AU2020230343A1 - Enhanced Modular Wall System - Google Patents

Abstract

A modular wall structure. The modular wall structure being adapted to be site- erected and concrete-filled. The modular wall structure including: a first wall skin panel and a second wall skin panel; a plurality of webbing stud elements coupled to each of the first wall skin panel and the second wall skin panel to thereby substantially locate the first wall skin panel relative to the second wall skin panel. 16/16 800 810 Provide formwork modules 820 Assemble wall panels, with webbing elements there between, to define a wall cavity 830 Insert reinforcement 840 Pour concrete into the wall cavity FIG. 21

Description

16/16 800

810

Provide formwork modules

820

Assemble wall panels, with webbing elements there between, to define a wall cavity

830

Insert reinforcement

840

Pour concrete into the wall cavity

FIG. 21

ENHANCED MODULAR WALL SYSTEM FIELD OF THE INVENTION

The present invention relates to building construction and in particular to reinforced

concrete wall construction.

The invention has been developed primarily for use as a site-erected concrete- filled

wall system and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field

of use.

BACKGROUND OF THE INVENTION

Any discussion of the prior art throughout the specification should in no way be

considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

Example modular wall systems are described in International Patent Publication

WO/2016/141418 (PCT/AU2016/000088) dated 15 September 2019, which is herewith incorporated by reference in their entirety.

The construction of concrete walls in high rise buildings is typically time consuming and

expensive. There is a need in the art for an improved apparatus for, and respective methods of, constructing concrete walls.

OBJECT OF THE INVENTION

It is an object of the present invention to overcome or ameliorate at least one of the

disadvantages of the prior art, or to provide a useful alternative.

It is an object of the invention in its preferred form to provide a site-erected concrete-filled wall system.

SUMMARY OF THE INVENTION

According to an aspect of the technology there is provided a modular wall system

adapted to be site-erected and concrete-filled. The modular wall system including:

a first wall skin panel and a second wall skin panel;

a plurality of webbing stud elements coupled to each of the first wall skin and the second wall skin to thereby substantially locate the first wall skin relative to the

second wall skin.

According to an aspect of the invention there is provided a formwork module adapted

to be site-erected, the formwork module including:

a pair of opposable wall skin panels;

a plurality of webbing stud elements releasably couplable to both of the opposing

panels; and

wherein the webbing elements, when coupled to the opposing panels, extend vertically between the opposing panels for stabilising and maintaining a spaced

apart configuration there between, such that the opposing panels extend in substantially parallel vertical planes.

According to an aspect of the invention there is provided a formwork module adapted

to be site-erected, the formwork module including:

a base tray for marking up the wall systems on solid ground or footings;

a first wall skin (sheeting or panelling) and a second wall skin (sheeting or panelling)

that is seated (or located) in the tray, wherein the first wall skin has a separate first

external lining and first internal lining, and the second wall skin has a separate second external lining and second internal lining.

Preferably, connection assemblies are provided for joining wall panels in a straight, or

angled configuration. More preferably, connection assemblies enable joining of wall panels in a 90 degree or 135 degree configuration (being internal or external). Most

preferably, the connection assemblies are formed by multiple elements that can be coupled on-site. The connection assembly preferably multiple elements that enables wall panels to be slid into coupling engagement.

Preferably, the internal linings defining connection channels for each receiving a respective vertical interconnecting studs element (typically constructed of PVC, plastics,

or the like) for interconnecting the first wall skin (sheeting or panelling) and a second wall skin (sheeting or panelling), wherein the stud elements vertically slide into, and

are retained by, the respective connection channel, thereby forming the wall cavity

with the desirable wall thickness and providing rigidity and stability to the wall system.

Preferably, each of the wall panels comprise a substantially rectangular configuration;

whereby each of the wall panels has a top edge, a bottom edge, and a pair of side

edges.

Preferably, each of the webbing or stud elements comprises a substantially rectangular

configuration; whereby each of the webbing elements has a top edge, a bottom edge,

and a pair of side edges.

Preferably, in use, the webbing or stud elements define wall thickness. More

preferably, the spaced apart configuration between the wall panels defines a cavity for receiving concrete therein. Most preferably, a webbing element has one or more

apertures for enabling concrete to flow across the cavity.

Preferably, the webbing elements are elongate having a retaining element or portion on each side-edge that is adapted to releasably engage the connection slot/channels of

opposing wall panels.

Preferably, the webbing elements are installed vertically between the first wall panel and the second wall panel. More preferably, the first wall panel and the second wall

panel are spaced apart. Most preferably, the first wall panel and the second wall panel

are substantially parallel in orientation.

Each webbing element preferably defines one or more apertures there through. Each

webbing element preferably defines a plurality of apertures. The webbing element

apertures being preferably sized for enabling concrete to flow there through. The webbing element apertures being preferably configured for enabling reinforcement bars to be located along a length of wall.

The assembly preferably further comprises a base tray for spanning between opposing wall panels and adapted to retain concrete poured within the cavity between wall

panels. More preferably, in use webbing element segments the cavity, and wherein webbing element has one or more apertures for enabling fluid communication across

the cavity.

Preferably, two or more wall modules can be interconnected. More preferably, the side edges of the wall units are adapted for abutting engagement. More preferably,

the side edges of the wall units are adapted for sealing abutting engagement.

According to the invention there is provided a method of on-site construction of

concrete walls, the method comprising the steps of:

(a) providing one or more formwork modules;

(b) assembling the wall panels, with webbing elements there between, to define a

wall cavity; and

(c) pouring concrete into the wall cavity.

Preferably, the formwork module are as herein described. More preferably, the

method further comprises the step of inserting reinforcement. Most preferably, wall

panels can be cut down to size. Alternatively, the wall panels are custom sized, and wall modules are assembled on-site.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention will now be described, by way of example

only, with reference to the accompanying drawings in which:

FIG.1 is a perspective view of a portion of a site-erected concrete-filled modular wall system according to the invention;

FIG.2 is a plan view of the wall system of FIG. 1, showing a 90 deg transition; FIG.3 is a perspective view of a base tray for the wall system;

FIG.4 is a perspective view of an embodiment wall skin for the wall system;

FIG.5 is a plan view of an embodiment wall skin for the wall system; FIG.6 is a plan view of two opposing embodiment wall skin portions, with a part

shown stud element inserted;

FIG.7 is a plan view of an embodiment 90 degree internal corner portion of the wall system;

FIG. 8 is a plan view of embodiment 90 degree internal corner coupling elements, shown in line for assembly;

FIG. 9 is a plan view of an embodiment 90 deg external corner portion of the wall system;

FIG. 10 is a plan view of embodiment 90 degree external corner coupling elements; FIG. 11 is a plan view of wall system with a 135 degree transition;

FIG. 12 is a plan view of an embodiment 135 degree internal corner portion of the wall system;

FIG. 13 is a plan view of embodiment 135 degree internal corner coupling elements,

shown in line for assembly; FIG. 14 is a plan view of an embodiment 135 degree external corner portion of the

wall system; FIG. 15 is a plan view of embodiment 135 degree external corner coupling elements;

FIG. 16 is a plan view of an embodiment straight joiner portion of the wall system; FIG. 17 is a plan view of the straight joiner coupling elements, shown in line for

assembly; FIG. 18 show a front view and a plan view of a stud element of the wall system;

FIG. 19 show a front view and a plan view of a stud element of the wall system;

FIG. 20 show a front view and a plan view of a stud element of the wall system; and FIG 21 is a flow chart for a method of installing a site-erected concrete-filled

modular wall system according to the invention.

PREFERRED EMBODIMENT OF THE INVENTION

In an embodiment, the modular wall system provides a fast, easy and simple

construction method specifically designed for on-site construction of concrete walls.

The system allows reinforced concrete walls to be constructed on site efficiently and with minimal waste.

The walls can be structural, load bearing, non-load bearing, energy efficient, fire rated

and soundproofed by means of additional layers within the system.

Workers would be able to measure and cut walls modules to the required size on site.

The wall modules would be assembled on site, reducing the delivered volume occupied

by construction materials.

The walls modules can be hand-assembled on-site and concrete poured to form a wall

(typically a structural or load bearing wall). Modules can be of varying thickness, height

and length, depending on the need.

Walls may be constructed from a series of modules.

FIG. 1 and FIG. 2 shows an embodiment modular wall system 100 that is adapted to be

site erected and concrete-filled. This modular wall system 100 includes:

a base tray 110 for marking up the wall systems on solid ground or footings (also

shown in FIG. 3);

a first wall skin (sheeting or panelling) 120 and a second wall skin (sheeting or

panelling) 130 that is seated (or located) in the tray, wherein the first wall skin 120 has a separate first external lining 122 and first internal lining 124, and the second

wall skin 130 has a separate second external lining 132 and second internal

lining 134;

a plurality of webbing stud elements 140 slidingly coupled across each of the first

wall skin and the second wall skin to thereby substantially locate the first wall skin

relative to the second wall skin.

The external lining (122, 132) is preferably selected to receive the finishing coats for

the wall. The external lining and internal lining are typically formed from fibre cement sheets, Magnesium Oxide (MGO) boards or panels, or the like. Inanembodiment, the external wall linings of the wall panels may be made of Magnesium Oxide sheets

(for example 9 or 6 mm thick) or Fibre Cement sheets (for example 6mm thick). The system provides a relatively smooth finish that is ready for skim coating and painting.

The system will reduce the additional plastering and/or rendering process.

An internal lining (124,134) is preferably selected to provide fire insulation, sound

insulation, energy efficiency to improve the thermal performance of a building. In an

embodiment, the internal lining, for example in the form of PVC extruded or injection moulded sheets, are about 3mm thick and bonded or glued to the inside surface of the

wall panels.

It will be appreciated that the external linings (122, 132) can be selected to comply with Australian standards relevant to use in a modular wall system. Australian

standards may relate to fire rating, structural durability, water resistance or other standards.

By way of example only, the external linings (122, 132) can be selected from MGO2

magnesium board 6.8mm-10mm thick, fiber boards 6.8mm-10mm thick or equivalent.

FIG. 3 shows an embodiment base tray 110, which includes rails 114,115 for abutting engagement with the wall panels (not shown). The base tray 110 (or track) is

typically fixed to the floor, following marking lines as per a building design.

Referring to FIG. 4 and FIG. 5, an embodiment internal lining (124,134), defines one or more connection channels 200, each configured or adapted to receiving a respective

vertical interconnecting studs element 140 (typically constructed of PVC, plastics, or the like) for interconnecting the first wall skin (sheeting or panelling) 120 and a second

wall skin (sheeting or panelling) 130, wherein the stud elements vertically slide into, and are retained by, the respective connection channel, thereby forming the wall

cavity with the desirable wall thickness and providing rigidity and stability to the wall system. The system is modular, with edges internal lining having a raised tab edge 220, for forming retaining slots 222 between the bonded internal and external linings (not shown).

By way of example, an embodiment internal lining 124,134 is formed as an elongate element of a desired length (for example, extruded or injection moulded). The internal

lining defines a plurality of elongate channel 200 to form a retaining recess that receives a coupling portion of a stud element. The stud element can be slid into

place for bracing opposing wall panels by using a tongue and groove like connection

with the respective connection slot.

The sandwich construction of the internal lining and external lining uses construction

adhesive embedded there-between. An adhesive cavity 210 provides room for

retaining adhesive, which increases contact area and can result in stronger adhesion.

Referring to FIG. 6, in an embodiment, by way of example only, the connection

channels are in the form of a "C" channel 202 that is adapted to receive an axial "T" formation 144 at the respective edge of the relevant stud element 140. The internal

lining 124,134 can also define adhesive cavity 210, which face the associated external

lining for enabling additional retention of adhesive at that location. In this example, adhesive cavities are located proximal to, and parallel with, the connection "C"

channel202. It will be appreciated that the adhesive cavities can increase contact area and enable stronger adhesion between the internal and external linings.

Wall panels (120,130) and stud elements 140 elements can be sized to conform to or

accommodate design requirements for height and wall thickness.

The stud elements 140, when located or retained between connection channels fixed to opposing wall panels, stabilise the wall system.

The stud elements 140, when installed vertically between the first wall skin and the

second wall skin, create or define the cavity or void for concrete to be poured. The stud elements typically include a plurality of apertures 142 for enabling the flow of

concrete within the wall cavity as it is concrete filled, while maintaining a required horizontal and vertical reinforcement.

It will be appreciated that the stud element apertures 142 also provide space for

reinforcement rods to be located along the length of the wall, as per design requirements. Reinforcement (not shown) can be placed vertically down through the

wall cavity, also placed horizontally by sliding it through the apertures of the vertical

studs element. Reinforcement is usually in the form of reinforcement bars or rods, as known in the art.

FIG. 7 through FIG 10 show features associated with defining a 90 degree wall join

comprising internal and external corners.

FIG. 7 shows a plan view of an example 90 degree internal corner 300, which utilises

three interlocking components 310, 320, 330 (as separately shown in FIG. 8) that are constrained by associated retaining slots 222 defined by a retaining tab 220 of an

internal lining.

As best shown in FIG. 8, use of interlocking components when forming the internal corner facilitates initial fitting of the wall edge components 310, 320 while enabling

the corner component 330 to be brought into engagement with each edge component

for interlocking the two associated wall skins.

In this embodiment, the interlocking components 310, 320, 330 are extruded or

moulded to form elongate interlocking components having respective coupling

elements. The corner component 330 also defines a pair of perpendicularly directed 'C' channels 340,342 for receiving a respective stud element (not shown). A webbing

element 344 is integrally formed between the 'C' channels for strengthening and supporting the corner.

In this embodiment, interlocking components are defined for coupling the corner

component 330to both wall edge components 310,320. In this example, each wall edge component 310, 320 comprises a receiving channel 350 having a pair of

oppositely inwardly directed tapered protrusions (ramp or hook) 352, 354 for interlocking the corner component 330. In this example, the corner component 330

includes a pair of integrally formed interlock assemblies 360, for engaging respective wall edge components 310, 320. The interlock assemblies 360 comprise pair of fingers or flanges 361, 363 each having an oppositely outwardly directed tapered protrusion (ram or hook) 362, 364. It will be appreciated that, as wall edge components 310, 320 are brought into coupling engagement with the corner component 330, the interlocking assembly fingers or flanges 361, 363 are flexible for enabling respective mating pairs of tapered protrusions 352/362 and 354/364 to slidingly-abut into locking engagement.

In this embodiment, the wall edge components 310, 320 also include an abutment flange 370 for locating the component on the respective wall skin panel, and providing

abutment services when wall sections are joined.

FIG. 9 shows a plan view of an example 90 degree external corner 400, which utilises two interlocking components 410, 420 (as separately shown in FIG. 10) that are

constrained by associated retaining slots 222 defined by a retaining tab 220 of an

internal lining.

As best shown in FIG. 8, use of interlocking components when forming the external

corner facilitates initial fitting of the wall edge components 410, 420 while enabling

them to be brought into engagement for interlocking the two associated wall skins.

In this embodiment, interlocking components 430,440 are integrally formed for

coupling the corner components 410, 420. In this example, corner component 410, comprises a receiving channel 430 formed by two fingers or flanges 431, 432. Wherein a finger or flange has an inwardly directed tapered protrusion (ramp or

hook) 433 located about the mouth of the channel. In this example, the corner component 420 includes an integrally formed interlock assembly 440, for engaging the

corresponding corner component 410. The interlock assembly 440 comprise a finger or flange 442 having an outwardly directed tapered protrusion (ramp or hook) 443. It

will be appreciated that, as components 410, 420 are brought into coupling engagement, the interlocking assembly fingers or flanges 432, 442 are flexible for

enabling respective mating pairs of tapered protrusions 433/443 to slidingly-abut into

locking engagement.

In this embodiment, each corner component 410, 420 defines a 'C' channel 450, such

that the mouth 452 is directed at an angle of 45 for enabling a webbing stud element 456 to be received between the 'C' channels 450 of the coupled corner

components 410, 420 (as best shown in FIG. 9). The 'C' channel 450 is typically

integrally formed with the corner component, and comprises bracing support 454,455 for added stability.

Referring to FIG. 7 and FIG. 8 a right angle internal corner component has a coupling elements that define a pair of perpendicularly defined connection slots. It will be

appreciated that the components can be fixed to the wall panels (perpendicularly

configured) when sandwiched between a internal lining raised tab edge 220 and external lining. The components define perpendicularly directed connection

slots 340, 342 that each receives a respective stud element. The male right angle internal corner component 330 has two cavities 340, 342 for each receiving a stud

element (not shown). The male right angle internal corner element has two pairs of protruded hook 362/364. The female internal corner components 310, 320 has a

flange 380 that is sandwiched between the external and internal lining. A pair of receiving hook 352/354 respectively interlock with protruded hook 362/364.

Right-angle tails 370 form a perpendicular connection when assembled.

Referring to FIG. 9 and FIG. 10, external corner 400 includes two corner components 410, 420 that interlock with each other to form a right-angle. The

corner components 410, 420 can abutted, fixed or bonded to the wall sheets to

stabilise the corner prior to concrete being poured. Adhesive cavities 470 are provide improve binding or adhesion. Stud elements 460, 462 can be installed. The male

external corner connection element 420, in this example, has a flange 442 which can be received by a receiving recess 430 of a female corner connection element 410 to

form an interlocked right angle corner. The connection elements 410, 420 form

connection slots 452 that together receive a stud element 456 (as shown in FIG. 9).

FIG. 11 through FIG 15 show features associated with defining a 135 degree wall join

comprising internal and external corners.

FIG. 11 shows a wall having a 1350 wall join comprising an internal corner 500, external

corner 600, and straight junctions 700. It will be appreciated that the internal corner 500 and external corner 600, are similar to those associated with the earlier

described 90 degree wall join assembly.

FIG. 12 shows a plan view of an example 135 degree internal corner 500, which utilises three interlocking components 510, 520, 530 (as separately shown in FIG. 13) that are

constrained by associated retaining slots 222 defined by a retaining tab 220 of an

internal lining.

As best shown in FIG. 13, use of interlocking components when forming the internal

corner facilitates initial fitting of the wall edge components 510, 520 while enabling the corner component 530 to be brought into engagement with each edge component

for interlocking the two associated wall skins.

In this embodiment, the interlocking components 510, 520, 530 are extruded or moulded to form elongate interlocking components having respective coupling

elements. The corner component 530 also defines a pair of perpendicularly directed 'C'

channels 540,542 for receiving a respective stud element (not shown). A webbing element 544 is integrally formed between the 'C' channels for strengthening and

supporting the corner.

In this embodiment, interlocking components are defined for coupling the corner component 530to both wall edge components 510, 520. In this example, each wall

edge component 510, 520 comprises a receiving channel 550 having a pair of oppositely inwardly directed tapered protrusions (ramp or hook) 552, 554 for

interlocking the corner component 330. In this example, the corner component 330 includes a pair of integrally formed interlock assemblies 560, for engaging respective

wall edge components 510, 520. The interlock assemblies 560 comprise pair of fingers or flanges 561, 563 each having an oppositely outwardly directed tapered

protrusion (ram or hook) 562, 564. It will be appreciated that, as wall edge

components 510, 520 are brought into coupling engagement with the corner component 530, the interlocking assembly fingers or flanges 561, 563 are flexible for enabling respective mating pairs of tapered protrusions 552/562 and 554/564 to slidingly-abut into locking engagement.

In this embodiment, the wall edge components 510, 520 also include an abutment flange 570 for locating the component on the respective wall skin panel, and providing

abutment services when wall sections are joined.

FIG. 14 shows a plan view of an example 135 degree external corner 600, which utilises two interlocking components 610, 620 (as separately shown in FIG. 10) that are

constrained by associated retaining slots 222 defined by a retaining tab 220 of an

internal lining.

As best shown in FIG. 15, use of interlocking components when forming the external

corner facilitates initial fitting of the wall edge components 610, 620 while enabling

them to be brought into engagement for interlocking the two associated wall skins.

In this embodiment, interlocking components 630, 640 are integrally formed for

coupling the corner components 610, 620. In this example, corner component 610, comprises a receiving channel 630 formed by two fingers or flanges 631, 632.

Wherein a finger or flange has an inwardly directed tapered protrusion (ramp or hook) 633 located about the mouth of the channel. In this example, the corner

component 620 includes an integrally formed interlock assembly 640, for engaging the

corresponding corner component 610. The interlock assembly 640 comprise a finger or flange 642 having an outwardly directed tapered protrusion (ramp or hook) 643. It

will be appreciated that, as components 610, 620 are brought into coupling engagement, the interlocking assembly fingers or flanges 632, 642 are flexible for

enabling respective mating pairs of tapered protrusions 633/643 to slidingly-abut into

locking engagement.

The interlocking assemblies 630, 640, when coupled, are configured to form a 135

degree intersection between the adjoining wall sections. The interlocking assemblies 630, 640 are typically integrally formed with the respective corner

component, and comprises bracing support 654, 655 for added stability. Stud elements 660, 662 (as shown in FIG. 14) can be received by integrally formed 'C' channels 661, 663.

It will be appreciated that the 135 degree internal corner assembly 500 has coupling channels for receiving stud element. It will be appreciated that the corner

components can be retained in the wall panels with flanges 580 sandwiched between the respective external lining and internal lining. The male 135 degree internal

corner component 530 has two pairs of protruded hook 562/564. The female 135 degree angle internal corner component 510, 520 is sandwiched between

the external and internal lining. A pair of receiving hooks 552/554 interlock with

respective protruded hooks 562/564. A sharp angle tails 570, when abutting, form a 135 degree corner engagement.

It will be appreciated that the 135 degree external corner assembly 600 includes two

corner connection components 610, 620, which interlock to form a 135 degree angle. The eternal corner connection components 610, 620 are abutted, fixed or bonded to

the respective wall sheets to stabilise the corner prior to concrete being poured. The male corner connection element 620, in this example, has a protruded head 642, 643

that can be received by a receiving recess 630 from female external corner connection

component 610 for forming an interlocked 135 degree angle corner.

It will be appreciated that connection assemblies similar to those taught in FIG. 7

through FIG. 15 can be adapted to joining wall panels in any suitable predefined angled configuration. The connection assemblies are formed by multiple elements that can

be coupled on-site.

FIG. 16 and FIG. 17 show an embodiment straight joiner assembly 700 of the wall system. The assembly 700 includes a pair of opposed straight joiner

components 710, 720, each adapted to receive a joiner stud element 730. Each joiner components 710, 720 have a flanged 711, 721that is retained by respective wall

panels by associated retaining slots 222 defined by a retaining tab 220 of an internal

lining. The joiner components 710, 720 define a respective 'C' channel 715, 725 for engaging the joiner stud element 730. There 'C' channel comprises an upper arm 716, 726 having an inwardly directed tapered protrusion (ramp or hook) 717, 727, and a second oppositely directed inwardly tapered protrusion (ramp or hook) 718, 728. The elongate joiner stud element 730 forms a 'T' configuration along its sides, such that each arms of the 'T' 732 is respectively received by one of the 'C' channels. Each arm further defines the detents 737, 738 that are adapted to receive and retain the protrusions 717, 718, 727, 728. Each joiner component 710, 720 can further include an abutment edge 744 locating the component with respect to the wall panel.

FIG. 18 through FIG. 20 show example embodiment stud like elements as previously

described.

It would be appreciated that stud elements are sized to define respective wall

thicknesses, and formed to provide suitable strength to stabilise opposing wall panels.

Referring to FIG. 18 and FIG. 19, a typical embodiment stud element (for example 140,

456, 660, 662) can be provided in multiple widths to define desired wall thicknesses.

FIG. 18 shows an embodiment stud element comprising a substantially planar body (or webbing) portion 146 that, when in a wall configuration, extends between the first

wall panel and the second wall panel. The stud element has a plurality of apertures 142. A coupling portion 144 is formed on each longitudinal edge of the stud

element for engaging a respective connection element fixed to the first wall panel and

the second wall panel. In this example, the coupling portion is "T" shaped to be slidingly received and retained by an elongated slot and retaining recess of the

respective connection element. A thinner stud element can also be provided (as shown in FIG. 19).

FIG. 20 shows an embodiment stud element (for example 730) that comprises a

substantially planar body (or webbing) portion 731 that, when in a wall configuration, extends between the first wall panel and the second wall panel. The stud element

has a plurality of apertures 154. A coupling portion 732 is formed on each longitudinal edge of the stud element for engaging a respective connection element fixed to the

first wall panel and the second wall panel. In this example, the coupling portion is triangular shaped with hooks 737,738 to be slidingly received and interlocked by a retaining recess. It will be appreciated that coupling portion is substantially an end projection or moulding adapted to co-operate with (slidingly received and retained by) an elongated slot and retaining recess of the respective connection element.

It will be appreciated that studs elements of different sizes will provide options of

creating multiple wall thicknesses for a combination of uses; such as adequate structural properties, energy efficiency, required fire and sound rating properties etc.

needed to obtain the certificates for the current policies.

In an embodiment, by way of example only, a modular formwork can be erected on

site, wherein each module may consist of:

(a) a base tray, providing geometric guidance on the floor, which can be inside or

outside of the wall;

(b) a pair of wall panels, being a first wall skin panel and a second wall skin panel,

with optional additional insulation layers if required;

(c) a plurality of stud elements, joined perpendicularly between the first wall skin

panel and the second wall skin for establishing the wall cavity and stabilising the wall system;

(d) one or more assembly elements, such as retaining elements for

erecting/continuing straight wall, forming corners, forming T junctions and forming attachments to an existing wall.

In use, by way of example only, a modular wall system can be constructed by:

(a) commencing with a base tray (for example formed of aluminium) that provided

alignment of the wall, such that the wall system will be formed on the base tray;

(b) installing wall skins onto the base tray, thereby guided to retain a straight line;

(c) installing vertical webbed stud elements to internal sides of the wall skins,

wherein the wall stud elements extend vertically to a desirable height, and have a selected width to define the wall thickness (as per design requirements), while

maintaining the wall skins parallel in orientation.

It will be appreciated that, each wall typically establishes a rectangular configuration

(having a top edge, a bottom edge, a pair of side edges), and the spacing between wall

skins or panels defines the size of the cavity for receiving concrete to be poured within.

When on-site pouring is complete, the side edges of the wall modules can be sealed

and patched or filled with concrete. Alternatively, a module may abut to an adjoining existing wall module, to extend the length of the wall or a corner module can be used

to adjoin an existing wall which abuts perpendicularly.

Two or more wall modules can be interconnected, for example a 'T' configuration or further extension of the wall panels. The ends or edges of wall units can be adapted for

abutting engagement. If wall modules require no further connection, the wall end or

edge can include a sealed finish.

In an embodiment, by way of example only, the method of constructing a concrete

wall can include the following steps:

(a) providing one or more formwork modules;

(b) assembling the wall panels above non-corrosive alignment tray, with vertical webbed studs to define the required wall cavity;

(c) inserting vertical and/or horizontal reinforcement, and

(d) pouring concrete into the wall cavity from the top;

(e) sealing edges of the wall (optional); and

(f) applying finishing materials to exposed surfaces (optional).

According to a preferred embodiment, by way of example only, the wall system may comprise one or more of the following aspects and/or advantages:

(a) formwork module are sized with a width from 800mm to 1200mm and height

from 600mm to 4000mm.

(b) the cavity width (distance in between connection channels) varies from 80mm to 200mm according to wall thickness;

(c) wall panels could be customsized with assembly on-site, or alternatively the wall

panels and associated vertical elements; can be cut down to size on-site;

(d) service, door and window openings can be pre-cut (according to design plans), with a nominated sub frame and door/window frame either installed on-site or

pre-installed (different wall sizes may require different sub-frames and

door/window frames);

(e) walls can include additional layers- if required- to provide Building Code fire

rating requirements for all classes of buildings, having a structural adequacy/

integrity/ insulation rating from 60/60/60 to 240/240/240.

(f) walls can be adapted to provide Building Code Acoustic Performance

requirements, using a variety of components as additional layers to obtain the

required Weighted Sound Reduction Index.

(g)walls can include insulation to obtain the required energy efficiency (for example,

as specified for BASIX legislation in NSW)

(h) exposed external or internal wall skins could be painted, rendered or waterproofed as required.

A Builder / Developer can specify wall dimensions (width/length/height), and the

trays/tracks can be fixed firmly to the floor using concrete nail guns or industrial fasteners. The walls panels, can be formed/glued together before delivery, or cut on

site. Typically, the connection elements and walls panels are glued using OEM

high-strength fire resistant adhesive at 200mm centres.

It would be appreciated that the modular wall system can be used to provide solid

concrete internal walls, external walls and retaining walls.

Referring back to the drawings, particularly FIG. 1 and FIG. 2, the modular wall system assembly 100 that can be site-erected and concrete-filled can include: a first wall skin

panel 120 and a second wall skin panel 130; and a plurality of spaced parallel stud elements 140 coupled to each of, and interconnecting between, the first wall skin panel and second wall skin panel; such that the first second wall skin panel is spaced apart from and parallel to the second wall skin panel.

The vertical stud elements 140, when installed by sliding down in between opposite/opposing wall panels, function as an initial connecting and stabilising

element for the wall.

When assembled to form a module assembly 100, the vertical stud elements 150, define a spaced apart configuration between the wall panels 120, 130. The stud

elements are typically installed vertically between the first panel and the second wall panel, in a way that the first wall panel and the second wall panel are parallel in

orientation, thereby defining a wall thickness and forming a wall cavity for receiving concrete (not shown) therein. It will be appreciated that a stud element has a series of

apertures 142 for enabling concrete to flow across the cavity.

In use, the stud element segments the wall cavity, while the apertures enable fluid communication across the cavity. The apertures can further be used for enabling

reinforcement rods to be located along a length of wall. The apertures have been

shaped in a way to allow sufficient concrete flow through the vertical elements.

In an embodiment, the assembly can include a base tray 110 for assisting with aligning

the opposing wall panels 120, 130, and to retain concrete poured within the cavity

between wall panels.

In an embodiment, the side edges of a module is adapted for sealed abutting

engagement with another module (for example as shown in FIG. 16), whereby two or

more wall module assemblies can be interconnected.

In an embodiment, wall panels, 120, the external lining are typically constructed from

6mm or 9mm Magnesium Oxide sheets or 6mm Fibre Cement materials. The internal

lining, for example in the form of PVC extruded or injection moulded sheets, are about 3mm thick and glued to the inside surface of the wall panels.

FIG. 21 shows an embodiment flowchart 800 for a method of on-site construction of

concrete walls. The method comprising the steps of:

STEP 810: providing one or more formwork modules;

STEP 820: assembling the wall panels, with stud element inserted, to define the wall

cavity;

STEP 830: inserting reinforcement into the wall cavity.

STEP 840: pouring concrete into the wall cavity.

By way of example only, the formwork modules are wall modules 100 as herein

described.

In an embodiment, the method can optionally comprises STEP 830 of inserting

reinforcement.

STEP 820 of assembling the wall panels can include cutting wall panels down to

required size on-site. Alternatively, the wall panels could be custom sized, and wall

modules will be assembled on-site.

It will be appreciated that, by way of example only, wall modules can be erected by:

OPTION A: Each wall side wall panel are positioned upright (in situ) then vertical

elements are slid into the wall cavity for coupling both side panels.

OPTION B: All the components can be first fixed together and the wall module is moved into position.

It will be appreciated that both options typically require fastening of both wall panels

to the bottom track. Further, once wall modules have been erected, reinforced rods can be threaded through the preformed apertures 142 in the stud webbing elements

140 and from the top of the wall between each stud webbing elements.

The apertures are typically shaped to enable the flow of poured concrete, thus reducing the risk of creating air pocket inside the walls. It should be noted that air

pockets can induce noise and reduce the strength of the wall.

Preferably, concrete is poured after every 3000mm high panel to allow for better control of concrete flow.

It should be noted that the illustrated wall module provides a site-erected concrete

filled wall system.

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.

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.

In the claims below and the description herein, any one of the terms comprising,

comprised of or which comprises is an open term that means including at least the

elements/features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or

elements or steps listed thereafter. For example, the scope of the expression a device comprising A and B should not be limited to devices consisting only of elements A and

B. 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.

Similarly, it is to be noticed that the term coupled, when used in the claims, should not

be interpreted as being limitative to direct connections only. The terms "coupled" and "connected", along with their derivatives, may be used. It should be understood that

these terms are not intended as synonyms for each other. Thus, the scope of the

expression a device A coupled to a device B should not be limited to devices or systems wherein an output of device A is directly connected to an input of device B. It means that there exists a path between an output of A and an input of B which may be a path including other devices or means. "Coupled" may mean that two or more elements are either in direct physical, or that two or more elements are not in direct contact with each other but yet still co-operate or interact with each other.

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.

As used herein, unless otherwise specified the use of terms "horizontal", "vertical", "left", "right", "up" and "down", as well as adjectival and adverbial derivatives thereof

(e.g., "horizontally", "rightwardly", "upwardly", etc.), simply refer to the orientation of

the illustrated structure as the particular drawing figure faces the reader, or with reference to the orientation of the structure during nominal use, as appropriate.

Similarly, the terms "inwardly" and "outwardly" generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

Similarly it should be appreciated that in the above description of exemplary

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 are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a

separate embodiment of this invention.

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.

Furthermore, an element described herein of an apparatus embodiment is an example

of a means for carrying out the function performed by the element for the purpose of

carrying out the invention.

In the description provided herein, numerous specific details are set forth. However, 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.

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.

It will be appreciated that an embodiment of the invention can consist essentially of features disclosed herein. Alternatively, an embodiment of the invention can consist of

features disclosed herein. The invention illustratively disclosed herein suitably may be

practiced in the absence of any element which is not specifically disclosed herein.

Claims (20)

WE CLAIM

1. A modular wall adapted to be site-erected and concrete-filled, the modular wall

including:

a first wall skin panel and a second wall skin panel;

a plurality of webbing stud elements coupled to each of the first wall skin panel and the second wall skin panel to thereby substantially locate the first wall skin panel

relative to the second wall skin panel.

2. The modular wall according to claim 1, wherein the plurality of webbing stud

elements are releasably couplable to both of the opposing panels.

3. The modular wall according to claim 2, wherein the webbing elements, when

coupled to the opposing panels, extend vertically between the opposing panels for stabilising and maintaining a spaced apart configuration there between, such that

the opposing panels extend in substantially parallel vertical planes.

4. The modular wall according to any one of the preceding claims, wherein each wall skin panel comprise a substantially rectangular configuration; whereby each wall

skin panels has a top edge, a bottom edge, and a pair of side edges.

5. The modular wall according to any one of the preceding claims, wherein each webbing stud elements comprises a substantially rectangular configuration;

whereby each webbing elements has a top edge, a bottom edge, and a pair of side

edges.

6. The modular wall according to any one of the preceding claims, wherein the

webbing stud elements define wall thickness when in use.

7. The modular wall according to any one of the preceding claims, wherein the spaced apart configuration between the wall panels defines a cavity for receiving concrete

therein.

8. The modular wall according to claim 7, wherein a webbing element has one or

more apertures for enabling concrete to flow across the cavity.

9. A modular wall adapted to be site-erected and concrete-filled, the modular wall

including:

a base tray for marking up the wall systems and providing solid footings;

a first wall skin panel and a second wall skin panel being located in the tray, the first wall skin panel has a separate first external lining and first internal lining, and

the second wall skin panel has a separate second external lining and second

internal lining;

the internal linings each defining connection slots for each receiving a respective

vertical interconnecting studs element for interconnecting the first wall skin panel and a second wall skin panel, wherein the stud elements vertically slides into

engagement with, and is retained by, the respective connection slot, thereby forming the wall cavity with the desirable wall thickness and providing rigidness

and stability to the wall system.

10. The modular wall according to claim 9, wherein the connection slots are evenly

spaced apart on wall panels.

11. The modular wall according to any one of claims 9 and 10, wherein connection slot

forms a retaining channel recess that receives a cooperating portion of a stud

element.

12. The modular wall according to any one of claims 9 to 11, wherein the webbing

element is elongate having a retaining element on each side-edge that is adapted

to releasably engage the connection slot of opposing wall panels.

13. The modular wall according to any one of claims 9 to 12, wherein the base tray

spans between opposing wall panels and is adapted to retain concrete poured

within the cavity between wall panels.

14. The modular wall according to any one of the preceding claims, wherein two or

more wall modules can be interconnected.

15. The modularwall according to anyone of the preceding claims, further including a

connection assembly for joining wall panels in a straight configuration.

16. The modularwall according to anyone of the preceding claims, further including a

connection assembly for joining wall panels in an angled configuration.

17. The modularwall according to claim 16, wherein the connection assembly is

adapted to join wall panels in a 90 degree or 135 degree configuration.

18. The modular wall according to any one of claims 15 to 17, wherein the connection assembly includes multiple elements that can be coupled on-site.

19. The modular wall according to any one of claims 15 to 18, wherein the connection

assembly includes multiple elements that enables wall panels to be slid into coupling engagement.

20. A method of on-site construction of concrete walls, the method comprising the

steps of:

a) providing one or more formwork wall modules according to anyone of the

preceding claims;

b) assembling the wall panels, with webbing elements there between, to define

a wall cavity; and

c) pouring concrete into the wall cavity.