US20040020147A1

US20040020147A1 - Sandwich wall construction and dwelling

Info

Publication number: US20040020147A1
Application number: US10/239,774
Authority: US
Inventors: Vincent Martella; Roberto Calderan
Original assignee: Individual
Current assignee: Individual
Priority date: 2000-03-27
Filing date: 2001-03-23
Publication date: 2004-02-05
Also published as: AU2001243991A1; CA2302137A1; WO2001073239A1

Abstract

A construction wall system having, rigid inner an outer rectangular panels on either side and end edges on ends. The panels spaced apart from one another, with parallel junction strips between the inner and outer panels, with end junction strips secured between the panels. End junction strips define junction channels along the side edges between the panels, with inwardly spaced spacer strips secured between the inner and outer panels relative to the end edges of the panels to define end junction channels between the inner and outer panels. Panels and strips all being formed of polymer-modified fibre reinforced concrete material, with synthetic plastic foam material filling the spaces between the inner and outer panels.

Description

TECHNICAL FIELD

The invention relates to a sandwich-type wall structure and to a wall construction using a plurality of sandwich wall structures, and to a dwelling constructed from such sandwich wall structures.

BACKGROUND ART

Conventional construction of walls involves the erection of framing and the exterior is then covered in with some form of sheathing, drywall, stucco and/or bricks or siding. Insulation is placed between the framing or studs, and the interior wall is then covered in usually with plaster board of some kind. This involves a large number of different operations, using on site labour, which is paid at relatively high hourly rates. Materials were often subject to damage by insects, and by rot.

Clearly it is desirable to provide for a low cost construction technique in which portions of a building may be pre-built and finished in a factory, and which use durable, long lasting materials not subject to attack by rot, weather or insects. It is further clearly desirable that such building components shall be capable of being manufactured by relatively unskilled factory labour, and may be erected to form a low cost dwelling or other building, in a speedy, efficient manner, using a minimum of on-site labour with minimum skills, and requiring only a minimum of heavy equipment. The buildings using this system will preferably be capable of withstanding hurricane winds and earthquake shocks.

A partial solution is to use wall panel systems, in which wall panels can be prefabricated to standard sizes. The panels are then simply put together to erect the completed walls. These systems however suffer from a variety of disadvantages such as the use of various different materials, having differential rates of expansion and contraction, and the use of some materials which may be subject to deterioration, rot, or attack by insects and the like.

In co-pending U.S. application Ser. No. 09/024,656, Title: Composite Wall Construction and Dwelling therefrom, and assigned to the assignee of this application, there is described a wall structure and dwelling meeting many of these objectives.

It is found however, that a sandwich like wall structure, which is somewhat less costly, but retains many useful qualities comparable to the earlier wall structure, can be made without significant loss of strength. In particular, in the system described in the aforesaid application, the system provided for the use of front and rear spaced apart panels, and partition walls extending between the front and rear panels of the wall structure, defining interior cavities and further called for the use of expanded polyurethane foam insulation material in the cavities. While this was relatively expensive, the walls resulting from such wall structures were strong and well-insulated and were otherwise satisfactory. It has been found that in practice significant economies can be made in cost, without any significant loss of properties, and at the same time production both at the factory, where the wall structures are produced, and also in the erection of such wall structures, can be substantially speeded up.

DISCLOSURE OF THE INVENTION

With a view to achieving the foregoing advantages the invention provides a sandwich wall structure comprising, an inner rigid panel and an outer rigid panel of rectangular shape formed of polymer-modified fibre reinforced concrete material and defining length and breadth dimensions and defining side edges on either side and upper and lower end edges on ends thereof said panels being spaced apart from one another, an insulation block formed of rigid expanded polystyrene thermal insulation material bonded between said inner and outer panels, the block defining upper and lower and end surfaces all such surfaces being spaced inwardly relative to the side and end edges of said panels whereby to define side and upper end junction channels, and lower registering channels, between said inner and outer panels.

The invention further comprises a wall construction having a plurality of such sandwich wall structures, and concrete filling in said side channels and said upper end junction channels between adjacent sides and extending between adjacent upper ends of said panels, said concrete extending integrally from one said junction channel into the adjacent junction channel of two adjacent wall structures.

The invention further comprises a rectangular composite wall which comprises a plurality of such sandwich wall structures erected side by side, and defining continuous horizontal junction channels at the upper ends of said wall structures, and including concrete filling said continuous horizontal junction channels and further concrete filling vertical junction channels between adjacent sides of adjacent panels.

The invention further comprises a wall construction as described and including a shallow locating channel formed along the lower edge of each said sandwich wall structures and including registering strip means secured to a construction footing, adapted to fit within said shallow registering channel, whereby to register said sandwich wall structures, and secure their lower edges against movement. Preferably there will also be a matching reinforcing strip within the interior of the locating channel secured along the downwardly directed surface of the insulation block, for contacting the registering strip means.

Reinforcing bars of steel may typically be incorporated in the vertical and upper horizontal junction channels and embedded in the concrete.

The invention further comprises a corner construction consisting of interlocking panels, formed at adjacent ends of adjacent sandwich wall structures with a shorter end edge and a longer end edge, and wherein, when said shorter and longer end edges are placed adjacent one another, they enclose a generally rectangular enclosure and metallic L-shaped angles secured to adjacent end edges of said inner and outer panels, and securing adjacent inner and adjacent outer panels together and concrete received in said generally rectangular enclosures thereby bonding said wall structures together at said corner. Preferably the rectangular enclosures will be of truncated L-shape in section.

The invention further comprises a dwelling or other housing structure having walls and a roof and said walls being formed of a plurality of sandwich wall structures each said wall structure comprising, inner and outer rigid panels of polymer-modified fibre reinforced concrete material and an insulation block formed of rigid expanded polystyrene between said panels and means bonding said panels to said insulation block with their planes parallel, junction channels formed along the sides and upper ends of each said wall structure, and, concrete filling in said junction channels between adjacent sides and extending between adjacent ends of said sandwich wall structures said concrete extending integrally from one said junction channel into the adjacent junction channel of an adjacent wall structure.

The roof preferably comprises a plurality of roof structures each consisting of upper and lower rigid panels of polymer modified concrete material, and a block of expanded polystyrene thermal insulation material bonded therebetween and steel reinforcing channels located between said upper and lower panels and bonded thereto, said upper and lower panels and said reinforcing channels defining open spaces therebetween, and connection means extending upwardly from said walls through said roof, and being secured in said roof panels.

The roof panels may be joined by stepped ledge formations in a form of “ship-lath” connection.

The invention further comprises the provision of a dwelling or other housing structure having both walls and the roof as described above, and further having an intermediate floor structure composed of floor structure panels substantially as described in connection with the roof structure panels.

The invention further comprises that said connection means are in the form of generally cone shaped openings formed in said roof panels, and being located and adapted to receive reinforcing bars extending upwardly from said walls, and concrete material filling said cone shaped recesses and bonding around said reinforcing bars and securing said roof in position.

Preferably the roof will be comprised of a plurality of relatively narrow roof panels, each of the roof panels having male channel formations and interlocking female channel formations at their respective side edges, whereby said roof panels may be mated together with said male and female channel formations interengaged, to form a roof spanning the space of a building.

The invention further comprises a method of constructing a wall panel structure having the foregoing advantages, and a method of constructing walls, and a dwelling using the wall structures according to the foregoing.

The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective illustration partially cut away of a sandwich wall structure illustrating one form of the invention; [0021]
FIG. 2 is a section along the line [0022] 2-2 of FIG. 1;
FIG. 3 is a section along the line [0023] 3-3 of FIG. 1;
FIG. 4 is a side elevational view partially cut away showing two composite wall structures erected on a concrete foundation, and showing them assembled together using poured concrete as the joining medium; [0024]
FIG. 5 is a section along the line [0025] 5-5 of FIG. 1 greatly enlarged to show the method of securing the portions of the composite wall structure together;
FIG. 6 is a section along the line [0026] 6-6 of FIG. 4;
FIG. 7 is a section along the line [0027] 7-7 of FIG. 4;
FIG. 8 is a schematic side elevational view of a simple dwelling illustrating the use of the invention in construction; [0028]
FIG. 9 is a top plan view of the building plan of the dwelling of FIG. 8; [0029]
FIG. 10 is a section along the line [0030] 9-9 of FIG. 9, showing joining two side walls at a right angular corner;
FIG. 11 is a section along the line [0031] 9-9 of FIG. 9 greatly enlarged showing joining side walls and a partition wall together at a Tee junction;
FIG. 12 is a section of a junction of four walls; [0032]
FIG. 13 is a sectional illustration illustrating the attachment of a floor panel between two upright walls; [0033]
FIG. 14 is a section illustrating the construction of a plurality of roof panels placed edge to edge in interlocking mating relation; [0034]
FIG. 15 is a section through the end edge of a typical roof or floor panel; [0035]
FIG. 16 is an exploded cut away view of another form of roof panel connection; [0036]
FIG. 17 is section along the line [0037] 16-16 of FIG. 8, illustrating the attachment of a roof panel to a side wall, and,
FIG. 18 is a section showing the junction of two roof panels at a ridge, where two portions of the roof meet one another, typically along the axis of an interior partition wall.[0038]

MODES OF CARRYING OUT THE INVENTION

As already indicated the invention relates generally to a modular sandwich-type wall structure, which is modular in nature and which is factory built. The modular wall structures can be transported in large numbers to a building site and then can be erected basically by hand labour, and using simple poured concrete facilities. [0039]
The basic wall structure is illustrated in FIGS. 1 through 3. It will be seen to comprise a modular sandwich wall structure illustrated generally as [0040] 10. The wall structure 10 has an outer panel 12 and an inner panel 14. They are both of rectangular shape and of the same size, and typically may be in the region of four feet by eight feet, or more depending upon the height of the dwelling, or other building to be erected.
[0041] Panels 12 and 14 are spaced apart from one another, and, between the panels 12 and 14, there is secured and a block of insulation material 16. The block of insulation material 16 is of rectangular shape being in the form of a flattened solid body, defining side edge walls 18 and 20, and top and bottom edge walls 22 and 24.
The block of [0042] insulation material 16 is formed of thermoplastic material, typically being expanded polystyrene bead material, of a type well known in the art, and requiring no special description or formulation.
The [0043] panels 12 and 14 are bonded together on opposite sides of the block 16 by any suitable adhesive means. The side edge and top and bottom edge dimensions of the block 16 are somewhat reduced in relation to the dimensions of the side edges and the top edges of the panels 12 and 14.
In this way, it will be seen that along either side of the sandwich wall structure, there are defined a generally open sided rectangular [0044] vertical channels 26, and along the top edge a horizontal channel 28. Along the lower edge of the wall structure there is defined a shallow lower rectangular channel 30 which it will be seen, is of reduced depth dimension in relation to the channels 26 and 28.
Each of the [0045] panels 12 and 14 are of identical construction. They will be seen to comprise sheets 32 of polymer-reinforced concrete material, typically having a thickness of about one half to three quarters of an inch. On at least one side of the polymer-reinforced concrete material, there are located fibre reinforced matting sheets 34. Such sheets of polymer-reinforced concrete, reinforced with fibre matting, typically resin fibre matting, form a structure of great strength and bending resistance and load carrying capacity.
The [0046] insulation block 16 is bonded to the interior of the inner and outer panels 12 and 14 by any suitable adhesive means. This will bond securely to the inner surfaces of the panels 12 and 14, defined by the fibre resin mesh reinforcement 34, thereby bonding the panels 12 and 14 together with the block 16 to make a homogenous integral solid sandwich wall structure.
All of these functions can be carried out in the factory with great precision, and also with a minimum of instruction. The [0047] wall structures 10 being largely formed of lightweight material are relatively light, and can be handled by manual labour without the use special mechanical lifting devices.
Referring now to FIGS. 4, 5, [0048] 6 and 7, the wall structures 10 can be associated together to form a wall shown generally as 40 in FIG. 4. The wall 40 illustrated in FIG. 4 is merely illustrative of the way in which the wall structures 10 can be used to be construct and erect a wall. Typically the wall of a single storey building or dwelling, will be defined by the height, i.e. the length dimension of each panel 10. As shown in FIG. 4, the panels 10 are erected on a concrete base or slab or foundation indicated as F. In order to locate the wall structures 10 a locating strip 42 is secured on the surface of the slab F by nails or other fastenings. The locating strip 42 in this embodiment is typically formed by a metal channel but may also be a strip of the polymer-reinforced concrete panel material. It fits within the channels 30 between the front and rear panels 12 and 14.
The lower channel [0049] 30 (FIG. 2) is arranged so that it has a sufficient height to fit over the locating strip 42, and make a snug fit thereon.
In order to join two [0050] adjacent wall structures 10 together, in edge to edge abutting relation, concrete material M is poured down through the channels 26 and 26, between two adjacent structures 10. Additional bracing is usually temporarily required adjacent the joints between the panels 12 and 14 of the adjacent wall structures 10, and this of course may be provided in any suitable manner. For example metal bracing channels 44 secured by wire clips 46 may be used. Such temporary bracing may be required in order to prevent the pressure of the concrete from distorting the edges of the panels 12 and 14 where they define the channels 26. However, the bracing can usually be removed after twenty-four hours as the concrete material M cures.
Usually, there will be a plurality of vertical reinforcing rods R placed in the [0051] channels 26 prior to pouring of the concrete, in accordance with well known construction techniques.
In order to provide a horizontal top beam, for supporting the roof concrete M is also poured in the [0052] horizontal channels 28 along the top of the wall structures 10. Generally speaking, since the depth of this concrete is only a few inches, there will be no additional bracing required at this point.
Such concrete M will usually be reinforced with suitable reinforcing rods. When the wall is finished, the [0053] individual wall structures 10 are joined edge to edge in abutting relation, and the wall is supported by vertical columns of cured concrete M, and by horizontal beams of concrete M, which are all poured integrally at the same time and form a structure of great strength. Additional rebars may be placed at intervals extending upwards for attachment of a roof.
It will now be apparent from the foregoing description that the [0054] sandwich wall structures 10 can be assembled together to provide walls for a dwelling or other building. Referring now to FIGS. 8 and 9, such a building is illustrated generally as 50. FIG. 8 is a schematic side elevation of such a building, typically a small, low cost dwelling, and FIG. 9 is a floor plan of such a building.
It will be seen that the building [0055] 50 is provided with four exterior walls 52, and a central partition wall 54, extending between two of the side exterior walls 52. All of the walls 52 and 54 are made of sandwich wall structures 10 as described in FIGS. 1 through 3, and all of the wall structures are joined by means of poured concrete columns. In FIG. 9 the poured concrete columns are indicated as C. The junction between the exterior side walls and the partition walls is achieved by means of a generally Tee-shaped poured corner containing concrete column C, illustrated in more detail in FIG. 11. Portions of the inner panels 14 of two abutting wall panels may be cut away as shown to allow concrete to flow into the Tee junction.
The corners of the walls [0056] 52 in this embodiment require modified wall structures shown in FIG. 10.
These modified wall structures are formed with outer panels [0057] 12A which are extended somewhat along one edge as at 56, and have modified interior panels 14A , which are cut somewhat shorter as at 58.
Two wall structures [0058] 10-10 as shown, may be formed into a corner by placing the longer and shorter edges 12A and 14A in edge abutting relation as shown in FIG. 10. This forms a right angular corner. Reinforcing corner angles 60 are secured whereas the interior at the junctions of the outer panels 12A and remain in place. Suitable reinforcing rods are placed down the L-shaped space defined by the longer and shorter portions 56 and 58, and concrete is poured down in the space. The rebars are interlocked by straps as needed. The concrete will form a generally L-shaped column, extending around the corner, and holding both wall structures securely together and holding them upright.
At this point, reviewing the simple dwelling structure of FIGS. 8 and 9 it will be seen that the four walls and the central partition wall are all constructed of the [0059] sandwich wall structures 10 as illustrated generally in FIG. 1, and that they are joined edge to edge to form the complete walls by means of poured concrete columns. The entire structure thus has great integral strength, and at the same time has great resistance to thermal transmission. Being provided with a plurality of vertical supporting concrete columns, reinforced as described, the structure will have great resistance to earthquake and other shocks. At the same time it is apparent that it can readily be erected, by manual labour simply taking the sandwich wall structures 10 illustrated in FIG. 1 and erecting them side by side and comer to corner, supporting them vertically, and pouring concrete using relatively primitive equipment such as will be readily available even in remote locations.
A floor can be constructed, in multi-storey dwelling, (not illustrated), by taking somewhat modified [0060] sandwich structures 70, and attaching them between lower and upper walls 72 and 74.
In this case, from the near [0061] upper channel 26 of the lower wall 72, a connecting rebar 76 extends upwardly.
The [0062] panel 70 is formed with a generally frusto-conical opening or recess 78. The rebar 76 fits within the recess, and concrete is then poured down into the recess and bonds the rebar thereby holding the floor in position.
The [0063] upper wall 74 is attached once again in the manner shown in connection with FIGS. 4 and 5.
Reference may now be made to the [0064] roof 80 of the dwelling.
The roof is best illustrated in FIGS. 14, 15, [0065] 16, 17 and 18. It will be made up of a plurality of elongated relatively narrow roof sandwich members 82. The roof members 82 comprise upper and lower panels 84 and 86 formed of polymer modified concrete, sandwiched around a polystyrene panel of induration 87.
A plurality of steel C channels [0066] 88 are bonded between the interior surfaces of the panels. The panels 84 and 86 are otherwise formed in the same way, with reinforcing fibre glass mesh, as described in connection with the panels of FIG. 1.
Along one side edge of each of the [0067] sandwich members 80, (FIG. 14) a metal C section 90 is recessed inwardly between the panels 82 and 84 so as to leave a shallow channel. Along the other side edge of the member 80, a C section 92 is secured flush with the ends of the roof members 80. A mating strip member 94 is bonded to the exterior of the C section 92 , and is dimensioned so as to make a snug fit between the space defined within C channel 90 along the other side edge.
In this way the [0068] roof members 82 can be set side by side together with a form of tongue and groove interconnection between them.
FIG. 15 illustrates and alternate form of interconnection. In this case two roof panels have identical edge portions formed by inwardly faced [0069] C channels 96.
The surfaces of the C channels can be bonded together by adhesive. [0070]
FIG. 16 illustrates a further form of roof panel junction. [0071]
In this case modified [0072] C channels 98 are used. These channels are formed with offset portions 100. They are turned to face upwardly along one edge and downwardly along the opposite edge of each panel. When the panels are placed edge to edge, the channels 98 will interfit and form a type of “ship lath” joint, having great strength and being weather proof. For added security a screw 102 can be inserted at spaced intervals along each joint.
In order to secure the roof panels to the walls vertically extending [0073] rebars 104 are located and dimensioned so as to interfit with generally conically shaped recesses 106 , formed at each end of each of the roof members or panels (FIGS. 17 and 18).
With this arrangement, concrete is then filled in around the conical recess thereby bonding to the rebars and holding the roof firmly in position. [0074]
Similar arrangements can be made for the pitched roof shown in FIG. 10, the details of which require no special description. [0075]
It will also be understood that, in a two storey structure, the floor members can be provided to serve as the floor of the second storey (FIG. 13). [0076]
The floor structures will be somewhat similar to the roof structures described above, but will usually be somewhat thicker, ie. in the region of seven inches overall, with a half inch panel top and bottom, and a six inch core of insulation block. [0077]
The floor structures will be reinforced along with side edges by metal reinforcing channels, and also similar reinforcing channels along their end edges. [0078]
Along one side edge, the channel will be turned outwardly so that it defines a U-shaped recess. Along the other edge the channel will be turned inwardly and simply fits over the insulation block. Alternatively the “ship lath” type of joint can be used as in the roof (FIG. 16). [0079]
Along the exterior of the wall a rectangular strip of polymer reinforced concrete material. [0080]
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims. [0081]

Claims

1. A construction wall system comprising;

an inner rigid panel and an outer rigid panel of rectangular shape and defining length and breadth dimensions and defining side edges on either side and end edges on ends thereof said panels being spaced apart from one another;

a plurality of intermediate junction strips having a predetermined width secured between said inner and outer panels, and said junction strips having a length less than the length of said panels, and being arranged in parallel spaced apart relation, at spaced intervals between said inner and outer panels;

a plurality of end junction strips having a predetermined width equal to said intermediate junction strips secured between said inner and outer panels adjacent opposite side edges thereof, and spaced inwardly from said side edges whereby to define junction channels along said side edges between said inner and outer panels, a plurality of spacer strips having a predetermined width equal to the width of said junction strips and secured between said inner and outer panels transverse to said junction strips and adjacent thereto, said spacer strips being spaced inwardly relative to said end edges of said panels whereby to define end junction channels between said inner and outer panels, said panels and said strips all being formed of polymer-modified fibre reinforced concrete material.

2. A wall system as claimed in claim 1, and including a synthetic plastic foam material filling the spaces between said side walls and said end walls and said intermediate junction strips.

3. A wall system as claimed in claim 2 and including a plurality of foam filling openings in one of said end walls, and foam filled into the spaces defined between the intermediate channels after the wall system has been assembled.

4. A wall system as claimed in claim 3 and including a plurality of such wall systems erected side by side, and defining a continuous open junction channel at the upper ends of said wall construction, and including concrete filling said continuous open topped junction channel.

5. A wall system as claimed in claim 3 and including a shallow locating channel formed along the lower edge of each said wall system, and including registering strip means secured to a construction footing, adapted to fit within said shallow registering channel, whereby to register all of said wall systems, and secure their lower ends against movement.

6. A wall construction having a plurality of such wall structures and each said wall structure comprising, inner and outer rigid panels of polymer-modified fibre reinforced concrete material, and means bonding said panels together in spaced apart relation with their planes parallel, junction channels formed along the sides and ends of said wall structure, and, concrete filling in said junction channels between adjacent sides and adjacent ends of said structure said concrete extending integrally from one said junction channel into the adjacent junction channel of two adjacent wall structures.

7. A wall construction as claimed in claim 6 and wherein same said wall panels are formed at adjacent ends with a shorter end edge and a longer end edge, and wherein, when said shorter and longer end edges are placed adjacent one another, they enclose a rectangular enclosure, and concrete received in said rectangular enclosures thereby bonding said wall panels together to form a corner.

8. A dwelling or other housing structure having walls and a transverse covering and a plurality of wall structures all being composed of composite wall structures and each said wall structure comprising;

inner and outer rigid panels of polymer-modified fibre reinforced concrete material and means bonding said panels together in spaced apart relation with their planes parallel;

junction channels formed along the sides and ends of said wall structure; and,

concrete filling in said junction channels between adjacent side and adjacent ends of said structure said concrete extending integrally from one said junction channel into the adjacent junction channel of two adjacent wall structures.

9. A dwelling structure as claimed in claim 8 and including a plurality of transverse panels, each consisting of upper and lower rigid panels of polymer modified concrete material, and steel reinforcing channels located between said upper and lower panels and bonded thereto, said upper and lower panels and said reinforcing channels defining open spaces therebetween, and foam plastic material filling said open spaces, and connection means extending upwardly from said walls through said transverse structure, and being secured in said transverse structure panels.

10. A dwelling structure as claimed in claim 9 wherein said connection means are in the form of generally cone shaped openings formed in said transverse panels, and being located and adapted to receive reinforcing bars extending upwardly from said walls, and concrete material filling said cone shaped recesses and bonding around said reinforcing bars and securing said transverse structure in position.

11. A dwelling structure as claimed in claim 10 and including a plurality of relatively narrow transverse panels, each of the transverse panels having interlocking male and female formations at their respective side edges, whereby said roof panels may be mated together, to form a transverse structure spanning the space of a building.

12. A dwelling structure as claimed in claim 11 wherein said transverse panels form a floor for a second storey of said dwelling structure.

13. A method of constructing a wall panel structure having an inner rigid panel and an outer rigid panel of rectangular shape and defining length and breadth dimensions and defining side edges on either side and end edges on ends thereof said panels being spaced apart from one another and, a plurality of intermediate junction strips having a predetermined width secured between said inner and outer panels, and said junction strips having a length less than the length of said panels, and being arranged in parallel spaced apart relation, at spaced intervals between said inner and outer panels and, a plurality of end junction strips having a predetermined width equal to said intermediate junction strips secured between said inner and outer panels adjacent opposite side edges thereof, and spaced inwardly from said side edges whereby to define junction channels along said side edges between said inner and outer panels, a plurality of spacer strips having a predetermined width equal to the width of said junction strips and secured between said inner and outer panels transverse to said junction strips and adjacent thereto, and comprising the steps of;

securing said spacer strips and said intermediate junction strips between said inner and said outer panels, said spacer strips being spaced being spaced inwardly relative to said end edges of said inner and outer panels panels whereby to define end junction channels between said inner and outer panels, said panels and said strips all being formed of polymer-modified fibre reinforced concrete material; and,

filling the spaces between said spacer strips and said inner and outer panels with synthetic plastic foam material.

14. A method of constructing walls, and a dwelling using wall structures having an inner rigid panel and an outer rigid panel of rectangular shape and defining length and breadth dimensions and defining side edges on either side and end edges on ends thereof said panels being spaced apart from one another, and a plurality of intermediate junction strips having a predetermined width secured between said inner and outer panels, and said junction strips having a length less than the length of said panels, and being arranged in parallel spaced apart relation, at spaced intervals between said inner and outer panels, and a plurality of end junction strips having a predetermined width equal to said intermediate junction strips secured between said inner and outer panels adjacent opposite side edges thereof, and spaced inwardly from said side edges whereby to define junction channels along said side edges between said inner and outer panels, a plurality of spacer strips having a predetermined width equal to the width of said junction strips and secured between said inner and outer panels transverse to said junction strips and adjacent thereto, said spacer strips being spaced inwardly relative to said end edges of said panels whereby to define end junction channels between said inner and outer panels, said panels and said strips all being formed of polymer-modified fibre reinforced concrete material; and, comprising the steps of;

erecting a plurality of said wall structures end to end to form dwelling walls;

pouring concrete in said junction channels between adjacent said wall structures to secure the same together, and,

erecting a plurality of transverse structures spanning said walls and forming a floor, roof or the like.