AU2005201164A1 - Construction Element and Method for Erecting a Wall - Google Patents

Description

P/00/011 28/5/91 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Name of Applicant: Actual Inventor Address for service is: Lomwest Enterprises Pty Ltd Richard Clifford Harris Clifford Leslie Strahan WRAY ASSOCIATES Level 4, The Quadrant 1 William Street Perth, WA 6000 Attorney code: WR Invention Title: Construction Element and Method for Erecting a Wall The following statement is a full description of this invention, including the best method of performing it known to me:- -2- O "Construction Element and Method for Erecting a Wall" SField of the Invention 00 The present invention relates to building systems. More particularly the invention relates to a method for erecting a wall and a construction element.

5 Background Art 0 As tyres become worn out they reduce in value. The large quantity of used tyres 1 that are produced in developed countries on a yearly basis has seen the introduction of specialised machines and methods for forming such tyres into bales. While some tyre bales are formed by strapping with wire, other methods of manufacture are available and it is certain that further methods will become available in the future. US Patent 5,214,896 describes one method of forming a tyre bale using a press.

Tyre bales produced with wire straps made from steel have been used as an economical form of light weight fill in a variety of construction applications including, but not limited to, land reclamation, retaining walls, stream bank stabilisation, fire range bullet proofing, fire proofing, road support, and erosion control. It would be advantageous if the properties of tyres and tyre bales could find useful application in areas in which they have not been employed. This would serve to assist in lessening well known storage and disposal problems associated with used tyres.

These problems include the creation of dump sites that have an adverse impact on the environment by presenting an eye sore, taking up valuable space, presenting a fire hazard and so on. The disposal of used tyres has become such a major ecological problem. As a consequence some government authorities provide compensation to those who use used tyres in an ecologically aware manner.

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0 While it is known that tyres are extremely durable and that they retain their durability long after their useful life on vehicles has ended, recycling used tyres has not proven to be a complete solution to the problems presented. This is 0 primarily due to the expense, large amount of energy required and the production of undesirable by-products during the recycling process.

If vehicular tyres could be used in other applications such as temperature buildings then this would limit the adverse ecological problems mentioned. In some buildings using Expanded Polystyrene there is a high fire Crisk. This has been met by high insurance premiums and a general reluctance of insurers to insure such buildings. Accordingly, there is a need to develop a system that offers an alternative to Expanded Polystyrene (EPS) systems.

One building system currently available involves tilting up flat concrete panels built horizontally on the ground. The system has been responsible for numerous accidents on building sites that typically occur while lifting the walls into position.

Even though this system has been in use for many years, safety issues continue to become evident and, because of this, the system is being subject to more and more regulation. This has a concomitant cost and there is a need for a safer and more cost effective alternative.

It is against this background that the present invention has been developed.

The above discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge in Australia as at the priority date of the application.

Disclosure of the Invention According to a first aspect of the invention there is provided a construction element comprising: a core having a first and a second end respectively fixed to a first and a second section of relatively rigid material, the first and second -4-

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sections presenting opposed first and second planar faces facing outwardly away from the core; wherein the first and second sections are disjoint and thermally insulated from each other by the core.

o00 Preferably the core is formed substantially from vehicular tyre material. In some arrangements the core is formed from used material, typically used or recycled tyres, that are held together by bale means which dispose the core in the form of a bale.

0 In particularly preferred embodiments of the invention the core comprises a bale 0 N of material formed substantially from used vehicular tyres that are held together to form the bale. In this way the construction element provides a new application for old vehicular tyres.

The used vehicular tyres may be held together by fixing means such as ties and straps.

By making use of the thermal characteristics of compressed bales of vehicular tyres, embodiments of the invention provide superior insulating properties for chiller type applications where one of the first and second sections provides part of the interior of a chiller wall, and the other of the first and second sections provides part of the exterior of that chiller wall. Embodiments of the invention also find application in temperature controlled buildings and other structures.

Preferably the first and second sections comprise concrete material. In this way the construction element exhibits the advantageous characteristics of fire resistance, hardness and rigidity at the first and second sections while also exhibiting low thermal conductivity by way of the tyre bale core.

Generally, concrete itself is a conductor of heat and is generally unsuitable by itself for application in cool rooms, chill rooms or refrigerated rooms. By having the first and second sections insulated from each other by the core, a suitable construction element can be provided for such applications.

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0 It is to be appreciated that embodiments of the construction element may find application in the construction of structures ranging from retaining walls to commercial buildings to houses. Other applications include commercial chillers 0 and controlled atmosphere rooms, warehouses, sea walls, fire rated partition walls, bulk storage buildings, roadways and acoustic walls.

The first and second sections may be fixed to the bale by way of concrete portions thereof having travelled through and solidified in interstices in the bale.

O The use of concrete allows the construction element to be used as a fully (1 resolved building system. Furthermore the relatively low density of the core provides for a relatively light weight construction element that can be more readily handled than concrete walls in tilt up systems. Thus while previous attempts have failed to provide a relatively light weight construction element for use in the construction of a concrete wall exhibiting the beneficial characteristics of concrete, embodiments of the present invention provide a viable solution.

Embodiments of the invention involving concrete and rubber are particularly suited to applications directed to seawalls, wharves, breakwaters and canal walls where the resistance of concrete and rubber to salt water are advantageous.

Preferably the first and second sections and the core define a void extending around the core. When a number of construction elements are located side by side to form a course and a number of such courses are stacked to form a first wall face comprising the first planar faces, and a second wall face comprising the second planar faces, with the cores of the elements extending therebetween, the voids may be filled with filler material such as polyurethane.

Thus one arrangement of the invention may comprise a wall formed of the construction elements as defined above which elements are located side by side to form a course and a number of such courses are stacked to form the wall, the first wall face thereof comprising the first planar faces, and a second wall face thereof comprising the second planar faces, with the cores of the elements extending therebetween.

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Filling the voids improves the insulation qualities of the wall between the first and second wall faces. Consequently embodiments of the invention relatively efficiently block the thermal flow of heat from the first wall face to the second wall 00 face thereby producing an insulating effect.

It is known that gaps allow the flow of drafts that aid heat flow. Thus it is 1 preferred that the first and second walls faces provided by the first and second portions have means to blocks drafts.

OPreferably shaped connecting means connect, and are fixed between, the core ci and first and second sections. Preferably the connecting means are pins.

Preferably the first and second sections include ends that contain openings that are located inwardly of the planar faces and face substantially perpendicularly thereto, the openings for use in connecting the construction element to another construction element that includes connecting means for connecting with the openings.

Preferably the openings contain sockets for receiving corresponding male elements. The sockets may be adapted to receive lifting lugs for lifting the construction element from one position to another. The sockets may be threaded.

Preferably both a top and a bottom end of the construction element contain the openings such that the construction element is adapted to take part in the stacking of construction elements of the same arrangement in an overlapping brick pattern with male elements extending from openings in the top ends of the elements to openings in the bottom ends of elements stacked thereon.

Preferably in the construction element the openings in the bottom end include passages that allow for the downward flow of fixing material over the male elements to fix the male elements when disposed in those openings.

-7- Preferably the elements contain roofing openings for connection to roof members.

oo Preferably the construction element contains a face opening extending from one of the planar surfaces towards the other of the planar surfaces, the opening for receiving a corresponding male element. With this preferred arrangement, when one end of the corresponding male element is located in say a concrete base providing a floor, the construction element may be readily located relative to the 1 base by locating the free end the male element in the face opening. Such an 0 arrangement may provide for reinforcement of the structural integrity of the base S 10 and construction element.

Preferably the bale of material comprises whole tyres bound together to form a bale.

Embodiments of the construction element have an insulation value of R41.6 and are able to withstand up to 150 tonnes of pressure.

According to a second aspect of the invention there is provided a method of constructing a wall including: stacking a course of construction elements in accordance with the first aspect of the invention on top of another course of construction elements so as to provide a first wall face comprising the first planar faces, and a second wall face comprising the second planar faces, with the cores of the elements extending therebetween.

Preferably gaps between the construction elements are covered with an industry standard thermal shield and hermetic seals to prevent drafts.

According to a third aspect of the invention there is provided a method of constructing a construction element, the method comprising: -8forming opposed first and second sections of relatively rigid material on opposed sides of a core such that the first and second sections are disjoint and thermally insulated from each other by the core, and the opposed first and second sections respectively present opposed planar faces facing 00 outwardly away from the core.

Preferably the method includes fixing connecting means on the opposed sides of the core such that the connecting means extend therefrom, and said forming N forms the opposed first and second sections on the core so that the connecting 0 means extend into both those second sections.

According to a fourth aspect of the invention there is provided a method of constructing a construction element, the method comprising: fixing connecting means on opposed sides of a core comprising a bale of material so that the connecting means extend therefrom; and forming opposed first and second sections of relatively rigid material on the opposed sides so that the connecting means extend into the first and second sections and the first and second sections are disjoint; wherein the first and second sections present opposed planar faces facing outwardly away from the core; and the first and second sections are thermally insulated from each other by the core.

Preferably forming the opposed first and second sections includes: disposing the first opposed side in a mould and solidifying a first amount of material about the connection means that extend from the first opposed side, so as to form the first section; and subsequently inverting the core and disposing the second opposed side in a corresponding mould and solidifying a second amount of material about the connection means that extend from the second opposed side so as to form the second section.

-9- 0 Preferably the moulds are removed once the first and second amounts of material have solidified to a predetermined strength.

Other aspects of the invention will be apparent from a reading of the specification 00 as a whole. For example, the invention provides a particular fixing mechanism.

Brief Description of the Drawings The invention will be better understood by reference to the following description Sof several specific embodiments thereof as shown in the accompanying drawings Cin which: Figure 1 is a perspective view of a construction element according to a first embodiment of the invention; Figure 2 is a front view of the construction element shown in Figure 1; Figure 3 is a plan view from above of the construction element shown in Figure 1; Figure 4 is an end view of the construction element shown in Figure 1; Figure 5 is a sectional end view of the construction element shown in Figure 1; Figure 6 is a front view of a first planar face of a wall containing the construction element shown in Figure 1 and construction elements of the same arrangement; Figure 7 is a sectional view of a wall made using a method of construction according to a second embodiment of the invention, the method using the construction element of Figure 1; Figure 8 is an end view of a mould frame for use in construction of the construction element shown in Figure 1; Figure 9 is a plan view from above of the mould frame shown in Figure 8; Figure 10 is a schematic view of a method in accordance with a third embodiment of the invention, the method for constructing the construction element shown in Figure 1; Figure 11 is a schematic section view of a fixing mechanism in accordance with a further embodiment of the invention; Figure 12 is a schematic underside view of the fixing mechanism shown in Figure 11; Figure 13 is a schematic perspective view of the fixing mechanism shown in Figures 11 and 12 incorporated into a construction element at four locations; Figure 14 is a schematic perspective view of a construction element according to another embodiment of the invention.

Best Mode(s) for Carrying Out the Invention A construction element 10 in accordance with a first embodiment of the invention is shown in Figures 1 to 5. The construction element 10 has improved weight and insulating properties when compared to a comparably sized solid concrete block.

The construction element 10 comprises a core 12 in the form of a bale 14 of used vehicular tyres. The tyres are held together by a plurality ties 15 as shown in Figure 3. The core 12 has a first end 16 and a second end 18 that are respectively fixed to a first section 20 and a second section 22 of the construction element The first and second sections 20, 22 respectively present opposed planar faces 24, 26 which face outwardly away from the core 12.

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0 Both the first section 20 and the second section 22 comprise reinforced concrete material. This makes the construction element 10 suitable for use in applications where fire resistance, rigidity and hardness associated with concrete are 0 required.

The bale 14 is formed by laying a first row of tyres against each other on their IN walls. After this a further row of tyres is placed on top of the first layer such that the further row of tyres leans in the opposite direction. Eight such layers are provided and the bale 14 is produced using a press. As described, ties 15 are 0provided that hold the tyres together. US 5,214,896 describes a related process.

While structures having a high thermal mass do provide some insulating properties, such structures are also often heat absorbers in the sense that they act as heat reservoirs. Such structures commonly absorb heat in the summer and the hold the heat so as to cause an increased cooling load, should air conditioning be employed. Basically such a situation arises because the temperature of the structure does not depend that greatly on how much heat is released during cooling. Similarly, in winter, such structures absorb cold, increasing the heating load, should air conditioning be employed.

Even though one would think that construction element 10 would act as a thermal reservoir, construction element 10 has good thermal properties in the sense that the element has a low thermal conductivity from the first section 20 to the second section 22 and vice versa. This arises because of the insulating properties of bale 14 and the fact that the first and second sections 20, 22 are disjoint so that the insulating properties of the core 12 are not negated by the presence of a thermal bridge.

The construction element 10 is relatively light in comparison to a similarly sized block of concrete material which would be comparatively heavy. This occurs because of the relative lightness of the core 12. Such a reduction in weight makes the construction element 10 more readily handled by lifting apparatus. In the construction of commercial buildings use of the element provides a viable alternative to lift up wall systems.

-12o By virtue of used tyres being utilised by the construction element 10 a useful area of application is provided which serves to reduce the ecological problems Sassociated with storage and disposal of used tyres. Furthermore, construction oo element 10 has both the beneficial qualities of concrete together with reduced weight and low thermal conductivity between the two opposing planar faces 24, 26. Previous attempts at producing such an element have failed.

In this arrangement, the construction element 10 is 900 mm wide, 1650 mm long ci and 1500mm high. This size is thought to be suitable for use in constructing 0 commercial buildings. It is to be appreciated however that other sizes may be (1 10 more suited to other applications such as domestic housing.

For strength, and to limit shrinkage, the reinforced concrete of the first and second sections 20, 22 comprises a 32 MPa mix having a super plasticiser to limit shrinkage. US 5,172,528 provides a related process.

A void 28 is defined by the first and second sections 20, 22 and the core 12, so that the void 28 extends around the core 12. The presence of void 28 shows an absence of a substantial thermal bridge that would otherwise be present if the core 12 was encased in concrete.

The first and second sections 20, 22 are fixed to the core 12 with the use of a number of connecting means 34. The connecting means 34 are provided in the form of a number of connecting pins 34 that extend outwardly away from the core 12 into the first and second sections 20, 22 so as to fix the core 12 thereto.

The first and second sections 20, 22 are also connected to the bale 14 by having previously flowed through and solidified in interstices formed by the tyres of the bale 14. The connecting pins 34 are however the primary means of attachment of the first and second portions 20, 22 to the core 12.

As shown in Figure 1 the core 12 includes a first end 36 and a second end 38.

The first end 36 corresponds with a top end of the construction element 10 and the second end 38 corresponds with a corresponding bottom end.

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0 Referring to Figures 1 and 2 the top and bottom ends 36, 38 include a plurality of openings 40 in the first and second sections 20, 22. The openings 40 are located inwardly of the planar faces 24, 26 and face in a direction substantially OO perpendicularly to those planar faces.

In the construction element 10 each of the openings 40 provides a socket 42 in N which a respective male element can be located. The sockets 42 are used for connecting the construction element 10 to another construction element of the same arrangement. For ease of explanation the sockets in the top section 36 Care referred to as sockets 43 while the sockets in the bottom end 38 are referred to as socket tubes In the construction element 10 cast in ferrules are provided in the sockets 43 while the tubes 45 are provide in the form of grout tubes allowing the flow of grout. As shown in Figure 6, each of the sockets 43 and grout tubes 45 is positioned so that when construction element 10 is stacked on top and midway along two adjoining construction elements 46, 48 of the same arrangement, each tube 45 lies directly over one of respective sockets 50 in the top ends of the two adjoining construction elements. Sockets 50 are of the same arrangement as sockets 43 in the top end 36 of the construction element 10. Each of the sockets 43 is also aligned with tubes 52 corresponding with the tubes 45 of the construction element Figures 2 and 3 show that each of the sockets 43 and 45 in the construction element 10 are centrally located in the first and second sections 20, 22 and are also spaced about one quarter of the length of the construction element 10 from each side 46 thereof. This ensures that the construction element 10 can be used to form an interlocking brickwork pattern of wall 54 in Figure 6. Half length construction elements will of course be required to finish a wall having a terminating end. One such half length construction element 55 is shown in Figure 6.

Specially shaped corner construction elements are provided for forming walls that change in direction to form a corner. Such corner construction elements -14include elements having right angled first and second sections and also elements having a mitred core and mitred first and second sections. The corner elements maintain the separation of the respective first and second sections so that the sections are disjoint and are thermally insulated by the cores.

00 It will be readily apparent that constructing the wall 54 involves stacking of courses of the construction elements in an overlapping brick pattem. To aid with locating the elements and to provide improved structural integrity male elements c-i in the form of starter bars 56 are located in the sockets 42 of the construction 0 block 10. As can be seen from Figure 5 tubes 45 have passages 58 that allow 0 N 10 for the insertion of fixing material in the form of grout over what in the wall 54 would be a male element 56 so as to secure the male element 56 and lock each of the construction elements in wall 54 together. Basically the sockets 45 include passages 58 which allow for the downward flow of fixing material over the male elements 56 to fix the male elements and construction elements in position.

The sockets 43 each have threaded means which enable the attachment of four lifting lugs to the construction element 10. This allows for a convention lifting systems to lift the construction elements into position.

Figure 7 shows a wall 60 made according to a method of construction of a second embodiment of the invention. The wall 60 includes a construction element 62 made in accordance with the first embodiment of the invention described above.

Included in element 62 are a plurality of openings 63 in first and second sections 64, 66. The openings 63 provide connection means for connection to roof members. The roof members connected to the first section 64 are thermally insulated from the roof members connected to the second section 66.

As can be seen from Figure 7 a number of construction elements including elements 62, 63, and 65 in three different courses of elements are stacked one on top of the other so as to form the wall 60. The stacking forms a first wall face 76 from construction elements 62, 63 and 65 and a second wall face 78 from

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O those same construction elements. Cores 80, 82 and 84 of those elements extend between the wall faces 76 and 78.

0 When viewed in isolation each of the construction elements 62, 63 and 65 would have a respective void extending all the way around their respective cores.

However in wall 60 these voids are partly occupied by insulation blankets 86 which are placed in position during construction of the wall. Filling the voids improves the insulation qualities of the wall 60 between the first and second wall faces 76 and 78. In other embodiments of the invention polyurethane is pumped into the voids surrounding the cores 80, 82 and 84 rather than the voids being partly filled by the insulation blankets 86.

Construction element 65 includes a first an opening 88 in the second wall face 78 that extends toward the first wall face 76. The opening 88 receives a male element in the form of a reinforcing starter bar 90. An end 92 of the starter bar is embedded in a ground slab 94 and the construction element 65 is located relative to the ground slab 94 by locating an opposed end 96 of the starer bar in the opening 88. In this way the location of construction element 65 is well defined and the structural integrity of the wall 60 is improved.

The method of constructing wall 60 as shown in Figure 7 is as follows. Firstly foundations are prepared as appropriate for the ground conditions that are present. With good ground conditions a trench filled with 300 mm of crushed rock to provide a footing may be appropriate.

After this a base course of construction elements including element 74 is brought into engagement with starter bar 90 in ground slab 94. A number of male elements 100 are located in openings 102 and an insulation blanket is placed on top of the cores of the base course. Following this a second course including element 63 is stacked on top of the base course. Corresponding grout tubes 104 in the second course receive the male elements 100. The method is then repeated fro a third course including element 62. With this arrangement high density plastic spacers are used between the courses to maintain even horizontal and vertical joints between the blocks.

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SFollowing this the roofing is attached by way of a steel beam and structural roof steel is then fixed thereto. After this joints between the construction elements are fitted with an backing rod and a silicon compound is used to fill and seal the 0 joints. As a final step grout is introduced into the grout tubes so as to rigidly fix the courses and male elements in place and so provide structural stability.

1In Figures 8 and 9 there is shown a mould frame 106 comprising a bottom part 107 and a top part 109 for use in constructing the construction element 10. The N mould 106 has four extensions (not shown) for the formation of sockets 43 and Sfour other extensions for the formation of tubes In Figure 10 there are detailed number of steps in accordance with a third embodiment of the invention whereby the construction element 10 of the first embodiment is produced. Opposed first and second sections 20, 22 on opposed sides 16, 18 of the core 12 are formed such that the first and second sections 22 are disjoint and thermally insulated from each other by the core 12. As before, the first and second sections 20, 22 respectively present opposed planar faces 24, 26 facing outwardly away from the core 12.

The manner of construction of element 10 is as follows. Firstly shaped connecting means are fixed to the first and second opposed sides 16 and 18 of the core 12 such that the connecting pins 34 extend therefrom. The first section 20 is then formed on side 16 of core 12 such that the connecting pins 34 on that side extend into the first section 20 so as to connect the bale 14 thereto. More particularly 125mm of 32 MPa concrete with a slump rate of 200mm is poured into the bottom part 107 of the mould 106 which is also provided with F-53 mesh 108. The core 12 is then is placed in the bottom mould 107 as shown in step 3 of Figure 10 such that the connecting means 34 on the first side 16 of the core 12 protrudes into the concrete by a depth of 50 mm. The concrete then solidifies around the connecting pins 34 to a stage when the concrete no longer is able to flow.

Following this 100mm of 32 MPa concrete with a slump rate of 200mm is poured into the top mould 109 over F-53 mesh 110. The bottom mould 107 and core 12 -17-

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0 are then inverted and second side of core 12 is disposed in the top mould 109 so that the connecting pins 34 on second side 18 of the core 12 protrude into the concrete by a depth of 50 mm. The completed block is then allowed to solidify to 0 a strength of 24 MPa before the mould 106 is then stripped to remove construction element With this method described ferrules are cast into the sockets 45 so that screw in lifting lugs can be fitted and used to roll the block through 90 degrees and allow Cthe construction element 10 to be picked up and carried about.

N Referring to Figures 11 to 13 there is shown a fixing mechanism 120 for fixing together construction elements such as construction element 10. The fixing mechanism 120 is provided in accordance with a further embodiment of the invention. The fixing mechanism 120 includes a recess means 124 and an elongate element 122. The elongate element 122 is provided in the form of a continuous reo bar.

Included in the recess means 124 are a plate 126 and a void 128 thereabove.

The void 128 is shaped to receive a nut 130 and the plate 126 includes an elongate hole 129. The plate 124 allows the nut to rest thereon and engage with a threaded end of a reo bar of another construction element of the same or similar arrangement, with the threaded end thereof extending through the hole 129. The hole 129 is elongate to provide a tolerance.

Referring to Figure 13 there is a construction element 132 including four mechanisms 134, 136, 137 and 139 of the same arrangement as mechanism 120. Each of the mechanisms 134, 136, 137 and 139 are cast into the element 132. Furthermore, each of the rods of the mechanisms have threaded portions 133 sitting proud of the top face 135 of the element 132 by about 60 mm.

To connect the element 132 to two elements of the same arrangement, sitting side by side, the element 132 is brought over these elements such that respective threaded ends 133 of the reo bars of those elements are received by elongate holes 140 of element 132. Nuts are then located in voids 142 and are -18turned to firmly fix the elements together. After this the voids 142 are filled with Sconcrete so as to secure the nuts in position and prevent them from turning.

00 The fixing mechanism 120 is therefore an alternative to the fixing system involving the tubes 43, 45 of the first embodiment. Lifting rings for moving and erection can be attached to the threaded portions 133.

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A construction element 150 according to another embodiment is shown in Figure 1 14. The element 150 is 1800 mm in length, 1500mm in height, and 900 mm 0 deep. In this arrangement two connecting means 152 extend from the base of Seach end section 154 to the top opposite end of their respective sections 154. At the base they each provide an opening 155, by way of a slotted washer 156, and at the top they each provide a corresponding male element 156 having a thread. The sections 154 are 125 mm thick and are formed for 32 Mpa, 200 slump concrete with 20mm aggregate and F56 mesh. The connecting means 152 comprise one continuous steel rod with a thread on one end and a triangle with a slotted steel washer at the other forming the opening 155.

In the element 150 a tyre bale 158 is connected to the sections 154 by six 200mm coach screws 160 that pass through each section 154 and join with the bale 158.

It will accordingly be seen that the core of tyre material 158 provides a highly desirable outcome for the use of old or rejected tyres. Furthermore the construction element 150 meets the need in the commercial market for an alternative to the use of Expanded Polystyrene (EPS) for temperature controlled buildings which has associated fire risks. Walls constructed using the construction elements have relatively high fire retardation properties. The core of tyre material 158 if properly treated can also be made fire retardant.

The method of construction described offers an alternative to the common tilt up method used in the construction industry. Rather than being titled up, the walls are made from construction elements that are built upwards by lifting from the ground and stacking in position.

-19o Variations of the invention that would be apparent to a person skilled in the art are within the scope of this disclosure. For example the voids between adjacent construction elements may be filled with filler to improve the insulation qualities oo of the wall. The male elements may be galvanized or made from plastics material.

SThroughout the specification, unless the context requires otherwise, the word ,6 "comprise" or variations such as "comprises" or "comprising", will be understood c to imply the inclusion of a stated integer or group of integers but not the 0 exclusion of any other integer or group of integers.

Claims (20)

1. A construction element comprising: a core having a first and a second end 00 respectively fixed to a first and a second section of relatively rigid material, the first and second sections presenting opposed first and second planar faces facing outwardly away from the core; wherein the first and second sections are disjoint and thermally insulated from each other by the core.

2. A construction element as claimed in claim 1 wherein the core is formed substantially from vehicular tyre material.

3. A construction element as claimed in claim 1 or 2 wherein the core is formed from used or recycled tyres that are held together by bale means which dispose the core in the form of a bale.

4. A construction element as claimed in any one of claims 1 to 3 wherein the core is held together by fixing means in the form of ties or straps. A construction element as claimed in any one of claims 1 to 4 wherein the first and second sections include ends that contain openings that are located inwardly of the planar faces and face substantially perpendicularly thereto, the openings for use in connecting the construction element to another construction element that includes connecting means for connecting with the openings.

6. A construction element as claimed in claim 5 wherein the openings contain sockets for receiving connecting means in the form of corresponding male elements.

7. A construction element as claimed in claim 6 wherein the sockets are adapted to receive lifting lugs for lifting the construction element from one position to another. -21-

8. A construction element as claimed in any one of claims 5, 6 or 7 wherein a top and a bottom end of the construction element contain the openings such that the construction element is adapted to take part in the stacking of 00 construction elements of the same arrangement in an overlapping pattern with male elements extending from openings in the top ends of the elements to openings in the bottom ends of elements stacked thereon. IND S9. A construction element as claimed in claim 8 wherein the openings in the N bottom end include passages that allow for the downward flow of fixing Smaterial over the male elements to fix the male elements when disposed in those openings. A construction element as claimed in any one of claims 1 to 9 wherein the construction element contains a face opening extending from one of the planar surfaces towards the other of the planar surfaces, the opening for receiving a corresponding male element for the purpose of locating the construction element adjacent a structure.

11. A construction element as claimed in any one of claims 1 to 10 suitable for use in a temperature controlled structure wherein one of the first and second sections is adapted to provide part of the interior of the structure, and the other of the first and second sections is adapted to provide part of the exterior of the structure.

12. A construction element as claimed in any one of claims 1 to 11 wherein the first and second sections comprise concrete material.

13. A construction element as claimed in any one of claims 1 to 12 wherein the first and second sections are be fixed to the core by way of concrete portions thereof having travelled through and solidified in interstices in the core.

14. A construction element as claimed in any one of claims 1 to 13 wherein the first and second sections and the core define a void extending around the core. -22 O 0 15. A construction element as claimed in any one of claims 1 to 14 including connecting means fixed between and connecting the core and first and second sections. 00

16. A construction element as claimed in claim 15 wherein the connecting means comprise pins. S17. A wall comprising construction elements as claimed in any one of claims 1 to N 16 in which the elements are located side by side to form a course and a 0 number of such courses are stacked to form the wall, the first wall face N thereof comprising the first planar faces, and a second wall face thereof comprising the second planar faces, with the cores of the elements extending therebetween.

18. A wall as claimed in claim 17 wherein the first and second sections and core of each element define a void extending around that core, and each void is filled with filler material during construction of the wall.

19. A wall as claimed in claim 17 or 18 wherein the first and second walls faces include means for blocking drafts. A method of constructing a wall including stacking a course of construction elements as claimed in any of claims 1 to 19 on top of another course of construction elements so as to provide a first wall face comprising the first planar faces, and a second wall face comprising the second planar faces, with the cores of the elements extending therebetween.

21. A method of constructing a construction element, the method comprising: forming opposed first and second sections of relatively rigid material on opposed sides of a core such that the first and second sections are disjoint and thermally insulated from each other by the core, and the opposed first and second sections respectively present opposed planar faces facing outwardly away from the core. -23

022. A method as claimed in claim 23 including fixing connecting means on the opposed sides of the core such that the connecting means extend therefrom, and said forming includes forming the opposed first and second sections on the core such that the connecting means extend into both those second sections.

23. A method as claimed in claim 22 wherein the each connecting means provides an opening on one side of a first or second sections and which 1 means extends through to an opposite side of that section to provide a male Oelement extending therefrom.

24. A method of constructing of a construction element, the method comprising: fixing connecting means on opposed sides of a core comprising a bale of material so that the connecting means extend therefrom; and forming opposed first and second sections of relatively rigid material on the opposed sides so that the connecting means extend into the first and second sections and the first and second sections are disjoint; wherein the first and second sections present opposed planar faces facing outwardly away from the core; and the first and second sections are thermally insulated from each other by the core. A method as claimed in claim 24 wherein forming the opposed first and second sections includes: disposing the first opposed side in a mould and solidifying a first amount of material about the connection means that extend from the first opposed side, so as to form the first section; and subsequently inverting the core and disposing the second opposed side in a corresponding mould and solidifying a second amount of material about the connection means that extend from the second opposed side so as to form the second section.

26. A method as claimed in claim 24 or 25 wherein the moulds are removed once the first and second amounts of material have solidified to a predetermined strength. -24- 0 27. A method substantially as herein described with reference to the accompanying drawings.

28. A construction element substantially as herein described with reference to oo the accompanying drawings. 0 Dated this Eighteenth day of March 2005. (N Lomwest Enterprises Pty Ltd Wray Associates Perth, Western Australia Patent Attorneys for the Applicant