WO2015052503A1

WO2015052503A1 - Precast wall segment

Info

Publication number: WO2015052503A1
Application number: PCT/GB2014/053016
Authority: WO
Inventors: Barry GALLAGHER
Original assignee: Wallline Limited
Priority date: 2013-09-18
Filing date: 2014-10-07
Publication date: 2015-04-16
Also published as: GB2519068A; GB201316555D0

Abstract

The present invention relates to a precast load bearing wall segment (10A) comprising a main body portion (12) and one or more finger portions (14) extending outwardly from at least one side of the main body portion (12).

Description

PRECAST WALL SEGMENT

The present invention relates to precast wall segments and methods for their use and manufacture.

Background to the Invention

Many large buildings are constructed from prefabricated concrete wall segments comprising large panels that are supported on pre-erected steel beams which provide a framework for the buildings. These prefabricated panels generally comprise precast concrete slabs having large surface area and which are positioned onto the steel support structure by crane or other heavy lifting equipment Generally, buildings constructed in this way are readily identifiable and usually comprise large-scale buildings such as commercial premises, factories, warehouses, hospitals, apartment blocks etc. Such precast wall panels are generally not used in the construction of individual dwellings where the more traditional method of block or brick construction still prevails.

It is therefore an object of the present invention to provide a precast wall segment that provides an alternative to known precast wall panels and which is particularly suited for use in the construction of domestic scaled premises.

Summary of the Invention In a first aspect of the invention there is provided a precast load bearing wall segment comprising a main body portion and one or more finger portions extending outwardly from at least one side edge of the main body portion.

Ideally, the one or more finger portions extend from opposing side edges of the main body portion. Preferably, there is provided a plurality of finger portions extending outwardly from at least one side edge of the main body portion, the finger portions on the at least one side edge being mutually spaced apart at regular intervals. Preferably still, there is provided a plurality of finger portions extending outwardly from opposing side edges of the main body portion, the finger portions on each respective side edge being mutually spaced apart at regular spacing.

Conveniently, precast wall segments in accordance with the invention can be configured as male or female segments, the finger portions of a male segment being adapted for inter-location with clearance into complementary spaces defined by the spaced apart finger portions of an adjacent female segment in use, and vice versa.

It will be appreciated that once the outwardly extending finger portions of respective adjacent male and female segments are inter-located, mechanical interlock is effected by the addition on-site of mortar into a clearance gap between the respective finger portions. In this way, a wall can be constructed on-site from a plurality of mutually interlocking male and female configured segments. Conveniently, male and/or female segments are cast having one or more abutment formations integrally formed on the main body portion, the formations adapted to abut adjacent segment(s] in use so that a desired clearance gap between adjacent interlocking segments is maintained. Advantageously, the or each abutment formation(s] are of a height such that the clearance gap between adjacent interlocking segments is equivalent to a desired or standard mortar course.

Optionally, load bearing precast wall segments in accordance with the invention comprise an integrally cast lifting means comprising a foot portion which is connectable to a top cap via a lifting rod, the foot portion being located at a lower in use end of the wall segment, and the lifting rod extending from the foot portion through the wall segment to an upper in use end of the segment where the top cap is attached in use. Advantageously, the top cap is removably attachable to the lifting end of an auxiliary lifting apparatus, such but not limited to, a crane, jack or sling or other similar apparatus, so that the wall segment can be lifted and moved into a desired position in use, and the top cap then removed. Advantageously, the foot portion is integrally cast into the wall segment and is of a height that is equivalent to a desired or standard mortar course.

Conveniently, the lifting rod is insertable through an aperture cast into the wall segment.

Preferably, the lifting rod is screw-threadedly or twist-lock connectable to the foot portion and top cap.

Preferably, the foot portion, lifting rod and top cap portion are formed from steel.

In one aspect of the invention, load bearing precast wall segments in accordance with the invention are formed as panel having a single layer, wherein at least one face of the panel provides an exterior wall surface in use. Preferably, two faces of the single layer panel provide an exterior wall surface in use.

In one aspect of the invention, precast load bearing wall segments in accordance with the invention are formed as composite panels having an outer precast layer and an inner precast layer, wherein the outer precast layer provides an exterior wall surface in use and wherein the inner precast layer provides an interior wall surface in use.

In one aspect of the invention, load bearing precast wall segments formed as panels having an outer precast layer and an inner precast layer further comprises one or more intermediate layers of insulating materials.

Advantageously, the insulating material comprises a plurality of projecting flutes on one surface, the surface in use creating a ventilated cavity in use. Optionally, the panels also comprise a plurality of projecting flutes on one surface, the surface in use creating a ventilated cavity in use.

Preferably, the load bearing precast wall segments in accordance with the various embodiments of the invention or one or more panels thereof are cast having the imprint of traditionally laid building block or brick wall on at least one face i.e. having the surface finish of blocks or bricks and traditional mortar course. In this way a completed wall constructed with a plurality of mutually interlocking male and female configured segments and having the clearance gap between adjacent segments filled with mortar, will have the outward appearance of a wall of traditional block and mortar construction.

Conveniently, a selection of precast load bearing wall segments in accordance with the invention can be provided having the necessary shapes, sizes and configurations to produce the walls of a building from a selection of standardized or non-standard segment types. In this way, wall segments in accordance with the invention provide an overall building system which can be utilized to construct a multitude of building types and designs.

Accordingly, the present invention also provides a method of automatically producing a list of segment types and associated assembly plan required to construct a building or one or more walls thereof, the method comprising the steps of:

deconstructing a plan, outline drawing, 3-D model or other graphical representation of a building design to define one or more external walls; deconstructing the plans of the one or more external walls to define an array of suitable standardized and non-standard segment types required to reproduce said wall(s] together with any in-fill blocks required; and generating lists and/or assembly drawings indicating the standardized or non-standard segment types in accordance the invention to reproduce said wall(s], together with any in-fill blocks required to fill the otherwise unoccupied spaces between finger portions, for example around openings such as doors or window frames, along the tops of sloping gables, or to accommodate lintels or window sills. In this way, a suitably configured programed computer or suitable software program configured to operate thereon can automatically produce a list of segment types and the assembly plan required to construct a building. Conveniently, precast wall segments in accordance with the invention are formed having embedded remotely readable identification means so that particular segment types and configurations may be assigned a unique identifier for the purposes of ordering, tracking and/or location. In this way, the constituent segments for a building can be defined and delivered to a site and subsequently assembled in their correct location and/or order. Preferably, the remotely readable identification means comprises radio-frequency identification (RFID] tags or other suitable means.

In a second aspect of the invention there is provided a method of casting a load bearing wall segment panel comprising the steps of:

- providing a jig or mould having a base portion and a plurality of upstanding side walls attachable to the base portion, the upstanding side walls defining a generally rectangular perimeter;

arranging one or more occluding members within the jig, the occluding members defining the extents of the wall segment and/or one or more outwardly extending finger portions;

pouring a fluid concrete mix into the jig to a desired fill level corresponding to a desired segment panel thickness; and

imprinting a surface of the fluid or semi-set concrete mix with the impression of a blocks or bricks and mortar courses.

It will be appreciated that the imprint may be effected by an imprint network provided on the surface of the base portion and/or by a stamp adapted to imprint an impression on an opposing surface of a fluid concreted mix poured into the mould. Optionally, the method of casting a load bearing wall segment comprises one or more of the optional steps of:

locating a foot portion at an end of the jig or mould corresponding to the lower in use end of the wall segment; inserting a tubular sleeve that is extensible between a foot portion and an opposing end of the jig;

embedding a remotely readable identification means such as an RFID tag within the fluid or semi-set concrete mix.

- arranging one or more occluding members within the jig, the occluding members defining one or more service corridors to allow the placing of lighting switches, switched sockets, wall lights, ducts etc. in the precast wall panel. In a third aspect of the invention there is provided a jig or mould for casting a wall panel forming part of a precast wall segment in accordance with the first aspect of the invention, the jig or mould comprising;

a base portion; and

a plurality of upstanding sidewalls attachable to said base portion and defining a generally rectangular perimeter about said base portion;

wherein the base portion comprises an imprint network adapted to imprint an impression of block or brick and mortar courses on a surface of a fluid concrete mix poured within the jig or mould. In exemplary embodiments, the imprint network comprises a plurality of ridges.

The plurality of ridges may be shaped to provide a desired mortar joint effect. For example, the ridges may be shaped to provide a concave, vee, weathered, raked, struck or grapevine effect impression on the surface of the wall panel

In alternative exemplary embodiments, the imprint network comprises a plurality of rebates.

The plurality of rebates may be shaped to provide a desired mortar joint effect. For example, the rebates may be shaped to provide a beaded or extruded effect impression on the surface of the wall panel. In a fourth aspect of the invention there is provided a jig or mould assembly for casting a wall panel forming part of a precast load bearing wall segment, the jig or mould assembly comprising:

a jig or mould in accordance with the third aspect of the invention; and - a plurality of occluding members adapted to define the extents of the wall segment and/or one or more outwardly extending finger portions.

In exemplary embodiments, the jig/mould assembly further comprises a stamp adapted to imprint an impression of block and mortar courses on an opposing surface of a fluid concrete mix poured within the jig or moulding process.

Brief Description of the Drawings

The invention will now be described by way of non-limiting example, with reference being made to the accompanying drawings, in which:

Figure la depicts a load bearing precast wall segment panel in accordance with a first embodiment of a first aspect of the invention; Figure lb depicts a precast load bearing wall segment panel in accordance with a second embodiment of a first aspect of the invention;

Figures 2a to 2e depict the assembly of a third embodiment of a wall segment in accordance with a first aspect of the invention;

Figures 3a to 3e depict the assembly of a fourth embodiment of a wall segment in accordance with a first aspect of the invention;

Figure 4a is a schematic view of a jig/mould and arrangement of occluding members therein forming part of a jig/mould assembly for forming a wall panel forming part of the first embodiment of the precast wall segment in accordance with the invention;

Figure 4b is a side view of an embodiment of an occluding member; Figure 4c is an end view of an embodiment of an occluding member;

Figure 4d is a partial view of the corner of the jig/mould with an extension member positioned between two side walls;

Figure 4e is a cross-sectional view of the jig of Figure 4a with fluid concrete mix therein;

Figure 5a is a schematic view of a jig/mould and arrangement of occluding members therein forming part of a jig/mould assembly for forming a wall panel forming part of the second embodiment of the precast wall segment in accordance with the invention;

Figure 5b is a side view of an embodiment of an occluding member;

Figure 5c is an end view of an embodiment of an occluding member;

Figure 5d is a partial view of the corner of the jig/mould with an extension member positioned between two side walls;

Figure 5e is a cross-sectional view of the jig of Figure 5a with fluid concrete mix therein;

Figure 6a is an embodiment of a jig/mould assembly in accordance with an aspect of the invention;

Figures 6b and 6c depict the imprinting of imprint an impression of brick and mortar courses on an opposing surface of a fluid concrete mix poured within the jig/mould;

Figure 7 is a schematic of precast wall segments in accordance with the invention comprising service corridors; Figures 8a to 8e are schematic illustrations showing a method in accordance with the invention to produce a list of segment types and the assembly plan required to construct an exemplary building; and Figures 9a and 9b show dimensions of preferred wall panel segments in accordance with the invention.

Description of the Preferred Embodiments

The preceding discussion of the background to the invention is intended only to facilitate an understanding of the present invention. It should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge as at the priority date of the application.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example "comprising" and "comprises", means "including but not limited to", and is not intended to (and does not] exclude other components, integers or steps.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers or characteristics, compounds described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

Referring initially to Figures la and lb, exemplary first and second embodiments of precast wall segments 10A, 10B in accordance with a first aspect of the invention are shown. In Figure la, segment 10A is configured as a male segment. In Figure lb, segment 10B is configured as a female segment.

In embodiments as shown in Figures la and lb, precast wall segments 10A, 10B are formed as panels 10A, 10B having a single layer wherein one or more faces 11a, lib of the panel provides an exterior wall surface in use. Preferably, both faces 11a, lib of the panel provide an exterior wall surface in use. Each panel 10A, 10B comprises a main body portion 12 and one or more finger portions 14 extending outwardly from at least one side edge of the main body portion 12. In Figures la and lb, a plurality of spaced apart finger portions 14 are shown extending outwardly from opposing side edges of the main body portion 12 of each panel 10A and 10B, the finger portions 14 on each respective side edge being mutually spaced apart at regular spacing. It will be appreciated however that the one or more finger portions might only extend from one side edge of a panel, e.g. to form a segment having a straight edge on one side.

The finger portions 14 of a male panel 10A are adapted for inter-location with clearance into the complementary spaces defined by the spaced apart finger portions 14 of an adjacent female panel 10B in use. Once the outwardly extending finger portions of respective adjacent male and female panels are inter-located, mechanical interlock is affected by the on-site addition of mortar into the clearance gap between the respective finger portions 14. In this way, a wall can be constructed on-site from a plurality of mutually interlocking male 10A and female 10B configured segments.

So that a desired clearance gap between adjacent interlocking wall segments 10A, 10B is maintained in use, one segment (shown as being the male segment 10A of Figure la] is cast having one or more abutment formations 24 integrally formed on the main body portion 12, the formations 24 adapted to abut adjacent wall segment(s] in use.

While in the embodiment shown, the abutment formations 24 are integrally formed on the main body portion of the male segment 10 A, abutment formations may alternatively or in addition be formed on the main body portion 12 of the female segment 10B and/or formed on one or more finger portions 14 of the male/female segments 10A, 10B.

Each abutment formation 24 is of a height such that the clearance gap between adjacent interlocking segments is equivalent to a desired or standard mortar course.

Wall segments 10A, 10B each comprise an integral lifting means comprising a foot portion 22 which is connectable to a top cap (not shown] via a lifting rod 30. The foot portion 22 is located at a lower in use end of the wall segment 10A, 10B, and the lifting rod 30 extends between the foot portion 22 through the wall segment 10 A, 10B to an upper in use end of the wall segment where the top cap is attached in use. The top cap is attachable to the lifting end of an auxiliary lifting apparatus, such but not limited to, a crane, jack or sling or other similar apparatus, so that the wall segment can be lifted and moved into a desired position in use.

The foot portion 22 is integrally cast into to the segment. The foot portion 22 is of a height that is equivalent to a desired or standard mortar course. For example the foot portion 22 may be 10mm in height in accordance with the general mortar course height in the UK.

In the embodiments shown, the lifting rod 30 is inserted through an aperture cast into the segment and is preferably screw-threadedly or turn or twist-lock connected to foot portion 22. The aperture though which the lifting rod 30 extends may be defined by a tubular plastic sleeve 31 that is formed integrally into the segment during casting.

The foot portion 22 and lifting rod 30 and top cap (not shown] are formed from steel but it would be understood by the skilled person that they may be formed of any suitable rigid material.

Referring to Figures 2e and 3e, exemplary third and fourth embodiments of wall segments 100A, 100B in accordance with the first aspect invention are shown.

In Figures 2e, segment 100A is configured as a male segment In Figure 3e, segment 100B is configured as a female segment.

In these exemplary embodiments, segments 100A and 100B are formed as multi-panel wall segments panels having an outer precast layer and an inner precast layer, wherein the outer precast layer provides an exterior wall surface in use and wherein the inner precast layer provides an interior wall surface in use. Between the outer and inner precast layers there is also provided one or more intermediate layers of insulating material. Specifically, Figure 2e shows an exemplary male segment 100A formed as multi multi- panel segment having an outer precast layer 101A and an inner precast 102A layer, wherein the outer precast layer 101 A provides an exterior wall surface in use, and wherein the inner precast layer 102 A provides an interior wall surface in use.

Similarly, Figure 3e shows of an equivalent exemplary female wall segment 100B formed as multi-panel segment having an outer precast layer 101B and an inner precast 102B layer, wherein the outer precast layer 101B provides an exterior wall surface in use, and wherein the inner precast layer 102B provides an interior wall surface in use.

It will be apparent to the skilled person that the multi-panel wall segments 10 OA, 100B as described herein generally comprise two precast wall segments that have been formed as individual panels having a single layer substantially as described above with respect to the respective first 10A and second 10B embodiments of the first aspect of the invention shown in Figures la and lb. In other words, precast layers 101A and 102A substantially correspond to exemplary segment 10A of Figure la, and precast layers 101B and 102B substantially correspond to exemplary segment 10B of Figure lb.

With reference to Figures 2a-2e and 3a-3e, the assembly of a multi-panel wall segment 100A, 100B will now be described.

Holes 21 are first drilled partly into the outer panel layer 101A, 101B and filled with resin. Wall ties 26 are then inserted into the pre-drilled resin filled holes 21 with a wall tie restraint ring 28 placed against an inner surface of the outer panel layer 101A, 101B (see Figures 2a and 3a]. Suitable ties include fibre basalt ties.

Referring to Figures 2b and 3b, pre-holed insulating material 16 (Figure 2b] ,116 (Figure 3b] having a projecting fluted surface on one side (not shown] and a substantially planar or 'flush' surface on the opposing side, is then aligned with the ties 26 with the flutes placed facing the inner surface of the outer panel layer 101A,101B.

With reference to Figures 2c and 3c, the insulation material 16, 116 is then pushed forward onto the wall ties until the insulating material 16,116 is in direct contact with its respective outer panel layer 101A, 101B, with the flutes creating narrow cavities which are ventilated (not shown in the Figures].

It will be appreciated that the inner surface of the panel layers may also or instead be provided with integrally formed flutes.

Holes 23 drilled fully through the inner panel layer 102A, 102B are filled with resin and aligned with the respective wall ties 26,126 (see Figure 2d and 3d]. The inner panel layer 102A, 1202B is pushed towards the respective outer panel layer 101A, 101B until it is in direct contact with the substantially planar or 'flush' surface of the insulating material 16,116 and the wall ties 26 are all in corresponding holes 23 in the inner panel layer 102A, 102B (see Figure 2e and 3e].

It will be appreciated that once the outwardly extending finger portions 14 of respective precast panels of adjacent male and female wall segments 100A, 100B are inter-located, mechanical interlock is affected by the addition of on-site applied mortar into the clearance gap as described previously. In this way, a wall can be constructed from a plurality of mutually interlocking male and female configured multi-panel segments 100A, 100B.

The precast wall segments 10A, 10B and segment panel layers 101A, 10 IB, 102A, 102B, of the multi-panel wall segments 100A, 100B are cast having the imprint of traditionally laid blocks on at least one face, i.e. having the surface finish of blocks 80 and traditional mortar course 90. In this way, a completed wall constructed with a plurality of mutually interlocking male and female configured segments will have the outward appearance and surface finish of a wall of traditional block and mortar construction. Such a surface finish beneficially provides a suitable key for variable supplementary surface finishes such as external renders, claddings etc. Similarly, the finish of such panels may be tailored to provide specific block or brick- type finishes. For example, a surface having a more refined looking brick-like finish my be applied where the wall segments are intended for 'fair-face' work and which may be intended for painting upon completion. In the embodiments shown, the precast wall segments 10A, 10B and one or more panels of a multi-panel wall segment 100A, 100B in accordance with the invention are formed having embedded remotely readable identification means 32 (Figures la, lb] so that particular segment types and configurations may be assigned a unique identifier for the purposes of ordering, tracking and/or location. In this way, the constituent segments for a building can be defined and delivered to a site and subsequently assembled in their correct location and/or order. Preferably, the remotely readable identification means comprises radio-frequency identification (RFID] tags or other suitable means. It will be understood that the precast wall segments, multi-panel wall segments and infill blocks in accordance with the various aspects and embodiments of the invention are load bearing structural elements. In other words, they are not merely veneers that are applied to the surfaces of existing structural or load bearing walls, but rather they are of a construction having a characteristic thickness and strength such that they are load bearing structural wall elements in the own right and are capable of supporting loads applied directly upon them. Furthermore, as discussed below, the thickness of such precast wall segments and multi-panel wall segments allows the formation of service corridors within the panels, said thickness being variable dependent upon the load bearing strength required.

Preferably, precast all segments, multi-panel wall segments and in-fill blocks in accordance with the various aspects and embodiments of the invention are cast from concrete or a mix comprising concrete. In accordance with the invention, a selection of precast wall segments and multi-panel segments in accordance with the invention can be provided having the necessary shapes, sizes and configurations to produce the walls of a building from a selection of standardized or non-standard segment types. It will thus be apparent to the skilled person that various possible segment types in accordance with the invention can be used to construct walls including walls having openings to accommodate windows, doors etc. In this way, wall segments in accordance with the invention provide an overall building system which can be utilized to construct a multitude of building types and designs. Thus, the present invention also provides a suitably programed computer or suitable software program configured to operate thereon to automatically produce a list of segment types and the assembly plan required to construct a building. The program is configured to deconstruct the plans, outline drawings, 3-D models or other graphical representations of a building design to produce a list of segment types and the assembly plan required to construct said building from a selection of standardized or nonstandard segment types in accordance with the invention, together with any in-fill blocks required. By way of example, Figure 8a shows an exemplary ground floor plan of a building; Figure 8b shows the ground floor plan with a grid overlaid and outer walls designated as walls A, B, C and D; Figure 8c shows a schematic elevation of wall A indicating the selection and arrangement of wall segments types required to construct said wall; Figure 8d shows a schematic elevation of wall C indicating the selection and arrangement of wall segments types required to construct said wall; and Figure 8e shows a schematic elevation of gable walls B and D indicating the selection and arrangement of wall segments types required to construct said gable walls.

In addition, it is envisaged that such a computer or program can identify or specify the need for any 'in-fill' blocks required to fill the otherwise unoccupied spaces between finger portions, for example around openings such as doors or window frames, along the tops of sloping gables, or to accommodate lintels or window sills. Examples of in-fill blocks 150 are shown in Figure 8e. Similarly, the program can identify or specify where lintel blocks or bricks 160 will exist as shown by way of example in Figure 8d.

The formation of the precast load bearing wall panels 10A, 10B 101A, 101B, 102A, 102B will now be described.

Referring to Figures 4a, 5a and 6a, a jig or mould forming part of a jig/mould assembly for casting a wall panel forming part of a precast wall segment is shown. The jig/mould 34,134 comprises a base portion 38,138; and a plurality of upstanding sidewalls 40,140 attachable to said base portion 38,138 and defining a generally rectangular perimeter about said base portion 38,138. The base portion 38,138 comprises an imprint network 42,142 adapted to imprint an impression of blocks or bricks and mortar courses on a surface of a fluid concrete mix 44,144 poured within the jig/mould 34,134. In the embodiment shown, the imprint network 42,142 comprises a plurality of ridges.

It would be understood that the imprint network 42,142 may alternatively comprise a plurality of rebates in order to provide a beaded or extruded effect impression on the surface of the wall panel. The side walls 40,140 comprise depth markings 46,146 thereon. In the embodiment shown, the depth making are positioned at a height of 100mm, 150mm and 215mm above the base portion 38,138 (see Figures 4e and 5e].

The jig/mould assembly 34,134 further comprises a plurality of occluding members 50 adapted to define the extents of the wall segment 10,110 and/or one or more outwardly extending finger portions 14.

The occluding members 50 may be of different heights 50, 50', 50" to correspond to the required depth of concrete mix being poured into the jig/mould 34,134.

The occluding members 50, 50', 50" comprise a recessed portion 52 for mating with the ridges of the imprint network 42,142.

If a straight edge in the wall panel is required, an occluding member 50, 50', 50" may be omitted or added as required to provide the desired shape.

As shown by way of example in Figure 6a, a jig/mould assembly 136 further comprises a stamp adapted to imprint an impression of brick and mortar courses on an opposing surface of a fluid concrete mix 44,144 poured within the jig/mould 34,134. With particular reference to Figures 6a to 6c, the stamp 152 comprises a grid like design corresponding to the imprint network 142 on the base portion 138 of the jig/mould 134.

Depending on the required depth of the wall panel, the length of the outer walls 154, 154', 154" of the stamp 152 is recessed from the length of an adjoining internal divider 156 of the stamp 152. The recess may be 123mm for a 100mm thick wall panel, 58mm for a 150mm thick wall panel and 8mm for a 215mm thick wall panel but other wall thicknesses can be accommodated.

In order to cast a wall segment panel, a user first takes the appropriate jig/mould 34,134 depending on whether a female or male wall panel is required.

One or more occluding members 50 are then arranged within the jig in order to define the extents of the panel of the wall segment and/or one or more outwardly extending finger portions.

The foot portion 22 is placed at the end of the jig/mould corresponding in position to the lower in use end of the wall segment A filler plate 58, 58', 58" is used to adjust the relative height of the foot portion 22 depending on the depth of the require wall panel layer.

The fluid concrete mix is then poured into the jig to the desired fill level corresponding to a desired segment panel thickness.

The remotely readable identification means such as an RFID tag is then embedded within the concrete mix when it is in a fluid or semi-set state.

The outer surface of the concrete mix is then imprinted with the impression of blocks and mortar courses by the stamp when in a fluid or semi-set state. With reference to Figure 7, one or more service corridors 60,66 may be formed in the concrete mix when in a fluid or semi-set state by placing polystyrene strips 62, 64 in the concrete at the desired locations. The service corridors 60, 66 for example allow the placing of lighting switches, switched sockets, wall lights, ducts etc in the wall panel but can accommodate most all other service corridor configurations/requirements. It is noted that the service corridors are formed within the main body portion 12 of the precast segments.

With reference to Figure 9a and 9b, the dimensions of preferred 'male' (Figure 9a] and 'female' (Figure 9b] standard sized wall panel segments are shown. The preferred overall width Wo is approximately 890mm. The preferred overall height H, (excluding the height of foot 22], is approximately 2540mm. The preferred overall with of the central portion Wc is approximately 440mm. The preferred height Hf of a finger portion is approximately 140mm. The preferred variable thicknesses T are 100mm, 150mm and 215mm. The arrangement of the preferred male panel shown in Figure 9a substantially corresponds with exemplary wall segments/panels 10A, 100A 101A, 102A described above. Similarly, the arrangement of the preferred female panel shown in Figure 9b substantially corresponds with exemplary wall segments/panels 10B, 100B 101B, 102B described above.

It will be appreciated that the strength of a wall segment or panel can be tailored to meet imposed design requirements, the strength being varied by changing the concrete mix strength and/or adding supplementary or auxiliary strengthening means such as, but not limited to reinforcing members, or mesh. However, in general, the weight of a standard sized wall panel having the dimensions shown in Figures 9a and 9b and having a thickness T of 100mm and formed from standard strength concrete mix is approximately 200kg.

With respect to the insulating material 16, 116 described in relation to multi-panel wall segments 100A, 100B and shown in Figures 2 and 3, respectively, in a preferred arrangement the insulating panel thickness 77 is in the range 200mm - 300mm however it will be appreciated that any suitable or desired insulating panel thickness may be employed. The terms "block" and "brick" are used throughout the specification, however it will be appreciated that the skilled person would recognise that whilst bricks are specific types of block, these terms are generally synonymous with each other and are thus interchangeable in the present context, the word 'brick' not being limiting.

It will be appreciated that the herein described embodiments of precast wall segments and their methods of manufacture provides variable single walls, composite insulated/ventilated walls having workable size and weights and which offer a greater flexibility of design with recognisable attributes of a traditional build.

Claims

1. A precast load bearing wall segment comprising a main body portion and one or more finger portions extending outwardly from at least one side edge of the main body portion.

2. A precast load bearing wall segment according to claim 1, wherein the one or more finger portions extend from opposing side edges of the main body portion.

3. A precast load bearing wall segment according to claim 1 or claim 2, comprising a plurality of finger portions extending outwardly from at least one side edge of the main body portion, the finger portions on the at least one side edge being mutually spaced apart at regular intervals.

4. A precast load bearing wall segment according to claim 1 or claim 2, comprising a plurality of finger portions extending outwardly from opposing side edges of the main body portion, the finger portions on each respective side being mutually spaced apart at regular spacing.

5. A precast load bearing wall segment according to any one of the preceding claims, having one or more abutment formations integrally formed on the main portion, the formations adapted to abut an adjacent segment in use so that a desired clearance gap between adjacent segments having inter-located finger portions is maintained.

6. A precast load bearing wall segment according to claim 5, wherein the or each abutment formation(s] are of a height such that the clearance gap between adjacent segments is equivalent to a desired or standard mortar course.

7. A precast load bearing wall segment according to any one of the preceding claims, comprising an integrally cast lifting means.

8. A precast load bearing wall segment according to claim 7, wherein the integrally cast lifting means comprises a foot portion which is connectable to a removable top cap via a lifting rod, the foot portion being located at a lower in use end of the segment, and the lifting rod extending from the foot portion through the segment to an upper in use end of the segment where the top cap is removably located in use.

9. A precast load bearing wall segment according to claim 8, wherein the foot portion is of a height that is equivalent to a desired or standard mortar course.

10. A precast load bearing wall segment according to claim 8 or claim 9, wherein the foot portion and lifting, rod and top cap are formed from steel.

11. A precast load bearing wall segment according to any one of claims 8 to 10, wherein the lifting rod is screw-threadedly or twist-lock connectable to the foot portion.

12. A precast load bearing wall segment according to any one of the preceding claims, wherein the precast wall segments are formed as a panel having a single layer, wherein two sides of the panel provide an exterior wall surface in use.

13. A precast load bearing wall segment according to any one of claims 1 to 11, wherein the wall segment is formed as a multi-panel segment having an outer precast layer and an inner precast layer, wherein the outer precast layer provides an exterior wall surface in use and wherein the inner precast layer provides an interior wall surface in use.

14. A precast load bearing wall segment according to claim 13, further comprising one or more intermediate layers of insulating material.

15. A precast load bearing wall segment according to claim 14, wherein at least one intermediate layer of insulating material comprises a plurality of projecting flutes on one surface and a substantially planner opposing, the projecting flutes on providing a ventilated cavity within the wall segment in use.

16. A precast load bearing wall segment according to any preceding claim, comprising an imprint of traditionally laid blocks or bricks on at least one face.

17. A precast load bearing wall segment according to any one of the previous claims, comprising embedded remotely readable identification means.

18. A precast load bearing wall segment according to claim 17, wherein the remotely readable identification means comprises radio frequency identification (RFID] tags or other suitable means.

19. A method of casting a load bearing wall segment panel comprising the steps of:

providing a jig or mould having a base portion and a plurality of upstanding side walls attachable to the base portion, the upstanding side walls defining a generally rectangular perimeter;

arranging one or more occluding members within the jig/mould, the occluding members defining the extents of the wall segment and/or one or more outwardly extending finger portions;

- pouring a fluid concrete mix into the jig to a desired fill level corresponding to a desired segment panel thickness; and

imprinting a surface of the fluid or semi-set concrete mix with the impression of bricks or blocks and mortar courses.

20. A method of casting a load bearing wall segment panel according to claim 19, further comprising one or more of the optional steps of:

locating a foot portion at an end of the jig or mould corresponding to the lower in use end of the wall segment; and/or

inserting a tubular sleeve that is extensible between a foot portion and an opposing end of the jig; and/or

arranging one or more occluding members within the jig, the occluding members defining one or more service corridors to allow the placing of lighting switches, switched sockets, wall lights, ducts etc. in the precast wall panel; and/or embedding a remotely readable identification means such as an RFID tag within the fluid or semi-set concrete mix.

21. A jig or mould for casting a load bearing wall panel forming part of a precast wall segment according to any one of claims 1 to 18, the jig/mould comprising;

a base portion; and a plurality of upstanding sidewalls attachable to said base portion and defining a generally rectangular perimeter about said base portion;

wherein the base portion comprises an imprint network adapted to imprint an impression of blocks or bricks and mortar courses on a surface of a fluid concrete mix poured within the jig or mould.

22. A jig/mould according to claim 21, wherein the imprint network comprises a plurality of ridges.

23. A jig/mould according to claim 22, wherein the plurality of ridges are shaped to provide a desired mortar joint effect.

24. A jig/mould according to claim 21, wherein the imprint network comprises a plurality of rebates.

25. A jig/mould according to claim 24, wherein the plurality of rebates are shaped to provide a desired mortar joint effect.

26. A jig or mould assembly for casting a wall panel forming part of a precast load bearing wall segment comprising a main body portion and one or more finger portions extending outwardly from at least one side of the main body portion, the jig/mould assembly comprising:

a jig/mould according to any one of claims 21 to 25; and

a plurality of occluding members adapted to define the extents of the wall segment and/or one or more outwardly extending finger portions.

27. A jig/mould assembly according to claim 26, further comprising a stamp adapted to imprint an impression of brick and mortar courses on an opposing surface of a fluid concrete mix poured within the jig or mould.

28. A method of automatically producing a list of segment types and associated assembly plan required to construct a building or one or more walls thereof, the method comprising the steps of: deconstructing a plan, outline drawing, 3-D model or other graphical representation of a building design to define one or more external walls; deconstructing the wall plan(s] to define an array of suitable standardized and non-standard segment types required to reproduce said wall(s] together with any in-fill blocks required; and

generating lists and/or assembly drawings indicating the standardized or non-standard segment types and in-fill blocks required to reproduce said wall(s].