Building systems, panel systems, and formwork systems, panels and formwork for building and methods of building using panels and formwork

A building system (5) including a panel system (10) and a formwork system (78). The panel system (10) includes a plurality of modular panels (12) arranged to fit with one another in a predetermined grid arrangement (13) to form side walls of a building in a fitted condition. At least the bottom sides (24) of each of the modular panels (12) includes a plurality of apertures (34) that are arranged at predetermined spaced apart locations along the bottom side (24) so as to coincide with the predetermined grid arrangement (13). The formwork system (78) includes a plurality of modular formwork members (80) that are associated with each of the modular panels (12) to provide a supporting slab (72) having slab apertures (76) to allow coupling with the modular panels (12). Modular panels (12), formwork members (80) and associated methods of use are also disclosed.

RELATED APPLICATIONS

This application claims priority from Australian provisional patent application no. 2016902067 filed on 31 May 2016, the contents of which are incorporated by reference.

TECHNICAL FIELD

The invention relates to a improvements in building systems, including a panel system, seals and coupling between panels, a slab forming system for building panels, a coupling for formwork members, and related methods including methods for fitting building panels to a building slab or foundation, methods for coupling formwork members, and methods for forming a slab using formwork members.

BACKGROUND

Building systems including modular wall panels are utilised in building to reduce costs and time during construction. Many types of building systems including modular wall panels are available and may be constructed from a cement composite material or a sandwich composite material including a polystyrene core sandwiched between Gypsum sheets. These panels may be available in a limited range of sizes and some may include pre-formed cut-outs for windows and doors.

In use, the modular wall panels are typically stood on a supporting ground surface and interconnected side-by-side by connector such as integral tongue and groove connectors carried by adjacent panels.

A problem with existing building systems relates to the modularity of the system such as number and configuration of panels and how these panels are connected or supported by a base such as a concrete slab. A more specific problem relates to a repeatable, robust and weather proof fit between the panels and, in particular, between panels and the concrete slab.

Another problem with existing modular wall panels relates to the adaptability of the panels to provide a suitable wall, such as a veneer wall, for a typically building structure such as a metal or timber framed house. Yet another problem relates to the ease and accuracy in which existing modular wall panels may be fitted with one another and with a supporting ground or base structure. Yet another problem with existing modular wall panels relates to the sealing between the panels and the supporting ground or base structure. Yet another problem with existing modular wall panels relates to the forming of a suitable ground or base structure to fit with and support the modular wall panels. Yet another problem with existing modular wall panels is the suitability for providing structural support.

Concrete slabs are typically formed with formwork. Traditionally such formwork includes an outer formwork member that defines an outer perimeter and a rebate formwork member that sits inside a top edge of the outer formwork member to define a rebate on which the building frame or bricks may be supported. The outer formwork member and the rebate formwork member are typically formed from wood and are cut to length for each new slab. The formwork members may be abutted against one another to increase length and jointed at a mitre joint at the corners thereof.

A problem with such formwork relates to repeatability, accuracy and joining of the formwork members that results in poor accuracy and repeatability of the formation of the rebate of the slab. Another problem is that such formwork may provide difficult for use with pre-formed modular panels due to misalignment between the formed rebate and the panels that result in issues with the accuracy repeatability, and suitability of fit between the resulting slab and modular panels.

The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.

SUMMARY

In accordance with a first broad aspect there is provided, a panel system including a plurality of modular panels arranged to fit with one another. The fit may be in a predetermined grid arrangement to form coextensive sidewalls of a building in a fitted condition. The modular panels may each include opposing sides, a bottom side and a topside. At least the bottom sides of each of the modular panels may include a plurality of apertures that are arranged at predetermined spaced apart locations along the bottom side. The predetermined spaced apart locations may coincide with the predetermined grid arrangement.

In an aspect, the topside includes a further plurality of apertures at spaced apart locations along the topside so as to coincide with the predetermined grid arrangement.

In another aspect, each of the modular panels each include a front side and an opposing backside, the backside having a rebated portion skirted by a frame, wherein the frame includes an inner side oriented toward the rebated portion and an opposing outer side, and wherein the plurality of apertures are arranged to pass between the inner side and outer side of the frame.

In yet another aspect, the outer side of the frame includes a sealing arrangement located toward the front side of the frame relative to the plurality of apertures.

In yet another aspect, the sealing arrangement includes a seal extending along each of the sides of the frame such that corresponding seals of adjacently arranged ones of the plurality of panels sealingly engage with one another in the fitted condition.

In yet another aspect, the outside of the frame includes a channel in which the plurality of apertures are located.

In yet another aspect, the bottom sides of each of the plurality of modular panels include a drain passage extending between the rebated portion and the outside of the bottom side of the frame.

In yet another aspect, the system further includes a plurality of fasteners arranged to pass between corresponding ones of the plurality of modular panels to secure adjacently arranged ones of the plurality of modular panels together in the fitted condition.

In accordance with a second broad aspect there is provided, a formwork system for a modular panel system as defined in any one of the previous claims, the formwork system including a plurality of modular formwork members that correspond to the plurality of the modular panels.

In an aspect, the plurality of modular formwork members each include a body adapted to form a rebate into a cast slab, the rebate being shaped to fit with the bottom side of a corresponding one of the plurality of modular panels in the fitted condition.

In another aspect, the body is adapted to carry a seal that is released by the body so as to be retained by the slab in a cured condition when the body is removed.

In yet another aspect, the releasable seal includes a head releasably retained by a retaining channel of the body and an anchor stem extending from the head, the anchor stem being embedded into the slab in the cured condition.

In yet another aspect, in the cured condition, the seal is arranged to sealing engage with corresponding seals carried by corresponding ones of the plurality of panels.

In yet another aspect, in the body is adapted to carry void formers that are arranged to form slab apertures that are aligned with at least some of the plurality of apertures of the corresponding plurality of modular panels.

In yet another aspect, the body includes a bottom side, a top side, an inner side and an outer side, the bottom side including a channel to initially carry the seal and a plurality of apertures, the channel extending lengthwise along the body and the plurality of apertures being located in a spaced apart lengthwise arrangement between the channel and the inner side.

In yet another aspect, the bottom side includes a lengthwise rib extending from the bottom side and wherein the plurality of apertures are located at spaced apart intervals along the lengthwise rib.

In yet another aspect, the top side includes a plurality of apertures that align with the plurality of apertures of the bottom side to allow a void former to be inserted therethrough so as to form voids that align with apertures of panels of the panel system.

In yet another aspect, the void formers include inserts that are cast into the slab in the cured condition, the inserts including a passage that provides the slab apertures.

In yet another aspect, the body of each of the formwork members is provided in the form of a hollow section.

In yet another aspect, the body of each of the formwork members is provided in the form of hollow sections that are adapted to couple with one another via a coupling.

In yet another aspect, one of the couplings includes a tongue having an tongue aperture and the other of the couplings includes flanking members that define a recess into which the tongue is received in the coupled condition.

In yet another aspect, the flanking members including a tapered entry aperture located in the coupled condition on one side of the tongue and a threaded aperture located in the coupled condition at an opposing side of the tongue that align with one another and the tongue aperture in the coupled condition such that a tapered portion of the fastener that is engagable with the tapered entry aperture is passed through the tongue aperture with a threaded end of the fastener being coupled to the threaded aperture thereby drawing the at least two formwork members into abutting alignment with one another.

In yet another aspect, the coupling is provided in the form of a male side and a female side that are provided at the ends of the respective ones of the bodies.

In yet another aspect, the male side includes a tongue that is received by a recess of the female side, the male and female sides including corresponding apertures that form a passage through which a fastener is fitted to secure the male and female sides together.

In yet another aspect, the passage and fastener are inwardly tapered between an entry end and an opposing end of the passage such that movement of the fastener between the entry end and the opposing end draws the male and female sides into aligned abutment.

In accordance with a third broad aspect there is provided, a building system as described above and herein.

In accordance with a fourth broad aspect there is provided, a panel for forming a wall, the panel including opposing sides, a bottom side a topside, a front side and an opposing backside, the backside being at least partially skirted by rib, the rib including an inner side face oriented toward the rebated portion and an opposing outer side face, wherein a plurality of apertures are arranged to pass between the inner side and outer side of the frame.

In an aspect, the outer side of the frame includes sealing arrangement located toward the front side of the frame relative to the plurality of apertures.

In another aspect, the rebated portion substantially spans the backside between the frame.

In accordance with a fifth broad aspect there is provided, a panel system including a plurality of panels as described above and herein, wherein the plurality of apertures of each of the plurality of panels are arranged to be aligned with one another in a fitted condition so as to allow a fastener to be passed there between.

In accordance with a sixth broad aspect there is provided, a formwork system for use with a panel system as described above, wherein the formwork system includes a plurality of formwork members that are each associated with one of the plurality of panels.

In accordance with a seventh broad aspect there is provided, a formwork system as described above and herein, wherein the plurality of formwork members each carry at least one of a releasable seal and a void forming insert that are cast into a slab in a cured condition so as to fit with corresponding ones of the plurality of panels in the fitted condition.

In accordance with an eighth broad aspect there is provided, a formwork system including at least two formwork members and a fastener, each of the form work members including corresponding couplings at opposing ends thereof that are fitted together in a coupled condition, wherein one of the couplings includes a tongue having an tapered tongue aperture and the other of the couplings includes flanking members that define a recess into which the tongue is received in the coupled condition, the flanking members including a tapered entry aperture located in the coupled condition on one side of the tongue and a threaded aperture located in the coupled condition at an opposing side of the tongue that align with one another and the tongue aperture in the coupled condition such that a tapered portion of the fastener that is engagable with the tapered entry aperture is passed through the tapered tongue aperture with a threaded end of the fastener being coupled to the threaded aperture thereby being actuable to draw the at least two formwork members into abutting alignment with one another.

In an aspect, the tongue and flanking members are set back relative to at least one opposing side and bottom side of the formwork members to define side abutment edges of the at least one opposing side and bottom side such that in the coupled condition the side abutment edges of the at the least one opposing side and bottom side of the adjacently coupled formwork members are abutted and outwardly oriented faces of least one opposing side and bottom side are generally flush with one another.

In accordance with an ninth broad aspect there is provided, a formwork member for forming a rebate in a concrete slab, the formwork member including an elongate body having opposing ends, a top side, a bottom side, an inner side and an outer side, wherein the bottom side includes a lengthwise channel arranged to releasably carry a head of a seal such that in use a stem of the seal is castable into the rebate and the formwork is removeable to expose the head of the seal so as to extend lengthwise along the rebate.

In an aspect, the bottom side includes a plurality of spaced apart apertures that extend parallel to the seal and are located toward the inner side relative to the seal.

In accordance with tenth broad aspect there is provided, a method of building using a panel system and an associated formwork system, the method may in some aspects include the steps of: selecting a plurality of panels of the panel system; selecting an plurality of formwork members of the formwork system that are associated with each of the plurality of panels; locating the plurality of formwork members such that a slab having a rebate is formable about the formwork members, the slab being formed with a least one slab aperture in the rebate associated with each of the formwork members; removing the plurality of formwork members from the slab in the cured condition, and locating the plurality of panels atop the rebate of the slabs, the plurality of panels being located in place of the removed associated formwork member; and fitting a fastener between an aperture of a bottom side of the plurality of panels and the associated slab aperture thereby coupling the plurality of panels to the slab.

In accordance with an eleventh broad aspect there is provided method of building using a panel system and an associated formwork system, the method including the steps of: locating a formwork member of the formwork system that carries a lengthwise seal such that a slab having a rebate is formed with the formwork member so as to have an exposed stem of the seal embedded in the rebate and a slab aperture extending into the rebate; removing the formwork member from the slab in a cured condition such that the seal is released from the formwork member and retained by the rebate; locating a panel of the panel system atop the rebate of the slab with a seal carried by the panel abutting with the seal of the rebate and aligning an aperture of the panel with the a slab aperture; and fitting a fastener between the aperture of the panel and the slab aperture thereby coupling the panel to the slab.

In accordance with an twelfth broad aspect there is provided, a method of building a supported wall using a panel and a formwork system, the method including: forming a concrete slab with a formwork member of the formwork system so as to have a rebate and an aperture extending depth wise into the rebate formed by a void former of the formwork system; locating the panel atop the rebate with an aperture of the panel being aligned with the aperture of the rebate; and coupling the panel to the slab via a fastener passed between the aperture of the panel and the aperture of the rebate so as to provide the supported wall.

In accordance with an thirteenth broad aspect there is provided, a method of building a supported wall using a panel and a formwork system, the method including: forming a concrete slab about a formwork member of the formwork system so as to have a rebate, a lengthwise seal carried by the formwork member, and an aperture extending depth wise into rebate formed by a void former of the formwork system; removing the formwork member from the slab in a cured condition such that the seal is released from the formwork member and retained by the rebate; locating a panel of the panel system atop the rebate of the slab with a seal carried by the panel abutting with the seal of the rebate and aligning an aperture of the panel with the slab aperture; and securing a fastener through the aperture of the panel into the slab aperture thereby coupling the panel to the slab in an upright orientation.

In accordance with an fourteenth broad aspect there is provided, a method of preparing a concrete slab for sealing with a wall panel supported by the slab, the method including: locating a formwork member that carries a lengthwise seal such that a slab having a rebate is formed along the formwork member, the slab having an exposed stem of the seal embedded therein and a slab aperture extending vertically downwardly into the rebate, and removing the formwork member from the slab in a cured condition such that the seal is released from the formwork member and is retained along the rebate by the cured concrete, the position of the seal being suitable to be abutted with a corresponding seal of the wall panel seatable thereon in an installed condition in which a fastener couples the wall panel to the rebate via the slab aperture.

DETAILED DESCRIPTION

Referring toFIG. 1, there is shown a building system5including a panel system10for forming walls of a building or the like. The panel system10including a plurality of modular panels12arranged to fit and couple with one in either a side-by-side or end-on end (or stacked) arrangement to form side walls of the building in a fitted condition such as that shown inFIG. 1.

The modular panels12include a variety of panel sizes and shapes and may be generally flat rectangular panels, such as panels12aas shown inFIG. 1, or angled corner panels as panels12b, as shown inFIG. 1. The types and configurations of the panels12are further described below with reference toFIGS. 3aand3b.

Referring toFIG. 2, each of the panels12includes a panel body14having a front side16, an opposing rear or backside18, opposing sides20, a topside22and a bottom or base side24. The backside18includes a rectangular rebated portion26skirted by a frame28. The frame28provides the opposing sides20, the topside22and the bottom side24.

The frame28is provided in the form of a skirting rib29that stands proud of the rebated portion26and includes an inner side30oriented toward the rebated portion26and an opposing outer side32that forms an outer perimeter of the panel12. The inner side30and outside32are both about perpendicular to a face35of the rebated portion26.

The panels12include a plurality of apertures34that are arranged in predetermined spaced apart intervals along each of the opposing sides20, the top side22and the bottom side24. More specifically, the plurality of apertures34include a plurality of horizontally spaced apart apertures31along each of the top side22and the bottom side24, and a plurality of vertically spaced apart apertures33along each of the opposing sides20.

The plurality of apertures34are arranged to pass through the frame28between the inner side30of the frame28and the outer side32of the frame28. This allows fasteners36passed through the apertures34to be accessible from the inner side30of the frame28at least partially within the rebated portion26. The fasteners36may be metal bolts or other suitable plastic fasteners.

The outer side32of the frame28includes a sealing arrangement38located toward the front side16of the panel12relative to the plurality of apertures34. The front side16is typically oriented toward the external environment and as such the sealing arrangement38is positioned to seal the plurality of apertures34from the external environment. Further details of the sealing arrangement38of the outer side32of the frame28are provided below with reference toFIGS. 4 to 7. The bottom side24of the panel12includes a drainage arrangement40that is further described below with reference toFIG. 10.

Referring now toFIGS. 3aand 3b, modular panels12may be provided in a series of predetermined sizes including straight panels12aand angled or corner panels12b. The modular panels12and preferably adapted to fit with a predetermined grid13and each of the plurality of apertures34, at least on the base24, is arranged and a predetermined spacing to fit with the predetermined grid13.

In this example, the predetermined spacing between horizontal apertures31of the plurality of apertures34is 150 mm and the predetermined grid may be a 900 mm grid as shown inFIG. 3aor a 600 mm grid as shown inFIG. 3b. The predetermined spacing between the vertical apertures33may be the same or different to the spacing between the horizontal apertures31, and in this example, the spacing between the vertical apertures33may be about 200 mm. The vertical aperture33allow for step down between adjacently coupled panels12.

Each of the sets of panels12associated with the 600 mm grid or the 900 mm grid are provided in approximately ten lengths and all sizes that may into fit with one another to provide most building shapes. A range of suitable dimensions is indicated onFIGS. 3aand 3b. It is also noted that the overall width of the panels12is preferably 110 mm which is the thickness of a common brick wall and as such the panels adapt well to existing building dimensions and construction practices. It is noted that the width of the skirting rib29may be about 70 mm and the depth of the rebated portion26, and hence the depth inside30of the frame28is about 85 mm. However, other suitable dimensions may be used.

Turning now to the modular panels12in more detail and referring toFIGS. 4 to 8, the sealing arrangement38includes an edge seal or sealing strip44extending along each of the sides20,22,24of the outer sides32of the frame28such that corresponding seals44of adjacently arranged ones of the plurality of panels12sealingly engage with one another in the fitted condition as best shown inFIGS. 6 to 8.

The seal44includes a head46and a stem48with a foot49that is embedded and anchors the seal44to the panel12. The head46is dome shaped and includes a void so as to be resiliently depressed when adjacent seals44are abutted against one another in the fitted condition. The seal44may be a fire rated silicon rubber or equivalent and are compressed between the panels12in use. The seals44, in particular, the stem48is embedded and cast into the panel12during production.

The outer sides32of the frame28of the panels12include elongate edged channels52in which the plurality of apertures34are located at spaced intervals within the channels52. The end seal44is positioned substantially between a front side edge50of the panel12and the channel52.

The channels52are arranged to receive a rod54as shown inFIG. 7that assists with alignment of the panels12with one another as is best shown inFIG. 7. The rod54may be circular in cross-section and may be provided in relatively short segments that may extend between adjacent panels12. Accordingly the channels52may be correspondingly curved fit with the rods54. The rods54may also be fitted between the panels12and a concrete slab72as is further described below.

Referring toFIGS. 8 and 9, the panels12may be formed entirely of a material such as resin with a polymer binder that is cast in a mould to form the panels12. In this example, the material of the panels12may be epoxy resin polymer with fillers. The panel12therefore may be monolithic or unitary in construction. The panels12may preferably also include an insulation insert board56that is fitted within the rebated portion26. The insulation insert board56may be fitted at the time of production and may be about 10 to 20 mm thickness. Although, other suitable thicknesses may be used, as appropriate. The fasteners36may pass between adjacently arranged panels12via the plurality of apertures34, as appropriate.

The front side16of the panels12may be formed or finished to represent a number of different surface finishes. For example, the front side16may be formed to represent brickwork or planks, as is shown for example inFIGS. 8 and 9. Other patterns may be possible.

Referring toFIG. 10, the drain arrangement40is preferably provided at or towards the base side24of the panels12. More specifically referring toFIG. 8andFIG. 10, the drain arrangement40includes V-shaped channel58that extends along a lower edge junction60between the rebated portion26and the inner side face30of the frame28, and a drain passage62that extends from the V-shaped channel58to the outer side32of the frame28toward the front side of the panel16. In particular, is noted that the drain passage62discharges toward the front side edged50and toward the external environment relative to the seals44. This ensures that any captured fluid such as condensation is ultimately discharged to the external environment.

Referring toFIGS. 11 and 12, the panels10may in some examples be seated in a fitted condition in a rebate70of the concrete slab72. The rebate70of the concrete slab72may be fitted with a seal74that is arranged to sealingly engage with the seal44carried by the panel12. The concrete slab72may include void or apertures76that are arranged to align with the respective one of the plurality of apertures34of the panels12so as to receive a fastener36to couple the panels12to the slab72.

Referring additionally toFIGS. 13ato17, in this example, the building system5further includes a formwork system78that complements the panel system10. The formwork system78is arranged to form the rebate70of the slab72. The components of the formwork system78are best shown inFIG. 13aand include a plurality of modular formwork members80that generally correspond to the plurality of the modular panels12. It is noted that the formwork system78may be provide as a stand-alone product or as part of the overall building system5.

The plurality of modular formwork members80each include a profile section or body82adapted to form the rebate70into the cast slab72. The rebate70being shaped to fit with the bottom side24of the corresponding one of the plurality of modular panels12in the fitted condition, as shown inFIG. 12. The members80are adapted to releasably carry the seal74that is released by the member80, upon the curing of the cement of the slab72, so as to be retained by the slab72in a cured condition when the member80is removed.

As best shown inFIG. 14, the releasable seal74includes a head75releasable retained by a retaining channel81of the member80and an anchor stem77with a foot73extending from the head75, the anchor stem77being embedded and cast into the slab72in the cured condition as shown inFIG. 12.

In this example, the sections82of the formwork members80are elongate hollow sections or profiles including a top side83, a bottom side84, an inner side85and an outer side86. The bottom side84includes the retaining channel81into which the releasable seal74is initially fitted. The bottom side84also includes a convex curved rib or locator87that includes a plurality of apertures88that are arranged to align with the plurality of apertures34of the panels12. The curved rib87forms a complimentary channel89(shown inFIG. 11) within the cured slab72and allows the alignment rods54to be fitted between the slab and the panels12to assist with location and alignment between the slab and the panels12. The sections82may be formed form aluminium extrudes. In use, the complimentary channel89is relatively inside of the releasable seal74that forms an outer barrier to the external environment.

The topside83of the sections82include a further aperture69that allows a void forming tool or part90to be inserted and removed from the topside83. The void forming tool90is used to form the apertures76.

Referring more specifically toFIGS. 15 and 16, the void forming tool90may include an elongate hollow cylindrical body91having a length to extend from the topside83through the apertures88of the bottom side84and extend into the slab72. The void forming tool or part90includes a retaining section93having an elongate body97that is fitted generally within the section82and a removable or consumable void forming insert94that is cast into the slab72and remains with the slab72when the formwork members80are removed.

The void forming insert94includes an elongate hollow cylindrical body being blinded at one end95by a slightly pointed tip and includes a flared opening96initially carried immediately below the bottom side84of the member80so as to be aligned with a top surface of the slab72in the cured condition when the formwork members80are removed. The retaining section93may include tabs98that are arranged to allow the retaining section93to be coupled with the section80. The apertures69of the topside83are shaped to selectively allow the retaining section93and the tabs carried thereby to pass through the apertures69. The apertures69and tops of void forming tool90may be covered by a cap99to inhibit the passage of concrete into the void forming tool90.

The inner side85is relatively flat to provide a corresponding flat slab surface and includes an upturned edge lip79. It is noted that the upturned edge lip79may end in a small flat edge, for example being 10-15 mm wide, for durability. The edge79may also be hardened such as by inclusion of wear part such as an imbedded stainless steel edge or part. The edge79allows any aggregate or slurry that rolls off the slab falls into the trough behind the edge and not to obstruct the finisher from achieving an accurate line against the top edge of the formwork member80.

The outer side86includes dove tail shaped recess100into which a corresponding dove tail shaped insert102is fitted. The dove tail shaped insert102may be formed from a material that is able to be nailed or drilled such a plywood or plastic and allows the formwork section80, that may be formed from a plastic or a metal such as aluminium, to be secured to external plywood supports as shown inFIG. 17by a nail, screw or the like.

Referring more specifically toFIGS. 13ato 13c, each of the formwork members80are adapted to couple with one another via a coupling110. The coupling110includes a male side or first part112and a female side or second part114that are provided at the free ends of the respective ones of the formwork members80. The male part112and the female part114are each arranged to be received by or formed with the open section of the formwork members80. The male part112includes a tongue116that is received by a recess118of the female part114. The tongue116and recess118being coupled by a fastener121.

The arrangement of the coupling110is such that the inter fit between adjacent coupled formwork members80is generally flush and continuous with adjacent sides edges129of the top side83, the bottom side84, the inner side85and the outer side86are generally abutting with one another. The adjacent sides edges129of the top side83include a cut out131for fastener121.

This allows the coupling formwork members80to provide substantially smooth elongate and corner forms in a variety of shapes and sizes. The side edges129are generally recessed back from the male part112and the female part114, and may be shaped in plan form view to be straight to provide straight couplings between the formwork members80or the side edges129may include 45 degree angles in plan form view to allow a mitre or 90 degree coupling between the formwork members80. It is noted that the coupling110can remain the same with shape of the relevant abutting side edges129defining the angle of the joint. Other arrangements include a step down arrangement in which at least one formwork member80extends vertically downwardly to accommodate step down in the slab.

In more detail, the male and female parts112,114include corresponding apertures117,120,123that form a passage115through which the fastener121is fitted to secure the male and female parts112,114together. The tongue116includes aperture117and the flanking members119that the define the recess118female part114each include apertures120,123with the lower most aperture123having a thread to couple with the fastener121. The upper aperture120is tapered and aperture123is threaded.

The passage115and fastener121are inwardly tapered between an entry end122and an opposing end124of the passage115such that movement of the fastener121between the entry end122and the opposing end124drawing the male and female parts112,114into aligned abutment via a wedge like fit. This assists to draw the respective formwork members80into abutting alignment thereby providing accuracy and repeatability to the formwork system78.

The tapered fastener121includes a tapered body section125with a head126and a threaded end128that is threadedly engaged with a corresponding female thread provided on a lowermost aperture123of the female part114. The tapered fastener121includes an inward step127between tapered body section125and threaded end128that is relatively straight. Accordingly, the tapering between the tapered body section125and the upper aperture120provides the self-alignment function and the relatively straight threaded end128provides the coupling with the step126providing an end of travel stop.

The head126may include a fitting such as a hex drive. It is noted that the male and female parts112,114may be used to couple straight sections or to couple internal or external corners, as is shown inFIGS. 13band13c.

Referring now toFIGS. 18 to 19, the panel system10may include a window or door reveal retaining arrangement130to fit with a door or window opening132of one of the panels12. The reveal retaining arrangement130includes a cast reveal structure134that is formed from a concrete polymer or epoxy resin polymer with filler, and a series of fittings136that are cast into the reveal structure134. The fittings136include a base138adapted to anchor the fitting136into the reveal structure134and a coupling portion140that is adapted to receive and lock with a clamping part142. The clamping part142includes a coupling portion143adapted to couple with the receiving portion140of the fitting136and a bearing pad150that bear against a face of the rebated portion26in a fitted condition.

The reveal structure134includes a skirting frame145with a flange146that fit against a front face of the panel12laterally of the door or window opening132. The frame142also includes a inner section148that extends from the flange146through the door or window opening132and extends into the void of the rebated portion26on the backside of the panel12.

The fittings136are located on the inner section148so that when the inner section148is fitted through the door or window opening132and the flange146abuts the front side of the panel, the clamping part142can be fitted to the fitting136and received by the coupling portion140thereof. The coupling portion140of the fitting136and the coupling portion143of the clamping part142are adapted to couple and interlock with one another to secure the reveal structure134to the door or window opening132.

In this example, the coupling portion140of the fitting136and the coupling portion143of the clamping part142each include uni-direction interlocking teeth151,153. The coupling portion140of the fitting136includes lengthwise slot161flanked by inward facing flanges163that terminate at the teeth151. The coupling portion143of the clamping part142includes slots or channels165on opposing sides thereof that receive the inward facing flanges163of the coupling portion140of the fitting136so that the teeth151,153engage and interlock with one another. The clamping part142is advanced on the teeth151,153so that the panel12is clamped between the flange146of the reveal structure134and the bearing pad150of the clamping part142.

Referring now toFIGS. 20 to 22, the building system5, in particular the panel system10, may further include structural members150arranged to support the panels12. The more specifically, in this example, the structural members150are arranged to fit within and vertically span the rebated portion26between the skirting rib29of the frame28. The structural members150each include an elongate body151having opposing ends152,154that each include flanges156,158that abut in the fitted condition with the inner side30on the frame toward the topside22and the bottom side24of the panel12, respectively. The flanges156,158each include apertures that of line with respective ones of the plurality of apertures34of the panels12.

The structural members150may also be adapted to directly support further horizontal structural members160. The structural members150may include sockets155toward each of the top ends152into which spigots159carried the horizontal structural members160are received. The horizontal structural members160may be fitted with an adapter bracket162that plugs into and is coupled to an open end164of the horizontal structural members160and the adapter may carry the spigot159. The arrangement of the spigots and the sockets may of course be reversed. Accordingly, in the fitted condition, the structural members150provide substantial structural support to the panels12thereby allowing the panels12to be load-bearing and be coupled to further horizontal structural members160.

A method of use of the building system5includes forming the panels12of the building system5that is typically conducted off-site. The panels12are formed in a series or set of predetermined sizes that fit with the pre-determined grid and the sizes are selected to skirt or provide the desired building wall structure. The set of panels12are formed in a mould (or the set sizes of panels may be preformed) as has been aforementioned. The panels12may be formed with window or door openings132in the panels, and fitting the window or door reveal retaining arrangement130to the openings132. The panels12and associated components of the panel system12such as the rod54and the structural members150are transported to site. The window or door openings132may be cut out with a machine such as a CNC (Computer Numerical Code) machine after the panels12are formed.

The associated set of formwork members80and the formwork system78, which are typically pre-formed to correspond with particular panels12, are also transported to site where the formwork members80are located and coupled with one another via the coupling110to form the rebate70of the concrete slab72. Use of the coupling110includes fitting the male side or part112and the female side or part114of the coupling110together such that corresponding apertures117,120that form the passage115through which the tapered fastener121is fitted to secure the male and female parts112,114together. The fastener121is then actuated to allow self-alignment of the adjacent formwork members80.

The formwork members80each carry the releasable seal74that is embedded in the slab72once cured and the void forming tool90provides the apertures76that are arranged to align with the respective one of the plurality of apertures34of the panels12so as to receive the fastener34to couple the panels12to the slab72. The curved rib87of the formwork members80is used to provide or form the channel89parallel to relatively inwardly of the seal74.

Once the slab72is cured, the formwork system78is removed leaving behind the releasable seal74and the insert94of the void forming tool90is cast into the slab72. The lower alignment rod54may be fitted along some or substantially the entire channel89between any fasteners36.

The set of panels12may be fitted to the slab72and coupled thereto by fasteners36passed between the respective ones of the plurality of apertures34of the panels12and the apertures76of the slab72. The rod54may be used to assist to align the panels12with one another and the panels12may be coupled to one another via fasteners36passed through the appropriate ones of the plurality of apertures34.

The corresponding seals44are sealingly engaged with one another to provide a seal between the panels12. The panels12may be stacked and/or bolstered using the vertical structural members150, as required. The further horizontal structural members160may also be fitted to the vertical structural members150.

The building system including the panel system and formwork system as described herein provide a number of advantages including, but not limited to, one or more of the following:Fits with or is compatible with existing building practices—such as fitting with a typical slab construction that is now used to support brick veneer walls;Panels have a pre-engineered construction and may be selected from a predetermined range of sizes thereby reducing tooling, procurement costs and lead times;Quick installation due to ease of fastenings and pre-alignment with predetermined grid formed into the slab;Lightweight panels only requiring, perhaps, one crane set up on a kerbside;High degree of flexibility due to the range of predetermined sizes and shapes of panels;Reusable formwork system that is predetermined to fit with associated panels to ensure a correct fit and alignment;Self-aligning coupling between formwork members;Improved sealing by having a releasable seal that becomes embedded within the slab and also having pre-fitted seals between the panels;Improve drainage by having a drainage passage that extends from and inner side of the panel to an outer side of the panel; andPanels may be optionally bolstered by structural members including vertical structural members that fit within a rebate of the panels so as to fit substantially flush therewith; andRebate portion of the panels allows further insulation panels to be fitted to the panels.

The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.