Methods, systems and components for multi-storey building construction

Abstract

A method of forming a multi-storey building structure, comprising the steps of erecting a series of vertically oriented support columns ( 2 ) in spaced apart relationship to define a generally vertical support structure, and connecting a series of horizontally oriented support beams ( 5 ) to the support columns in spaced apart relationship to define a generally horizontal support structure for a floor. Furthermore, releasably attaching a crane carriage assembly ( 70 ) to a rail formation ( 63 ) attached to the support structure (B), whereby the carriage assembly is adapted securely to traverse the rail, and hoist, position and secure a plurality of prefabricated lightweight structural panels ( 10 ), in substantially contiguous side-by-side relationship on the horizontal support structure to form a structural floor.

1 - 53 . (canceled) 
     
     
         54 . A method of forming a building, comprising the steps of:
 erecting a series of vertically oriented support columns in spaced apart relationship to define a generally vertical support structure;   connecting a series of horizontally oriented support beams to the support columns in spaced apart relationship to define a generally horizontal support structure for a floor;   providing a plurality of pre-fabricated structural panels, each including at least one lifting hole extending through the panel from a front face to a rear face thereof, to facilitate crane lifting of the panels to selected floor levels in the building structure;   releasably securing a lifting attachment incorporating a pair of lifting formations to each of the structural panels such that one of the lifting formations is accessible from the front face of each panel and the other lifting formation is accessible from the rear face of each panel, and such that the lifting formations are interconnected directly by a load-bearing connecting element extending through each of the respective lifting holes;   releasably interconnecting two or more of the panels in series by means of at least one intermediate linking element positioned to extend between the respective lifting formations;   hoisting the interconnected panels in the series substantially simultaneously to a required height whereby the panels are supported in vertically spaced apart relationship by the linking elements during the hoisting operation, with each panel being directly connected to an upper and/or lower panel in the series during the lifting operation; and   positioning the structural panels in substantially contiguous side-by-side relationship on the horizontal or vertical support structure to form a structural floor or wall section for the building.   
     
     
         55 . A method according to  claim 54 , wherein the structural panels are formed from a relatively light weight low density concrete material. 
     
     
         56 . A method according to  claim 54 , wherein the structural panels are formed substantially from an autoclaved aerated concrete (AAC) material. 
     
     
         57 . A method according to  claim 54 , including the further step of filling respective clearance spaces defined between adjacent edges of respective pairs of adjoining structural panels with a compatible cementitious material, thereby to form a substantially continuous upper surface on the structural floor. 
     
     
         58 . A method according to  claim 54 , wherein the support columns are formed at least predominantly from steel sections, and wherein the method includes the step of fastening the steel sections together by bolting, bracketing or welding. 
     
     
         59 . A method according to  claim 58 , wherein the method includes the step of fastening a plurality of the steel sections together off-site, to form pre-fabricated structural sub-assemblies adapted for installation on site as part of the support structure. 
     
     
         60 . A method according to  claim 54 , wherein the structural panels are formed in a generally rectangular configuration, and wherein the horizontal support beams are disposed in generally parallel spaced apart relationship, at orientations and intervals that are complementary with the orientation, size and strength of the structural panels to be supported. 
     
     
         61 . A method according to  claim 54 , wherein the structural panels are formed with complementary or partially complementary edge profiles. 
     
     
         62 . A method according to  claim 61 , wherein the adjoining edge profiles of adjacent pairs of the structural panels are adapted upon abutting engagement to define respective channels, each of said channels extending longitudinally between the corresponding pair of adjoining structural panels. 
     
     
         63 . A method according to  claim 62 , including the further steps of placing an elongate reinforcing bar longitudinally in each of the channels and subsequently filling the channel with a cementitious material, thereby to form a substantially continuous upper surface extending between the adjoining structural panels, while reinforcing the intermediate joints. 
     
     
         64 . A method according to  claim 54 , wherein each lifting attachment includes an eye-bolt having a head with an integral lifting eye and a complementary eye-nut incorporating an integral lifting eye, configured such that a shank of the eye-bolt is adapted in use to extend through the lifting hole in the panel for releasable engagement with the eye-nut on the opposite side of the panel. 
     
     
         65 . A method according to  claim 64 , wherein the lifting attachment further includes a base plate with a mounting hole adapted to accommodate the shank of the eye-bolt, the base plate being adapted to be positioned between either the eye-bolt or the eye-nut and an outer face of the associated panel, thereby to distribute load and reduce stress concentrations in the structural panel around the lifting hole. 
     
     
         66 . A method according to  claim 54 , wherein a plurality of the structural panels each include a single centrally located lifting hole. 
     
     
         67 . A method according to  claim 54 , wherein at least one of the structural panels includes a pair of said lifting holes disposed in spaced apart relationship generally symmetrically along or about a centreline of the panel, wherein each of the lifting holes is adapted releasably to receive a respective one of the lifting attachments. 
     
     
         68 . A building structure formed substantially in accordance with the method as defined in any one of the preceding claims, the building structure including:
 a series of vertically oriented support columns disposed in spaced apart relationship to define a generally vertical support structure;   a series of horizontally oriented support beams connected to the support columns in spaced apart relationship to define a generally horizontal support structure for a floor; and   a plurality of pre-fabricated structural panels positioned in contiguous side-by-side relationship on the horizontal support structure to form a structural floor, wherein each panel includes at least one lifting hole extending from a front face to a rear face of the panel so as to be adapted to releasably receive a lifting attachment, the lifting attachment having at least one lifting formation and a load-bearing connecting element for extending through the respective lifting hole.   
     
     
         69 . A building structure according to  claim 68 , wherein a plurality of the prefabricated structural panels are positioned in contiguous side-by-side relationship on the support structure to form a wall. 
     
     
         70 . A prefabricated structural building panel adapted for use in a method or building structure according to any one of the preceding claims, the panel adapted to be supported in contiguous side-by-side relationship with a plurality of like panels to form a structural floor or wall between supporting frame elements in a building structure, each panel including at least one pre-formed lifting hole extending through the panel from one face to an opposing face, the or each lifting hole being adapted to receive a lifting attachment incorporating a pair of lifting formations such that one of the lifting formations is accessible from one face and the other lifting formation is accessible from an opposing face, and such that the lifting formations are interconnected directly by a load-bearing connecting element extending through the respective lifting hole, to enable inter-linking of multiple panels in series by means of the respective lifting attachments and thereby to enable simultaneous lifting of multiple panels in vertically spaced apart relationship, the panel further including supplementary internal reinforcement or a concentration of reinforcement in the vicinity of at least one of the lifting holes. 
     
     
         71 . A prefabricated structural building panel according to  claim 70 , being generally rectangular prismatic in shape, and being formed substantially from reinforced autoclaved aerated concrete (AAC). 
     
     
         72 . A structural panel according to  claim 70 , wherein the panel includes complementary or partially complementary profiles on opposing longitudinal edges, whereby when the panel is positioned in abutting side-by-side relationship with a like panel, the adjacent edge profiles are adapted in combination to define a diverging generally V-shaped or generally U-shaped channel therebetween. 
     
     
         73 . A structural panel according to  claim 72 , wherein at least one of the lifting holes is formed before the panel is autoclaved. 
     
     
         74 . A structural panel according to  claim 71 , wherein the panel has a density in the range of 500 kg/m 3  to 1,000 kg/m 3 . 
     
     
         75 . A structural panel according to  claim 70 , wherein the panel includes at least two of the lifting holes, distributed substantially uniformly about a centre of gravity of the panel. 
     
     
         76 . A method of installing a wall section in a multi-storey building, the building including a series of vertically oriented support columns disposed in spaced apart relationship to define a generally vertical support structure, the method including the steps of:
 providing a plurality of pre-fabricated structural panels, each panel including at least one lifting hole extending from a front face to a rear face of the panel;   releasably securing a lifting attachment to each of the structural panels, the lifting attachment having at least one lifting formation and a load-bearing connecting element extending through the respective lifting hole;   releasably attaching a rail formation to the support structure in a substantially horizontal orientation generally above an intended location for the wall section;   providing a crane carriage assembly incorporating a panel engagement mechanism and a rail traversing mechanism;   releasably attaching the crane carriage assembly to the rail formation by means of the rail traversing mechanism whereby the carriage assembly is adapted securely to traverse the rail;   releasably connecting the panel engagement mechanism on the carriage assembly with the lifting formation on the panel, whereby the panel is suspended from the rail formation;   moving the carriage assembly along the rail so as to position the suspended panel adjacent an intended location for the wall section;   positioning and securing the panel in the wall section;   releasing the panel engagement mechanism;   repeating the foregoing steps with successive panels positioned in contiguous side-by-side relationship to form the wall section of the building.   
     
     
         77 . A method according to  claim 76 , including releasably connecting the panel engagement mechanism with the lifting formation by means of a selectively disengageable lifting frame, the lifting frame including lifting arms adapted in use to extend downwardly from an upper bridge section along opposite faces of the panel to a lifting element extending through the associated lifting hole. 
     
     
         78 . A method according to  claim 76 , wherein the rail formation is attached by a series of spaced apart removable connecting brackets, each in use extending from a respective support column to a corresponding position on the rail formation. 
     
     
         79 . A method according to  claim 76 , wherein the panel engagement mechanism on the carriage assembly includes a wire rope, cable or chain terminating in a hook formation adapted for releasable engagement with the lifting eye on the panel. 
     
     
         80 . A method according to  claim 76 , wherein the rail formation takes the form of an I-beam comprising horizontally oriented upper and lower flanges and a vertically oriented interconnecting web, and the carriage assembly includes a rail traversing mechanism incorporating guide wheels adapted for rolling engagement with the lower flange of the I-beam. 
     
     
         81 . A method according to  claim 80 , wherein the carriage assembly is motorised, incorporating a first drive mechanism adapted to drive the carriage on the rail, and a second drive mechanism adapted progressively to raise and lower the suspended panel via the engagement mechanism. 
     
     
         82 . A method according to  claim 81 , wherein the second drive mechanism is connected with a winch, adapted to control a wire rope connected to the panel and hence to regulate the height of the panel during lifting. 
     
     
         83 . A method according to  claim 76 , including the further steps of:
 releasably interconnecting a plurality of the panels together as a series using a plurality of intermediate linking elements,   connecting the first panel in the series to the carriage assembly by means of the engagement mechanism on the carriage and the lifting formation on the first panel;   lifting the first panel by means of a drive mechanism in the carriage and thereby hoisting the subsequent interconnected panels in the series to a required height for the lowermost panel;   positioning, securing and releasing the lowermost panel; and   positioning, securing and releasing the subsequent panels in the series successively using the drive mechanism to facilitate formation of a corresponding wall section or sub-section in the building.