BUILDING ELEMENTS AND JOINTS THEREFOR

Abstract: A method of building a free standing or building wall using prefabricated wall panels (10, 12, 14) comprises factory assembly of a wall panel from traditional or other building bricks or blocks and providing the panel with integral support means (26) to resist separation of the bricks or blocks when lifted for transport. A joint element (118) for placement between adjacent edges of the panels provides a labyrinth seal (102) with interleaved seal elements extending lengthwise of the joint. Spring means (124) acts between opposite sides (120, 122) of the joint so that it is resiliently compressible to accommodate differing spacings between the panels. A thermal insulation compartment (126, 128) is provided within the joint element.

Description: BUILDING ELEMENTS AND JOINTS THEREFOR This invention relates to building elements or panels, methods of building a wall or like structure therefrom, and to joint elements for placement between building or wall elements or panels to provide a seal therebetween. An example of the application of the invention is to prefabricated wall panels and methods of constructing and assembling same with joint means between them. The invention is applicable to industrial and commercial and residential buildings, free-standing walls such as garden walls, boundary walls, barrier walls or any other kind of wall whether for residential industrial or commercial purposes, and to other structures. The construction of buildings using sectional or prefabricated components has been undertaken for many years throughout the world. In the United Kingdom, buildings employing prefabricated panels and structures have consistently failed, for various reasons, to meet the requirements made of them. As a result, there is now considerable resistance to their continued use. The reasons for these problems include ineffective sealing between adjacent edges of the panel, poor thermal insulation provided by the panel and a lack of choice of decorative finishes for the panel and an inability to match traditional materials such as brick, stone and timber in this regard. The conventional way of constructing prefab icated building panels involves the use of reinforced concrete which is cast in moulds. An object of the present invention is to provide a method and apparatus offering improvements in relation to one or more of the matters discussed above, or generally. According to the invention there is provided a method and apparatus as defined in the accompanying claims. In a preferred embodiment, faced building blocks or bricks are bonded in vertically stacked relationship, in a factory, using a suitable mortar, to produce a prefabricated panel. Each panel consists of two leaves of masonry with a cavity space between them. A precast concrete beam or a beam of any other suitable material such as stone (whether natural or artif ical) , ferrous or non- ferrous metal or a combination of all these, is provided both at the top and the bottom of the panel. The lower beam has two threaded sockets cast or otherwise provided in its upper surface. The upper beam has two slot holes positioned to align with the threaded sockets in the lower beam. Two vertical threaded tie bolts or tie-wires or the like are passed through the upper beam, through the cavity and are screwed into the threaded sockets in the lower beam. Tension is applied to the bolts to produce corresponding compression in the panel, by means, for example, of tensioning nuts screw-threadedly engaging the upper ends of the bolts or ties. The result is a composite cohesive cavity walling panel. The panels can be lifted mechanically for storage and placement. On assembly, successive panels are secured to each other by straps. The bolts or ties may be slackened after assembly, and removed if desired, or left fully tensioned. Sealing between successive panels is provided by means of a joint element. The joint element comprises a metal or plastic based material and provides for a gap of from 25 to 100 millimetres, and preferably 40 to 80 millimetres gap between the panels to be sealed. The joint element resists water penetration across the joint and provides a high insulation portion minimising heat losses through the joint. A capping on the internal and external surfaces of the joint element provides a decorative finish and prevents the entry of dust and vermin. Once fitted, the joint element does not reguire adjustment or maintenance. It may constitute a structural element of the assembled wall for example it may be fixed to the panel beams to provide support, particularly in free-standing walls. The joint element comprises four parts. Two side units are located between adjacent panel edges and positioned by means of lugs which fit into the exposed cavity at the end of each panel. An internal capping piece incorporating insulation is press fitted and clipped between the shoulders of the side units of the joint element. The external capping is screwed to the projecting portion of the nearest projecting fin of the joint element. A water tray is incorporated at the base of the wall to collect and shed any water which has penetrated. The joint element may be constructed of masonry, ferrous or non-ferrous metals, plastics (synthetic polymers) or other suitable materials and can be produced using traditional fabrication techniques or by an extrusion process. The embodiments of the invention described below provide significant advantages including, effectively, the transfer of the traditional masonry crafts into a factory controlled environment. This leads to the opportunity for greater quality assurance to be achieved, than is normally attainable on building sites. Also, a reduction in the high percentage of materials and labour wastage normally associated with building site activities is achieved, and an increase in the speed at which walls can be built. There is also the distinct possibility that, after training, semi-skilled labour could be used to produce panels. This will enable the creation of numerous employment opportunities nationally. Also, the external facing material may be selected from a wide range of colours and textures to satisfy local authority planners, architects and clients. A range of different panel sizes can be produced to satisfy the type of building proposed, and the thermal transraittance value of a wall may be adjusted to suit individual and/or statutory requirements. Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which : Figs 1, 2 and 3 show, somewhat diagrammatically, a range of wall elements or panels according to the invention, each figure showing at A, B and C three variations on a given panel size, and Figs 1, 2 and 3 showing panels of progressively increasing width; igs 4, 5 and 6 show front elevation views of buildings incorporating the panels of the preceding figures; Fig 7 shows a vertical section through a panel, for example in the building shown in Figs 5 and 6, for a single storey situation; Fig 8 shows, in a view similar to that of Fig 7, the arrangement of the wall panel in a two storey building, as indicated in Fig 4; Fig 9 shows, on a larger scale, a horizontal section through a joint element for sealing between wallpanels in the structures of the preceding figures; Fig 10 shows a modification of the joint element of Fig 9; Fig 11 shows a perspective view of a connector or continuity bar for connecting adjacent panels; and Fig 12 shows a perspective view of a water tray provided at the base of ajoint between successive panels in a wall constructed according to the invention. As shown in Figs 1, 2 and 3, prefabricated wall panels 10, 12 and 14 may be formed with varying panel widths as shown, without windows as shown at A, with windows as shown at B and C, and with the windows 16, 18, 20 located at upper and lower locations as shown at C and B respectively in Figs 1, 2 and 3. Figs 4, 5 and 6 show prefabricated panels, similar to those of the preceding Figures, installed in a two storey building (Fig 4) and in single storey buildings (Figs 5 and 6). The building panels of the invention are principally applicable to the construction of the ground floor portion of a building, though other applications are by no means excluded . Turning now to the construction shown in Figs 7 and 8, it will be seen that the panel 22 comprises a main body portion 24 formed of building bricks or blocks together with support means 26 to resist separation of the building bricks or blocks. The support means 26 comprises upper and lower structural elements 28, 30 in the form of concrete beams linked by tension members 32 in the form of threaded rods of mild steel or other suitable material. The rods are threaded at their ends 34, 36 for co-operative engagement with internally threaded nut or the like members associated with the beams 28 and 30, whereby the beams can be caused to apply compressive loads to the panel assembly, thereby setting up tension in the rods 32. The upper beam can be in the form of a shaped coping to fit on top of the blocks or br icks directly to act as a means of weather protection when used on free-standing walls. The method of making panels 22 comprises placement of the lower concrete beam 30 in a j ig , bu i lding in super imposed vertical relationship successive rows o f bricks or blocks with mortar in an otherwise conventional manner , but carried out within the j ig and at a factory location. When the panel has been built up to the required height the upper beam 28 is secured in position and the tensioning rods 32 are inserted. Before transportation, the necessary tension is set up in these rods whereby the panel as a whole is prov ided with a unitary and cohesive structure. The beams remain a structural part of the panel after assembly with other panels into a wall. It will be noted that the panels 22 have inner and outer layers 38 , 40 separated by a cavity 42 through which the rods 32 extend. The building br icks or bloc ks 44 are shown individually, j ust at the upper portion of each of Figs 7 and 8 , by way of example. The lower beam 30 has a locating r idge 46 which co¬ operates with a corresponding channel in a foundation beam 48 suitably set into the ground 50. A shoulder 52 on beam 48 serves to support a floor structure 54. Directly above this, a horizontally extending plate 56 , equal in width to the full width of the panel 22 serves to support fully the inner course or layer 38 of the cavity wall . Fig 7 shows panel 22 hav ing a roof structure 58 directly mounted on upper beam 28 , whereas F ig 8 shows a floor structure 60 supported on beam 28. Fig 11 shows a connector 62 which is of generally channel-shaped section and may be of any similar section and formed of stainless steel which is adapted to co¬ operate with corresponding recess 64 formed in the upper side of upper beam 28, to link successive panels 22 together. Connector 62 fits into the recess 64 at both sides of the joint, and is then grouted-in. Turning now to the structure of the joint element shown in Fig 9, it will be seen that this comprises a labyrinth seal 100 having interleaved seal elements 102 extending lengthwise of the joint element to provide a seal between the adjacent edges 104, 106, 108, 110 of the inner and outer layers of a cavity wall formed by panels 22 and described above. Cavities 112 are provided between the inner blockwork layers 114 and the outer brick layers 116. Each joint element 118 comprises joint side members 120, 122 having spring means 124 acting between them whereby the joint assembly is resiliently compressible. The spring means 124 is in the form of a generally V-shaped leaf spring located between compartments 126 and 128 containing thermal insulation material 130, which also fills the space between the inner walls of the compartments 126, 128. It can now be seen that the joint element 118 is in the form of a four piece structure comprising the two side members 120, 122 carrying the labyrinth seal elements 102 and formed with chambers 132, 134 defining the cavities 128, 126 respectively. The other two pieces are outer and inner cap members 136, 138 respectively. These are of channel-shaped cross-section, extend vertically between the confronting edges 106, 108 and 104,110 of the outer and inner leaves of the cavity wall constructions. Joggles 140 formed in the side members 120, 122 provide space for the caps 136, 138. Leaf spring 124 is secured to cap 138, and thus serves to hold same in position by engagement with chambers 132, 134. Likewise, outer cap 136 is secured by self tapping screws 142 to the outer roost seal member 102 of the labyrinth seal 100. Cap 136 constitues decorative panel means to provide a visually pleasing cover over the joint element 118. It can be provided with any desired surface finish or may otherwise be adapted to enhance its appearance . Fig 10 shows a modification of cap 138 whereby it is provided with a portion 144 standing proud of the inner surface 146 of the wall. A suitable rebate 148 is formed in the wall to receive the side limbs 150 of the cap 152. The location of the joint element with respect to the cavity wall itself is provided by means of lugs 154 extending into the cavity 112. Fig 12 shows the construction of a water tray provided at the base of the joint element 118 to receive any water entering the joint, and to deflect the water outwards. For this purpose, the water tray 156 is of generally rectangular shape construction. The joint element rests with its lower end on the water tray and with the labyrinth seal 100 located over an outwardly sloping surface 158, whereby water separated by the seal is deflected outwardly of the wall structure in the direction indicated by arrow O. In Fig 12 the location of cavity 112, and of the inner and outer cavity wall layers 114 and 116 respectively are indicated by dotted lines. In use, joint element 118 is readily inserted into the space between the adjacent edges of the assembled panels 22. Its resilient construction enables it to be inwardly compressed. Lugs 154 are located within cavity 112. Then, the inner and outer caps 138 and 136 are attached and assembly is complete. Inward movement of water from brick panel 116 across cavity 112 is inhibited by the labyrinth seal 100. Liquid entering the joint element tends to pass downwards and onto water tray 156 and thus to be ejected outwards. The insulating material 130 provides a thermal barrier between the panel elements, with a thermal insulation co¬ efficient comparable to that of the wall itself. In a further embodiment (not illustrated), the joint element is modified to form a structural member of the assembled wall and can be fixed to the perimeter foundation beams of the panels to give support to the wall panels for use on free-standing walls. Interestingly, in the above embodiments, the provision of prefabricated wall panels with tension type supporting structure enables the panels to be assembled in a factory environment in an efficient and controlled manner, using basically conventional vertical stacking type assembly techniques. The assembled panels can then be transported without danger of disintegration, by virtue of the supporting structure, and assembled with an absolute minimum of modification. In principle none of the panel structure has to be removed for asembly of a wall. After assembly, the hitherto intractable problems of heat loss and entry of moisture together with loss of heat are solved by means of the joint element. This provides an easily mounted structure which resiliently accommodates varying gap sizes between the panels and offers a thermal insulation co-efficient comparable to a brick wall itself. Its labyrinth seal substantially prevents ingress of moisture and it has a decorative finish which serves to enhance rather than, as is usually the case, allowing the joint area to detract from the appearance of the assembly. The wall panels and the joint elements are suitable to be made either in whole or in part using robotic technology. Amongst other modifications which could be made in the above embodiments while remaining within the scope of the claims are the following. Firstly, the wall panels or elements can be readily constructed to any suitable shape or size by suitably adapting the jig used for construction purposes. Likewise, instead of conventional bricks or other building blocks, any suitable building material may be employed to provide an assembly of building elements from which the panel is constructed. A further modification comprises forming the panel with a single leaf construction and no internal cavity. Also, various modifications to the support structure can be envisaged whereby the latter might comprise a removeable structure rather than an integral part of the panel itself. In the above embodiment, after assembly, the tension rods can be removed or retained as desired.

Claims: CLAIMS 1 A method of building a wall or like structure, to be erected at a building site, comprising assembling a wall element or panel from two or more building bricks or blocks at a location remote from said site, providing the assembled wall element or panel with support means to resist separation of said building bricks or blocks when lifting forces are applied thereto, and then applying such lifting forces to the wall element or panel and transporting same to said erection site and erecting same in its assembled condition at said site. 2 A method according to claim 1 characterised in that said support means comprises a support beam which is allowed to remain part of said panel in the erected wall. 3 A method according to claim 1 or claim 2 characterised by said wall element being assembled in a jig in which said bricks or blocks are assembled on said beam in vertically stacked relationship with jointing and/or adhering means, such as mortar, adhesive or the like. 4 A method according to any one of claims 1 to 3 characterised by said bricks or blocks being assembled to form a double layer wall with a cavity between said layers and said beam bridging the cavity.. 5 A method according to any one of the preceding claims characterised by the step of forming a framework comprising said support beam.. 6 A method according to claim 5 characte ised by forming said framework with an upper beam, with said bricks or blocks located between the beams, and providing tension members extending between said beams. 7 A method according to claim 6 characterised by the step of tensioning said tension members prior to transporting the wall element or panel. 8 A method according to claim 7 characterised by the step of releasing the tension in said tension members after erecting said wall element or panel at said site. 9 A method according to claim 8 characterised by the step of removing said tension members after erecting said wall element or panel at said site. 10 A transportable wall panel or element characte ised by an assembly of bricks or blocks and associated support means for said bricks or blocks to resist separation thereof when lifting forces are applied thereto for transportation of the assembly from an assembly location to an erection site for the panel or element. 11 In a wall panel or element according to claim 10 characterised by said support means comprising a support beam for said bricks or blocks which remains part of the panel in an erected wall. 12 A wall panel or element according to claim 10 or claim 11 characterised by said support means comprising an upper beam, and tension members extending between said beams . 13 A panel or element according to claim 12 characterised by said tension members comprising threaded rods or tie members or the like. 14 A panel or element according to claim 12 or claim 13 characterised by said tension members being provided with connection means, such as an eye, to receive a hook or the like for lifting purposes. 15 A joint element for placement between adjacent edges of building elements or panels to provide a seal therebetween, characte ised by labyrinth seal means comprising interleaved seal elements extending lengthwise of said joint element. 16 A joint element for placement between adjacent edges of building elements or panels to provide a seal therebetween, characterised by lengthwise extending joint side members having spring means acting between them whereby the assembly is resiliently compressible to accommodate differing spacings between said adjacent edges. 17 A joint element for placement between adjacent edges of building elements or panels to provide a seal therebetween characterised by structure defining a thermal insulation compartment within said joint element, and thermal insulation material located in said compartment. 18 A joint element according to any one of claims 15 to 17 characterised by detachable decorative panel means securable to said joint element so as to extend lengthwise of the joint between said adjacent edges of said building elements in use, to provide a visually pleasing cover over the remainder of said joint element on an outer or inner surface of the wall or the like formed by said building elements. 19 A joint element according to any one of the claims 15 to 18 characterised by locating means on said joint element to enter and locate same with respect to the cavity between the inner and outer layers of a cavity wall. 20 A joint element according to any one of claims 15 to 19 characterised by the width of said joint element, measured between said adjacent edges of said building elements in use, lies in the range 25 to 100 millimetres. 21 A joint element according to claim 20 characterised in that said width lies in the range 40 to 80 millimetres.

Inventors: BATEMAN COLIN NORMAN, CARTER WILLIAM GEOFFREY, CLARK PETER LEWIS, BATEMAN, COLIN, NORMAN, CARTER, WILLIAM, GEOFFREY, CLARK, PETER, LEWIS
Applicants: NAT RES DEV, NATIONAL RESEARCH DEVELOPMENT CORPORATION
Application year: 1989
Main classification: E04B1
IPC codes: E04B1, E04B2, E04C2