WO2006042343A1

WO2006042343A1 - Construction element and use thereof

Info

Publication number: WO2006042343A1
Application number: PCT/ZA2005/000155
Authority: WO
Inventors: Imrich Skarupa
Original assignee: Imrich Skarupa
Priority date: 2004-10-14
Filing date: 2005-10-13
Publication date: 2006-04-20

Abstract

The invention provides a method of making a construction element. The method includes the steps of forming a peripheral frame, placing the frame on a generally horizontal support surface such that the support surface and the frame together define an upwardly open mould cavity; introducing a settable filler substance into the mould cavity, allowing the filler substance to set sufficiently such that it is fixed to the frame, attaching reinforcing to the frame which reinforcing serves to reinforce the set settable filler substance, wherein the frame is formed of angle iron frame elements, each of which has a pair of perpendicular limbs, the frame being formed and placed on the support surface such that one of the limbs of each frame member extends upwardly from the support surface generally perpendicular thereto and the other limb of each frame member extends inwardly from the upper edge of the associated one limb generally parallel to and spaced from the support surface. The invention also provides a construction element produced by the method and a method of erecting a structure using the construction element of the invention and a structure erected by that method.

Description

CONSTRUCTIONELEMENTANDUSETHEREOF

This application claims priority from South African Patent Application 2004/8345 of 14 October 2004 only to the extent of the new matter filed in that application.

Field of the Invention

The invention relates to building. More particularly it relates to a method of making a construction element and to a construction element. It further relates to a method of erecting a building and to a building.

Summary of the Invention

According to one aspect of the invention there is provided a method of making a construction element which includes the steps of: forming a peripheral frame; placing the frame on a generally horizontal support surface such that the support surface and the frame together define an upwardly open mould cavity; introducing a settable filler substance into the mould cavity; and - allowing the filler substance to set sufficiently such that it is fixed to the frame.

The method may include, prior to placing the frame on the support surface, attaching reinforcing to the frame which reinforcing serves to reinforce the set settable filler substance. The reinforcing is typically attached to the frame such that when the settable filler substance is introduced into the mould cavity, the reinforcing is then embedded in the settable filler substance.

The method may include forming the frame of angle iron frame elements, each of which has a pair of perpendicular limbs, the frame being formed and placed on the support surface such that one of the limbs of each frame element extends upwardly from the support surface generally perpendicular thereto and the other limb of each frame element extends inwardly from the upper edge of the associated one limb generally parallel to and spaced from the support surface.

The method may include providing at least one surface of the settable filler substance with a decorative surface finish. Typically, the at least one surface will be the operatively outer surface of the construction element.

Providing the surface of the settable filler substance with a decorative surface finish may include positioning material arranged to provide a desired surface finish on the support surface and positioning the frame on the material. Hence, the material will provide an imprint in the surface of the settable filler substance providing the settable filler substance with the decorative surface finish. The material may be a synthetic plastics material, e.g. in the form of plastic bags.

The settable filler substance is typically a cementitious material, the method including, after the settable filler substance is introduced into the mould cavity, covering an exposed surface thereof, i.e. that surface facing away from the support surface, with a liquid impervious material. More particularly, the exposed surface may be covered with a sheet of synthetic plastics material. Further, the method may include periodically sprinkling water over the upper surface of the settable filler substance. This, the inventor believes will assist in preventing wind cracks and enabling the cementitious material to achieve its maximum strength.

It will be appreciated that the settable filler substance must set sufficiently before the construction element can be moved. This will naturally depend on ambient conditions. The inventor believes that under optimal conditions, it will take about five days for the settable filler substance to set sufficiently in order to enable the construction element to be lifted. The inventor believes that water should be sprinkled on the exposed surface of the settable filler substance at least for the three days several times per day. In particular, the inventor has found that in several instances sprinkling of water on the exposed surface twice a day is adequate.

According to another aspect of the invention there is provided a construction element which includes a peripheral metal frame; and a settable filler substance contained within and fast with the frame.

The settable filler substance may be a cementitious material having a compressive strength of between 10 and 42.5 MPa.

The cementitious material will typically be formed of a mixture of cement, sand and stone. In a preferred embodiment of the invention, the inventor believes that the cementitious material will comprise cement, sand and stone mixed in the ratio of five portions of cement to six to eleven portions of sand and six to eleven portions of stone. The cement may have a strength of between 32.2 and 42.3 MPa. The sand will typically be river sand or building sand. The stone will typically have a size of between 6 mm and 19 mm.

The construction element may include reinforcing which is attached to the frame and which is embedded in the settable filler substance.

The frame may be rectangular in shape and the reinforcing may include a plurality of parallel spaced apart elongate reinforcing elements, the ends of which are connected respectively, e.g. by welding, to opposed sides of the frame.

In a preferred embodiment of the invention, the construction element has a length of from 0.5 m to 3.6 m, typically 2.4 m, and a width of from 0.5 m to 0.9 m. The frame is typically formed from angle iron which is supplied in 6 m lengths. Accordingly, if the frame has a perimeter of 6 m, exactly one length of angle iron is required to form the frame. Each limb of the angle iron may have a width of from 20 mm to 50 mm. Preferably, the angle iron is 25 x 25 mm. The reinforcing may be formed of round bar, typically having a diameter of 10 mm.

According to yet another aspect of the invention there is provided a method of erecting a building which includes the steps of forming a foundation; and positioning a plurality of construction elements as described above, on the foundation side-by-side and connecting adjacent construction elements together so as to form walls of the building.

Forming the foundation may include leveling and compacting soil on which the building is to be erected.

Instead, or in addition, the foundation may be formed of a cementitious material. More particularly, a slab of cementitous material may be cast on the compacted soil. The slab of cementitous material will typically have dimensions which are larger than the intended footprint of the building such that portions of the slab protrude beyond the sides of the building.

Connecting adjacent construction elements together may include securing adjacent frame elements of the εtdjacent construction elements together.

In one embodiment of the invention, the adjacent frame elements are secured together by welding.

In another embodiment of the invention, the adjacent frame elements are secured together by positioning adjacent edges of adjacent construction elements in angularly spaced formations formed by an elongate connecting element. In this regard, the connecting elements may be secured to the foundation such that they extend vertically upwardly therefrom. According to still yet another aspect of the invention there is provided a building which includes a foundation; and a plurality of construction elements as described above, positioned on the foundation side-by-side and connected together so as to form walls of the building.

The foundation may be formed of leveled and compacted soil.

The foundation may be formed by a settable cementitous material. More particularly, the settable cementitious material may be cast in a slab on top of the leveled and compacted soil.

The adjacent frame elements of adjacent construction elements may be secured together.

In one embodiment of the invention, frame elements are connected together by welding.

In another embodiment of the invention, a plurality of spaced apart elongate connecting elements extend vertically upwardly from the foundation, each connecting element defining a pair of angularly spaced channel-formations within which adjacent edges of adjacent construction elements are positioned.

The building may include a roof structure mounted on top of the walls.

Specific Description of Embodiments of the Invention

The invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings. In the drawings:

Figure 1 shows a frame forming part of a construction element in accordance with the invention;

Figure 2 shows a sectional elevation of a construction element being made in accordance with the invention;

Figure 3 shows a side view of part of a building erected in accordance with the invention;

Figure 4 shows a plan view of the connection of two construction elements forming part of another building in accordance with the invention; Figure 5 shows schematically a gable arrangement of a building in accordance with the invention;

Figure 6 shows a construction element incorporating a window;

Figure 7 shows another construction element incorporating a window;

Figure 8 shows a door element; Figure 9 shows a construction element in accordance with the invention incorporating a light switch; and

Figure 10 show a construction element in accordance with the invention incorporating an electrical plug socket.

In Figure 2 of the drawings, reference numeral 10 refers generally to a construction element in accordance with the invention. The construction element 10 includes a peripheral frame, generally indicated by reference numeral 12 and a settable filler substance 14 contained within and secured to the frame 12.

Referring now also to Figure 1 of the drawings, the frame 12 is rectangular in shape and has two parallel side frame elements 16 and two parallel end frame elements 18 connected to and extending between corresponding ends of the side frame element 16. Each of the frame elements 16, 18 is formed of 25 mm x 25 mm angle iron. The angle iron is typically supplied in 6 m lengths. The frame 12 has a length L of 2.4 m and a width W of 900 mm thereby providing the frame 12 with a perimeter of 6 m enabling the frame 12 to be constructed from a single length of angle iron without any waste. Two 10 mm reinforcing bars 20 are connected to and extend between the side frame elements 16 at longitudinally spaced apart positions. Naturally any suitable form of reinforcing could be used. The frame elements 16, 18 and bars 20 are typically connected together by welding. In the embodiment shown, the bars 20 are positioned about 700 mm from the closest end frame element 18. Instead of using angle iron the frame could be formed from lengths of channel section.

As can best be seen in Figure 2 of the drawings, in order to form the construction element 10, the frame 12 is placed on a generally horizontal support surface 22. If it is desired to provide the construction element 10 with a decorative surface finish, sheet material 24, e.g. in the form of plastic bags, is positioned on the support surface and the frame 12 is then positioned on top of the sheet material 24. By crumpling the sheet material 24, an irregular surface can be formed which is then imparted to the surface of the construction element 10. As can clearly be seen in Figure 2 of the drawings, the frame 12 is positioned on the sheet material 24 such that one limb 26 of each frame element 16, 18 extends upwardly from the support surface 22, generally perpendicular thereto and the other limb 28 extends inwardly from the upper edge of the associated one limb 26, generally parallel to and spaced from the support surface 22. The frame 12 and the support surface 22 hence, together, define an upwardly open mould cavity 30. The filler substance 14 is poured into the mould cavity 30 and allowed to cure until it becomes integral with the frame 12.

The filler substance 14, in the embodiment shown, is formed of a mixture of cement, sand and stone. The cement, sand and stone are mixed in the ratio of five portions of cement, six to eleven portions of sand and six to eleven portions of stone. Typically, a cementitious material is used, which material has a compressive strength of between 10 and 42.5 MPa. After the filler substance has been poured into the mould cavity 30, the frame and filler substance 14 are covered with liquid impervious material such as a water impervious material. Periodically, typically twice a day, the cover is lifted and water is sprinkled onto the upper surface of the construction element 10. This allows the cementitious material to cure to its optimum strength and at the same time avoid the formation of wind cracks.

Once the filler substance 14 has set sufficiently, the construction element 10 can be lifted and used to erect a building as described in more detail herebelow. The inventor believes that the curing process, under ideal conditions, the filler substance should be allowed to cure for at least five days.

It will be appreciated that the particular composition of the filler substance 14 may vary. Hence, for example, in order to reduce the weight of the construction element 10, a lightweight filter material such as that which is available under the trademark Pratlyperl from Pratley (Proprietary) Limited could be used.

Reference is now made to Figure 3 of the drawings, in which reference numeral 40 refers generally to part of a building in accordance with the invention and, unless otherwise indicated, the same reference numerals used above are used to designate similar parts. The building 40 includes a foundation, generally indicated by reference numeral 42 on which a plurality of construction elements 10 are supported and secured together side-by-side to form walls 44 of the building 40.

The foundation 42 can be formed by leveling and compacting soil 46 on which the building 40 is to be erected. In the embodiment shown, after leveling and compacting of the soil 46, a slab 48 of cementitous material is cast on top of the compacted soil 46. The dimensions of the slab 48 are selected to be larger than that of the intended footprint of the building 40 so that an edge portion of the slab 48 protrudes beyond the walls 44. The construction elements 10 are secured together by welding adjacent frame elements 16, 18 of adjacent construction elements 10 together.

In another embodiment of the invention, as illustrated in Figure 4 of the drawings, instead of connecting the construction elements 10 together by welding the adjacent frame elements 16, 18 together, use is made of a plurality of spaced apart elongate connecting elements 50, one of which is shown in plan view in Figure 4 of the drawings. Each connecting element 50 is generally H-shaped in transverse cross-section and defines a pair of oppositely disposed channel formations 52 within which edge portions of adjacent construction elements 10 are snugly receivable. A plurality of the channel formations 52 is typically secured at spaced apart positions to the foundation 42 such that they extend vertically upwardly therefrom. The edges of the construction elements 10 are then positioned in the channel formations 52 to locate the construction elements 10 in position. In the connecting element 50, the channel formations 52 are spaced apart by 180°. When it is desired to form a corner of the building 40, use will be made of a connecting element 50 in which the channel formations 52 are spaced at right angles or some other appropriate angular spacing.

Naturally, variations in the construction elements 10 are possible. Hence, for example, in Figure 6 of the drawings, reference numeral 56 refers generally to another construction element in accordance with the invention which incorporates a window 58. In this embodiment, the window 58 includes a fixed lower pane 60 and a displaceable upper pane 62, the upper pane 62 being displaceable about a generally horizontal hinge axis 62.1.

In Figure 7 of the drawings, reference numeral 64 refers generally to another construction element in accordance with the invention incorporating a window 66. In this embodiment, the window 66 includes a fixed pane 68 and a displaceable pane70 which is displaceable abut a generally vertical hinge axis 70.1 In Figure 8 of the drawings, reference numeral 80 refers generally to another construction element in accordance with the invention. In this embodiment of the invention, the frame 12 has a width W of 1.8 mm, i.e. twice the width of the construction elements 10, 56, 64. An intermediate frame element 82 extends between the end frame elements 18 dividing the frame into a larger opening 84 and a smaller opening 86. A desired settable filler material is poured into the larger opening 84 and allowed to set in the manner described above. A door 88 is hingedly mounted in the smaller opening 86.

In Figure 9 of the drawings, reference numeral 90 refers generally to yet another construction element in accordance with the invention. The construction element 90 is substantially the same as the construction element 10 except that a light switch 92 and a cable conduit 94 which leads from the light switch 92 are positioned in the mould cavity prior to introducing a desired filler material. Similarly, in Figure 10 of the drawings, reference numeral 100 refers generally to another construction element in accordance with the invention. In this embodiment of the invention, the light switch 92 of the construction element 90 is replaced with a plug socket 102.

By making use of any combination of the construction elements described above, walls of a building can be formed incorporating doors, windows, light switches and plug sockets. If desired, upper edges of any combination of the construction elements may be secured together by bracing. A roof structure is then mounted on to the walls of the building. In this regard, if it is desired to have a pitched roof then roof structures in the form of gable ends 110, as illustrated in Figure 5 of the drawings, may be used. The gable ends 110 include a plurality of construction elements 112 which are formed in a similar manner as described above making use of a peripheral frame into which a desired settable cementitious substance is introduced and allowed to set. The construction elements 112 which have the same width as the construction elements 10, 50, 56, 64, 80, 90, 100 or a multiple thereof, are positioned on top of the construction elements to form the gables. A roof structure (not shown) is then mounted on the gables in a conventional manner. The roof structure can be of conventional construction using for example corrugated sheeting or tiles. Instead, the roof may incorporate a plurality of roof panels, each of which comprises a frame containing a set settable substance as described above. Typically the roof panels will have a thickness of abut 25 mm. The width of the roof panels will typically be about 900 mm, i.e. corresponding to the width of the construction elements which are used to form the walls of the building. The length of the panels will depend upon the pitch of the roof and the size of the building being constructed.

The inventor believes that a building constructed in accordance with the invention can be constructed quickly and cost effectively. Further, by virtue of its modular construction, the versatility of the building process is enhanced.

Claims

1. A method of making a construction element which includes the steps of: forming a peripheral frame; placing the frame on a generally horizontal support surface such that the support surface and the frame together define an upwardly open mould cavity; introducing a settable filler substance into the mould cavity; allowing the filler substance to set sufficiently such that it is fixed to the frame; attaching reinforcing to the frame which reinforcing serves to reinforce the set settable filler substance, wherein the frame is formed of angle iron frame elements, each of which has a pair of perpendicular limbs, the frame being formed and placed on the support surface such that one of the limbs of each frame member extends upwardly from the support surface generally perpendicular thereto and the other limb of each frame member extends inwardly from the upper edge of the associated one limb generally parallel to and spaced from the support surface.

2. A method as claimed in claim 1 , which includes providing at least one surface of the settable filler substance with a decorative surface finish.

3. A method as claim in claim 2, in which providing the surface of the settable filler substance with a decorative surface finish includes positioning material arranged to provide a desired surface finish on the support surface and positioning the frame on the material.

4. A method as claimed in claim 2 or claim 3, wherein the material is a synthetic plastics material.

5. A method as claimed in claim 4, wherein the material is in the form of plastic bags.

6. A method as claimed in any one of the preceding claims, in which the settable filler substance is a cementitioϋs material, the method including, after the settable filler substance is introduced into the mould cavity, covering an exposed surface thereof with a liquid impervious material.

7. A construction element which includes a peripheral metal frame; and a settable filler substance contained within and fast with the frame, in which the settable filler substance is a cementitious material having a compressive strength of between 10 and 42.5 MPa.

8. A construction element as claimed in claim 7, in which the cementitious material comprises cement, sand and stone mixed in the ratio of five portions of cement to six to eleven portions of sand and six to eleven portions of stone.

9. A construction element as claimed in claim 8, wherein the cement has a strength of between 32.2 and 42.3 MPa, the sand is river sand or building sand, and the stone has a nominal size of between 6 mm and 19 mm.

10. A construction element as claimed in claim 7, which includes reinforcing which is attached to the frame and which is embedded in the settable filler substance, in which the frame is formed from angle iron and is rectangular in shape, the reinforcing including a plurality of parallel spaced apart elongate reinforcing elements, the ends of which are connected respectively to opposed sides of the frame.

11. A constructions element as claimed in any one of claims 7 to 10, inclusive, which is rectangular in shape and has a length of from 0.5 m to 3.6 m, typically

2.4 mm, and a width of from 0.5 m to 0.9 m.

12. A method of erecting a building which includes the steps of forming a foundation; and positioning a plurality of construction elements as claimed in any one of claims 7 to 11 , inclusive, on the foundation side-by-side and connecting adjacent construction elements together so as to form walls of the building.

13. A method as claimed in claim 12, in which forming the foundation includes leveling and compacting soil on which the building is to be erected.

14. A method as claimed in claim 13, in which forming the foundation includes casting a slab of cementitious material on the compacted soil.

15. A method as claimed in any one of claims 12 to 14, inclusive, in which connecting adjacent construction elements together includes securing adjacent frame elements of the adjacent construction elements together.

16. A method as claimed in claim 15, in which the adjacent frame elements are secured together by welding.

17. A method as claimed in claim 15, in which the adjacent frame elements are secured together by positioning adjacent edges of adjacent construction elements in angularly spaced channel formations formed by an elongate connecting element.

18. A building which includes a foundation; and a plurality of construction elements as claimed in any one of claims 7 to 11 , inclusive, positioned on the foundation side-by-side and connected together so as to form walls of the building.

19. A building as claimed in claim 18, in which the foundation is formed of leveled and compacted soil.

20. A building as claimed in claim 18, in which the foundation is formed by a settable cementitious material.

21. A building as claimed in any one of claims 18 to 20, inclusive, in which adjacent frame elements of adjacent construction elements are secured together.

22. A building as claimed in claim 21 , in which the adjacent frame elements are connected together by welding.

23. A building as claimed in claim 21 , which includes a plurality of spaced apart elongate connecting elements which extend vertically upwardly from the foundation, each connecting element defining a pair of angularly spaced channel- formations within which adjacent edges of adjacent construction elements are positioned.

24. A building as claimed in any one of claims 18 to 23, inclusive, which includes a roof structure mounted on the tops of the walls.

25. A method of making a construction element as claimed in claim 1 , substantially as described and illustrated herein.

26. A construction element as claimed in claim 7, substantially as described and illustrated herein.

27. A method of erecting a building as claimed in claim 12, substantially as described and illustrated herein.

28. A building as claimed in claim 18, substantially as described and illustrated herein.