US 9,856,639 B2Granted

Wall assembly and a building structure including the wall assembly

OwnerNandor Koszoinventor

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Abstract

A wall assembly for forming an external wall on a building structure is disclosed. The wall assembly comprises a cladding and a plurality of vertical formwork members spaced along the wall assembly, and a horizontal formwork member extending along the top of the wall assembly. The formwork members are elongate profiles having a substantially constant cross sectional shape and they are arranged so that with the cladding they form an interconnected formwork defining a formwork space. A cementitious material cast within the formwork space is interconnected and forms a single underlying structural frame within the constructed wall assembly. The assembly includes connectors extending between the vertical and horizontal formwork members and the cladding on which they are mounted. Each connector extends from the cladding through the formwork space to the formwork member and is cast within the cementitious material. A method of building a wall assembly is also disclosed.

Claims18

Dependent claims

A wall assembly constructed on a wall support, comprising:

a cladding and at least one formwork member mounted on the wall support, wherein the formwork member is arranged to form at least a part of a formwork defining a formwork space configured to receive a cementitious material therein on site, the cladding also forming a part of the formwork, the formwork member comprising an elongate channel section having a substantially uniform cross-sectional shape having two channel sides joined by a substantially orthogonal channel base, and mounting flanges on the channel sides fixing the formwork member to the cladding,
a vertical reinforcing rod mounted on the wall support and received within the formwork member;
at least one elongate connector having two ends, wherein the at least one connector is fixed to the cladding towards one end and to the channel base of the section formwork member towards the other end, and extends through the formwork space and is surrounded by the cementitious material between said one and other ends,
wherein the at least one connector is fixed to the reinforcing rod to tie the formwork member and the cladding to the vertical reinforcing rod and thereby the wall support;
and
a filler body received within the channel section positioned against the channel base spaced from the cladding, wherein the filler body is penetrated by the at least one connector to fix the at least one connector to the formwork member;
wherein the formwork member forms a permanent feature of the constructed wall assembly and the at least one connector is surrounded with cementitious material which anchors the connector in the cementitious material.

4 more elements

A method of constructing a wall assembly, the method including:

placing a plurality of pre-assembled wall units on a wall support, each pre-assembled wall unit comprising a cladding, at least one formwork member mounted on the cladding, the at least one formwork member comprising an elongate channel section of substantially uniform cross sectional shape including two channel sides joined by a substantially orthogonal channel base, and mounting flanges along the two channel sides fixing the at least one formwork member to the cladding, and at least one elongate connector having two ends, the at least one connector fixed to the cladding towards one end, and fixed to the formwork member towards the other end, and
arranging the pre-assembled wall units such that the formwork members and the claddings form a formwork defining a formwork space through which the at least one elongate connector extends;
positioning a vertically extending reinforcing bar within the formwork member and fixing a lower end of the reinforcing bar to the wall support;
fixing the reinforcing bar to the at least one elongate connector within the formwork space;
bracing the formwork members and the cladding with a temporary brace to hold the formwork firmly in position on the wall support by fixing the temporary brace to at least one formwork member and the wall support;
pouring a cementitious material in a flowable form into the formwork space and allowing the cementitious material to set to form an elongated structural member of cast cementitious material within the formwork that encloses the elongate connector and anchors the connector in the cementitious material;
and
removing the temporary bracing and support after the cementitious material has set while retaining the at least one formwork member which forms a permanent feature of the constructed wall assembly and the connector is surrounded with cementitious material which anchors the connector in the cementitious material.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 14/420,170Filed 7 Aug 2013
Priority: AU 20129033777 Aug 2012
Published: US 2015/0204085 A123 Jul 2015
Granted: 2 Jan 2018
Term ends: Not estimatedThe source records don’t support an estimate.

Classification11 codes

E04B 1/165
Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as…: with…
E04B 1/167
Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as…: with…
E04B 2/38
Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of…: the…
E04B 2/40
Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of…: the…