Wall and Method of Forming a Wall

Field of the Invention

The present invention relates to a method of forming a wall, and to such a wall. The invention has been developed primarily to overcome the challenges of building in remote locations and will be described hereinafter with reference to this application. However, it will be appreciated that the invention may also be used for conventional urban/rural residential housing, as well as in special purpose applications such as community housing in indigenous communities and mining communities.

Background of the Invention Known steel frame walls typically comprise spaced apart, vertical, C-section studs. Noggins typically extend between the studs to resist buckling. A cladding material, such as a curtain masonry wall or cladding sheets, must be provided around the exterior of the stud wall to provide waterproofing and thermal insulation. The interior of the stud wall is typically clad for aesthetic purposes. Venting of hot air and moisture within the wall is typically provided by an air gap provided between the cladding material and the studs.

A disadvantage of known steel frame walls is that they are relatively time- consuming to erect and clad.

A further disadvantage is that the presence of the noggins inhibits venting of moisture and hot air within the wall.

Object of the Invention

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

Summary of the Invention There is disclosed herein a method of forming a wall, comprising the steps of: providing a plurality of channel members, each member having a longitudinally extending web and two longitudinally extending flanges separated by the web and extending generally perpendicularly from the web so as to be at least partly co-extensive transversely relative to the web; placing the channel members side-by-side;

joining the flange of one of said channel members to a flange of the flange of an adjacent one of channel members, such that the webs of the adjacent channel members create a substantial continuous surface of the wall remote from the flanges.

Preferably, the webs of the adjacent channel members are substantially co- planar.

Preferably, the channel members are longitudinally substantially oriented vertically.

Preferably, the method further comprises connecting said flanges by battens extending transverse relative to said members. Preferably, said battens extend generally perpendicularly to said channel members.

Preferably the method further comprises connecting a lining material to said battens so that the battens are located between the lining and the flanges.

Preferably, the battens are top hat battens. Preferably, the method further comprises providing a first layer of insulation between said channel members and said battens.

Preferably, the method further comprises providing a second layer of insulation between said battens and said lining material.

Preferably, the channel members have a generally C-shaped transverse cross- section.

Preferably, the method further comprises providing a longitudinally elongated lower track members providing a longitudinal groove, and engaging a longitudinal end of each of the channel members in the groove.

Preferably, the method further comprises fixing each one longitudinal end to said track member.

Preferably, the method further comprises providing a longitudinally elongated upper track member having a longitudinal groove, and engaging an opposite longitudinal end of each channel member into the groove of the upper track member.

Preferably, the method further comprises fixing each opposite longitudinal end of said channel members to said upper track member.

Preferably, adjacent flanges of adjacent channel members abut. There is further disclosed herein a wall comprising: a plurality of channel members, each having a longitudinal extending web and two longitudinally extending flanges separated by the web and extending generally

perpendicularly from the web so as to be at least partly co-extensive transverse relative to the web; and wherein the channel members are located side-by-side with a flange of one of the flanges of one of said channel members is joined to a flange of the flanges of an adjacent one of the channel members, such that the webs of the channel members create a substantially continuous surface of the wall remote from the flanges.

Preferably, the webs of the adjacent channel members are substantially co- planar.

Preferably, the channel members are longitudinally substantially oriented vertically.

Preferably, the wall further comprises battens extending connected thereto said flanges and extending transverse relative thereto.

Preferably, said battens extend generally perpendicularly to said channel members. Preferably, the wall further comprises a lining material connected to said battens so that said battens are located between the lining and flanges.

Preferably, the battens are top hat battens.

Preferably, the wall further comprises a first layer of insulation between said channel members and said battens. Preferably, the wall further comprises a second layer of insulation between said battens and said lining material.

Preferably, the channel members have a generally C-shaped transverse cross- section.

Preferably, the wall further comprises a first longitudinally elongated lower track member having a longitudinal groove, wherein a longitudinal end of each channel member is engaged the groove of lower track member.

Preferably, each longitudinal end is fixed to said track member.

Preferably, the wall further comprises a longitudinally extending upper track member having a longitudinal groove, wherein an opposite longitudinal end of each channel members is engaged in the groove of the upper track member.

Preferably, each opposite longitudinal end is fixed to said upper track member.

Brief Description of the Drawings

Preferred embodiments are described hereinafter, by way of examples only, with reference to the accompanying drawings, in which:

Figure 1 is an exploded perspective view of an external wall embodiment; Figure 2 is an assembled perspective view of an external wall embodiment, with the insulating material omitted to allow other components to be seen;

Figure 3 is an exploded perspective view showing connection of the wall of Figure 1 to a roof purlin;

Figure 4 is a upper perspective assembled view of the wall of Figure 1; and Figure 5 is an exploded perspective view of an internal wall embodiment.

Preferred Embodiments of the Invention

Referring to Figures 1 to 4 of the drawings, there is shown an external wall 10 comprising a plurality of vertical channel members 12, in the form of steel C-sections, having a longitudinal axis 12a. Each of the channel members 12 has a web 12b and two flanges 12c extending generally perpendicularly from the same side of the web 12b so as to be co-extensive in a direction normal to the members 12. The channel members 12 are located side-by-side so as to be co-extensive, with their webs 12b being aligned to create a continuous surface of the wall. The adjacent flanges 2c abut. Apertures 12d are provided in the flanges 12c at predetermined intervals to facilitate interconnection of adjacent channel members 12 by mechanical fasteners, in the form of bolts 14a and nuts 14b. The webs 12b are substantially co-planar.

The web 12b is approximately 300mm wide, the flanges 12c approximately 90mm wide, and the return lips 12e approximately 20mm wide. The C-section is formed from 2.4mm thick galvanised high tensile steel. The compressive strength of the channel members 12 is between 490MPa and 550MPa and the tensile strength of the channel members 12 is between 450MPa and 580MPa.

Top hat battens 16 extend across the flanges 12c of the channel members 12 and are connected thereto by fasteners (not shown). The top hat battens 16 are oriented generally perpendicularly to a longitudinal axis 12a of the channel members 12. As shown in Figures 1 and 4, a first layer of insulation 18, in the form of an 8mm closed cell foam structure sandwiched between highly reflective foil surfaces, is provided between the channel members 12 and the top hat battens 16. A second layer of insulation 20, in the form of an 8 mm closed cell foam structure sandwiched between highly reflective foil

surfaces, is provided between the top hat battens 16 and vertical battens 22, which extend generally perpendicularly to the top hat battens 16 and are mechanically fastened thereto. A lining material 24, in the form of fibre cement sheets, is connected to the vertical battens 22, which are on a side of the top hat battens 16 opposite the flanges 12c. The total thickness of the wall, from the exterior surface of the webs 12b to the exposed surface of the lining material 24, is approximately 250mm, including two ventilated and unventilated insulated 90mm air spaces 34 and 36.

One longitudinal (lower) end 12e of the channel members 12 is engaged in a lower track 26a, defined by a groove in a first longitudinal cap member 26, to facilitate alignment of the channel members 12. An opposite (upper) longitudinal end 12f of the channel members 12 is engaged in an upper track 28a, defined by a groove in a second longitudinal cap member 28, to facilitate alignment of the channel members 12. Apertures 26b, 28b are provided in the upper and lower tracks 26, 28 at regular intervals. An upper bracket 30 is provided at the upper end 12f of every third to fifth channel members 12 to facilitate connection of the wall 10 to a roof purlin 32, as shown in Figure 3. Similarly, a lower bracket 34 is provided at the lower end 12e of the channel members 12 to facilitate connection of the wall 10 to a concrete slab or floor joist.

The exterior surface of the webs is pre-coated with a protective and insulating polymer coating, which has proven effective in reducing internal temperatures in numerous large scale industrial applications. The interior surface of the webs is also pre- coated with an insulating coating derived from nano-technology.

As can be seen from Figure 4, the external wall 10 provides dual insulation cavities 34 and 36. The first cavity 34 is provided between the web 12b and the first layer of insulation 22. The second cavity 36 is provided between the first layer of insulation 22 and the second layer of insulation 24. The first cavity 34 is clear of obstructions and facilitates upward ventilation of hot air from within the wall 10, into the associated building's roof cavity (not shown) and out into the atmosphere. The first and second cavities 34, 36 also each provide an insulating air gap, and allow for ease of installing electrical, plumbing and communications lines. Testing of the wall system 10, under AS4859.1:2002/AMDT 1 2006, Clause

K3.1, has shown insulation performance providing a winter total R-value of R3.65 m ² .K/W for an air temperature difference of 18°-12° = 12K and a summer total R-value of R3.16 m ² XfW for an air temperature difference of 36°-24° = 12K. These R-values compare most favourably with benchmarks such as 200mm double brick wall (R0.364 m ² K/W) and brick veneer with 10mm plasterboard (R0.535 m ² K/W).

The wall system was also tested to measure sound reduction performance, in terms of Airborne Sound Insulation. The wall section sample was tested to Australian Standard ASl 191, Acoustics-Method for Laboratory Measurement of Airborne Sound insulation of Building Elements. The weighted sound reduction index R _w for the sample was determined in accordance with AS/NZS-ISO 717.1 Acoustics. The Resultant R _w achieved was 52, and with spectrum adaption terms: Resultant R _w + C _tr 45 k

Figure 4 shows an embodiment of an internal wall 50. The internal wall shares many components in common with the external wall 10 of Figures 1 to 3, where corresponding reference numerals indicate corresponding features with corresponding functions.

It will be appreciated that a building constructed with the illustrated wall 10 is quick and easy to erect, since the wall 10 does not require external cladding for waterproofing or thermal insulation. The wall 10 can also be quickly and easily fixed to the floor slab or joist and to the roof. Also, the walls 10 and 50 can be pre-assembled to further shorten construction times and allow construction by less-skilled construction workers. The wall 10 is also very structurally sound, making it suitable for use in extreme climatic conditions, such as in CAT D cyclonic regions. The channel members 12, and accordingly the walls 10 and 50, are also lightweight, which assists with transportability and provides occupational health and safety advantages for construction workers. Construction of the walls 10 and 50 is a dry process, which does not require concrete or mortar, and, accordingly, construction can continue during inclement weather. The walls 10 and 50 are also waterproof and fire proof, non-corrosive, non-toxic and termite resistant. The walls 10 and 50 also have good durability and are highly resistant to warping, twisting and shrinkage. The walls 10 and 50 can also cater for the installation of doors and windows, as can be seen in Figure 2, without requiring any cutting. The continuous surface provided by the adjoining webs 12b does not require finishing. However, a cement render finish, stone or architectural cladding can be applied, if desired. The modular nature of the walls 10 and 50 also makes them relatively easy to dismantle and re-use. The wall materials and structure also provides for ease of repair and reduces maintenance costs.

Moreover, the provision of the dual cavities 34, 36 advantageously provides high thermal insulation and good acoustic insulation. The provision of the first cavity 34 also advantageously facilitates venting of hot air within the wall 10 into the building's ceiling cavity for external exhaust, which reduces the energy demand of the building for cooling. The walls 10 and 50 also provide high strength, which ensures structural stability of the

building, particularly in areas of extreme climatic conditions, such as cyclone or hurricane prone areas.

Whilst the invention has been described with reference to specific embodiments, it will be appreciated that it may also be embodied in many other forms. For example: • the channel members can be interconnected by alternative means, such as welding, or engagement in the upper and lower tracks 26a, 28a;

• the top hat battens 16 can be replaced by battens of other cross-sectional shapes, such as U-section, C-section or box-section;

• the C-section channel members can be replaced by members of other cross-sectional shapes, such as U-section, box-section or I beam;

• the external wall system total thickness can be reduced from 250mm to allow for various housing agencies requirements, without detriment to the load bearing capacity of the structure and with minimal detriment to thermal and acoustic performance; and/or • windows and door framing and lintels may be modified for ease of fitting, depending on requirements.