AU2018203645B2 - Connection system - Google Patents

Abstract

Embodiments generally relate to connection systems, kits and construction methods involving connections between column elements, as well as structures and structural elements including such column elements and the column elements themselves. Some embodiments relate to a column element, comprising: a hollow column, an elongate tendon, a locator, a tendon coupler and a bearing plate. The hollow column has first and second ends and defines one or more side walls at least partially surrounding a hollow cavity. The elongate tendon is at least partially disposed in the cavity, the tendon having a first male threaded end and a second male threaded end. The locator is disposed at or near the first end of the hollow column and is configured to substantially align the first end of the tendon with a central axis of the hollow column. The tendon coupler is coupled to the tendon and defines a first female threaded portion threadedly engaged with at least part of the first male threaded end of the tendon up to a restriction, such that rotation of the tendon coupler causes rotation of the tendon. The tendon coupler further defines a second female threaded portion coaxial with the first female threaded portion and configured to receive and threadedly engage the second male threaded end of a tendon of another similar column element. The tendon coupler also defines a keyed surface configured to engage a complimentary surface of a tool to assist in rotating the tendon coupler and tendon. The bearing plate is disposed at or near the first end of the hollow column and configured to transfer axial forces between the tendon coupler and the hollow column. The tendon coupler and the first end of the tendon are disposed at or near the first end of the hollow column and the second end of the tendon is disposed at or near the second end of the hollow column. 1/11 100 500 600 100b -310 30 400 210400 200b 202--,00a 2000 500b 100a 200a 00b N10 00 4000 400 1O&a 312 300a 212 20 Fig.lA Fig.lC

Description

1/11 100

500

600 100b -310 30 400 210400 200b

202--,00a

2000

500b 100a

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Fig.lA Fig.lC

"Connection system"

Technical Field

[0001] Embodiments generally relate to connection systems, kits and construction methods involving connections between column elements, as well as structures and structural elements including such column elements and the column elements themselves.

Background

[0002] Building structures are often erected using modular structural elements such as wall panels, columns or frame elements. There are various methods and connection systems for connecting the structural elements together to form a building. However, some existing constructions methods and connection systems can be time consuming to use, or the parts expensive to manufacture.

[0003] It is desired to address or ameliorate one or more shortcomings or disadvantages associated with existing construction methods, or to at least provide a useful alternative thereto.

[0004] Throughout this specification and claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", 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.

[0005] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Summary

[0006] Some embodiments relate to a column element, comprising: a hollow column having first and second ends and defining one or more side walls at least partially surrounding a hollow cavity; an elongate tendon at least partially disposed in the cavity, the tendon having a first male threaded end and a second male threaded end; a locator at or near thefirst end of the hollow column configured to substantially align the first end of the tendon with a central axis of the hollow column; a tendon coupler coupled to the tendon, the tendon coupler defining: a first female threaded portion threadedly engaged with at least part of the first male threaded end of the tendon up to a restriction, such that rotation of the tendon coupler causes rotation of the tendon; a second female threaded portion coaxial with the first female threaded portion and configured to receive and threadedly engage the second male threaded end of a tendon of another similar column element; and a keyed surface configured to engage a complimentary surface of a tool to assist in rotating the tendon coupler and tendon; and a bearing plate at or near the first end of the hollow column configured to transfer axial forces between the tendon coupler and the hollow column, wherein the tendon coupler and the first end of the tendon are disposed at or near the first end of the hollow column and the second end of the tendon is disposed at or near the second end of the hollow column.

[0007] In some embodiments, the bearing plate may be arranged between the tendon coupler and the hollow column, with the tendon passing through a tendon aperture defined in the bearing plate.

[0008] In some embodiments, the tendon coupler may further define a tapered surface configured to be at least partially received in the hollow column of another similar column element and assist in locating and aligning adjacent column elements. The tapered surface of the tendon coupler may be at least partially conical. The keyed surface of the tendon coupler may be at least partially defined by a hexagonal prism. An opening of the second female threaded portion of the coupler may be surrounded by a chamfered edge to assist in locating the second male threaded end of a tendon of another similar column element relative to the second female threaded portion.

[0009] In some embodiments, the male threaded ends of the tendon may be separated by a non-threaded portion of the tendon.

[0010] In some embodiments, the column element may further comprise one or more mounting plates attached to the hollow column and configured to allow the hollow column to be fixed to another structural element.

[0011] In some embodiments, the column element may further comprise a connection plate at or near the first end of the hollow column to assist in connecting horizontally adjacent column elements, the connection plate comprising two connection rods extending substantially perpendicularly away from a surface of the connection plate, wherein the connection rods are configured to be received in corresponding apertures of a connection plate coupler to connect respective connection plates of horizontally adjacent column elements.

[0012] In some embodiments, the connection plate may comprise the bearing plate. In some embodiments, the bearing plate may comprise the locator.

[0013] Some embodiments relate to a structural element comprising one or more of the described column elements fixed to the structural element. The structural element may comprise a wall panel, for example. The or each column element may be fixed to the structural element by one or more selected from: mechanical fasteners, adhesive bonding or welding. The or each hollow column may be arranged along a height of the wall panel to assist in connecting vertically adjacent wall panels.

[0014] In some embodiments, the connection rods are threaded and configured to receive nuts after insertion through the apertures of the connection plate coupler to restrict the connection rods from being removed from the connection plate coupler. The connection plate may be fixed to the wall panel by a number of mechanical fasteners extending through respective fastener apertures defined in the connection plate.

[0015] Some embodiments relate to a construction process comprising: positioning a first one of the described structural elements on a base; rotating the or each tendon coupler of the first structural element to screw the second male threaded end of the or each tendon into one or more female threaded portions in or on the base; positioning a second one of the described structural elements above the first structural element, such that the or each hollow column and tendon of the second structural element is aligned with the or each hollow column and tendon of the first structural element; and rotating the or each tendon coupler of the second structural element to screw the second male threaded end of the or each tendon of the second structural element into the second female threaded portion of the or each tendon coupler of the first structural element.

[0016] In some embodiments, the construction process may further comprise: subsequently positioning one or more further ones of the described structural elements above the previous structural element, such that the or each hollow column and tendon of the or each further structural element is aligned with the or each hollow column and tendon of the previous structural element; and rotating the or each tendon coupler of the or each further structural element to screw the second male threaded end of the or each tendon of the or each further structural element into the second female threaded portion of the or each tendon coupler of the previous structural element.

[0017] Some embodiments relate to a structure formed according to anyone of the described construction processes.

[0018] Some embodiments relate to a structure comprising one or more of the described column elements.

[0019] Some embodiments relate to a structure comprising one or more of the described structural elements.

[0020] Some embodiments relate to a kit of parts comprising at least one of each component of any one of the described column elements in an unassembled configuration.

[0021] Some embodiments relate to a kit of parts comprising at least one of each component of any one of the described structural elements in an unassembled configuration.

[0022] Some embodiments relate to a tendon coupler comprising: a body having a first end and a second end; a first female threaded portion formed in the first end of the body and configured to receive and threadedly engage at least part of a male threaded end of a first tendon, an innermost end of the first female threaded portion defining a restriction configured to restrict the male threaded end from progressing beyond the restriction towards the second end of the body; and a second female threaded portion formed in the second end of the body, the second female threaded portion being coaxially aligned with the first female threaded portion and configured to receive and threadedly engage at least part of a male threaded end of a second tendon to couple the second tendon to the first tendon; wherein the body defines a keyed surface at or near the second end configured to engage a complimentary surface of a tool to assist in rotating the tendon coupler relative to the first tendon to threadedly engage the first female threaded portion with the male threaded end of the first tendon until the progression of the first tendon into the female threaded portion is restricted by the restriction, such that the coupler can act as a tendon head with rotation of the coupler causing rotation of the first tendon, and wherein the body defines a tapered surface at or near the first end configured to be received in and assist in locating one hollow column relative to another hollow column.

[0023] In some embodiments, the tapered surface of the tendon coupler may be at least partially conical. The keyed surface of the tendon coupler may be at least partially defined by a hexagonal prism. An opening of the second female threaded portion of the coupler may be surrounded by a chamfered edge to assist in locating the male threaded end of the second tendon relative to the second female threaded portion.

Brief Description of Drawings

[0024] Embodiments are described in further detail by way of reference to the accompanying drawings, in which:

[0025] Figure 1A is a front view of a column element according to some embodiments;

[0026] Figure 1B is a front view of the column element of Figure 1A positioned below a similar column element to be connected to the column element of Figure 1A;

[0027] Figure IC is a front view of the column elements of Figure 1B connected to each other;

[0028] Figure 2A is a front view of a hollow column component of the column element of Figure lA;

[0029] Figure 2B is a side view of part of the hollow column of Figure 2A;

[0030] Figure 3 is a side view of a tendon component of the column element of Figure 1A;

[0031] Figure 4A is a plan view of a locator component of the column element of Figure lA;

[0032] Figure 4B is a side view of the locator of Figure 4A;

[0033] Figure 5A is a perspective view of a tendon coupler component of the column element of Figure 1A;

[0034] Figure 5B is a cross-sectional view of the tendon coupler of Figure 5A showing section B-B (i.e., in a sectional plane parallel to line B-B and central axis 530);

[0035] Figure 6A is a plan view of a bearing plate (or connection plate) component of the column element of Figure 1A;

[0036] Figure 6B is a side view of the bearing plate of Figure 6A;

[0037] Figure 7A is a plan view of a connection plate coupler according to some embodiments;

[0038] Figure 7B is a plan view of a connection plate coupler according to some embodiments;

[0039] Figure 7C is a plan view of a connection plate coupler according to some embodiments;

[0040] Figure 7D is a plan view of a connection plate coupler according to some embodiments;

[0041] Figure 8 is a front view of a structural element comprising a plurality of column elements showing a partial cross-section of one of the column elements;

[0042] Figure 9A is a perspective view of a base according to some embodiments;

[0043] Figure 9B is a partial perspective view of the base of Figure 9A fixed to a foundation in the form of a concrete slab;

[0044] Figure 10 is a cross-sectional view of a building structure comprising a plurality of structural elements connected to each other and to a base by a plurality of column elements, according to some embodiments;

[0045] Figure 11A is a perspective view of a floor section placed between two wall panels in a disconnected configuration;

[0046] Figure 11B is a perspective view of the floor section and wall panels of Figure 11A in a connected configuration;

[0047] Figure 12A is a perspective view of a locator according to some embodiments;

[0048] Figure 12B is a plan view of the locator of Figure 12A; and

[0049] Figure 12C is a side view of the locator of Figure 12A.

Description of Embodiments

[0050] Embodiments generally relate to connection systems, kits and construction methods involving connections between column elements, as well as structures and structural elements including such column elements and the column elements themselves.

[0051] Referring to Figures lAto IC, a column element 100 is shown according to some embodiments. The column element 100 generally comprises a hollow column 200 (Figures 2A and 2B), a tendon 300 (Figure 3), a locator 400 (Figures 4A and 4B), a tendon coupler 500 (Figures 5A and 5B), and a bearing plate 600 (Figures 6A and 6B).

[0052] The column element 100 is configured to be connected to similar vertically adjacent column elements 100 via the tendons 300 and tendon couplers 500 to form a column 1002 in a structure 1000 (Figure 10). In some embodiments, the column elements 100 may be mounted in structural elements 800, such as wall panels, for example (Figure 8A), to assist in connecting vertically adjacent structural elements 800.

In some embodiments, the column elements 100 may be configured to be connected to similar horizontally adjacent column elements, and may assist in connecting horizontally adjacent structural elements 800 or wall panels (Figure 10).

[0053] The column elements and connection systems described herein may allow for more efficient manufacturing and construction methods by simplifying the construction process.

[0054] Referring to Figures 2A and 2B, a hollow column 200 is shown according to some embodiments. The hollow column 200 may have a first end 210 and a second end 212 and may define one or more side walls 202 at least partially surrounding a hollow cavity 204. The hollow cavity 204 may define any suitable shape for accommodating at least part of the tendon 300. For example, the hollow column 200 may comprise a square hollow section defining four side walls 202 surrounding a cavity 204 in the shape of a square prism. In some embodiments, one side of the hollow column 200 may be open, and the side walls 202 may define an elongate channel. In some embodiments, the hollow column 200 may define any other suitable profile, such as round, elliptical, cylindrical, rectangular, triangular, polygonal, U-section, I-section or H-section, for example. In some embodiments, the profile of the hollow column 200 may be selected to enhance a stiffness of the hollow column 200.

[0055] In some embodiments, the column element 100 may comprise one or more mounting brackets or mounting plates 240 for mounting the hollow column 200 on or in a structural element 700. The mounting plates 240 may define one or more fastener apertures 242 configured to receive one or more mechanical fasteners to fix the hollow column 200 to the structural element 700. The mounting plates 240 may be fixed to the hollow column 200 by welding, adhesive bonding, or mechanical fastening. In some embodiments, the mounting plates 240 may be arranged at a standoff from the hollow column 200 (i.e., with a gap between each mounting plate 240 and the hollow column 200). This may be achieved with a spacer or shim 244 disposed between the mounting plate 240 and the hollow column 200. For example, the mounting plate 240 may have a thickness of about 4mm, and the standoff distance may be about 1mm.

[0056] The hollow column 200 and mounting plates 240 may be formed of any suitable materials having sufficient strength and stiffness, when acting as a column or part of a column, to support a structure against the expected loads for a given application. For example, the hollow column 200 may be formed of a polymer, composite material, concrete, metal, metal alloy, steel or structural steel, for example.

[0057] Referring to Figure 3, a tendon 300 is shown according to some embodiments. The tendon 300 may comprise an elongate rod 302 having a first male threaded end 310 and a second male threaded end 312. In some embodiments, the tendon 300 may be threaded along its entire length. In some embodiments, the tendon 300 may only be threaded near the ends 310, 312 with a non-threaded portion 304 extending between the two threaded ends 310, 312 as shown in Figure 3. The tendon 300 may be at least partially disposed in the cavity 204 of the hollow column 200 of the column element 100 as shown in Figure 1A.

[0058] The tendon 300 may be formed of any suitable material having sufficient tensile strength and torsional stiffness to connect vertically adjacent column elements 100 and/or structural elements 700 with sufficient strength to withstand the expected loads for a given application. For example, the tendon 300 may be formed of a polymer, composite material, metal, metal alloy, steel or high tensile steel, for example.

[0059] The locator 400 maybe disposed at or near the first end 210 of the hollow column 200 between the tendon 300 and the side walls 202 to substantially align the first end 310 of the tendon 300 with a central axis 230 of the hollow column 200 (Figure 1A). In some embodiments, the column element 100 may comprise a second locator 400 disposed at or near the second end 212 of the hollow column 200 between the tendon 300 and the side walls 202 to substantially align the second end 312 of the tendon 300 with the central axis 230 of the hollow column 200. The locators 400 may each restrict lateral movement of at least part of the tendon 300 relative to the hollow column 200 (i.e., away from the central axis 230), but allow rotation of the tendon 300 relative to the hollow column 200. The locators 400 may transfer shear loads from the tendon 300 to the structure and/or structural elements 800 via the hollow column 200.

The locators 400 may also protect the tendon 300 during manufacture, transport, storage and/or assembly.

[0060] In some embodiments, one or both of the locators 400 may be fixed to the hollow column 200, such as by welding or mechanical fastening, for example. In some embodiments, one or both of the locators 400 may be disposed within the cavity 204. In some embodiments, one or both of the locators 400 may be disposed outside the cavity 204 at the first end 210 or second end 212 of the hollow column 200. In some embodiments, one or both of the locators 400 may not be fixed to the hollow column 200, and may only rest against the side walls 202. For example, in some embodiments one or both of the locators 400 may comprise separate inserts.

[0061] In some embodiments, the locators 400 maybe formed of a rigid material such as metal or steel, for example. In some embodiments, the locators 400 may be formed of a flexible material such as a polymer, elastomer or rubber, for example. In some embodiments, one of the locators 400 may be formed of a rigid material and the other may be formed of a flexible material. For example, one locator 400 may be formed of a rigid material such as steel and welded to the hollow column 200 at or near the first end 210, while a second locator 400 may comprise a rubber insert disposed at or near the second end 212.

[0062] Referring to Figures 4A and 4B, the locator 400 is shown according to some embodiments. The locator 400 may comprise a plate 402 defining a tendon aperture 404. The plate 402 may have a shape configured to closely fit within the side walls 202 of the hollow column 200 to thereby align the tendon aperture 404 with the central axis 230 of the hollow column 200. For example, the locator plate 402 may be configured to fit within the cavity of a segment of square hollow section structural steel, and may define a generally square shape with rounded corners.

[0063] Referring to Figures 12A to 12C, another locator 1200 is shown according to some embodiments. The form of locator 1200 shown here may be better suited to a separate insert, such as a flexible locator insert, for example. The locator 1200 may comprise a body 1202 defining a tendon aperture 1204. If the locator 1200 is to be used as a separate (non-fixed) insert, it may be formed with a depth (in a direction along a central axis of the tendon aperture 1204) large enough to mitigate against rotation of the body 1202 away from the central axis 230 of the hollow column 200, i.e., to maintain the tendon aperture 1204 substantially in alignment with the central axis 230.

[0064] Referring to Figures 5A and 5B, a tendon coupler 500 is shown according to some embodiments. The tendon coupler 500 may comprise a body 502 having a first end 504 and a second end 506, with a first female threaded portion 510 formed in the first end 504 of the body 502 and a second female threaded portion 512 formed in the second end 506 of the body 502.

[0065] The first female threaded portion 510 is configured to receive and threadedly engage at least part of the first male threaded end 310 of a first tendon 300 (e.g., tendon 300a of column element 100a, as shown in Figures lB and IC), and the second female threaded portion 512 is configured to receive and threadedly engage at least part of the second male threaded end 312 of a second tendon 300 (e.g., tendon 300b of another similar column element 100b, as shown in Figure IC) to couple the second tendon 300b to the first tendon 300a.

[0066] The second female threaded portion 512 may be coaxially aligned with the first female threaded portion 510, such that the first and second tendons 300a, 300b are coaxially aligned with each other (and the tendon coupler 500) when threadedly engaged with the tendon coupler 500. For example, the first and second female threaded portions 510, 512 may be coaxially aligned with a central axis 530 of the tendon coupler 500.

[0067] The tendon coupler 500 may include a restriction 516 between the first and second female threaded portions 510, 512 configured to restrict the first male threaded end 310 (threadedly engaged with the first female threaded portion 512) from progressing beyond the restriction 516 towards the second end 506 of the body 502. The restriction 516 may be formed at an innermost end of the first female threaded portion 510. In some embodiments, the restriction 516 may comprise a physical barrier, such as a wall, for example. In some embodiments, the restriction 516 may comprise a non-threaded section of a bore extending between the first and second female threaded portions 510, 512 as shown in Figure 5B.

[0068] In some embodiments, the tendon coupler 500 may be fixed to the tendon by welding, adhesive bonding, or a thread locking compound, for example. In some embodiments, first male threaded end 310 may be bound to the tendon coupler 500 by threaded engagement with the first female threaded portion 510 and abutment against the restriction 516.

[0069] When the tendon coupler 500 is coupled to the first end 310 of a tendon 300 (e.g. tendon 300a in Figure 1B), the first female threaded portion 510 maybe threadedly engaged with at least part of the first male threaded end 310 of the tendon 300 up to the restriction 516, such that rotation of the tendon coupler 500 causes rotation of the tendon 300. That is, so that the tendon coupler 500 acts as a tendon head of the tendon 300. The tendon coupler 500 can then be rotated to threadedly engage the second male threaded end 312 of the tendon 300 with the second female threaded portion 512 of another similar tendon coupler 500. In this way, a plurality of similar column elements 100 may be connected to each other via the tendon 300 and tendon coupler 500 of each column element 100.

[0070] The body 502 of the tendon coupler 500 may define a keyed surface 520 at or near the second end 506 configured to engage a complimentary surface of a tool (not shown) to assist in rotating the tendon coupler 500. For example, a tool may be used to engage the keyed surface 520 and rotate the tendon coupler 500 relative to the tendon 300 to threadedly engage the first female threaded portion 510 with the first male threaded end 310 of the tendon 300 until the progression of the tendon 300 into the first female threaded portion 510 is restricted by the restriction 516. The tendon coupler 500 may then be used as a tendon head to rotate the tendon 300 and threadedly engage the second male threaded end 312 into the second female threaded portion 512 of a similar tendon coupler 500. For example, the tendon coupler 500 of a vertically adjacent column element 100.

[0071] The body 502 may define a tapered surface 522 at or near the first end 504 configured to be received in and assist in locating one hollow column 200 (e.g. hollow column 200b in Figure 1B) relative to another hollow column 200 (e.g. hollow column 200a in Figure IB). For example, a first diameter of the tapered surface 522 nearer the first end 504 may be similar or slightly less than an internal diameter of the hollow column 200, to achieve a close fit of the tendon coupler 500 in the cavity 204 of the hollow column 200; and a second diameter of the tapered surface 522 nearer the second end 506 may be significantly less than the first diameter to make it easier to locate the hollow column 200 relative to the tendon coupler 500.

[0072] In some embodiments, the tapered surface 522 of the tendon coupler 500 may be conical, frusto-conical, at least partially conical, or pyramidal, for example. In some embodiments, the keyed surface 520 of the tendon coupler 500 may be at least partially defined by a polygonal prism, such as a hexagonal prism, for example. In some embodiments, an opening of the second female threaded portion 512 of the coupler may be surrounded by a tapered surface 524, such as a conical or chamfered surface, or a chamfered edge, for example, to assist in locating the second male threaded end of a tendon of another similar column element relative to the second female threaded portion.

[0073] In some embodiments, the keyed surface 520 may correspond to a standard sized hex head, such as M20, M22, M24, M27, M30, M33, M36, M39, M42, 1", 12", 2", 212", or 3", for example. Similarly, the first and second male threaded ends 310, 312 and first and second female threaded portions 510, 512 may comprise a standard thread size, such as M20, M22, M24, M27, M30, M33, M36, M39, M42, 1", 1%",2",212", or 3", for example. In some embodiments, the thread size may be different to the head size. For example, the thread size of the first and second male threaded ends 310, 312 and first and second female threaded portions 510, 512 may be less than the hex head size. This may allow for the tapered surface 524 to be larger than it could be otherwise.

[0074] In some embodiments, the tendon coupler 500 may be machined from a single piece of material. In some embodiments, the tendon coupler 500 may comprise a combination of joined components, such as a separate hex head portion (corresponding to the keyed surface 520) welded to a main body (corresponding to the tapered surface 522).

[0075] The tendon coupler 500 may be formed of any suitable material having sufficient tensile strength, shear strength and torsional stiffness to connect vertically adjacent column elements 100 and/or structural elements 700 with sufficient strength to withstand the expected loads for a given application. For example, the tendon coupler 500 may be formed of a polymer, composite material, metal, metal alloy, steel or high tensile steel, for example.

[0076] Referring to Figures 6A and 6B, a bearing plate 600 is shown according to some embodiments. The bearing plate 600 may be disposed at or near the first end 210 of the hollow column 200 and configured to transfer axial forces between the tendon coupler 500 and the hollow column 200.

[0077] The bearing plate 600 may define a tendon aperture 604 configured to receive at least part of the tendon 300, such that, in the assembled column element 100, the tendon coupler 500 is disposed on one side of the bearing plate 600 and the hollow column 200 and a major portion of the tendon 300 are disposed on the other side of the bearing plate 600. That is, the tendon coupler 500 and first end 310 of the tendon 300 are disposed at or near the first end 210 of the hollow column 200 and the second end 312 of the tendon 300 is disposed at or near the second end 212 of the hollow column 200.

[0078] When the tendon 300 of a column element 100 is connected to a tendon coupler 500 of a vertically adjacent column element 100 and tensioned, the tension in the tendon 300 exerts a force on each of the tendon couplers 500 to which it is connected in opposite directions towards each other. These forces are transferred via the bearing plates 600 to apply a compression force to the hollow column 200 which is resisted by the hollow column 200 and bearing plates 600.

[0079] The bearing plate 600 may further define one or more fastening apertures 606 configured to receive one or more mechanical fasteners (not shown) for fastening the bearing plate 600 to the hollow column 200 and/or another structural element 700. In some embodiments, the bearing plate 600 may be configured to bear directly on the structural element 700 (such as the top and/or bottom of a wall panel) rather than on the hollow column 200.The bearing plate 600 may alternatively be referred to as a top plate, base plate or support plate, for example, for supporting the tendon 300 under tension.

[0080] In some embodiments, the bearing plate 600 may comprise the locator 400, i.e., the bearing plate 600 may be configured to substantially align the first end 310 of the tendon 300 with the central axis 230 of the hollow column 200. For example, in some embodiments, the bearing plate 600 may comprise one or more protrusions configured to rest against internal and/or external surfaces of the side walls 202. In some embodiments, the bearing plate 600 may be fixed to the hollow column 200, such as by welding or mechanical fastening, for example.

[0081] In some embodiments, the column element 100 may comprise a connection plate at or near the first end 210 of the hollow column 200 to assist in connecting horizontally adjacent column elements 100. In some embodiments, such as the embodiment shown in Figures 1 to 7, the bearing plate 600 may also be configured to function as a connection plate 600. In other embodiments, the connection plate may be separate from the bearing plate 600.

[0082] The connection plate 600 may comprise one or more connection rods 616 extending away from a surface 602 of the connection plate 600. For example, the connection plate 600 may comprise two connection rods, as shown in Figure 6A. The connection rods 616 may be configured to be received in corresponding apertures 716 of a connection plate coupler 700 (Figure 7A) to connect respective connection plates 600 of horizontally adjacent column elements.

[0083] In some embodiments, the connection rods 616 may extend substantially perpendicularly away from the surface 602 of the connection plate 600. In some embodiments, the connection rods 616 may be threaded and configured to receive nuts 626 (Figure 10) after insertion through the apertures 716 of the connection plate coupler 700 to restrict the connection rods 616 from being removed from the connection plate coupler 700.

[0084] Referring to Figures 7A to 7D, a number of exemplary connection plate couplers 700 are shown according to some embodiments. The connection plate coupler 700 may comprise a body 702, which may be in the form of a plate, for example. The body 702 may comprise two or more branches 720, with each branch 720 defining one or more apertures 716 configured to receive corresponding connection rods 616 of a connection plate 600, to thereby connect two or more connection plates 600 to each other. In this way, two or more horizontally adjacent structural elements 800 (e.g. wall panels) comprising column elements 100 with connection plates 600 may be connected via a connection plate coupler 700.

[0085] In some embodiments, the body 702 may comprise two branches 720 as shown in Figures 7A, 7B and 7D, which may be arranged at different relative angles. For example, the branches 720 may extend away from each other as shown in Figure 7A.

[0086] Referring to Figure 7B, another exemplary connection plate coupler 700b is shown according to some embodiments, with two branches 720 arranged perpendicularly relative to each other. In some embodiments, an angle between the branches 720 may be greater than, less than or substantially equal to 90. For example, referring to Figure 7C, another exemplary connection plate coupler 700c is shown according to some embodiments, with two branches 720 separated by an angle of about 135°. Referring to Figure 7D, another connection plate coupler 700d is shown according to some embodiments, with three branches 720 arranged perpendicularly in a T-shaped configuration.

[0087] In various embodiments, the connection plate coupler 700 may comprise two, three, four, five, six or more branches 720, which may be arranged with equal or differing angles between each adjacent pair of branches 720, which may include acute, perpendicular, obtuse, straight or reflex angles.

[0088] Referring to Figure 8, a structural element 800 is shown according to some embodiments. A partial cross-section of the structural element 800 is shown, indicated by bounding box 804, illustrating the components of the column elements 100 as discussed above in relation to Figures 1 to 6.

[0089] The structural element 800 shown comprises a wall panel 802 with two column elements 100 mounted to the wall panel 802. However, in various other embodiments, a structural element 800 may comprise one, two, three, four, five, six, seven or more column elements 100 as suitable for a given application. In some embodiments, the structural element 800 may comprise any one or more of: a wall panel, a column segment, a floor element, a roof element, or a frame module, for example.

[0090] The column elements 100 maybe fixed to the wall panel 802 by one or more of: welding, adhesive bonding, or mechanical fastening, for example. In some embodiments, the column elements 100 may be mounted to the wall panel 802 via mounting plates 240 as discussed above, for example.

[0091] Referring to Figures 9A and 9B, abase element 900 is shown according to some embodiments. The base element 900 may comprise one or more base plates 902. The base plates 902 may be fixed to a rail 904, or in some embodiments, the base element 900 may comprise a single base plate 902 in the form of a rail 904. The base plate(s) 902 and/or rail 904 may be fixed to a foundation 920, such as a concrete slab as shown in Figure 9B, for example.

[0092] Each base plate 902 may define one or more fixing apertures 906 configured to receive mechanical fasteners 916 (such as bolts, for example), to fasten the base plate 902 to the foundation 920. In some embodiments, the fixing apertures 906 may be significantly larger in diameter than the mechanical fasteners 916 to allow for lateral adjustment of the position of the base plate 902 relative to the foundation. In some embodiments, washers 918 (such as slotted washers, for example) may be used in conjunction with the mechanical fasteners 916 to transfer loads between the mechanical fastener 916 and the base plate 902. In some embodiments, the mechanical fasteners 916 may comprise bolts driven into the foundation 920. In some embodiments, the mechanical fasteners 916 may comprise nuts configured to engage threaded rods protruding from the foundation 920. For example, where the foundation 920 is a concrete slab, the threaded rods may be chemset (resin-bonded) into the slab.

[0093] Each base plate 902 may comprise a male threaded protrusion 910 configured to be received in and threadedly engage with the first female threaded portion 510 of a corresponding base tendon coupler 500a as shown in Figures 9B and 10 (which may be substantially as described above in relation to tendon coupler 500).

[0094] The structural element 800 may then be positioned on top of the base element 900 such that the tendon 300b of a corresponding column element 100b of the structural element 800 are aligned with the base tendon coupler 500a, and the tendon coupler 500b of the column element 100b may be rotated to threadedly engage the second male threaded end 312 of the tendon 300b with the second female threaded portion 512 of the base tendon coupler 500a. In this way, the structural element 800 may be connected to the base 900 via the column element 100b, tendon coupler 500b, tendon 300b, base tendon coupler 500a, male threaded protrusion 910 and base plate 902, as shown in Figure 10.

[0095] In some embodiments, multiple structural elements 800, such as wall panels, may be connected to an array of base elements 900, as shown in Figure 10, to form a structure 1000, such as a building, for example.

[0096] In some embodiments, horizontally adjacent structural elements 800 may be connected to each other by connection plates 600 and connection plate couplers 700 as described above and as shown in Figure 10.

[0097] In some embodiments, one or more successive rows of structural elements 800, such as wall panels, may be connected to previously installed vertically adjacent structural elements 800 via the tendons 300 and tendon couplers 500 of the column elements 100 of the structural elements 800, as described above and as shown in Figure 10.

[0098] In various embodiments, the dimensions of the column elements 100 and components thereof may vary depending on the given application. In some embodiments, the structural elements 800 may comprise partial height wall panels 802 having a height less than that of a full storey of a building structure 1000. For example, the height of the wall panels 802, hollow columns 200 and tendons 300 suitable for such wall panels 802 may be approximately Im, or a fraction of the full height of a storey of the building structure 1000.

[0099] In some embodiments, the structural elements 800 may comprise full height wall panels 802, in which case, the height of the wall panels 802, hollow columns 200 and tendons 300 suitable for such wall panels 802 may be approximately equal to one full storey height of the building structure 1000, such as in the range of about 2m to 4m, or about 2.4m to 3m, for example.

[0100] Referring to Figures 11A and 11B, in some embodiments, some of the structural elements 800 may comprise a wall panels 802 with column elements 100 that extend beyond the height of the wall panel 802 to allow for placement of other structural elements, such as floor sections 1100, between vertically adjacent wall panels 802. A first wall panel 802a of a first structural element 800a may be fixed to a base element 900; then a floor section 1100 may be placed above the first wall panel 802a; and then a second wall panel 802b of a second structural element 800b may be placed above the floor section 1100 and first wall panel 802a with its column elements 100b extending beyond the second wall panel 802b alongside the floor section 1100 and down to connect to the column elements 100a of the first wall panel 802a.

[0101] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims (21)

CLAIMS:

1. A column element, comprising: a hollow column having first and second ends and defining one or more side walls at least partially surrounding a hollow cavity; an elongate tendon at least partially disposed in the cavity, the tendon having a first male threaded end and a second male threaded end; a locator at or near the first end of the hollow column configured to substantially align the first end of the tendon with a central axis of the hollow column; a tendon coupler coupled to the tendon, the tendon coupler defining: a first female threaded portion threadedly engaged with at least part of the first male threaded end of the tendon up to a restriction, such that rotation of the tendon coupler causes rotation of the tendon; a second female threaded portion coaxial with the first female threaded portion and configured to receive and threadedly engage the second male threaded end of a tendon of another similar column element; and a keyed surface configured to engage a complimentary surface of a tool to assist in rotating the tendon coupler and tendon; and a bearing plate at or near the first end of the hollow column configured to transfer axial forces between the tendon coupler and the hollow column, wherein the tendon coupler and the first end of the tendon are disposed at or near the first end of the hollow column and the second end of the tendon is disposed at or near the second end of the hollow column.

2. A column element according to claim 1, wherein the bearing plate is arranged between the tendon coupler and the hollow column, with the tendon passing through a tendon aperture defined in the bearing plate.

3. A column element according to claim 1 or 2, wherein the tendon coupler further defines a tapered surface configured to be at least partially received in the hollow column of another similar column element and assist in locating and aligning adjacent column elements.

4. A column element according to any one of claims I to 3, wherein the tapered surface of the tendon coupler is at least partially conical.

5. A column element according to any one of claims 1 to 4, wherein the keyed surface of the tendon coupler is at least partially defined by a hexagonal prism.

6. A column element according to any one of claims I to 5, wherein an opening of the second female threaded portion of the coupler is surrounded by a chamfered edge to assist in locating the second male threaded end of a tendon of another similar column element relative to the second female threaded portion.

7. A column element according to any one of claims 1 to 6, wherein the male threaded ends of the tendon are separated by a non-threaded portion of the tendon.

8. A column element according to any one of claims I to 7, further comprising one or more mounting plates attached to the hollow column and configured to allow the hollow column to be fixed to another structural element.

9. A column element according to any one of claims 1 to 8, further comprising a connection plate at or near the first end of the hollow column to assist in connecting horizontally adjacent column elements, the connection plate comprising two connection rods extending substantially perpendicularly away from a surface of the connection plate, wherein the connection rods are configured to be received in corresponding apertures of a connection plate coupler to connect respective connection plates of horizontally adjacent column elements.

10. A column element according to claim 9, wherein the connection plate comprises the bearing plate.

11. A column element according to any one of claims 1 to 10, wherein the bearing plate comprises the locator.

12. A structural element comprising one or more column elements according to any one of claims 1 to 11 fixed to the structural element.

13. A structural element according to claim 12, wherein the or each column element is fixed to the structural element by one or more selected from: mechanical fasteners, adhesive bonding or welding.

14. A structural element according to claim 12 or 13, wherein the structural element comprises a wall panel.

15. A structural element according to claim 14, wherein the or each hollow column is arranged along a height of the wall panel to assist in connecting vertically adjacent wall panels.

16. A structural element according to any one of claims 12 to 15 when dependent on claim 9, wherein the connection rods are threaded and configured to receive nuts after insertion through the apertures of the connection plate coupler to restrict the connection rods from being removed from the connection plate coupler.

17. A structural element according to any one of claims 12 to 16 when dependent on claim 9, wherein the connection plate is fixed to the wall panel by a number of mechanical fasteners extending through respective fastener apertures defined in the connection plate.

18. A construction process comprising: positioning a first structural element according to any one of claims 12 to 17 on a base; rotating the or each tendon coupler of the first structural element to screw the second male threaded end of the or each tendon into one or more female threaded portions in or on the base; positioning a second structural element according to any one of claims 12 to 17 above the first structural element, such that the or each hollow column and tendon of the second structural element is aligned with the or each hollow column and tendon of the first structural element; and rotating the or each tendon coupler of the second structural element to screw the second male threaded end of the or each tendon of the second structural element into the second female threaded portion of the or each tendon coupler of the first structural element.

19. A construction process according to claim 18, further comprising: subsequently positioning one or more further structural elements according to any one of claims 12 to 17 above the previous structural element, such that the or each hollow column and tendon of the or each further structural element is aligned with the or each hollow column and tendon of the previous structural element; and rotating the or each tendon coupler of the or each further structural element to screw the second male threaded end of the or each tendon of the or each further structural element into the second female threaded portion of the or each tendon coupler of the previous structural element.

20. A structure formed according to the construction process of claim 18 or 19, or comprising any one or more of: a column element according to any one of claims 1 to 11; and a structural element according to any one of claims 12 to 17.

21. A kit of parts comprising at least one of each component recited in any one of claims 1 to 17 in an unassembled configuration.