AU2318401A - Improvement to the strongwall (TM) construction system - Google Patents

Description

P/00/011 28/5/91 Regulation 32(2)

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Application Number: Lodged: Invention Title: IMPROVEMENT TO THE STRONGWALL T M CONSTRUCTION SYSTEM The following statement is a full description of this invention, including the best method of performing it known to us 1 IMPROVEMENT TO THE STRONGWALL TM CONSTRUCTION SYSTEM Field of the Invention This invention relates to an improved system or method for the modular construction of walls of the type used in the building industry generally and in the housing industry in particular. The improved system or method is suitable construction of both load and non-load bearing walls. The improved system is an improvement to the STRONGWALLTM construction system.

Background to the Invention Structural walls, as generally used in the building and housing industries, fall into one of the following categories, being blockwork construction; in situ concrete, or similar curing material; or prefabricated panels, requiring a secondary process, such as post-tensioning, or on site bolting.

Brickwork or blockwork wall construction requires the slow, labour intensive process of mortaring each joint, maintaining strict discipline to horizontal 15 and vertical alignments and requires scaffolding for lifts greater than 1.8 metres, increasing cost and slowing construction. This category is greatly affected by the weather.

Clad framework is also labour intensive whether the framework is fabricated from steel, timber or other material. Modern construction tools, 20 fasteners and equipment needs to be employed. It is also greatly affected by ooo.

weather conditions.

In situ concrete walls construction is similarly labour intensive, requiring teams to construct framework, place reinforcement erect scaffolding, propping and shoring; and then pour the concrete. The forming, placing and curing time 25 create extra costs and lengthy construction time. Any errors in the process necessitate expensive remedies and long delays and, again, the process is greatly affected by weather conditions.

Prefabricated panels relieve many of the problems associated with the previous methods, by substantially reducing the time on site, and confining much of the labour intensive work of fabrication to an efficient factory environment.

However, to make such a system cost effective, the panels need to be of such a scale that cranes are required in the factory and on site to move and place the panels, and methods of connection and alignment become secondary processes that add to the cost of construction.

In each of the prior art methods of construction, 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.

To that end, there is described in International Patent Application No.

PCT/AU98/00652, the contents of which are hereby incorporated herein by reference, a modular construction system which is fast and economical for construction of single and multi-storey structures and which reduces the dependency on skilled labour; cranes; modern construction tools and fasteners; and scaffolding for the construction of load bearing and non load bearing walls.

Specifically, that system proposes a method for construction of a wall from discrete modules. These discrete modules are so-called first, second and end modules. Each module has a portion forming part of the constructed wall. The S 15 first or first and end modules are aligned in a desired alignment for the wall to be constructed and connected together with at least one connection means to form a supporting structure for the second modules. The connection means has a tie portion, typically a rod or other tie means, generally extending in the direction of the alignment.

20 The second module is then connected to the supporting structure by co- ,Oil operation of a connection portion of the second module with a corresponding connection portion of the supporting structure to form at least part of the wall.

In a preferred construction, the second modules have a T-section with a flange portion and a vertically extending web portion provided with at least two 25 connection portions. In a particularly preferred construction, these connection portions take the form of bevelled slots or cuts at fixed locations along the vertically extending web. It is these bevelled slots or cuts which, during construction, engage with the tie portion rods for connecting the second modules to the supporting structure.

In practice it has been found that fixed location of the bevelled slots or cuts in the second module is somewhat inflexible. More advantageously, in certain cases, the location of the bevelled cuts or slots should be flexible in order to accommodate the many different design conditions and different heights of walls encountered in actual practice.

Moreover, having large bevelled slots or cuts provided in the web of the second module may complicate certain module manufacturing processes when certain types of materials are used. This could slow down production.

Summary of the Invention It is the object of the present invention to provide an improved system or method of construction of a wall to that disclosed in the Applicant's co-pending International Patent Application No. PCT/AU98/00652, which achieves further flexibility and facilitates module manufacture at minimal cost.

With this object in view, the present invention provides in a first aspect, a method of construction of a wall from first, second and end modules each having a portion forming part of the wall including: aligning a first or end module with one of: a first and an end module in a 15 desired alignment; connecting the two modules together with at least one connection means, :-...having a tie portion generally extending in the direction of alignment, to S.form a supporting structure for at least one second module; connecting a second module to the supporting structure by co-operation of oleo• a connection portion of the second module with a corresponding connection portion of said supporting structure to form at least a portion of the wall; wherein said connection portion of said second module is formed at least partly by a connection assembly located at one or more desired locations S 25 on said second module during or after manufacture of said second module.

The manufacturing process for the various modules making up a system for use in the above method may be distinguished from the construction phase in which the structure is built. As alluded to above, the second module may have a T-section with a flange portion and a vertically extending web portion. In accordance with the invention, the second modules need not have bevelled cuts or slots cast, machined, or otherwise formed, in their webs during the manufacturing process of the modules.

Each second module connection means is formed by a connection assembly independently put in place preferably by the builder or contractor, during construction phase of the structure. Less advantageously, the connection assembly may be put in place during manufacture. This allows the builder or contractor to decide on site where the connection portions of the wall being constructed should be though the location(s) should still be established in accordance with sound engineering and construction principles.

A suitable connection assembly may be, or may include a readily prefabricated clip or bracket which the builder locates at one or more desired locations along the web of the second modules. Such a bracket, which forms a second aspect of the present invention, may have a web engaging portion to engage or otherwise connect with the web of a second module. Such engagement should be secure. That web engaging portion is either connected to, or connectable to a support structure engaging portion. The supporting structure 15 engaging portion, which may be a tie portion engaging portion, may be formed with connection means that will co-operate with the supporting structure connection portion or tie portion to secure the second module to the supporting structure. The tie portion engaging portion may, for example, take the form of bevelled slots or cuts.

S 20 The bracket may be U-shaped with the web engaging portion comprising a plurality, advantageously two, web engaging plates connected together in a Ushape configuration. Such connection of the web engaging plates may be detachable, being made by a removable locking plate or like means. The web engaging plates may form a spring or be connected to a plate spring of open or S: 25 closed U-shape configuration. Each web engaging plate opposes the other to form a recess that accommodates the web. The web engaging plates, where spring loaded, may be biased to close against each other to assist in making connection with the web. Each web engaging plate may adjoin or merge into a side plate forming the support structure engaging portion. These opposing side plates incorporate the connection means that co-operate with the supporting structure connection portion. Slot(s) or cut(s) may form the connection means.

The bracket may be formed from a suitable material such as a metal. The metal may be resilient or springy.

During connection to a web of a second module the bracket, of U-shape, is connected to the web in any suitable manner. For example, taking the spring clip or bracket, the builder may open the web engaging plates against the spring force by pressing the side plates together. The builder locates the web in the recess between the opened web engaging plates. Then, when the desired alignment of the bracket with the second module web is achieved, the web engaging plates are allowed to close towards each other, due to the spring forces, by release of pressure on the side plates to make the connection with the web. As many brackets are connected to a web as necessary. The process is then repeated for all second modules. In this case, the web engaging plates may require to be accommodated within slots or recesses formed in the web. These recesses may extend through the web.

15 Advantageously, the connection between bracket and web involves reinforcing connection means which may take the form of a tongue or plate extending at an angle, generally perpendicular, to the plane of each web engaging portion. Such tongues or plates co-operate, under action of the spring force or otherwise, with complementary holes, grooves, slots or like functional 20 means formed in the second modules, for example, adjacent the intersection between second module web and flange. Such co-operation, on release of S" pressure on the side plates, allows secure connection between bracket or clip and slots, recesses or grooves formed in the web of the second module. The holes, slots, grooves, or like functional means, may be formed by casting, by machining 25 or other acceptable process during or after manufacturing of the second modules.

Alternatively, or additionally, connection of bracket to web may involve use of a plurality of locking plates that connectively cooperate with the web and bracket to achieve positive fixity and resistance, for example, to wind loading and other forces acting on the wall. Such brackets need not incorporate a spring characteristic.

A number of such brackets may be located along the web of a second module in desired locations as selected by the builder. The manufacturing method will no longer impede flexibility in that respect. Such brackets may be used in cooperation with other types of specially designed bracket for connection of door frames, windows and other walls to a given wall. Columns may also be constructed using such brackets.

Otherwise the method and system may be practiced or used in accordance with the disclosure of the Applicant's co-pending International Patent Application No. PCT/AU98/00652, the contents of which are hereby incorporated herein by reference. One benefit conferred by use of the method and system of the present invention is simpler second module manufacture with modules being readily formed in various lengths without necessary customisation in terms of locating bevelled slots at different intervals in the second module webs. Greater flexibility in use will likewise be achieved.

The improved method and system may still be used for construction of internal and external walls and fences and partitions, generally as described in 15 PCT/AU98/00652, the term "wall" being intended to be used as a compendious and non-limiting description of all such structures. Kits for use in the method or system may incorporate brackets and second modules as above described.

S: Brief Description of the Drawings This invention may be more fully understood from the following exemplary 20 description made with reference to the accompanying drawings in which: oooo Figure la is a side elevation of one example of a second module used in International Patent Application No. PCT/AU98/00652; Figure lb shows a cross-section view along section line B-B of Figure 1 a; Figure 1 c shows a detail of the bevelled cuts shown in Figure 1 a; 25 Figure 2a shows side elevation of one example of an alternative second 0 l module for use in an alternative embodiment of PCT/AU98/00652; Figure 2b shows a cross-section view along section line B-B of Figure 2a; Figure 3 shows a side elevation of an assembly of a second module and second module connection means used in accordance with one embodiment of the method and system of the present invention; Figure 4 shows a side elevation of a first type of a bracket used to form the second module connection means in accordance with the embodiment of the present invention shown in Figure 3; Figure 5 shows a plan view of the bracket shown in Figure 4; Figure 6 shows a side elevation of a second embodiment of bracket to that shown in Figure 4; Figure 7 shows a plan view in situ of the bracket shown in Figure 6; Figure 8 shows a side elevation view of a locking plate for the bracket shown in Figures 6 and 7; Figure 9 shows a side elevation of an assembly of a second module and bracket as shown in Figures 6 and 7; Figure 10 shows a side elevation of a second module design that may be used in accordance with a further embodiment of the present invention; Figure 11 shows a cross-section view along section line A-A of Figure 15 Figure 12 shows a side elevation of a third type of bracket used to form the second module connection means alternative to the embodiments shown in eeeee i: Figures 4 to 7; Figure 13 shows a plan view of the bracket of Figure 12 in a "locked" position as when connected to a second module; S 20 Figure 14 shows a front elevation view of the bracket of Figure 12; Figure 15 shows a side elevation of a locking plate for the bracket shown in Figures 12 to 14; Figure 16 shows a side elevation of an assembly of a second module and second connection means being the bracket of Figures 12 to 14; S 25 Figure 17 shows a side elevation of a fourth type of bracket to connect a door frame to a wall through second module connection means; Figure 18 is a plan view of the bracket of Figure 17; Figure 19 is a front elevation of the bracket of Figures 17 and 18; Figure 20 is a rear elevation of the bracket of Figures 17 to 19; Figure 21 is a plan view of a wall to door frame connection using the bracket of Figures 17 to 8 Figure 22 shows a side elevation of a fifth type of bracket used to connect a first wall to a second wall through a second module connection means; Figure 23 is a plan view of the bracket of Figure 22; Figure 24 is a front elevation of the bracket of Figures 22 and 23; Figure 25 is a plan view of a wall to wall connection using the bracket of Figures 22 to 24; Figure 26 is a side section view of a wall to wall connection using the bracket of Figures 22 to 24; Figure 27 is a front elevation of a bracket for connecting single and/or multiple module piers to a wall assembled in accordance with the invention; Figure 28 is a plan view of the bracket of Figure 27; Figure 29 is a plan view of a wall with a single module pier constructed in accordance with one embodiment of the method of the present invention; Figure 30 is a plan view of a wall with a single module pier constructed in 15 accordance with a further embodiment of the method of the present invention; Figure 31 is a plan view of a wall with a multiple module pier constructed in ~:.••accordance with a still further embodiment of the method of the present invention; S: Figure 32 is a plan view of a column constructed in accordance with one embodiment of the method of the present invention; 20 Figure 33 is a side section view of the column of Figure 32 taken along section line 1-1; Figure 34 is a front elevation of a tie rod to be used in constructing the column of Figures 32 and 33; and Figure 35 is a plan view of the tie rod of Figure 34.

S 25 Detailed Description of the Drawings There now follows, with reference to Figures 1 and 2, a description of the second module and connection means in accordance with a preferred embodiment of International Application No. PCT/AU98/000652 the contents of which are hereby incorporated herein by reference.

Second module 20 is a T-cross section panel as shown in Figures 1 a and lb. The second module 20 has a length generally the full height of the wall to be constructed. The first and end modules are as described in International Patent i.

9 Application No. PCT/AU98/00652, and it may be noted that the end modules are half T-cross-section modules or L-shaped modules.

The various modules may be made from polymer concrete, fibre reinforced concrete, from reinforced concrete, from pre-stressed concrete, from metal, from timber or from any other suitable material. Polymeric materials may especially advantageously be used as the material of construction.

The module could also be made of composite construction whereby the flange of the T-section and the half T-section is made from one material and the web from another. For example, the module may have a reinforced concrete, fibre reinforced concrete or cement flange with metal web or vice versa. For another example, the module may have a timber flange with metal web or vice versa and so on.

Turning more specifically to the construction of the second module 20, the width and thickness of the flange 21 and web 22 of the module depend on the .:00 design of the wall to be constructed.

The second module 20 has large angled slots 26 in its web 22. These .".large angled slots 26 are in the form of bevelled cuts at predetermined angle from Sathe horizontal, for example 300 or 450 (see Figure Ic) and desired locations, for example proximate the ends of the web 22.

oeeoe The bevelled cuts or slots could be sawn, laser cut, machined or otherwise formed in the factory or elsewhere.

S:.7 Alternatively, cuts or slots 26 could be formed in web portion 22 by moulding.

The number, size and angle of these bevelled slots 26 depend on the S. 25 height of the wall 40 to be constructed and on the design loading of the same wall Two such bevelled slots 26 may suffice as second module connection means. The width of the bevelled cuts 26 is selected to snugly fit a tie rod for connecting the first and second module 10 and 20 together. The tie rod is not shown here but its design and function is described in International Patent Application No PCT/AU98/00652.

The main function of bevelled slots 26 is to guide, positively anchor and fix a second module 20 to a corresponding tie portion of the supporting structure or the above mentioned tie rod. Alternative designs of second module 20 are possible, as shown in Figures 2a, 2b, 10 and 11.

The bevelled slots 26 are formed during manufacture of second modules and it emerges from the above description that the location of the bevelled cuts 26 will be dictated during manufacture, losing construction flexibility on site.

Further, manufacturing-while a straightforward process-requires some care.

In response to these issues, the Applicant has developed a method of construction allowing the second module connection means to be formed after module manufacture. In one embodiment, the method involves appropriately configured and designed second modules and second module connection means.

Referring now to Figure 3, there is shown an elevation of a second module 120 and second module connection means 150 constructed or used in 15 accordance with one embodiment of the method or system of the present invention.

0 Second module 120 has a flange portion 121 and a web portion 122, which in elevation look generally the same as those of second modules 20. However, in distinction to second modules 20, no bevelled cuts 26 are formed in the web 122 too**: 20 of second module 120 during manufacture. The web 122 and/or flange portion 121 could be hollow with one or a series of holes or cavities which may run the too.. full length of module 120. The shape of the holes or cavities could be any geometry, for example, circular or ovoid. The arrangement of holes may be random or ordered in any number. For example, flange 121 could be provided S. 25 with a line of oval cavities. All modules may be designed in similar manner. First and end module webs may be provided with drip grooves running along their lengths for channelling water. Second module flanges may be provided with such drip grooves again running along their length.

Second module connection means 150 is advantageously formed during the construction process just prior to assembly of a wall though it could also be formed during manufacture. The key component of second module connection 11 means 150 is a bracket which is so designed that it can be fitted to the web 122 of second module 120 on site.

One embodiment of the bracket 150, with spring characteristic, will now be described with reference to Figures 4 and 5 of the drawings which show one suitable embodiment thereof.

Bracket 150 has two opposed planar web engaging plates 152 connected to a U-shape plate spring 154 to achieve a spring clip action in which the plates 152 bias closed to connect with web 122 which is accommodated in the U-shape recess formed between them. The U-shape plate spring 154 is formed of metal, or other suitable material, of acceptable spring characteristic. The web engaging plates 152 further include two reinforcing connection portions 156, which take the form of tongues or protruding plates. These reinforcing connection portions or tongues 156 extend generally perpendicularly to the plane of the web engaging plates 152. Tongues 156 are designed to snugly fit into slots 180 formed in second module web 122 close to the intersection with flange 121 at locations which may correspond with likely locations for bracket(s) 150. The number and location of the slots 180 is selected in accordance with engineering or construction principles and also to give flexibility. Slots 180 may be rectangular, this being a simple shape. Other slot 180 configurations could be used and any 20 practical method of forming these slots may be employed.

Adjacent each of the two opposed web engaging plates 152 are located planar side cleats or side plates 153 that are formed with bevelled cuts 166. Side 'plates 153 oppose one another. Cuts 166 co-operate with tie rods, as described in PCT/AU98/00652 to connect the second module 120 to the supporting structure. These bevelled cuts 166 could have the same angle as used for .second modules 20 shown in Figures 1 and 2.

The bracket 150 may generally be formed from metal, hard plastic or other o suitable material of construction. The material selected should be suitable for construction and building applications.

Fitting of the bracket 150 to web 122 of second module 120 is straightforward in accordance with the method of the invention.

Prior to or during construction of a wall, which otherwise proceeds as described in International patent Application No. PCT/AU98/00652, the contents of which are hereby incorporated herein by reference, the builder selects the locations at which second module connection means 150 are to be set. All modules, that is first, second and end modules may be provided with hollow cavities of any chosen number or geometry, arranged if desired in any ordered or random pattern. For example, the flange portion 121 could be formed with a line of cylindrical or oval cavities.

The builder then takes a bracket 150 and presses side plates or cleats 153 inwardly together to open the U-shape spring 154. This opens the web engaging plates 152 about web 122. The bracket 150 is then pushed towards the flange 121 of second module 120, particularly at the location of selected slots 180. At this point, the tongues 156 coincide with the chosen location of slots 180 at each face 122b of the web 122. The builder then releases pressure from side plates 153 with the bias of the plate spring 154 pulling the web engaging plates 152 tightly against the web 122 of second module 120 such that tongues 156 engage chosen slots 180. In this way, the bracket 150 is effectively anchored to second :i module 120 to form a connection portion thereof.

The affixation of brackets 150 proceeds, as described, in any desired manner as construction proceeds. Typically, two such brackets 150 are connected to the web 122 of each second module 120. An elevation of one bracket 150 and connection to web 122 is shown in plan in Figure 8. No other changes are necessary to the method or system described in International Patent Application No. PCT/AU98/00652. It is noteworthy that kits for practicing a S: 25 method or system of the present invention will be identical to those described in International Patent Application No. PCT/AU98/00652, except that brackets 150 should be included. Further, second modules 120 may be included in such kits.

The use of the method and bracket of the present invention achieves greater flexibility and eases manufacture. The manufacture of second module 120 may also be simplified and rendered less expensive. That is because second modules 120 may omit bevelled cuts 166. Further, the second module 120 of length and width has a smaller cross-sectional area and depth, as shown 13 in Figures 10 and 11, than second modules 20 (shown in Figures 1 and 2).

Hence, the second modules 120 of Figures 10 and 11 have less weight and greater economy than second modules 20 shown in Figures 1 and 2.

A modified bracket 250 is shown in Figures 6 to 8 in which the spring 154 is omitted. Rather a loose detachable connecting plate 270 is used to connect the two side cleats 252 together to form the bracket 250. Each side cleat 252 has a large bevelled cut 226 and a protruded tongue 253 as reinforcing connection means at the web engaging end. The bracket 250 also has a rectangular slot 274 to engage the loose connecting plate 270 shown in elevation in Figure 8. The connecting plate 270 has two rectangular slots 272, one proximate each end 270a and 270b of plate 270. Each slot 272 reaches only partially across the width of plate 270 and is wider at its outward end to assist ready location at slot 274.

The clear distance between the slots 272 is equal to the width of the web 122 of the second module. The width of the slots 272 is equal to the thickness of the side cleats 252. An outward portion 273 of each slot 272 is of greater width than the inward portion 272a. This allows ready engagement when connecting the two side cleats 252 together.

To fit this type of bracket 250 to the second module 120, first the protruding tongues 253 of each side cleat 252 are engaged in the chosen rectangular hole 20 180 of the web 122, the holes 180 being formed as previously discussed. The .i connecting plate 270 is then threaded through the slots 272 facing downward.

The plate 270 is then driven down by tapping the ends of the plate 270 which .ooooi protrudes past the side cleats 252 until it is fully engaged. This action should press the side face 270a of the connecting plate 270 hard against the face 122a o. 25 of the web 122 of second module 120. This should anchor the bracket 250 tightly and effectively to the web 122 of module 120.

A further modified bracket 350 is shown in Figures 12 to 16. Again, no o• So: spring is included. Rather, the generally U-shaped bracket 350 has a portion 351 for accommodating a web of a second module. Portion 351 is defined by two side plates 352 joined by web 353. Each side plate 352 includes a large bevelled cut 326 but the tongue may be omitted as positive fixity of bracket 350 to the web of a E 14 second module is provided by two locking plates 370 as shown in Figure 15 in side elevation.

The bracket 350 accommodates a first locking plate 370 through provision of rectangular slots 362 at the bottom outward edge of side plates 352 In some cases, this one first locking plate 370 may be sufficient to achieve positive fixity.

The illustrated embodiment shows employment of a second locking plate 370, similar to the first, accommodated through provision of rectangular slots 382 at the upper inward edge of side plates 352. This second plate 370 is needed for certain wall constructions only. If not required, second locking plate 370 and slot 382 may be omitted. It may be seen, in each case, that the width of rectangular slots 362 and 382 is identical to the width of locking plates 370. Also, the outward portion 363 of each slot 362 is of greater width than the inward portion 362a. The outward portion 383 of each slot 382 is of greater width than the inward portion 382a. This allows ready engagement of locking plates 370 with side plates 352 on connection to the web 222 of a second module.

Locking plate 370, (similar to that shown in Figure 8) is provided with two slots 372 which are designed to function in a similar manner to the slots 272 of locking plate 270. It may be noted that locking plate 370 has chamfered corners for easier fitting into holes 180 of the second module 120.

20 The bracket 350 is connected to the web 222 of a second module 220 in the following manner. A desired bracket 350 location on web 222 is selected to correspond with the location of a particular slot 280 provided in web 222 in the manner as above described for alternative embodiments of bracket. Such connection is shown in Figure 8.

25 A first locking plate 370, with slots 372 facing upward, is fitted through slots 280 of web 222. Bracket 350 is then pressed downward such that the lower rectangular slots 362 of bracket 350 co-operate with slots 372 of locking plate 370. This will be sufficient, in many cases, to lock bracket 350 to web 222 of second module 220. In other cases, a second locking plate 370 with slots 372 facing downward, may additionally be employed. The second locking plate 370 is pressed downward to engage the upper rectangular slots 382 of bracket 350 and tapped downward into place.

As may be seen from Figure 16, at this stage, face 371 of locking plate 370 is flush with the outward face 222a of web 222. On completion of this operation, the bracket 350 is positively connected to the second module 220. The operation is continued for a given second module 220 as many times as necessary.

Generally, two such brackets 350 will be attached to the web 222 of a second module 220, desirably at locations corresponding to locations of the tie rods connecting first or first and end modules. This may vary with wall height and other factors.

A further feature of bracket 350 may now be described. In web 353, there is optionally provided a further slot 354 which may be located generally centrally of the upper edge of web 353. This slot 354 may be used for connection of doorframes or further walls to a wall, at an end module thereof, in the manner described below.

Turning to connection of doorframes first, a further bracket 450, as shown in Figures 17 to 20, may be used for this purpose. Bracket 450 consists of a web 453 from which extend, in one direction, two side plates 452 defining a U-shape cavity. A plate 454 extends perpendicularly from web 453 in the other direction.

At the bottom edge 454a of plate 454, is located a rectangular slot 455 of *generally similar design to slots described previously. The central location is not essential. Location depends on desired spacing of the door frame from the wall.

It is this slot 455 that allows engagement of bracket 450 to the second module connection means, advantageously being bracket 350 and hence to the wall.

eeeee Side plates 452 are each provided with slots 456 of similar design to slot 455 at the upper edges 452a of side plates 452. These slots 456 accommodate 25 the hook bracket assemblies 515, having co-operating downward facing slots, of a door frame in a manner similar to that described in the Applicant's International 0Patent Application No. WO 99/09628 the contents of which are hereby incorporated herein by reference. It is these hook bracket assemblies that allow connection of one side of the door frame 500 to a wall 1200 comprised of first modules 110 and second module 120 in accordance with the method of construction of the invention. On the other side of doorframe 500, end module f 16 130 of wall 1300 is connected thereto by co-operation of bracket assemblies 510 and 515.

Connection of first and further walls 1400 and 1500 may be achieved using a bracket 550, as shown in Figures 22 to 24, having a T shaped configuration with perpendicularly extending flanges 555 and 557. Flange 555 is provided on its bottom edge 555a with a slot 556 of similar design to slots described previously.

It is this slot 556 that allows engagement of bracket 550 to the second module connection means. Advantageously, bracket 350 located at the junction of the two walls to be connected is the second module connection means.

Flange 557 is provided with a rectangular slot 556 allowing an end module 130 of one wall to be connected to the second module 120 of a further wall 1500 in a manner similar to that described in the Applicant's co-pending International patent Application No. WO 99/09628. First, key 85 is fitted through slot 56 and flange 131 of end module 130. Wedge 88 is then fitted into place to make the connection secure. Such connection of walls 1400 and 1500 is shown in plan view in Figure 25 and in side section view in Figure 26.

Bracket 350 may also accommodate a bracket 650 for connection of piers, particularly in the case of fence walls, for increasing resistance to wind loads and hence increasing the lateral stability of the wall. A solid fence wall may be 20 constructed in accordance with a method of the invention with piers 1680 being located on one face 1640a of the fence wall 1640. The piers 1680 may be of single or multi-module construction.

At each pier centre line position along wall 1640, the same wall is intersected by a pier bracket 650 for connecting the piers 1680 to the face 1640a 25 of wall 1640.

At the location of each pier 1680, the wall 1640 comprises two end modules 130 arranged back to back between which plate 654 of bracket 650 passes. Slot 655 of plate 654, of similar design to slots previously described to make fitting easier, co-operates with slot 354 of bracket 350 to connect bracket 650 to second module 120 and hence to the wall.

Slots 653, again of wider dimension at the top to ease fitting, face upward to positively connect the pier 1680 to the wall 1640. The pier 1680 is then 4 It 17 constructed in the same manner as described in Application No. W099/09268 with the tie rod 660 connecting end modules 130 together being accommodated within slots 653 of bracket 650. The resulting structures are shown for single module piers in Figures 29 and 30 and for multi-module piers in Figure 31. In Figure 31, a first module 1110 spaces end modules 130 apart.

A difference between Figures 29 and 30 may also be noted. The pier 1680 of Figure 30 is of wider dimension than pier 1680 of Figure 29. In addition, in Figure 29, bracket 350 abuts bracket 650 with adjoining flanges of modules 130 also abutting each other.

Figure 30 shows that this is not essential. There, bracket 1650 spaces end modules 130 apart with plate 1652 of bracket 1650 being flush with the flange of first module 11 0a and 11 Ob. Plate 353 of bracket 650 is spaced from plate 1652.

Two adjoining walls may be constructed using technique similar to that described above.

Columns may also be constructed using brackets 350. Description of column construction using brackets 350 is made with reference to Figures 32 to First, a steel column 2120 if required to provide sufficient resistance to the column is located into position. Two first modules 11 0a and 11 0b are then placed 20 in opposition with faces 113 of webs 112a and 112b abutting column 2120. The first modules 110a and 110b may then be connected together. Keys 89a and 89b of (of design as described in Application No WO 99/09268) are first fitted through ooooo slots formed in the webs 112a and 112b of first modules 110a and 110b at desired position along their length.

25 Two tie rods 2200 and 2201 of U-shaped construction, and shown in Figures 34 and 35, are then located such that plates 1283 thereof align with apertures 1272 of keys 89a. Keys 89 and plates 1283 of tie rods 2200 are then wedged together using wedges At the completion of this stage, modules 110a and 110b are connected together and a supporting structure is ready for second modules 120a and 120b to be connected to the structure.

Modules 120a and 120b, already being fitted with brackets 350 in the manner above described, are then connected to the supporting structure in accordance with the method of the invention.

Modifications and variations may be made to the method, bracket and system of the present invention by the skilled reader of this disclosure. Such modifications and variations fall within the scope of the present invention.

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Claims (9)

1. A method of construction of a wall from first, second and end modules each having a portion forming part of the wall including: aligning a first or end module with one of: a first and an end module in a desired alignment; connecting the two modules together with at least one connection means, having a tie portion generally extending in the direction of alignment, to form a supporting structure for at least one second module; connecting a second module to the supporting structure by co-operation of a connection portion of the second module with a corresponding connection portion of said supporting structure to form at least a portion of the wall wherein; said connection portion of said second module is formed at least partly by a connection assembly located at one or more desired locations on said second module during or after manufacture of said second module.

2. The method of claim 1 wherein said second module has a flange and web and each connection assembly is a U-shaped bracket having a web engaging portion to engage a web of said second module. 9 9

3. The method of claim 2 wherein said bracket further includes a support °oooo structure engaging portion having connection means to secure said second module to said supporting structure. Li

4. The method of claim 3 wherein said support structure engaging portion is a tie portion. *-.99 The method of any one of claims 2 to 4 wherein said web engaging portion of said bracket comprises a plurality of web engaging plates connected together in U-shaped configuration. *is

6. The method of claim 5 wherein said bracket has a spring characteristic.

7. The method of claim 5 wherein said plurality of web engaging plates form a spring.

8. The method of any one of the preceding claims wherein said bracket is connected to said web by at least one locking plate that connectively co-operates with the web and bracket.

9. The method of claim 8 wherein said bracket is connected to said web by a plurality of locking plates. The method of any one of the preceding claims wherein said bracket co-operates with a further bracket for connection of doorframes or windows to said wall.

11. The method of any one of the preceding claims wherein said bracket So co-operates with a further bracket for connection of a plurality of walls. DATED this 2 0 th day of February, 2001 STRONGWALL INTERNATIONAL LTD. see... WATERMARK PATENT TRADEMARK ATTORNEYS 4TH FLOOR "DURACK CENTRE" 263 ADELAIDE TERRACE PERTH WA 6000 S SO