GB2605481A

GB2605481A - A wall and a method of constructing a wall

Info

Publication number: GB2605481A
Application number: GB2117100.4A
Authority: GB
Inventors: Coyle Sean
Original assignee: Keystone Lintels Ltd
Current assignee: Keystone Lintels Ltd
Priority date: 2020-11-27
Filing date: 2021-11-26
Publication date: 2022-10-05
Also published as: GB202107983D0; GB202117100D0; IE20210202A2; GB2605481A8; GB202018756D0

Abstract

A wall 1 comprising an inner structure 2 and an outer structure 4. The outer structure 4 is in abutment with or spaced apart from the inner structure 2. At least part of the outer structure 4 comprises a panel 8a, 8b. The panel 8a, 8b has a backing member 10a, 10b and covering elements 12a, 12b attached to the backing member 10a, 10b. The vertical weight of the outer structure 4 is supported independently of the rest of the wall.

Description

A WALL AND A METHOD OF CONSTRUCTING A WALL

The present invention relates to a wall and in particular to a wall having an inner structure and an outer structure, and a method of constructing said wall.

There are numerous ways in which walls are constructed. Brick walls, for example, are formed by placing layers of brick or block courses to a desired height, whereas timber frame walls are typically formed by erecting a timber frame, providing insulation within the frame, and cladding the outside of the timber frame with bricks, or attaching panels to the frame to encase the frame and the insulation. Cladding can be also be installed on walls to provide additional weatherproofing and insulation, and to alter the finished appearance of the construction. Walls may alternatively be constructed from panels of concrete, or from structural insulated panels (SIPs), that are placed side by side and connected in a continuous series to produce a wall. Cavity walls can be formed by erecting two spaced apart, parallel walls, with the space being left void or filled with insulating material.

Prefabrication of building components is becoming increasingly popular. Assembly of prefabricated building components on site is less time consuming and usually requires less skill than constructing a building or building component de novo on site. Prefabrication further allows for frequent and rigorous quality control checks, so the final constructions are consistent and of high quality. One method of constructing a wall involves providing an inner structure, either with masonry blocks or timber framing, and then mounting cladding onto the outer surface of the inner structure to provide a finished appearance. A cavity is provided between the cladding and the inner structure and the size of the cavity is defined by the size and configuration of the brackets used for mounting the cladding on the inner structure. As the cladding is directly mounted onto the inner structure, the weight of the cladding is transferred to the inner structure and the cladding therefore puts a substantial force on the inner structure and on the foundation on which the inner structure is set. As a result, there are limitations on the size of such walls, and the inner structure may have to be reinforced depending on the weight and coverage of the cladding.

It is an object of the present invention to obviate or mitigate the above-mentioned problems regarding construction of walls.

Accordingly, there is provided a wall comprising an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein at least part of the outer structure comprises a panel, wherein the vertical weight of the outer structure is supported independently of the rest of the wall.

Advantageously, the outer structure is not mounted on and is not transmitting any vertical load to the inner structure.

Ideally, the vertical weight of the outer structure is transmitted directly to the structural support member upon which the outer structure is mounted.

Preferably, the vertical weight of the outer structure is transmitted directly to the structural support member such as a foundation or plinth or base wall upon which the outer structure is mounted.

Advantageously, the panel is not mounted on and is not transmitting any vertical load onto the inner structure.

Ideally, the vertical weight of the panel is transmitted directly to the structural support member upon which the panel is mounted.

Preferably, the vertical weight of the panel is transmitted directly to the structural support member such as a foundation or plinth or base wall upon which the panel is mounted.

Ideally, the panel comprises a backing member.

Preferably, the panel comprises covering elements attached to the backing member.

Advantageously, as the outer structure is not mounted on the inner structure, the inner structure does not bear the weight of the outer structure and so no vertical load is applied to the inner structure compared with prior art arrangements where the outer structure, comprising panels of covering elements, is directly mounted onto the inner structure as cladding. Further advantageously, the size of the cavity is not defined by the size and shape of the mounting brackets, so the builder can determine the size of the cavity when constructing the wall. Yet further advantageously, as at least part of the outer structure is formed from a panel having covering elements attached to it, this reduces the onsite time and the level of skill required to construct the wall.

Preferably, the weight of the outer structure is transferred to the structural support member such as a foundation or plinth or base wall directly below the outer structure.

Preferably, the outer structure is independently supported such that the outer structure can remain upright without transmitting any vertical load through the inner structure.

Ideally, the weight of the panel is independently supported such that the panel can remain upright without transmitting any vertical load through the inner structure.

Ideally, the panel can be supported on the structural support member such as a foundation or plinth or base wall so that the weight of the panel is transmitted directly to the structural support member.

Preferably, the panel is set on or into the structural support member such as a foundation or plinth or base wall of the wall, the structural support member such as a foundation or plinth or base wall supporting the entire weight of the panel.

Preferably, the outer structure may be reinforced by reinforcing structures.

Ideally, the outer structure is tied to the inner structure by tying means. The tying means provide lateral support only and do not provide the outer structure with any vertical load support.

Ideally, the outer structure may be connected to the inner structure by wall ties extending between the inner and outer structures.

Ideally, lintels or cavity trays may be placed traversing any cavity between the inner and outer structures.

Preferably, the inner structure is a timber frame wall.

Ideally, the majority of the outer structure is formed from one or more panels, each panel having a backing member and covering elements attached to the backing member. Preferably, over 50% of the outer structure is formed from one or more panels.

Ideally, over 60% of the outer structure is formed from one or more panels. Ideally, over 70% of the outer structure is formed from one or more panels.

Ideally, over 80% of the outer structure is formed from one or more panels.

Ideally, over 90% of the outer structure is formed from one or more panels.

Ideally, over 95% of the outer structure is formed from one or more panels.

Ideally, the entire outer structure is formed from one or more panels, each panel having a backing member and covering elements attached to the backing member.

Ideally, the panels are connected to one another.

Preferably, the outer structure comprises two panels placed laterally adjacent to one another.

In an embodiment, the outer structure comprises a plurality of panels stacked vertically, the lower panel supporting the weight, most preferably the entire weight, of the upper panel or panels.

Preferably, the wall is a part of a building.

Ideally, the panel comprises a supporting structure, the backing member being fixed to the supporting structure.

Ideally, the supporting structure comprises light gauge steel Preferably, the supporting structure comprises one or more elongate support members fixed extending along the backing member.

Ideally, the elongate support member has a C-shaped cross section.

Ideally, the longitudinal axis of the elongate support member is substantially vertically aligned.

Preferably, the panel comprises a plurality of elongate support members arranged spaced apart from one another, most preferably at least some of the elongate support members being arranged at an equal distance from one another.

Preferably, the backing member is formed at least partially from fibre cement board, mineral particle board such as magnesium oxide particle board, concrete, fibre-reinforced polymers (FRPs, including wood comprising cellulose fibres in a lignin and hemicellulose matrix), carbon-fibre reinforced plastic (CFRP) or glass-reinforced plastic (GRP), thermoplastic composite (short fibre thermoplastics, long fibre thermoplastics or long fibre-reinforced thermoplastics), thermoset composite, and/or aramid fibre and carbon fibre in an epoxy resin matrix.

Advantageously, where the backing member is formed from mineral particle board, such materials are typically non-flammable and light in weight in comparison to metals typically used in construction. Further advantageously, such materials can readily receive screws and other fixings which can be used to mechanically fix the covering elements to the backing member.

Alternatively, the backing member is formed from metal such as steel or similar and is ideally perforated.

Ideally, the covering elements are masonry slips, such as brick, block or stone slips, or are formed from composite or synthetic material, or are cement render.

Preferably, the covering elements are attached to the backing member by adhesives or by mechanical attachment or a combination of both. Advantageously, use of mechanical means to attach the covering elements to the backing member reduces reliance on adhesives which can be toxic when burnt and/or are liable to fail over time resulting in the covering element being released from the backing member.

Ideally, the covering elements are arranged creating a brickwork pattern such as stretch bond, English bond or Flemish bond or any similar bond. This provides the appearance of a traditional brickwork wall.

Ideally, the panels comprise a plurality of rows of covering elements Alternatively, the panels could comprise a single row of covering elements.

In one embodiment, the wall comprises a corner section.

Ideally, the panel comprises a corner section. Advantageously, as the panel provides the corner section, it is not required to join two panels on site to form the corner and the corner detailing is provided by the panel. This reduces the complexity of the onsite construction and the skill level required for the construction.

Preferably, at the corner section, the panel is angled so that one part of the panel is at an angle relative to another part of the panel thereby forming a corner.

Ideally, at the corner section, the backing member is angled or alternatively the backing member is formed by two parts wherein one part is set at an angle relative to the other part.

Preferably, an elongate support member is set into the angled part of the corner section.

Ideally, the backing member extends around the elongate support member at the corner section.

Ideally, at least one covering element at the corner section is also angled to extend around the angled part of the backing member.

Preferably, at least one covering element comprises an L-shaped configuration.

Ideally, the corner is a right-angled corner although alternative angles are also possible.

Ideally, the wall is a cavity wall with a space between the inner structure and outer structure.

Preferably, the cavity is between 50 to 80 mm wide.

Ideally, the cavity is around 65 mm wide. Advantageously, current UK building control requirements necessitate a minimum of a 50 mm clear cavity. A cavity of 65 mm provides a 10 mm tolerance to ensure that this requirement is met at all times.

Preferably, the wall comprises weatherproofing materials.

Ideally, the inner structure comprises weatherproofing materials.

Preferably, the inner structure comprises a sheet of material on the surface facing the outer structure.

Ideally, the sheet of material is oriented strand board (OSB) or other suitable material.

Ideally, the inner structure comprises weatherproofing materials on the surface facing the outer structure.

Preferably, the weatherproofing material is fixed to the sheet of material.

Ideally, the weatherproofing materials comprise reflective breather paper membrane and/or a vapour control layer.

Preferably, the inner structure comprises inner structure support structures.

Ideally, the inner structure support structures are timber studs or other suitable support structure.

Ideally, the sheet of material extends between the inner structure support structures.

Ideally, the inner structure comprises insulation material.

Preferably, the inner structure has an interior surface, the interior surface being the opposite surface to that which faces the outer structure.

Ideally, the inner structure comprises spacing means disposed at the interior surface. Ideally, the spacing means comprises one or more battens. Advantageously, the spacing means provides a service zone to accommodate electric cables and plumbing.

Ideally, the inner structure comprises plasterboard fixed to the spacing means. Preferably, the panels are prefabricated.

Ideally, the panels can extend vertically up to a complete storey of a building. Preferably, the panels can extend vertically from a lower floor to a floor above.

According to an aspect of the invention there is provided a wall comprising an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein at least part of the outer structure comprises a panel, wherein the outer structure is not mounted on nor suspended from the inner structure.

The outer structure may be an outer leaf and the inner structure may be an inner leaf.

The outer structure may be a load-bearing wall. Advantageously, the outer structure can bear the weight of structural components placed on and above the outer structure.

Preferably, the majority of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Ideally, over 50% of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Ideally, over 60% of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Ideally, over 70% of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Ideally, over 80% of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Ideally, over 90% of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Ideally, over 95% of the weight of the outer structure is transferred to the foundation directly below the outer structure.

Preferably, the outer structure, ideally the panel, is self-supporting such that the outer structure can remain upright without being mounted on or suspended from the inner structure or other supporting structure Preferably, the panel can be engaged with the wall foundation so that the panel may be self-supporting.

Ideally, the panel is set on or into the foundation of the wall, the foundation supporting the entire weight of the panel.

According to another aspect of the invention there is provided a building, the building comprising a wall having an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein at least part of the outer structure comprises a panel, wherein the vertical weight of the outer structure is supported independently of the rest of the wall.

Ideally, the vertical weight of the outer structure is supported independently of the rest of the wall. Ideally, the vertical weight of the outer structure is transmitted directly to the structural support member upon which the outer structure is mounted.

Ideally, the wall is an outside wall of the building.

According to another aspect of the invention there is provided a building, the building comprising a wall having an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein at least part of the outer structure comprises a panel, wherein the outer structure is not mounted on nor suspended from the inner structure.

Preferably, the outer structure is a load bearing wall.

According to another aspect of the invention there is provided a method of constructing a wall the method comprising constructing an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein the method comprises constructing at least part of the outer structure by providing at least one panel, the method further comprising the step of mounting the outer structure so that the vertical weight of the outer structure is supported independently of the rest of the wall.

Ideally, the method further comprising the step of mounting the outer structure so that the vertical weight of the outer structure is transmitted directly to the structural support member upon which the outer structure is mounted.

S

Preferably, the method further comprising the step of mounting the outer structure so that the vertical weight of the outer structure is transmitted directly to the structural support member such as a foundation or plinth or base wall upon which the outer structure is mounted.

Advantageously, the method of constructing the wall means that the panel is not mounted on and is not transmitting any vertical load onto the inner structure.

Ideally, the method further comprising the step of mounting the outer structure so that the vertical weight of the panel is transmitted directly to the structural support member upon which the panel is mounted.

Preferably, the method further comprising the step of mounting the outer structure so that the vertical weight of the panel is transmitted directly to the structural support member such as a foundation or plinth or base wall upon which the panel is mounted.

Ideally, the method further comprising the step of providing the panel comprising a backing member and covering elements attached to the backing member.

Ideally, the method comprises locating the panel on or into the structural support member such as a foundation or plinth or base wall upon which the panel is mounted, the structural support member supporting the weight of the panel.

In one embodiment, the method comprises reinforcing the outer structure.

In one embodiment, the method comprises fitting wall ties extending between the inner and outer structures.

In one embodiment, the method comprises fitting lintels or cavity trays traversing the cavity between the inner and outer structures.

Ideally, the method comprises constructing the inner structure by providing a timber frame.

Preferably, the method comprises forming the majority of the outer structure from one or more panels.

Ideally, the method comprises providing each panel having a backing member and covering elements attached to the backing member.

Ideally, the method comprises connecting the panels to one another.

Preferably, the method comprises placing two panels laterally adjacent to one another.

In an embodiment, the method comprises vertically stacking panels to form at least part of the outer structure.

Ideally, the method comprises prefabricating the panel or panels before transporting to the site of construction of the wall.

Ideally, the method comprises providing a supporting structure and fixing a backing member to the support structure.

Preferably, the method comprises forming the supporting structure by arranging a plurality of elongate support members fixed to the backing member, the elongate support members supporting the backing member.

Ideally, the method comprises arranging the longitudinal axis of the elongate support members so that they are substantially vertically aligned when the panel is installed in the outer structure.

Preferably, the method comprises attaching covering elements to the backing member by adhesives or mechanical attachment means or a combination of both.

Ideally, the method comprises arranging the covering elements to create a brickwork pattern such as stretch bond, English bond or Flemish bond.

In one embodiment, the method comprises forming a corner section in the panel.

Ideally, the method involves forming the corner section by attaching one part of the backing member to the supporting structure at an angle to one other part of the backing member.

Preferably, the method comprises forming the backing member at an angle around an elongate support structure.

Ideally, the method comprises attaching an angled covering element to the backing member extending around the corner.

Preferably, at the corner section, the method comprises angling the panel so that one part of the panel is at an angle relative to another part of the panel thereby forming a corner.

Ideally, the method comprises forming the outer structure so as to be at a distance from the inner structure defining a cavity of between 50 to 80 mm wide.

Ideally, the method comprises fitting weatherproofing materials to the wall.

Ideally, the method comprises fitting weatherproofing materials to the inner structure.

Ideally, the method comprises forming the inner structure from inner-structure support structures, the support structures preferably being timber studs or other suitable support structure.

Ideally, the method comprises fitting a sheet of material extending between the inner-structure support structures, most preferably on the side of the inner-structure support structures that will face the outer structure, or on both sides of the inner-structure support structures, to provide inner/outer surfaces.

Preferably, the method comprises fitting insulation material in the inner structure, most preferably in spacing between the timber studs.

Ideally, the method comprises fitting weatherproofing material on one or both main planar surfaces of the inner structure.

Ideally, the method comprises fitting weatherproofing material on the sheet of material extending between the inner-structure support structures, or fitting the weatherproofing material extending between the inner-structure support structures.

Preferably, the method comprises fitting a spacing means on the interior surface of the inner structure.

Ideally, the method comprises attaching the spacing means to the inner-structure support structures. Preferably, the method comprises attaching plasterboard or other suitable material to the spacing means.

Ideally, the method comprises prefabricating the panels in a factory environment Accordingly, the present invention provides a method of manufacturing a panel for a wall, the wall comprising an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein at least part of the outer structure comprises the panel, such that the vertical weight of the outer structure is capable of being supported independently of the rest of the wall.

Ideally, the method comprises providing a supporting structure and fixing a backing member to the supporting structure.

Preferably, the method comprises attaching covering elements to the backing member by adhesive or mechanical attachment means or a combination of both.

In one embodiment, the method comprises forming a corner section in the panel.

Ideally, the method comprises forming the outer structure to be at a distance from the inner structure defining a cavity of between 50 to 80 mm wide.

Ideally, the method comprises fitting weatherproofing materials to the wall.

Ideally, the method comprises attaching the spacing means to the inner structure support structures.

Preferably, the method comprises attaching plasterboard or other suitable material to the spacing means.

According to another aspect of the invention there is provided a method of constructing a building wherein at least one or all of the outer walls of the building are formed by constructing an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein the method comprises constructing at least part of the outer structure by providing at least one panel, the panel comprising a backing member and covering elements attached to the backing member.

The invention will now be described, by way of example only, with reference to the accompanying drawings in which: -Figure 1 shows a top view of a wall according to the invention.

In the drawings there is shown a wall indicated generally by reference numeral 1. The wall has an inner structure 2 and an outer structure 4. In this embodiment, the outer structure 4 is spaced apart from the inner structure 2, defining a cavity 6 between the structures 2, 4.

The cavity 6 is 65 mm wide in this embodiment but other sized cavities may be implemented where desirable and depending on building restriction requirements. The outer structure 4 is formed from a plurality of panels 8a, 8b, two of which are illustrated in Figure 1. Each panel 8a, 8b has a backing member 10a, 10b with covering elements 12a, 12b attached to the tr) backing member 10a, 10b. The outer structure 4 is a wall and the majority or all of the weight of the outer structure 4 is transferred to the load bearing structure directly below the outer structure 4. The weight of the outer structure 4 is transmitted directly to the load bearing structure. In particular, the weight of the panels 8a, 8b are supported independently from the rest of the wall. The panels 8a, 8b are set onto the structural support member such as a foundation or plinth or base wall upon which the panel is mounted (not shown) which supports the weight of the panels 8a, 8b. This is in contrast to prior art arrangements where the panel is mounted on the inner structure and the inner structure partially or totally bears the weight of the panels. In other embodiments not shown, the outer structure may be reinforced by reinforcing structures. Wall ties may also be placed extending between the inner and outer structures. Cavity trays or lintels may also be placed extending between the inner and outer structures.

In this embodiment, the majority of the outer structure 4 is formed from panels 8a, 8b. The panels 8a, 8b are placed laterally adjacent to one another. In other embodiments not shown, the outer structure 4 can have panels vertically stacked such that the lower panel supports the weight of the upper panel. The wall 1 can form a part of a building and can be arranged to form the entire outer wall of a building.

The panels 8a, 8b each have a supporting structure 14a, 14b formed from a plurality of elongate support members 16. The backing member 10a, 10b of each panel 8a, 8b is fixed to the supporting structure 14a, 14b respectively. The supporting structures 14a, 14b and more specifically the elongate support members 16 are formed from light gauge steel. In other embodiments the elongate support members 16 may be formed from a different gauge of steel or a different metal or metal alloy, or a non-metallic material. Each elongate support member 16 is fixed extending along the backing member 10a, 10b of each panel 8a, 8b. In particular, the longitudinal axis of the elongate support members 16 are vertically aligned in the outer structure 4. The elongate support members 16 are arranged equal distance apart in the planar section of the panels 8a, 8b but there is a different arrangement in a corner section of panel 8a as will be described later. Each elongate support member 16 has a C-shaped cross section although of course it will be appreciated that the invention is not limited to a specific configuration of cross section. Each elongate support member 16 extends for the entire height of the panel 8a, 8b. At the lateral end portion of each panel 8a, 8b, an elongate support member 16 is positioned thereby defining a part of the end face of the panel 8a, 8b. The base 18 of the elongate support member 16 is arranged at the end face and is coplanar with the end face of the backing member 10a, 10b. Each elongate support member 16 has a base 18 that is 90 mm wide, and sidewalls 20, 47 mm in height, extending perpendicularly from the base 18. The thickness of the material forming the elongate support member 16 is 1.2 mm. Each sidewall 20 terminates with an inward bend 22. Alternative size and shapes of elongate support member may also be used in other embodiments.

In this embodiment the backing members 10a, 10b are formed from fibre cement board of a thickness of 12-15 mm. Other thicknesses will also be suitable and other materials may be used such as magnesium oxide particle board, concrete, fibre-reinforced polymers, (FRPs, including wood comprising cellulose fibres in a lignin and hemicellulose matrix), carbon-fibre reinforced plastic (CFRP) or glass-reinforced plastic (GRP), thermoplastic composite (short fibre thermoplastics, long fibre thermoplastics or long fibre-reinforced thermoplastics), thermoset composite, and/or aramid fibre and carbon fibre in an epoxy resin matrix. In yet a further alternative embodiment, the backing member is formed from a metal or metal alloy such as steel and can be perforated to suit bespoke requirements.

The covering elements 12a, 12b are 20-25 mm brick slips that are mechanically and adhesively bonded to the backing member 10a, 10b. It should be noted that different thicknesses of brick slips could be used or different materials such as block or stone slips, or composite or synthetic materials. The backing member 10a, 10b could even be covered by a cement render as an alternative option. The covering elements 12a, 12b need not be both adhesively and mechanically fixed to the backing member 10a, 10b but could alternatively be either mechanically or adhesively fixed. The covering elements 12a, 12b are arranged in a stretch bond pattern on the backing members 10a, 10b. In alternative embodiments any desirable pattern of brickwork could be used such as English bond or Flemish bond.

The wall 1 has a corner section 24 and in particular the panel 8a has a corner section 26. At the corner section 26, the panel 8a is angled so that one part of the panel 28 is at an angle relative to another part 30 of the panel thereby forming a corner. At the corner section 26 the backing member 10a is formed by two parts wherein one part is set at an angle relative to the other part. In this embodiment, the corner section 26 is formed by arranging two elongate support members 16 back-to-back with their bases 18 abutting and attaching the backing member 10a. One part of the backing member 10 extends along the coplanar sidewalls 20 of the back-to-back elongate support members 16, and the other part extends over the open channel section of one elongate support member 16, resting on the inward bends 22. In this embodiment, some of the covering elements 12a are L-shaped, with the inner angle of the L extending around and resting on the corner of the backing members 10a. The corner section 24 is a right-angled corner in this embodiment but the wall could be built with other angles if desired.

The wall 1 further has weatherproofing materials 32 and in particular the inner structure 2 has weatherproofing materials 32. The inner structure 2 has inner-structure support structures 34 which in this embodiment are timber studs 36 but may be other alternative suitable support structures in other embodiments. The timber studs 36 are spaced apart at 600 mm centre to centre and are 50 x 140 mm timber studs. Alternative sizes and spacings may also be used as desired. The inner structure 2 further has sheets of material 38 arranged at the surface facing the outer structure 4. The sheets of material 38 are 9-mm oriented strand board (OSB) in this embodiment and they are arranged traversing spaced apart inner-structure support structures 34. Other suitable thickness and/or materials may be used as desired. A reflective breather membrane 40 provides weatherproofing over the sheets of material 38. There is further a vapour control later 42 arranged extending between the inner-structure support structures 34. Other types of weatherproofing material may be arranged in place of the reflective breather membrane 40 and/or vapour control layer 42 if desired. Insulation material 44 is provided by 140 mm mineral wool insulation disposed between the inner-structure support structures 34. Variations in the type of insulation or thickness may be implemented as desired. The inner structure 2 has an interior surface 46, the interior surface 46 being the opposite surface to that which faces the outer structure 4. Spacing means 48 are provided on the interior surface 46 by battens that are arranged fixed on to the inner-structure support structures 34. The battens are 25 x 38 mm battens but other sizes may be used as desired. The spacing means 48 provides a service zone to accommodate electric cables and plumbing. The service zone is correspondingly 25 mm wide as the size of the zone is defined by the size of the battens, so use of different size battens can adjust the size of the service zone. The inner structure 2 further has plasterboard 50 fixed to the spacing means 48. The plasterboard 50 is 12.5 mm thick plasterboard, although different thickness or materials may be used if desired, with a 3 mm skim finish but it could alternatively be taped and jointed. The panels 8a, 8b are prefabricated in a factory setting before transporting to site and installing.

In use, a wall 1 is constructed by constructing the timber frame inner structure 2 and then arranging the panels 8a, 8b to form the outer structure 4. The two structures 2, 4 may be connected by wall ties and such, but the vertical weight of the outer structure 4 is supported independently of the rest of the wall and the weight of the outer structure 4 is transferred to the load bearing structure below the outer structure 4. After placing the panels 8a, 8b into position they are joined and sealed. A building can be formed wherein the entire outer wall is formed from a wall 1 as herein described.

A further aspect of the invention is a method of constructing the wall 1. The method involves constructing the inner structure 2. In this embodiment, the inner structure 2 is constructed by arranging the inner-structure support structures 34 spaced apart. A corner section 24 is formed by arranging the inner-structure support structures 34 together at the corner section 24 to define a corner. Sheets of material 38 (OSB in this embodiment) are fitted extending between the spaced apart inner-structure support structures 34 at the outward facing surface of the inner structure 2. A reflective breather membrane 40 is fit on the sheets of material 36. Insulation material 44 is placed disposed between the inner-structure support structures 34 and a vapour control layer 42 is arranged extending between the inner-structure support structures 34 on the inner surface. Spacing means 48 are fitted to the inner-structure support structures 34 at the inner surface and plasterboard 50 is fitted to the spacing means 48 and skim finished. The inner structure could alternatively be provided by structural insulated panels (SIPs) or by traditional brickwork.

The outer structure 4 is formed by prefabricating the panels 8a, 8b in a factory. The panels 8a, 8b are formed by first providing a supporting structure 14a, 14b. The supporting structure 14a, 14b is provided by elongate support members 16 and attaching a backing member 10a, 10b to spaced apart elongate support members 16. The elongate support members 16 are arranged so their longitudinal axis is vertically aligned when the panels 8a, 8b are installed onsite. A corner section 26 can be formed by placing two elongate support members 16 back-to-back and arranging the backing member 10a around the back-to-back structures to form a corner. Covering elements 12a, 12b are fixed to the backing members 10a, 10b using adhesives and mechanical fixes (not shown) in a traditional brickwork pattern.

The spacing between the covering elements 12a, 12b is pointed and the panels 8a, 8b are transported to the site and arranged around and spaced apart from the inner structure 2 to provide a cavity. The panels 8a, 8b are fixed into the structural support member such as a foundation or plinth or base wall upon which the panel is mounted and are sealed and connected. The weight of the panels 8a, 8b is supported independently from the rest of the wall. Panels may be vertically stacked (not shown) and they can be reinforced in the factory or on site if necessary. An entire outer wall of a building may be constructed by repeating this method to form a wall of desired length and height.

The skilled person will appreciate that all preferred or optional features of the invention described with reference to only some aspects or embodiments of the invention may be applied to all aspects of the invention.

It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.

In relation to the detailed description of the different embodiments of the invention, it will be understood that one or more technical features of one embodiment can be used in combination with one or more technical features of any other embodiment where the transferred use of the one or more technical features would be immediately apparent to a person of ordinary skill in the art to carry out a similar function in a similar way on the other embodiment.

The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof.

Claims

CLAIMS1. A wall comprising an inner structure and an outer structure, the outer structure being in abutment with or spaced apart from the inner structure, and wherein at least part of the outer structure comprises a panel, the panel comprising a backing member and covering elements attached to the backing member, wherein the vertical weight of the outer structure is supported independently of the rest of the wall and/or wherein the outer structure is not mounted on nor suspended from the inner structure.
2. A wall as claimed in any claim 1 wherein the outer structure is independently supported such that the outer structure can remain upright without transmitting any vertical load through the inner structure.
3. A wall as claimed in claim 1 or claim 2 wherein the vertical weight of the outer structure is transmitted directly to a structural support member upon which the outer structure is mounted.
4. A wall as claimed in claim 3 wherein the vertical weight of the outer structure is transmitted directly to the structural support member such as a foundation or plinth or base wall upon which the outer structure is mounted.
5. A wall as claimed in any preceding claim wherein the panel comprises a supporting structure, the backing member being fixed to the supporting structure.
6. A wall as claimed in claim 5 wherein the supporting structure comprises light gauge steel.
7. A wall as claimed in claim 5 or claim 6 wherein the supporting structure comprises one or more elongate support members fixed extending along the backing member.
8. A wall as claimed in claim 7 wherein the panel comprises a plurality of elongate support members arranged spaced apart from one another.
9. A wall as claimed in any preceding claim wherein the backing member is formed at least partially from fibre cement board, mineral particle board such as magnesium oxide particle board, concrete, fibre-reinforced polymers, carbon-fibre reinforced plastic or glass-reinforced plastic, thermoplastic composite, thermoset composite, and/or aramid fibre and carbon fibre in an epoxy resin matrix.
10. A wall as claimed in any preceding claim wherein the covering elements are masonry slips, such as brick, block or stone slips, or are formed from composite or synthetic material, or are cement render.
11. A wall as claimed in claim 10 wherein the covering elements are attached to the backing member by mechanical attachment.
12. A wall as claimed in any preceding claim wherein the majority of the outer structure is formed from one or more panels, each panel having a backing member and covering elements attached to the backing member.
13. A wall as claimed in claim 12 wherein the outer structure comprises a plurality of panels stacked vertically, the lower panel supporting the entire weight, most preferably the entire weight, of the upper panel or panels.
14. A wall as claimed in any preceding claim wherein the panel comprises a corner section and wherein, at the corner section, the panel is angled so that one part of the panel is at an angle relative to another part of the panel thereby forming a corner.
15. A wall as claimed in claim 14 when dependent on claim 7 wherein, at the corner section, the backing member is angled or alternatively the backing member is formed by two parts wherein one part is set at an angle relative to the other part.
16. A wall as claimed in claim 15 wherein an elongate support member is set into the angled part of the corner section.
17. A wall as claimed in claim 16 wherein the backing member extends around the elongate support member at the corner section.
18. A wall as claimed in claim 15 wherein at least one covering element at the corner section is angled to extend around the angled part of the backing member.
19. A wall as claimed in any preceding claim, wherein the wall is a cavity wall with a space between the inner structure and outer structure.
20. A wall as claimed in any preceding claim further comprising weatherproofing materials.
21. A wall as claimed in any preceding claim wherein the inner structure comprises inner structure support structures, wherein the inner structure support structures are timber studs or other suitable support structure.
22. A wall as claimed in any preceding claim wherein the inner structure comprises insulation material.
23. A wall as claimed in any preceding claim wherein the outer structure is tied to the inner structure by tying means.
24. A wall as claimed in any preceding claim wherein the inner structure has an interior surface, the interior surface being the opposite surface to that which faces the outer structure, and wherein the inner structure comprises spacing means disposed at the interior surface, and wherein the spacing means comprises one or more battens, the spacing means providing a service zone to accommodate electric cables and plumbing.