect position with its strength members extending vertically and with the stabbing bars projecting above the remainder of the panel structure, by filling the void between the construction boards with a settable material, by locating, before, during or after said filling step, a second said panel structure vertically above the first by lowering the second said panel structure on to the first such panel structure so that respective stabbing bars of the first panel structure slot into respective stabbing bar receiving portions of strength members in the second panel structure, and by thereafter filling the void between the construction boards of the second panel structure with said settable material. 17. A panel structure according to claim 16, wherein each strength member comprises a steel stud forming said web and flanges, and the projecting bars are also formed of steel, each bar being welded to an upper portion of a stud. 18. A panel structure according to claim 17, wherein each said stud is provided with a single stabbing bar projecting substantially along the centreline of the stud, and formed from a profiled plate having a first surface on one side and a second surface on its other side, a looped portion of reinforcing rod being welded to at least one of said first and second surfaces to provide enhanced keying between the stabbing bar and the settable material. 19. A panel structure according to claim 18, wherein each stabbing bar receiving portion comprises a cage formed at said opposite end of said stud by welding an inverted insert to said stud adjacent said opposite end, a said single stabbing bar being adapted to be received longitudinally in a central space defined within said cage as a said second panel is located vertically above a said first panel. 20. A panel structure according to claim 16, wherein the construction boards are attached to the strength members by an adhesive including an intumescing additive. 21. A panel structure according to claim 16, wherein each strength member includes a plurality of through apertures sized to receive reinforcing rods, and wherein reinforcing rods interconnect aligned said apertures in the strength members of the panel structure to provide lateral reinforcement to the panel structure. 22. A panel structure according to claim 16, wherein each strength member has an upper reference surface adjacent an end that is vertically uppermost in use and a lower reference surface adjacent an opposite end, the separation of one said surface from the other for each strength member being controlled to a predetermined value, the upper reference surfaces for all the strength members of a panel structure being aligned, and the upper and lower reference surfaces being related to each other such that when a said second panel structure is located vertically above a said first panel structure and the stabbing bars of strength members of the first panel structure slotted into bar receiving portions of strength members of the second panel structure, the respective upper reference surfaces of the strength members of the first panel structure make facial contact with the respective lower reference surfaces of aligned strength members of the second panel structure.