AU2011100636A4 - Wall construction methods - Google Patents

Abstract

Apparatus for use in constructing a wall, the apparatus including a wall panel having first and second wall sheets, a number of elongate spacer members for supporting the wall sheets in a spaced apart arrangement to allow a filling material to be provided therebetween and at least one end spacer member positioned substantially at an end of the first and second wall sheets, the end spacer member including at least one connector for allowing the wal

Description

Our Ref: 40142759/AJS/GMS/seh P/00/0 1 1 Regulation 3:2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION INNOVATION PATENT Applicant(s): Building Solutions Pty Ltd 19 Lower Mill Road, Cooroy, Queensland, 4563 Address for Service: DAVIES COLLISON CAVE Patent & Trade Mark Attorneys Level 10, 301 Coronation Drive Milton QLD 4064 Invention Title: "Wall construction methods" The following statement is a full description of this invention, including the best method of performing it known to me:- C \NRPonbl\DCOSE1N1615_1.51DOC-2535/2011 WALL CONSTRUCTION METHODS Background of the Invention This invention relates to a wall panel, a method of constructing a wall panel, and a method of a constructing a wall using a wall panel. 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. WO2009/070830 describes a method of constructing a wall, the method including providing first and second spaced apart wall portions for receiving a filling material. Each wall portion includes at least one track on a support, at least two support members, each support member being aligned with the track and extending from the support, a wall panel supported by the at 15 least one track and the at least two support members and at least one joining member coupled to the wall panel and the support members. Spacers are also coupled to and extend between the wall portions. W02005/019552 describes a building system in which paired studs attach to inside surfaces of facing sheets to provide panel formwork for concrete walls. The studs comprise a head and 20 outwardly extending spaced flanges with inwardly directed teeth and lips. Spacer elements are engaged with the recess between the flanges and may be formed from off-cuts of sheet material or as specifically formed elements. The latter are formed from hard plastic and in a preferred embodiment are formed as a rectangular box which can be orientated in alternate directions. The system may include end elements, internal top and bottom plates, internal 25 corners, external corners and a shadow line junction between panels.

C \NRPorbl\CC\SEHM 365615_ IDOC-25/05/2011 -2 Summary of the Present Invention In a first broad form the present invention seeks to provide apparatus for use in constructing a wall, the apparatus including a wall panel having: a) first and second wall sheets; 5 b) a number of elongate spacer members for supporting the wall sheets in a spaced apart arrangement to allow a filling material to be provided therebetween; and, c) at least one end spacer member positioned substantially at an end of the first and second wall sheets, the end spacer member including at least one connector for allowing the wall panel to be connected to other parts of a wall. 10 Typically the connector engages a connecting member, the connecting member being coupled to at least one other part of the wall. Typically the connecting member engages the connector using at least one of a clip-fit and an interference-fit. Typically the connector includes a connector flange defining a recess for receiving the 15 connecting member. Typically the connector extends substantially along a length of the end spacer member. Typically the end spacer member includes a lip for aligning the end spacer member with the end of at least one wall sheet. Typically at least one spacer member includes: 20 a) first and second studs for coupling to inner faces of the first and second wall sheets respectively; and, b) a plurality of spacers, each spacer engaging a respective first and second stud. Typically each stud includes: a) a substantially flat head for coupling to the face of a wall sheet; and, 25 b) a pair of spaced apart flanges extending from the head to thereby define a recess for receiving a finger of each spacer.

C:\NRPonbl\DCC\SE\3635615_L DOC-25O5/20 I -3 Typically the spacers engage the recess using at least one of a clip-fit and an interference-fit. Typically each of the studs include at least one tooth provided on each flange, the teeth being for engaging a shoulder on the finger. Typically the end spacer member includes at least one end stud having: 5 a) a head for coupling to the face of a wall sheet; b) a pair of spaced apart flanges extending from the head to thereby define a recess for receiving a finger of each spacer; and, c) the connector. Typically the connector includes a connector flange extending substantially parallel to the 10 head to define a connector recess for receiving the connecting member. Typically the end stud includes a lip extending from an edge of the head, the lip being for engaging an end of the wall sheet. Typically the flanges extend from the head in a first direction, the lip extending from the head in a second direction substantially opposite the first direction. 15 Typically each wall sheet includes a plurality of spacer members arranged substantially in parallel. Typically spacer members are bonded to the wall sheets using adhesive. Typically the spacer members define supports for receiving reinforcing members. Typically the apparatus includes a track for receiving the first and second wall sheets, the 20 track being provided on a substrate. Typically the track defines spaced apart tracks for receiving the first and second wall sheets. Typically the track includes fixing plates for coupling the track to the substrate. Typically the other parts of a wall include at least one of: a) another wall panel; C:WRPonb\DCCSEH\3635615_ DOC-255/201 I -4 b) a wall corner panel; c) a wall end panel; d) a stud of another wall sheet; e) another wall sheet; 5 f) an end piece; g) a corner piece; and, h) a sheet clip. Typically the wall panel includes at least one a insulation sheet. Typically the wall panel includes a insulation sheet between each spacer member, each 10 insulation sheet being positioned against one of the first and second wall sheets. Typically the insulation sheet is made of at least one of EPS (expanded polystyrene), XPS (extruded polystyrene), PUR (Rigid polyurethane) and PIR (polyisocyanurate). Typically at least one insulation sheet includes a number of notches for engaging spacers of the elongate spacer members. 15 In a second broad form the present invention seeks to provide a method of constructing a wall panel, wherein the method includes: a) supporting a plurality of elongate spacer members in a frame, at least one of the spacer members being an end spacer member including at least one connector for allowing the wall panel to be connected to other parts of a wall; 20 b) coupling each spacer member to a face of a first wall sheet, with the end spacer member being positioned substantially at an end of the first wall sheet; c) coupling each spacer member to a face of a second wall sheet, with the end spacer member being positioned substantially at an end of the second wall sheet, thereby supporting the wall sheets in a spaced apart arrangement; and, 25 d) removing the frame.

C:NRPonbrDCC\SEH\.165615.1 DOC-25/05/20ll -5 Typically each spacer member being formed from a plurality of spacers engaging with elongate first and second studs, and wherein the method includes coupling the first and second studs to the first and second wall sheets. Typically the method includes coupling the first and second studs using adhesive. 5 Typically two of the spacer members are end spacer members, and wherein the method includes positioning the end spacer member substantially at opposing ends of the first and second wall sheets. Typically the end spacer member includes at least one lip, and wherein the method includes engaging an end of at least one wall sheet with the at least one lip. 10 Typically the method includes providing an insulation sheet between each spacer member, each insulation sheet being positioned against one of the first and second wall sheets. Typically the insulation sheet includes notches, and wherein the method includes: a) inserting each insulation sheet between respective spacer members; and, b) rotating each insulation sheet so that the notches engage spacers of the respective 15 spacer members with the notches. Typically the insulation sheet is held in position with adhesive, and wherein the method includes urging the insulation sheet against one of the wall sheets to thereby engage the adhesive. In a third broad form the present invention seeks to provide a method of constructing at least 20 part of a wall using a wall panel, the method including: a) mounting the wall panel to a track, the wall panel including: i) a number of elongate spacer members for supporting the wall sheets in a spaced apart arrangement to allow a filling material to be provided therebetween; and, ii) at least one end spacer member positioned substantially at an end of the first and 25 second wall sheets, the end spacer member including at least one connector; and, b) connecting the wall panel to at least one other part of the wall using the at least one connector.

C :NRPonbl\DCOSEH\3635615I.DOC-25A15/21111 -6 Typically the method includes: a) engaging a connecting member with the connector; and, b) connecting the least one part panel of the wall to the connecting member. Typically the method includes engaging the connecting member using at least one of a clip-fit 5 and an interference-fit. Typically the spacer members include: a) first and second studs for coupling to inner faces of the first and second wall sheets respectively; and, b) a plurality of spacers, each spacer engaging a respective first and second stud, and 10 wherein the method includes positioning one or more receiving reinforcing members on the spacers. Typically the track defines spaced apart tracks, and wherein the method includes position the first and second wall sheets in the tracks. Typically the other part of a wall includes at least one of: 15 a) a wall panel; b) a wall sheet; c) an end piece; and, d) a corner piece. Typically the method includes providing an insulation sheet between each spacer member, 20 each insulation panel being positioned against one of the first and second wall sheets. In a fourth broad form the present invention seeks to provide apparatus for use in constructing a wall, the apparatus including a wall panel having: a) first and second wall sheets; b) a number of elongate spacer members for supporting the wall sheets in a spaced apart 25 arrangement to allow a filling material to be provided therebetween; and, c) at least one insulation sheet.

C:RPotbDCCSEH\635615.1.DOC-25A15/2iI1 -7 Typically the wall panel includes an insulation sheet between each spacer member, each insulation sheet being positioned against one of the first and second wall sheets. Typically the insulation sheet is made of at least one of EPS (expanded polystyrene), XPS (extruded polystyrene), PUR (Rigid polyurethane) and PIR (polyisocyanurate). 5 Typically at least one insulation sheet includes a number of notches along each edge for engaging spacers of the elongate spacer members. Typically the at least one insulation sheet is for providing at least one of thermal, acoustic and fire insulation. In a fifth broad form the present invention seeks to provide a method of constructing a wall 10 panel, wherein the method includes: a) supporting a plurality of elongate spacer members in a frame; b) coupling each spacer member to a face of a first wall sheet; c) coupling each spacer member to a face of a second wall sheet; d) removing the frame; and, 15 e) providing an insulation sheet between each spacer member, each insulation sheet being positioned against one of the first and second wall sheets. Typically the insulation sheet includes notches, and wherein the method includes: a) inserting each insulation sheet between respective spacer members; and, b) rotating each insulation sheet so that the notches engage spacers of the respective 20 spacer members with the notches. Typically the insulation sheet is held in position with adhesive, and wherein the method includes urging the insulation sheet against one of the wall sheets to thereby engage the adhesive. Brief Description of the Drawings 25 An example of the present invention will now be described with reference to the accompanying drawings, in which: - C:NRPonbl\DCCSEH\3635615 1.DOC-25)5/2Dlu I -8 Figure lA is schematic plan view of an example of a wall panel; Figure IB is an exploded schematic isometric view of an example of a wall incorporating a number of wall panels; Figure IC is schematic end view of an example of a wall panel of Figure lA in the wall of 5 Figure 1B; Figure ID is a schematic isometric end view of the wall panel of Figure 1A; Figure 2A is a schematic isometric view of an example of a spacer member; Figure 2B is a schematic end view of an example of a stud; Figure 2C is a schematic end view of an example of an end stud; 1o Figure 2D is a schematic plan view of an example of a spacer; Figure 2E is a schematic side view of the spacer of Figure 4A; Figure 2F is a schematic isometric view of the spacer of Figure 4A; Figure 2G is a schematic plan view of an example of a spacer member; Figure 2H is a schematic plan view of an example of an end spacer member; .5 Figure 3A is a schematic plan view of an example of a frame and number of spacer members used in constructing a wall panel; Figure 3B is a schematic end view of an example of the frame and spacer members of Figure 3A; Figure 4A is a schematic end view of an example of a connecting member; 20 Figure 4B is a schematic end view of an example of two end studs connected using the connecting member of Figure 4A; Figure 4C is a schematic plan view of an example of two wall panels connected with connecting members of Figure 4A; Figure 4D to 4F are schematic isometric views of the method of connecting two wall panels 25 with a connecting member; Figure 5A is a schematic end view of an example of an end piece; Figure 5B is a schematic plan view of an example of a wall panel connected with the end piece of Figure 5A; Figures 5C and 5D are schematic isometric views of the method of connecting a wall panel 30 with the end piece of Figure 5A; Figure 5E is a schematic plan view of an example of a wall panel connected to a second C:WRPonbiDCCSEH1635615I.DOC.25/f52011 -9 example end piece; Figure 6A is a schematic end view of an example of a corner connecting member; Figure 6B is a schematic end view of an example of a sheet connecting member; Figure 6C is a schematic end view of an example of a corner sheet connecting member; 5 Figures 6D and 6E are schematic isometric views of an example of a method of connecting two wall panels with a wall corner part; Figure 6F is a schematic plan an example of two wall panels connected with a wall corner part; Figure 7 is a schematic plan an example of three wall panels connected at a T-intersection; .o Figure 8 is a schematic plan an example of a wall panel connected to a fire door frame; Figures 9A to 9D are schematic isometric views of an example of a method of inserting insulation sheets in a wall panel; Figures IOA and 10B are schematic isometric views of an example of a wall in an exploded and constructed configuration; 15 Figure 1 IA is a plan view of an example of an alternative end spacer member; Figure 11 B is an isometric front view of the end spacer member of Figure Ii A; and, Figure 1IC is a plan view of a second example of an alternative end spacer member. Detailed Description of the Preferred Embodiments An example of a wall panel for use in constructing a wall is shown in Figure IA. 20 In this example, the wall panel 110 include first and second wall sheets 111, 112 and a number of elongate spacer members 113, 114 for supporting the wall sheets in a spaced apart arrangement, thereby allowing a filling material to be provided there between. The wall sheets may be made of any suitable material, and in one example are fibre cement sheets. The spacer members include spacer members 113 and at least one end spacer member 114 25 (with two being shown in this example). The end spacer members 114 include a connector 115 for allowing the wall panel 110 to be connected to other parts of a wall, such as other wall panels, wall sheets, end pieces, corner pieces, or the like. The connector 115 can be of any suitable form, and in one example, engages with a connecting member using at least one C NRPonbl\DCC\SEH\363565_L DOC-255/20fI I -10 of a clip-fit and an interference-fit, with the connecting member being in turn coupled to, or part of, the other part of the wall. An example of a wall incorporating a wall panel 110 will now be described with reference to Figures IB to ID. 5 In this example, the wall 100 includes a number of wall panels 110, which in use are mounted to a track 120, provided on a substrate such as the ground 123. As shown in Figure IC, the track 120 includes spaced apart channels 121, 122 for receiving the first and second wall sheets 111, 112. The track 120 also typically includes fixing plates 124 for coupling the track 120 to the substrate 123. 10 The wall 100 includes a number of wall panels 110, as well as other wall parts including a corner piece 130, provided at an outer corner of the wall 100, allowing the wall panels 110 to be joined. End pieces 140 are used to close the ends of the wall panel 1 10 at a location where the walls are to end, which in this example occurs where an opening is to be provided for a window or the like. A track 150 is provided for an upper edge of the wall panels 110 at the 15 window opening, whilst a lintel 160 can be used to support wall panels 1 10 mounted above the window opening. A track 170 can also be used to support an upper edge of the wall panels 110, with the track 170 including channels 171, 172 for receiving the first and second wall sheets 111, 112. In one example, a further track 175 can be mounted on the track 170 to allow further wall panels 110 to be mounted on top of the wall panel 110, thereby allowing 20 multiple levels to be provided. In this example the track 175 includes channels 173, 174, which are positioned to receive the first and second wall sheets 111, 112 of an upper panel 110, as shown. The spacer members 113, 114 can be used to support reinforcing bars 180, which can in turn be coupled to starter bars 190 extending upwardly from the substrate, as will be appreciated 25 by persons skilled in the art. In one example, the fixing plates 124 are movable with respect to the track 120, thereby allow these to be positioned around the starter bars 190. Example spacer members 113, 114 will now be described in more detail with reference to Figures 2A to 2F.

C.\NRPortbl\DCCSEH\3615615_1 DOC-25/51/2011 - 11 In this example, the spacer element 113, 114 includes two studs 200, 210 coupled together via spacers 220. In Figure 2A five spacers 220 are shown for illustration only, and it will be appreciated that any number of spacers 220 may be used depending, for example, on the length of the spacer members 113. 5 Two example stud types are provided, with the stud 200, shown in Figures 2B, being for a spacer member 113, and an end stud 210, shown in Figure 2C, being for the end spacer member 114. Each stud 200, 210 is typically in the form of an elongate extrusion, and may be made of any suitable material, including polymer materials, such as PVC, or metals, such as aluminium, or 1o the like. Each stud 200, 210 includes a head 201, presenting a generally flat surface 202 for coupling to the wall sheets 111, 112, and flanges 203 extending from the head 201, so as to define a recess 204. The flanges 203 generally have flared ends 205, so that the recess 203 widens away from the head 201, as well as a tooth 206, for engaging a spacer, as will be described in detail below. 15 The end stud 210 also includes the connector 115, which in this example is formed form a connector flange 213, extending upwardly from and then substantially parallel to the head 201, to thereby define a connector recess 214, between the flange 213 and the head 201. The connector flange 213 includes a flared end 215 to assist with insertion of a connecting member and a connector tooth 216 for engaging the connecting member, as will be described 20 in more detail below. Additionally, in this example the end stud 210 includes an optional lip 217 for aligning the end spacer member 114 with the end of a wall sheet 111, 112. An example spacer 220 is shown in Figures 2D to 2F. In this example, the spacer 220 includes an elongate body 221, having generally flat sides 222, and concave upper and lower faces 223, which assist with positioning of the reinforcing members 180. The spacers 220 25 include fingers 224 extending from each end of the body 221, with each finger 224 being shaped so as to define shoulders 225. In use, the fingers 224 are adapted to be inserted into the recesses 204 of the studs 200, 210. In this regard, the shaping of the fingers 224 and the flared ends 205 of the flanges 203 assist C \RPonb\DCC\SEHU635615_1 DOC.2551201l - 12 in guiding the fingers 224 into the recesses 204. Once fully inserted, the shoulders 225 engage with the teeth 206, thereby retaining the spacers 220 in engagement with the studs 200, 210. It will be appreciated that this allows a spacer member 113 and end spacer member 114 to be 5 provided, as shown in Figures 2G and 2H, respectively. Whilst the use of studs and separate spacers are shown in this example, this is not essential and alternatively integrally formed spacer members may be used, as will be described in more detail below. A method of constructing a wall panel 110 will now be described with reference to Figures 3A and 3B. 0 In this example, the method includes supporting a plurality of spacer members in frames 300, including at least one spacer member 113 and at least one an end spacer member 114. The frames 300 can be any suitable frame that can support the spacer members 113, 114 in the correct relative positions for coupling to the first and second wall sheets 111, 112, which typically includes having the spacer members 113, 114 aligned substantially parallel and 15 separated by equal distances. Typically, the frame will be a reusable frame, having mountings 301 for receiving the spacer members 113, 114 in the desired arrangement. Once provided in the frames, each spacer member 113, 114 is coupled to a face of the first wall sheet 111, with the end spacer member 114 being positioned substantially at an end of the first wall sheet 111. In one example, this is achieved by applying adhesive to either the 20 first wall sheet 11l, or the surface 202 of the studs 200, 210, and then bringing the spacer members 113, 114 into contact with the first wall sheet 111, as shown by the arrow 310. Each spacer member 113, 114 is then connected to a face of a second wall sheet 112, with the end spacer member 114 being positioned substantially at an end of the second wall sheet 112, thereby supporting the wall sheets in a spaced apart arrangement. Again this is achieved by 25 applying adhesive to either the second wall sheet 112, or the surface 202 of the studs 200, 210, and then bringing the second wall 112 sheet into contact with the spacer members 113, 114 as shown by the arrow 320.

C:\NRPonbl\DCC\SEH\1635615_I.DOC.25/05/201 I - 13 In the event that a lip 217 is present, the lip 217 helps ensure correct alignment of the spacer members 113, 114. In this regard, the lip 217 will align the end spacer member 114 squarely with the end of the first and second wall sheets 111, 112. Furthermore, with each of the other spacer members 113 being held in the frame in a substantially parallel orientation with 5 respect to the end spacer member 114, this helps ensure that the other spacer members 113 are also correctly aligned on the first and second sheets 111, 112. Additionally, the lip 217 can assist in ensuring that any excess adhesive squeezed out from between the spacer member 113 and the first and second wall sheets 111, 112 does project outwardly from the end of the panel wall sheets 111, 112. This reduces the workload in 10 removing excess adhesive, and helps ensure a square edge is presented when bringing the wall panel 1 10 into alignment with other parts of the wall 100. However, the use of a lip 217 is not essential and this can be omitted depending on the preferred implementation. Following mounting of the spacer members 113, 114 to the first and second sheets 111, 112, 15 the frames 300 can be removed, with the adhesive being allowed to cure, thereby bonding the spacer members 113, 114 with the first and second wall sheets 111, 112. It will be appreciated that this allows the wall panels 110 to be manufactured and delivered to the construction site pre-built. This reduces the amount of onsite work involved in constructing the wall 100, allowing walls to be built with a reduced number of workers, 20 which in turn reduces costs. In this situation, the wall panels can easily be lifted by having workers grasp the spacers 220, which provide safe areas for manual lifting, with no sharp metal edges. Wall panels 110 of this form are also lighter than other conventional metal framed walls, allowing the wall panels 110 to be easily manoeuvred. During wall construction, the wall panel 110 is easily positioned with the wall sheets 111, 25 112 provided in the channels 121, 122 on the track 120. The wall portion can then be coupled to other wall parts as will now be described in more detail with reference to Figures 4 to 10. For these examples, similar reference numerals are used to those used above to describe similar components, which will not therefore be described in detail.

C:\NRPorthlbDCC\SEH\36356 15 .DOC-.251512011 - 14 Figures 4A to 4F show the process of connecting two wall panels I 1A, I IOB. For this example, suffixes A and B will be used to identify elements belonging to the wall panels I 1A, 1 IOB respectively. In this example, a connecting member 400 is used as shown in Figure 4A. The connecting 5 member 400 includes a body 410 that is typically an elongate substantially laminar body that is dimensioned to extend substantially along a length of the end spacer member 114. The body 410 includes teeth 411, 412 extending along either edge of the body 410, with a tongue 413 also optionally being provided projecting from one edge of the body 410, beyond the corresponding tooth 411, as shown. 10 In use, the tongue 413 is inserted into the connector recess 214A of the connector I 15A on the wall sheet I 1IA of the first wall panel 11 OA, as shown by the arrow 420 in Figure 4D. During this process, the flared portion 215A of the connector flange 213A assists in guiding the tongue 413A into the connector recess 214A. Once fully inserted, the tooth 411 engages the connector tooth 216A, thereby retaining the connecting member 400 in the connector 15 115A. It will be appreciated that this process is duplicated with another connecting member 400, for a connector I 15A on the second sheet 1 12A, and this will not be described in further detail for clarity purposes. Following this the second wall panel 110B is moved towards the first wall panel 1 A, typically by sliding it along the channels 121, 122 of the track 120 in the direction of arrow 20 430, shown in Figure 4E. Again, the flared portion 215B of the connector flange 213B on the connector I1 5B of the second wall panel l1OB assists in guiding the tooth 412 into the connector recess 214B. Once fully inserted, the tooth 412 engages the connector tooth 216B, thereby retaining the connecting member 410 in the connector 115B. Again, the process is duplicated for the second connecting member associated with the second sheets I 12A, I1 2B, 25 so that the first and second sheets lIlA, 111 B; 11 2A, 11 2B of the wall panels 11 OA, I1 OB are connected via respective connecting members 400 as shown in Figure 4C. When the first and second wall panels 11 OA, 11 OB are connected as shown in Figure 4C, the lips 217A, 217B of the spacer members I 14A, 1 14B are in contact. It will be appreciated that C:\NRPonblDCC\SEH\363565_ DOC-25A5/211 - 15 as these are pre-shaped, this can assist in ensuring wall panels 1 10A, l1OB align squarely. The resulting gap between the wall sheets IIlA, 11 IB; 1 I2A, 112B is typically rendered over during finishing of the wall 100, and this does not therefore adversely affect the final appearance of the wall 100. However, this is not essential, and alternative the gap between 5 the sheets I l lA, 111 B; 1 l2A, I12B can be left uncovered, and expressed as a joint. This may be used in a wide range of situations, for example in external walls, car ports, or the like. Additionally, as apparent in Figure 48, when the connecting member 400 is engaged with the connectors 11 5A, I1 5B on the wall panels 11 OA, 1108, there is a gap between the tongue 413 and the end of the connector recess 214A, and between the tooth 412 and the connector l0 tooth 216B. This allows for some movement of the connecting member 400 within the connectors I I5A, 115B, which in turn can help accommodate any variation in alignment of the wall sheets lllA, 11181; 112A, 112B. Figures 5A to 5D show the process of connecting a wall panel 110, to an end piece 140. In this example, the end piece 140 includes a substantially elongate body 510, having lips 511 1s projecting perpendicularly from either edge of the body 510. A tongue 512 is provided inwardly of each lip 511 projecting away from the body 510, in the direction of the lips 511, each tongue including a tooth 513 provided thereon. In use, the tongues 512 are inserted into the connector recesses 214 of the connectors 115 on the wall panel 110, as shown by the arrow 520 in Figure 5C. During this process, the flared 20 portions 215 of the connector flanges 213 assist in guiding the tongues 512 into the connector recesses 214. Once fully inserted, the connector teeth 216 engage the teeth 513, thereby retaining the end piece 140 in position. An alternative end piece 140 is shown in Figure 5E. In this example, the end piece 140 includes two end piece connectors 540, each including arms 541, 542 defining a channel 543 25 for receiving a wall sheet 545. In this example, each end piece connector 540 includes a lip 511 projecting perpendicularly from the arm 541, and a tongue 512 provided inwardly of each lip 511 projecting away from the arm 541, in the direction of the lip 511, each tongue including a tooth 513 provided thereon. This allows the wall sheet 545 to be mounted in the C:WRPorb \CC SEH\635615_1.DOC-25/05/2011 - 16 channel 543, for example using adhesive or a friction fit arrangement, with the resulting end piece 140 being coupled to the wall panel, as described above with respect to Figures 5C and 5D. Figures 6A to 6F show the process of connecting a corner piece 130 to two wall panels 1 A, 5 11 OB. For this example, suffixes A and B will be used to identify elements belonging to the wall panels 1 1OA, 1 OB respectively. In this example, a corner connecting member 600 is used, as shown in Figure 6A. The corner connecting member 600 includes a body 610, having an elongate substantially L-shape that extends substantially along the length of the end spacer member 114. The body 610 includes to teeth 611, 612 provided at the edges of the body 610. A sheet connecting member 620 is used, as shown in Figure 6B. The sheet connecting member 620 includes an elongate body 630, having arms 631, 632 defining a channel 633 that extends along a length of the body 630. In use, a wall sheet can be inserted into the channel 633 and held in position using any suitable fixing mechanism, such as a friction fit, .5 clip fit, bonding, or the like, depending on the preferred implementation. A corner sheet connecting member 640 is also used, as shown in Figure 6C. The corner sheet connecting member 640 includes an elongate body 650, having first and second sets of arms 651, 652, 655, 656 defining respective channels 653, 657 angled at 90*. It will be appreciated that alternative angles may be used to define a corner that is offset from 900. 20 Again, a wall sheet can be inserted into the channels 653, 657 and held in position using any suitable fixing mechanism, such as a friction fit, clip fit, bonding, or the like, depending on the preferred implementation. In use, the corner connecting member 600 is coupled to the connector 11 5A on the first sheet 11 l A of the first wall panel I 10A, as shown by the arrow 670 in Figure 6D. The technique is 25 substantially as described above with respect to other connectors, and will not therefore be described in detail. Following this the second wall panel IOB is moved towards the corner connecting member 600 as shown by the arrow 680, so that the corner connecting member C:\NRPortb\DCC\SEH\635615 _tDOC-25A)512011 -17 600 is also coupled to the connector 1 15B on the first sheet 111 B of the second wall panel 1IOB. Meanwhile, the corner piece 130 is formed by inserting first edges of wall sheets 661, 662 into the channels 653, 657 of the corner sheet connecting member 640. Sheet connecting 5 members 620 are then attached to second edges of wall sheets 661, 662, the second edges being opposite the first. Following this, the corner piece 130 is slid into engagement with the wall panels I IOA, 11 OB in the direction of the arrows 690, by sliding the sheet connecting members 620A, 620B into the connectors 115A, 115B on the second sheets 112A, 112B of the wall panels I IOA, 1 lOB. 10 It will be appreciated that this technique allows a corner to be easily formed. Additionally, sliding in of the corner piece 130 can left until the reinforcement bars 180 are installed, further simplifying the wall construction process. A similar arrangement to that described above can be used to construct a number of different arrangements. An example of a T-intersection between three wall panels 11 OA, I I OB, 11 OC 15 is shown in Figure 7. In this example, only the end spacer members 1 14A, 1 14B, 1 14C of the wall panels I 1A, IOB, 1 1OC are shown. In this example, the wall sheets 11 C, 1 12C of the wall panel 1 lOC, are connected to the wall sheets 1 IlA, 111 B of the wall panels 1 OA, 110B, via corner connecting members 600. Similarly the wall sheets I l2A, I 12B of the wall panels l1OA, 1 OB are further connected 20 via a wall sheet 700 and two sheet connecting members 620. As a result, the wall panel I IOC extends away from the wall panels 1OA, 1 IOB, which are arranged in a line. It will further be appreciated that any shape of wall part can be connected to the wall panels 110. An example of a fire door frame 800 is shown in Figure 8. Additionally, the wall panels 110 can incorporate different filling materials. In one example, 25 the panels are filled entirely with concrete. However, in another example an insulation sheet can be incorporated into the wall panel to provide additional insulative properties.

C:NRPorbl\DCC\SEH\3635615_ DOC-25A5/2111 -18 An example will now be described with reference to Figures 9A to 9D. In this example, insulation sheets 900 are inserted between the wall sheets 111, 112 into the wall panel, between the spacer members 113, 114 in the direction of the arrow 910. The insulation sheets 900 are urged up against the wall sheet 112, and rotated in the direction of the arrow 5 920, to lie flush against an inner surface of the wall sheet 112. The sheets 900 may also be shaped, for example, to include the notches 901 along each edge. The notches are shaped so that as the insulation sheet is rotated, the notches engage the spacers 220. Engagement of the spacers can be used to assist in retaining the insulation sheet in position. Additionally, the notches allow the insulation sheets to extend into the gaps between spacers, so that the edges to of adjacent insulation sheets are in contact, thereby preventing gaps arising between adjacent insulation sheets, which could unduly compromise the effectiveness of the insulation provided. The insulation sheets 900 may also be bonded to the wall sheet 112, although alternatively the insulation sheets may be lose or retained in some other manner. The insulation sheets can be formed from any suitable material, but in one example are made 15 of EPS (expanded polystyrene), XPS (extruded polystyrene), PUR (Rigid polyurethane) or PIR (polyisocyanurate) sheets. Accordingly, this allows the insulation sheets to be easily cut to size, as well as to allow the insulation sheets to be shaped, for example, to include the notches 901. The shaping made also be made so that the profile of edges of the insulation sheet are complementary to the shapes of the studs 200, 210, thereby ensuring contact 20 between the insulation sheets 900 and the wall sheet 112. The sheets can be adapted to provide different insulating properties depending on the materials used. Thus for example, the sheets could be adapted to provide thermal, acoustic and/or fire insulation. It will be appreciated that the materials outlined above, such as EPS, XPS or the like, typically provide good thermal and acoustic insulation, and additional fire 25 resistance can be achieved by providing a suitable coating on the insulation sheets. In any event, by selecting appropriate materials, any one or more of thermal, acoustic and fire insulation can be provided. It will be appreciated that insulation sheets 900 can be fitted during manufacture or can alternatively be fitted during onsite prior to filling of the wall panel.

C:WRPotbI\DCC\SEH\3635615 DOC-2510/201 -19 It will also be appreciated that the insulation sheets could be used with alternative arrangements of wall panel, such as those that do not include connectors 115. Thus these could be used in any wall panel system that includes first and second wall sheets and a number of elongate spacer members for supporting the wall sheets in a spaced apart 5 arrangement to allow a filling material to be provided therebetween. Examples of alternative arrangements are described in W02005/019552. An example wall configuration is shown in Figures I0A and lOB. In this example, eight wall panels 1 OA, 110B, 1 IOC, I IOD, I 1E, I IOF, 1 OG, I IH are connected via corner pieces 130A, 130B, two straight pieces 1010, 1020, an internal corner 0 piece 1030, and six corner connecting members 600, thereby forming a wall 1000. Insulation sheets 900 are provided on an inner face of the wall sheets that form the outside of the wall, thereby providing additional insulation. It will be appreciated that the wall is constructed using the mechanisms outlined above, and this will not therefore be described in any further detail. 5 An example of an alternative configuration of end spacer member 114 will now be described with reference to Figures 1 A and I1 B. For the purpose of this example, similar reference numerals to those above are used to identify similar features. In this example, the end spacer 114 therefore includes two heads 201 integrally formed with a substantially elongate interconnecting web 1100. The web 1100 and heads 201 can be 20 manufactured as a single extrusion from a suitable material, such as aluminium or the like. As in the previous example, the head 201 includes a connector 115, and lip 217, for aligning with first and second wall sheets 111, 112, as shown in dotted lines. The web 1100, includes a number of apertures 1110 spaced along the length of the web. The apertures can be of any suitable form, and in one example, are elongate apertures. The 25 apertures 1110 allow reinforcing bars 180 to be supported, as well as allowing flow of filling material along the length of the resulting wall panels. The apertures therefore are sized to ensure suitable flow of filling material. In one example, the apertures also include a lip 1111, C\NRPortbl\DCC\SEHX1635615_1 DOC-25/05/2011 - 20 typically created when the apertures are formed by punching out material from the web. In one example, the lip I 11 can assist with flow of filling material. An alternative arrangement is shown in Figure 1 IC. In this example, the web 1100 is bent into a U-shape to thereby define the heads 201, with the aperture 1110 being created by 5 punching out portions of the web. As in the previous example, the head 201 includes a connector 115, which in this example is formed by bonding the connector flange 213 to the head 201 using a suitable bonding process, such as welding or the like, as well as lips 217. It will be appreciated from this that any suitable spacer arrangement can be used, although the use of studs 200, 210 and spacers 220, tends to provide a greater degree of flexibility and .0 improved flow of filling material, and is therefore generally preferred. It will also be appreciated that this arrangement can be used with other features described above, such as the use of the insulation sheets, and this will not therefore be described in any further detail. In any event, the above described wall panels can be easily constructed, allowing them to be built either onsite, or pre-built for delivery to site. The wall panels include end spacer 15 members that have connectors to allow the wall panels to be connected to other parts of a wall, such as other wall panels, using a clip-fit mechanism. This allows wall panels and other wall parts to be rapidly interconnected, requiring little skill by the workers. Furthermore, the wall panels are light and easy to manoeuvre, allowing the walls to be rapidly, cheaply and safely constructed, whilst maintaining the quality of the final wall. This is in contrast to prior 20 art techniques that require the use of screws and other fittings to allow the wall panels to be constructed in situ. 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.