AU753030B2 - Structural modules - Google Patents

Description

t S F Ref: 454206

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

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Name and Address of Applicant: Actual Inventor(s): Address for Service: Invention Title: Richard Warren 53 Station Street Pymble New South Wales 2073

AUSTRALIA

Richard Warren Spruson Ferguson, Patent Attorneys Level 33 St Martins Tower, 31 Market Street Sydney, New South Wales, 2000, Australia Structural Modules ASSOCIATED PROVISIONAL APPLICATION DETAILS [31] Application No(s) [33] Country PP1981 AU PP5814 AU [32] Application Date 24 February 1998 10 September 1998 The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5815 1 STRUCTURAL MODULES Field of the Invention The following invention relates to structural modules. More particularly, though not exclusively, the invention relates to galvanised steel modular elements adapted to replace bricks or blocks in the construction of walls, safety barriers, retaining walls and other structures.

The invention also relates to the fabrication of pipes.

Background of the Invention It is known to erect walls such as sea walls, retaining walls and embankment lo walls with concrete or other heavy blocks. Transportation costs associated with this form of construction are high due to the shear bulk to be transported.

Safety barriers are known. For example, at the end of concrete lane dividing walls, it is known to provide crushable barriers which absorb energy during vehicular collision therewith. Such known structures are expensive to produce and replace.

Various forms of causeways, military matting, temporary runways, filter drains, quay walls, fencing, landscaping blocks, cattle grids, emergency bunding for oil leakage containment or for the containment of other spilled liquids which may be noxious or otherwise, sea walls, abutments for bridge work, scaffolding and other structures are known. All such known structures are expensive to produce because special, individual design constraints apply to each form.

Pipes for use in conveying water, other liquids or flowable substances are generally fabricated in a factory and transported to site. Transportation costs associated with this known practice are high as the space occupied by prefabricated pipes is large. It would be beneficial to the efficiency of transportation of pipes if the transportation density of the same could be increased.

Object of the Invention It is an object of the present invention to overcome or ameliorate some of the disadvantages of the prior art, or at least to provide a useful alternative.

[R:\LIBLL] 12942specie.doc:keh Summary of the Invention There is disclosed herein a structural module including two opposed side walls and two opposed end walls, the side walls and end walls defining a hollow body having open ends defined by edges of the walls, wherein each side wall includes a pair of opposed end portions between which there resides a mid portion which is displaced from the plane of the end portions and wherein a deviation extends between the mid portion and each end portion.

Preferably, the end portions sit proud of the mid portions.

Preferably, the mid portions sit proud of the end portions.

Preferably, the deviation is delimited by a pair of slots at upper and lower edges of the module.

Preferably, the mid portion is approximately twice as long as each end portion as measured in the length direction of the side wall from end wall-to-end wall.

Preferably, the deviation extends substantially at 450 from the plane of the side wall.

Preferably, the modules are stacked one upon another in a brick pattern with the slots at the upper edge of a structural module interacting with the slots at the lower edge of a module in a row thereabove such that the mid portions of all of the modules in the wall are substantially coplanar.

20 Preferably, at least at one of said ends of at least some of the walls have engaging means at or nearby their edges which are adapted to engage with other structural modules in a structure formed thereof.

o.

Preferably, the engaging means include slots into which side wall edges of a neighbouring module can be received.

Preferably, each side wall includes a number of said engaging means.

Preferably, the structural modules are stacked side-to-side and one upon another in a "brick pattern".

Preferably, each row of the structural modules are stacked substantially vertically.

Preferably, each row of the structural modules are horizontally displaced with respect to the row of the structural modules therebelow.

Preferably, the structural wall is mounted upon a longitudinally extending &locating track or parallel tracks, the track or tracks being received by some of the Sengaging means of the structural modules in a bottom row of the structural wall.

[R:\LBLL] I 2942specie. doc:keh 3 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, wherein: Fig. 1 is a schematic isometric representation of a structural module, Fig. 2 is a schematic isometric illustration of an inclined retaining wall formed from a plurality of the structural modules of Fig. 1, Fig. 3 is a schematic isometric illustration of a vertical structural wall formed from a plurality of connected structural modules of Fig. 1 seated upon a base beam, Fig. 4 is a schematic end elevational view of the module of Fig. 1, Fig. 5 is a schematic cross-sectional detailed view of a lip forming part of the module of Fig. 4, Fig. 6 is a schematic plan view of a module, Fig. 7 is a schematic front or rear elevational view of the module, Fig. 8 is a schematic elevational view of a blank from which the module can be formed, Fig. 9 is a schematic plan view of a cover plate situated adjacent to an end-most module in a wall of modules, ~Fig. 10 is a schematic plan view of a row of cylindrical modules following a "•curved line, 20 Fig. 11 is a schematic plan view of a row of cylindrical modules following a straight line, Fig. 12 is a schematic elevational view of a cylindrical module, Fig. 13 is another schematic plan view of a wall formed from cylindrical modules, 25 Fig. 13A is a schematic perspective view of a clip, 0 Fig. 14 is a schematic plan view of the end of the wall of cylindrical modules having a cover plate associated therewith, Fig. 15 is a schematic plan view of a portion of a wall formed from octagonal modules at a corner region thereof, Fig. 16 is a schematic plan view of an adaptor module for use in a corner as shown in Fig. Fig. 17 is a schematic plan view of a vertical brace, AFigs. 18 and 19 are schematic plan views of cover panels, [R:\LIBLL] 12942specie.doc:keh 4 Fig. 20 is a schematic plan view of an octagonal module having tile-connecting strips affixed thereto, Fig. 21 is a schematic side elevational view of a connecting strip, Figs. 22 and 23 are schematic plan, cross-sectional illustrations of tiles, Fig. 24 is a schematic perspective illustration of a base plate into which the end portions of adjoining longitudinal flexible strips can be received and located, Fig. 25 is a schematic plan view of a cylindrical module, Fig. 26 is a schematic plan view of a pair of folded interlocking strip means in a pre-engaged configuration, Fig. 27 is a schematic plan view of a pair of folded interlocking strip means in a engaged configuration, Fig. 28 is a schematic plan view of a portion of an octagonal module having folded interlocking strip means, Fig. 29 is a schematic plan view of the interengaging portions of an alternative Is folded interlocking strip means, Fig. 30 is a schematic plan view of the interengaging portions of an alternative folded interlocking strip means, typically adapted for fabrication of pipes, ~Figs. 31 and 32 are schematic plan views of infill cover plates, .Figs. 33, 34 and 35 are schematic cross-sectional illustrations of alternative interlocking strip means in engaged configurations, Fig. 36 is a schematic perspective view of an engaging brace adapted to be plastically deformed for engagement with the upper edges of substantially cylindrical S"modules and upper edges of curved infill panels, Fig. 37 is a schematic plan illustration of a plurality of substantially cylindrical 0.0. 25 modules in a constructed wall having a plastically deformed brace associated therewith, Go..

Fig. 38 is a schematic perspective view of a structural module according to an 0.0 embodiment of the present invention, Fig. 39 is a schematic elevational view of a blank from which the structural module of Fig. 38 is folded, and Fig. 40 is a schematic perspective view of a module according to an embodiment of the present invention.

Description of the Preferred Embodiments In Fig. 1 of the accompanying drawings there is schematically depicted a structural module 10. Module 10 is typically fabricated from mild steel or galvanised [R:\LLBLL] 12942specie. doc:keh steel. Alternatively, the module can be formed from moulded plastics material, aluminium plate or extruded aluminium or any other material suitable for a particular application of the module.

Module 10 includes a front wall 11, a rear wall 12, side walls 13 and 14 and corner walls 15. The walls 11, 12, 13, 14 and 15 define a hollow octagonal body.

However, it should be appreciated that the module 10 need not be octagonal. It might be triangular, square or otherwise polygonal when viewed in plan.

Each side wall 13, 14 includes three side wall slots 19 formed adjacent to the lower edge of the side wall. The number three is arbitrary as none, one, two, three or lo more side wall slots 19 might be provided. The purpose of slots 19 is to define the degree of stagger of vertically adjacent rows of modules in an inclined retaining wall or like structure. The function of slots 19 will be described below.

At the intersection of each of the front wall 11, rear wall 12 and side walls 13 and 14 with the respective corner walls 15, there is provided a corner notch 16 at the lower edge of the module. The function of corner notches 16 shall be described below.

Both the front wall 11 and rear wall 12 include a lip 17 which resides in a plane which is substantially parallel with, though outwardly offset from the plane of the respective wall 11 or 12. The offset is best depicted in Fig. 5. Formed within each lip 17 is a lip slot 18 alongside the lower edge of the module. The function of lip slot 18 shall 20 be described below.

Where module 10 is to be formed from sheet material such as mild steel, a blank as shown in Fig. 8 will be required. The blank 80 includes seven fold lines 82 defining the corners of the octagonal plan configuration of the module. Distally remote edges 81 of the blank 80 can be welded together after the blank is cold formed into the octagonal configuration.

In Fig. 2 there is schematically depicted a retaining wall 20 formed from a plurality of stacked modules 10. Each row 21 of modules 10 is horizontally staggered with respect to a row 21 therebelow. The degree of stagger is determined by the choice of side wall slot 19 fitted over the upper edge of rear wall 12 in the adjacent row of modules therebelow.

A staggered wall of the form depicted in Fig. 2 can be used to retain an embankment. That is, a lower row 21 of modules 10 can be positioned and in-fill material can be filled into an area behind the wall to a level just below the upper edge of Srear wall 12. A second row 21 of modules can then be fitted in place upon the first row [R:\LIBLL] 12942specie.doc:keh 6 and in-fill material can then be filled behind the second row to a level just below the upper edge of rear wall 12 and so on. Furthermore, the hollow space within each module can be filled with bulk material such as blue metal, gravel, soil, rocks or the like.

It can be desirable to provide horizontal plates to prevent the material which fills the individual modules from falling through openings therein. To this end, and as shown in Figs. 31 and 32, triangular plates 310 and 320 can be provided. These plates can be fitted in position in between the individual modules of a constructed wall to fill the triangular spaces therebetween. Plate 310 includes three foldable lips 311 which can be folded over the upper edge of the front or back walls of each module. Plate 310 of Fig. 32 lo includes only a single lip 311 for this purpose. When fitted in place, such plates would prevent the escape of infill material from the stacked modules.

Another type of wall construction is shown in Fig. 3. In the arrangement of Fig.

3, individual rows 21 of modules 10 are stacked vertically one upon another in a brick pattern. The first row of modules 10 is positioned upon surface 31 which can take the form of a concrete footing or road base for example. Alternatively, it can be a length of wood or any other form of support extending either horizontally or inclined from one end to another. Extending out of surface 31 is a pair of locating tracks 32 which can be galvanised steel strips, or the upwardly extending walls of a "U channel". The locating i otracks 32 are received within each of the corner notches 16 of the lower row of modules.

This interengagement will provide lateral stability to the wall and provide the desired alignment of the wall structure.

The modules 10 in the second row are individually interconnected with a pair of modules 10 in the first row. To this end, comer notches 16 of the modules in the second row are fitted over the point at which the front wall 11 or rear wall 12 meets with the respective corner walls Once a wall is completed, there will be left at the end of every other row, a halfmodule space. This half-module space can be filled with a half-module (not shown).

However, a half-module would take the form when viewed in plan of either half of the module shown in Fig. 6 and as divided by separation plane 21 shown in phantom. That is, in a half-module, an edge-wall would extend along the plane 21 between the front and rear walls.

In order to increase the stability of the wall of Fig. 3, a number of vertical braces S33 can be included. Each vertical brace 33 is typically a length of galvanised steel or other strong material, examples of which were mentioned earlier. Each brace 33 is [R:\LIBLL] I 2942specie. doc:keh 7 typically in the form of an angle piece with each leg of the angle piece having a length substantially corresponding with the width of each corner wall 15. The vertical brace passes alongside the comer walls of horizontally adjacent modules in every other row, but passes behind the front wall 11 of a module in the alternate intervening rows. Cover plates (not shown) can be fitted between the respective front walls in each space, two of which are indicated as 34 in Fig. 3. This will produce a substantially flat surface which might be cement rendered or otherwise coated or tiled The wall as constructed in Fig. 3 can be filled with gravel, concrete, earth, blue metal or other bulk or settable material such as expandable foam.

lo In each of the structures exemplified in Figs. 2 and 3, the fact that the lip 17 extends out of the plane of the front wall 11 or rear wall 12 is not exploited. In alternative structures, the lip 17 can slide over the upper edge of either the front wall 11, rear wall 12 or either of side walls 13 or 14 of a module positioned immediately therebelow so as to reside inside the hollow cavity defined by those walls.

There are many potential uses of the modules disclosed herein. For example, the :":modules could be interconnected for the construction of causeways filled with gravel, blue metal or other bulk material.

""Military matting and temporary runways could be constructed from a matrix of side-by-side and end-to-end interconnecting modules. Likewise, such a matrix of modules could be used to reinforce road base or provide taxi-way foundations filled with gravel.

Where at least some of the front, rear, side or corner walls are perforated, the modules might be used in filter drains.

Also, the module could be interconnected in a three-dimensional matrix to produce quay walls and sea walls or "rip-rap" walls or abutments in bridge construction.

Other possible uses are in fencing construction, as a substitute for landscaping blocks, for use as cattle grids in a horizontal two-dimensional matrix, emergency bunding walls for oil spillage containment or spillage of other liquid, noxious or otherwise, for the construction of temporary silos, for the construction of indigenous housing, temporary safety barriers, scaffolding and even in the construction of temporary grand stands, levee banks or sound barriers.

It is envisaged that the "honeycomb" nature of structures formed by interconnecting the modules will display high levels of strength and rigidity.

[R:\LIBLL] 12942specie.doc:keh 8 One particular use envisaged for the modules is in the construction of safety barriers. For example, a wall could be constructed from the modules for placement at the leading end of concrete divider walls on highways. By appropriate testing and selection of material thickness, a wall can be constructed from the modules to dissipate the energy of end-on vehicular collision impact.

A guard rail can be supported around the structure for additional rigidity and impact protection.

Water barrels can be placed inside the modules to burst upwardly upon vehicular impact, thus dissipating energy.

Another use envisaged for the modules is in the construction of explosion barriers for military aircraft bases. That is, military aircraft could be housed within bays defined by walls constructed of the modules. If an explosion occurs at one aircraft, the shock wave might be absorbed by a wall so constructed, thus substantially mitigating the progression of the shock wave to other aircraft at the military installation.

Although by no means intended as limiting, examples of material thickness in the modules formed from steel can be 1.6 mm or 2.7 mm.

As an example only, the height of each module can be about 240 mm and the overall length of blank 80 can be about 1364 mm using a blank thickness of 2.7 mm. Of course, these dimensions can be varied enormously. For example, it can be desired to produce a cattle grid from a horizontal planar matrix of modules. Each module in this instance would be substantially smaller.

Similarly, a matrix of modules can be used in the construction of a stream bed where each module is filled with rocks to prevent stream erosion.

*O q Other examples of potential uses for the modules are in arch foundations, ooo• 25 formwork, and the construction of dam walls. For example, in the construction of dam

OS..

walls, the modules can be substantially larger than as exemplified above.

In Fig. 9 of the accompanying drawings there is schematically depicted an end module 10 as positioned at the end position at every other row of a constructed wall. An end cover plate 90 can be positioned in the space in between the end modules 10 in the rows above and below, instead of the half-module described above. The end cover plate 19 is dimensioned so as to be slightly smaller than the size of the adjoining modules.

That is, the end cover plate 90 fits within the end portions of the vertically adjacent modules to slide into position. An alternative to the cover plate 90 shown in Fig. 9 is [R:\LIBLL] 12942specie.doc:keh 9 shown in Fig. 18. In the Fig. 18 alternative, small wall sections 91 can include slots in their lower edges for interengagement over the upper edges of a module therebelow.

In Fig 10 there is a schematically depicted a curved line of substantially cylindricai modules forming a wall. A flexible metal strip 100 can define the profile of the wall and be embedded in concrete, road base or other base materials.

Alternatively, and as shown in Fig. 11, strip 100 might be straight.

A substantially cylindrical module 120 is shown in Fig. 12. The module includes a number of peripheral slots 121 around its base, serving the same function as slots 16, 17, and 19 of the octagonal embodiment of Fig. 1. The flexible strip 100 can be received by two of the slots in each module. Furthermore, the slots can serve to interlock the modules together in a stacked configuration.

ad In Fig. 13 there is schematically depicted two rows of cylindrical modules 120 and 120'. A vertical brace or cover strip 130 can extend through a number of rows to oprovide structural rigidity and a relatively clean appearance to the exposed surface of the constructed wall. Each vertical brace or cover strip 130 might initially be formed flat, though take on a curved configuration as a result of its interaction with the adjacent modules.

To provide further rigidity to the constructed wall, a number of clips 131 can be used to interengage the upper edges of adjacent modules in each row.

In Fig. 14, an end cover strip 140 is shown. The cover strip passes between the end modules in every other row in a constructed wall. Like the vertical strips 130 in Fig.

13, the end cover strip 140 in Fig. 14 might be formed of relatively thin material which will ordinarily lie flat, but takes the curved form as a result of its interaction with the °inside surface of the end modules in the constructed wall.

In Fig. 15, there is schematically depicted in plan view a 45 degree corner in a wall constructed of octagonal modules. As can be seen, a corner fill module 160 can be positioned alongside the comer region of the constructed wall. Such a module is shown in Fig. 16 and includes a transverse wall 161, a small portion of which would reside against the corner wall 15 in an adjacent module.

In order to increase the rigidity of, and/or to improve the aesthetic appearance of the constructed wall, in-fill or bracing sections 170 can be installed. These are somewhat similar in function to items 33, 130 and 140 described above. Members 170 are generally R, triangular, though are not joined at one corner as shown. This results in a degree of transverse resilience.

[R:\LIBLL] 12942specie.doc:keh In Fig. 19, there is shown a cover plate 190 to be installed in the position indicated by reference numeral 190 in Fig. 15. The plate 190 can include small end sections 191 having slots in their lower edges to be received by the upper edges of modules in a row therebelow.

In Fig. 20 there is depicted in plan a module 10. To the front and rear walls of the module 10, a tile connecting strip 210, 211 can be affixed. The tile connecting strips 210 or 211 can take on either of the forms depicted. In both forms, the strip would include downwardly projecting tabs 212 to be slotted over the upper edges of the front and rear walls 11 and 12. It should be appreciated in this regard that although two forms of the tile connecting strip are shown in Fig. 20, it is not essential that both forms be placed on a single module. Furthermore, in most instances, a strip would only be provided at one face of the module A tile 220 is shown in Fig. 22. The tile 220 includes a front face 221 and a slot .•222 in its rear face. Slot 222 is adapted to be slidingly engaged over the tile connecting .:o0 15 strip211.

An alternative tile 230 is shown in Fig. 23. Likewise, the tile 230 includes a front face 231 and this time, a pair of slots 232. Each of the slots 232 is adapted to be received either by an edge of tile connecting strip 211 or 210.

0 Tile connecting strips are to be connected to each of the modules of a constructed 20 wall and each tile would typically be dimensioned so as to cover one module.

•In Fig. 24 there is depicted a plate 240 having a channel 241 into which the ends of a pair of lengths of flexible strip 100 can be received for the purpose of location. The plate 240 can be embedded in road base or otherwise secured in place.

0:ooo0 Where substantially cylindrical modules are to be formed, a flat blank of sheet material can be rolled into the circular configuration and the adjoining edges welded. As an alternative, and as shown in Fig. 25, folded interlocking strip means 250 can be provided. Different forms of this strip means are shown in Figs. 26 to In Fig. 26 the strip means includes a first down-turned lip 260 at one edge of the sheet material 261. At the other edge of sheet material 261, there is provided an upturned lip 262. Each lip 260 and 262 includes a locking strip 263, each of which are snap-engaged over one another when the edges are interconnected to the configuration shown in Fig. 27.

A similar arrangement can be provided nearby the corner of an octagonal or other polygonal module as shown in Fig. 28.

[R:\LIBLL 12942specie.doc:keh 11 A development on the theme is shown in Fig. 29. In this case, the locking strip 291 is flattened to provide increased rigidity.

A further development of this theme is in the construction of pipes. As shown in Fig. 30, a water-proof seam is depicted. A resilient bead 300 is received between the lip 260 and the locking strip 263. Water or other flowable substance 301 within the pipe is prevented from leaking through the seam by means of the bead 300.

A particular advantage of the cylindrical modules as disclosed herein and which include the interlocking strip means is that transportation costs can be significantly reduced. That is the modules can be transported in a flat-packed out-folded configuration lo to a construction site. In order to form each module, each flat-packed blank can be folded into the cylindrical configurations depicted at which point the interlocking strips can be engaged to retain the cylindrical form of each module.

All of the modules or pipes as disclosed above can be formed from steel which is either black or galvanised, stainless steel, copper, aluminium, plastics, rubber or other materials. The modules can be powder coated, painted with "Colourbond" material or otherwise painted.

In non flat-packed, foldable form, glass is another viable material. Likewise, pre-fabricated modules could be cast, extruded, cold formed or moulded. Other examples of possible materials are manufactured stone, foam, wood, wire mesh for use in gabion blocks. Other ceramics might also be employed, depending on the intended use. In this regard, other possible uses are in the construction of building foundations, temporary stairways, piers for wharfs and bridges and the like. In the construction of a pier for example, it would not be necessary to provide concrete footings at the river or ocean bed as the modules could be filled with rocks, blue metal or other heavy material to serve the same purpose.

In Fig. 33 of the accompanying drawings there is schematically depicted an alternate interengaging strip means for use in pipe construction or the construction of substantially cylindrical structural modules. The form is somewhat similar to that depicted in Figs. 26 and 27, however, the dimensions of the folds are such as to provide a tight interengagement between the mating strips.

Yet a further alternative configuration is shown in Fig. 34. In this form, each over-folded edge is substantially flat providing little or no spaces between the mating /surfaces.

[R:\LIBLL] I 2942specie.doc:keh 12 In Fig. 35, an alternative configuration to that of Fig. 34 is depicted. However, a back-folded segment 350 of one folded lip abuts a back-folded segment 351 of the other folded lip at point 352. Substantially no space is left between the mating surfaces.

In Fig. 36 there is schematically depicted a plastically deformable engagement brace 360. Brace 360 is typically formed of galvanised steel sheet being folded over into a U shape with a plurality of slots 361 defined by individual fingers 362 therebetween being provided in one side only to enable the brace to be curved about an imaginary axis shown by the letter A. That is, during folding, the slots 361 close in upon themselves to enable the curved shape to be formed. In use, the engaging brace which can be provided in discretely lengthened segments or continuous lengths can be fitted over the upper edge of a segment S of a substantially cylindrical module 120 where it meets with a curved infill panel 370 fitting in spaces therebetween. That is, curved infill panels 370 sit above corresponding segments S in a row of modules 120 therebelow. To keep these infill panels 370 in place, the engaging brace is deformed to take on a number of adjoining 5 curved segments. The fingers 362 of the engaging brace fit over the upper edges of the segments S and infill panels 370 to retain the infill panels in position.

In Figs. 38 to 40 of the accompanying drawings there is schematically depicted structural module 500 or 600 of preferred embodiments of the present invention.

S• Referring to Fig. 38, module 500 is typically folded from a flat blank of mild steel. The module 500 might typically be galvanised after fabrication. However, as an alternative, it i' might be formed from aluminium, plastics material, or any other material displaying strength properties suitable for a particular application.

Module 500 includes side walls 503 and end walls 501 and 502. The side walls connect with the end walls by a 90' fold line 509. Each side wall 503 includes a pair of end portions 505 and 506 between which there resides a mid portion 504 which sits proud of the end portions 505 and 506 due to a pair of deviations 507. As the structural module 500 is fabricated from a single blank as shown in Fig. 39, the deviations 507 are continuous with the end portions 505 and mid portion 504. The deviations 507 extend out of the respective planes of the end portions 505 and 507 at an angle a which is typically 300. At the upper and lower ends of each deviation 507 there is provided a slot 508.

With reference to Fig. 39, there is shown a blank 500' from which the structural module 500 of Fig. 38 is folded. A weld seam line 510 is provided at the centre of end wall 501.

[R:\LIBLL] 12942specie.doc:keh 13 The modules 500 can be stacked end-to-end and one upon another in a brick pattern. When so stacked, the lower edge of the mid portion 504 extends over the upper edges of the end portions 505 of a pair of laterally adjacent modules 500. That is, the lower slots 508 of one module interengage with the upper slots 508 of a module therebelow such that the mid portions 504 of all of the modules in a constructed wall are substantially co-planar. The distance between the outwardly facing surface of end portion 505 and the inwardly facing surface of the mid portion 504 approximates the thickness of the material from which the module is fabricated. That is, interengagement of the modules in a constructed wall is to be by close or tight fitting interrelationship of the module as the slots 508 interengage with one another.

In order to render the need for welding at the weld seam line 501 unnecessary, the 900 corners 509 might be replaced with 450 deviations with a long slot extending from an upper edge of the module 500 to approximately midway between the upper edge and lower edge. This way, the end wall 502 of one module can be slotted in behind the end 0: 0.

wall 501 of adjacent module by interaction of the slots. That is, the slots in one module would project downwardly from the top edge whereas the slots in the other module would project upwardly from the bottom edge. As the end wall with the join 510 would be interengaged "inside" a solid end wall, there would be no need to weld the seam 510 closed.

Fig. 40 shows yet a further alternative structural module 600. Module 600 is •..similar to module 500 in providing end portions 505 and 506 between which there resides a mid portion 504. However, the end portions 505 and 506 sit proud of the mid portion 504 as the deviations 507 are angled outwardly from the respective ends of the mid *portion 504. The deviations 507 extend out of the plane of the mid portion by an angle a which is typically 30'. Slots 508 are provided at the upper and lower ends of each deviation 507 and additional slots 610 are provided in the upper and lower edges of the mid section 504 as depicted. Also, small slots 611 are provided at each corner of the module. The modules 600 can be stacked end-to-end and one upon another in a brick pattern. When so stacked, the lower edge of the mid portion 504 extends behind the upper edge of the end portions 505 in a pair of laterally adjacent modules 600. That is, the lower slots 508 of one module interengage with the upper slots 508 of a module therebelow such that the end portions 504 and 506 of all the modules in a constructed wall are substantially co-planar. The slots 610 in the upper edge of the mid portion 504 [R\LIBLL] I 2942specie. doc:keh 14 are adapted to receive the lower edge of end wall 501 of an adjoining module. That is, slots 611 and 610 interengage with one another.

It should be appreciated that modifications and alterations obvious to those skilled in the art are not to be considered as beyond the scope of the present invention.

For example, it might be desirable to produce modules which are approximately twice as long as they are wide. That is, the length of the front and rear walls might be extended with respect to the length of the side walls.

[R:\LIBLL l2942specie.doc:keh

Claims (16)

1. A structural module including two opposed side walls and two opposed end walls, the side walls and end walls defining a hollow body having open ends defined by edges of the walls, wherein each side wall includes a pair of opposed end portions between which there resides a mid portion which is displaced from the plane of the end portions and wherein a deviation extends between the mid portion and each end portion.

2. A structural module as claimed in claim 1, wherein the end portions sit proud of the mid portions.

3. A structural module as claimed in claim 1, wherein the mid portions sit proud of the end portions.

4. A structural module as claimed in claim 1, 2 or 3, wherein the deviation is delimited by a pair of slots at upper and lower edges of the module.

A structural module as claimed in any one of claims 1 to 4, wherein the mid portion is approximately twice as long as each end portion as measured in the length 606 direction of the side wall from end wall-to-end wall.

6. A structural module as claimed in any one of claims 1 to 5, wherein the deviation extends substantially at 450 from the plane of the side wall.

7. A structural module as claimed in any one of claims 1 to 6, wherein at least at one of said ends of at least some of the walls have engaging means at or nearby oo 20 their edges which are adapted to engage with other structural modules in a structure formed thereof

8. A structural module as claimed in claim 7, wherein the engaging means include slots into which side wall edges of a neighbouring module can be received. i

9. A structural module as claimed in claims 7 or 8, wherein each side wall includes a number of said engaging means.

A wall constructed from the structural modules claimed in any one of claims 1 to 9, wherein the modules are stacked one upon another in a brick pattern with the slots at the upper edge of a structural module interacting with the slots at the lower edge of a module in a row thereabove such that the mid portions of all of the modules in the wall are substantially coplanar.

11. A structural wall including a plurality of the structural modules claimed in any one of claims 1 to 9, wherein the structural modules are stacked side-to-side and RG one upon another in a "brick pattemrn". [RALIBLL] 12942specie.doc*eh [R:\LIBLL] I 2942spece.doc:keh 16

12. A structural wall as claimed in claim 11, wherein each row of the structural modules are stacked substantially vertically.

13. A structural wall as claimed in claim 11, wherein each row of the structural modules are horizontally displaced with respect to the row of the structural modules therebelow.

14. A structural wall as claimed in claim 11, 12 or 13, wherein the structural wall is mounted upon a longitudinally extending locating track or parallel tracks, the track or tracks being received by some of the engaging means of the structural modules in a bottom row of the structural wall.

15. A structural module substantially as hereinbefore described with reference to Figs. 38 to 40 of the accompanying drawings. Dated

16 July, 2002 Richard Warren Patent Attorneys for the Applicant/Nominated Person ;15 SPRUSON FERGUSON *o *•go *o *O *o o* o• [R:\LJBLL] I 2942specie. doc:keh