GB2580544A

GB2580544A - Improved panel and post systems

Info

Publication number: GB2580544A
Application number: GB1918972.9A
Authority: GB
Inventors: Holden Nicholas
Original assignee: Modular Innovations Pty Ltd
Current assignee: Modular Innovations Pty Ltd
Priority date: 2016-07-11
Filing date: 2017-07-11
Publication date: 2020-07-22
Anticipated expiration: 2037-07-11
Also published as: GB2580544B; GB2554506A; GB201918972D0; GB2554506B; GB201711151D0

Abstract

An acoustic wall panel 100 comprises a pair of outer layers 102, at least one inner layer 106 formed from a sheet having a plurality of perforations 108 and a sound attenuating centre core 104 between the inner layers. A layer of adhesive or bonding material is located between the core and one of the pair of outer layers. The adhesive passes through the perforations of the inner layer to form a bonding matrix, and is configured to expand during lamination. The panel may comprise layers of core and reinforcing material extending along the width of the panel, bonded together with the outer layers by the adhesive. The inner layer may be formed from steel, aluminium or carbon fibre, and the core may be formed from expanded polystyrene. The reinforcing material may be formed from square hollow section steel or galvanized steel, and the outer layers may be formed from fibre cement. The upper and lower edges of the panel may have caps which allow connection to join adjacent panels. Also claimed is a retaining wall formed from an assembly of posts and panels.

Description

Improved panel and post systems

Field of the invention

[1] The present invention relates to panels used to construct fencing and barriers, and additionally relates to retaining panels, in particular those that can be used in retaining wall construction.

Background of the invention

[2] Sound barriers or sound attenuating fences are needed along roadsides, especially busy highways, to reduce noise pollution from the road. These barriers or fences are often constructed from panels erected between posts. The panels therefore need to have the sound attenuating properties, aside from structural integrity and strength that allows these panels to be used in roadside applications. Sound attenuating and/or endurable panels also have applications in residential or industrial fencing, e.g. around the playground of a childcare centre to contain the noises from the children playing within, or to reduce noises from the machinery in a factory.

[3] Additionally in situations where retaining of earth is required, whether or not in combination with a fence, generally retaining wall construction materials and elements are used to construct the retaining wall. The construction of such retaining walls has traditionally required the construction of brick or block assemblies and specialist tradespersons.

[4] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[5] The present invention provides a panel for a fence or barrier, comprising: a pair of outer layers; at least one inner layer, the at least one inner layer being located adjacent and inboard of one respective outer layer; the at least one inner layer being a sheet having a plurality of perforations; and a centre core between the inner layers.

[6] The at least one inner layer can have a thickness in the range of about 0.25 to 2 millimetres.

[7] A layer of adhesive or bonding material located between the centre core and outer layer can form a bonding matrix through the intervening at least one inner layer.

[8] A layer of bonding material applied to or located on one face of the at least one inner layer will pass through the perforations and reach an opposite face of said at least one inner layer.

[9] Perforations on said at least one layer result in a combined open area of about 25% to 45% of a total area of the said at least one layer.

[10] Perforations on the at least one inner layer can be about 3 millimetres in diameter.

[11] Adjacent perforations on the at least one inner layer can be distanced so that their centres are about 5 millimetres apart.

[12] The outer layers can be about 4 to 5 millimetres in thickness.

[13] The panel can have an overall thickness in the range of about 75 to 300 millimetres.

[14] The panel can have a height in the range of about 0.5 to 2 metres.

[15] The perforations on the inner layer can be produced by drilling, punching, or milling, any appropriate forming process such as the inner layer being cast.

[16] The perforated at least one inner layer can be formed from one of a range of materials including steel, aluminium, or carbon fibre.

[17] The outer layers can be made from fibre cement.

[18] The central core can be made from a noise attenuating material.

[19] The central core can be expanded polystyrene.

[20] The panel can include a second inner layer which is also a sheet having a plurality of perforations.

[21] The present invention also provides a method of constructing a panel for a fence or barrier mentioned in the paragraphs above, including the steps of providing a centre core having two opposite lateral faces; laminating first an inner perforated sheet and then an outer layer to each lateral face, whereby a bonding material located between the centre core and the outer layers is pressed through perforations of the inner perforated sheets and then cured to bond the outer layers and the inner perforated sheets to the centre core.

[22] The bonding material can expand during lamination.

[23] The present invention also provides a panel for a fence or barrier, comprising a first outer layer on a first side of the panel, and a second outer layer on a second side of the panel opposite the first side, the second outer layer being spaced from the first outer layer, and a sound absorbing layer and a core layer located between the first and second outer layers.

[24] There can be an intervening panel member located between the first and second outer layers.

[25] The sound absorbing layer and the core layer can be located one on each side of the intervening panel member.

[26] The first outer layer can be perforated [27] The intervening panel member can be located closer to the second outer layer than the first outer layer.

[28] The core layer can be of a different material than the sound absorbing layer.

[29] The core layer can be another sound absorbing material.

[30] The core layer can be expanded polystyrene.

[31] A position of the intervening panel member can be chosen depending on sound absorption requirements on the panel.

[32] The intervening panel member can be made from wood or another material with dense fibres.

[33] The sound absorbing layer can be made from rock wool, glass wool, or a fibrous or shredded polyethylene terephthalate material.

[34] The outer layers can be made from aluminium.

[35] The present invention also provides a panel component for a fence or barrier, the panel component having an inner face which in use faces an interior of the fence or barrier, and an outer face which in use faces an exterior of the fence or barrier, the panel component having a body portion, a first edge that extends along a longitudinal length of the body portion, and a second edge that opposite the first edge across the body portion, the first edge and second edge both being profiled so that the panel component is adapted to be assembled to a like panel component whereby the first edge of the component is adjacent to the second edge of the like component, and the respective profiles of the first edge and the second edge together providing one or more joining locations inboard of the exterior of the fence or barrier, the profile of the first edge being at least partially in conformance with the profile of the second edge.

[36] The first edge can include a bevelled attachment end adjacent the body portion, the attachment part extending at an angle away from the body portion.

[37] The bevelled attachment end of the first edge can extend into a channel portion.

[38] The sidewalls of the channel portion can be generally parallel to the body portion.

[39] A base of the channel portion can be generally perpendicular to the body portion.

[40] The intermediate arm can be generally perpendicular to the body portion.

[41] The profile of the second edge can be the same as the profile of the second edge.

[42] The profile of the second edge partially can conform to the profile of the second edge.

[43] The second edge can have a bevelled portion extending from the body portion, and the bevelled portion of the second edge mirrors the bevelled attachment part of the first edge.

[44] The bevelled portion of the second edge can be connected to an end section.

[45] The end section can have an overhang or hook.

[46] The body portion can include a series of grooves where a profile of the grooves complements those of the bevelled portion(s).

[47] Two like panel components can be assembled in an end-to-end fashion whereby the second edge of one panel component is adapted to be located adjacent to, and at least partially conforms to the profile of, the first edge of the other panel component.

[48] The present invention also provides a panel for a barrier or fence, comprising: two panel components as mentioned in the paragraphs above, the two panel components being in alignment and positioned so that the inner faces of the panel components face each other; a generally U or C shaped cap section having two free arms separated by a middle arm, the cap section being located between the free ends of the second edges of the two panel components, whereby each free end of the respective second edge is positioned against a respective one of the two free arms of the cap section, the corresponding free end of the second end portion and free arm of the cap section being secured together.

[49] The first edges of the two panel components can be secured together at their respective free ends.

[50] The panel can have another generally U or C-shaped cap section having two free arms separated by a middle arm, the other cap section being located between the free ends of the first edges of the panel components, wherein the free end of each first edge is secured to corresponding respective free arm of the other cap section.

[51] The securing can be done by clinching, bolting, welding or screwing.

[52] The present invention also provides an extrusion for a barrier or fence post, including a first projection which ends in a first end formation, and a second projection which ends in a second end formation, the first and second formations being parallel to each other, the first and second end formation being adapted to engage respectively with second and first end formations of a like extrusion, one of the first and second formations being of an arcuate keyway shape, and the other one of the first and second formations being of a curved shape adapted to complement and engage with the arcuate keyway shape.

[53] The post component can include an inner face and an outer face, two side edges each extending between the inner and outer faces, wherein the first and second projections extends generally perpendicularly from the inner face.

[54] The inner face can be symmetrical about a midline of the extrusion.

[55] A width between the inner and outer faces can increase from the midline to each side edge [56] The post component can further have hooks extending from the inner face, the hooks being located adjacent the side edges.

[57] The present invention also provides a post comprising a pair of post components mentioned above which are inter-engaging.

[58] The present invention further provides a corner post comprising a post component mentioned in the paragraph above, and a corner component which engages the post component.

[59] The corner component can include a first portion which has a first projection arm, the first projection arm having a first end formation which engages the first end formation of the post component, the corner component further having a panel receiving channel adjacent the first portion, a base of the channel having a second end formation located outside of the channel, the second end formation engaging the second end formation of the post component, wherein the channel is oriented so that its base is generally perpendicular to the first projection arm.

[60] The present invention also provides a retaining wall panel having an upper and lower edge and sides, the panel including two outer skins of an environmentally resistant or hardy material between which are sandwiched, in a generally horizontal arrangement, layers of core material and reinforcing material which alternate in the direction of the upper edge to the lower edge of the panel, the reinforcing material extending along the whole width of the panel, and wherein each of the skins, the core material and the reinforcing material are bonded together by a bonding material or adhesive.

[61] There can be at least one reinforcing material layers per panel.

[62] A respective reinforcing material layer can be located between 80 mm and 200mm from the respective upper and or lower edges of the panel.

[63] The core material can be selected from one of the following: polystyrene foam EPS; or other appropriate polymeric material.

[64] The reinforcing material can be a rectangular or square hollow section.

[65] The reinforcing material can have, or be made from, one or more than one of the following: steel; 65x65 SHS being of steel and having a wall thickness of 2 to 5mm; 100x100 SHS being of steel and having a wall section of 2mm to 5mm; galvanized steel.

[66] The at least one outer skin can be made of fibre cement sheet.

[67] The panel can have its upper and lower edges capped by profiled steel caps which will allow adjacent like constructed panels to be joined in a retaining wall assembly. The lower edges are preferably capped by a cap of stainless steel.

[68] The caps can be secured and sealed in place with respect to the outer skin and or the core material by means of a polyurethane construction sealant.

[69] The panel can have one or more than one of the following characteristics: a length of the order of 1 m to 2.5m; a height of the order of 300 to 1200mm; a thickness of the order of 75 mm to 120mm.

[70] The present invention also provides a retaining wall constructed from an assembly of posts and panels, the panels being as mentioned in the above paragraphs.

[71] The panels can have different densities, wherein at least one of panels have a different density than the remaining panels.

[72] There can be at least two panels assembled, one on top of the other, characterized in that a lower panel has a greater strength capability or resistance to pressure of retained earth than an upper panel.

Brief description of the drawings

[73] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [74] Figure 1 is a perspective view of a first panel, where a portion of the outer layer and an inner layer is partially cut away to show the layers beneath; [75] Figure 2 is a cross section view of the panel shown in Figure 1 and [76] Figure 3 is a side view of a second panel; [77] Figure 4 is an exploded perspective view of the outer and inner layers of the panel shown in Figure 3; [78] Figure 5 is a cross section of a panel similar to and a mirror image of figures 3 and 4; [79] Figure 6 is a cross section of another panel similar to that shown in figure 5; [80] Figure 7 is a partial perspective view of the outer layers of the panel of figures 3 and 4, joined by an assembly flange; [81] Figure 8 is a partial perspective view of two panels of Figures 3 and 4 joined together; [82] Figure 9 is a cross section of the outer layers of the panel being joined by joining flanges to achieve a wider width; [83] Figure 10 is a schematic cross section of the outer layers of the panel being joined by only one joining flange to achieve a narrower width; [84] Figure 11 is a schematic cross section of a join between two panels in a first embodiment, where the panels have differently profiled longitudinal edges; [85] Figure 12 is a schematic cross section of the join between two panels in a second embodiment, where the panels have longitudinal edges of the same profile, each panel including a joining flange to connect its outer layers; [86] Figure 13 is a schematic cross section of the join between two panels in a third embodiment, where the panels have longitudinal edges of the same profile, where the outer layers of each panel are directly joined to each other; [87] Figure 14 is a schematic cross section of the join between two panels in a fourth embodiment, where the panels have longitudinal edges of the same profile, where the outer layers of each panel are joined to each other by a joining channel; [88] Figure 15 is a schematic cross section of two post extrusion to be joined to form a post for two panels arranged in a straight line; [89] Figure 16 is a schematic cross section of a corner panel extrusion for forming a corner post, [90] Figure 17 is a schematic cross section of a corner post formed by the assembly of the corner extrusion shown in Figure 16 and the linear extrusion shown in Figure 15; [91] Figure 18 is a perspective view of the post shown in Figure 15; [92] Figure 19 is a perspective view of the corner extrusion shown in Figure 16; [93] Figure 20 is a perspective view of the corner post shown in Figure 17.

[94] Figure 21 is a cross section of a panel having a three core layers and two reinforcing layers, [95] Figure 22 is a front view of the panel shown in Figure 21; [96] Figure 23 is a cross section of another panel having three core layers and two larger reinforcing layers than that of Figures 21 and 22, [97] Figure 24 is a front view of the panel shown in Figure 33; [98] Figure 25 is a partial cross section view of the panel; [99] Figure 26 is a partial side view showing a join between two adjacent panels assembled in a top-to-bottom orientation; [0100] Figure 27 is a partial side view of a top portion of a panel with a closing or sealing cap; [0101] Figure 28 is a partial side view of a bottom portion of a panel with a closing or sealing cap; [0102] Figure 29 is a cross section view of a post and two panels joined to the post in a linear side-by-side orientation; [0103] Figure 30 is a cross section view of a corner section formed of an assembly of two posts and two panels; [0104] Figure 31 is a front view and partial cross section of a retaining wall constructed from an assembly of posts and panels, the posts being retained in bored footings; [0105] Figure 32 is a side cross section view of a retaining wall, footing, and draining layer and earth layer behind the retaining wall; [0106] Figure 33 is a side cross section view of tiered retaining walls, as well as the footings, and drainage and earth layers behind the walls, [0107] Figure 34 is a front view of a 300mm high panel, showing a single no-cut zone as it has a single reinforcing layer, [0108] Figure 35 is a side view of the panel of Figure 34; [0109] Figure 36 is a front view of a 600mm high panel, showing two no-cut zones as it has two reinforcing layers; [0110] Figure 37 is a side view of the panel of Figure 36, [0111] Figure 38 is a front view of a 900mm high panel, showing three no-cut zones as it has three reinforcing layers; [0112] Figure 39 is a side view of the panel of Figure 38; [0113] Figure 40 is a front view of a 1200mm high panel, showing four no-cut zones as it has four reinforcing layers; [0114] Figure 41 is a side view of the panel of Figure 40. Detailed description of the embodiment or embodiments [0115] Figure 1 depicts an acoustic fencing or barrier panel 100. It is suitable for constructing fences or barriers which have sound absorbing or attenuating qualifies, either along or around a property or along the road side. The embodiment of the acoustic panel 100 for roadside use, e.g. along a highway, further needs to withstand potential impacts from stones, rocks or the like, or any other particles which may fly off from trucks or cars at speed. The acoustic panel 100 is a composite panel made from a laminate structure.

[0116] As shown in Figures 1 and 2, the laminate structure includes a pair of outer layers 102, which provide the exterior surfaces of the panel 100. Adjacent and inboard of each outer layer 102 is a respective inner layer 106. One or both of the inner layer 106 being a perforated sheet having a plurality or array of perforations, holes, or apertures 108 throughout the inner layer 106. The pair of inner layers 106 are located on either side of a centre core 104, and is of a suitable material to provide rigidity and strength to the laminate structure 100. The centre core 104 provides mechanical properties and sound attenuating properties of the panel 100, and is thus made from a sound attenuating or absorbing material, such as expanded polystyrene or another suitable material.

[0117] Figure 2 depicts both inner layers 106 as being perforated sheets, but in some embodiments, only one of the inner layers 106 need be present or if a second inner layer is present it need not be perforated.

[0118] The outer layers 102 are fibre cement sheets of about 4 to 5 millimetres in thickness. The pair of inner layers 106 are each about 0.25 to 2 millimetres in thickness. The inner layers 106 are steel sheets, but can be made from other material that provides a sufficient strength per weight ratio of the panel 100. Possible alternative materials include, but are not restricted to, aluminium and carbon fibre. The perforations on the inner sheets 106 are produced by drilling, punching, or milling, laser cutting, electron beam cutting, water jet. If needs be, the inner sheets can be cast.

[0119] The perforations 108 of each inner sheet 106 result in a combined "open area" of about 25% to 45%, and most preferably 30%, of the total area of the perforated layer 106. In one example, the perforations are about 3 millimetres in diameter, with a 5 millimetre distance between the centres of adjacent perforations.

[0120] The thickness of the centre core 104 makes up a large portion of the overall thickness of the panel 100, and is chosen in accordance with the required mechanical and acoustic properties. The panel 100 generally has a thickness in the range of about 75 to 150 millimetres. A thicker panel 100 has a thicker core 104 to provide more bulk and or sound attenuation or absorption. The panel 100 can have a height as required or needed but generally in the range of 0.5 to 2 metres meets most needs.

[0121] A layer or layers 105 of adhesive or bonding material is applied between the centre core 104 and each outer layer 102. The adhesive or bonding layer 105 forms a bonding matrix through the apertures or holes of the intervening inner sheet 106, by the application of the laminating process which presses the layers together. In a preferred embodiment, the adhesive or bonding glue chosen will expand slightly during lamination, to ensure the adhesive, bonding material, or glue will pass through the perforations to form the bonding matrix.

[0122] Therefore, the layer or layers of bonding material 105 which is or are applied to or located on one or both faces of each perforated sheet 106 will pass through the perforations 108 and reach, or progress through to an opposite face of the perforated layer 106, on the overlying of the corresponding outer layer 102 and by it being pressed to the centre core 104, or vice versa.

[0123] The bonding matrix which results from the bonding material and layers 105 expanding through the perforations 108 of the inner sheets 106 further helps the cohesion of the layers. The perforations 108 and the resulting bonding matrix help prevent or reduce risks of delamination caused by the thermal expansion differential between the different materials of the layers in the laminate structure.

[0124] A method of constructing the panel involves providing a centre core 104 having two opposite faces. First a layer of bonding material or adhesive 105 is laid or applied, next an inner perforated layer 106 and another layer of bonding material or adhesive 105 is applied, and then an outer layer 102 applied. The layers of bonding material 105 will be pressed or otherwise flow through and occupy the perforations 108 of the inner perforated layer 106. This then cures to bond the outer layers 102, the inner layer 106, and the centre core 104 together. The bonding material 105 expands during lamination which assists entering the perforations 108. Then the process is repeated for the other side. If there is no perforated inner sheet on the other side, the outer layer 102 can be directly bonded to the core 104, or a non-perforated layer bonded to the core 104 and another outer layer applied.

[0125] Figures 3 to 4 depict another fence or barrier panel 200 for the construction of a fence or barrier. This panel 200 has a series of V-shaped grooves 214 which extend along the outer length of the panel 200. To enhance the sound transmission into the panel 200 to be absorbed by the materials in the panel, one or both of the outer layers 202, 204 of the panel 200 is perforated, but if required, the outer layers 202, 204 can have no perforations if sound absorption is not needed.

[0126] Referring to Figure 4, the panel 200 has two outer panel components, being a first outer layer 202 on a first side of the panel 200, and a second outer layer 204 on a second side of the panel 200 opposite the first side. The second outer layer 204 is spaced from the first outer layer 202, to provide a space or gap in which materials contributing to the mechanical properties including the sound attenuating or absorbing qualities of the panel 200 are located.

[0127] The first outer layer 202 can be perforated to help the transmission of soundwaves through the layer 202 to the core. The first outer layer 202 can be made from steel, e.g. from a perforated steel sheet. However other materials, such as aluminium or carbon fibre, providing suitable strength are alternative options. One of the outer layer 202, 204 in use, if sound absorption is required, will preferably have perforations and will be generally oriented toward a source of sound or noise. The perforations help reduce the reflection of the sound or noise by the outer layer. The second outer layer 204 can also be perforated, to create a panel that is suitable for locations where noise emanates from either sides of the fence or barrier or for aesthetic reasons. While the outer layers 202,204 are perforated in the preferred embodiment, in other embodiments this does not need to be the case.

[0128] To provide the panel 200 with "tuneable" acoustic qualities so as to improve sound absorption effectiveness, an optional intervening panel member, plank, or board 206 is provided between the first and second outer layers 202, 204. The intervening or interior plank 206 is made from a dense fibrous material, such as wood or any other appropriate method. As will be discussed, the space between the interior plank 206 and the first outer layer 202 will be occupied by a sound attenuating layer 210 (see figures 5 and 6). Between the interior plank 206 and the second outer layer 204 there is a core layer 208 made from expanded polystyrene. The two outer layers 202, 204 are closed at the top by an assembly or joining flange 234. A side cap 290 closes the panel 200 at each side by covering the space between the first and second outer layers 202, 204. As shown in Figure 4, the side cap 290 also has a series of grooves 292 to match the grooves 214 on the outer layers 202, 204.

[0129] Figures 5 and 6 are cross sections taken through a panel of the type shown in Figure 4 except that figures 5 and 6 are a mirror image construction of the panel of Figure 4. The interior plank 206 is shown in Figures 5 and 6 to be located closer to the second outer layer 204 than the first outer layer 202, however it can instead be located midway between the outer layers 202, 204 as in Fig 4, or closer to the first outer layer 202 as may be required according to the sound attenuation desired. Generally speaking, if one of the outer layers 202, 204 has perforations and the other one 204, 202 does not, the interior plank 206 will be located closer to the outer layer without the perforations.

[0130] As can be seen in Figures 5 and 6, a sound absorbing layer 210 is located between the second outer layer 202 and the intervening panel member 206. The sound absorbing layer or "wadding" layer 210 is made from, for example, rock wool, glass wool, or a fibrous or shredded polyethylene terephthalate (PET) material. On the other side of the intervening panel member 206, there is a core layer 208, which is preferably expanded polystyrene (EPS). In embodiments where the intervening panel member 206 is not provided, the sound absorbing layer 210 is located next to the core layer 208.

[0131] The acoustic qualities of the panel 200 are determined by a range of factors. These include the thickness and characteristics of the wadding layer 210 and of the core layer 208; the characteristics of the interior plank 206 if one is provided; the thickness and characteristics of the outer layers 202, 204, and the thickness of the intervening or tuning panel 206. Other factors being the same, the acoustic qualities of the panel 200 are in particular tuneable, by varying the thickness of the wadding layer 210, or in other words the position of the intervening panel 206 in relation to the second outer layer 204. An increased distance between the intervening panel 206 and the second outer layer 204 (adjacent the sound source) will mean an increased thickness of the wadding layer 210 there between. This allows more sound attenuation or absorption to be achieved. Therefore, panels with the same thickness can be tuned to have different sound absorption properties, i.e. allow different sound transmission.

[0132] The sound waves which pass through the perforated second outer layer 204 will be attenuated or absorbed by the sound absorbing layer 210. The sound waves will be further reduced by the intervening plank or tuning panel 206.

[0133] The difference between the panels shown in Figures 5 and 6 is that the panel 200 shown in Figure 5 has a smaller thickness compared to the panel 200 shown in Figure 6. The panels are constructed slightly differently to achieve the different thicknesses. The panel construction will be discussed below.

[0134] In Figures 5 and 6, each outer layer 202 and mirror image layer 204 have profiled longitudinal upper and lower edges 218, 216, and a main body 211 which extends between the profiled edges 216, 218. The edges 216, 218 are profiled to enable the outer layers 202, 204 of like panels to be assembled together directly or indirectly, by clinching, welding, screwing, or by another means, to form a section or a partial section of a barrier or fence.

[0135] In Figure 5, the outer layers 202, 204 are not directly joined to each other. Whereas lower and upper joining channels 232, 234 are needed to join the outer layers 202, 204. Whereas in Figure 6, the outer layers 202, 204 are spaced apart by a smaller distance to create a thinner panel with a less wide channel 234, and no channel 232. The lower horizontal edges 216 of the outer panels 202, 204 of Fig 6 meet and are secured against each other, eliminating the lower joining flange 232. The upper joining flange 234 is still needed to join the upper longitudinal edges 218, but a smaller joining flange 232 is required for the panel of Figure 6 compared to that required for the panel of Figure 5. The widths of the joining channels 232, 234 will be selected according to the final width desired of the panel 200.

[0136] The assembly of like panels 200 will increase the width or height of the assembled section thus formed, depending on whether the panels 200 are oriented horizontally or vertically.

[0137] As can be seen in Figures 4 to 7, the outer layers 202, 204 have profiled faces and edges in the form of V-shaped grooves that are mirror images of one another, but the main body 211 between the profiled edges need not have V-shaped grooves. The edges of the outer layers 202, 204 have clinchings 212 (see Figure 7) which secure the outer layers 202, 204 to the side cap 290 (shown in Figure 4).

[0138] A panel 200 is formed with two opposing panel outer layers 202, 204 and any attachment feature which enables the assembly of the two opposing outer layers 202, 204, and any filling or acoustic components provided between the two opposing outer layers 202, 204. Features of the profiled edges discussed in relation to an outer layer 202, 204 will mirror in their profiled edges of the opposite outer layer 204, 202. The same reference numerals will thus be used to refer to the same mirrored features of the profiled edges on the outer layers 202, 204.

[0139] In the following discussion, for simplicity the panel member will be assumed to be horizontally oriented in use. That is, the panel member's longitudinal axis will be horizontally oriented. The first longitudinal side will be the top side of the panel member, and the second longitudinal side will be the bottom side of the panel member. However, the skilled addressee will appreciate that the panel member can be oriented in any direction in use, to be assembled so that they lie horizontally, vertically, or obliquely.

[0140] As best shown in Figures 7 and 8, in the depicted embodiment the outer layers 202, 204 have a lengthwise profiled or corrugated pattern, there being a generally V-shaped pattern 214 in its profile at regular intervals. Each panel outer layers 202, 204 has a profiled first longitudinal edge 216 and a profiled second longitudinal edge 218, running along the longitudinal length of the panel outer layers 202, 204. In the embodiment shown the first profiled edge 216 is the lower edge and the second profiled edge 218 is the upper edge. The outer layers 202, 204 of the neighbour panels will be assembled so that the lower edges 216 of the outer layers 202, 204 of one panel will be joined to the upper edges 218 of the outer layers 202, 204 of the next panel.

[0141] It is preferred that the first and second edges 216, 218 are profiled to include a bevel 220, 222 (shown in Figures 5 and 6). When the upper edge 218 and the lower edge 216 from neighbouring panels 200 are joined together, the bevels 222, 220 will be placed adjacent each other and complement or replicate the V grooves 214 of the body portion 211 of the outer layers 202, 204. This is done by providing bevelled portions 220, 222 in the profiled edges 216, 218 with gradients that match those of the V grooves 214.

[0142] In embodiments where the panel outer layers 202, 204 do not in itself include a pattern (e.g. see Figures 9 and 10), the profiles of the lower and upper edges 216, 218 will enable an overall pattern to be formed by the joining of the edges of adjacent outer layers. Like panels will be assembled so that their respective first and second longitudinal sides will be joined together.

[0143] The discussion below in relation to one of the outer layers will also apply to the opposite outer layer, which has the same or a mirror image profiled edge.

[0144] As shown in Figures 5 to 11 but as can be best seen in Figures 9 to 11, the first profiled edge 216 of the outer or external layer 202, 204 includes a bevelled attachment end 220 which is directly adjacent the main body 211 of the external layer 202, 204. As discussed above, the attachment part 216 is bevelled to the body portion 211, for example at an angle that forms or matches an intended V-shaped groove.

[0145] The bevelled attachment end 220 extends away from the body portion 211, and toward an interior direction. Therefore in use the attachment end 222 will extend toward a matching end 220 on the opposite panel outer layer 204, 202. The attachment end 220 is connected to a channel made up of a first sidewall 224 which is connected to the bevelled attachment end 220, a channel base 226, and then a second sidewall 228 which is a free end or flange of the profiled edge 216. The channel's base 226 is generally perpendicular to the main body 211, and the channel's sidewalls 224, 228 are generally parallel to the main body 211.

[0146] In the embodiments of Figures 4 to 11, the profile of the second edge 218 is different from that of the first edge 216, but will generally or at least partially complement or matingly engage the profile of the first edge 216. The second edge 218 also has a bevelled attachment end 222, to match with the bevelled attachment end 220 in the first edge 216. The bevelled part 222 of the second edge 218 is angled away from the main body 211 portion and inwards so that in use, it obliquely extends toward its mirrored attachment end 222 on the opposite outer layer. The bevelled part 222 of the second edge 218 extends into an end projection or flange 230 which has an overhang 231. The end projection 230 is the depicted embodiment is generally parallel to the main body 211 of the outer layers 202, 204, except for its overhang 231 which is at an angle of approximately 90 degrees to the main body 211.

[0147] The spacing between the two outer layers 202, 204 is determined by the desired thickness of the panel 200. In Figure 9, the two outer layers 202, 204 are spaced apart far enough that the first edges 216 of the respective outer layers 202, 204 do not meet. To close the panel, a generally U or C shaped assembly, attachment, or joining flange or channel 232 will be placed between the free ends 228 of the profiled edges 216 of the opposite outer layers 202, 204. The free legs or flanges 232.1, 232.2 of the joining channel 232 will preferably be placed flush against the respective free ends or flanges 228 of the profiled edges 216 of the opposite outer layers 202, 204. The free legs 232.1, 232.2 of the joining channel are secured to the respective free ends 228 by welding, clinching, screws, pop rivets or bolts as indicated by lines 240. The most preferred method of securement is by clinching.

[0148] A second attachment or assembly flange or channel 234 of a generally U or C shape is provided between the end flanges 230 of the opposing second edges 218. The free legs 234.1, 234.2 of the second attachment flange 234 will preferably be provided flush against, and secured to the respective end sections 230. The free legs 234.1, 234.2 of the second attachment flange 234 are secured to the respective end projections 230 on the opposite profiled edges 218 by welding, clinching, screws, pop rivets or bolts as indicated by lines 260.

[0149] In the embodiment shown in Figure 10, the outer layers 202, 204 are placed closer together to form a thinner panel 200. The mirrored first profiled edges 216 are located directly adjacent each other. Their respective free ends 228 can be directly secured together by welding, clinching, screwing, or bolting as indicated by line 270, without any joining flange. The mirrored second profiled edges 218 are joined by a joining flange 234 similar to those of the panel 200 shown in Figure 9.

[0150] By making the outer layers 202 and 204 with their respective joining flanges 228 and 230 mirror images of each other, only a single inventory for layers 202 and 204 need be had to make panels of any desired thickness by simply adding appropriately sized channels 232 and correspondingly sized channels 234.

[0151] The end projection 230 of the second profiled edge 218 extends further outboard or away from the main body 211 than the channel 224, 226, 228 of the first profiled edge 216. Specifically, the end projection 230 of the second profiled edge 218 will extend further from the main body 211 than the first sidewall 224 of the channel. Figure 11 shows that when two panels 200, 200' are assembled, the edges 216', 218 from neighbouring panels are adapted to be fitted together, that is, one within the other, and assembled. The effect of this configuration is that the second profiled edges 218 of one panel 200 will be inserted into the space between the first profiled edges 216' in the adjacent panel 200'. Therefore, the first profiled edge 216 is also considered a receiving edge, and the second edge 218 is also considered an insertion edge. The receiving edges 216' on the opposing outer layers of a panel 200' therefore also form (together with the attachment flange 232 if one is used) a receiving end of the panel 200'. Similarly, the insertion edges 218 on the opposing outer layers of the panel 200 form (together with the attachment flange 234) an insertion end of the panel 200. The insertion end of panel 200 is fitted into the receiving end of panel 200'. The two panels 200, 200' are assembled with either a clearance fit or a friction fit.

[0152] Therefore, as can be seen from Figures 3 to 11 above, two adjacent panels, each being formed by a pair of opposing panel components, are adapted to be assembled in an end-to-end fashion. The insertion edge of the one panel is adapted to be received by the receiving edge of the adjacent panel. Thus the insertion edge preferably at least partially conforms to the profile of the receiving edge, and vice versa. Within each panel, one or more joining locations whereby the opposite panel components are secured together or secured to an attachment flange, will be located inboard of the exterior of the panel.

[0153] In the embodiments shown in Figures 3 toll, the first and second edges 216, 218 are different to each other. However, in alternative embodiments, the first and second profiled edges 216, 218 can be the same as will be described below with reference to figures 12 to 14.

[0154] Figure 12 depicts an alternative panel construction and embodiment of the attachment between adjacent like panel components 300, 300'. Both longitudinal edges 316, 318 (316', 318') of the panels 300 (300') are the same as the "receiving edge" 216 shown in Figures 3 to 11. To assemble two panels 300, 300' together, assembly bars or blocks 390 are be placed into the spaces created between and defined by the adjacent edges 316, 318'. Specifically each space is generally defined by the channel portions 224, 226, 228 in the profiled edges. The bars or blocks 390 can be RHS or SHS or may be extruded joining pieces.

[0155] Figure 13 depicts a similar embodiment as that shown in Figure 12, except that channels 432, 432' are also included between the outer layers 402, 404 for each panel 400, 400'. An assembly block 490 is provided in the space bound by the two assembly flanges 432, 432'. Other assembly blocks 491 (drawn in dashed lines) placed in the spaces defined between the adjacent edges 416, 418' can replace the assembly block 490 provided between the assembly flanges 432, 432'. Alternatively they can be provided in addition to the assembly block 490 between the assembly flanges 432, 432'.

[0156] Figure 14 depicts another alternative embodiment, where both longitudinal edges 516, 518 (516', 518') of the adjacent panels 500, 500' are the same as the insertion edges 218 shown in Figures 3 to 11. As the two panels 500, 500' are placed against each other, a space 505 will be formed between the attachment flanges 324, 324' for the respective panels 500, 500'. An assembly bar or block 590 is placed inside this space 505 to help prevent the assembled panels 500, 500' from moving from side to side.

[0157] In the above embodiments depicted in Figures 12 to 14, the assembly bar or blocks 390, 490, 590 can extend through substantially the full length of the panel, or substantially the full length of a section or all of the barrier. Alternatively, the assembly bar or blocks 390, 490, 590 can be provided at discrete locations, e.g. at regular intervals along the length of the panels.

[0158] Figures 15 to 20 depict a post system or post assembly, to accept panels in a fencing or barrier system. The post system generally includes post components which are profiled extrusions, whereby two extrusions can be interlocked together, to create spaces which are adapted to accept the panels. Generally there are two types of post extrusion components, including a linear extrusion and a corner extrusion. Two linear components are placed in opposition to each other and interlocked, to create spaces for adjacent panels which are arranged in a linear or straight line. A linear component and a corner component are interlocked together to create spaces for adjacent panels that are arranged in a corner.

[0159] Figure 15 shows two linear extrusions 1500 to be interlocked together to form one post between two adjacent panels (not shown) arranged in a straight line. Each linear extrusion 1500 is generally shaped similar to one half of an "H". The extrusion 1500 includes an exterior face 1505 and an interior face 1510 which will respectively face the sides of the barrier or fence. The linear component 1500 is generally symmetrical about a midline 1515 which extends between the exterior face 1505 and the interior face 1510, and located about half way between the two side edges 1520, 1525. The exterior face 1505 is depicted as having a straight profile between its two side edges 1520, 1525, but an alternative profile can be provided. The interior face 1510 preferably has a sloping profile, so that the linear component 1500 is narrowest at or closer to the midline 1515, and widest toward the edges 1520, 1525.

[0160] A first and a second assembly projection 1530 and 1535, respectively being a female assembly projection 1530 and a male assembly projection 1535, extend from the interior face 1510. The assembly projections 1530, 1535 are provided generally at a right angle in relation to the exterior face 1505. The assembly projections 1530, 1535 are one provided on either side of the midline 1515, being equidistant from the midline 1515. Therefore, when two linear components 1500, 1500' are arranged to face each other, the female projection 1530 of one linear component 1500 will align with the male projection 1535' of the opposite linear component 1500', and vice versa.

[0161] The female assembly projection 1530 has an end receiving formation 1532, which is or includes a keyway of preferably an arcuate shape. Optionally, an attachment extension 1533 extends from the female projection 1530 so that in use the extension 1533 will overlap with the male projection 1535' of the opposite linear post 1500'; to provide an assembly location, where one or more screws, rivets, clinches or bolts as indicated by the dashed lines 1560 can be used to permanently secure the linear extrusions 1500 together.

[0162] The male assembly projection 1535 has a second end insertion formation 1537. The first end receiving formation 1532 is shaped and sized to receive and retain an end insertion formation 1537. Therefore, when the two linear components 1500, 1500' are assembled, the end receiving formation 1532 of one linear component 1500 will retain the insertion formation 1537' of the opposite linear component 1500', and the insertion formation 1537 of the first linear component 1500 will be retained by the receiving formation 1532' of the opposite linear component 1500'. It will be understood that the positions of the female and male projections 1530, 1535 can be swapped, where the first projection is male and the second projection is female.

[0163] The assembly projections 1530, 1535 can further optionally have side formations 1534, 1539 which extend a short distance toward the nearest side edge 1525, 1520 of the linear component 1500. These optional formations 1534, 1539 help define assembly positions between adjacent extrusions 1500, 1500'. For instance, the attachment extension 1533 of extrusion 1500 will reach the formation 1539' provided on the male projection 1535' of its cooperating extrusion 1500'.

[0164] The interior face 1510 of the linear component 1500 further has hooks 1540, one located near each side edge 1520, 1525. The ends of the hooks 1540 are oriented toward the middle of the component 1500. As will be described later, these hooks 1540 enable the assembly between a linear component 1500 and a corner component 1600 (see Figure 16).

[0165] When two linear extrusions 1500 placed in opposing orientations are slidingly assembled, they generally form an H-shaped post. Opposed spaces 1550, are created between the two linear components 1500. Because of the sloping profiles of the interior faces 1510 of the linear components 1500, the spaces 1550 will be bound by sloping sidewalls, such that the space is narrowest at the opening into which the panels are to be inserted, and widens toward the interior of the post. The panels will preferably have a slight taper in their side edges, so that they can be forced into the sloping spaces 1550, but prevented from easily reversing out of the spaces 1550 by the narrower openings.

[0166] Interior hooks 1551 are provided around the interior corners of the linear extrusion 1500, for example, at the inside corners between the exterior panel 1505 and the side edges 1520, 1525. These allow an end cap (not shown) with aligned cooperating assembly stubs to be assembled on the assembled post or on each linear extrusion, to help close off and protect the extrusion 1500 against e.g. moisture or dirt. Potentially linear extrusions can also stacked on top of each other, and assembled by poles or rods received by the hooks 1551.

[0167] When assembling the post, a reinforcing square hollow section or RHS 1593 can be located internally. The RHS 1593 can be a fence post concreted or otherwise set into the ground and the post of extrusions 1500 and 1500' slid over the RHS 1593. The projection 1534 and 1539 keep the post assembly 1500 and 1500' centrally located relative to the RHS 1593 [0168] Figure 16 depicts a corner component 1600 which can be interlocked with a linear component 500 described above, to provide insertion spaces for corner panels in a fencing or barrier system. Figure 17 depicts the corner component 1600 in an interlocking or engaging relationship with the linear component 1500.

[0169] The corner extrusion 1600 has two end arms 1605, 1610 which are substantially parallel to each other. Both end arms 1605, 1610 are generally or substantially perpendicular to a middle extent 1607 of the extrusion 1600. The 1st portion 1601 of the extrusion 1600 is formed by the first arm 1605, the middle extent 1607, and the parts there between. The first portion 1601 has generally a very similar geometry as one half of the linear component 1500, because the first portion 1601 in use will form a first panel receiving space with a linear component 1500. To enable interlocking between the first portion 1601 and the cooperating linear component 1500, the first arm 1605 will have first end formation 1608 which complements the first end formation on the cooperating linear component.

[0170] A second portion, being a panel receiving channel 1616 is provided adjacent the first portion 1601. Specifically adjacent the middle extent 1607 which is part of the first portion1601, receive another corner panel (not shown). Preferably, the channel 1616 has sloping sidewalls 1625, 1630, so that it is narrowest at its mouth 1616 and widest at its base 1619, the base 1619 being parallel to the middle extent 1607 of the first portion 1601. The gradient of the sloping sidewalls will be the same as those bounding the receiving spaces 1550 bound between opposing interlocked linear components 1500. To enable the second portion 1615 to interlock with or attached to the cooperating linear component 1500, the channel base 1619 has a second end formation 1621 which is located on the side of the base 1619 external to the channel 1615, which will complement the second end formation 1537 on the linear component. Therefore, the distance between the first and second end formations 1608, 1621 is the same as that between the male and female end formations 1532, 1537 in the linear component 1500. Further both end formations 1608, 1621 of the corner component 1600 will be spaced from the middle extent 1607 by the same distance.

[0171] As depicted in figs 16 and 17, the first and second end formations 1608, 1621 are respectively a male end formation and a female end formation to complement the female and male end formations on the linear component 1500 shown in Figure 15. It will be understood that the reverse embodiment, where the first and second end formations 1608, 1621 are respectively female and male, will be used, if the cooperating linear component 1500 also has the locations of its female and male end formations swapped.

[0172] The first end formation 1608 of the first arm 1605 is a male formation to cooperate with a female end formation 1532 on the cooperating linear component. However, the first end formation 1608 will be a female formation, if the formation on the cooperating linear component 1600 is male.

[0173] The corner component 1600 has a third portion 1603 located adjacent the channel 1616, comprising a corner edge extent 1604 and the second projection 1610. The corner edge extent 1604 is collinear or aligned with the middle extent 1607 and generally perpendicular to the second projection 1610. So that the third portion 1603 can interlock or engage with the cooperating linear component 1500, the second projection 1610 includes a hooked projection which ends in a hook 1612, adapted to receive a hook 1440 of the linear component 1500.

[0174] Other hooks 1620 similar to those provided on the interior face 1510 of the linear component 1500 are provided at various locations in the corner extrusion 1600. For instance they are located near the mouth of the channel 1615, and also in the first portion 1601 at a location which will align with a hook 1540 of the same configuration in the linear component 1500. Hooks 1540 on extrusion 1500, and 1620 on extrusion 1600 also provide a single line of contact between the walls of the fence or barrier panels inserted in spaces 1550 and 1715/1716 making it easier to insert fence or barrier panels, by comparison to having multiple lines or areas of contact.

[0175] Interior hooks 1651 are provided around the interior corners of the corner extrusion 1600. These allow the extrusions 1500, 1600 to be closed by end caps having cooperating studs or projections. Potentially adjacent extrusions can be stacked on top of each other, and assembled by poles or rods received by the hooks 1651.

[0176] As seen from Figure 17, when assembled, the first and second end formations of the linear component 1500 respectively interlock or engage with the first and second end formations of the corner component 1600. The hook 1612 on the second projection 1610 will engage an aligned hook 1540 on the cooperating linear component 1500. In this way 3 locations of engagement between extrusions 1500 and 1600 are present. A panel receiving space 1716 is bound between the linear component 1500 and the first portion 1601 of the corner extrusion 1600, and the channel 1715 in the corner extrusion 1600 provides the second panel receiving space. It can be seen that the first and second panel receiving spaces 1716, 1715 are at a 90 degree angle to each other, to correspond with the angle between the corner panels.

[0177] The above extrusions or post components are preferably made from 1.5mm thick aluminium. The thickness can be according to design or utilization requirements. The following dimensions are also provided as examples only. The linear component 1500 is approx. 250mm wide. It is about 78.2mm in width as measured from the external face 1505 to the tips of the assembly projections 1530, 1535, and 39.6mm in width across its side edges 1520, 1525. The distance between each assembly projection 1530 (1535) and the nearest side edge 1525 (1520) is about 67.5mm. In use, each pair of opposing linear components 1500 are spaced part so that the aligned hooks 1540 provided on the interior faces 1510 of the pair of components 1500 are spaced apart by about 76.2mm.

[0178] Figure 18 shows in three-dimension, a linear H-post constructed from two linear extrusions 1500 discussed above. Figure 19 shows in three-dimension, the corner extrusion 1600 discussed above. Figure 20 shows in three dimensions a corner post, constructed from one half-H extrusion and a corner extrusion as discussed above.

[0179] Figures 21 and 12 depict a retaining wall panel 2100 having an upper edge 2102, a lower edge 2104, and sides 2106, 2108. The panel 2100 includes two outer skins 2110 of an environment resistant, corrosion resistant, or hardy material. The thickness of the retaining wall panel 2100 is set by the spacing between the two outer skins 2110. Between the two outer skins 2110 there are sandwiched, in a generally horizontal arrangement, layers of core material 2114 and layers of reinforcing material 2116 which alternate in the direction of the upper or lower edge to the lower or upper edge of the panel. The reinforcing material layer 2116 extends along the whole width of the panel 2100, as measured between the sides 2106, 2108.

[0180] The sides 2106 and 2108 are preferably sealed off by a side or end cap (not illustrated) which can be of a metal such as steel or stainless steel or can be made of fibre cement. The side or end caps, which are impermeable to water, and are joined to the panel components and sealed with respect thereto by a construction adhesive (polyurethane adhesive), will seal the ends 2106 and 2108 to prevent ingress of water and or gases to thereby maintain the integrity of the inner layers and their bonding material matrix.

[0181] The thicknesses or heights of the layers of the reinforcing material 2116 and layers of the core material 2114 can be varied. For instance Figures 23 and 24 show a retaining wall panel with no cut zones 2150 which are representative of higher layers of reinforcing material 2116. In the case of figures 21 and 22 the layers 2116 are comprised of 65mmx65mmx3mm Square hollow sections making up panels of approx. 80mm in overall nominal thickness, while in figures 23 and 24, the layers 2116 are comprised of 100mmx100mmx2mm square hollow sections making up a panel of approx. 125mm in nominal thickness.

[0182] It is an optional feature that the panels 2100 are marked with an external indication 2150 as to where the reinforcing material layers 2116 are located. It is generally undesirable to horizontally cut through the panels, as this will weaken the reinforcing provided. Whereas, with appropriate cutting tools, lateral cuts from the top to the bottom of the panel can be made to reduce the panel's length. Therefore, the external indicia 2150 will indicate the zones of the panel which should not be horizontally cut, corresponding to where the reinforcing material is positioned.

[0183] As shown in Figure 25, each of the skins 2110, the core material 2114 and the reinforcing material 2116 are each bonded together to adjacent components by a bonding material or adhesive 2120, which can be a polyurethane laminating adhesive or similar.

[0184] An example of the material that can be used to make the outer skins 2110 is fibre cement sheeting having a thickness of 6mm. The core material 2114 can be polystyrene foam, expanded polystyrene (EPS); or another appropriate polymeric material, and be of a matching thickness to the size of the SHS that will be used, such as 65mmx65mmx3mm thick or 100mmx100mmx2mm thick.

[0185] The strength of the retaining wall is provided by the reinforcing material 2116, which is preferably made from steel or galvanized steel, but any appropriate reinforcing material can be used which meets the strength requirements, e.g. carbon fibre tubes or such like. Preferably the reinforcing material 2116 is a rectangular or square steel hollow section to keep the strength to weight ratio as high as possible if for example steel is utilised. The hollow section provides strength and at the same time is a relatively light weight material compared to e.g. a solid steel bar of the same cross sectional dimension. The steel hollow section can have a wall thickness of between 2 to 5 millimetres (mm). In the case of a square hollow section, the outer cross sectional dimensions are in the range of 50 x 50 mm to 100 x 100 MM.

[0186] As best shown in Figures 26 to 28, the uppermost and lowermost edges of an assembly of panels 2100 are preferably sealed off by a top cap 2134 and a lower cap 2136. The caps 2134 and 2136 are preferably sealed by a polyurethane adhesive to the upper edge of the uppermost panel and to the lower edge of the lowermost panel. This prevents water from entering the innards of the uppermost panel and the lower most panel. The caps 2134 and 2136 form a gap 2130 which is left between the cap 2134 and the upper extremity of core 2114, while a gap 2132 is left between the cap 2136 and the lower extremity of its core 2114. Preferably the lower cap 2136 is made from stainless steel to give it greater environmental resistance, in view of being on, in or very near a ground location when in an assembled wall.

[0187] As best seen in Figure 21 and 22 the panel 2100 has the reinforcing layers 2116 are spaced from the upper and lower edges 2102, 2104 of the panel 2100, by a distance of between 80mm to 200mm. In the specific embodiment shown in Figures 21 and 22, a respective reinforcing material layer 2116 is located between 80 mm and 200mm from the respective upper 2102 and or lower edges 2104 of the panel 2100.

[0188] The upper and lower edges 2102 and 2104 of panels which are to be assembled to an adjacent panel above or below, has an edge treatment as best illustrated in figure 26. A sealing channel 2137 has two vertical sides and a horizontal base. The sealing channels 2137 are sealed to the inner free sides of the skins 2110, and to the otherwise free edge or exposed edge of the core 2114. The sealing channels 2137 on opposed panels 2100, will thus form a rectangular or square space by adjacent spaces 2130 and 2132 between the extremities of the core sections 2114. The rectangular or square space can then receive a joining profile 2138, which is a generally square or rectangular section of about 1 mm (of the order 0.9mm to 1.2mm) base metal thickness RHS, SHS or rolled channel profile, to serve to prevent the upper edge of one, and an adjacent lowest edge of another panel, from laterally moving with respect to each other once assembled.

[0189] Figure 26 shows two like panels 2100, 2100' which are placed in top-to-bottom arrangement as depicted so that the lower edge 2104 of the top panel 2100 is located directed atop the upper edge 2102' of the lower panel 2100'. The gap 2130' between the top most layer and the upper edge 2102' of the bottom panel 2100', and also the gap 2133 between the bottom most layer and the lower edge 2104 of the top panel 2100, combine to form a space between the upper and lower panels 2100, 2100'. This space allows the top and bottom panels 2100, 2100' to be joined by a profiled joining channel 2138 being inserted into this space, and the panels 2100, 2100' are assembled via the joining channel 2138. If desired an adhesive, such as a polyurethane construction sealant, could be used to bond the joining channel or profile 2138 to the inner surfaces of the skins 2110, 2100'.

[0190] In one example, the end caps 2134, 2136, and the joining profile or channel 2138 are made from galvanized steel hollow sections having a base metal thickness of about 1mm (of the order of 0.9mm to 1.2mm).

[0191] The upper edge 2102 is capped by a profiled cap 2134 (see Figure 27). Similarly the lower edge 2104 is capped by another profiled cap 2136 (see Figure 28). The upper cap 2134 has an end cap portion across the thickness of the panel 2100 and side portions of about 25 mm in height depending downwardly from the end cap portion, the side portions lying on the outside of the panel skins 2110. The lower cap 2136 has a similar configuration to the top cap 2132. The end caps 2134, 2136 can further provide colour coding to distinguish between panels of different interior configurations. If required, adjacent like constructed panels to be joined in a retaining wall assembly can also be joined by bonding their respective profiled caps 2134 and 2136 together. The caps 2134, 2136 are secured and sealed in place with respect to the outer skin 2110 by means of a polyurethane construction sealant, such as SikaFex Pro or equivalent.

[0192] Referring to Figures 29 to 30, the retaining wall further includes posts which will be inserted into the ground, and also have receiving spaces, channels, or receptacles, to receive neighboring panels 2100, 2100 to be placed in a side-by-side fashion to construct the retaining wall. Between two neighbouring panels 2100 there can be two Charlie or C-shaped post placed side by side to each receive one panel as in Figure 30 to form an angled corner, or an I-shaped post as in figure 29 that has the spaces to receive both panels to form an in line arrangement of panels. A C-shaped post can be used as an end post located at the ends or edges of the retaining wall.

[0193] As shown in Figures 29 to 31, an 1-shaped post 2200 includes a centre web or divider 2202 and two side faces or flanges 2204, 2206 extending perpendicularly to the web or divider 2202, one located on each end of the web or divider 2202, each end of the web or divider marking the mid-point of its respective bearing face. One panel 2100 is located on each side of the divider 2202, and bearing against one of the side faces 2206. The width, as measured in the direction from one side of the panel to the other side of the panel, by which each panel bears against the post 2200 is preferably at least 20 mm.

[0194] In the depicted embodiment, the length of the web or divider 2202 is greater than the thickness of the panel 2100, as measured between the two outer skins 2110 of the panels 2100. In this case, a filler block, insert, or reinforced rib 2210, made from a non-deteriorating material, can be placed between the panel 2100 and the side face 2204 of the post 2200 which does not bear against the panel 2100. This is done before backfilling the earth or ground up to the retaining wall.

[0195] In embodiments such as figure 30, where C-shaped posts are used, each C-shaped post will present a receiving channel to receive one panel 2100. Similarly, where the channel is wider than the thickness of the panel 2100, a filler block or insert 2210 is used adjacent the panel 2100 to fill the channel. As shown in Figure 30, two C-shaped posts 2300 can further be placed at an angle to each other to create a corner in the retaining wall. A joining or finishing cap or cover 2310 connects between the two C-shaped posts 2300 to finish the corner.

[0196] Figure 31 depicts a retaining wall constructed from an assembly of posts and panels as discussed above. As shown, to construct the full height of the retaining wall, a number of panels are assembled in a top-to bottom fashion. However not all of the panels across the full height of the retaining wall 2010 need to be identical. For the example in the illustration of figure 31, the lowermost panel 2100" can be made with 100mmx100mmx2mm SHS reinforcing layers 2116, so as to bear a surcharge loading of the order of 10 KPa, due to the depth of back filled soil and earth. Whereas the next level up, the panels 2100' can have their reinforcing sized to bear the range of surcharge loading that may be present due to a lesser depth of retained soil. While the upper layer of panels 2100, may only need to bear a loading of up to 2.5 KPa, such as may result from lesser strength of reinforcing layers such as 65mmx65mmx3mm SHS.

[0197] Also as shown in Figure 31, each post 2200 (or 2300) includes a footing portion 2250 which will be inserted or buried either directly into the ground, or has formed around it a concrete pier or footing 2400 that is formed in the ground to the required depth. To ensure proper leveling of the retaining wall, the bored footing or pier 2400 will need to have a topmost or ground surface that is level, or to accept a bracket that will set the panel to be at a level orientation relative to the ground. Adjacent posts 2200 will have centres spaced apart by about 2400mm maximum. The depths and diameters of the footings will depend on the height of the retaining wall, the material to be retained, and the retaining height required. Generally the footing diameters are in the range of about 400 to 700 mm. The footing depths are generally in the range between 1000 to 2500mm for ground matter comprising mainly cohesive soil such as stiff clay or exerting a bearing pressure up to 150 Kilo Pascal's (KPa), between 1000 to 3000mm for ground matter comprising mainly clay or exerting a bearing pressure of up to 100KPa, and between 1000mm to 4500mm for retained earth exerting a bearing pressure to 75 KPa such as sand.

[0198] Figure 32 depicts the backfilling of ground and drainage systems behind a retaining wall 2010. In the part of the panel wall (i.e. posts and skins of the panels) in the area where the wall will come in contact with the soil, all junctions between the adjacent panels or adjacent panels and posts, will be coated and sealed with beads of a construction sealant. A sealing coating will further be applied to the areas of the panels and posts that will come into contact with the soil. Preferably a minimum of two coats will be applied, in orthogonal direction to each other. For instance, one coat will be applied with horizontal strokes, and the next will be applied in vertical strokes. The portion of the retaining wall up to about 100mm above the finished ground level is also preferably coated.

[0199] As shown in Figure 32, behind the retaining wall 2010, there is a layer of free draining material 2020 in the form of granules, below the retained earth. The free draining particles are generally aggregates of 20mm or more in diameter. The free draining material layer 2020 is contained by a bounding material or fabric 2022 such as a geotextile fabric which allows drainage and resists environmental degradation. The drainage layer should be of a width of no less than 300mm, as measured from the retaining wall 2010. A drainage pipe 2024, such as slotted or aperture drainage pipe, is provided in the drainage layer 2020, near the bottom of the retaining wall 2010. In one embodiment, the drainage pipe 2024 will be constructed from a flexible polythene pipe of about 100mm in diameter. Class 400 flexible polythene or equivalent material is preferred. The drainage pipe 2024 is preferably directed to an outlet or to the storm water at maximum 20 metre intervals.

[0200] The retained earth layer 2030 is filled above the drainage layer 2020, and also behind the drainage layer 2020, up to the finished ground level 2032. To aid the ground level water flow or drainage, a drain groove such as a spoon drain 2034 is made into the finished ground level.

[0201] Figure 33 shows an installed tiered or terraced retaining wall system, where concrete footings 2400 are installed at different or tiered levels, where a lower footing 2400' is installed below the full height of the adjacent higher footing 2400. Posts 2200 (or 2300) will be inserted into the footings 2400, 2400', and panels installed between the posts, as per normal installation.

[0202] The panels discussed above generally have a length of the order of lm to 2.5m, a height of the order of 300 to 1200mm, and a panel thickness of the order of 80 mm to 120mm. Depending on the layering configuration between the outer skins 2110, the panel 2100 can have different densities to suit different load requirements. A panel with a higher panel density will be more suitable in a location where a higher surface or vertical surcharge load (i.e. higher retaining height) exists. Panels constructed in accordance with the above can have densities of for example, about 35 Kilogram per metre squared (Kg/m2) or about 50 Kg/m2. A retaining wall can be constructed from panels having different interior layering configurations, and hence different densities.

[0203] Table 1 provides an example of the footings, panels and posts that may be used for the different retaining requirements.

2.5 KPa Vertical Surcharge Load Max retaini ng height (mm) Panel densit Mid post End post Min. footing diamete r (mm) Min. footing depth for stiff clay 150KPa Min. footing depth for clay 100KPa Min. footing depth for sand 75KPa

Y

(Kg/m2 ) 1000 37.6 180UB16 150PFC18 450 1100 1200 1300 2600 37.6 for the top 2m and 49 for the bottom 250UB31 200PFC23 600 2000 2200 3200 3200 37.6 for the top 2m and 49 for the bottom 310UB46 250PFC36 600 2300 2600 3900 5.0 KPa Vertical Surcharge Load 1000 37.6 18OUB16 150PFC18 450 1100 1200 1400 2600 37.6 for the top 2m and 49 for the bottom 250UB31 230PFC25 600 2000 2300 3400 3200 37.6 for the top 2m and 49 for the bottom 310U1346 250PFC36 600 2400 2700 4100 10.0 KPa Vertical Surcharge Load 1000 37.6 18OUB16 150PFC18 450 1200 1300 1700 2600 37.6 for the top 2m and 49 for the bottom 250UB37 230PFC25 600 2200 2500 3700 3200 37.6 for the top 2m and 49 for the bottom 360UB51 300PFC40 600 2500 3000 4400 [0204] Illustrated in Figures 34 to 41 are examples showing panels similar to panels 2100, which have in the case of figures 34 &35 having a single reinforcing layer of 65x65x3 or 100x1 00x2 SHS to give a height of 300mm and two core layers 2114. If made as illustrated in Figures 34 and 35, the panel thickness will be 113mm, and the reinforcing layer is located in the centre of the No-Cut-Zone and the SHS used is a 100x100x2 which is protected by a distance of 30mm on each side as the No-Cut-Zone is 160mm in height, and starts some 70mm from the upper and lower edges. The core layers 2114 are positioned above and below the reinforcing layers. The length of the panel illustrated being 2400mm.

[0205] In the case of figures 36&37 the panel has a two reinforcing layers of 65x65x3 or 100x100x2 SHS, and three core layers 2114, as in figure 21 to give a height of 600mm. If made as illustrated in Figures 36&37, the panel thickness will be 113mm as seen in Figure 36, with the reinforcing layers being located respectively in the centre of the No-Cut-Zones with the SHS used being a 100x1 00x2 which is protected by a distance of 30mm on each side, as the No-Cut-Zone is 160mm in height, and starts some 70mm from the upper and lower edges. The distance between the No-Cut-Zones being 140mm. The core layers 2114 are positioned above and below and in between the reinforcing layers. The length of the panel illustrated being 2400mm.

[0206] In the case of figures 38&39 the panel has three reinforcing layers of 65x65x3 or 100x100x2 SHS, and four core layers 2114, to give a height of 900mm. If made as illustrated in Figures 38&39, the panel thickness will be 113mm as seen in Figure 39, with the reinforcing layers being located respectively in the centre of the No-Cut-Zones with the SHS used being a 100x100x2 which is protected by a distance of 30mm on each side, as the No-Cut-Zone is 160mm in height, and starts some 70mm from the upper and lower edges. The distance between the No-Cut-Zones being 140mm. The core layers 2114 are positioned above and below and in between the reinforcing layers. The length of the panel illustrated being 2400mm.

[0207] In the case of figures 40&41 the panel has four reinforcing layers of 65x65x3 or 100x100x2 SHS and five core layers 2114, to give a height of 1200mm. If made as illustrated in Figures 20&21, the panel thickness will be 113mm as seen in Figure 41, with the reinforcing layers being located respectively in the centre of the No-Cut-Zones with the SHS used being a 100x100x2 which is protected by a distance of 30mm on each side, as the NoCut-Zone is 160mm in height, and starts some 70mm from the upper and lower edges. The distance between the No-Cut-Zones being 140mm. The core layers 2114 are positioned above and below and in between the reinforcing layers. The length of the panel illustrated being 2400mm.

[0208] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only or. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[0209] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention [0210] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims

Claims 1 A panel for a fence or barrier or retaining wall, comprising: a pair of outer layers, at least one inner layer, the at least one inner layer being located adjacent and inboard of one respective outer layer; the at least one inner layer being a sheet having a plurality of perforations, a centre core between the inner layers, and a layer of adhesive or bonding material located between the centre core and one of the pair of outer layers configured to pass through the perforations and reach an opposite face of the at least one inner layer and form a bonding matrix through the intervening at least one inner layer, wherein the adhesive or bonding material is configured to expand during lamination.
2 A panel as claimed in claim 1, wherein the outer layers outer are of an environmentally resistant or hardy material between which are sandwiched, in a generally horizontal arrangement, layers of core material and reinforcing material which alternate in the direction of the upper edge to the lower edge of the panel, said reinforcing material extending along the whole width of the panel, and wherein each of said outer layers, said core material and said reinforcing material are bonded together by the adhesive or bonding material.
3 A panel as claimed in claim 1 or 2, wherein said at least one inner layer has a thickness in the range of 0.25 to 2 millimetres 4 A panel as claimed in any one of the preceding claims, wherein perforations on said at least one layer result in a combined open area of 25% to 45% of a total area of the said at least one layer.A panel as claimed in any one of the preceding claims, wherein perforations on said at least one inner layers are each substantially 3 millimetres in diameter.6 A panel as claimed in any one of the preceding claims, wherein adjacent perforations on said at least one inner layer are distanced so that their centres are substantially 5 millimetres apart.7 A panel as claimed in any one of the preceding claims, wherein the outer layers are 4 to 5 millimetres in thickness.8 A panel as claimed in any one of the preceding claims, having an overall thickness in the range of 75 to 300 millimetres 3 0 9. A panel as claimed in any one of the preceding claims, having a height in the range of 0.5 to 2 metres.A panel as claimed in any one of the preceding claims, wherein said at least one inner layer is formed from one of steel, aluminium, or carbon fibre.11 A panel as claimed in any one of the preceding claims, wherein the central core is expanded polystyrene.12 A panel as claimed in any one of the preceding claims, wherein said panel has a second inner layer which is also a sheet having a plurality of perforations.13 A panel as claimed in any one of claims Ito 12, wherein there is at least one reinforcing material layer per panel.14 A panel as claimed in any one of claims 1 to 13, wherein a respective reinforcing material layer is located between 80 mm and 200mm from the respective upper and or lower edges of said panel.A panel as claimed in any one of claims 1 to 14, wherein said core material is selected from one of the following: polystyrene foam; EPS; or other appropriate polymeric material.16 A panel as claimed in any one of the preceding claims wherein, said reinforcing material is a rectangular or square hollow section.17 A panel as claimed in claim 16, wherein said reinforcing material has, or is made from, one or more than one of the following: steel; 65x65 SHS being of steel and having a wall thickness of 2 to 5mm; 100x100 SHS being of steel and having a wall thickness of 2mm to 5mm; galvanized steel.18 A panel as claimed in any one of claims 1 to 17, wherein said outer layers are made of fibre cement or fibre cement sheet.19 A panel as claimed in any one of claims 1 to 18, wherein said panel has its upper and lower edges capped by caps which will allow adjacent like constructed panels to be joined in a retaining wall assembly.A panel as claimed in claim19, wherein said caps are secured and sealed in place with respect to said outer layers and or said core material by means of a polyurethane construction sealant.21 A panel as claimed in any one of claims Ito 20, wherein said panel has one or more than one of the following characteristics: a length of the order of 1m to 2.5m; a height of the order of 300 to 1200mm; a thickness of the order of 75 mm to 120mm.22 A retaining wall constructed from an assembly of posts and panels, said panels being as claimed in any one of claims 1 to 21.23 A retaining wall as claimed in claim 22, wherein said at least one of said panels have a different density than the remaining panels.24 A retaining wall as claimed in clam 22 or 23, wherein there are at least two panels assembled, one on top of the other, characterized in that a lower panel has a greater strength or resistance to pressure of retained earth capability than an upper panel.