AU2011253571B2 - A wall assembly for a building structure - Google Patents

Abstract

5 A wall assembly 10 is disclosed including a plurality of panels 12 extending in a line. Each panel 12 has front and rear panel faces 14, an operatively upper edge 18 and an operatively lower edge 19 and two sides 20 and 22 extending between the upper and lower edges 18 and 19. The wall assembly 10 also includes a bottom plate 28 which runs along the operatively lower edges 28 of the panels 12 10 and which is fixed thereto, and a top plate 30 which is mounted on the operatively upper edge 18 of the panels 12 and fixed thereto. The wall assembly 10 includes a plurality of support posts 32 positioned at spaced intervals along the wall. The wall assembly 10 and specifically the bottom plate 28 and the support posts 32 thereof are mounted on a support that is conveniently a concrete slab. The panels define a 15 post receiving channel 34 in each side thereof that is sized so that it can receive at least part of a support post therein. Abutting sides 20 and 22 of adjacent panels 12 each have channels 34 that open into each other and form a combined channel and each support post 32 is received within a combined channel. 20 Figure 1 for publication

Description

1 A WALL ASSEMBLY FOR A BUILDING STRUCTURE FIELD OF THE INVENTION 5 This invention relates to a wall assembly for a building structure. It also extends to a building structure including the wall assembly. This invention relates particularly to a wall assembly for use In a building structure that is a 10 free standing house or home that is built on a land allotment. Often these homes are used to house a single family and are referred to as a family home. It will therefore be convenient to hereinafter describe the invention with reference to this example application. However at the same time it must be recognized that the invention Is capable of broader application. For example the invention could be used for free standing wall assemblies 15 that do not form part of a building structure. DEFINITIONS In the specification the term "comprising" shall be understood to have a broad meaning 20 similar to the term "including" and will be understood to imply the inclusion of a stated Integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term "comprising" such as "comprise" and "comprises". 25 In the specification the term "post top bracket" is to be interpreted broadly and to cover any formation mounted on the post at or towards the top thereof. BACKGROUND TO THE INVENTION 30 Currently many homes are being built using an internal timber structural frame and a surrounding brick veneer that is tied to the timber frame, The timber frame comprises a series of horizontally extending plates that are interconnected by a corresponding number of vertically extending studs to form a sequence of repeating single frame units which 2 together make up the structural frame of the house. The frame is typically constructed by a carpenter from linear members of framing timber that are cut to length and then interconnected to build the structural frame. 5 Conventionally insulated panels may be connected along longitudinal side edges as described for example in US Patent 5 269 109, 6 314 704, 6 502 357 and 4 276 730 which all refer to tongue and groove formations which interconnect adjacent insulated panels along adjoining vertical side edges. These prior art references will now be described in greater detail below. 10 US Patent 5 269 109 refers to an insulated load bearing wall comprising panels of extruded polymer foam in which tubular load carrying members have been incorporated which are bonded to the foam. A tongue is formed at one vertical edge and a groove is formed at the opposite vertical edge for connection of adjacent panels. 15 US Patent 6 314 704 refers to a structural building panel having first and second composite skins. A composite connector extends along a side edge of the panel which includes a tongue and groove adjacent one another defining an inside face having an elongate aperture therein that extends parallel to the side edge. The connector engages 20 with a similar connector on an adjacent panel whereby adjoining tongues and grooves interlock whereby the apertures together define a channel through which a rod-like locking member is received. A base connector is bolted to a foundation on wall panels placed on the base connector and a clip attached to the base connector to secure the side panels to the base connector. A cap member Is attached to an upper edge of the wall panels and a 25 plurality of roof panels placed on the cap member and a cap retaining clip attached to secure the roof panels to the wall panels. US Patent 6 502 357 refers to a wall panel system having a plurality of inter-connecting tongue and groove panels which are framed by top, bottom and side channel members to 30 form walls which may be easily erected and taken down. The panels may have internal dividers to form chambers which are adapted to receive vertical boards as reinforcements. US Patent 4 276 730 refers to wall structure modules with a thickness of insulation moulded between a pair of light weight concrete. There are tongue and groove 3 configurations along opposite sides of the panels conditioning them to be nested together. A full height steel stud is encased in each panel and has a small bracket at the top exposed for attachment of a channel top plate which fits over the panels of a complete wall section to unitize it. There is also provided a channel base member welded to a lower end 5 of each of the studs to extend across the bottom of each of the channels, The channel base member may be secured to a floor by steel channel rim joints by means of screws. The above prior art citations require that adjacent panels to be nested together by tongue and groove formations and require additional structure such as load carrying rods, tubes or 10 boards to strengthen the panels. Clearly it would be advantageous if a wall assembly and a building structure could be devised that was quicker to build than prior art buildings and that reduced the level of skill required by builders to build the building, while still satisfying building regulations and 15 standards. It would also be advantageous if the wall assembly and building structure could be assembled from fewer components than traditional prior art methods. This would simplify the process of ordering the building components and materials and delivering them to the site and would also simplify the building process. It would also be advantageous if a wall assembly and building structure that had these features also had 20 good energy saving properties. It would also be advantageous if a wall could be engineered to have a high strength when subjected to high wind forces. SUMMARY OF THE INVENTION 25 According to one aspect of the invention there is provided a wall assembly including: a wall support a plurality of panels extending in a panel line along a length of the wall assembly, each panel having front and rear panel faces, an operatively upper edge and an operatively lower edge and two sides extending between the upper and lower edges; 30 a bottom plate that runs along the operatively lower edges of the panels; a top plate which is mounted on the operatively upper edge of the panels and which is fixed to the panels, the top plate being configured to receive the upper edge of the panels; and 4 a plurality of load bearing support posts positioned at spaced intervals along the length of the wall assembly anchored to the wall support, each support post being positioned between the sides of two adjacent panels of the plurality of panels, and at least one support post including a post top bracket configured to hold the panels down and 5 resist fore and aft displacement of the panels out of the panel line. The wall may be suitable for use in a building structure, e.g. forming an external load bearing structure of a wall assembly. Advantageously each post may include a post top bracket thereon. The post top brackets may be configured to complement the profile of the 10 top plate and the post top brackets are fixed to the top plate. The top plate may define a panel receiving channel for receiving the upper edges of the panels therein. The bottom plate may be configured to locate the panels and resist fore and aft displacement of the panels out of the panel line. 15 Each support post may be received within the plurality of panels by being spaced inward from the front and rear faces of the panels. Two or more of the panels define post receiving channels in the sides thereof, and each support post may be received within a said post receiving channel. In particular the post 20 receiving channels on abutting sides of adjacent panels may form a combined channel, and each support post may be received within a said combined channel. Each panel may comprise two outer layers and an insulating core sandwiched between the two outer layers. The panels may have complementary engagement formations such 25 that when the abutting sides of adjacent panels are engaged they locate the adjacent panels and hold the adjacent panels in position relative to each other. The two outer layers may be formed of a sheet of metallic material such as steel and have a thickness in the 4A range of 0.3mm-1.0mm. Further the insulating core may be formed of a polymeric insulating material, e.g. extruded or expanded polystyrene. The post receiving channels defined in the sides of the panels may be formed in the 5 insulating core between the two outer layers. That is they may be spaced inwardly of the front and rear faces of the panels. The post receiving channels on the abutting sides of adjacent panels may be aligned with each other so that they open into each other. For example the channels on the abutting sides may form an enlarged channel. 10 The support posts may be located at substantially evenly spaced intervals along the length of the wall assembly. The panel receiving channel of the top plate may comprise a bridge that extends at least part of the way across the operatively upper edge of the panel, and also skirts that extend 15 from the bridge down the front and rear faces of the panels. The top plate may be fixed to the panels by means of a plurality of fastening elements that are passed through the top plate and into the panel along the length of the top plate. 20 The fastening elements may pass through one of the skirts on the panel receiving channel and into one of the front and rear faces of the panels. The top plate may further include a load bearing top cap that projects up above the panel receiving channel for supporting a roof member thereon. The top cap may comprise two 25 wall sections extending away from the bridge and a top section extending across the tops of the two wall sections and joining them together. The top plate may comprise a plurality of top plate sections that are arranged in series along the upper edge of the panels that are Indirectly attached to each other by means of 30 the post top brackets.

4B Each post top bracket may comprise a post fixing portion that is mounted over the operatively upper edge of the adjacent panels and defines a fastening element opening therein. Each post top bracket may include a top plate fixing portion mounted on the post fixing 5 portion that is configured to complement the top plate so that it can be nested with the top plate. Each support post may include a bore formed in the upper and lower ends thereof. The post top bracket may be mounted on each support post by means of a post fastening 10 element that is passed through the fastening element opening in the post fixing portion of the post top plate, and is received within the bore formed in the upper end of the support post and engaged therewith. The bore defined in the upper end of each support post may have a screw thread formed 15 thereon and the post fastening element may be a bolt having an enlarged head and a complementary external screw thread formed on the shank thereof for engaging the thread In the bore. The top plate fixing portion of the post top bracket may be sandwiched between the upper 20 edges of the adjacent panels and a portion of the top plate that overlaps therewith. The top plate may be fixed to the top plate fixing portion by means of fastening elements that are passed through the top plate and the top plate fixing portion. The lower end of each support post may be fixed to the wall support and the lower end of 25 each support post is also operatively connected to the bottom plate. The lower end of each support post may be fixed to the wall support by means of a lower post fastening element that is fixed to the support post. Further the lower post fastening element may be passed through a bolt opening in the bottom plate and may be anchored 30 in the support.

4C The bottom plate defines a bottom channel having two channel walls that receive the operatively lower edges of the panels therein whereby to resist fore and aft dIsplacement of the panels out of the panel line. 5 The bottom plate may be fixed to each of the panels by means of fastening elements that are passed through one of the channel walls and into the panel along the length of the bottom plate. The wall assembly may further include hold down brackets located at spaced intervals 10 along the bottom plate. Each hold down bracket may be mounted on the wall support and may fix the bottom plate down onto the support for holding the bottom plate down when the wall assembly is subjected to high load. According to another aspect of this invention there Is provided a wall assembly including: 15 a plurality of panels extending in a line along a length of the wall assembly, each panel having front and rear panel faces, an operatively upper edge and an operatively lower edge and two sides extending between the upper and lower edges; 20 a bottom plate which runs along the operatively lower edges of the panels and which is fixed to the panels; a top plate which is mounted on the operatively upper edge of the panels and which is fixed to the panels; and 26 a plurality of support posts positioned at spaced intervals along the length of the wall assembly, each support post being positioned between the sides of two adjacent panels of the plurality of panels. 30 The wall assembly may further include a support on which the bottom plate is mounted, and the support posts may be fixed to the support. Further the bottom plate may be mounted on the support and may be fixed thereto. The support may be in the form of a 4D slab of settable material on which the wall assembly is mounted. Conveniently the slab may be a concrete slab that is mounted on the ground. Each support post may be fixed to the top plate and may also be directly or indirectly 5 connected to the bottom plate. At least two of said plurality of panels may define a post receiving channel in at least one side thereof, and each channel may be sized so that it can receive at least part of a support post therein. 10 Two or more of said plurality of panels may define a post receiving channel in each side thereof. Conveniently all the panels may define post receiving channels in each side thereof. 15 5 The post receiving channels within which the support posts are received may have a substantially rectangular cross sectional shape. Instead the post receiving channels may have a semi-circular cross sectional shape. It is convenient if the 5 post receiving channels complement the post received therein but it is not essential that this be the case. Each panel may comprise two outer layers and an insulating core sandwiched between the two outer layers. 10 The two outer layers may each be formed of a sheet of metallic material such as steel and have a thickness in the range of 0.3mm-1.0mm. Conveniently the outer layers have some stiffness and in some forms are formed from sheets of steel having a thickness of 0.5mm to 0.7 mm. 15 The insulating core may be formed of a polymeric insulating material, e.g. extruded or expanded polystyrene. The post receiving channels defined in the sides of the panels may be formed in the insulating core between the two outer layers. 20 In some forms of the invention the panels have complementary engagement formations that when engaged act to locate adjacent panels relative to each other, e.g. align adjacent panels with each other, and also hold and support adjacent panels in position relative to each other. The complementary engagement formations may be formed by configuring the two outer layers to form 25 complementary male and female formations, e.g. tongue and groove formations. Each support post may be received within the panels by being spaced in from the front and rear faces of the panels. That is the panel defines a panel body and the support post is received within the panel body. 30 The post receiving channels may be located in a position on the sides of the panels such that the channels of abutting sides of adjacent panels open into each other 6 and form an enlarged channel. Conveniently the post receiving channels may be disposed substantially centrally with respect to the thickness or depth of the panel and if this is the case the post receiving channels of abutting sides of adjacent panels will always open into each other provided that the panels are aligned with 5 each other. Each support post may be received within a combined channel formed by the post receiving channels on the abutting sides of adjacent panels. 10 Further the support posts may be located at substantially evenly spaced intervals along the length of the wall assembly. As the posts may only be located on the sides of the panel the spacing of the posts away from each other will always be a multiple of the width of the panels. For example a support post may be located every third, fourth, fifth of sixth panel in which case the posts will be respectively 15 three, four, five, or six panel widths away from each other. The top plate may define a panel receiving channel that is configured to receive an upper edge region of a panel snugly therein. 20 The panel receiving channel may comprise, a bridge that extends at least part of the way across the operatively upper edge of the panel, and skirts extending from the bridge down the front and rear faces of the panels. The top plate may further include a top cap that projects up above the panel 25 receiving channel when mounted on a wall assembly. The top cap may comprise two wall sections extending away from the bridge and a top section extending across upper ends of the two wall sections and joining them together. 30 7 The top plate may be fixed to each of the panels by means of a plurality of fastening elements that are located at spaced intervals along the length of the top plate, and that pass through the top plate and into the panel beneath the top plate. 5 The fastening elements may be passed through one of the skirts on the panel receiving channel and into one of the front and rear faces of the panels. The fastening elements may be passed though the top plate and into the panels at spaced intervals along the length of the wall assembly, e.g. at closely spaced intervals along the length of the wall assembly. Conveniently the fastening 10 elements may be nails that are driven through the skirts and into the panels. The wall assembly may further include a plurality of post top brackets and one post top bracket may be mounted on the upper end of each support post for fixing the support posts to the top plate and thereby indirectly to the wall panels. 15 Each post top bracket may comprise a post fixing portion that is mounted over the operatively upper edge of the adjacent panels and has a fastening element opening defined therein, and a top plate fixing portion on the post fixing portion that is configured to complement the top plate so that it can be nested with the top 20 plate. Each support post may include a bore formed in the upper and lower ends thereof, and the post top bracket may be mounted on each support post by means of a post fastening element, e.g. a bolt, that is passed through the fastening element 25 opening in the post fixing portion of the post top plate, and is received within the bore formed in the upper end of the post and engaged therewith. The bores defined in the upper and lower ends of the post may have a screw thread formed thereon and the post fastening element that is a bolt may have a 30 complementary external screw thread formed on the shank thereof for engaging the thread in the bore. The bolt may have an enlarged head for resting on the post fixing portion and resisting its passage through the fastening element opening.

8 The top plate fixing portion of the post top bracket may be sandwiched between the upper edges of the adjacent panels and a portion of the top plate that overlaps therewith. 5 The top plate may be fixed to the top plate fixing portion by means of fastening elements that are passed through the top plate and the top plate fixing portion of the post top bracket. The fastening elements may be nails that are driven through the top plate and into the top plate fixing portion. 10 The top plate may comprise a plurality of top plate sections that are arranged in series along the upper edge of the panels that are directly or indirectly attached to each other. For example the top plate sections may be indirectly attached to each other by means of a post top bracket. 15 The lower end of each support post may be mounted on the bottom plate by means of another post fastening element, e.g. a bolt. The other post fastening element that is a bolt may have a shank portion that is 20 received in the bore in the lower end of the support post and is engaged therewith. The shank portion may have an external screw thread that engages a screw thread within the bore. The bolt may have another shank portion that is passed through a bolt opening in 25 the bottom plate and is anchored in the support. The bottom plate may define a bottom channel having two channel walls that receive the operatively lower edges of the panels therein, and the bottom plate may be fixed to each of the panels by means of fastening elements that are located 30 at spaced intervals along the bottom plate.

9 The fastening elements may be passed through one of the channel walls and into the panel behind the channel wall through one of the front and rear faces thereof. The fastening elements may be nails or the like that can be driven through the bottom plate and into the panels. 5 The wall assembly may further include hold down brackets mounted on the bottom plate located at spaced intervals along the bottom rail for further fixing the bottom plate to the support and holding down the bottom plate when the wall assembly is subjected to a high load. 10 Each hold down bracket may be received within the bottom channel and may extend substantially fully across the width of the bottom channel whereby to assist in holding down the bottom plate across the width of the bottom channel. 15 The wall assembly may include hold down bracket fastening elements for mounting the hold down brackets on the bottom plate, and each hold down bracket fastening element may be passed through the hold down bracket, and the bottom plate and be anchored in the support. The hold down bracket fastening elements may be in the form of bolts having an enlarged head. 20 According to another aspect of this invention there is provided a building structure including a wall assembly as defined in the preceding aspect of the invention and a roof mounted on the wall assembly. 25 The wall assembly may include any one or more of the optional features described above in the first aspect of the invention. The roof may comprise a plurality of roof panels arranged side by side along at least part of the length of the wall assembly. 30 In particular the top plate may include a panel receiving portion and a top cap portion, and each roof panel may be mounted on the top cap portion of the top 10 plate and be fixed to the top plate by means of fastening elements that are passed through the roof panels and into the top cap portion of the top plate. The fastening elements may be in the form of nails that are driven through the roof 5 panels and into the top cap of the top plate. The building structure may further include cover strips that extend between upper regions of the inner and outer faces of the wall panel and the roof whereby to cover over the top plate. The cover strips may be a fascia board. 10 DETAILED DESCRIPTION OF THE INVENTION A wall assembly and a building structure in accordance with this invention may manifest itself in a variety of forms. It will be convenient to hereinafter describe at 15 least one embodiment of the invention in detail with reference to the accompanying drawings. The purpose of providing this detailed description is to instruct persons having an interest in the subject matter of the invention how to carry the invention into practical effect. However it is to be clearly understood that the specific nature of this detailed description does not supersede the generality of the preceding 20 broad description. In the drawings: Fig 1 is a partly exploded perspective view of a partly erected wall assembly in accordance with the embodiment of the invention; 25 Fig 2 is a cross-sectional view of a building structure including the wall assembly illustrated in Figure 1; Fig 3 is an upper perspective view of a top plate for the wall assembly in Figure 1; 30 Fig 4 is a lower perspective view of a top plate for the wall assembly in Figure 1; 11 Fig 5 is a close up exploded perspective view of an upper region of the wall assembly in Figure 1; Fig 6 is a close up perspective view of the upper region of the wall assembly in Fig 5 5 in an assembled condition; Fig 7 is an upper perspective view of the bottom plate of the wall assembly shown in Fig 1; 10 Figure 8 is a cross sectional view of the bottom plate shown in Fig 7; Fig 9 is an upper perspective view of a lower region of a wall assembly similar to that shown in Fig 1; 15 Fig 10 is a cross sectional view of a part of the lower region of the wall assembly shown in Figure 9 showing the bottom plate hold down bracket in section; Fig 11 is an upper perspective view of a panel of the wall assembly on Fig 1; 20 Fig 12 is an exploded perspective view of the panel of Fig 11; Fig 13 is a sectional plan view showing two panels engaged with each other and showing a support post received within the channels formed by the adjacent panels; 25 Fig 14 is an upper perspective view of a building structure like that shown in Fig 2, showing a support post in a combined channel defined by two adjacent panels and an electrical conduit being passed down another combined channel between adjacent panels; 30 12 Fig 15 is a sectional plan view showing two panels engaged with each other and showing a support post received within the channels formed by the adjacent panels that is a variation on that shown in Fig 13; 5 Fig 16 is a sectional view of a lower region of the wall assembly showing how the operatively lower end of the panel interacts with the hold down bracket; Fig 17 is a perspective view showing a builder fixing two panels to each other by passing fastening elements through the engaged formations of adjacent panels; 10 and Fig 18 is a close up perspective view showing how each fastening element is passed through the different layers of the engaged formations of adjacent panels. 15 In Fig 1 reference numeral 10 refers generally to a wall assembly in accordance with the invention. The wall assembly 10 comprises broadly a plurality of panels 12 arranged side by side in a line along the length of the wall assembly 10. Each panel 12 has front 20 and rear panel faces 14 and 16, an operatively upper edge 18 and an operatively lower edge 19, and two sides 20 and 22 extending between the upper and lower edges 18 and 19. The wall assembly 10 also includes a wall support in the form of a concrete slab 26 on the ground and a bottom plate 28 that is mounted on the slab 26. The panels 12 are mounted on the bottom plate 28 which runs along the 25 operatively lower edges 19 of the panels 12. The wall assembly 10 also includes a top plate 30 mounted on the operatively upper edge 18 of the panels 12 and which is fixed to the panels 12. Further the wall assembly 10 includes a plurality of support posts 32 positioned at spaced intervals along the length of the wall assembly 10. Each support post 32 is positioned between the abutting sides of 30 two adjacent panels 12 and is fixed to the top plate 20 and the bottom plate 28. Each of these components will now be described in more detail below.

13 The panels 12 define a post receiving channel 34 in each side 20 and 22 thereof, and each channel 34 is sized so that it can receive about one half of the cross sectional area of a support post 32 therein. In one illustrated embodiment shown 5 in Figures 1 to 14, the post receiving channels 34 have a rectangular cross sectional shape although it will be appreciated that other cross-sectional shapes such as a semi-circular cross sectional shape as shown in Figure 15 can also be used. 10 Each panel 12 comprises two outer layers 35, 36 and an insulating core 38 sandwiched between the two outer layers 35, 36. The two outer layers 35, 36 are formed of a sheet of steel of steel having some stiffness having a thickness in the range of 0.5mm to 0.7 mm. The insulating core 38 is made out of a solid insulating material such as expanded or extruded polystyrene foam. The post receiving 15 channels 34 are defined in that part of the sides of the panel formed by the insulating core 38. During manufacture of the panels, the channels 34 can be formed in the insulating core 38 by simply cutting the material out of the insulating core. Instead the core 38 which as a constant cross sectional shape along its length can be extruded with the channels 34 formed therein. In some forms of the 20 invention the post receiving channels 34 are rectangular and have a width of 20 to 40 mm and a depth of 20 to 40 mm. The two sides 20 and 22 of the panels 12 have complementary male and female engagement formations, shown generally by the numerals 40 and 42 in Figures 11 25 and 12. The abutting sides 20, 22 of adjacent panels 12 can be aligned with each other, and located in a correct position relative to each other, by engaging the male and female engagement formations 40 and 42 as shown in Figures 13 and 18. These joints that are used for positioning adjacent panels by engaging adjacent panels 12 with each other can conveniently be described as 'slip joints'. 30 The top plate 30 comprises one or more top plate sections of constant cross sectional profile that are arranged in series along the upper edges 18 of the panels 14 12. The top plate 30 comprises a panel receiving channel 44 that is configured to receive an upper edge region of the panels 12 therein. The panel receiving channel 44 in turn comprises a panel bridge 45 that extends across part of the operatively upper edge 18 of the panel 12 and panel skirts 46 extending over the 5 front and rear faces 14 and 16 of the panels 12. The top plate 30 further includes a top cap 50 that projects up above the panel receiving channel 44 when the top plate 30 is mounted on the panels 12. The top cap 50 comprises two cap wall sections 52 extending up away from the bridge 45 and a top cap bridge 54 extending between upper ends of the cap wall sections 52 and joining them 10 together. In the illustrated embodiment the panel bridge 45 extends from the front and rear faces 14 and 16 of the panel 12 to the cap wall sections 52 of the top cap 50, where it terminates. Thus it does not extend fully across the full thickness or depth 15 of the upper edge of the panels 12 from the front face 14 to the rear face 16 thereof. In other embodiments it could extend fully across the upper end 18 of the panels 12. The bottom plate 28 has walls that define two channel walls 56 that define a 20 bottom channel 58 that receive the operatively lower edges 19 of the panels 12 therein. The bottom plate 28 also has a skirt 59 extending away there from at an oblique angle therefrom on one side thereof corresponding to the rear face 16 of the panels 12. The walls 56 of the bottom channel 58 are low and define openings at spaced intervals along their length. The openings permit moisture to pass 25 through the walls, for example to drain any retained moisture, and to permit air to pass there through. As shown in Figure 8 the bottom plate 28 can be formed by deforming or working a single sheet of steel along its length to form the low walls and the oblique skirt. 30 The manner in which the support posts 12 are mounted to the top plate 30 and the bottom plate 28 will now be described in more detail. Each support post 32 has an 15 upper end 60 and a lower end 62. Each post also has a bore defining an internal screw thread formed in each of the upper and lower ends 60 and 62 thereof. Each support post 32 has a post top bracket 64 mounted on the upper end 60 5 thereof. Each post top bracket 64 comprises a post fixing portion 66 that is mounted over the operatively upper edge 18 of the panels 12 that are adjacent thereto, and has a fastening element opening 68 defined therein. Each post top bracket 64 also has a top plate fixing portion 70 extending over and round the post fixing portion 66 that is configured to complement the top plate 30 so that it can be 10 nested with the top plate 30. That is it complements the profile of the top plate channel 44 and the top cap 50 of the top plate 30. Each post top bracket 64 is mounted to its associated support post 32 by means of a post fastening element that is in the form of a bolt 72 having an enlarged head 15 and a screw threaded shank that complements the screw threaded bore within the upper end 60 of the post 32. The bolt 72 is passed through the fastening element opening 68 in the post fixing portion 66, and its screw threaded shank is received within and engaged with the screw threaded bore in the post 32. The head of the bolt 72 is retained above the post fixing portion 66. 20 The top plate fixing portion 70 of the post top bracket 64 is sandwiched between the upper edges 18 of the adjacent panels 12 and the top plate 30. Often different top plate sections have their adjacent edges mounted over the top of the post top bracket 64 as shown in Figures 5 and 6. The top plate 30 is fixed to the top plate 25 fixing portion 70 by means of fastening elements that are passed through the top plate 30 and the top plate fixing portion 70 of the post top bracket 64, and then into the panel 12 underneath the post top bracket 64. This is described immediately below with reference to fixing of the top plate 30 generally to the panels 12. 30 The top plate 30 is fixed to each of the panels 12 by means of fastening elements 78 that are passed through the top plate 30 and into the panels 12 adjacent to the top plate 30. The fastening elements 78 are each passed through one of the skirts 16 46 on the top plate channel 44, and into one of the front or rear faces 14 or 16 of the panels 12. The fastening elements 78 are positioned at closely spaced intervals along the length of the wall assembly. Conveniently the fastening elements 78 that are used for this purpose are nails that are driven through the top 5 plate 30 and into the panel 12. Other fastening elements 78 are passed through the top plate 30 and then through the panel top bracket 64 and then into the panel 12. The lower end 72 of each support post 32 is fixed to the bottom plate 28 by means 10 of a fastening element that is a bolt 76. The bolt 76 has an operatively upper portion having a screw threaded shank that is received within the bore in the lower end 72 of the post 32 and is engaged therewith. The bolt 76 has an operatively lower portion that also has a shank with a screw thread is passed through a bolt opening in the bottom plate 28 and is anchored in the concrete slab 26. It is 15 thereby fixed to each of the support post 32 and the slab 26 and in the process anchors down the bottom plate 28. This bolt 76 unlike the bolt 74 does not have an enlarged head. The bottom plate 28 is fixed to each of the panels 12 by means of fastening 20 elements that are nails 80 that are driven through the channel walls 56 of the bottom plate 28 and into the panel 12 behind the wall 56. As with the top plate these fixing nails are located at spaced intervals along the length of the bottom plate 28. Further there are nails that are driven horizontally through one of the channel walls 56 into the panel in one direction and other nails that driven 25 horizontally through the other channel wall 56 and into the panel 12 in an opposite direction. The bottom plate 28 is fixed to the slab 26 on which the wall assembly 10 is mounted by means of the bolts 76 which mount the lower ends 72 of the posts 32 30 on the slab 26. The bolts 76 mounted on the posts 32 pass through a bolt opening in the bottom plate 28 before entering the slab 26 so that the bottom plate 28 is sandwiched between the post 32 and the slab 26 and firmly fixed thereto. Also the 17 panels 12 bear down on the bottom plate 28 and apply some retaining force to the bottom plate 28. The panels in turn are held down by the top plate 30 which in turn is held down by the posts 32 through the post top bracket 64 . 5 In addition the wall assembly has hold down brackets for the express purpose of augmenting fixing of the assembly 10 by the support posts 32 for holding the bottom plate 28 firmly on the slab support 26 in all conditions. The hold down brackets 82 that are located at spaced intervals along the length of the bottom plate 28. 10 Each hold down bracket 82 comprises a bracket body 84 having a bracket bolt 86 passed there through which is received within the concrete slab 26. The bracket body 84 has a width that is sized to be received within the bottom channel 58 of the bottom plate 28 with a working clearance. This enables it to hold down the bottom 15 plate 28 across its full width when subjected to load, such as that due to high wind strength. In the illustrated embodiment the bracket 82 has two corrugations 85 extending in the direction of width of the bottom channel 58 which helps to strengthen it. The bracket bolt 86 has a screw threaded shank that is received within an opening in the slab 26 and is engaged therewith. Part of the shank of the 20 bracket bolt 86 projects up through the bracket body 84 and a nut 88 is mounted over the shank which is screwed down onto the bracket body 84. Figures 2 and 14 illustrate a building structure that is a house in accordance with one embodiment of the invention. The house is indicated generally by the 25 reference numeral 90. The house 90 comprises broadly a slab 26 and a wall assembly 10 as described above and a roof 92 mounted on the wall assembly. Unless otherwise indicated the same components will be indicated by the same reference numerals as in the 30 other drawings. In the house 90 the front face 14 of the panels faces into the inside of the house 90 and the rear of the panel 12 faces out to the outside of the house 90.

18 The roof 92 comprises a plurality of roof panels 94 having opposed ends that are similar in some respects to the wall panels 12. Each roof panel 94 is mounted on two spaced supports. One support is formed by the wall assembly 10 as described 5 above and shown in the drawings and the other support (not shown) is typically a structural beam for the roof spaced from the wall assembly 10 and extending parallel thereto. Each roof panel 94 comprises two outer layers of a sheet 35, 36 and an insulating core 38 sandwiched between the outer layers 35, 36. 10 As shown in the drawings the roof panels 94, towards said one ends thereof, are mounted on the wall assembly 19. The roof panels 94 rest on the top cap 50 of the top plate 30 spaced above the operatively upper edge 18 of the panels 12. Fastening elements that are nails 96 are driven through the panels 12 and into the top cap 50 of the top plate 30. The nails 96 are located at spaced intervals along 15 the length of the wall. The roof panels 94 are arranged at a slight pitch as shown in the drawings so that water falling on the roof can run to the edge of the roof 92. The roof panel 94 can form an eave as shown in Figure 2 to provide shade and also provide some shelter 20 against rain coming in through windows formed in the wall assembly. Further the roof 92 includes gutters 98 at the end of the panels 94 to collect water running off the roof 92 and run it off as storm water. Figure 14 shows some added features of the wall assembly 10 and the house 90. 25 In the house in Fig 14, the wall assembly has support posts received within the channels in the sides of adjacent panels every third panel along the length of the wall. One such support post is indicated by the reference numeral 100. Accordingly there are two channels formed abutting sides of adjacent panels 30 having channels 34 that do not have a support post received therein between successive support posts 32.

19 These channels 34 in the sides of adjacent panels 12 that are positioned between the support posts 32 are used to form conduit spaces for carrying conduits or pipes for water and electricity and data services to be provided within the house 90. For example electrical conduits carrying electrical cables are received in some of the 5 conduits and water pipes carrying water are received in some of the other conduits. In Fig 14 an electrical conduit 102 extends along the top plate 30 in a horizontal conduit space defined by the top plate 30 above the front faces 14 of the panels 12 on the inside of the house 90. One or more electrical cables 104 are received 10 inside the electrical conduit 102. The electrical cables 104 are directed down through an opening in the top plate 30 and into a vertical conduit space 106 formed by a combined channel comprising the channels 34 in the abutting sides 30, 32 of adjacent panels 12. These channels 34 are spaced one panel width apart from the channels 34 that receive the support post 100. 15 Further in Fig 14 a water conduit that is a water pipe extends along the top plate 30 in another horizontal conduit formed by the top plate 30. The water pipe can be directed into a different vertical conduit space (not shown) that is formed by different channels 34 again of abutting sides of adjacent panels 12. Thus the 20 channels 34 can be used to receive support posts 32 and also to form vertical conduit spaces running within the wall that receive electrical conduits and cables or water pipes. In use a wall assembly 10 (wall) and then a building structure 90 is built by casting 25 the concrete slab 26 on the ground according to known techniques. A wall line is then marked out on the slab 26 and a bottom plate 28 is laid out on the slab 26. The bottom plate 28 is fixed to the slab 26 by means of the spaced hold down brackets 82 located along the length of the wall. 30 A plurality of panels 12 is then mounted in position on the bottom plate 28 and a plurality of vertical support posts 32 is located between adjacent panels 12 at prescribed spaced intervals along the length of the wall. Typically the posts may 20 be positioned at three, four, five or six panel width intervals along the length of the wall. The spacing of the support posts 32 along the wall is a matter of engineering design. In one form the wall has a support post located at three panel intervals along the length thereof. 5 The panels 12 are initially placed in position by engaging the complementary male and female formations 40 and 42 of abutting sides 30, 32 of adjacent panels 12 with each other. This locates the panels 12 in the correct positions relative to each other along the line of the wall. Thereafter the panels 12 are fixed to each other by 10 means of fastening elements indicated generally by numeral 110 extending along each side of the front and rear faces 14 and 16 of each of the panels 12. As shown in Figures 13 and 18 each fastening element 110 is passed through three layers of steel sheet forming the female formation 42 and two layers of sheet forming the male formation 40. This leads to a very strong attachment of the 15 panels 12 to each other. Further as shown in Figure 17 a worker screws the screws 110 into the engaged panels at spaced intervals up the height of the panels 12 using a powered hand tool. As shown in Figure 16 recesses 112 are formed in the operatively lower edges 19 of the panels 12 to receive the hold down brackets 82 therein. This ensures that the upper edges 18 of the panels 12, and also that 20 the top plate 30, have a horizontally extending orientation. As shown in the drawings and particularly Figures 13 and 15 thereof, each support post 32 is received within the combined channel formed by the channels 34 of the abutting sides 30, 32 of two adjacent panels 12 as described above with a snug fit. 25 Once the support posts 32 and the panels 12 are in position the post top brackets 64 are mounted on each of the support posts 12. Each post top bracket 64 has a post fixing portion 66 that has a bolt opening 68 therein and a bolt 72 is passed through the post fixing portion 66 and into the threaded bore defined in the upper 30 end 60 of the support post 32. This fixes the post top bracket 64 to the upper end 60 of the post 32. Adjacent side regions of the adjacent panels 12 are sandwiched 21 between the post top bracket 64 and the upper edges of the panels 12 as shown in Figures 5 and 6 of the drawings. Thereafter the top plate 30 is mounted on the post top brackets 64 and the 5 operatively upper end 18 of the panels 12 to complete the wall assembly 10. The top plate 30 comprises a plurality of discrete top plate sections that are arranged in series along the top of the panels 12. The top plate sections are mounted over the upper edges 18 of the panels 12 and also over the top plate fixing portions 70 of the post top brackets 64. Thus each post top bracket 64 is sandwiched between 10 the top plate 30 and the post top bracket 64. Adjacent top plate sections are attached to each other indirectly by their respective attachments to the post top bracket. As described above the top plate 30 is fixed to the post top brackets 64 and also 15 the panels 12 by means of fastening elements that are nails 78 that are horizontally passed through the skirts 46 of the top plate channel 44 and into the panels 12. In those regions where the post top brackets 64 are sandwiched between the top plate 30 and a said panel 12 then the fastening elements are passed through the post top brackets 64 as well as the panel 12. 20 Thereafter the roof 92 can be mounted on the wall assembly 10. This is accomplished by mounting opposing end regions of the roof panels 94 on the wall assembly 10 and also on a spaced roof support (not shown). The roof panels 94 are fixed to the top plate 30 by means of fastening elements that are nails 96 that 25 are passed through the roof panel 94 and into the top cap 50 of the top plate 30. Thereafter the house built according to this invention is finished in the usual way. This includes rendering of the walls and adding electrical and water services and also finishing the house generally including installing fittings in the bathrooms and the kitchen. As this part of the building structure or house does not form part of the 30 invention defined in this application it will not be described further in this application.

22 An advantage of the wall assembly and building structure described above with reference to the drawings is that the building is built from a very limited number of building components. The panel acts as a structural member, an insulating material, and also as external and internal cladding. The spaced posts are made 5 of steel as are the upper and lower wall channels. This fewer number of building components results in fewer deliveries being made from suppliers of the different building materials to the building site to deliver the building materials. This in itself leads to a reduced carbon foot print during the construction process. Further it is much simpler to order the components used in this building structure and it takes 10 less time to order the components from the suppliers and then co-ordinate the delivery of the components with the suppliers. Further it will readily be appreciated that the construction of a home using these building components takes considerably less time than it takes to build a typical 15 timber frame home with a brick veneer. Applicant estimates that the construction technique described in the specification above leads to a 34% reduction in the length of time taken to progress the building process from pouring the slab to lockup of the building. The shorter construction time in turn leads to substantial financial savings. 20 Another advantage of the wall assembly and building structure described above with reference to the drawings is that it can be assembled very speedily by a worker having minimal skills. It does not require a skilled and experienced carpenter to build a timber frame and qualified bricklayer to build a brick veneer. 25 Further it will also be appreciated that overall fewer tradesmen having different trades relating to the basic structure, such as carpentry, bricklaying and plastering, are required to build the home. The use of different tradesmen having different skills adds considerably to the expense of building a home using traditional building techniques. 30 Yet another advantage of the wall assembly and building structure described above with reference to the drawings is that the thermal insulation properties of the 23 building are considerably improved over a typical prior art brick veneer construction. The building panels have a high level of insulation. Yet another advantage of the wall assembly and building structure described above with reference to the drawings is that they have a high level of sound insulation. The 5 solid panels described above with their foam layer between the steel skins are 'acoustic panels' that are every effective at insulating travel of sound through internal walls and also sound travel through external walls. Yet another advantage of the wall assembly and building structure described 10 above with reference to the drawings is that there is no risk of termite infestation. The wall panels have skin layers made of sheet steel and an inner core made of insulating foam. The steel and foam materials are not eaten or consumed by termites. Therefore there is no risk of termite infestation and no need to conduct regular checks for termites and install costly termite treatments in this building. 15 It will of course be realized that the above has been given only by way of illustrative example of the invention and that all such modifications and variations thereto, as would be apparent to persons skilled in the art, are deemed to fall within the broad scope and ambit of the invention as is herein set forth. 20

Claims (27)

1. A wall assembly for use in a building structure, including: 5 a wall support; a plurality of panels extending in a panel line along a length of the wall assembly, each panel having front and rear panel faces, an operatively upper edge and an operatively lower edge and two sides extending between the upper and lower edges; a bottom plate that runs along the operatively lower edge of the panels; 10 a top plate which is mounted on the operatively upper edge of the panels and which is fixed to the panels, the top plate being configured to receive the upper edge of the panels; and; a plurality of load bearing support posts positioned at spaced intervals along the length of the wall assembly anchored to the wall support, each support post being positioned 15 between the sides of two adjacent panels of the plurality of panels, and each support post including a post top bracket configured to hold the panels down and resist fore and aft displacement of the panels out of the panel line.

2. A wall assembly according to claim 1, wherein the post top brackets are configured 20 to complement the profile of the top plate and the post top brackets are fixed to the top plate.

3. A wall assembly according to claim 1 or claim 2, wherein the top plate defines a panel receiving channel for receiving the upper edges of the panels therein. 25

4. A wall assembly according to any one of claims 1 to 3, wherein the bottom plate is configured to locate the panels and resist fore and aft displacement of the panels out of the panel line. 30

5. A wall assembly according to any one of claims 1 to 4, wherein each support post is received within the plurality of panels by being spaced inward from the front and rear faces of the panels. 25

6. A wall assembly according to claim 1, wherein two or more of the panels define post receiving channels in the sides thereof, and each support post is received within a post receiving channel. 5

7. A wall assembly according to claim 6, wherein each panel comprises two outer layers and an insulating core sandwiched between the two outer layers, and wherein the panels have complementary engagement formations such that when the abutting sides of adjacent panels are engaged they locate the adjacent panels and hold the adjacent panels in position relative to each other. 10

8. A wall assembly according to claim 7, wherein the post receiving channels defined in the sides of the panels are formed in the Insulating core between the two outer layers and are spaced inwardly of the front and rear faces of the panels, and the post receiving channels on the abutting sides of adjacent panels are aligned with each other so that they 15 open into each other.

9. A wall assembly according to any one of claims 1 to 8, wherein the panel receiving channel of the top plate comprises a bridge that extends at least part of the way across the operatively upper edge of the panel, and skirts that extend from the bridge down the front 20 and rear faces of the panels.

10. A wall assembly according to claim 9, wherein the top plate is fixed to the panels by means of a plurality of fastening elements that are passed through the top plate and into the panel along the length of the top plate. 25

11. A wall assembly according to claim 10, wherein the fastening elements pass through one of the skirts on the panel receiving channel and into one of the front and rear faces of the panels. 30

12. A wall assembly according to any one of claims 9 to 11, wherein the top plate further includes a load bearing top cap that projects up above the panel receiving channel for supporting a roof member thereon. 26

13. A wall assembly according to claim 12, wherein the top cap comprises two wall sections extending away from the bridge and a top section extending across the tops of the two wall sections and joining them together. 5

14. A wall assembly according to any one of claims 1 to 13, wherein the top plate comprises a plurality of top plate sections that are arranged in series along the upper edge of the panels that are indirectly attached to each other by means of the post top brackets.

15. A wall assembly according to any one of claims 1 to 14, wherein each post top 10 bracket includes a top plate fixing portion mounted on the post fixing portion that Is configured to complement the top plate so that it can be nested with the top plate

16. A wall assembly according to claim 15, wherein the top plate fixing portion of the post top bracket is positioned between a portion of the top plate above it, and the upper 15 edges of the adjacent panels.

17. A wall assembly according to claim 16, wherein the top plate is fixed to each top plate fixing portion by means of fastening elements that are passed through the top plate and the top plate fixing portion. 20

18. A wall assembly according to any one of claims 15 to 17, wherein each post top bracket includes a post fixing portion that is mounted over the operatively upper edge of the adjacent panels and defines a fastening element opening therein, and a top plate fixing portion mounted on the post fixing portion that is configured to complement the top plate 25 so that it can be nested with the top plate.

19. A wall assembly according to claim 18, wherein each support post includes a bore formed in the upper and lower ends thereof, and the post top bracket is mounted on each support post by means of a post fastening element that is passed through the fastening 30 element opening in the post fixing portion of the post top plate, and is received within the bore formed in the upper end of the support post and engaged therewith. 27

20. A wall assembly according to claim 19, wherein the bore defined in the upper end of each support post has a screw thread formed thereon and the post fastening element is a bolt having an enlarged head and a complementary external screw thread formed on the shank thereof for engaging the thread in the bore. 5

21. A wall assembly according to any one of claims I to 20, wherein the lower end of each support post is fixed to the wall support and the lower end of each support post is also operatively connected to the bottom plate. 10

22. A wall assembly according to claim 21, wherein the lower end of each support post is fixed to the wall support by means of a lower post fastening element that is fixed to the support post, and the lower post fastening element is passed through a bolt opening In the bottom plate and is anchored in the support. 15

23. A wall assembly according to any one of claims 1 to 22, wherein the bottom plate defines a bottom channel having two channel walls that receive the operatively lower edges of the panels therein whereby to resist fore and aft displacement of the panels out of the panel line. 20

24. A wall assembly according to claim 23, wherein the bottom plate is fixed to each of the panels by means of fastening elements that are passed through one of the channel walls and into the panel along the length of the bottom plate, and the wall assembly further includes hold down brackets located at spaced intervals along the bottom plate, wherein each hold down bracket is mounted on the wall support and fixes the bottom plate down 25 onto the support for holding the bottom plate down when the wall assembly is subjected to high load.

25, A building structure including: a wall assembly as defined in any one of claims 1 to 24; and 30 a roof mounted on the wall assembly.

26. A building structure according to claim 25, wherein the top plate includes a panel receiving portion and a top cap portion, and the roof comprises a plurality of roof panels 28 arranged side by side along at least part of the length of the wall assembly and each roof panel is mounted on the top cap portion of the top plate and is fixed to the top plate by means of fastening elements that are passed through the roof panels and into the top cap portion of the top plate. 5

27. A wall assembly substantially as herein described in the detailed description of the invention with reference to Figures 1 to 14 of the drawings