AU2004293493B2

AU2004293493B2 - A set of construction panels and building construction method

Info

Publication number: AU2004293493B2
Application number: AU2004293493A
Authority: AU
Inventors: Darren Mcintyre
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-11-26
Filing date: 2004-11-26
Publication date: 2009-12-10
Anticipated expiration: 2024-11-26
Also published as: AU2004293493A1

Description

WO 2005/052271 PCT/AU2004/001658 1 A SET OF CONSTRUCTION PANELS AND BUILDING CONSTRUCTION METHOD FIELD 5 The present invention relates to the construction of a building and in particular to a set of construction panels and a building construction method such as for use in the construction of dry wall buildings using stone masonry building panels. For convenience the present invention will be described with reference to the construction of stone masonry buildings but it will be appreciated that the 10 construction method may be used in the construction of building using other construction materials such as metals or plastics. BACKGROUND Stone buildings have previously involved cutting stone masonry blocks 15 from quarry walls to provide building blocks for domestic and commercial purposes. More recently, changes in standards of living and building codes has meant such blocks are no longer practical or desirable. In particular the solid blocks do not cater for the wiring and plumbing needs of modem buildings. As the appearance of stone faced buildings is still greatly desired, the 20 solid brick walls have been replaced by stone veneer and other such treatments to hide the construction of the walls under the attractive outer stone face. This process is generally costly and cumbersome as a wall must be erected and tiles or cladding must be applied to the exterior of the wall, effectively doubling the labour required to construct each wall. 25 Further the inside wall requires further work to provide a suitable interior for the building. Generally ply board may be applied or the inner surface may be rendered to make the finish of the inner wall suitable for occupation. A gap may need to be left between the wall and the inner surface to accommodate conduits for services such as wiring or plumbing. 30 Further the use of grouting in traditional building methods is expensive and time consuming relying on the expertise of the bricklayer in preparing the grout and laying the brickwork. This has been overcome by the use of drywalls, but these are not as attractive as the stone surfacing.

WO 2005/052271 PCT/AU2004/001658 2 We have now found a set of construction panels and a building construction method which provides an attractive appearance and substantially ameliorates the above problems or at least provides the consumer with a useful or commercial choice. 5 STATEMENT OF INVENTION According to a first broad form of the present invention there is provided a set of panels for constructing a building, wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity located 10 between the side walls and extending the height of the panel; and wherein each of said end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; and wherein each of said panels have the base and the top formed from a distal portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each 15 of the side walls comprises a longitudinal recess; a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess. 20 According to a second broad form of the present invention there is provided a method of constructing a building from a plurality of panels wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity located between the side walls and extending the height of the panel; and wherein each of said end walls have key slots extending the height of the panel for 25 joining and stabilising overlaid panels; said method comprising the steps of: a) laying a first course of panels on a footing wherein the first course of panels comprise panels having a top formed from a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess; 30 b) laying a slab floor on the ledge of the first course of panels; c) laying at least one wall course of panels on top of the first course of panels and slab wherein the wall course of panels comprises panels having a WO 2005/052271 PCT/AU2004/001658 3 top and base formed from a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; d) optionally laying a slab supporting course of panels on top of the at least one wall course of panels wherein the slab supporting course of panels 5 comprises panels having a top formed from a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess; e) optionally laying a further slab floor on the ledge of the slab supporting course of panels; 10 f) optionally laying at least one further wall course of panels on top of the slab course of panels and the further slab floor wherein the further wall course of panels comprises panels having a top and base formed from a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; and 15 g) optionally laying a roof truss supporting course of panels wherein the roof truss course of panels comprise panels having a top formed from a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess, mounting a bond beam in the U-shaped channel and fixing roof trusses to said bond beam. 20 In a third broad form of the invention there is provided a construction, such as a wall constructed of building panels, said construction comprising a plurality of overlaid courses of dry stacked panels arranged in courses wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity located between the side walls and extending the height of the panel; and 25 wherein each of said end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; and wherein each of said panels have the base and the top formed from a distal portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; 30 a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess.

WO 2005/052271 PCT/AU2004/001658 4 In one embodiment of the third broad form of the invention there is provided a building constructed of building panels wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity located between the side walls and extending the height of the panel; and wherein each of said 5 end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; and wherein each of said panels have the base and the top formed from a distal portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; 10 a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess. The set of panels preferably includes panels that are generally planar 15 for use in forming walls and panels that are generally L-shaped for use in forming corners in the construction. Panels that are formed in an L-shape or other non-planar form comprise side walls that are parallel and follow the configuration of the panel through the corner or curve whereby the panels are of generally constant thickness. The end walls are disposed on the ends of the panels that are for abutment with 20 adjacent panels disposed on the same course. For example, planar panels have end walls that are disposed on laterally opposed ends of the panels. In panels that form the corners of a construction, the end walls may be offset whereby the end walls are in abutment with the end walls of adjacent panels. The key slots in the end walls that extend the height of the panel may 25 be filled with a concrete core, optionally reinforced with reinforcing steel tie rods. Alternatively the key slots may engage with key members that interengage with key slots in abutting panels. Suitable key members may be of solid or hollow construction. Key members may preferably be formed in opposed tapering halves whereby each tapering half may extend into a pair of adjacent key slots in one course 30 of panels and also extend into a pair of adjacent key slots in an adjacent course of panels. In a preferred form the key members may be hollow allowing the keys to be filled with the concrete core. Alternatively the key members may be solid and also be formed from concrete.

WO 2005/052271 PCT/AU2004/001658 5 The building panels may be interlockingly connectable by placing keys within two or more key slots of adjacent blocks. Alternatively the keys may be placed in aligned cavities. Thus a dry wall may be formed by overlaid rows of building panels and joining adjacent panels with adjacent rows by placing at least one key 5 vertically within the aligned key slots. The panels may be overlaid in a staggered arrangement to add stability to the wall. Thus key slots may be formed within the panels to accept the keys intermediate the ends of the panels. At least one key slot may be located in an intermediate position between the end walls, to allow the building blocks to be arranged in a staggered arrangement. Thus a key slot in an end 10 wall may align with an intermediate key slot, such as a vertical cavity, in the adjacent row to be locked together to overlap adjacent rows in a staggered array forming the course. Preferably the keys are pre-moulded. The keys may be formed from cement covering one or more steel reinforcing rods to form reinforced cement keys 15 over, the height of the wall. These keys may be inserted into the key slots of the blocks forming the wall. Alternatively the keys may be provided by filling the key slots with grout. Thus the grout may be poured into the key slots when the blocks are overlaid, and the key slots aligned. This results in the wall being an integrally formed dry wall of the building blocks. 20 Preferably the building panels are formed from a single piece of stone having cavities between the side walls. When the panels are laid in a wall the side walls form the inner and outer walls of a building. Thus the panelsmay be used in a number of orientations providing the end walls are connectable and the side walls are aligned. Alternatively, the side walls may be formed out of stone tiles or bricks so 25 that an outer wall has a stone finish, while the inner wall has a different finish. Further the side walls may be formed of differing colours or textures of stone, or other finishes as desired. It would be understood that the side walls may be curved or rounded to provide a curved face. The top and base are generally planar to allow the building panels to be 30 stacked on top of one another when forming a course. The cavities may be equally spaced to allow cavities to be in alignment when the panels are stacked in rows. At least one cavity may be in the shape of a key slot to accommodate a key to lock the rows of building panels in place.

WO 2005/052271 PCT/AU2004/001658 6 The building panels may include at least one cavity between the sidewalls being filled with polystyrene foam. The use of polystyrene foam provides insulation from heat loss and noise providing damping of the side walls. Other forms of insulation including rock wool, fibreglass, cellulose, polyurethane foam and 5 polyisocyanurate foam, may be used instead of polystyrene foam, as would be understood by a person skilled in the art. The cavities may also accommodate services such as plumbed water or electricity. Preferably the building panels are formed from solid masonry sandstone with the cavities and key slots bored through the building panels. 10 Generally, the building panels provide two faces of sandstone for the building, the faces may be interchangeable to form the inner and outer walls. The building panels may preferably be strong enough to bear the load of the wall without the need for a separate load bearing structure. The building panels may be core filled and reinforced by using steel rod within the cavities and key slots 15 over the height of the wall. The building panels may be formed as an L-shape to be used as corner blocks in a building. The building panels may accommodate reveals to engage with an end wall, a top or a base to forma a jamb or sill for a window or door. The panels may include a variety of decorative panels, such as may be used to form archways or 20 other decorative or architectural features in the construction. The cavities and key slots may be sufficiently large to accommodate a variety of uses such as the egress of wiring therethrough. Thus the cavity may allow a conduit of wires to be fed through the aligned cavities of the building panels in the wall to desired locations, within the building. It will be understood by a person 25 skilled in the art that the cavities may be used for plumbing, cabling or other services to be contained within the walls and delivered to a localised site or sites within the building. The building panels may be formed to allow for particular structures such as windows, doors, fireplaces, stairwells and arches, for example, so that the 30 cavities pass only partially therethrough. The building panels used to form an arch may include key slots along the top and ends of the panels only, with the arch remaining free from cavities. This may be desirable for instance when an arch is WO 2005/052271 PCT/AU2004/001658 7 formed for a fireplace, as it may be unsuitable to pass cables or plumbing too close to the heat. Similarly with stair structures it may be preferable to form the building panels into treads and risers forming the stairs. These building panels may not 5 include cavities in order that they may carry more load, but include key slots on at least one end for alignment in the wall or building. It may be preferable to form a lintel with recesses on the top of the panels so they may be joined to adjacent panels, without compromising the strength of the lintel by providing cavities therein. 10 In contrast, building panels for piers and columns may be formed to include a single cavity within the centre of the building panels so that the building blocks may be filled with sufficient steel and concrete to form a stronger supporting structure. The panels for use in the present invention are preferably dimension to 15 be substantially larger than blocks used for block work construction. Typically the height of the panes will be greater than 300mm. Preferably the set of panels may include panels of 300, 450 and 600mm. The panels are typically 600 or 900mm in length although longer panels may also be used, such as for use in corner panels and the like. Preferably the panels are dimensioned such that their weight allows for 20 ready handling and ease of construction. The top and base of the panels are formed from a distal portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; 25 a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess. Whilst the panels may have a base and top formed from any 30 combination described above, it is preferable that a panel for use in an intermediate wall course be formed with a distal portion at the top end base that is substantially flat and wherein the side walls comprise longitudinal recesses. In this manner, the panels can be conveniently interlocked by placing a jointing member such as an elongate WO 2005/052271 PCT/AU2004/001658 8 tube into corresponding recesses on adjacent courses. Also, informing a wall section in this way, services such as plumbing and electricity may be provided in the corresponding recesses between adjacent courses. A course of panels for supporting a slab as either a ground or upper 5 floor preferably includes a top formed from a distal portion that includes a protruding sidewall whereby an L-shaped ledge is formed to support the slab and wherein the protruding sidewall comprises a longitudinal recess. It is not narrowly critical as to the configuration of the base of such a panel when laid on top of a foundation such as a series of piers or a continuous footing. However, when used to form an upper floor 10 on top of a wall course of panels, it is preferably that the base be formed from a distal portion that is substantially flat and includes side walls wherein each of the side walls comprises a longitudinal recess. The top course for supporting a roof is preferably formed with a top formed from a distal portion that includes protruding sidewalls that form a U-shaped 15 channel wherein each of the sidewalls comprises a longitudinal recess. The U-shaped channel may receive a bond beam that may be used to support a roof truss or other roofing framework. It is preferred that the base of the panel be formed from a substantially flat distal portion that includes side walls wherein each of the side walls comprise a longitudinal recess. 20 The building panels may include a bond beam to be used at the base of a wall to provide support to the wall horizontally. The bond beam may be in the form of an elongate block or blocks running the length of the wall and extending the thickness of the wall. The bond beam may include cavities so that it may be attached to other building blocks in the wall. 25 The slabs may be preformed or poured in-situ. The slabs may be formed from a solid concrete block having key slots formed in two ends so the slabs may fit together interlockingly to form the floor or roof of the building. The slabs may include partial cavities cut into the slab to accommodate tie down rods or to allow egress of conduits, piping, wiring or other infrastructure therethrough. The slab 30 may include reinforcing such as steel rods to make it strong enough to bear loads as a roof or floor. A floor may include a steel footing connected to a tie rod to allow secure connection of the floor and wall to the roof to form a building.

WO 2005/052271 PCT/AU2004/001658 9 A roof slab may include a top plate such that the tie rod from the footing may run through the walls the height of the building to be secured to the top plate thereby strengthening the building structure. The slabs may include a locking system to allow adjacent slabs to be 5 interlockingly connected. The locking system may include keys and key slots formed on the ends of the slabs so that a key fits into a corresponding key slot on an adjacent slab to allow the slabs to be locked together. In particular, a locking nut may be used to secure the tie down and may be rotated to create a tighter or loser screw fit, thereby adjusting the tension of the 10 slabs and walls. The locking nut may be used to join and tension adjacent slabs. The tie rods may be threaded so that the nut can be screwed up or down the rod to tension the walls and slab. In the method of constructing a building according to the second broad form of the invention, the first course of panels may be laid on a footing and the 15 footing may be in the form of a series of piers or a continuous footing that supports the first course of panels. The first course of panels form an L-shaped ledge for supporting a slab floor. The slab floor may be formed from a preforned slab or may be poured in situ. Once the slab is laid on the first course of panels, a series of wall courses may be laid which wall courses are formed from panels having top and base 20 formed from a substantially flat distal portion that includes sidewalls comprising longitudinal recesses. Doors and windows may be included in the construction by terminating the wall and using a reveal that may be slideably engaged over the wall panels. Preferably the reveals include an extended pair of flanges that enable the reveal to be 25 positioned such that the size of the opening to form the door or window may be readily adjusted. The cavity formed between the inside of the reveal and the wall panel may be filled using cement and optionally reinforced with steel reinforcing rods. Other features may be incorporated into the wall such as vents, 30 decorations and the like and the vents, decorations and the like may preferably be formed of a size suitable for interlocking with the wall panels. In order to form a multiple storey building, a further slab supporting course of panels may be laid on top of the at least one wall course of panels whereby WO 2005/052271 PCT/AU2004/001658 10 the slab supporting course of panels forms a further L-shaped ledge for supporting a further slab floor. The further slab floor is preferably precast and positioned on the ledge, although the further slab floor may also be poured in situ using known techniques. A further wall course or courses may be laid upon the further slab to 5 extend the height of the building. In order to support the roof of the building, it is preferably to lay a roof truss supporting course of panels which comprise panels having a top formed from a distal portion that includes protruding side walls that form a U-shaped channel. The U-shaped channel may preferably receive a bond beam that allows the roof trusses or 10 other roofing framework to be mounted on the walls. Further, a building may be formed by joining the dry walls with one or more slabs to form a floor and one or more slabs via a tie rod attached to a footing to form a roof, connected to a top plate in the slab. A preferred embodiment of the invention will now be described by way 15 of example only, in reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS FIG 1 shows a cross sectional view of a wall formed according to an embodiment of the invention; 20 FIG 2 shows a perspective view of a wall formed according to an embodiment of the invention; FIG 3 shows a cross sectional view of a wall formed according to an embodiment of the invention; FIG 4 shows a perspective view of a first course of slab supporting 25 panels according to an embodiment of the invention; FIG 5 shows a perspective view of a building constructed according to an embodiment of the invention; FIG 6 shows a perspective external view of a corner slab supporting panel according to an embodiment of the invention; 30 FIG 7 shows a perspective internal view of a corner slab supporting panel according to an embodiment of the invention; FIG 8 shows a perspective external view of a slab supporting panel according to an embodiment of the invention; WO 2005/052271 PCT/AU2004/001658 11 FIG 9 shows a sectional view of a slab supporting panel according to an embodiment of the invention; FIG 10 shows an end view of a slab supporting panel according to an embodiment of the invention; 5 FIG 11 shows a perspective external view of a wall panel according to an embodiment of the invention; FIG 12 shows a perspective internal view of a wall panel according to an embodiment of the invention; FIG 13 shows a perspective external view of a wall panel according to 10 an embodiment of the invention; FIG 14 shows a sectional view of a wall panel according to an embodiment of the invention; FIG 15 shows an end view of a wall panel according to an embodiment of the invention; 15 FIG 16 shows a perspective external view of a roof frame supporting panel according to an embodiment of the invention; FIG 17 shows a perspective internal view of a roof frame supporting panel according to an embodiment of the invention; FIG 18 shows a perspective external view of a roof frame supporting 20 panel according to an embodiment of the invention; FIG 19 shows a sectional view of a roof frame supporting panel according to an embodiment of the invention; FIG 20 shows an end view of a roof frame supporting panel according to an embodiment of the invention; 25 FIG 21 shows a perspective view of a key according to an embodiment of the invention; FIG 22 shows a series of sectional views of a reveal according to an embodiment of the invention; FIG 23 shows a sectional view of a sill according to an embodiment of 30 the invention; FIG 24 shows an exploded perspective view of a window according to an embodiment of the invention; WO 2005/052271 PCT/AU2004/001658 12 FIG 25 shows a series of sectional views of a reveal according to an embodiment of the invention; and FIG 26 shows a sectional view of a wall according to an embodiment of the invention. 5 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Figure 1 shows a wall 10 constructed on a footing 20. A slab supporting panel 21 is laid on the footing 20. A slab 22 is seated on a ledge 23 of the slab supporting panel 21. The outer side wall 24 of the slab supporting panel 21 retains 10 the slab 22 seated on the ledge 23. The ledge 23 is in part formed from the inner side wall 25. A first wall panel 26 is disposed on top of the slab 22 and the slab supporting panel 21. A locating rod 30 is located between the slab supporting panel 21 and the 15 first wall panel 26 in corresponding recesses in the outer walls of the respective panels. A second course of wall panels 27 are laid over the first course of wall panels 26 and a locating rod 30 in the outer wall of the respective panels locate the panels relative to each other. The recesses 28 in the inner wall of the respective wall panels form a cavity which is suitable for receiving services such as electricity and/or 20 plumbing. A second slab supporting panel 29 is located on the second wall panels 27 and retained in place by a locating rod 30. A second slab 31 is located on the ledge 32 of the second slab supporting panel 29. 25 Figure 2 shows a wall 34 of similar construction to wall 10. A first slab supporting panel 21 bears a slab 22 on a ledge 23. A first wall panel 26 is disposed on the slab and the slab supporting panel. A second wall panel 27 is disposed upon the first wall panel 26. A bond beam supporting panel 35 is disposed on the second wall 30 panel 27 and includes a U-shaped channel in its top to receive a bond beam for supporting a roof frame.

WO 2005/052271 PCT/AU2004/001658 13 Figure 3 shows a building 12 having a wall 13 constructed on a footing 20 a slab supporting panel 21 supports a slab 22 on ledge 23. A first course of wall panels 26 are located on the slab 22 and the slab supporting panel 21 by a locating rod 30 disposed in recesses in the outer walls of the respective panels. A window sill 40 is 5 disposed on the first wall panel 26 to receive a window assembly 41. A reveal 42 is slideably engaged on a bond beam supporting panel 35 to frame the window 41. Bond beam 36 is disposed in a U-shaped channel 37 in the top of the roof frame supporting panel 35. A roof truss 38 is affixed to the bond beam 36 on which the roofing members are mounted. 10 Figure 4 shows a first course of slab supporting panels constructed to form the outer shell of a room. The slab supporting panels 21 include corner slab supporting panels 47 in addition to the planar slab supporting panels 21. The slab supporting panels 21 and 47 show cavities 50 that extend vertically through the 15 panels. A slab (not shown) may be poured or lowered in precast form on to the slab supporting panels. Figure 5 shows a building 50 mounted on pier footings 51. A first course of slab supporting panels 52 support slab members 53. Wall courses 53 are disposed on 20 top of the slab supporting panel and include window frames 54. A top course roof frame supporting panels 55 is disposed on top of the two courses of wall panels 53. Figures 6 and 7 show a corner floor slab supporting panel 60 that has an outer wall 61 the top of which includes a recess 62. The corner slab supporting panel 25 60 has a ledge 63 for supporting a slab member (not shown). The slab supporting panel has a series of vertical cavities 64 that allow services to be disposed through the panel 60 or that the panel may be core filled with concrete and reinforcing steel. The inner wall 65 and the outer wall 61 both include recesses disposed at their base. The side walls 66 includes a key slot 67 that can align with corresponding key slots or 30 cavities from panels in adjacent courses. Figures 8, 9 and 10 show a planar slab supporting panel 70. The outer wall 71 has recesses 72 in the top and bottom of the side wall 71. The inner wall also WO 2005/052271 PCT/AU2004/001658 14 includes a recess at its base. The panel 70 has a ledge 73 for supporting a slab (not shown) and includes vertical cavities 74 along its length. The end wall 75 includes a key slot 77. 5 Figures 11 and 12 show a corner wall panel 80 that has an outer wall 81 the top of which includes a recess 82. The corner wall panel 80 has a top surface 83 for supporting a adjacent course of panels (not shown). The wall panel has a series of vertical cavities 84 that allow services to be disposed through the panel 60 or that the panel may be core filled with concrete and reinforcing steel. The inner wall 85 and 10 the outer wall 81 both include recesses disposed at their base. The side walls 86 includes a key slot 87 that can align with corresponding key slots or cavities from panels in adjacent courses. Figures 13, 14 and 15 show a planar wall panel 90. The outer wall 91 has 15 recesses 92 in the top and bottom of the side wall 91. The inner wall also includes a recess at its top and its base. The panel 90 has a upper surface 93 for supporting an adjacent course of panels (not shown) and includes vertical cavities 94 along its length. The end wall 95 includes a key slot 97. 20 Figures 16 and 17 show a corner roof frame supporting panel 170 that has an outer wall 171 the top of which includes a recess 172. The corner roof frame supporting panel 170 has a U-shaped channel 173 for supporting a roof frame member (not shown). The roof frame supporting panel has a series of vertical cavities 174 that allow services to be disposed through the panel 170 or that the panel may be core 25 filled with concrete and reinforcing steel. The inner wall 175 and the outer wall 171 both include recesses disposed at their base. The side walls 176 includes a key slot 67 that can align with corresponding key slots or cavities from panels in adjacent courses. 30 Figures 18, 19 and 20 show a planar roof frame supporting panel 180. The outer wall 181 has recesses 182 in the top and bottom of the side wall 181. The inner wall also includes a recess at its base and top. The panel 180 has a ledge 183 for WO 2005/052271 PCT/AU2004/001658 15 supporting a roof frame (not shown) and includes vertical cavities 184 along its length. The end wall 185 includes a key slot 187. Figure 21 shows a key 100. The key 100 has an upper tapered member 101 5 and a lower tapered member 102. The respective tapered members may be received in key slots or cavities of adjacent courses of panels. Detents 103 prevent the key from being fully disposed within a cavity or key slot. The key 100 may be in solid form or may include a vertical channel that permits services and/or core filling to penetrate therethrough. 10 Figure 22 shows a series of sized reveals 110. The reveals 110 include flanges 111 that can slideably engage the panels of the construction. By providing flanges of varying lengths it is possible to adjust the size of the window or other aperture to suit an architectural or engineering requirement. 15 Figure 23 shows a sill of similar construction to the reveals shown in figure 22. The outer surface 116 of the sill is inclined to facilitate the removal of water such as rain water and prevent the ponding of water and potential for leakage and/or other water damage. 20 Figure 24 shows an exploded view of a window frame 120. The window franie 120 consists of a sill 121 a pair of opposed reveals 122 and an upper reveal 123. The sill and reveals are constructed according to the designs shown in figures 22 and 23. 25 Figure 25 shows an enlarges view of the interlocking between adjacent panels. Recesses 130 are formed in the top and base of the outer wall of the panels and permit a locking rod 131 to be received in the recesses and locate the respective adjacent panels. Recesses 135 are located in the inner wall of adjacent panels and co 30 operate to form a channel 136 for receiving services such as electricity and/or plumbing.

WO 2005/052271 PCT/AU2004/001658 16 Figure 26 shows a horizontal cross section of a wall 150 constructed in accordance with the present invention. Wall panel 151 is located in abutment with panel 152 and the respective key slots 153 receive a core filling of concrete 154. Window reveal 155 is disposed in abutment with panel 152 and the key slot 156 is 5 core filled with concrete 157. Window assembly 158 is attached to window reveal 155. Reveal 159 is attached to the window assembly 158 and receives between flanges 160 a corner wall panel 161. The key slot 162 is core filled with concrete 163. Wall panel 161 is in abutment with wall panel 162 and key slots 163 are filled with concrete 164. 10 Whilst the above has been given by way of illustrative example of the invention, many modifications and variations may be made thereto by persons skilled in the art without departing from the broad scope and ambit of the invention as herein set forth. 15 The term "comprise", or variations of the term such as "comprises" or "comprising", are used herein to denote the inclusion of a stated integer or stated integers but not to exclude any other integer or any other integers, unless in the context or usage an exclusive interpretation of the term is required.

Claims

1. A set of panels for constructing a building, wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity located between the side walls and extending the height of the panel; and wherein 5 each of said end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; and wherein each of said panels have the base and the top formed from a distal portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; 10 a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess.

2. A set of panels according to claim 1 wherein the panels include wall 15 panels and corner panels.

3. A set of panels according to claim 1 further comprising reveals for doorways and windows.

4. A set of panels according to claim 3 wherein the reveals comprise an extended pair of spaced apart flanges for slideable engagement with the panels. 20

5. A set of panels according to claim 1 further comprising a bond beam for engagement with a roof frame.

6. A set of panels according to claim 1 wherein the set further comprises locking strips for interengagement with recess between adjacent courses of panels.

7. A set of panels according to claim 1 wherein the set further comprises 25 keys for positioning adjacent panels relative to each other.

8. A set of panels according to claim 7 wherein the keys include opposed tapering halves whereby each tapering half may extend into a pair of adjacent key slots in one course of panels and also extend into a pair of adjacent key slots in an adjacent course of panels. WO 2005/052271 PCT/AU2004/001658 18

9. A set of panels according to claim 7 wherein the key members are hollow, tube-like members.

10. A method of constructing a building from a plurality of panels wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at 5 least one cavity located between the side walls and extending the height of the panel; and wherein each of said end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; said method comprising the steps of: a) laying a first course of panels on a footing wherein the first course of panels comprise panels having a top formed from a distal portion including 10 on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess; b) laying a slab floor on the ledge of the first course of panels; c) laying at least one wall course of panels on top of the first course of panels and slab wherein the wall course of panels comprises panels having a 15 top and base formed from a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; d) optionally laying a slab supporting course of panels on top of the at least one wall course of panels wherein the slab supporting course of panels comprises panels having a top formed from a distal portion including on protruding 20 side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess; e) optionally laying a further slab floor on the ledge of the slab supporting course of panels; f) optionally laying at least one further wall course of panels on 25 top of the slab course of panels and the further slab floor wherein the further wall course of panels comprises panels having a top and base formed from a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; and g) optionally laying a roof truss supporting course of panels 30 wherein the roof truss course of panels comprise panels having a top formed from a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess, mounting a bond beam in the U-shaped channel and fixing roof trusses to said bond beam. WO 2005/052271 PCT/AU2004/001658 19

11. A set of panels according to claim 10 wherein the panels include wall panels and corner panels.

12. A set of panels according to claim 10 further comprising reveals for doorways and windows. 5

13. A set of panels according to claim 12 wherein the reveals comprise an extended pair of spaced apart flanges for slidable engagement with the panels.

14. A set of panels according to claim 10 further comprising a bond beam for engagement with a roof frame.

15. A set of panels according to claim 10 wherein the set further comprises 10 locking strips for interengagement with recess between adjacent courses of panels.

16. A set of panels according to claim 10 wherein the set further comprises keys for positioning adjacent panels relative to each other.

17. A set of panels according to claim 16 wherein the keys include opposed tapering halves whereby each tapering half may extend into a pair of 15 adjacent key slots in one course of panels and also extend into a pair of adjacent key slots in an adjacent course of panels.

18. A set of panels according to claim 16 wherein the key members are hollow, tube-like members.

19. A construction comprising a plurality of overlaid courses of dry 20 stacked panels arranged in courses wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity located between the side walls and extending the height of the panel; and wherein each of said end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; and wherein each of said panels have the base and the top formed from a distal 25 portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each of the side walls comprises a longitudinal recess; a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; WO 2005/052271 PCT/AU2004/001658 20 a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess.

20. A building constructed of building panels wherein each of said panels has a base, a top, two end walls, a pair of parallel side walls and at least one cavity 5 located between the side walls and extending the height of the panel; and wherein each of said end walls have key slots extending the height of the panel for joining and stabilising overlaid panels; and wherein each of said panels have the base and the top formed from a distal portion selected from the group consisting of: a substantially flat distal portion including the side walls wherein each 10 of the side walls comprises a longitudinal recess; a distal portion including the side walls protruding to form a U-shaped channel wherein each of the side walls comprises a longitudinal recess; a distal portion including on protruding side wall to form an L-shaped ledge wherein the protruding side wall comprises a longitudinal recess. 15