# US 8,769,900 B2 · Building construction system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,769,900 B2 - Document ID: US8769900B2 - Status: Granted - Kind: B2 - Application number: 12/664,521 - Filed: 2008-05-12 - Published: 2010-10-21 - Granted: 2014-07-08 - Earliest claimed: 2007-06-15 - Assignees: Macholdings (Aust) Pty Ltd - Applicants: Ian MacDonald - Inventors: Ian MacDonald - Web page: https://patentgrep.com/patent/US8769900B2 ## CPC - E04B 2/842: {by projecting or otherwise applying hardenable masses to the exterior of a form leaf} - E04C 2/34: composed of two or more spaced sheet-like parts (E04C2/32 takes precedence; spacers for cavity walls E04B2/44) - E04B 2002/8682: {Mixed technique using permanent and reusable forms} - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract A panel assembly for a building structure including a support frame that is mountable relative to a building substrate, the support frame including a plurality of first members extending in a first direction and at least one member extending in a second direction and overlaying the members in the first direction, at least one sheeting member provided on at least one side of the support frame so that the support frame and the structural sheeting define a zone for a cementitious material, and a layer of cementitious material positioned against the structural sheeting to at least partially fill the zone. ## Claims ### Claim 1 A building construction system including a panel assembly for a building structure including a support frame that is mountable on a substrate, structural sheeting provided on the support frame so that the support frame is positioned between a pair of structural sheets and the support frame and the structural sheeting together define a zone for a cementitious material, a layer of cementitious material positioned against the structural sheeting to at least partially fill the zone wherein the support frame includes a plurality of members extending in a first direction, all of the members extending in the first direction being first members and at least a pair of members extending in a second direction, all of the members extending in the second direction being second members, each of the first members and second members having at least a pair of attachment surfaces extending parallel to each other, each of the said parallel attachment surfaces of each said first member and each said second member attaching either structural sheeting or other first members or second members through the respective parallel attachment surfaces. ### Claim 2 (depends on 1) A building construction system as claimed in claim 1 including a plurality of panel assemblies attached relative to one another. ### Claim 3 (depends on 1) A building construction system as claimed in claim 1 wherein the support frame is oriented such that a plurality of first members are provided substantially vertically and oriented towards an outer side of the building and a plurality of second members are provided horizontally members and oriented towards an inner side of the building. ### Claim 4 A method of constructing a panel assembly for a building structure, the method including the steps of erecting a support frame on a substrate, the support frame including a plurality of members extending in a first direction, all of the members extending in the first direction being first members and at least two members extending in a second direction, all of the members extending in the second direction being second members each of the first members and second members having at least a pair of attachment surfaces extending parallel to each other, each of the said parallel attachment surfaces of each said first member and each said second member attaching either structural sheeting or other first members or second members through the respective parallel attachment surfaces, attaching structural sheeting on the support frame so that the support frame is positioned between a pair of structural sheets and the support frame and structural sheeting together define a zone in which cementitious material is to be set, applying a cementitious, settable material to an inner surface of the structural sheeting to at least partially fill the zone with the settable material; and allowing the cementitious material to set. ### Claim 5 (depends on 4) A method as claimed in claim 4 further including the steps of mounting formwork on the support frame so that the zone is bounded by the structural sheeting, the support frame and the formwork and introducing the cementitious material into the zone to cast the cementitious material in situ. ### Claim 6 (depends on 5) A method as claimed in claim 5 further including the step of removing the formwork once the cementitious material has set. ### Claim 7 (depends on 4) A method as claimed in claim 4 further including the step of spraying the cementitious material into the zone. ### Claim 8 (depends on 4) A method as claimed in claim 4 further including the step of removably securing transverse support members to the structural sheeting to support the structural sheeting while the cementitious material is sprayed onto the structural sheet. ### Claim 9 A panel assembly for a building structure including a support frame that is mountable relative to a building substrate, the support frame including a plurality of first members extending in a first direction, all of the members extending in the first direction being first members and at least two members extending in a second direction and overlaying the members in the first direction, all of the members extending in the second direction being second members, each of the first members and second members having at least a pair of attachment surfaces extending parallel to each other, each of the said parallel attachment surfaces of each said first member and each said second member attaching either structural sheeting or other members through the respective parallel attachment surfaces, at least one sheeting member attached on at least one side of the support frame so that the support frame and the structural sheeting define a zone for a cementitious material, and a layer of cementitious material positioned against the structural sheeting to at least partially fill the zone. ### Claim 10 (depends on 9) A panel assembly according to claim 9 wherein the support frame further includes a third set of members extending substantially horizontally and attached on the opposite side of the second member to the first members. ### Claim 11 (depends on 9) A panel assembly according to claim 9 further including one or more post-tensioning members. ### Claim 12 (depends on 11) A panel assembly according to claim 11 wherein the one or more post-tensioning members extend through the cementitious settable material and once the cementitious material has set to a predetermined extent, a predetermined tension is applied to the one or more post-tensioning members. ### Claim 13 A building construction system including a panel assembly for a building structure including a support frame that is mountable on a substrate, structural sheeting provided on the support frame so that the support frame is positioned between a pair of structural sheets and the support frame and the structural sheeting together define a hollow zone between the structural sheeting wherein the support frame includes a plurality of members extending in a first direction, all of the members extending in the first direction being first members and at least two members extending in a second direction, all of the members extending in the second direction being second members, each of the first members and second members having at least a pair of attachment surfaces extending parallel to each other, each of the said parallel attachment surfaces of each said first member and each said second member attaching either structural sheeting or other first members or second members through the respective parallel attachment surfaces. ### Claim 14 A method of forming a panel assembly including the steps of erecting a support frame on a substrate, the support frame including a plurality of members extending in a first direction, all of the members extending in the first direction being first members and at least one member extending in a second direction, all of the members extending in the second direction being second members, each of the members having at least a pair of attachment surfaces extending parallel to each other, attaching structural sheeting on the support frame so that the support frame is positioned on one side of the structural sheeting, the support frame and structural sheeting together define one or more hollow zones in which cementitious material is to be set, initially applying the cementitious settable material to an inner surface of the structural sheeting in some of the hollow zones, allowing the material in those zones to at least partially set, applying the settable material to remaining zones, and using the at least partially set material in the zones as a guide for screeding the material in the remaining zones; and allowing the cementitious material to set. ### Claim 15 (depends on 14) A method of forming a panel assembly as claimed in claim 14 wherein the step of initially applying the cementitious settable material to some of the hollow zones, occurs in alternating zones.