AU2008331422A1 - Wall construction methods - Google Patents

Description

WO 2009/070830 PCT/AU2008/001780 WALL CONSTRUCTION METHODS Background of the Invention This invention relates to a wall and a method of construction a wall, and in particular to a filled wall for using in commercial or residential buildings, or for civil works. 5 Description of the Prior Art The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to 10 which this specification relates. A wide range of wall structures and methods for constructing both dry walls and concrete filled walls are known, as described in WO 2005/019552 for example. There are a number of important characteristics such as strength and speed of construction, an option to form the wall on site rather than using preformed components, the need to involve cranes or props, and 15 cost. Flexible and efficient construction systems involve some or all of these considerations. Summary of the Present Invention In a first broad form the present invention provides a method of constructing a wall, the method including: a) providing first and second spaced apart wall portions for receiving a filling material, 20 each wall portion including: i) at least one track on a support; ii) at least two support members, each support member being aligned with the track and extending from the support; iii) a wall panel supported by the at least one track and the at least two support 25 members; iv) at least one joining member coupled to the wall panel and the support members; b) providing spacers coupled to and extending between the wall portions.

WO 2009/070830 PCT/AU2008/001780 -2 Typically each track and each support member includes a channel, and wherein the method includes providing the wall panel in the channels. Typically the method includes, constructing each wall portion by: a) attaching the track to the support; 5 b) attaching the support members to the track; and, c) mounting the wall panel to the track and the support members. Typically the method includes, attaching the track to the support using a fixing plate. Typically the method includes, attaching two tracks to the support using a fixing plate adapted to engage each of the tracks, the fixing plate defining a separation between the first 10 and second wall portions. Typically each track includes a ridge for engaging the fixing plate and wherein the method includes, positioning the tracks on the support, and engaging the ridge with a corresponding recess on the fixing plate. Typically the method includes coupling the fixing place to the support using at least one 15 fastening element. Typically the method includes attaching the support members to at least one of the track and a joining member using at least one fastening element. Typically the method includes providing the fastening element on a side of the support member positioned between the two wall panels of the first and second wall portions. 20 Typically the at least one fastening element includes a screw. Typically the method includes attaching the spacer to the joining member. Typically the joining members include channels, and wherein the method includes coupling each spacer to a channel of a joining member in each wall portion. Typically each spacer includes channel engaging portions, and wherein the method includes: WO 2009/070830 PCT/AU2008/001780 -3 a) providing the spacer with each channel engaging portions being positioned within a spacer channel of a respective joining member; and, b) rotating the spacer to thereby couple the spacer to the spacer channels. Typically the method includes: 5 a) providing the spacer between the joining members; and, b) rotating the spacer so that the channel engaging portions are positioned within a spacer channel of a respective joining member. Typically the method includes: a) coupling a number of spacers to the wall portions; and, 10 b) positioning at least one reinforcing member between the wall portions so that the reinforcing member is supported by the spacers. Typically the method includes positioning the at least one reinforcing member on a concave surface of the spacers. Typically the method includes attaching a second wall panel to the joining member and the 15 support members so that the second wall panel is positioned substantially above the wall panel. Typically the method includes, constructing each wall portion by attaching further joining members and further wall panels so that the wall portion has a required height. Typically the method includes, providing a number of wall panels in the track, each wall 20 panel being coupled to two supporting members, so that the wall portion has a required length. Typically the method includes: a) providing a number of wall portions arranged so as to define an enclosed space between the wall portions; and, 25 b) filling the space with filling material to thereby form at least part of a wall.

WO 2009/070830 PCT/AU2008/001780 -4 Typically the method includes bracing at least part of the wall prior to filling the space with filling material. In a second broad form the present invention provides apparatus for constructing a wall, the apparatus including: 5 a) first and second spaced apart wall portions for receiving a filling material, each wall portion including: i) at least one track on a support; ii) at least two support members, each support member being aligned with the track and extending from the support; 10 iii) a wall panel supported by the at least one track and the at least two support members; iv) at least one joining member coupled to the wall panel and the support members; and, b) spacers coupled to the wall portion. 15 Typically the each track and each support member includes at least one channel for receiving wall panels. Typically the at least one support member includes at multiple channels for receiving wall panels of different wall portions. Typically the at least one support member is formed from an extrusion. 20 Typically the apparatus further includes a fixing plate for attaching the track to the support. Typically each track includes a ridge for engaging a corresponding recess on the fixing plate. Typically the fixing plate includes at least one aperture for receiving at least one fastening element for coupling the fixing place to the support. Typically the apparatus includes at least one fastening element for attaching ach support 25 member to at least one of the track and a joining member. Typically the at least one fastening element includes a screw.

WO 2009/070830 PCT/AU2008/001780 -5 Typically the joining members include channels for receiving the spacers. Typically each spacer includes channel engaging portions for engaging the channel upon rotation of the spacer. Typically the apparatus includes at least one reinforcing member positioned between the wall 5 portions so that the reinforcing member is supported by the spacers. Typically the spacer includes a concave surface for receiving the reinforcing member. Typically the apparatus includes a second wall panel coupled to the joining member and the support members so that the second wall panel is positioned substantially above the wall panel. 10 Typically the apparatus includes further joining members and further wall panels arranged so that the wall portion has a required height. Typically the apparatus includes, a number of wall panels provided in the track, each wall panel being coupled to two supporting members, so that the wall portion has a required length. 15 In a third broad form the present invention provides a method of building a wall, the method including: a) locating one or more studs to form a framework for the wall; b) attaching a first pair of panels in parallel on opposite sides of the framework; c) attaching a pair of joining members along respective upper edges of the panels; 20 d) connecting the joining members together with a plurality of spacers; and, e) attaching a second pair of panels on opposite sides of the framework, with lower edges of the second panels located in respective joining members. Typically the method further includes connecting each spacer to the pair of joining members by holding the spacer between the members, rotating the spacer about a vertical axis in the 25 framework until end portions of the spacer contact respective members, and then rotating the spacer about a horizontal axis in the framework to engage the end portions with the members.

WO 2009/070830 PCT/AU2008/001780 -6 Typically the method further includes connecting each spacer to the pair of joining members includes holding the spacer between the members, rotating the spacer about a transverse axis until end portions of the spacer contact respective members, and then rotating the spacer about a longitudinal axis to engage the end portions with the members. 5 Typically each joining member includes a longitudinal channel having a relatively narrow mouth, and each spacer has a pair of end portions with respective tongues, wherein each tongue is shaped to fit through the mouth of the channel in a first orientation and then to engage the channel when rotated to a second orientation. Typically the method further includes: 10 a) attaching a second pair of joining members to upper edges of the second panels; b) connecting the second pair of joining members together with a plurality of spacers; and, c) attaching a third pair of panels on opposite sides of the framework, with lower edges of the third panels located in respective joining members. 15 Typically the method further includes completing the wall by adding further joining members, spacers and panels in sequence, until the wall reaches a required height and length. Typically the method further includes: a) locating a bottom track as part of the framework; b) locating the vertical studs on the bottom track; and 20 c) locating lower edge portions of the first pair of panels in the base plate. Typically the method further includes adding further vertical studs to the framework, between existing studs, after the first pair of panels has been attached to the framework. Typically each vertical stud is formed as a pair of vertical members connected by a plurality of spacers. 25 Typically the method further includes filling the wall a filler material. In a fourth broad form the present invention provides a wall including: WO 2009/070830 PCT/AU2008/001780 -7 a) multiple panels provided in each of two spaced wall portions; b) joining members for joining adjacent panels in each wall portion; and, c) spacers for connecting joining members in the spaced wall portions. Typically each wall portion includes a framework. 5 Typically the framework includes vertical studs, and the panels and joining members are attached horizontally to the studs. In a fifth broad form the present invention provides joining member for wall panels, including: a pair of channels which are parallel and open in opposite directions, for receiving edge portions of coplanar panels, and a third channel opening perpendicular to the pair of 10 channels, for engaging an end portion of a spacer. Typically each of the pair of channels has a width which is uniform from a mouth to a respective base, and the third channel has mouth which is relatively narrower than the respective base. Brief Description of the Drawings 15 An example of the present invention will now be described with reference to the accompanying drawings, in which: Figure 1 is a schematic side view of an example of a wall; Figure 2 is a schematic plan view of the wall of Figure 1; Figure 3 is a schematic end view of the wall of Figure 1; 20 Figure 4A is a schematic perspective view of the wall of Figure 1 during a first construction step; Figure 4B is a close-up schematic perspective view of one of the spacers of Figure 4A; Figure 5A is a schematic perspective view of the wall of Figure 1 during a second construction step; 25 Figure 5B is a close-up schematic perspective view of one of the reinforcing bars of Figure 5A; Figure 6A is a schematic perspective view of the wall of Figure 1 during a third construction step; WO 2009/070830 PCT/AU2008/001780 -8 Figure 6B is a close-up schematic perspective view of a joining strip of Figure 6A; Figure 6C is a close-up schematic perspective view of the installation of a spacer of Figure 6A; Figure 7A is a schematic perspective view of the wall of Figure 1 during a fourth construction 5 step; Figure 7B is a close-up schematic perspective view of one of the studs of Figure 7B; Figure 8A is a schematic perspective view of the wall of Figure 1 during a fifth construction step; Figure 8B is a close-up schematic perspective view of one of the studs of Figure 8A; 10 Figure 9 is a schematic perspective view showing an optional straight edge profile; Figures 1 OA and 1 OB are schematic perspective views showing a first step in an example process for installing a spacer; Figures 11 A and 11 B are schematic perspective views showing a second step in an example process for installing a spacer; 15 Figure 12A is a schematic perspective view of a second example of a wall during a first construction step; Figure 12B is a schematic plan view of the wall construction step of Figure 12A; Figure 12C is a close-up schematic end view of the wall construction step of Figure 12A along the line A-A'; 20 Figure 12D is a close-up schematic plan view of a corner of the wall construction step of Figure 12A; Figure 12E is a schematic perspective view of a fitting plate of Figure 12A; Figure 13A is a schematic perspective view showing the second example of a wall during a second construction step; 25 Figure 13B is a schematic plan view of an example of a first supporting member; Figure 13C is a schematic plan view of an example of second supporting member; Figure 13D is a schematic side view of a fixing plate in the wall construction step of Figure 13A; Figure 13E is a schematic perspective view of a track coupled to a support member in the 30 wall construction step of Figure 13A; Figure 13F is a schematic perspective view of a joining member coupled to a support member WO 2009/070830 PCT/AU2008/001780 -9 in the wall construction step of Figure 13A; Figure 13G is a schematic end view of a spacer in the wall construction step of Figure 13A; Figure 13H is a schematic plan view showing the use of clamps in the wall construction step of Figure 13A; 5 Figure 131 is a schematic end view of the clamps of Figure 131; Figure 14A is a schematic perspective view of the second example wall during a third construction step; Figure 14B is a schematic end view of the wall construction step of Figure 14A; Figure 15A is a schematic perspective view of the second example wall during a fourth 10 construction step; Figure 15B is a first schematic perspective view of the spacers of Figure 15A; Figure 15C is a second schematic perspective view of the spacers of Figure 15A; Figure 15D is a schematic end view of the wall construction step of Figure 15A; Figure 16A is a schematic perspective view of the second example wall during a fifth 15 construction step; Figure 16B is a schematic end view of the arrangement of Figure 16A; Figure 16C is a schematic close-up view of a bracing element of Figure 16B; and, Figure 16D is a schematic side view of a bracing member bracket. Detailed Description of the Preferred Embodiments 20 Referring to these drawings it will be appreciated that the invention can be implemented in various ways for a wide range of wall structures. These embodiments are described by way of example only. Figure 1 is a side view showing the main components of a wall having panels 10 held in place by vertical support members in the form of studs 11 and horizontal support members in the 25 form of horizontal joiners 12. The vertical studs are mounted on a bottom track 13 which in turn is typically fastened to a slab or other foundation. An optional corner post 14 can also be provided. A wall of this kind is typically a double sided structure intended to filled with concrete for a commercial, e residential building or civil works.

WO 2009/070830 PCT/AU2008/001780 -10 The vertical studs in Figure 1 are each formed by a pair of vertical strips 20 separated by spacers 21, such as shown in WO 2005/019552. The horizontal joiners are similarly each formed by a pair of horizontal strips 22 separated by spacers 23. The vertical strips 20 and horizontal strips 22 are typically formed from metal such as extruded aluminium. Spacers 21 5 and 23 are typically formed from plastic. These strips and spacers can take a range of different shapes. Panels 10 are typically of a synthetic material depending on the particular building under construction. Figures 2 and 3 are top and end views of the wall respectively, showing in more detail how the horizontal joiners in Figure 1 are formed from the strips 22 separated by spacers 23. Steel 10 reinforcing members 25 may also be provided. Figures 4 to 10 outline the main steps in construction of a wall such as shown in Figures 1 to 3. In Figure 4, bottom tracks 13 have been fixed to a slab, and a stud 40 has been formed vertically on the track. Another vertical stud is formed towards the other end of the track. 15 The studs can be pre-assembled from a pair of strips 41 and about ten or more spacers 42. Braces 43 on the vertical stud are temporary. Vertical reinforcement starter bars 44 were included in the slab. In Figure 5 a row of panels 50 have been fitted to the bottom track and the vertical stud 40, one panel each side of the vertical stud to form a central space. The lower edge of each panel 20 fits in a slot in the bottom track. These may be formed from any suitable material, such as cement sheeting panels, metal panels, plastic, or the like, depending on the preferred implementation. Similarly, the central space will normally be filled with concrete or another suitable material having desired acoustic, structural or thermal properties. A reinforcing bar 51 has also been added. 25 In Figure 6 a horizontal joiner 60 having a pair of parallel joining strips 61 has been attached to the upper edges of the panels 50. The joining strips are connected by spacers 62 which are put in place by a sequence of manual actions described further below.

WO 2009/070830 PCT/AU2008/001780 - 11 In Figure 7 additional vertical studs 70, 71 have been included and fastened to the horizontal joiner 60. The location and height of these studs is determined by the features which are required in this particular wall. In Figure 8 further rows of panels 80 and 81 are added to increase the height of the wall, 5 using joining strips and spacers as described in relation to Figure 6. Vertical reinforcing rods 83 have also been added. Figure 9 shows an alternative wall construction using one or more additional braces as a straight edge profile. A stud 90 is located at one end of the wall, and another is typically also located at another end (not shown). Temporary braces 91 are used between the studs to 10 support panels 92 until the wall is filled with concrete. Figures 10 and 11 relate to the horizontal joiners 60 in Figure 6 and show steps in locating a spacer 62 between joining strips 61. Each joining strip has a cross section with a pair of opposed channels 100 which receive the edges of vertically adjacent panels, and a transverse channel 101 which receives one end of a spacer 62. The spacer has end portions 102 which 15 are shaped to fit transverse channels 101. In Figure 10, the first step when connecting a pair of joining strips involves manually locating a spacer between the strips and rotating about a vertical axis, until the end portions of the spacer are aligned with the transverse channels in the strips. The spacer is then perpendicular to the strips. 20 In Figure 11, the second step involves a second rotation about a horizontal axis to engage the end portions of the spacer with the transverse channels in the strips, and thereby lock the spacer in place. In the above described example, the use of studs is for the purpose of illustration only, and is not essential to the operation of the system, as will be apparent from the following example. 25 It will therefore be appreciated that throughout the above example, the studs should be considered as optional.

WO 2009/070830 PCT/AU2008/001780 - 12 A second example of a wall construction method and constructed wall will now be described with reference to Figures 12 to 16. As will be described in more detail below, the method of constructing the wall typically involves providing first and second spaced apart wall portions for receiving a filling material 5 therebetween. For the purpose of this example, the wall is shown with four wall portions defined generally the tracks 1210, 1211, 1212, 1213. In this example, a first pair of first and second wall portions are arranged to provide a first wall 1660, with the second pair of wall portions being arranged to provide a second wall 1661 extending from the first wall at a 90* corner, as shown in Figure 16A. It will be appreciated that this is for the purpose of example 10 only, and that in practice any suitable arrangement may be used. Once formed, a wall portion includes at least one track 1210 provided on a support 1200 and at least two support members 1223, 1225 aligned with the track 1210 and extending from the support 1200, allowing a wall panel 1300 to be supported by the track 1210 and the support members 1223, 1225. A joining member 1330 is also typically coupled to the wall panel 15 1300 and the support members 1223, 1225, so that each edge of the panel is surrounded by a frame formed from the track 1210, the support members 1223, 1225 and the joining member 1330. It will be appreciated that other wall portions have a similar arrangement. Spacers 1350 can be provided coupled to and extending between spaced apart wall portions, thereby maintaining the spaced apart relationship between the wall portions, and adding strength to 20 the resulting wall. A first construction step is shown in Figure 12A to 12E. In this example, the wall is constructed in a support 1200, such as a building foundation, concrete slab or the like. The support 1200 typically includes one or more starter bars 1201 extending upwardly therefrom. The starter bars are used in providing reinforcing as will be appreciated by a person skilled in 25 the art. In this example, the wall construction method involves initially positioning a number of tracks 1210, 1211, 1212, 1213, which are held in position by respective fixing plates 1215. The tracks may be of any suitable form but typically, as they are elongate and have a WO 2009/070830 PCT/AU2008/001780 -13 substantially consistent cross section, they are made of aluminium or another suitable material that can be shaped during an extrusion process. As shown for example in Figure 12C, each of the tracks 1210, 1211, 1212, 1213 includes a channel 1210A, 1211 A for receiving a wall panel, and a mounting portion 1210B, 1211 B 5 having a ridge 1211 C, 1210C provided thereon. The ridge 1210C, 1211 C runs along the length of the track 1210, 1211, 1212, 1213 and in use cooperates with a corresponding recess 1215A, provided in the fixing plates 1215, to thereby retain the tracks 1210, 1211, 1212, 1213 in position. In use, the mounting plates may be fixed to the support 1200 a suitable fastening method. In one example, this is achieved via fastening elements, such as fastening 10 screws 1216, although any suitable technique may be used. A number of upright support members 1221, 1222, 1223, 1224, 1225, 1226 are coupled to the tracks via appropriate fastening elements, such as fastening screws, shown generally at 1230, 1231. It will be appreciated that the tracks 1210, 1211, 1212, 1213 are positioned to ensure that the 15 final layout of the wall is as required. In this regard, as the fixing plates 1215 are of an identical size, and are coupled to the ridges 1210C, 1211 C, this results in an arrangement in which the tracks 1210, 1211 and the tracks 1212, 1213 are provided in a parallel spaced apart arrangement. Accordingly, the use of the fixing plates 1215 ensures that each of the tracks in a given pair of tracks 1210, 1211; 1212, 1213 are parallel to each other. 20 Further guidance can be provided by the support members 1221, 1222, 1223, 1224, 1225, 1226. For example, as shown in Figure 12D, and as will be described in more detail below, two different arrangements of upright support members 1223, 1224 are provided to allow adjacent tracks 1210, 1212; 1211, 1213 to be interconnected at right angles to thereby define outside and inside corners. Further support members (not shown), may be used to extend the 25 length of a wall portion, as will be described in more detail below. Accordingly, by connecting the tracks 1210, 1211, 1212, 1213 to the fixing plate 1215 and the supporting members 1221, 1222, 1223, 1224, 1225, 1226, prior to attaching the fixing plates 1215 to the support 1200, this ensures that each of the tracks in a given pair 1210, WO 2009/070830 PCT/AU2008/001780 -14 1211; 1212, 1213 are parallel to each other, with each pair of tracks being arranged at 90* This, in turn, ensures that each pair of first and second wall portions are arranged in a spaced parallel configuration to thereby form walls 1660, 1661 of a constant width, whilst also ensuring that the walls 1660, 1661 meet at 90". Furthermore, this can be achieved without 5 requiring complex measurements to be performed by the individual constructing the wall, thereby significantly simplifying in the construction process. It will be appreciated that further support members, similar in form to the joining members described in more detail below, could be used to allow wall panels to be provided adjacent to each other and connected in-line, for example to a common track, thereby extending the 10 length of each wall portion. Once the tracks 1210, 1211, 1212, 1213 and the support members 1221, 1222, 1223, 1224, 1225, 1226 have been configured as shown in Figure 12A, the second construction step may be performed, as will now be described with reference to Figures 13A to 131. In this example, wall panels 1300, 1301, 1302, 1303 are inserted into channels in the support 15 members 1221, 1222, 1223, 1224, 1225, 1226 and the channels 1210A, 1211A of the tracks 1210, 1211, 1212, 1213, before joining members 1330, 1331, 1332, 1333 are mounted thereon to form four wall portions, as will be described in more detail below. Examples of the support member configurations incorporating channels for receiving the wall panels are shown in Figures 13B and 13C. 20 In the example of Figure 13B, the support member 1223 is shown, which is intended to be used as an outside corner for the completed wall. This support member 1223 includes two channels 1310, 1312, each of which is adapted to receive a respective wall panel 1300, 1302. The channels include external channel walls 131 OA, 1312A, which are visible on the outside of the completed wall, and internal channel walls 13101B, 1312B, which will be located 25 within the completed wall. The support member 1223 is coupled to the tracks 1210, 1212 (shown in dotted lines), via fixing screws 1230 extending through the internal channel walls 13101B, 1312B so that in use the fixing screws are hidden from external view, as shown in Figures 13D and 13E.

WO 2009/070830 PCT/AU2008/001780 - 15 Similarly, the support member 1224 shown in Figure 13C, is intended to be used as an inside corner for the completed wall. The support member 1224 therefore includes two channels 1311, 1313, each of which is adapted to receive a respective wall panel 1301, 1303. The channels 1311, 1313 include external channel walls 1311 A, 1313A, which are visible on the 5 outside of the completed wall, and internal channel walls 13111B, 1313B, which will be located within the completed wall. The support member 1223 is coupled to the tracks 1211, 1213 (shown in dotted lines), via fixing screws 1230 extending through the internal channel walls 13111B, 1313B so that in use the fixing screws are hidden from external view, as shown in Figures 13D and 13E. 10 An end view showing the inclusion of the wall members 1300, 1301 positioned in the respective bottom tracks 1210, 1211 is shown, together with a fixing plate 1215 coupled via screws 1216 to the support 1200. As shown in this example, the projections 1210C, 1211 C may include teeth 1320 for cooperating with the recesses 1215A provided in the fixing plate 1215, thereby assisting in attaching the fixing plate to the bottom tracks 1210, 1211. 15 In addition to the above described features, once the wall members 1300, 1301, 1302, 1303 have been mounted, a respective joining member 1330, 1331, 1332, 1333 is mounted thereon and attached to the upright support members 1221, 1222, 1223, 1224, 1225, 1226 via respective mounting screws shown generally at 1340. As shown in Figure 13F the mounting screw 1340 may be included in a mounting 1341 20 which helps position the mounting screw 1340, and also enhances the appearance of the screw 1340. The joining members 1330, 1331, 1332, 1333 include upper and lower channels 1330A, 1330B, 1331A, 1331B and a spacer channel 1330C, 1331C. The joining members 1330, 1331, 1332, 1333 are arranged so that the spacer channel 1330C on a joining member 1330 25 faces the spacer channel 1331C on a joining member 1331 of an opposing wall portion. In use, a spacer 1350 is coupled to the spacer channels 1330C, 1331C to maintain the spacing between the joining members 1330, 1331, and hence between the wall portions. The spacers 1350 also include apertures shown generally at 1352, which help assist with even flow of WO 2009/070830 PCT/AU2008/001780 - 16 filling material throughout the entire wall cavity, when the wall is filled, as will be described in more detail below. In this example, the spacer 1350 also includes a concave upper surface 1351 that allows reinforcing bars 1360 to be positioned thereon, in use. Additionally, vertical reinforcing bars 5 1380 may be coupled to the starter bars, allowing vertical and horizontal reinforcing bars to be provided throughout the wall, as will be appreciated by persons skilled in the art. The spacers may be coupled to the joining members 1330, 1331 in any suitable manner. Thus, in one example, this is achieved in a manner similar to that described above with respect to Figures 1OA, 10B, 1 lA, 11 B, in which the spacer is rotated into alignment with the 10 spacer channels 1330C, 1331C, and then further rotated about a different axis into engagement with the spacer channels 1330C, 1331. However, other mounting techniques may be used. For example, it will be appreciated that the spacer channel is generally open at each end, and accordingly, this allows spacers to be slid into the spacer channels 1330C, 1331 C either prior or after installation of the joining members on the wall panels. 15 As shown in Figures 13H and 131, temporary holding members 1370, which in this example in the form of butterfly screw clamps, are used to maintain the spatial relationship between the upright support members 1223, 1224 and the joining members 1330, 1331, during construction. This assists with the construction process but is not essential. Once the wall members and joining members have been completed, a next level in the wall 20 can be constructed in the wall in a similar manner, as shown in Figure 14A. Thus, in this example, further wall panels 1400, 1401, 1402, 1403 are positioned in channels of the joining members 1330, 1331, 1332, 1333 and the support members 1221, 1222, 1223, 1224, 1225, 1226. A further set of joining members 1430, 1431, 1432, 1433 are then also coupled to the wall panels 1400, 1401, 1402, 1403 and the respective support members 1221, 25 1222, 1223, 1224, 1225, 1226. These are attached in a similar manner to the joining members 1330, 1331, 1332, 1333 described above and this will not therefore be described in any further detail. In this example, the joining members 1430, 1431 are again held in position by corresponding spacers 1450 with reinforcing bars 1460 mounted thereon, as WO 2009/070830 PCT/AU2008/001780 -17 shown in Figure 14B, and it will be appreciated that a similar arrangement is used for the joining members 1432, 1433. As shown in Figure 15A a third layer can then be mounted, with additional wall panels 1500, 1501, 1502, 1503 being coupled to the upright support members 1221, 1222, 1223, 1224, 5 1225, 1226 and the joining members 1431, 1432, 1433, 1430, in a similar manner. In this example upper finishing members 1530, 1531, 1532, 1533 are mounted thereon, which are similar in form to the joining members, but without the upper channel, so that further wall panels cannot be mounted thereto. It will be appreciated that in this example the wall is three layers high, however this is for the purpose of example only, and it will be appreciated that in 10 practice, any number of layers may be provided. As shown in Figures 15B and 15C, spacer plates 1515, similar to the fixing plates 1215, are used to maintain the spaced apart relationship between the finishing members 1500, 1501, 1502, 1503. An end view of the completed wall structure is shown in Figure 15D. Thus, as shown, the 15 separate walls are maintained in the spaced apart relationship by the spacers 1350, 1450, which support the reinforcing bars 1360, 1460 as well as by the fixing plate 1215 and the spacer plates 1515. Once the wall has been constructed to the desired height, the next step is to fill to cavity created between the wall portions with a filling material that provides desired properties, such 20 as desired thermal, acoustic and/or structural properties. In one example, the filling material is concrete. It will be appreciated, however, that other filling materials may be used depending on the preferred implementation. Thus, for example, the filling material may include a material that provides improved thermal or acoustic insulating properties if insulating walls are required. 25 Prior to filling, the wall may be braced to provide additional support. In one example, to achieve this upright bracing members 1600, 1601 coupled to the support 1200 via a bracket 1602, 1603. Arms 1604, 1605 extend from an upper end of the buttress support 1600, 1601 and are mounted in the ground 1610 to provide support.

WO 2009/070830 PCT/AU2008/001780 - 18 Each bracing member 1600, 1601 also includes bracing elements 1620, 1621 which affix to the joining members, such as the joining members 1330, 1430, in this example, thereby providing additional support during the filling process. The bracing element 1620 is shown in more detail in Figure 16C. As shown the bracing element includes a screw piece 1640 5 which extends into the bracing member 1600 and which is coupled via a bracket 1641 to arms 1642, that are urged against the respective joining member 1330, 1430 thereby holding the joining member 1330, 1430 in position. The bracket 1602 is shown in more detail in Figure 16D. As shown the bracket prevents movement of the bracing member 1600, 1601 away from the wall, thereby ensuring that bracing is maintained during filling of the cavity. 10 It will be appreciated that in use, each of the wall portions may be braced, allowing the wall to be filled with filling material, without risk of this damaging the wall portions. Once filled, and the filling material is set, the strength of the wall is increased, allowing the bracing to be removed. It will be appreciated that in filling the wall, it is necessary to define a cavity. In the current 15 example, this can be achieved through the use of end panels 1630, 1631. However, this is for the purpose of example only, and in practice, this may be achieved in part by the configuration of the wall portions, as will be appreciated by a person skilled in the art. Accordingly, the above described examples provide a method and apparatus for constructing a wall. The walls are straightforward to construct, and can be built using a limited number of 20 components coupled together in a modular fashion. It will be appreciated that this allows common construction elements to be used to form walls of a range of different shapes and sizes. The individual components can be interconnected easily, whilst assisting in ensuring that the wall is correctly constructed. In particular this arrangement allows the layout of the wall to 25 be defined using the tracks, with the required vertical orientation being provided by either support members or studs. This allows the wall to be constructed using relatively unskilled labour which is important in many situations, such as where there is a skilled labour shortage.

WO 2009/070830 PCT/AU2008/001780 -19 A further benefit is that the majority of components can be provided in a flat pack arrangement. This allows the wall construction materials to be easily and efficiently transported to the building site, thereby resulting in significant cost savings. A further benefit of the above described arrangement is that it can be used with a wide range 5 of filling materials. In one example, the preferred filling material is concrete as this will result in a robust wall having high strength and good noise and thermal insulation characteristics. Alternatively, different filling materials may be used such as sound insulating foams, thermal insulating materials or the like. It will also be appreciated that a combination of different materials can be used. Thus, for example, concrete could be used for the filling 10 material with sound insulating or thermal insulating materials provided therein to thereby enhance the thermal or sound characteristics of the wall. It will be appreciated from the above that the wall can be formed in a freestanding arrangement, or alternatively can be incorporated into all or part of a building or other similar structure. This allows the wall construction method to be utilised in a wide range of different 15 scenarios. It will be appreciated that the above described examples are for the purpose of illustration only and are not intended to be limiting. Thus, for example, the studs of the examples of Figures 1 to 11 may be replaced with supporting members of the arrangement of Figures 12 to 16. Similarly, in the arrangement of Figures 12 to 16, if the supporting members are 20 suitably arranged, spacers may be provided therebetween. The spacers of the first and second examples may also be used interchangeably. Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention 25 broadly appearing before described.

Claims (1)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

   1) A method of constructing a wall, the method including: a) providing first and second spaced apart wall portions for receiving a filling material, each wall portion including: i) at least one track on a support; ii) at least two support members, each support member being aligned with the track and extending from the support; iii) a wall panel supported by the at least one track and the at least two support members; iv) at least one joining member coupled to the wall panel and the support members; b) providing spacers coupled to and extending between the wall portions.

   2) A method according to claim 1, wherein each track and each support member includes a channel, and wherein the method includes providing the wall panel in the channels.

   3) A method according to claim 1 or claim 2, wherein the method includes, constructing each wall portion by: a) attaching the track to the support; b) attaching the support members to the track; and, c) mounting the wall panel to the track and the support members.

   4) A method according to any one of the claims 1 to 3, wherein the method includes, attaching the track to the support using a fixing plate.

   5) A method according to claim 4, wherein the method includes, attaching two tracks to the support using a fixing plate adapted to engage each of the tracks, the fixing plate defining a separation between the first and second wall portions.

   6) A method according to claim 5, wherein each track includes a ridge for engaging the fixing plate and wherein the method includes, positioning the tracks on the support, and engaging the ridge with a corresponding recess on the fixing plate.

   7) A method according to claim 5 or claim 6, wherein the method includes coupling the fixing place to the support using at least one fastening element.

   8) A method according to any one of the claims 1 to 7, wherein the method includes attaching the support members to at least one of the track and a joining member using at least one fastening element. 9) A method according to claim 8, wherein the method includes providing the fastening element on a side of the support member positioned between the two wall panels of the first and second wall portions.

   1O) A method according to any one of the claims 7 to 9, wherein the at least one fastening element includes a screw.

   H) A method according to any one of the claims 1 to 10, wherein the method includes attaching the spacer to the joining member.

   12) A method according to any one of the claims 1 to 11, wherein the joining members include channels, and wherein the method includes coupling each spacer to a channel of a joining member in each wall portion.

   13) A method according to claim 12, wherein each spacer includes channel engaging portions, and wherein the method includes: a) providing the spacer with each channel engaging portions being positioned within a spacer channel of a respective joining member; and, b) rotating the spacer to thereby couple the spacer to the spacer channels.

   14) A method according to claim 13, wherein the method includes: a) providing the spacer between the joining members; and, b) rotating the spacer so that the channel engaging portions are positioned within a spacer channel of a respective joining member. 15) A method according to any one of the claims 1 to 14, wherein the method includes: a) coupling a number of spacers to the wall portions; and, b) positioning at least one reinforcing member between the wall portions so that the reinforcing member is supported by the spacers.

   16) A method according to claim 15, wherein the method includes positioning the at least one reinforcing member on a concave surface of the spacers.

   17) A method according to any one of the claims 1 to 16, wherein the method includes attaching a second wall panel to the joining member and the support members so that the second wall panel is positioned substantially above the wall panel.

   18) A method according to claim 17, wherein the method includes, constructing each wall portion by attaching further joining members and further wall panels so that the wall portion has a required height. 19) A method according to any one of the claims 1 to 18, wherein the method includes, providing a number of wall panels in the track, each wall panel being coupled to two supporting members, so that the wall portion has a required length. 2O) A method according to any one of the claims 1 to 19, wherein the method includes: a) providing a number of wall portions arranged so as to define an enclosed space between the wall portions; and, b) filling the space with filling material to thereby form at least part of a wall. 2I) A method according to claim 20, wherein the method includes bracing at least part of the wall prior to filling the space with filling material. 22) Apparatus for constructing a wall, the apparatus including: a) first and second spaced apart wall portions for receiving a filling material, each wall portion including: i) at least one track on a support; ii) at least two support members, each support member being aligned with the track and extending from the support; iii) a wall panel supported by the at least one track and the at least two support members; iv) at least one joining member coupled to the wall panel and the support members; and, b) spacers coupled to the wall portion.

   23) Apparatus according to claim 22, wherein the each track and each support member includes at least one channel for receiving wall panels.

   24) Apparatus according to claim 23, wherein the at least one support member includes at multiple channels for receiving wall panels of different wall portions. 25) Apparatus according to any one of the claims 22 to 24, wherein the at least one support member is formed from an extrusion.

   26) Apparatus according to any one of the claims 22 to 24, wherein the apparatus further includes a fixing plate for attaching the track to the support.

   27) Apparatus according to claim 26, wherein each track includes a ridge for engaging a corresponding recess on the fixing plate. 28) Apparatus according to claim 26 or claim 27, wherein the fixing plate includes at least one aperture for receiving at least one fastening element for coupling the fixing place to the support.

   29) Apparatus according to any one of the claims 22 to 28, wherein the apparatus includes at least one fastening element for attaching ach support member to at least one of the track and a joining member.

   30) Apparatus according to claim 28 or claim 29, wherein the at least one fastening element includes a screw.

   31) Apparatus according to any one of the claims 22 to 30, wherein the joining members include channels for receiving the spacers.

   32) Apparatus according to claim 31, wherein each spacer includes channel engaging portions for engaging the channel upon rotation of the spacer.

   33) Apparatus according to any one of the claims 22 to 32, wherein the apparatus includes at least one reinforcing member positioned between the wall portions so that the reinforcing member is supported by the spacers.

   34) Apparatus according to claim 33, wherein the spacer includes a concave surface for receiving the reinforcing member.

   35) Apparatus according to any one of the claims 22 to 34, wherein the apparatus includes a second wall panel coupled to the joining member and the support members so that the second wall panel is positioned substantially above the wall panel.

   36) Apparatus according to claim 35, wherein the apparatus includes further joining members and further wall panels arranged so that the wall portion has a required height.

   37) Apparatus according to any one of the claims 22 to 36, wherein the apparatus includes, a number of wall panels provided in the track, each wall panel being coupled to two supporting members, so that the wall portion has a required length.

   38) A method of building a wall, the method including: a) locating one or more studs to form a framework for the wall; b) attaching a first pair of panels in parallel on opposite sides of the framework; c) attaching a pair of joining members along respective upper edges of the panels; d) connecting the joining members together with a plurality of spacers; and, e) attaching a second pair of panels on opposite sides of the framework, with lower edges of the second panels located in respective joining members.

   39) A method according to claim 38, wherein the method further includes connecting each spacer to the pair of joining members by holding the spacer between the members, rotating the spacer about a vertical axis in the framework until end portions of the spacer contact respective members, and then rotating the spacer about a horizontal axis in the framework to engage the end portions with the members.

   4O) A method according to claim 39, wherein the method further includes connecting each spacer to the pair of joining members includes holding the spacer between the members, rotating the spacer about a transverse axis until end portions of the spacer contact respective members, and then rotating the spacer about a longitudinal axis to engage the end portions with the members.

   4I) A method according to any one of the claims 38 to 40, wherein each joining member includes a longitudinal channel having a relatively narrow mouth, and each spacer has a pair of end portions with respective tongues, wherein each tongue is shaped to fit through the mouth of the channel in a first orientation and then to engage the channel when rotated to a second orientation.

   42) A method according to any one of the claims 38 to 41, wherein the method further includes: a) attaching a second pair of joining members to upper edges of the second panels; b) connecting the second pair of joining members together with a plurality of spacers; and, c) attaching a third pair of panels on opposite sides of the framework, with lower edges of the third panels located in respective joining members. 43) A method according to any one of the claims 38 to 42, wherein the method further includes completing the wall by adding further joining members, spacers and panels in sequence, until the wall reaches a required height and length. 44) A method according to any one of the claims 38 to 43, wherein the method further includes: a) locating a bottom track as part of the framework; b) locating the vertical studs on the bottom track; and c) locating lower edge portions of the first pair of panels in the base plate. 45) A method according to any one of the claims 38 to 44, wherein the method further includes adding further vertical studs to the framework, between existing studs, after the first pair of panels has been attached to the framework. 46) A method according to any one of the claims 38 to 45, wherein each vertical stud is formed as a pair of vertical members connected by a plurality of spacers.

   47) A method according to any one of the claims 38 to 43, wherein the method further includes filling the wall a filler material.

   48) A wall constructed according to the method of any one of the claims 1 to 21, and 38 to 47.

   49) A wall including: a) multiple panels provided in each of two spaced wall portions; b) joining members for joining adjacent panels in each wall portion; and, c) spacers for connecting joining members in the spaced wall portions. 50) A wall according to claim 49, wherein each wall portion includes a framework.

   5I) A wall according to claim 50, wherein the framework includes vertical studs, and the panels and joining members are attached horizontally to the studs.

   52) A joining member for wall panels, including: a pair of channels which are parallel and open in opposite directions, for receiving edge portions of coplanar panels, and a third channel opening perpendicular to the pair of channels, for engaging an end portion of a spacer.

   53) A joining member according to claim 52, wherein each of the pair of channels has a width which is uniform from a mouth to a respective base, and the third channel has mouth which is relatively narrower than the respective base.