GB2522208A

GB2522208A - A modular wall assembly and method for constructing a modular wall

Info

Publication number: GB2522208A
Application number: GB1400700.9A
Authority: GB
Inventors: Andrew Aird
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-01-16
Filing date: 2014-01-16
Publication date: 2015-07-22
Also published as: WO2015107355A3; GB201407754D0; WO2015107355A2; GB201400700D0; GB2522284A

Abstract

The wall assembly comprises, two panels 2a, 2b with brackets 6, 7 extending from respective surfaces of each panel. The panels being spaced apart and arranged faces to face and a clip 9 is connectable to the first and brackets to maintain a predetermined distance between the panel. The assembly can receive settable concrete in use. The clip may snap fit with each anchor and be removably attachable. The brackets may have portions that extend parallel to the respective surfaces of the panels. The wall may be covered with top 23 and side caps. The wall may have adjustable feet. The panels may be attachable to other panels by a tang and bracket arrangement or a tongue 21a, and groove 23a arrangement. Also claimed is a clip comprising: two brackets attachable to panels and a connector portion attached to the brackets via a snap fit. Also claimed is a method of constructing a wall where a clip is secured over end portions of two brackets by a snap fit, the brackets extending from surfaces of two panels. Also claimed is a method of constructing a cavity wall by having first and second wall assemblies spaced apart in a parallel configuration.

Description

A modular wall assembly and method for constructing a modular wall This invention relates to a modular wall assembly, in particular for use with concrete permanent walls used for eco-buildings.

Traditionally walls for boundaries, dwellings and commercial purposes have been built using wood, brick or stone and the construction of such walls has been carried out by skilled tradesman. However, the construction process is slow, costly and hampered by poor weather conditions. Also traditional construction techniques can be dangerous, especially when using heavy bricks or stones and may also be detrimental to the construction workers health, for example skin disease associated with skin contact with mortar. There is also a considerable amount of wasted materials when using the traditional techniques, for example mortar waste or cut bricks.

Concrete is a highly versatile material that is used in many forms of man-made structures from bridges to dwellings. It is a strong, extremely durable, sustainable, low maintenance and highly affordable material which is quick and easy to apply, making it a desirable alternative to the more traditional materials used in the past. Its resistance to fire makes it particularly suitable for use in highly populated areas and for structures used in our every day lives. It is also remarkably environmentally friendly. For example, it is generally locally produced, saving on transport costs and has an energy efficient production process that is relatively low in CO2 emissions (when compared to some other materials e.g. quarrying of stone). Further, it has an excellent thermal mass enabling the maintenance of internal temperatures of a building and reducing the energy needs for the building i.e. minimising the use of heating and air conditioning, thereby saving energy consumption over the lifetime of the building. This consequently reduces the cost to the habitant of a dwelling, or user of a commercial property.

The albedo effect is another beneficial property of concrete, whereby light is reflected from the surface of concrete resulting in less heat being absorbed by it. This consequently reduces the heat island effect and consequentially further reduces the energy required for use in air conditioning. The ever increasing cost of energy makes concrete a desirable material to use in construction due to it's energy saving characteristics.

The above-mentioned benefits of using concrete for the walls in buildings is well known, making the material highly desirable for eco-buildings. However, concrete is generally deemed to be aesthetically displeasing to the eye, and therefore is not always readily welcomed for certain applications. The aesthetics of a concrete wall can be improved by the application of panels applied to existing concrete walls. In WO 99/43904 the panels were used as moulds and are left in situ to provide extra reinforcement. However to construct such a wall, the panels need to be secured in a suitable foundation and props are required to ensure the panels remain in the correct position whilst the concrete hardens.

Any misalignment of the props, due to bad weather or human error, has a negative consequence to the orientation of the wall, for example the wall could be set off-vertical. This is especially problematic on sloped surfaces.

Concrete moulds of the type mentioned in WO 99/43904 have a first and second panel separated by a spacer. The spacers are usually fixed between the opposing surfaces of the two panels. However, this is problematic since such panels are constructed in a factory resulting in the need for a bulky structure to be transported to the desired site, which can be costly and inconvenient when placing on site.

WO 2005/014948 overcomes this problem by having a three part hinged spacing arrangement. The hinge arrangement enables the panels to be reconfigured for storage and transport prior to use. However, the hinge is a complicated arrangement formed of costly components. Further, the panels are made of polystyrene and as such are untreated leaving them open to the elements and susceptible to vandalism. The panels are therefore required to be rendered and this additional further process of cladding or tiling the external surface is time-consuming and costly and is best carried out by a skilled labourer.

The energy efficiency of a concrete wall can be improved further by inserting a cavity within the concrete. It is known to insert tubular members between the two parallel panels prior to inserting the concrete between the panels, but this can complicate the construction of the wall, consequently increasing the time and the money for its installation. This also requires a skilled tradesman to carry out the work.

The present invention is derived from the realisation that there exists a need to provide a simplified wall assembly for use in eco-building that maintains the benefits of known concrete arrangements whilst easing construction of the wall and improving the integrity of alignment of the walls. The assembly also enables cavity walls to be constructed by a low-skilled person in a fast, reliable and easily reproducible manner. The assembly is also safer compared to traditional techniques since heavy stones or bricks are no longer needed to be placed by hand and mortar no longer needs to be touched, since the concrete is filled mechanically. There is also less waste associated with the construction process of the present invention since the panels are precision made and the precise amount of ready mix concrete can be calculated and ordered to site.

According to the invention there is provided a modular wall assembly for an eco-building, comprising at least a first panel having a first bracket extending from a surface thereof; at least a second panel having a second bracket extending from a surface thereof; the at least first and second panel being spaced apart and arranged face to face; a connector clip connectable to the first and second bracket so as to maintain a predetermined distance between the at least first and second panel, for receiving settable concrete when in use.

Preferably, wherein the first and second brackets have a recess for receiving a correspondingly shaped protrusion located at respective ends of the connector clip. This simplifies the connection means between panels and enables them to be transported from the factory in flat-pack.

Desirably, wherein the first and second brackets have end portions configured to extend parallel to the surface of the respective panels to which they are connected, whereby the recess is positioned on the side of the end portions facing the respective panels. This advantageously helps guide the protrusion of the clip into the recess of the first and second bracket.

Beneficially, wherein the connector clip and the first and second bracket are configurable to be received together in a snap fit. This provides a quick, reliable connection between the connector clip and the brackets.

Preferably, wherein the connector clip is removeably attachable to the first and second bracket. This enables the clip to be removed from the bracket so as to reposition the panels if necessary.

Beneficially, wherein an outer surface of at least one of the first and second panels has a finished weatherproof surface. This prevents the need for cladding or rendering the outer surface, saving time and cost.

Desirably, wherein the outer surface is made from a composite material.

Preferably including a top cap attachable to at least part of a top edge of the modular wall assembly to cover the space between the first and second panels Additionally, including a side cap attachable to at least part of a side edge of the wall assembly, for preventing the escape of settable concrete from between the first and second panels.

Beneficially, wherein a side edge thereof is configurable to receive a further modular wall assembly. This provides the modular nature of the wall assembly making it suitable for use in many different applications requiring different dimensions.

Desirably, wherein a top edge thereof is configurable to receive a further modular wall assembly. This enables the height of the wall assembly to be varied as desired.

In one embodiment the modular wall system comprises a first corner panel having a first portion and a second portion positioned substantially perpendicular to the first portion and a second corner panel having a first portion and a second portion positioned substantially perpendicular to the first portion, the first portions of respective panels and the second portions of respective panels being parallel. This enables a turn in the wall to be created with ease.

Alternatively, the modular wall assembly comprises a first planar panel and a second planar panel configured in a parallel arrangement, with respective side edges in alignment.

Beneficially, including at least one adjustable foot arrangement. This enables the wall assembly to be levelled on ragged terrain.

Desirably, wherein the foot arrangement has a base plate, wall assembly receiving means and an adjustor disposed there-between for varying the distance between the base plate and the wall assembly receiving means.

Preferably the wall assembly having a tang which extends from a first side edge of a first panel of a first modular wall assembly and which is receivable in a bracket located at a side edge of a first panel in a second adjacent modular wall assembly.

Preferably the wall assembly having a tongue arrangement along at least part of a first side edge thereof and a groove arrangement arranged along at least a second side edge thereof.

In a second aspect of the invention there is included a modular wall assembly clip for use with a first and second wall panel, the clip configured to secure the first and second panel in spaced relation, the clip comprising a first bracket attached or attachable to a surface of a first panel; a second bracket attached or attachable to a surface of a second panel; and a connector portion connectable there-between by means of a snap fit.

Preferably, wherein the connector portion is releasably attachable to the first and second bracket.

In a third aspect of the invention there is included a cavity wall assembly comprising at least two above-mentioned wall assemblies configured in a face to face, spaced apart and parallel arrangement to define a cavity there-between.

This further improves the insulation properties of the wall.

Preferably, including a spacer positioned between and attached to the at least two wall assemblies and wherein the spacer is the above-mentioned modular wall assembly clip. Therefore, the same clip design is used for the single skin wall assembly and the cavity wall assembly, ensuring the cavity wall assembly can be created with ease.

In a fourth aspect of the invention there is included a method of constructing a wall, comprising arranging a first panel having a first bracket extending from a surface thereof and a second panel having a second bracket extending from a surface thereof in spaced relation, securing a connecting clip over end portions of the first and second bracket so as to enable a snap fit; and pouring a settable slurry between the first and second panel.

Preferably, comprising adjusting the alignment of the first and second panel, using an adjustable foot arrangement.

Beneficially, the method further comprising coupling further modular wall assemblies until the desired wall height or length is achieved.

Desirably, wherein a top cap is subsequently fitted to a top edge of the uppermost first and second panel once the desired wall height is achieved.

In a fifth aspect of the invention there is provided a method of constructing a cavity wall, including: arranging a first and second wall assembly according to claim 1 in a spaced apart and parallel configuration; configuring a connector clip between first and second brackets located on adjacent surfaces of respective first and second wall assemblies so as to secure the first and second wall assembly in spaced relation; and pouring a settable slurry between first and second panels of each wall assembly.

In a sixth aspect of the invention there is provided an eco-building incorporating the above-mentioned modular assembly.

Whilst the invention has been disclosed above it extends to any inventive combination of the features set out above, or in the following description, drawings or claims.

The invention will now be described, by way of example only, with reference to the accompanying drawings in which:-Figure 1 is a perspective view of the wall assembly of the invention; Figures 2a is a perspective view of a connector clip forming part of the wall assembly of Figure 1; Figure 2b is a perspective view of the brackets forming part of the wall assembly of Figure 1 Figure 2c is a perspective view of the connector clip and the brackets in a connected state; Figure 3 is an exploded perspective view of an internal surface of a panel of the wall assembly of Figure 1; Figure 4a is a side view of a secondary fixing means in an unconnected state; Figure 4b is a side view of a secondary fixing means in a connected state; Figure 5 is a perspective view of the wall assembly of Figure 1 with a top cap applied thereto; Figure 6 is a cross-sectional view of the top cap; Figure 7a is a planar view of a corner wall panel assembly in the unconnected state; Figure 7b is a planar view of the corner wall assembly in the connected state; Figure Ba is a perspective view of an outer surface of a wall panel having a tongue portioned side edge; Figure 8b is a perspective view of an outer surface of a wall panel having a groove portioned side edge; Figures 9a is a front view of an adjustable foot arrangement; Figure 9b is a side view of an adjustable foot arrangement; Figure 10 is a side view of the modular wall assembly of Figure 1 in use with the adjustable feet; Figure 11 is a cross-sectional view of the wall assembly of Figure 1 with an end cap attached at either end; Figure 12a is a perspective view of an end cap of a first embodiment with groove terminated side edges; Figure 12b is a perspective view of an end cap of a first embodiment with tongue terminated side edges; Figure 13a is a perspective view of an end cap of a second embodiment with groove terminated side edges; Figure 13b is a perspective view of an end cap of a second embodiment with tongue terminated side edges; Figure 14 shows a cross-section of an exploded wall assembly with feet and top cap; and Figures iSa to 15d show the steps for constructing a wall using the wall assembly of Figure 1, the adjustable base plate of Figures 9a and 9b; and the top cap of Figure 6; Figure 16 shows a cross-section of a cavity wall created using a pair of wall assemblies of Figure 1; and Figure 17 shows a side edge of panel of the wall assembly for use in a cavity wall.

Referring firstly to Figure 1, there is shown a modular wall assembly 1 having a first and second planar panel 2a, 2b separated in a parallel arrangement by a spacing means 3. The respective side edges of the panels 2a, 2b are in alignment. The adjacent surfaces of the wall assembly are the internal surfaces 4a, 4b of the panels 2a, 2b which come into contact with the settable concrete 5 that is applied there-between. The panels 2a, 2b are left in situ and provide a small reinforcement effect, although the majority of the strength is borne by the set concrete 5 contained there-between.

The spacing means 3 comprises three parts 6, 7, 8 as shown in Figures 2a to 2c. The first part 6 extends from the internal surface 4a of the first panel 2a and attached thereto, the second part 7 extends from the internal surface 4b of the second panel 2b and attached thereto and the third part 8, being a linking member or connecting clip 9, is configured to extend between the free end of the first and second parts 6, 7 so as to maintain a spaced relation between the first and second panel 2a, 2b in a face to face arrangement. Therefore, a predetermined distance is maintained between the first and second panel 2a, 2b. The spacing means 3 is arranged substantially perpendicular to the planar surface of the first and second panel 2a, 2b, although other angles could be implemented if desired.

The spacing 3 between the panels 2a, 2b is defined by the length of the spacing means 3 implemented i.e. the width of the walls can be adjusted by using shorter or longer spacing means 3. The first part of the spacing means 6 is a mirror image of the second part of the spacing means 7, but both comprise an elongate bracket having a substantially L-shaped profile. The first bracket 6 extends from the internal surface 4a of the panel 2a to which it is connected, perpendicular to the surface of the first panel and extending towards the second panel 2a and then turns at a corner whereby the bracket extends parallel to the panel 2b in a spaced relation therewith to create an end portion ba. The resulting end portion 1 Oa of the bracket is therefore the free or remote end of the bracket which is spaced from the panel 2a to which it is connected. The end portion ba is terminated at its top edge by a lip 11 which extends towards the surface 4a of the panel 2a to which it is connected, so as to form a recess 12a below the lip. Alternatively, the side of the end portion facing the panel to which it is connected contains a recess therein.

Similarly, the second part of the spacing means 7 is configured such that the lip lOb extends towards the internal surface 4b of the second panel 2b thereby creating a recess 1 2b. Therefore, the lips 1 Oa, 1 Ob of respective brackets 6, 7 extend away from each other.

The third connection partS, or linking member is a connector clip 9 that is formed of a substantially elongate element 13 terminated at either end by arm portions 14a, 14b extending perpendicular to the longitudinal axis of the elongate element 13. The connector clip 9 has a substantially U-shaped cross section. The internal edges of the arm portions 14a, 14b are terminated by a flange or protrusion iSa, 15b extending inwardly towards each other. The first flange isa of the clip 9, and the lip ha and recess 12a of the first bracket 6, are co-operable; and the second flange 1 5b of the clip 9, and the lip 11 b and recess 12b of the second bracket 7, are co-operable. Therefore, the first arm portion 14a of the connector clip cooperates with the first bracket 6 and the second arm portion 14b of the connector clip cooperates with the second bracket 7. When connected, the resulting spacing means 3 acts as a brace member located between the first and second panel 2a, 2b. When the panels 2a, 2b are to be separated by a predetermined distance, the flanged ends of the clip 14a, 14b are inserted past the lips ha, lib and are received in the respective recesses 12a, 12b of the brackets in a snap fit. The lip, recess and flange arrangements prevent separation of the clip 9 from the brackets 6, 7 in the reverse direction of motion so as to form a locked state. An unlocked state may only be achieved if the flange or protrusion 15a, 15b of the clip 9 is forced to extend past the respective lips 11 a, 11 b of the respective brackets 6, 7. Therefore, on application of a tool, the clip 9 and brackets 6, 7 may be detached prior to the insertion of any settable concrete between panels so as to reposition panels if necessary.

The distance between the first and second panel 2a, 2b is determined by the width of the clip and bracket arrangement. To optimise the locked state, the recesses 12a, 12b of the first and second brackets 6, 7 receive a correspondingly shaped protrusion or flange 1 Sa, 1 Sb located at respective ends of the connector clip 9. The clip 9 and the brackets 6,7 are formed of a resilient material that also has the strength to maintain the desired distance between the first and second panel 2a, 2b, for example plastic or a composite material.

Figure 3 shows that two brackets 6, 7 are applied to the inner surfaces 4a, 4b of the panels 2a, 2b in a spaced apart arrangement such that the first bracket 6a for the first panel 2a is applied adjacent a first side edge of the panel and a second bracket 6b on a first panel 2a is positioned adjacent the other side edge of the panel 2a, although the number of brackets per panel need not be limited to two and the position of the brackets may differ in vertical height if desired, however the bracket arrangement must correspond to the bracket arrangement on the partner panel to which it is to be connected.

The panels 2a, 2b are finite in size, therefore for wall lengths that are greater than the width of a panel multiple panels are to be installed side by side.

Therefore, Figure 3 also shows a secondary bracket 16 forming half of the secondary fixing means 17, whereby a tang 18 extending past the side edge of a neighbour panel is to be inserted within the channel 19 of the secondary bracket, so as to fixably secure the side edge of a first panel to a side edge of a second adjacent panel 2c. The tang 18 is moulded to the internal surface 4a of the first panel and the secondary bracket 16 is moulded to the internal surface 4c of the second neighbour panel 2c. As shown in Figure 4a and 4b, the tang 16 is an elongate member, the free end iSa of which extends past the side edge of the panel 2a to which it is affixed. The other end is attached to the internal surface 4a of the panel 2a (or alternatively is an integral part thereof).

The free end of the tang is terminated by a barb 20 and is configured to permit insertion of the tang 16 through the channel 19 of the secondary bracket 16 on application of a force in a first direction, but once the barb 20 extends past the remote end 1 9a of the secondary bracket 16, it returns to its un-biased state and extends past the outer wall 19b of the secondary bracket 16 so as to prevent extraction of the tang 18 from the secondary bracket 16 on application of movement in a second direction opposing the first direction, as shown in Figure 4b.

Figures 1 and 4 also show the use of a co-operable tongue 21 and groove 22 arrangement enabling the panel 2a of a first modular wall assembly 1 to be configured to receive a corresponding side edge of a panel of a further modular wall assembly la. Ultimately, the tongue 21 and groove 22 arrangement permits a tight joint between neighbouring panels 2a, 2c and minimises gaps there-between which would allow concrete to escape. The tongue 21 and groove 22 arrangement is applicable to all the edges of the panel and as such is beneficial for arranging the panels 2a, 2c in a side to side or in a stacked arrangement. For example, in the side to side assembly shown in Figure 3, the first panel 2a has a tongue 21 which co-operates with a groove 22 of a panel of a second, adjacent wall assembly 2c. The tongue 21 extends continuously along a significant length of the side edge of the first panel 2a, but this need not be the case, whereby an array of spaced tongue portions may instead be implemented along the edge of the panel. The tongue 21 is the male part of the arrangement and the groove 22 the female part, whereby the two parts are co-operable. The groove 22 compliments the shape of the tongue 21 such that a snug fit of the tongue therein is enabled. Figure 1 shows that the top tongue 21a extends the entire width of a first edge (top edge) of the panel 2a and the opposing edge (base edge) has a groove which extends along the entirety of the width of the panel, although this need not be the case, and the tongue and groove may extend along only part of the width of the panel. It is shown in Figure 1 that opposing edges of a panel have different termination portions. However, it is also valid for only tongues 21 or grooves 22 to be applied to the side edges of a given panel 2a. Of course, this arrangement would then require two different types of panel to be made available. Figure 1 also shows that both the first panel 2a and the second panel 2c have the tongue arrangement at the upper side edge (top) of the wall and the groove arrangement at the lower side edge (base) of the wall.

In order to enclose the concrete completely within the wall, thereby covering the space between the first and second panel 2a, 2b, a top cap member 23 may be applied to the top edge of the modular wall assembly over the upper tongues 21 a of the first and second panel 2a, 2b, so as to straddle the two tongues 21a and secure the first and second panels 2a, 2b together as shown in Figure 5. Figure 6 shows the top cap member 23 to have a substantially inverted U-shaped cross section and a groove 23a at the first end and a tongue (not shown) at the second end, to permit interlocking and therefore stability between adjacent top cap members. The thickness of the side walls of the top cap member 23 are chosen so as to lie flush with the outer surface of the panels. A plastic rod 24 extends from the internal surface of the top cap member 23 so as to stabilise the top cap 23 into the required position, by extending into the settable concrete 5 positioned between the panels 2a, 2b and allowing the concrete S to subsequently set, thereby maintaining the top cap member 23 in the desired position. The top cap member 23 is of use to protect the concrete 5 and provides an aesthetically pleasing terminus to the wall 25.

Figures 7a and 7b shows the corner wall assembly 26 which is to be implemented with the before-described planar wall assembly. It comprises an inner corner wall panel 26a spaced apart from an outer corner wall panel 26b.

The corners create a 90 degree angle, but other angles may be implemented if desired. The inner corner panel 26a has a first portion 27a and a second portion 27b positioned substantially perpendicular to the first portion 27a and the outer corner panel 26b has a first portion 28a and a second portion 28b positioned substantially perpendicular to each other, whereby the first portions 27a, 28a of respective panels and the second portions 27b, 28b of respective panels 26a, 26b are configured in a parallel arrangement.

Similar to the standard planar wall panel arrangement the inner corner wall panel 26a has a groove 22 at one side edge and a tongue 23 at the other side edge. The outer corner wall panel 26b also has this arrangement, whereby at one end of the corner wall assembly the parallel portions have the same termination type. The secondary fixing means 17 will also be used to further ensure the corner wall assembly and the planar wall assemblies remain in a secured position. Further, the clip 9 and bracket 6, 7 arrangement maintains the desired distance between the inner corner wall panel 26a and the outer corner wall panel 2Gb. The corner wall panel assembly 26 is further joined to the end of a linear wall panel assembly 1 with a spring dowel (not shown), or other suitable fixing means.

The outer surface 29 of the panels 2a, 2b, i.e. those which are positioned remotely from the concrete, are finished to look like a desired material. For example, Figures 8a and Sb show the composite face of the wall with a brick effect. Alternative effects may be implemented, for example stone or wood. The outer surface 29 is weatherproof removing the need for a cladding (or other) process to be applied. In contrast, the internal wall 4a of the panel 2a is finished with a plain yet roughly textured surface that encourages the concrete 5 to adhere to the internal surface 4a of the panel 2a.

Figures 9a and 9b show the adjustable foot arrangement 30 of the wall assembly 1 whereby a base plate 31 is positioned at the base of the foot and a panel receiving portion 32 is configured at the top of the foot 30 with an adjustor 33, for example a screw and thread arrangement 33a, located there-between.

The panel receiving portion 32 has a slot 34 for receiving the base of the wall assembly 2a and for tightly holding it in place. The screw and thread 33a of the adjustor 33 is rotatable enabling variation in the distance between the base plate 31 and the panel receiving portion 32 so as to level the wall assembly when it is constructed on uneven terrain.

Figure 10 shows how the wall assembly is received in the slot 34 of the panel receiving portion 32.

Similar to the need to make the top of the wall aesthetically pleasing to the eye, when a wall is not intended to be joined to another wall assembly an end cap 35 may be applied as shown in Figure 11. Similar to the top cap 23, this is an elongate portion having a substantially U-shaped cross-section so that it can be secured to the end of a wall assembly. The end cap 35 prevents the escape of settable concrete from between the first and second panels. The elongate ends of the end panel either have the tongue 21 or the groove 22 arrangement to be applied to corresponding grooves 21 or tongues 22 of the planar 1 or corner wall panels 26. Whilst the lower region of the end cap 35 will have a groove, the top end may have either a tongue 21 or a groove 22 as required and shown in Figures 12a and 12b. The end cap 35 is secured to the assembly with a spring dowel (not shown). Alternatively, other fixing means may be suitably applied, e.g. a rivet. In an alternative arrangement, the end cap may be enclosed at its top end as shown in Figures 13a and 13b.

Figure 14 shows the modular aspect of the wall assembly and, importantly, the stackable nature of the panels 2a, 2b, wherein the top edge of a panel is configurable to receive a bottom edge of a panel in a further modular wall assembly lb. Therefore multiple wall assemblies are coupled together. The foot 30 is at the lowermost part of the wall arrangement. The grooved end 23a at the base of the panel (lower end) is inserted into the slot 35 of the panel receiving portion 32 of the foot 30. The walls of the slot 35 extend along the internal and external surface of respective panels 2a, 2b. The connector clip 9 is then applied. Alternatively, the connector clip 9 can be applied prior to the panels 2a, 2b being received by the slot 35 of the foot 30. A second panel assembly lb may then be applied to the top edge of the first panel assembly 1, whereby the lower end grooves of the second panel assembly lb receive the respective upper end (top) tongues of the first panel assembly 1. The connector clip 9 is then applied so as to maintain the distance between the planar panels of the second panel assembly. Alternatively, the connector clip 9 can be applied prior to mating the tongues 21 of the first panel assembly 1 with respective grooves 22 of the second panel assembly lb. At the top of the stacked wall, and once the desired wall height has been achieved, a top cap 23 is positioned. The end result is an instantly installed seamless wall structure.

As shown in Figures 15a, 15b, 15c and 15d, in use, the feet 30 incorporating the panels 2a, 2b are inserted into a trench. The panels 2a, 2b are then locked into position with the connector clip 9 and the feet 30 are configured to the desired height so as to level or align the arrangement. Concrete 5 is then poured into the trench up to the top of the trench. Concrete 5 is also inserted between the panels 2a, 2b until a point just below the top of the panels 2a, 2b.

The concrete foundation is then given 48hrs to set. Once the foundation has set, a second row of panels 2c, 2d are stacked on top of the first row, ensuring that respective tongue 21 and grooves 22 co-operate appropriately. The connecting clips 9 are then inserted in respective brackets 6, 7 and secondary fixing means 17 are applied so as to lock the second row of panels to the first row of panels. This continues until the desired height of the wall is achieved.

Concrete 5 is then poured between the panels 2a, 2b until it reaches just below the top of the top-most row. Finally the top wall cap 23 is fitted into place and the whole structure is left for the concrete 5 to set. This method optimises the alignment of the wall and removes the need to use props or other bracing techniques to keep the wall in the optimum position while the foundation is setting, which can be cumbersome, time consuming and incorrectly implemented.

A pair of wall assemblies la, lb may be arranged in a face to face, spaced apart and parallel configuration to create a cavity 36 there-between.

Such a cavity wall arrangement 39 is shown in Figure 16 and improves insulation of the wall. To enable this to work effectively the adjacent panels 37a, 37b of respective wall assemblies la, lb have a bracket arranged on both faces thereof, as shown in Figure 17. In addition the internal walls of the cavity wall arrangement 39 will have plain, yet rough surfaces on both sides as the composite finish is not required on the internal surfaces. This then allows a connecting clip 9 to be applied between brackets so as to lock the adjacent faces 37a, 37b of the first and second wall assemblies la, lb together in a spaced relation. The connecting clip 9 and bracket arrangement 6, 38 once again acts as a spacer to fix the distance between wall assemblies la, lb and maintain the width of the cavity 36. The connector clip 9 and the brackets 7, 38 are received in a snap fit as the projections or flanges or protrusions 1 5a, 1 Sb of the connector clip 9 are received by the recesses in the brackets. This is achieved by placing the clip over the end portion of respective brackets.

A top cap 23 is then resized and arranged to cover the top of the cavity wall arrangement 39. The arrangement provides three chambers 40a, 40b, 40c.

Concrete 5 is then only filled in the external chambers 40a, 40b of the cavity wall arrangement 39 and the central or intermediate chamber 40c remains a void.

This arrangement removes the need to insert separate tubular elements between panels, which can be a cumbersome and time consuming process and the width of the cavity can be adjusted by merely varying the length of the connector clip and bracket assembly.

Beneficially, this wall assembly enables the panels to be delivered flat packed to site and allows a wall that is attractive, robust and weatherproof to be created instantly, whereby such a wall also benefits from the desirable properties of concrete so as to provide an economical structure that is aesthetically pleasing to the user which can satisfy building requirements in areas of outstanding natural beauty.

Various modifications to the principles described above would suggest themselves to the skilled person. For example, instead of being integrally formed with the panel, the brackets and secondary fixing clip may be separate and distinct parts attachable to the internal surface of the panel by a fixing means e.g. a physical fixing means such as a screw or chemical fixing means such as an adhesive.

When constructing the wall, enforcement rods may also be used to provide extra strength and steel re-enforcement wire mesh can be fitted prior to fitting the connector clips.

Whilst standard wall panels are 1 m by 0.4 m, any size of panel may be producible as desired. Further, whilst a planar and a corner panel assembly has been described, other shapes can be produced, for example a curved structure or a tapered corner assembly.

When considering a cavity wall arrangement 39, whilst only two wall assemblies have been described, more than two wall assemblies may be implemented creating more than 1 void region, thereby further improving the insulation characteristic of the wall.

Whilst the end 35 and top cap 23 have been described as being substantially U-shaped, other shapes may be preferred, for example a V' shape and the corners of the end cap may be tapered, curved or sharply pointed.

Another settable slurry material may be implemented instead of concrete.

Claims

Claims 1. A modular wall assembly for an eco-building, comprising at least a first panel having a first bracket extending from a surface thereof; at least a second panel having a second bracket extending from a surface thereof; the at least first and second panel being spaced apart and arranged face to face; a connector clip connectable to the first and second bracket so as to maintain a predetermined distance between the at least first and second panel, for receiving settable concrete when in use.
2. A modular wall assembly according to claim 1, wherein the first and second brackets have a recess for receiving a correspondingly shaped protrusion located at respective ends of the connector clip.
3. A modular wall assembly according to claim 2, wherein the first and second brackets have end portions configured to extend parallel to the surface of respective panels to which they are connected, whereby the recess is positioned on the side of the end portions facing the respective panels.
4. A modular wall assembly according to claim 2 or 3, wherein the connector clip and the first and second bracket are configurable to be received together in a snap fit.
5. A modular wall assembly according to any preceding claim, wherein the connector clip is removably attachable to the first and second bracket.
6. A modular wall assembly according to any preceding claim, wherein an outer surface of at least one of the first and second panels has a finished weatherproof surface.
7. A modular wall assembly according to claim 6, wherein the outer surface is made from a composite material.
8. A modular wall assembly according to any preceding claim, including a top cap attachable to at least part of a top edge of the modular wall assembly to cover the space between the first and second panels
9. A modular wall assembly according to any preceding claim, including a side cap attachable to at least part of a side edge of the wall assembly, for preventing the escape of settable concrete from between the first and second panels.
10.A modular wall assembly according to any preceding claim, wherein a side edge thereof is configurable to receive a further modular wall assembly.
11.A modular wall assembly according to any preceding claim, wherein a top edge thereof is configurable to receive a further modular wall assembly.
12.A modular wall assembly according to any preceding claim, comprising: a first corner panel having a first portion and a second portion positioned substantially perpendicular to the first portion and a second corner panel having a first portion and a second portion positioned substantially perpendicular to the first portion, the first portions of respective panels and the second portions of respective panels being parallel.
13.A modular wall assembly according to any preceding claim, wherein the modular wall assembly comprises a first planar panel and a second planar panel configured in a parallel arrangement, with respective side edges in alignment.
14.A modular wall assembly according to any preceding claim, further including at least one adjustable foot arrangement.
15.A modular wall assembly according to claim 14, wherein the foot arrangement has a base plate, wall assembly receiving means and an adjustor disposed there-between for varying the distance between the base plate and the wall assembly receiving means.
16.A modular wall assembly according to any preceding claim, wherein the modular wall assembly is connectable to at least one further modular wall assembly via a tang and bracket arrangement.
17.A modular wall assembly according to any preceding claim, further including a tongue arrangement along at least part of a first side edge thereof and a groove arrangement arranged along at least a second side edge thereof.
18.A modular wall assembly clip for use with a first and second wall panel, the clip configured to secure the first and second panel in spaced relation, the clip comprising: a first bracket attached or attachable to a surface of a first panel; a second bracket attached or attachable to a surface of a second panel; and a connector portion connectable there-between by means of a snap fit.
19.A modular wall assembly clip according to claim 18, wherein the connector portion is releasably attachable to the first and second bracket.
20.A cavity wall assembly comprising at least two wall assemblies of any of claims 1 to 17 configured in a face to face, spaced apart and parallel arrangement to define a cavity there-between.
21.A cavity wall assembly according to claim 20, including a spacer positioned between and attached to the at least two wall assemblies.
22.A cavity wall assembly according to claim 21, wherein the spacer is the modular wall assembly clip of claim 18.
23.A method of constructing a wall, comprising arranging a first panel having a first bracket extending from a surface thereof and a second panel having a second bracket extending from a surface thereof in spaced relation, securing a connecting clip over end portions of the first and second bracket so as to enable a snap fit; and pouring a settable slurry between the first and second panel.
24.A method of constructing a wall according to claim 23, further including adjusting the alignment of the first and second panel using an adjustable foot arrangement.
25.A method of constructing a wall according to claim 24, further including coupling further modular wall assemblies until the desired wall height or length is achieved.
26.A method of constructing a wall according to claims 23 to 25, wherein a top cap is subsequently fitted to a top edge of the uppermost first and second panel once the desired wall height is achieved.
27.A method of constructing a cavity wall, including: arranging a first and second wall assembly according to claim 1 in a spaced apart and parallel configuration; configuring a connector clip between first and second brackets located on adjacent surfaces of respective first and second wall assemblies so as to secure the first and second wall assemblies in a spaced relation; and pouring a settable slurry between first and second panels of each assembly.
28.An Eco-Building incorporating a modular wall assembly according to any of claims ito 17.
29.A modular wall assembly as hereinbefore described with reference to Figures ito lSd.
30.A modular wall assembly clip as hereinbefore described with reference to Figure 2a, 2b and 2c.
31.A cavity wall assembly as hereinbefore described with reference to Figures 16 and 17.