Composite wall panel, wall system and components thereof, and a method of construction thereof

Abstract

A composite wall, ceiling or floor panel ( 10 ), system and method, including a sheet ( 14 ) having a first face ( 18 ) including at least one first mounting portion ( 16 ), and at least one formwork member ( 20 ) with at least one second mounting portion ( 30 ) arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. Structural support comes from piers (for a wall) or beams (ceiling or floor) formed in the spacing between adjacent formwork members. The formwork members act as the core of a wall, ceiling or floor panel. An external coating ( 123 ) is applied to the formwork members, such as spray shotcrete or render. Channels ( 28 ) formed by the formwork members defines integrated ducting for services to be run.

1 - 21 . (canceled) 
     
     
         22 . A composite wall, ceiling or floor panel including a sheet having a first face and a second face, the first face including at least one first mounting portion, the panel further including at least one formwork member having at least one second mounting portion arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. 
     
     
         23 . A composite panel according to  claim 22 , wherein the sheet includes an insulation layer and a lining layer. 
     
     
         24 . A composite panel according to  claim 23 , wherein the insulation layer also provides the first face of the sheet and the lining layer provides the second face of the sheet. 
     
     
         25 . A composite panel according to  claim 22 , wherein the first and second mounting portions include respective projections and recesses arranged such that the projections are received into the recesses. 
     
     
         26 . A composite panel according to  claim 25 , wherein the arrangement of projections and recesses provides a keyway arrangement whereby the projections and recesses have an inter-cooperating keyway projection and keyway channel locking one to the other. 
     
     
         27 . A composite panel according to  claim 22 , wherein the formwork member acts as a column section of the panel having at least one leg projecting from a main body portion. 
     
     
         28 . A composite panel according to  claim 22 , wherein the body portion of the formwork member includes an exterior surface profile configured to receive and assist retention of a coating. 
     
     
         29 . A composite panel according to  claim 22 , including a coating of concrete applied to at least one of the faces. 
     
     
         30 . A composite panel according to  claim 22 , wherein the at least one formwork member includes a complex exterior profile or a textured surface or combinations thereof to increase surface area for adhesion of the coating. 
     
     
         31 . A composite panel according to  claim 22 , wherein the sheet includes a moisture barrier material. 
     
     
         32 . A composite panel according to  claim 22 , wherein the at least one formwork member includes at least one core channel running along a longitudinal direction of the at least one formwork member. 
     
     
         33 . A composite panel according to  claim 32 , wherein the at least one core channel provides one or more voids as service/utility conduits. 
     
     
         34 . A composite panel according to  claim 22 , wherein the panel is provided as a wall panel or as a floor panel. 
     
     
         35 . A composite panel according to  claim 29 , wherein the concrete is spray applied concrete. 
     
     
         36 . A method of constructing a structural composite wall, ceiling or floor, the method including connecting at least one formwork member to a first face of a panel sheet, erecting and supporting the panel sheet and connected formwork member(s), and coating at least a portion of the first face of the panel sheet and the formwork member(s) with concrete, and allowing the concrete to harden to form a wall section. 
     
     
         37 . A method according to  claim 36 , wherein the at least one formwork member includes projections inserted into respective channels in the first face of the panel. 
     
     
         38 . A method according to  claim 36 , including connecting adjacent erected panels with a metal or non-ferrous locking member spanning adjoining wall panels. 
     
     
         39 . A method according to  claim 36 , including placing one or more reinforcing bars in at least one void or space formed between two adjacent said formwork members. 
     
     
         40 . A method according to  claim 36 , including forming a floor panel by placing the panel horizontally to create a reinforced floor slab using voids or spaces formed between two adjacent said formwork members to form a vault structure onto which concrete is poured and leveled. 
     
     
         41 . A method according to  claim 40 , including placing one or more reinforcing bars in at least one void or space formed between two adjacent said formwork members.