AU2017200582A1 - A pre-fabricated component structural wall system - Google Patents

Abstract

Abstract There is provided a pre-fabricated component structural wall system having a plurality of pre fabricated wall panel component. Each wall panel comprises a frame; sarking fastened to the frame; spacers fastened to the frame over the sarking; and cladding fastened to the spacers. The plurality of wall panels may have differing dimensions and be arranged in differing orientations so as to be configured for accommodation windows or doors of differing sizes and orientations VERTICAL BATTE X! j" Folded composite panef fixed to structural wall. Scale: 1-25 Figure 5

Description

A pre-fabricated component structural wall system 2017200582 30 Jan 2017

Field of the Invention [1] The present invention relates to a pre-fabricated component structural wall system.

Background of the Invention [2] The present invention seeks to provide a pre-fabricated component structural wall system, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[3] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Disclosure [4] According to one aspect, there is provided a wall panel for a pre-fabricated component structural wall system comprising: a frame; sarking fastened to the frame; spacers fastened to the frame over the sarking; and cladding fastened to the spacers.

[5] The sarking may be moisture permeable.

[6] The wall panel further may comprise a gasket for creating a seal with an adjacently located other wall panel in use.

[7] The spacers comprise spacer battens.

[8] The battens comprise lateral battens and wherein the cladding may be folded around the lateral battens.

[9] The gasket may be fastened to a folded portion of the cladding [10] The lateral battens are slightly inwardly located to allow for accommodation of the gasket.

[11] The gasket may be compressible.

[12] The gasket may be compressible to a minimum of approximately 3mm.

[13] The wall panel further may comprise an internal lining.

[14] The internal lining may comprise at least one of plasterboard and plywood.

[15] The wall panel may be configured for use for a concrete slab setdown wherein the frame may comprise a bottom stud for fastening to the setdown and wherein at least the cladding extends down beyond the bottom stud to reach beyond the level of the setdown.

[16] The wall panel may comprise an internal lining and wherein the internal lining may be shortened for making space for the ground slab.

[17] The wall panel may further comprise a plug located between the cladding and the sarking along a bottom edge of the panel. 1 [18] The plug may comprise foam. 2017200582 30 Jan 2017 [19] The wall panel may be configured for a ground floor bearer and joist system comprising at least a joist and wherein the frame may comprise a bottom stud for fastening to the flooring panel and wherein the cladding extends beyond the bottom stud to reach beyond the joist.

[20] The ground floor bearer and joist system may comprise a flooring material and wherein the panel may comprise an interior lining and wherein the interior lining may be shortened to make space for the flooring material.

[21] The wall panel may further comprise a plug located between the cladding and the sarking along a bottom edge of the panel.

[22] The plug may comprise foam.

[23] According to another aspect, there is provided a pre-fabricated component structural wall system comprising a plurality of rectangular wall panels as described herein.

[24] The plurality of wall panels have differing dimensions and are arranged in differing orientations so as to be configured for accommodation windows or doors of differing sizes and orientations.

[25] The wall system may comprise a first and second wall panel configured to form a T-junction and wherein the system further may comprise two right angle sections fasten respective corners of the respective frames of the wall panels.

[26] The wall system may comprise a first and second wall panel configured to form a corner joint wherein: the respective frames of the wall panels are fastened together; and the second wall panel further may comprise a further vertical stud for fastening to the frame of the first panel.

[27] The cladding may comprise a corner fold.

[28] The wall system may comprise a first wall panel configured to form a window/door junction with a window/door frame wherein the system may comprise a gasket located between the frame of the first panel and the window/door frame.

[29] The gasket may be exterior the cladding of the first panel.

[30] Fasteners, penetrating the cladding and the gasket, fasten the window/door frame and the wall panel.

[31] The wall panel further may comprise a further centre stud.

[32] At least one of the fasteners fastens to the further centre stud.

[33] Other aspects of the invention are also disclosed. 2

Brief Description of the Drawings 2017200582 30 Jan 2017 [34] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which: [35] Figures 1-5 show the construction of a wall panel in accordance with a preferred embodiment of the present disclosure; [36] Figures 6-14 show the utilisation of the wall panel of Figure 1 for forming wall systems comprising differing dimensions and accommodations for windows, doors and the like in accordance with embodiments of the present disclosure; [37] Figure 15 shows the utilisation of the wall panel for a ground floor slab set down in accordance with an embodiment of the present disclosure; [38] Figures 16-17 shows the utilisation of the wall panel for a bearer and joist building system in accordance with an embodiment of the present disclosure; [39] Figure 18 shows the formation of a standard panel connection joint utilising the wall panels of Figure 1 in accordance with an embodiment of the present disclosure; [40] Figure 19 shows the formation of a T-junction utilising the wall panels of Figure 1 in accordance with an embodiment of the present disclosure; [41] Figures 20-21 shows the formation of a corner junction utilising the wall panels of Figure 1 in accordance with an embodiment of the present disclosure; [42] Figure 19 shows the formation of a window/door junction utilising the wall panels of Figure 1 in accordance with an embodiment of the present disclosure; [43] Figures 24 - 26 show the utilisation of the wall system for differing types of exterior finish in accordance with embodiments of the present disclosure; and [44] Figures 27 - 28 shows a T-section gasket seal used in the junction between the two structural wall studs to provide two waterproof layers to the external wall in accordance with embodiments of the present disclosure.

Description of Embodiments [45] For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure. 3 [46] Before the structures, systems and associated methods relating to the pre-fabricated component structural wall system are disclosed and described, it is to be understood that this disclosure is not limited to the particular configurations, process steps, and materials disclosed herein as such may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the disclosure will be limited only by the claims and equivalents thereof. 2017200582 30 Jan 2017 [47] In describing and claiming the subject matter of the disclosure, the following terminology will be used in accordance with the definitions set out below.

[48] It must be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[49] As used herein, the terms "comprising," "including," "containing," "characterised by," and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.

[50] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

System 1 [51] In the accompanying figures, there is provided a prefabricated component structural wall system 1 for use in construction of buildings such as residential, commercial and industrial buildings. As will be appreciated from the ensuing description, the system 1 greatly reduces construction time and costs. Specifically, the construction process entails the off-site prefabrication of a plurality of wall panels 2 and other associated building materials for a particular building design and the subsequent on-site fastening together of the wall panels 2 preferably by way of simple screw fasteners.

[52] Specifically, turning to figure 18, there is shown a connection joint between adjoining wall panels 2 of the system 1. As can be seen, each wall panel 2 has an internal side comprising an internal lining 3, such as plasterboard, plywood or similar. The internal lining 3 may be installed on site in embodiments after services (i.e. electrical/plumbing) have been installed.

[53] Each wall panel 2 comprises a frame 4, preferably a steel frame 4 for supporting the wall panels. The frame 4 may be manufactured by fastening as steel top stud, bottom stud studs and noggings as will be described in further detail with reference to figure 1.

[54] As can be seen, the adjacently located frames 4 of each wall panel 2 may be fastened together by way of screw type fasteners 5. In this manner, no specialised construction equipment is necessary during the construction process and building workers may piece together the building quickly and easily requiring only an electric screwdriver, for example. 4 [55] On an exterior side of the frame 4 is fastened sarking 6. In a preferred embodiment, the sarking 6 is made from a breathable material. The sarking 6 may be fastened to the exterior edges of the frame 4 by way of double sided tape. 2017200582 30 Jan 2017 [56] Each wall panel 2 further comprises spacers 7 located on the external side of the sarking 6.

[57] In the embodiment shown, the spacers 7 comprise battens as will be described in further detail below.

[58] Each wall panel 2 further comprises cladding 8 fastened on an external side of the spacers 7. The cladding 8 may be folded around the corner edges of the spacers 7 as only shown in figure 18.

[59] Furthermore, a gasket seal 9 may be provided between the folded portions of cladding so as to create a seal between the cladding 8 sections.

Wall panels 2 [60] Figures 1-5 will now be described in further detail to illustrate the construction process of the above-described wall panels 2.

[61] Specifically, turning to figure 1, there is shown the frame 4 of the wall panel 2. As alluded to above, in a preferred embodiment, the frame 4 is manufactured from steel so as to comprise structural integrity suitable for building construction.

[62] In the preferred embodiment, the frame 4 is manufactured from 90 x 35 (or similar) steel studs, these being readily available within the construction industry. These steel studs are utilised to form a steel top stud 10, a steel bottom stud 11, an interior steel stud 12 and horizontal steel nogging 13.

[63] Turning now to figure 2, having constructed the frame 4, the sarking 6 is fastened to an external side of the frame 4, which may include folding around the edges of the frame. As alluded to above, in a preferred embodiment, the sarking 6 is a vapour/moisture the breathable barrier. The sarking 6 may be fastened to the frame 4 by way of double sided tape or other suitable adhesive.

[64] Turning now to figure 3, once the sarking 6 has been fastened to the external side of the frame 4, the spacers 7 are fastened to the external side of the sarking 6.

[65] As alluded to above, in a preferred embodiment, the spacers 7 comprise battens 43.

[66] In one embodiment, each battens 43 is manufactured from two 46 x 45 folded steel angles, fastened together to form a batten 43 comprising a C-shape. In one embodiment, the steel angles may be manufactured from cutting the above-described steel studs lengthwise in half.

[67] Turning now to figure 4, there is shown the fastening together of the respective steel angles to form each battens 43. The battens 43 thereby create a spacing of substantially 45 mm from the sarking 6 in the preferred embodiment. 5 [68] In other embodiments, each batten in the 43 may be manufactured from a rectangular section comprising predrilled holes for fixing. 2017200582 30 Jan 2017 [69] In the preferred embodiment shown, three battens 43 are used for each wall panel 2 comprising a middle spacer and respective laterally opposite lateral spacers. Furthermore, in the preferred embodiment shown, the battens 43 are preferably vertically orientated.

[70] Turning now to figure 5, cladding 8 is then fastened to the external side of the spacers 7. The cladding 8 may be manufactured from a suitable composite material or the like comprising weather resistant properties.

[71] As can be seen in the embodiment shown in figure 5, the lateral edges of the cladding 8 may be folded around the edges of the battens 43. As such, so as to accommodate the folding of the cladding 8 around the lateral edges of the battens 43, the lateral battens 43 may be slightly laterally inset with respect to the lateral edge of the frame 4 as is best seen from figure 18.

[72] Turning now to figure 6, as can be seen, once the cladding 8 has been applied to the spacers 7, lateral gasket seals 9 may be fastened to at least one edge of the wall panel 2, and specifically to the folded edge of the cladding 8. The gasket seal 9 allows for the creation of a seal with an adjacently located wall panel 2 in use. Specifically, returning to figure 18, there is shown the gasket 9 located between the folded edges of the cladding 8. In a preferred embodiment, the gasket seal 9 is compressible.

[73] As such, turning now to figure 7, there is shown the joining together of two wall panels 2. An embodiment shown in figure 7, the wall panels 2 shown comprise substantially identical dimensions. However, for the purposes of making allowance for windows, doors and the like wall panels 2 of differing dimensions and may be provided.

[74] Specifically, turning to figure 8, there is shown wall panels 2 of differing dimensions being utilised (including in differing orientations) so as to make allowance for a window or door. Specifically, in the embodiment shown in figure 8, the wall panels 2 comprise a standard wall panel 2A and a sill panel 2B, the latter being used for the purposes of creating a sill as will be described in further detail below. As can be seen, the sill panel 2B has been rotated 90° with respect to the conventional wall panel 2A.

[75] Specifically, turning to figure 9, there is shown how the combination of differing dimensions and orientated wall panels 2 creates an allowance for a window or door 16 to be inserted therein.

[76] Specifically, in the embodiment shown, the wall system 1 comprises the standard wall panel 2A, the sill panel 2B and the spandrel panel 2C configured to make allowance for the insertion of a window 16 therein. As can also be seen, the gasket 9 is applied to the edge of the assembly so as to create a seal with an adjacent section. 6 [77] The address in section may be in line or at right angles. Specifically, Figure 12 shows the adjoining of a section of wall at right angles. 2017200582 30 Jan 2017 [78] Turning to figure 11 there is shown the utilisation of a wall panels 2 of differing dimensions and orientations for the construction building structures of substantial variety.

[79] Specifically, turning to figure 13, there is shown the wall system 1 illustrating the accommodation of windows and doors of differing dimensions and differing locations therein.

[80] Having described the structural wall system 1 above, there will now be described various specific construction techniques for the wall system 1.

Ground slab set down [81] Turning now to figure 15, there is shown the utilisation of the wall system 1 for applications comprising a ground floor slab. In this embodiment, a ground slab is utilised as the foundation for the building where after the wall panels 2 are constructed thereon as will be described in further detail below.

[82] As can be seen in the embodiment a fastener 20 is utilised to anchor the steel bottom stud 11 to the floor slab 19. Also, in this embodiment, the internal lining 3 may be shortened so as to not extend to the full extent of the steel bottom stud 11 so as to make allowance for the ground slab 19. Furthermore, the cladding 8 may extend beyond the steel bottom stud 11 so as to extend beyond the set down.

[83] During construction, the ground slab 19 maybe cut away or the steel bottom stud 8 located prior to the pouring of the concrete to form the set down.

[84] In this embodiment, a foam filling 26 may be employed to substantially seal the bottom openings of the wall panels 2 between the cladding and the sarking 6 so as to, for example, prevent the entrance of insects and the like.

Ground floor bearer and joist system [85] Turning now to figure 16, there is shown the utilisation of the wall system 1 for buildings having bearers and joists. The embodiment shown in figure 16 shows the ground floor of the building.

[86] As can be seen in this embodiment, the construction comprises a floor joist 21, joist hanger 22 joist bearer 23 and subflooring panel 24. Finished flooring material 25 is overlaid the subflooring panel 24.

[87] In this embodiment, the internal lining 13 is similarly shortened so as to make allowance for the finished flooring material 25. Furthermore, the exterior spacers 7, sarking 6 and cladding 8 extend downwards beyond the extent of the joist hanger 22 and joist bearer 23 as shown. In this embodiment, the foam filling 26 may similarly be employed. 7

First floor bearer and joist system 2017200582 30 Jan 2017 [88] Turning now to figure 17, there is shown the application of the wall system 1 to an intermediate bearer and joist flooring system, being the first floor in this embodiment.

[89] As can be seen, the wall system 1 configuration as substantially that which was described above in figure 16 with reference to the ground floor bearer and joist system except in that Z flashing 44 is utilised between the vertically adjacent sarking 6, spacers 7 and cladding 8.

Connection joint [90] Turning now to figure 19, there is shown the construction of a standard panel connection joint 27 between an external wall panel 2D and an internal wall panel 2E. In this embodiment, half cut right angle steel sections 45 are fixed between the frames 4.

[91] As can be appreciated, in this embodiment, the internal wall panel 2E may be located substantially anywhere along the width of the exterior wall panel 28 thereby negating the need to manufacture wall panels 2 having specific dimensions to coincide at the connection joint is 27.

Corner Junction [92] Turning now to figure 20, there is shown the utilisation of the wall system 1 for the construction of a corner junction.

[93] As can be seen, in this embodiment, the corner comprises a standard wall panel 2F having a width of approximately 120 mm and a custom wall panel 2G.

[94] The custom wall panel 2G has been modified in that a centre steel stud 33 has been provided so as to provide purchase for the fasteners 5 extending through the studs of the standard wall panel 2F. As can also be seen, the exterior cladding 8 is furthermore folded at the corner 45 so as to provide a right angle at the corner.

[95] Figure 21 shows the centre steel stud 33 in further detail. As can be appreciated from figure 21, a fastener 5 need only be provided at one edge of the centre steel stud 33

Window/door Junction [96] Turning now to figure 22, there is shown the utilisation of the wall system 1 for forming a window/door junction.

[97] As can be seen, junction comprises a wall panel 2H and a window or door frame 34.

[98] The wall panel 2H similarly comprises a further centre steel stud 46, but wherein the centre steel stud 46 is arranged in the same direction as the lateral stud 4.

[99] Furthermore, a gasket 35 is provided between the cladding 8 and the window or door frame 34. As also be seen, the interior lining 3 extends only as far as the gasket 35 and the edge of the cladding 8. 8 [100] Fasteners 46 fasten to the respective studs 46,4 and the window or door frame 34 and extend through the cladding 8 and the gasket 35. 2017200582 30 Jan 2017 [101] There will now be described the application of the wall system 14 differing types of cladding 8.

[102] It should be noted that in embodiments the window or door frame 34 need not necessarily be provided in the configuration shown in figure 22 and may be located at other locations and orientations.

Composite cladding [103] Turning now to figure 23, there is shown the utilisation of the wall system 14 the abovedescribed composite cladding.

[104] In embodiments, the concert cladding may be supplied by Alucobond™ or similar. As can be seen, and as was similarly described above, the composite cladding 8 may be folded at the edges of the battens 43 and the gasket 9 provided therebetween.

Insulated render finish [105] Turning now to figure 24, there is shown the utilisation of exterior insulated render finish comprising insulated panels 48.

[106] As can be appreciated from this embodiment, on account of there being no folding of the cladding as was described above, the battens 9 are spaced closer together yet with the gasket 9 therebetween.

[107] Furthermore, a sealant 47 such as polyurethane foam or the like is provided between the adjacent insulated panels 48.

[108] The insulator panels 36 may be secured to the battens 43 by way of fasteners 37.

Terracotta tiles [109] Turning now to figure 25, there is shown the utilisation of terracotta tiles 38. In this embodiment, the terracotta tiles 8 may be fastened by way of horizontal battens 39 (such as those supplied by Terracade™ or similar) so as to avoid the utilisation of fasteners.

[110] As can be seen, the arrangement is similar to that which was described above with regard to the insulated render finish as was substantially described in figure 24 in that the battens 43 are spaced closer together so as to accommodate the gasket 9 therein.

Fire panel connection joint [111] Turning now to figure 26, there is shown the utilisation of the wall system 1 for fire panel connection joints. As can be seen, in this embodiment, each wall comprises internally and externally located fire rated linings 40. 9 [112] Furthermore, the battens 43 are fastened to the exterior surface of the external fire rated lining 40 by way of batten screw 41. Furthermore, a fire rated sealant 42 may be provided between the external fire rated lining panels 40. 2017200582 30 Jan 2017 T-junction gasket seal [113] Figures 27-29 show the utilisation of a T-section gasket seal in the junction between the two structural wall studs used to provide two waterproof layers to the external wall.

[114] Specifically, figure 27 shows the utilisation of the T-section gasket seal for a wall system 1 comprises composite cladding.

[115] Figure 28 shows the utilisation of the T-section gasket seal for a wall system 1 comprising an insulative render finish and figure 29 shows the utilisation of the T-section section gasket seal for a wall system 1 comprising external terracotta tiles. 10

Interpretation 2017200582 30 Jan 2017

Embodiments: [116] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[117] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[118] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Different Instances of Objects [119] As used herein, unless otherwise specified the use of the ordinal adjectives "first", "second", "third", etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details [120] In the description provided herein, numerous specific details are set forth. Flowever, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description. 11

Terminology 2017200582 30 Jan 2017 [121] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

Comprising and Including [122] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[123] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention [124] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[125] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability [126] It is apparent from the above, that the arrangements described are applicable to the construction industries. 12

Claims (29)

1. Claims

   1. A wall panel for a pre-fabricated component structural wall system comprising: a frame; sarking fastened to the frame; spacers fastened to the frame over the sarking; and cladding fastened to the spacers.
2. 2. A wall panel as claimed in claim 1, wherein the sarking is moisture permeable.
3. 3. A wall panel as claimed in claim 1, wherein the wall panel further comprises a gasket for creating a seal with an adjacently located other wall panel in use.
4. 4. A wall panel as claimed in claim 3 wherein the spacers comprise spacer battens.
5. 5. A wall panel as claimed in claim 4, wherein the battens comprise lateral battens and wherein the cladding is folded around the lateral battens.
6. 6. A wall panel as claimed in claim 5, wherein the gasket is fastened to a folded portion of the cladding
7. 7. A wall panel as claimed in claim 6, wherein the lateral battens are slightly inwardly located to allow for accommodation of the gasket.
8. 8. A wall panel as claimed in claim 3, wherein the gasket is compressible.
9. 9. A wall panel as claimed in claim 8, wherein the gasket is compressible to a minimum of approximately 3mm.
10. 10. A wall panel as claimed in claim 1, wherein the wall panel further comprises an internal lining.
11. 11. A wall panel as claimed in claim 10, wherein the internal lining comprises at least one of plasterboard and plywood.
12. 12. A wall panel as claimed in claim 1, wherein the wall panel is configured for use for a concrete slab setdown wherein the frame comprises a bottom stud for fastening to the setdown and wherein at least the cladding extends down beyond the bottom stud to reach beyond the level of the setdown.
13. 13. A wall panel as claimed in claim 12, wherein the wall panel comprises an internal lining and wherein the internal lining is shortened for making space for the ground slab.
14. 14. A wall panel as claimed in claim 12, further comprising a plug located between the cladding and the sarking along a bottom edge of the panel.
15. 15. A wall panel as claimed in claim 14, wherein the plug comprises foam.
16. 16. A wall panel as claimed in claim 1, wherein the wall panel is configured for a ground floor bearer and joist system comprising at least a joist and wherein the frame comprises a bottom stud for fastening to the flooring panel and wherein the cladding extends beyond the bottom stud to reach beyond the joist.
17. 17. A wall panel as claimed in claim 16, wherein the ground floor bearer and joist system comprises a flooring material and wherein the panel comprises an interior lining and wherein the interior lining is shortened to make space for the flooring material.
18. 18. A wall panel as claimed in claim 17, further comprising a plug located between the cladding and the sarking along a bottom edge of the panel.
19. 19. A wall panel as claimed in claim 18, wherein the plug comprises foam.
20. 20. A pre-fabricated component structural wall system comprising a plurality of rectangular wall panels as claimed in any one of claims 1-19.
21. 21. A structural wall system as claimed in claim 20, wherein the plurality of wall panels have differing dimensions and are arranged in differing orientations so as to be configured for accommodation windows or doors of differing sizes and orientations.
22. 22. A structural wall system as claimed in claim 20, wherein the wall system comprises a first and second wall panel configured to form a T-junction and wherein the system further comprises two right angle sections fasten respective corners of the respective frames of the wall panels.
23. 23. A structural wall system as claimed in claim 20, wherein the wall system comprises a first and second wall panel configured to form a corner joint wherein: the respective frames of the wall panels are fastened together; and the second wall panel further comprises a further vertical stud for fastening to the frame of the first panel.
24. 24. A structural wall system as claimed in claim 23, wherein the cladding comprises a corner fold.
25. 25. A structural wall system as claimed in claim 20, wherein the wall system comprises a first wall panel configured to form a window/door junction with a window/door frame wherein the system comprises a gasket located between the frame of the first panel and the window/door frame.
26. 26. A structural wall system as claimed in claim 25, wherein the gasket is exterior the cladding of the first panel.
27. 27. A structural wall system as claimed in claim 26, wherein fasteners, penetrating the cladding and the gasket, fasten the window/door frame and the wall panel.
28. 28. A structural wall system as claimed in claim 27, wherein the wall panel further comprises a further centre stud.
29. 29. A structural wall system as claimed in claim 28, wherein at least one of the fasteners fastens to the further centre stud.