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Pre-welded steel reinforcing panels are placed into moulds, concrete, which has been specially formulated, is poured into these moulds while they are vibrated to compact the concrete.
The concrete is allowed to ‘cure’ for a set time before the panels are removed. The pre-cast panel is then placed in a humidifier curing room so uniform maximum strength is consistently accomplished.
The Roof
The Cathedral Roof design is pivotal to the structural integrity of the entire unit.
The concrete weight applied against itself is transferred and locked onto/over the wall tying the whole module together through the diaphragm action of the roof. The beam design feature in the Roof is a key element. A Industrial High Quality Adhesive/Sealant is placed between the roof perimeter key area and wall top to provide a watertight seal above the gutter.
There are no point loads on the external Roof beam so the weight is evenly distributed to the Walls and through to the reinforced wall sections and end-columns. The structural Engineering design has been carried out and certified by Morris Boyd - Bachelor of Engineering, CP Engineer, MIE, RPEQ Civil – from Nustar Engineering Group, Rockhampton.
The Concrete Technology
The Chameleon Company has made use of the most up to date technology in the matrix of the concrete to improve thermal performance, strength and aesthetics of the finished product. The “lightweight” concrete construction is due to the addition of polystyrene “regrind” beads combined with advanced chemical additives (environmentally compatible).
The exact content of the Roof “Lightweight” Concrete is still under research & development and will potentially have Patent application. The beads also have the effect of improving the thermal/acoustic properties of the roof by reducing the transfer of heat and absorbing sound. The thermal rating can be further enhanced, up to 30%, by the external application of a number of corporate paint type products that can reduce radiation absorption from the sun, due to their reflective qualities.
The simple construction method using the moulds, a mobile “batching” plant and a crane allows for the training of local unskilled workers to carry out the majority of the work. The roof and wall steel reinforcing inserts could be pre-fabricated in welding jig’s in another location then bulk transported to remote sites.
This building system is world first technology – offering huge opportunities to communities located across Australia and the world who encounter restrictions due to distance, locality or lack of tradespeople.
