AU2017101589A4 - Improved modular wall construction - Google Patents

Abstract

A method of construction of a wall (10) from a plurality of primary modules(12A, 12B) and at least one secondary module (30,50), each primary module 5 (12A,12B) having an outer face portion (16) and two side portions (20,22), each secondary module (30) having an outer face portion (34) , two side portions (36,38) and at least one mounting portion (42,43), the method including the steps of: aligning at least two primary modules (12A,12B) together such that their 10 outer face portions (16) both form part of a first face (202) of the wall (10), with a first side portion (20) of a first primary module (12A) abutting a second side portion (22) of a second primary module (12B); connecting the first side portion (20) of the first primary module (12A) to the second side portion (22) of the second primary module (12B) such that the 15 first and second primary modules (12A,12B) are constrained to move together; and mounting a secondary module (30) or onto the connected primary modules such that the outer face portion (34) of the secondary module (30) forms at least part of a second face (204) of the wall (10), wherein the at least one 20 mounting portion (42,43) of the secondary module (30) engages with a primary module (12B) to restrain movement in at least one direction of the secondary module (30) wherein an end of a primary module (12A,12B) includes a stiffener (23) extending between said side portions of said primary module (20,22). 10 23B 23B17 23C 2AfAI '~.500 30 5 515 50 30 Fig. 12a

Description

IMPROVED MODULAR WALL CONSTRUCTION FIELD OF THE INVENTION

The invention relates to the modular construction of walls in the building industry. It is particularly suitable for use within the housing industry. The improved construction method is suitable for use in relation to both load-bearing and non load-bearing walls.

BACKGROUND TO THE INVENTION

The use of prefabricated panels to form structural walls of buildings such as houses, shops, schools, factories, fences and the like has several advantages over other construction methods. Principally, these advantages are gained by moving labour intensive fabrication work away from a building site into an efficient factory controlled environment. This greatly reduces the time required to be spent by builders on the site without compromising the quality of the finished walls.

Traditionally, to make such a system cost effective, the panels are fabricated in large sizes and are consequently extremely heavy. Machinery such as cranes is required both in the factory and on site to move, handle, place and erect the panels. Secondary processes of connection and alignment further add to the cost of construction.

Using such panels, a high degree of direct supervision and/or a highly skilled work force is required to efficiently and safely construct a wall of acceptable quality and standard. A construction method addressing these issues is described in the International Patent Publication No. WO 1999/09268, the contents of which are hereby incorporated herein by reference. The method proposes a modular construction system which is fast and economical for construction of single and multi-story structures. The method reduces the dependency on skilled labour, cranes, scaffolding, and elaborate construction tools and fasteners during the construction of both load bearing and non-load bearing walls.

Specifically, the system proposes a method for constructing a wall from discrete modules. In a preferred form, the modules are of three types: T-shaped first modules, T-shaped second modules and L-shaped end modules. The wall is constructed firstly by aligning a desired number of first modules between two end modules, such that the flanges of each module combine to form a substantially continuous outer surface. The webs of successive first modules are connected by steel tie rods. This structure, including one face of the wall, is then able to support a second face of the wall. In its preferred form, the tie rods provide a supporting frame on which second modules can be hung, with the flanges of the second modules forming a second substantially continuous outer surface opposed to the first outer surface. The spaces in between webs of the first and second modules provide a cavity wall space in which pipes, electrical conduits and other building services can be provided.

In practice, it has been found that the structural behaviour of a wall constructed from these modules is influenced by many aspects of the wall design. These include the shape and configuration of the modules, particularly the cross-sectional shape of the first modules, the manner in which they are connected together to form a supporting structure for the second modules, and the type of connection means used to connect the first modules together. These factors have substantial influence on the distribution of forces in the wall, for example in the tie rods, on the ultimate strength capacity and on the cost of the wall. In particular, the response of the wall to different racking and lateral wind loading conditions varies greatly as the wall design factors are varied.

Demonstrating the above issues, some difficulties arose when using T-shaped modules to build a wall, as described in the above mentioned patent application, for use in cyclone-prone areas. When subjected to powerful winds, lateral forces acting perpendicular to the plane of wall and racking forces acting on top of the wall along the plane of the same wall induced substantial bending in the tie rod connection means connecting the first modules together. The forces also resulted in high localised stresses in the first and end modules at the connection point. As a result, high localised stresses were created in the webs of modules adjacent the connection point. These stresses could be sufficiently high to cause failure of the web.

In practice, the possibility of high racking forces combined with high lateral forces in cyclone-prone areas necessitated the use of larger, more rigid tie rods with special end connections. This adds significantly to the cost of the construction, noting that the construction industry can be both conservative and highly cost sensitive, and also created a variable which complicated the supply of panels in modular form. Even when using larger rods with special end connections, the resistance to bending of the rods still provided a limit to the strength of the modular wall.

To that end, the Applicant developed a method of construction of a wall from a plurality of primary modules and at least one secondary module, each primary module being open ended having an outer face portion and two side portions, each secondary module having an outer face portion and at least one mounting portion. This method, described in International Patent Publication WO 2007/128054, the contents of which are hereby incorporated herein by reference, includes the steps of: aligning at least two primary modules together such that their outer face portions both form part of a first face of the wall, with a first side portion of a first primary module abutting a second side portion of a second primary module; connecting the first side portion of the first primary module to the second side portion of the second primary module such that the first and second primary modules are constrained to move together; and mounting a secondary module onto the wall such that the outer face portion of the secondary module forms at least part of a second face of the wall, wherein the at least one mounting portion of the secondary module engages with a primary module to restrain movement in at least one direction of the secondary module.

This method addresses the issue(s) described above. However, the construction method described above still leaves matters to be addressed in terms of structural performance, construction safety and economy. While the previous methods of construction appreciated that the primary modules forming a wall section required fixity at the base and at the top of the wall, this could not be done cost effectively with L-shaped floor brackets and the specially designed roof bolt described in the above Patent. The L shaped floor brackets would have one side fixed to a base structure such as a slab or a footing and another side connected to a side portion of the primary module. Structural failure at these bracket connections could occur due to high racking and lateral forces.

The present invention, among other objectives, seeks to enable required wall fixity at the bottom and at the top in stronger, simpler, easier and in a more cost effective manner and to enable a safer wall construction method.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a method of construction of a wall from a plurality of primary modules and optionally at least one secondary module, each primary module having an outer face portion and two side portions, each secondary module having an outer face portion two side portions and at least one mounting portion, the method including the steps of: aligning at least two primary modules together such that their outer face portions both form part of a first face of the wall, with a first side portion of a first primary module abutting a second side portion of a second primary module; connecting the first side portion of the first primary module to the second side portion of the second primary module such that the first and second primary modules are constrained to move together; and mounting a secondary module onto the wall such that the outer face portion of the secondary module forms at least part of a second face of the wall, wherein the at least one mounting portion of the secondary module engages with a primary module to restrain movement in at least one direction of the secondary module wherein an end of a primary module includes a stiffener extending between said side portions of said primary module.

Preferably, the primary module is provided with a pair of stiffeners, one stiffener being disposed at a first end of the primary module, for example the base connected by fixing means to a supporting structure such as a footing or slab. Another stiffener is conveniently also disposed at the second end of the primary module, for example the top connected to another member such as a wall plate in single storey house construction, or to the soffit of a suspended reinforced concrete slab in the case of partition wall construction on multi-storey buildings. In this way, the primary modules become closed ended with the stiffeners having dimension - especially thickness - selected for sufficient stiffness, especially to provide structural resistance to substantial racking and lateral forces and during handling, transport and erection.

The stiffeners conveniently have a planar geometry for ease of construction. The planar geometry also allows a primary module to bear on a larger surface area than with the open ended primary modules. This is advantageous where the primary modules are heavily loaded axially for example from a multi-storey building (say of up to two or three floors). Module bearing pressures can then more easily be constrained within regulatory standards relating to structural use of concrete such as the Australian Standard 3600-2009.

The connected primary modules, including the first face of the wall, provide a support structure for the secondary modules and the second face of the wall. The connected primary modules are thus the principal load bearing elements. Advantageously, the transmission of forces between adjoining primary modules is carried by a connection means connecting abutting side portions. Lateral and racking forces applied to a wall are transmitted through this connection means primarily as shear forces, rather than inducing combined bending and axial forces as in the prior art.

In one form of the invention, the primary modules are provided with a mounting support, such that the mounting portion of the secondary module engages with at least one mounting support. Mounting supports are described in further detail in WO 2007/128054 incorporated herein by reference.

In one embodiment of the invention secondary modules are provided in at least two forms: intermediate secondary modules and end secondary modules. Intermediate secondary modules can be formed in similar fashion to primary modules, with an outer face and two side portions, the mounting portion being contained within the side portions. In this way, a wall can be constructed with the side portions of an intermediate secondary module each being located within cavities of adjoining primary modules, such that the outer face of the secondary module effectively covers the abutting side portions of the primary module.

In this arrangement, end secondary modules may be formed, effectively, as half intermediate modules, having an outer face and a single side portion which includes a mounting portion. Such an arrangement simplifies both manufacture of the modules and construction of the wall.

Preferably both the primary modules and intermediate secondary modules are substantially channel shaped, for example “C” shaped (in cross section, with the outer face portion forming the web and the side portions forming the flanges of the “C” shape section. The methods of construction described in this specification may therefore be described as The C-Wall Construction System. The end secondary modules may thus be substantially “L” shaped in cross section.

As the cross sectional shape of each of these modules is similar, they can be produced using a single mould with various modifications.

For some applications, for example construction of a wall in the form of a fence, a primary module may simply comprise an outer face portion and two side portions without end stiffeners, that is, being open ended. Such a module may act also as a footing in a fence application as described below.

The connection means connecting abutting side portions of primary modules may comprise bolts passing through aligned holes in the side portions, or a dowel and screw arrangement. In a preferred construction, the connection means comprises horizontal keys which pass through aligned, rectangular holes in the side portions and are secured in position by vertically applied securing wedges. Advantageously, this increases the bearing area of the connection means, and the area through which shear forces act due to racking and lateral forces on the wall, thus safely dissipating the shear force. This reduces the localised stresses within the modules. The shear force is further dissipated by the inclusion of additional keys, which may be spaced vertically along the side portions. The inclusion of additional keys further increases the load capacity of the wall. In a preferred form, the keys each have an enlarged head which bears against one side portion, with the vertical wedge bearing against the other side portion. A further advantage of using keys and wedges is the speed and ease of connections of the primary modules.

The mounting support of a secondary module may extend across each primary module, from the first side portion to the second side portion. The mounting support may be at least one rod receivable within apertures in the side portions. Preferably, the mounting support comprises two parallel, vertically spaced rods across each primary module. The apertures may extend through the side portions, such that a rod may be inserted from outside the primary module. The apertures of abutting side portions may be aligned, such that a rod may span more than one primary module. Mounting supports may protrude from the primary and the secondary module, for example being provided in the form of brackets which may have U or C shape.

Mounting supports may be fitted on site to primary modules during or prior to alignment. One preferred mounting portion of the secondary modules preferably comprises angled slots within the side portions which extend diagonally upwardly within the side portions. This allows each secondary module to be hung and effectively wedged over the mounting rod supports. In this way the weight of the secondary module together with the wedging effect assists in maintaining it in position, without necessarily requiring the use of additional fasteners. However, in practice, hanging secondary modules over mounting supports on long primary modules may create challenges for hanging where two slots are located far apart, as in the prior art, one towards the top and one disposed intermediate though towards the bottom end of the secondary module. Due to the shape of the angled slots and weight of the secondary module, during hanging, a secondary module could drop suddenly under its own inertia into the slots causing extra impact load on the angled slots. Such extra impact load could cause the acting loads on the slots to far exceed the design load capacity of the slots and could result in catastrophic structural failure. Further, any misjudgement in locating and engaging the top angled slot during erection of the secondary modules, as described in the prior art, could cause sudden engagement of slots to mounting support, for example a tie rod, forcing a secondary module to suddenly engage with the slots and without any notice or control. This could result in serious injury if an erector’s hand was caught between it and the adjacent hanging secondary module. To minimise this risk, a slot is located proximate the bottom end of a secondary module. This slot advantageously replaces the second slot described above. In another aspect then, the present invention provides a method of construction as above described wherein a secondary module comprises a mounting portion comprising angled slots within the side portions which extend diagonally upwardly within the side portion and at least one slot is located proximate the bottom end of a secondary module. This arrangement allows the erector, with full control, to fully engage first, the end slot of the secondary module to the corresponding mounting support of a primary module so that the secondary module can be temporarily fully supported by the said mounting support, before fully engaging the top slot of the secondary module to the corresponding mounting support of a primary module.

In an alternative form of the invention, the secondary modules may comprise cladding or lining sheets or panelling which is connected to the primary modules. The cladding or the lining sheets or panelling may be connected to a mounting support within the primary modules, or protruding past the primary modules by connection means. Such connection means may include a plurality of one or more of connection means selected from mounting brackets, packings, furring channels and/or top hats to be connected directly to the primary modules, horizontally or vertically for instance: top hats vertically by the same keys and wedges of the connection means, furring channels horizontally by screwed fasteners, glue or both glue and screws together. Such construction may be used for both external walls and internal partition walls.

Internal partition walls particularly, a hollow face wall - similar to a stud wall - may be formed on one side and a solid face wall may be formed on the other side, from primary modules. A hollow face side of a partition wall would not typically be the preferred side of a wall for fixing, hanging or fitting items - such as household items including paintings, shelving, cupboards and the like - or for fitting items such as power points, light points or communication sockets. While the side portions of a primary module could be drilled for hanging heavier items, this could cause structural damage to the point of failure. In addition, drilling must avoid the connection means for joining the primary modules together and the connection means apertures provided in the primary module flanges. To avoid such issues, the primary modules may be aligned and connected in a staggered configuration so that an outer face of one primary module faces one side of a wall and the outer face of an adjacent connected primary module faces the other side of the wall. Such configuration requires both faces of an internal partition wall to be lined. The wall lining could be glued and screwed directly to the face of the adjacent primary modules without the need for plurality of additional mounting supports resulting in large savings. Also, such an arrangement of a wall does not affect the structural integrity of the wall, yet it appreciably improves its functionality, serviceability and acoustic performance while allowing greater assurance of convenient and safe hanging and fixing of items such as those mentioned above, on either face of an internal wall.

Primary modules of internal partition walls may, if desired, be staggered in groups. So, for example, any number “n” of primary modules could be connected to face to one side of a wall and the next “m” primary modules could be connected to face to another side of the wall. The number “m” may be the same or different to “n”. Advantageously, connection means provided in the primary modules for this aspect of the method of construction of the invention are centrally located in the width of the side portions.

The new method allows construction of corners. In one option, corner primary modules could be provided, in which an outer edge of a modified side portion extends from an outer corner of the module at an acute angle. In this way two corner primary modules can be abutted to form a corner of a building. The corner may be further strengthened by the use of a corner bracket. In its simplest form the acute angle will be 45°, allowing the abutting modules to form a 90° corner. This option for corner primary modules would keep the weight of the module down for handling and erection purposes so that no more than two persons would be needed to erect a corner. Modular uniformity in which each module has the same width could also be achieved.

However, such a construction - resulting in a mitre joint corner - can prove difficult, time consuming and leaves room for structural improvement. In addition, no matter how accurate the mitre joint is, the corner joint may always be visible, perfect mitre is improbable and chipping may occur during handling and erection. Maintenance requirements are also higher. To avoid such issues, such primary corner modules may be replaced with a single primary corner module having a length, two ends and a hollow core wherein an end of the primary corner module includes a stiffener substantially closing the hollow core. A further aspect of the present invention provides a method of construction as above described wherein corners are formed by connection of a primary corner module having a length, two ends and a hollow core, an end of the primary corner module including a stiffener substantially closing the hollow core.

Both ends of the primary corner module preferably include such stiffeners with the same characteristics as described above. The primary corner module may also be connected to supporting structure above and below by connection means extending through each stiffener as required. Conveniently, a primary corner module as above described also has a generally square cross-section. A width of the primary corner module is advantageously a fraction, for example one half, of the width of a primary module used for constructing a wall as described above.

Primary corner modules may be connected with primary modules forming abutting side walls by angle brackets or bolts or other connection means but preferably keys and wedges. Such keys have arms angled at the angle of the corner, for example at 90s for a right angle corner. A plurality of angle keys may be used to make the connection with the primary modules through complementary connection means. By way of example, three or four angle keys could be used. The keys may be formed integral with a primary corner module to reduce number of parts and make construction easier and quicker. Conveniently, a primary corner module may be propped during construction of a corner. One or more props, conveniently two props, may be connected to the primary corner module when in upright position, for example to a removable pin engaged with the top stiffener. A bottom pin could be fixed to the supporting structure (such as footings) at the corner, to engage the bottom stiffener to the supporting structure The primary corner module is then correctly positioned to the lines and level of the corner to be constructed, being plumbed in both directions. Following connection of the side walls primary modules to the corner module and the supporting structure, the props may be removed.

Windows and doors may be fitted to a wall either during or after construction of a wall. A preferred way is to fit windows after a wall has been constructed. This helps keep the construction site clear allowing more space to move on site, less risk of damage to the windows and most importantly to speed construction time. Windows are conveniently fitted by fixing them directly to primary modules framing a window opening provided during construction. Such primary modules typically extend the full height of the wall. Where required, shorter length primary modules may be used above and below the window opening. In the case of larger windows, lintels may be used to span the window opening.

Similar considerations apply to doors. Metal door frames are designed for direct fitting to walls during construction. The door frame is connected to primary modules framing the door opening by desired connection means conveniently in the form of at least one, preferably four, U bracket(s) to each side of the door frame. Standard and non-standard door sizes can be used, with a door frame being connected, if necessary, to a packing on one side or both sides of the door frame, to provide flexibility to adapt to the selected standard or non- standard door size. One preferred packing is an elongate packing member comprising a plurality of vertically spaced slots to accommodate door brackets for door connection and connection means for connecting said elongate packing member to said primary module. Bolts or keys and wedges is preferred connection means to connect the packings to the primary modules framing the door opening. Where required, shorter length primary modules may be used above the door.

The new method also conveniently enables fence construction. A fence is constructed in the manner described for a wall with wall sections (wall panels) extending between fence piers. Open ended primary modules or other suitable support provides a base support structure for the fence. Piers may comprise columns for which a range of design options are available. Such pier columns could be embedded into the ground with mass concrete surround, to become main anchors of the fence panels. One option constructs a pier column from two primary modules connected back to back. Other options include the primary corner module described above or suitable metal (typically structural steel) sections whether solid or hollow. Pier covers are preferably deployed to cover the pier column and the column could include mounting supports for the pier covers. Cover modules may be connected to the pier’s column by bolts, dowels and screws, or in the same manner as used in connecting secondary modules to primary modules as described above. In one embodiment, a method of construction of a fence comprises the steps of: locating a plurality of columnar fence supporting piers along a desired fence line, each pier column includes connection means for connection to fence panels and pier covers to cover said fence pier supporting column; connecting fence panels comprising a plurality of modules selected from primary modules, secondary modules and end modules, optionally excluding end stiffeners in the fence construction case, to each said columnar fence supporting pier; and connecting a plurality of pier covers to each columnar fence supporting pier.

Conveniently, each pier cover, like a primary module, has an outer face portion and two side portions and is, additionally, fitted with a plurality of first connection means for engaging with complementary connection means provided on said pier column. Conveniently, the first connection means are supporting rods and the complementary connection means are brackets with upwardly extending angled slots for engaging with said supporting rods. This form of connection is effectively the reverse of the secondary to primary module connection described above

It will be appreciated that the primary and secondary modules can be made from any suitable materials. Such materials include reinforced concrete, fibre reinforced concrete, fibre reinforced geopolymer concrete, fibre reinforced polymer concrete, polymer concrete, fibre reinforced gypsum, fibre reinforced cementitious materials, metal, treated foams materials, and timber, in addition to other suitable building materials. The modules could have a composite construction whereby an end wall of the module is made from a first material and the side portions from another material, for instance the end wall could be concrete with metal side portions. Advantageously, these materials enable the construction of a module which is sufficiently lightweight to be conveniently handled by one or two workers.

The method of construction described here can be used also on multistorey structure. Where each storey is formed from independent framed structure of columns, beams and floor slab system or in case of concrete structure, of columns and slab only. Primary, secondary and end modules could be employed, using the above described wall construction method, as external cladding or as non-load bearing internal partition walls.

In another embodiment, when building up to 3 storey height, the walls may be constructed by the same method of construction, and used as load bearing walls to support the story above it. Such construction is subject to certification by the design engineer.

BRIEF DESCRIPTION OF THE DRAWINGS

It will be convenient to further describe the invention with reference to the accompanying drawings which illustrate preferred embodiments of the modular wall construction of the present invention. Other embodiments are possible, and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:

Figure 1a is a side elevation view of a primary module for use in a wall construction in accordance with the present invention;

Figure 1 b is a cross sectional view of the primary module of Figure 1 a;

Figure 1c is a longitudinal cross sectional view of the primary module of Figure 1a;

Figure 2a is a side elevation view of an intermediate secondary module for use in conjunction with the primary module of Figure 1a;

Figure 2b is a cross sectional view of the intermediate secondary module of Figure 2a;

Figure 3a is a side elevation view of an end secondary module for use in conjunction with the primary module of Figure 1a;

Figure 3b is a cross sectional view of the end secondary module of Figure 3a;

Figure 3c is a cross sectional view of an end secondary module alternative to that shown in Figure 3b.

Figure 4a is an enlarged side view of a first portion of a secondary module shown in Figures 2 and 3;

Figure 4b is an enlarged view of a bottom portion of the secondary module shown in Figures 2 and 3;

Figure 4c is an enlarged side elevation view of a first portion of the primary module such as shown in Figure 1a;

Figure 4d is an enlarged side view of a second portion of the primary module of Figure 1a;

Figure 5a is a side view of a corner primary module for use in a wall construction.

Figure 5b is a cross sectional view of the corner primary module of Figure 5a;

Figure 5c is a cross sectional plan view of an external corner and/or internal corner assembly of one embodiment of an external wall using the corner primary module of Figure 5a.

Figure 6a is a side elevation of a packing used in connecting a door frame to a wall constructed in a method according to one embodiment of the present invention;

Figure 6b is a cross sectional view of the packing of Figure 6a.

Figure 6c is a side elevation of an alternative packing used in connecting a door frame to a wall constructed in a method according to alternative embodiment of the present invention;

Figure 6d is a cross sectional view of the packing of Figure 6c;

Figure 7a is a plan view of a key for use in a wall construction in accordance with the present invention;

Figure 7b is a side view of the key of Figure 7a;

Figure 7c is a side view of a bolt which may be used as an alternative to the key of Figure 7a;

Figure 7d is a side view of a circular tie rod for use in a wall construction in accordance with the present invention;

Figure 7e is a side view of a securing wedge for use in conjunction with the key of Figure 7a;

Figure 8a is a side elevation view of a top hat section support means for use in another alternative secondary module in accordance with the present invention;

Figure 8b is a sectional view of 8a.

Figure 8c is a plan view of a furring channel support means for use in yet another alternative secondary module in accordance with the present invention.

Figure 8d is a sectional view of Figure 8c.

Figure 9a is a front elevation view of portion of a wall constructed in accordance with the present invention;

Figure 9b is a cross sectional plan view of the portion of the wall of Figure 9a;

Figure 10a is a part front elevation view of an external corner and/or internal corner of an external building wall constructed using the corner module shown in Figures 5a and 5b;

Figure 10b is a cross sectional plan view of the portion of the wall shown in Figure 10a;

Figure 11a is a cross sectional plan view of an internal partition wall to an external wall connection for a building constructed according to one embodiment of the present invention;

Figure 11b is an elevation view of a bracket used in the internal wall to external wall connection of Figure 11a;

Figure 11 c is a side view of the bracket of Figure 11 b;

Figure 11 d is a plan view of the bracket of Figures 11 b and 11 c;

Figure 11 e is a plan view of a doorframe bracket used in the wall portion of Figures 12a to 13b;

Figure 11 f is a side view of the doorframe bracket of Figure 11 e;

Figure 12a is a front elevation of a wall including a metal door frame to be as constructed according to an embodiment of the present invention;

Figure 12b is a schematic detail view of the door frame of Figure 12a;

Figure 12c is a section view along section line 1 -1 of Figure 12b;

Figure 13a is an enlarged sectional plan view of a connection detail of a doorframe to an external and/or internal wall using door packing of Figures 6c and 6d according to an embodiment of the present invention;

Figure 13b is an enlarged sectional plan view of a connection detail of a doorframe to an internal wall using an alternative U-shaped metal packing according to another embodiment of the present invention;

Figure 14 is a front elevation of portion of a fence constructed according to an embodiment of the present invention;

Figure 15a is enlarged front elevation view of the fence pier shown in Figure 14;

Figure 15b is an enlarged sectional plan view of the fence pier along section line 1-1 of Figure 14 and Figure 15a;

Figure 15c is an enlarged detail part sectional elevation of the fence wall panel taken along section line 2-2 of Figure 14;

Figure 15d is a schematic side elevation view of the pier column shown in Figures 14, 15a and 15b;

Figure 16a is an enlarged detail side view of a top bracket of the pier column shown in Figures 15a, 15b and 15d;

Figure 16b is an enlarged detail view of a bottom bracket of the pier column shown in Figures 15a, 15b and 15d;

Figure 17 is a front elevation of portion of a wall at the location of a window, constructed according to an embodiment of the invention. DESCRIPTION OF PREFERRED EMBODIMENT(S)

Referring to the figures, there is shown in Figs. 9a and 9b, a wall 10 constructed on support structure 400, which could be a suspended slab or ground slab, or concrete footing, from a plurality of primary modules 12 and secondary modules 30, 50 together with various other components as will be described below. The construction is described by the Applicant as The C-Wall Construction System. A primary module 12 is shown in Figs. 1a to 1c. The primary module 12 is elongate, and substantially C shaped in cross section. In a typical embodiment of the invention the primary module 12 has a height (shown as length in Fig. 1a) a width and a depth. It will be understood that these dimensions may be of any suitable and practical combination so that to afford the section the structural loading capacity and the limited weight requirements.

The primary module 12 consists of a rear wall 16 having an outer face portion 18; and two side portions: a first side portion 20 and a second side portion 22. The side portions 20, 22 protrude from either end of the rear wall away from the outer face portion 18 in a direction substantially perpendicular to the outer face portion 18. External corners of 90° are formed between the outer face portion 18 and respective outer faces of each of the side portions 20, 22.

Each primary module 12 includes a pair of stiffeners 23, one located at each end of primary module 12 and extending between side portions 20 and 22. Consequently, each primary module 12 is closed ended except for circular apertures 21 through which connection means, such as bolts, can be inserted to enable connection to the supporting structure 400 and top structure (not shown) with the required fixity.

Each stiffener 23 is of planar geometry and has thickness sufficient to provide structural resistance to substantial racking and lateral forces and during handling, transport and erection. Each stiffener 23 also has sufficient contact area with supporting structure that bearing loads for concrete construction are not exceeded.

Internal corners 24 are formed between inner faces of the side portions 20, 22 and an inner face of the rear wall 16 of primary module 12. In the embodiment of the drawings, the internal corners 24 are bevelled. In an alternative embodiment, the internal corners may be curved with specified radius.

Each side portion 20, 22 includes a plurality of first apertures 26 and a plurality of second apertures 28 shown also in detail in Figs. 4c and 4d. Each of the first apertures 26 is rectangular, with a long edge aligned horizontally, in use, and a short edge aligned vertically. The first apertures 26 are spaced along a vertical span of each side portion 20, 22. Each first aperture 26 is located almost centrally between a front most edge of the side portion 20, 22 and the outer face portion 18 for reasons to be described below. This is shown in more detail in Fig. 4c.

Each of the second apertures 28 is substantially circular, and is located slightly closer to the front most edge of the side portion 20, 22 than to the outer face portion 18. This is shown in more detail in Fig.4d. Second apertures 28 are positioned such that, in use, they are located substantially centrally of a wall 10 as will be described further below. At least one of the second apertures 28 is located towards the top, in use, of the side portion 20, 22. At least one other is located towards the bottom, in use, of the side portion 20, 22. A secondary module 14, being an intermediate secondary module 30, is shown in Figs. 2a and 2b. The intermediate secondary module 30 is elongate, and substantially C shaped in cross section. The intermediate secondary module 30 is substantially similar in shape and dimension to the primary module 12.

The intermediate secondary module 30 consists of a rear wall 32 having an outer face portion 34; and two side portions: a first side portion 36 and a second side portion 38. The side portions 36, 38 protrude from either end of the rear wall away from the outer face portion 34 in a direction substantially perpendicular to the outer face portion 34. External corners of 90° are formed between the outer face portion 34 and respective outer faces of the side portions 36, 38.

Internal corners 40 are formed between inner faces of the side portions 36, 38 and an inner face of the rear wall 32 of secondary module 14. In the embodiment of the drawings, the internal corners 40 are bevelled. In an alternative embodiment, the internal corners may be curved.

The side portions 36, 38 each include a mounting portion in the form of two inclined slots 42 and 43. The slots 42 and 43 extend upwardly at an incline within the side portions 36, 38 from openings 44, 45 in the front most edge of the relevant side portion 36, 38, to a rounded end 46 within the side portion 36, 38.

The slots 42 and 43 are in the form of bevelled cuts at a particular angle a from the horizontal, for example 60° or 45° as shown in Figs. 4a and 4b. Angle a and the locations of cuts along the flanges are selected having regards to the required strength of the module. The bevelled cuts are intersected by a horizontal cut at the openings 44 and 45 as shown generally in Fig. 2a and in detail in Figs. 4a and 4b. The size, location and spacing of the slots 42 and 43 depend on the height of the wall 10 to be constructed and on the design loading of the same wall 10. The higher the wall, the larger the permissible spacing between the slots 42, 43.

In the embodiment shown in the drawings, each side portion has two slots 42 and 43. The slots 42 and 43 are positioned such that, in use, their rounded ends 46 are at the same level as sets of second apertures 28 in primary modules 12.

Slot 43 is shown as located at a bottom end of each secondary module 30. The advantage, of this location is for safety and ease of construction as described below. It will be understood that secondary modules 30 as described in WO 2007/128054 incorporated herein could be employed as a less preferred alternative when considering internal partition walls. A secondary module 14A, being an end secondary module 50, is shown in Figs. 3a and 3b and 3c. The end secondary module 50 is elongate, and substantially L shaped in cross section. The end secondary module 50 is effectively identical to an intermediate secondary module 30 which has been halved along a central elongate line.

The end secondary module 50 consists of a rear wall 52 having an outer face portion 54; and a first side portion 56. The first side portion 56 protrudes from one end of the rear wall 52 away from the outer face portion 54 in a direction substantially perpendicular to the outer face portion 54. An external corner of 90° is formed between the outer face portion 54 and an outer face of the first side portion 56.

An internal corner 60 is formed between inner face of the first side portions 56 and an inner face of the rear wall 52 of end secondary module 50. In the embodiment of the drawings, the internal corner 60 is bevelled. In an alternative embodiment, the internal corner may be curved. The end secondary module 50 of Fig. 3b differs from that shown in Fig. 3c by a protrusion 52a which is used for sealing at the end of walls where a gap 140 is provided between the primary and secondary modules for example external walls, as shown in Fig. 9a and 9b. The end secondary module shown in Fig. 3c is used in walls where no gap is required for example internal walls and fence walls.

The first side portion 56 includes a mounting portion in the form of two inclined slots 42 and 43 similar in shape and form to those in the intermediate secondary modules 30. Again, slot 43 - for reasons to be described below - is located at the bottom end of end secondary module 50. A corner primary module 62 is shown in Figs. 5a to 5c. The corner primary module 62 has a square cross-section with dimension equal to one half the width of the outer face 18 of a primary module 12. As with primary modules 12, each end of corner primary module 62 is provided with a stiffener plate 62a so is closed ended except for circular apertures 63 through which connection means, such as bolts, can be inserted to enable connection to a supporting structure and top structure (not shown) with the required fixity. Other features of stiffener plates 62a are the same as for the stiffener plates 23 described above.

Figs. 5a and 5b also show a corner angle bracket 68 used for connection of corner primary module 62 to primary modules 12 forming joining side walls as described below. A minimum of three corner angle brackets 68 are used, each being spaced along the length of the corner primary module 62 (desirably towards the top, towards the bottom and centrally) and conveniently integrated with the corner primary module 62 during fabrication. Each corner angle bracket 68 comprises two elongate sides 70 disposed at right angles to each other and each having an aperture 76. Each side 70 is similar in dimension and fits a first side portion 20 of a primary module 12. Corner module 62 is connected to supporting structure comprised by primary modules 12 by wedging the sides using wedge 86 of Fig. 7e at apertures 76. A packing member 78 (or 278 in an alternative embodiment) for use in conjunction with the primary modules 12 may be provided with alternative configurations as shown in Figures 6a, 6b, 6c and 6d. In one configuration, as shown in Figs. 6a and 6b, the packing member 78 is an elongate channel, having a web 80 and two flanges 82. The web 80 is of the same width as a wall 10, the formation of which is described below. The web includes a plurality of first apertures 26 positioned to align, in use, with some of the first apertures 26 of a first module 12. In the embodiment of the drawings, the web 80 includes three even spaced first apertures 26. An elongate packing member 278 could also be provided, in a different embodiment in metal such as steel or aluminium, as shown in Fig. 13b or as a solid section as shown in Fig. 6c and 6d in which spaced slots 515 are formed to accommodate door brackets 168 as described below and apertures 512 are formed to align with first apertures 26 of a first module 12.

The flanges 82 of packing member 78 are arranged to receive an internal door frame as described below with reference to Fig. 13b. Packing member 278 is arranged to receive an external door frame 500 as described below with reference to Figs. 12a to 13a. A connection means for use in connection with the primary modules 12, secondary and end modules 14, 50 and corner primary modules 62 is shown in

Figs. 7a, 7b, 7c and 7e. The connection means includes a flat key 90, a securing wedge 86 and bolt 96.

The flat key 90 includes an enlarged head 88, a body portion 84 extending away from the head 88 tapered end region 92 remote from the head 88. The body portion 84 is slightly smaller, in cross section, than the first apertures 26 in the primary modules 12, and is arranged to be moveable from within the first apertures 26. The enlarged head 88 has width greater than that of the first apertures 26, and thus bears against a side portion 20, 22 of a primary module 12 when the body portion 84 is inserted within a first aperture 26.

The body portion 84 of a standard key 90 has a length slightly greater than the combined width of a first side portion 20 and a second side portion 22 of primary modules 12. When two primary modules 12 are placed alongside each other in the vertical direction, with the first side portion 20 of one primary module abutting the second side portion 22 of the other side module, the flat key 90 can be inserted within aligned first apertures 26 of the abutting first and second side portions 20, 22, with the enlarged head on one side of the aligned first apertures 26 and the end region 92 extending from the other side of the aligned first apertures 26. Where the key is to be used in other applications, as described below, the length of the body potion 84 may need to be altered accordingly.

The end region 92 includes a slot 94 which locates, in use, immediately adjacent a first or second side portion 20, 22 of a primary module 12. The slot 94 is sized to receive the securing wedge 86, which is inserted vertically into slot 94. When the flat key 84 is inserted into two aligned first apertures 26, the enlarged head 88 bears on the first side portion 20 and the securing wedge 86 bears on the second side portion 22.

In an alternative embodiment of the invention the first apertures 26 may be round, and the connection means may consist of a bolt and nut 96 as shown in Fig. 7c. A mounting support in the form of a tie rod 98 is shown in Fig. 7d. The rod 98 is circular in cross section, and is sized to be receivable in the second apertures 28 in a sliding fit. In the embodiment of the drawings, the tie rod 98 is approximately equal in length to the width of the rear wall 16 of a primary module 12. When the tie rod 98 is inserted into a second aperture 28 from outside a primary module 12, it can be slid through to a corresponding second aperture 28 in an opposite side portion, thus spanning the first module 12. It will be appreciated that in an alternative embodiment the tie rod 98 may be longer than the width of the rear wall 16, although preferably it will be equal to a multiple of this length. A first alternative mounting support in the form of a top hat mounting bracket 275 is shown in Figs. 8a and 8b. The mounting bracket 275 is formed from a strip of rigid material, such as steel, and is substantially U-shaped with two side arms 275aa and ends 275c separated by a central portion 275ab. The side arms 275aa are substantially parallel, and are spaced such that when one side arm 275aa is against an internal wall of a first side portion 20 of a primary module 12, the other side arm 275aa is against an internal wall of the second side portion 22 of the adjacent primary module 12. The central portion 105 thus spans the side portions 20, 22 of the two adjacent primary modules 12.

Each of the side arms 275aa of top hat bracket 275 has a rectangular aperture 275a which is of the same dimensions as the first apertures 26. In use, the top hat mounting bracket 275 is positioned across a pair of primary module 12 side portions 20, 22, such that its rectangular apertures 275a align with a pair of first apertures 26 in the primary modules 12. A furring channel U-shaped mounting bracket 270, preferably formed from fireproof and rust proof materials such as galvanised steel or aluminium, is shown in Figs. 8c and 8d. The U-shaped bracket 270 has a central spacing portion 271 and two arms 272 and ends 273. The arms 272 are spaced to give sufficient strength to the bracket and enough fixity width and support for the sheeting affixed to it. The spacing portion is sufficiently deep to provide an air gap between sheeting affixed to outer face of the central spacing portion 271 and the front most edge of the abutting side portions 20, 22. In use, the furring channel 270 spans between the vertically standing side portions 20, 22, of primary modules 12.

The construction of a first wall 10 in accordance with a first embodiment of the invention will now be described with reference to Figs. 9a and 9b. The construction of the wall 10 is begun by placing a first primary module 12A at a desired end point of the wall 10. The first primary module 12A is placed such that its outer face portion 18 forms part of a first face 202 of the wall 10. A second primary module 12B is then aligned next to the first primary module 12A, such that their outer face portions 18 form a substantially continuous surface. It will be appreciated that the first side portion 20 of the first primary module 12A abuts the second side portion 22 of the second primary module. 12B As a result both the first apertures 26 and the second apertures 28 of the first side portion 20 align with the respective first apertures 26 and second apertures 28 of the second side portion 22. It will also be appreciated that the bottom stiffeners 23 of primary modules 12A, 12B provide sufficient contact area with supporting structure 400 -for example a footing or slab - to maintain bearing loads within limits set by codes such as Australian Standard 3600-2009.

First primary module 12A, is connected by direct fixing, to supporting structure 400 by anchor bolting with anchor bolts 23A directly through the apertures 21 provided in the stiffeners 23. Anchor bolts 23A are used at specified spacing along the wall to resist the lateral and racking forces acting on the wall. Similar connections, using standard bolts at specified spacing, can later be made to a wall plate at the top of the wall. Floor brackets, custom made roof bolts and different sizes of keys and wedges have been eliminated thus assisting cost effectiveness. Bolting to upper structural components can be done with bolts 23B. Using stiffeners 23, accidental damage to the side portions 20, 22 at each end of the primary modules 12A, 12B can also be avoided whilst the structural stiffness of the modules 12A, 12B is much improved over the modular construction systems described in WO 1999/09268 and WO 2007/128054 incorporated herein by reference.

The first and second primary modules 12A, 12B are then connected by use of the connection means as described above. In a desired number of aligned first apertures 26, which may be two as in Fig. 9a or, more generally, three, depending on the height of the wall, a flat key 84 is inserted and secured by a securing wedge 86. This constrains the first and second primary modules 12A, 12B to move together.

Mounting supports in the form of two (which is a typically sufficient number) tie rods 98a and 98b are then inserted into two aligned second apertures 28. Tie rod 98a is a bottom tie rod and tie rod 98b is an upper tie rod. The tie rods 98a and 98b are threaded through the second apertures 28 so as to extend across each of the first and second primary modules 12A and 12B.

It will be appreciated that the structure thus created, defining the first face 202 of the wall 10, is entirely self supporting. In fact, it forms a support structure on which the second face 204 can be constructed. External loads are borne by this structure, resisted through the primary modules 12.

An intermediate secondary module 30 can be located on the wall 10. The intermediate secondary module 30 is positioned such that the openings 45 of bottom slot 43 of the first and second side portions 36 and 38 is located over the bottom tie rods 98a of the first and second primary module 12A. The erector can then fully engage the bottom slots 43 to tie rods 98a. Secondary module 30 rests fully and supported on the bottom tie rods 98a. Secondary module 30 is then allowed by the erector to rotate upward on the supporting tie rods 98a towards the upper tie rods 98b. When the side portions 36 and 38 contact the tie rods 98b, secondary module 30 is now fully engaged and securely held at the bottom by tie rod 98a. Given the weight of secondary module 30 (preferably less than 50kg), little effort is required to hold the secondary module 30 into position.

With this step complete, the top openings 44 of the slots 42 of the first and second side portion 36 and 38 are located over the tie rods 98b of the first and second primary modules 12A and 12B. The intermediate secondary module 30 can then be mounted onto the wall by engaging slots 42 over the tie rods 98b, with the assistance of a tool such as a crow bar, slots 42 are allowed to slide over rods 98b until the rounded ends 46 locate at the end of slots 42 of the side portions 36 and 38 come in contact with the tie rods 98b causing module 30 to stop. Module 30 is then allowed to hang from the top tie rod 98b under its own weight.

It will be appreciated that the location of tie rods 98a and 98b horizontally along the depth of the first and second portions 20 and 22 of primary modules 12 and the corresponding location of the round ends 46 of slots 42 and 43 of secondary modules 30 and end secondary module 50, determines the width of the gaps 140 created between the two modules on both sides of the wall.

As the intermediate secondary module 30 is in an opposite orientation to the primary modules 12A and 12B, its outer face portion 34 forms part of a second face 204 of the wall 10.

It will be appreciated that the weight of the intermediate secondary module 30 and the wedging effect of the slots 42 assist and 43 to maintain it in position over the tie rods 98a and 98b. The tie rods 98 restrain movement of the intermediate secondary module 30 perpendicular to the plane of the wall faces 202, 204. In order for the intermediate secondary module 30 to be moved or removed completely, therefore, an upward force must be applied to it.

An end secondary member 50 can be similarly mounted over the tie rods 98a and 98b of the first primary module 12a adjacent the intermediate secondary module 30. The end secondary member 50 is positioned such that the outer protrusion 52a of its outer face portion 54 rests flush against the second side portion 22 of the first primary module 12A, creating a rectangular end face for the wall 10.

Further primary modules 12 and intermediate secondary modules 30 can be added in similar fashion to extend the length of the wall. When the final primary module 12 has been added to complete the first face 202 of the wall, a final intermediate secondary module 30 can be mounted, and then a further end secondary module 50 can be mounted to complete another rectangular end. It will be appreciated that this further end secondary module will be a mirror image of the first one. Wall 10 may need propping at specified intervals as construction of the wall proceeds.

Bolts 23B can be introduced to connect a wall plate to the top of wall 10 to secure a roof structure to it and to allow axial, lateral and racking forces acting on the roof to be transmitted from the roof structure to the primary modules 12 forming wall 10. The wall plate can be connected to the primary module 12 by bolting the wall plate through aperture 21 provided in the top stiffener of primary modules 12 that form the supporting structure of wall 10.

As described above, gaps 140 are created on both sides of the wall: between the side portions 20, 22 of the primary modules and the secondary modules 30; and between side portions 36 and 38 of the secondary modules 30 and the walls 16 of primary modules 12A, 12B. These gaps 140 assist in reducing the propensity for water to be drawn through the wall joints and through direct module to module contact. Acoustic and thermal properties are also improved, particularly by including insulation. In order to take advantage of this arrangement, wall 10 should be constructed and used as an external wall of a building. For use as internal wall of a building the same wall 10 can be constructed in the same manner described above without the gaps 140 such that the primary and secondary and end module are in contact with each other.

It will be appreciated that the length of wall 10 created using this method increases in increments equal to the breadth of the primary modules 12. The overall length of the wall 10 may be a whole number of these increments, or it may include an additional half module width increment. Full increment walls are recommended for external walls of a building to maintain uniformity and standardization which results in more economical wall.

Non incremental walls of any length may also be achieved by constructing, in the same manner described above, two independent wall portions with gap in-between them.

The size of the gap will necessarily be smaller than half an increment. This gap can be closed with filling material such as concrete in a known fashion. The concrete gap filling could be reinforced and made stronger by horizontally bridging the gap with steel reinforcing rods spaning horizontally between the two portions of the wall and passing through apertures 28 of the primary modules 12 that frame the gap. Bridging the gap with steel rods will also help tie the two portions of the wall together for better alignment. It will be appreciated that this situation is most likely to occur when constructing internal walls in existing structures. A building can be constructed with walls 10 as described above. As walls of a structure typically include corners, methods for constructing a corner will now be described.

Figs. 10a and 10b show an external corner 212 of a wall section 210 of a building. The corner 212 is constructed using a corner primary module 62 as follows.

Before standing the hollow core corner primary module 62 in an upright position, a temporary removable pin (not shown) is fitted at the top through circular aperture 63 provided in the top stiffener 62a. The corner primary module 62 is then placed standing in the upright position to the lines and level of the external corner 212. Props may then be engaged in the top pin. The upstanding corner primary module 62 is plumbed in both directions and held in the plumb position by securing the ends of the props firmly to the supporting structure, to the natural ground or to any solid base. Corner primary module 62 now stands freely and securely on its own. Two primary modules 412a and 412b are connected to the standing corner primary module 62, each corresponding with a side wall forming the corner 212 using the three corner angle brackets 68 as above described as connection means. Primary modules 412a and 412b are connected to a supporting structure by bolting through apertures 21 of their bottom stiffeners 23. Suitable anchor bolts are to be used for this purpose to provide the requisite fixity and stability to allow construction of the side walls to proceed in both directions following the methods as described above.

Secondary modules 30, 50 can be added following the completion of the corner 212. It will be appreciated that an internal corner of an external wall could be constructed using the same method and arrangement, including corner primary module 62 as above. In this case, the erector would switch the positions of primary modules 12 of the same wall to the external face of the wall and the secondary modules 30 and end secondary modules 50 to the internal face of the same wall. Referring back to Fig. 5c, secondary modules can be omitted at an internal corner 75 with a lining 204 being used instead of secondary modules 30 and 50. Lining 204 is fixed to the primary modules 12 using top hats 275 as described above. Partial top hats 275A are used for making connections between the corner module 62 and adjacent primary modules 12 forming the corner 75.

Referring now to Fig. 11a, there is shown an intersection between an external wall portion 208 and an internal partition wall 101 where secondary modules 30, 50 are deleted and replaced with a lining board 204. External wall portion 208 is constructed by connecting primary modules 12 as described above but without mounting of secondary modules.

The method of constructing internal partition wall 101, lined on both sides by lining 204, has much in common with construction of other walls as described above. However, the primary modules 12C, 12D are staggered so that the face portion of primary module 12C faces one side of internal partition wall 101 and the face portion of primary module 12D faces another side of internal partition wall 101. Anchor bolting of primary modules 12C and 12D of the internal wall 101 is the same as for external walls. Internal partition wall 101 is connected by bolts 211 to the U shaped bracket 207, shown in detail in Figs. 11 b to 11 d, is also fixed to the side portions 20 and 22 of adjacent primary modules 12A and 12B by the same key 90 and wedge 86 that connects the primary modules 12 together. Keys 90 are inserted through slots 207A formed in walls 207C and wedged as described above. U shaped bracket 207 also has a wall 207D with holes 207B for enabling connection to primary module 12C by bolt 211. Only one bolt 211 is required for internal partition wall 101.

This internal wall construction method has much improved capacity for fixing, hanging or fitting items - such as household items including paintings, shelving, cupboards and the like - or for fitting items such as power points, light points or communication sockets to internal partition wall 101. Such an arrangement does not affect the structural integrity of the internal partition wall 101, yet it appreciably improves its functionality, serviceability and acoustic performance while allowing greater assurance of convenient and safe hanging and fixing of items such as those mentioned above.

Referring now to Figs. 11 e to 13b, a method for constructing a doorframe 500 to suit door 270 in a wall portion 117 constructed in the above manner but the following sequence is described. Door 270 is one of the standard size doors available in the Australian market. Metal doorframe 500 is fitted into wall portion 117 during its construction. Doorframe 500 is connected using doorframe U brackets 168 (shown in Figs. 11 e, 11f and 12c) and packing 278.

First, metal doorframe 500 is stood in position along the line of planned wall portion 117. U shaped door brackets 168 are engaged over the packing 278, Fig.6c by aligning them with the recesses 515. This should hold the doorframe 500 to the wall portion 117 without need for propping.

For an external door, fitting details of which is schematically illustrated in Fig. 13a, doorframe 500 is plumbed and the engaged door brackets 168 are fixed to the door packing 278 with screws 78a. Door packing 278 is also fixed to primary module 12, also connected to end module 50 in the above described manner, through packing 278, by bolts 78b. Four door brackets 168 and four bolts 78b, fastened through bracket holes 168a, are required and spaced along the height of doorframe 500, one bolt 78b being shown in Fig. 13a. With doorframe 500 held plumb and fixed to the wall 10 on both sides, short modules 12AA are erected above the doorframe 500. Construction of wall portion 10 continues in the same manner on the other side of the doorframe 500.

Internal doorframe 500 can be fitted in similar manner as illustrated in Fig. 13b. In this case, secondary module 14 is not required and the internal wall portion is formed using primary module 12 and lining 204. Such an internal wall could use the staggered arrangement of primary modules as described above. Alternative metal packing 78, and in particular its web 80, is connected to the primary module by bolt 268 and to the bracket 168 by screws 78a fastened through bracket holes 168a. The construction is otherwise completed in the same manner as for an external doorframe.

The method of construction described here still enables connection of doorframes as described in WO 1999/09268 and WO 2007/128054 as incorporated herein by reference if desired.

Referring now to Figs. 14 -16b, a method for constructing a wall in the form of fence 300 is described. Fence 300 is constructed using primary modules 12, secondary modules 30 and secondary end modules 50 as well as columnar fence supporting piers 310. When primary modules 12 are effectively joined with keys and wedges 90 and 86, they form a solid panel that is capable of spanning the distance between fence piers 310. Since most of the loading on fence 300 is lateral loading due to wind, except of the deadweight of fence 300 itself, heavy structural footings are not essential, provided that fence 300 is supported during construction of the individual modules forming the panel. However, top and bottom restraints to the fence panel are still required for alignment and to help transfer the lateral forces acting on the fence panel to the pier columns at each end of the fence panels. Open ended primary modules 112 placed flat on faces 16 with side portions 20, 22 facing upwards, can be used as a support base and as a bottom restraint. For a top restraint a concrete or metal (colorbond) capping spanning from pier to pier could be used as described below. Due to the rigidity of the fence panel 300, its spanning ability, and its individual modular structure, it is not as susceptible to cracking damage due to ground movement. Moreover, the horizontal movement of the fence panel due to temperature expansion and contraction is accommodated at each pier 310. A selection of fence face finishes, whether plain (relying on the module material) or painted, are available.

Ground is cleared along the line of fence 300 for a width at least equal to the width of open ended primary modules 112 to form the base support modules. Pier centre lines are marked. A trench is prepared to a depth of about 100mm with the top of side portions 20, 22 end approximately level with natural ground level (NGL) from which fence 300 height is measured. A first base support module 112 is placed in the trench along the required line and level of fence 300. Each end of each base support module 112 is placed at a distance from the centre line of the pier, equal to one half of the pier cover module 12E plus a clearance, say 10mm. This allows pier covers 12E to fit comfortably between the base support modules 112. The base support modules 112 are secured into position against side movement by backfilling against side portions 20, 22. Securing using pegs could also be done. Base support modules 112 support fence panels 12 and pier’s column 310 at the correct height while at the same time gauging and controlling the portion of the pier column 310 that need to be embedded in the column concrete footings 320. Base support modules 112 can also be used to control the top level of the column concrete footings 320, the alignment and centre line of the piers 310 to assist in fast and simple construction. A preferred pier 310 includes a steel square hollow section column comprising supporting rods 311 and brackets 313, 317 and 318 as conveniently shown in Fig. 15d. A pair of each of brackets 313, 317 and 318 is provided (each welded to pier column 310), one at or towards the base portion of pier column 310 and the other pair of which is provided towards the top of pier column 310. Brackets 317 and 318, shown in detail in Figs. 15d to 16b, are used for connecting pier cover modules 12E to pier column 310. Supporting rods 311 act as a gauge for the depth of the portion of pier column 310 that is required to be embedded in the column’s concrete footing 320. Brackets 317 and 318 include angled slots 319 and openings 344, 345 of similar design and benefit to those slots and openings 42,43, 44 and 45 described above, for enabling connection of pier column 310 to pier covers 12E.

Once a hole for pier column 310 footing has been dug, for example by auger, a pier column 310 is placed in upright position at exactly half the spacing between base support modules 112. Supporting rods 311 are allowed to rest and be supported at each end by the base support modules 312. This will automatically gauge the depth of the portion of the column 310 required to be embedded in a column’s concrete footing 320. Pier column 310 is plumbed, held into position and premixed concrete is filled around the pier 310 up to the surface level of the base support modules 112. Piers 310 may be propped whilst the concrete hardens. The method continues along fence 300.

After footings 320 have hardened, fence panels 12 may be erected by connecting primary, secondary and secondary end modules 12, 14 and 14A in the above described manner for the C-Wall Construction System and as schematically illustrated by Fig. 15c. Propping may be required during construction.

Once all fence panels 12, are standing and securely fixed to pier columns 310, metal capping 300B can be fitted at the top and over the complete wall panel including secondary modules 14 and end secondary modules 14A. Capping 300B spans from pier column 310 to pier column 310 and is fixed securely to the top of each pier column 310.

Two pier covers 12E are then installed at each pier 310 using the reverse procedure to that used above for connecting a secondary module 30 to a primary module 12. Two support rods 316 are fitted on site to each primary module serving as a pier cover 12E, through the round apertures 28 provided in the sides of the primary modules 12E, one towards the bottom and one towards the top. Top level support rods 316 are shown in Fig. 15b. Pier cover 12E is lifted and allowed to fully engage first to the corresponding slotted bottom bracket 317 that are fitted on two sides of pier 310. Once fully engaged and supported, pier cover 12E is rotated upward on the supporting bracket 317 until the top support rod 316 touches the top corresponding slotted bracket 317 of the pier 310. With the aid of a tool, such as a crowbar, cover module 12E is lifted slightly and allowed to fully engage the top slotted bracket 317. Pier covers 12E are installed on two sides of pier 310 corresponding with each face of a fence panel 12. When fully engaged, pier covers 12E will be left protruding slightly above pier panel 12 in order to engage with geometrically shaped (e.g conical) pier top hat 312 and will be hard pressed against the fence panel face 12 on each side of pier 310. Pier top hats 312 are designed to fit snugly over the protruding portion of the pier covers 12E and engaged through a recessed opening arrangement (not shown). No further fixity is then required.

Final completion of fence 300 requires restraint of fence panels 12 at the bottom, in order to conform with structural design requirements for fence 300. This could be done by spot filling with cement mortar both at the centre and towards each end of each fence panel 12 for a distance equal to at least the width of one panel module 12 on each side of each fence panel 12, the space between the side portions 20, 22 of base support module 112 and fence panel 12. Cement mortar should finish flush with the top of side portions 20, 22, as shown in Fig. 15c.

Referring now to, Fig.17 installation of a window or sliding door 497 in wall portion 302 is described. A preferred way is to fit window 497 after wall portion 302 has been constructed. This helps keep the construction site clear allowing more space to move on site, less risk of damage to the windows and most importantly to speed construction time. Window frame 497A is fitted by fixing to primary modules 12 framing a window opening 497 provided during construction. Such primary modules 12 extend the full height of the wall portion 10. Shorter length primary modules 12A are used above and below the window 497.

Screws are used to fix the window frame 497A to primary modules 12. The number of screws to be used depends on the design wind loads which in turns depends on the locality of the building. Different types of windows and doors may require different type of fixity in accordance with the manufacturer’s specification.

For large window and sliding door openings, lintels could be used to span the large openings.

Modifications and variations to the above described method of construction as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

Claims (12)

1. CLAIMS:

   1. A method of construction of a wall from a plurality of primary modules and at least one secondary module, each primary module having an outer face portion and two side portions, each secondary module having an outer face portion, two side portions and at least one mounting portion, the method including the steps of: aligning at least two primary modules together such that their outer face portions both form part of a first face of the wall, with a first side portion of a first primary module abutting a second side portion of a second primary module; connecting the first side portion of the first primary module to the second side portion of the second primary module such that the first and second primary modules are constrained to move together; and mounting a secondary module or onto the connected primary modules such that the outer face portion of the secondary module forms at least part of a second face of the wall, wherein the at least one mounting portion of the secondary module engages with a primary module to restrain movement in at least one direction of the secondary module wherein an end of a primary module includes a stiffener extending between said side portions of said primary module.
2. 2. A method of construction according to claim 1 wherein said primary module comprises a pair of stiffeners, each stiffener extending between said side portions of said primary module such that said primary module is closed ended.
3. 3. A method of construction according to claim 1 or 2 wherein said mounting portion of said secondary module comprises angled slots within the side portions which extend diagonally upwardly within the side portions and at least one said angled slot is located proximate an end of said secondary module.
4. 4. A method of construction according to any one of the preceding claims wherein a corner is formed by connecting an elongate corner primary module having a hollow core and stiffeners at each end to a supporting structure and connecting said corner primary module to said supporting structure and primary modules forming abutting side walls with a plurality of angle connection means.
5. 5. A method of construction according to any one of the preceding claims wherein, in a structure including said wall, a wall section is constructed with primary modules being aligned and connected in a staggered configuration so that an outer face of one primary module faces one side of the wall section and the outer face of an adjacent connected primary module faces the other side of the wall section.
6. 6. A method of construction as claimed in any one of the preceding claims wherein, in a structure including said wall, at least a portion of a wall section is constructed with primary modules connected to a lining forming a face of the wall.
7. 7. A method of construction as claimed in any one of the preceding claims further comprising, in a structure including said wall, a door frame connected to an adjacent primary module by a packing selected from an elongate packing member comprising a plurality of vertically spaced slots to accommodate door brackets, optionally U shaped brackets, for door connection and a U shaped packing; and connection means for connecting said packing to said primary module.
8. 8. A method of construction according to any one of the preceding claims wherein said wall is a fence and further comprising the steps of: locating a plurality of fence supporting piers along a desired fence line, each said pier column including connection means for connection to fence panels and pier covers to cover said columnar fence supporting piers’ columns; and constructing a fence panel by connecting fence panels comprising a plurality of modules selected from primary modules, secondary modules and end modules, optionally excluding end stiffeners, to each said columnar fence supporting pier; and connecting a plurality of pier covers to cover each said columnar fence supporting pier column.
9. 9. A method of construction according to claim 8 wherein said fence comprises a plurality of open ended primary modules having an outer face portion and two side portions as supporting base structure for the fence wall panels between the pier columns.
10. 10. A method of construction according to claim 8 or 9 wherein each said pier cover has an outer face portion and two side portions and is fitted with a plurality of first connection means for engaging with complementary connection means of each said pier column
11. 11. A method of construction according to claim 10 wherein said first connection means are supporting rods and said complementary connection means are brackets with upwardly extending angled slots for engaging with said supporting rods.
12. 12. A packing selected from an elongate packing member comprising a plurality of vertically spaced slots to accommodate door brackets, optionally U shaped brackets, for door connection; and a U shaped packing when used in the method as claimed in claim 7.