BUILDING WALL CONSTRCUTION

Abstract: A method of constructing a wall in which hollow units analogous to blocks are built up in overlapping superimposed courses, each unit having two spaced parallel vertical panels (10) or skins of rectangular form, the units being held by concealed fastening members (11); characterized in that each panel (10) has edge grooves (12, 13) extending along its upper and lower horizontal surfaces to be contiguous with those of adjacent panels, and each fastening member (11) has a body portion (17) to extend between spaced panels (10), the ends of the body portion (17) each having hook portions (20) extending upwards and downwards respectively into adjacent grooves (12, 13) of the panel edges, while said body portion (17) between adjacent panels has two upper lugs (18) extending into contact with respective upper panels, and two lower lugs (19) extending down and into contact with respective spaced lower panels, the fastening member (11) constituting a one-piece connector and spacing member.

Description: BUILDING WALL CONSTRUCTION TECHNICAL FIELD THIS INVENTION relates to building wall construction and it has particular reference to a novel method of a means for constructing a wall of the type having space parallel, vertical panel assemblies interconnected to fo a cavity-wall structure or one filled with concrete other cementatious materials, insulating materials or oth desired filling, such as fire-retarding polyurethane fo or the like. The invention also is applicable to t mounting of wall cladding on a wall. BACKGROUND ART Many different wall construction techniques have bee devised to date in order to avoid the use of heavy soli building blocks of concrete and the like, a typica construction being one in which initially-hollow unit similar to blocks are made up of relatively thi rectangular panels or so-called "skins" arranged in space parallel vertical relationship and laterally in register interconnected preferably by concealed fas eners. Units o this type can be used like blocks in overlapping courses o tiers on a horizontal foundation and built up to th desired wall formation, being either used as a cavity-typ wall or as a form assembly into which concrete or othe material may be poured, usually being poured progressivel as the wall units are placed in position. Examples of such wall constructions can be found i numerous prior patent specifications, such as that o United States Patent No. 4,433,520 of Jack Maschhoff whic shows constructions aimed generally at achieving some o the principal benefits of using these methods by compariso with the use of solid blocks. However, the Maschhof features leave room for considerable improvements i certain respects, particularly so far as th interconnecting means or concealed fasteners are concerned My present invention has been devised to overcome o alleviate the disadvantages and shortcomings associate with the building of walls by methods and means as set out above, and it has for its principal object the provision of a novel system for building a wall of the type described using concealed fastening clips of such improved nature that firm and accurate location of components may be achieved with maximum simplicity. The invention further aims to provide a total system of method and components which will be more effective than hitherto in providing either a cavity-type wall or a filled wall, but which lends itself most readily to use as a concrete/foam, sacrificed for work constructions system. The invention has as a further object to provide such a system in which the hollow units are assembled and erected in groups akin to standard blocks, and they are then filled with concrete, steel reinforcing being placed during erection if required, while plumbing and electrical services can be similarly introduced before pouring, the invention being designed so that fire retarding polyurethane foam could be used as the filler in some cases, such as in home construction walls. Another object of the invention is to provide a wall construction system of the character described which enables a selected wall finish to be achieved, either by finishing the erected walls in the desired covering or by using pre-rendered panels. For example, in up-market situations, stone veneers may be pre-fixed to the panels to give the appearance of a stone-like block. Yet another object of the invention is to provide a novel form of concealed clip for use with the structures described above, such clip being made relatively easily and inexpensively, being simple to affix, extremely secure and effective in operation, and acting to reduce substantially the number of components previously considered necessary to effect concealed fixing. Other objects and advantages of the invention will be hereinafter apparent, particularly those applying to the general application of systems of this type, such as transportability of components, and ease and speed o erection using unskilled labour with competent supervision Such a system also will be found very cost effective, whil having unlimited application in relation to low rise up t high rise constructions, and external and internal wall can be assembled ready for final finishes or coverings wit minimum surface preparation. While the initial objects of the invention have bee in relation to the building of walls having spaced skins a aforementioned, another object is to use similar principle in attaching a cladding sheet to a wall structure, whethe the latter be an existing wall of known type or one havin spaced skins according to the present invention. DISCLOSURE OF THE INVENTION With the foregoing and other objects in view, th invention resides broadly, according to one aspect, in wall construction method in which hollow units analogous t blocks are built up in overlapping superimposed courses, each unit having two spaced parallel vertical panels o skins of rectangular form, the units being held b concealed fastening members; characterized in that eac panel has edge grooves extending along its upper and lowe horizontal surfaces to be contiguous with those of adjacen panels, and each fastening member has a body portion t extend between spaced panels, the ends of the body portion each having hook portions extending upwards and downwards respectively into adjacent grooves of the panel edges, while said body portion between adjacent panels has two upper lugs extending into contact with respective upper panels, and two lower lugs extending down and into contact with respective spaced lower panels, the fastening member constituting a one-piece connector and spacing member. The invention according to another aspect, resides in a concealed fastening member for use with a plurality of similar members in constructing a wall of hollow units analogous to blocks built up in overlapping superimposed courses, each unit having two spaced parallel vertical panels or skins of rectangular form, said fastening member including a body adapted to extend between spaced panels of the separate skins, upper and lower hook portions at each end of the body and adapted to engage in edge grooves at the lower and upper edges respectively of said upper and lower panels of the respective skins, upper and lower locating lugs at each end of the body between said hook portions and adapted to contact the inner faces of the upper and lower panels of the respective skins, and wherein said hook portions and locating lugs are adapted in use to locate the upper and lower panels of both spaced skins fixedly relative to one another. In applying the invention to the attachment of a cladding sheet, according to another aspect of the invention, there is provided a method of .constructing a cladding sheet on and spaced from a wall surface, said cladding sheet being made up of cladding panels each of rectangular form and built up in overlapping superimposed courses with their outer surfaces vertical and coplanar, the cladding panels being held by concealed fastening members; characterised in that (1) each panel has edge grooves extending along its upper and lower horizontal surfaces to be contiguous with those of adjacent panels in the same course, and (2) each fastening member has (a) a body one end of which is operatively connected to the wall while its other outer end is connected to the panels, (b) hook portions at the outer end of the body extending upwards and downwards respectively into edge grooves at the lower and upper edges of said upper and lower cladding panels, and (c) upper and lower locating lugs at the outer end of the body inwardly of said hook portions and adapted to contact the respective inner faces of said upper and low cladding panels whereby the hook portions and locating lu in use locate the upper and lower cladding panels fixedl relative to one another and in spaced relationship to sai wall. For the purpose of this aspect of the invention, ther is provided, broadly stated, a concealed fastening membe for use with a plurality of similar members in mounting cladding sheet on a wall, said cladding sheet being made u of cladding panels each of rectangular form arranged wit their outer faces vertical and coplanar and with the panel lying in overlapping superimposed courses, said fastenin members including a body having an inner end adapted to be operativel connected to the wall and its outer end adapted to b connected to upper and lower cladding sheet panels space from the wall; upper and lower hook portions at the outer end of th body and adapted to engage in edge grooves at the lower an upper edges respectively of said upper and lower claddin panels; upper and lower locating lugs at said outer end of th body inwardly of said hook portions and adapted to contac the inner faces respectively of said upper and lowe cladding panels, and wherein said hook portions and locating lugs ar adapted in use to locate the upper and lower claddin panels fixedly relative to one another and in space relationship to said wall. Preferably, each fastening member can be cut t desired length from an elongated extruded metal bar. Wher the fastening member connects to spaced skins, the extrude bar may in cross-section have two three-point connector linked by a common body web, the middle connector bein adapted to grip at the junction of two panels while th other two connectors either lie flat against inner faces o the panels or are arranged to engage in horizontal groove provided for that purpose in the inner faces of the panels. In other aspects of the invention, there are provided double-skin walls constructed in accordance with the above described methods or employing fasteners as described, while the invention also embraces cladding sheets mounted by the methods described or using fastening members as described. Other features of the invention will be hereinafter apparent. BEST METHOD OF CARRYING OUT THE INVENTION In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings, wherein:- Fig. 1 shows in fragmentary perspective view the erection of two panels for one unit according to the invention, interconnected by one form of fastening member; Fig. 2 shows in sectional end view the components of Fig. 1 together with parts of panels of an upper superimposed unit; Fig. 3 shows in perspective view a modified form of fastening member, and illustrating how all such fasteners can be cut from an extruded metal section; Fig. 4 is a cross-sectional view of another extruded section from which a preferred form of fastening member can be cut for use with panels which do not have engagement grooves on their inner faces; Fig. 5 shows in perspective view part of a wall constructed by means of the invention and using novel stabilising means found useful in certain applications or certain erection conditions; Fig. 6 shows in sectional end view a modified fastening member arranged to mount cladding sheets in spaced relationship to an existing wall of known type, and Fig. 7 shows in sectional end view yet another modified fastening member arranged to mount cladding sheets in spaced relationship to a wall embodying the basic components of the invention. The general principles follow those described in th U.S. Patent to Maschhoff, and thus the disclosures therei are to be taken as part hereof to the extent that same ma be desirable or useful for clarity of understanding. I will be seen that I provide rectangular panels 10 t constitute opposite sides of elongated rectangular unit which overlap the joints of the courses above and beneat in standard manner, and the panels 10 are bot interconnected and held in spaced relationship and stabl form by concealed fasteners having the numeral 11 in Figs 1 and 2. As shown in Figs. 1 and 2, each panel 10 has longitudinal groove 12 along its upper horizontal edge an a similar groove 13 in register along its lower edge. I this instance, each panel 10 has a horizontal groove 1 towards its upper edge and a similar groove 15 towards it lower edge, all grooves 14 and 15 being cut into the pane faces 16 which face inwards towards the space between th panels. The fastener 11 in this case has a flat middle web o body portion 17 interconnecting two three-point connecto portions in the form of a top lug 18, bottom lug 19 an double hook member 20. The two hook members 20 act t interconnect top and bottom grooves 12 and 13 to hold th courses of panels above one another while . simultaneousl holding the second set of panels at a fixed spacing whic may for example be 110 mm in a practical example. The lug 18 and 19 are so spaced and dimensioned as to be clear o the panel faces 16 with their terminal portions 21 shape to hook into the grooves 14 and 15 to prevent separation of upper and lower courses as well as to provide firm grippin and a separating thrust between the spaced parallel panels for stability. Design details and dimensions may be varie as desired, and it will be seen that minimum trimming of the panel faces on the inner sides of the grooves 12 and 13 will be desirable to cater for the thickness of the web 17 and thus prevent the formation of a horizontal gap between upper and lower panels on the outer side of the double hook member 20. The fastener 11 of Figs. 1 and 2 can be modified without losing its effectiveness, one form 11a being shown in Fig. 3, the principal difference being that the terminal portions 21a . are of rounded bead form instead of having a sharp hook, such beads fitting snugly into the panel inner face grooves. In the embodiment of Fig. 4, the fastener lib has been modified so that its terminal portions 21b are not hooked at all and are turned back inwards so that junction ridges 22 will bear frictionally against the inner faces of the panels which thus do not need to be provided with grooves such as 14 and 15. In Figs. 3 and 4 other parts are denoted by the same numerals as in Figs. 1 and 2 with the addition of "a" or "b" respectively. While apparatus as described and illustrated will be found very effective in achieving the objects for which the invention has been devised, it will be apparent that many further modifications of constructional detail and design may be incorporated and that all dimensions may be as required within practical considerations. The concealed fasteners may be provided in desired numbers and at desired locations but of course should preferably be used to traverse all or most joints between units of each course or tier. The invention may be employed in conjunction with standard practices so far as base mountings, wall corners and the like are concerned. Cavity-type walls may be in order in some instances, with the use of tie-rods or cyclone bolts if desired. Also, a hollow wall being built may be filled with any materials as aforementioned, either progressively for preference or by a final complete pour if applicable. One type of finish may involve taping over the joints and then finishing in Granosite-like products for exterior wear, or as previously mentioned the panels may be pre-rendered as desired to give an imitation stone or other appearance. With reference to Fig. 5 of the drawings, there i shown part of a wall 23 built up of hollow block-like unit as aforedescribed, having in this instance four courses o units constituted by panels 10 interconnected by fastener such as that shown at lie.. A similar clip or fastener li at desired position along the top of the wall has its uppe lugs removed so as not to have unnecessary upwar projections. The illustrated wall 23 could for example b a long single "free-standing" wall without abutting wall providing mutual support and it could be subject to win loading during erection. According to the invention threaded rods such as that indicated at 24 are connected t starter bars at the base of the wall and have the panels 1 erected to enclose same. To ensure that such a threade rod 24 remains vertical and plumb, a temporary plate 2 engages over it, having grooves 26 on its undersurface t locate the top edges of the panels 10, while a nut 27 ca be tightened to effect downward compression. Pivotally connected to the temporary plate 25 is th upper end of an adjustably extendible support rod 28 whic has its lower end pivotally connected to an anchor plate 2 adapted to be secured by pegs 30 to the ground. Thi variable length stay or rod 28 will ensure that the wall i secure and plumb, acting to counter the effects of win loading as the concrete or the like is poured between th panel assemblies. In this instance, a single pour o concrete is effected after the four courses of unit panel have been placed in position. There is also shown an en capping channel 31 to be fitted vertically to t_he end o the wall structure prior to pouring. The threaded rods 2 may of course be used in addition to or in place o vertical reinforcing bars. There may be a selected numbe of threaded rods 24 at desired positions, each having stay rod 28 so that the wall frame may be plumbed a necessary and secured before pouring, during pouring an for a long as necessary after pouring. The application of the fastening members of the invention to the mounting of a cladding sheet on and spaced from a wall surface will be clear from Fig. 6 which shows an existing solid wall 32 of any known type having a mounting surface 33 to which stone cladding 34 is to be secured in spaced-relationship to permit the insertion of foamed light weight cement 35 therebetween. In this case, the cladding sheet 34 is made up of cladding panels lOe which have similar features to those shown in Fig. 2 except that there are mortar-receiving openings 36 at the joint where the hook members 20e are operative. The concealed fastener lie. has its outer end similar to that of Fig. 4 but its inner end has a socket 37 whereby it may be operatively connected to the wall surface 33 by means of a dyna-bolt 38. Thus the wall is spaced from a cladding sheet which is equivalent to a single skin of the embodiments of Figs. 1 to 5, with the fastening member being modified to suit. The mounting of a cladding sheet to a double-skin wall is shown in Fig. 7 which is similar to Fig. 6 so far as the panels 10f_, hook members 2Of . and lugs 18f_ and 19f. are concerned. However, in this case the concealed fastener llf has at its inner end a lateral slot to receive the male clip portion 39 of a connector sleeve 40 for connection to the end hooks 20g of another fastener llg_ identical with the fastener lib of Fig. 4. It will be noted that the fastener llg . connects a normal thickness panel (not shown) to thin panels lOg; and the cladding panels 10f_ are secured in spaced relationship, foamed light weight cement being interposed at 41 and 42. It will be understood that the aforementioned and other variations will be readily apparent to persons skilled in the art and are deemed to reside within the scope and ambit of the invention as defined by the appended claims.

Claims: CLAIMS 1. A method of constructing a wall in which hollow unit analogous to blocks are built up in overlappin superimposed courses, each unit having two spaced paralle vertical panels or skins of rectangular form, the unit being held by concealed fastening members; characterized i that each panel has edge grooves extending along its uppe and lower horizontal surfaces to be contiguous with thos of adjacent panels, and each fastening member has a bod portion to extend between spaced panels, the ends of th body portion each having hook portions extending upward and downwards respectively into adjacent grooves of th panel edges, while said body portion between adjacen panels has two upper lugs extending into contact wit respective upper panels, and two lower lugs extending dow and into contact with respective spaced lower panels, th fastening member constituting a one-piece connector an spacing member. 2. A concealed fastening member for use with a pluralit of similar members in constructing a wall of hollow unit analogous to blocks built up in overlapping superimpose courses, each unit having two spaced parallel vertica panels or skins of rectangular form, said fastening membe including a body adapted to extend between spaced panels of th separate skins, upper and lower hook portions at each end of the bod and adapted to engage in edge grooves at the lower an upper edges respectively of said upper and lower panels o the respective skins, upper and lower locating lugs at each end of the bod between said hook portions and adapted to contact the inne faces of the upper and lower panels of the respectiv skins, and wherein said hook portions and locating lugs ar adapted in use to locate the upper and lower panels of bot spaced skins fixedly relative to one another. 3. A method of constructing a cladding sheet on and spaced from a wall surface, said cladding sheet being made up of cladding panels each of rectangular form and built up in overlapping superimposed courses with their outer surfaces vertical and coplanar, the cladding panels being held by concealed fastening members; characterised in that (i) each panel has edge grooves extending along its upper and lower horizontal surfaces to be contiguous with those of adjacent panels in the same course, and (ii) each fastening member has (a) a body one end of which is operatively connected to the wall while its other outer end is connected to the panels, (b) hook portions at the outer end of the body extending upwards and downwards respectively into edge grooves at the lower and upper edges of said upper and lower cladding panels, and (c) upper and lower locating lugs at the outer end of the body inwardly of said hook portions and adapted to contact the respective inner faces of said upper and lower cladding panels whereby the hook portions and locating lugs in use locate the upper and lower cladding panels fixedly relative to one another and in spaced relationship to said wall. 4. A concealed fastening member for use with a plurality of similar members in mounting a cladding sheet on a wall, said cladding sheet being made up of cladding panels each of rectangular form arranged with their outer faces vertical and coplanar and with the panels lying in overlapping superimposed courses, said fastening members including a body having an inner end adapted to be operatively connected to the wall and its outer end adapted to be connected to upper and lower cladding sheet panels spaced from the wall; upper and lower hook portions at the outer end of the body and adapted to engage in edge grooves at the lower and upper edges respectively of said upper and lower claddin panels; upper and lower locating lugs at said outer end of th body inwardly of said hook portions and adapted to contac the inner faces respectively of said upper and lowe cladding panels, and wherein said hook portions and locating lugs are adapted in use to locate the upper and lower cladding panels fixedly relative to one another and in spaced relationship to said wall. 5. A wall in which hollow units analogous to blocks are built up in overlapping superimposed courses, when made by the method defined in Claim 1. 6. An assembly of cladding sheet on and spaced from a wall surface, said cladding sheet being made up of cladding panels in overlapping superimposed courses, when made by the method defined in Claim 3. 7. A concealed fastening member as defined in either of Claims 2 or 4 or for use in the method defined in Claim 1 or Claim 3, characterised in that said fastening member is cut to desired length from an elongated extruded metal bar. 8. A f stening member according to Claim 7 when used for connecting two spaced panels, the fastening member having in cross-section two three-point connectors, linked by a common body web, the middle connector being adapted to grip at the junction of two panels while the other two connectors lie flat against inner faces of the panels or engage in horizontal grooves in the inner faces of the panels. 9. A method of constructing a wall, as defined in Claim 1, and further characterised in that the grooves are provided in the panels midway between the opposite faces which are disposed vertically in use. 10. A method of constructing a wall in which hollow units analogous to blocks are built up in overlapping superimposed courses, substantially as hereinbefore described with reference to the accompanying drawings. 11. A method of constructing a cladding sheet on and spaced from a wall surface, said cladding sheet being made up of cladding panels in overlapping superimposed courses, substantially as hereinbefore described with reference to the accompanying drawings. 12. A concealed fencing member substantially as hereinbefore described with reference to the accompanying drawings.

Inventors: BEAMES DOUGLAS MCCLEOD, BEAMES, DOUGLAS, MCCLEOD
Applicants: BEAMES DOUGLAS MCCLEOD, BEAMES, DOUGLAS, MCCLEOD
Application year: 1990
Main classification: E04D3
IPC codes: E04B2, E04F13, E04G21