Cross-Reference to Related Applications

[0001] The present application claims priority from Australian Provisional Patent

Application No 2015901106 filed on 27 March 2015, the content of which is incorporated herein by reference.

Technical Field

[0002] The present disclosure relates to a system for forming an insulated structural concrete wall. The system has been developed for use in walls in a variety of structures, such as commercial, residential, industrial, institutional and health care buildings, hotels,

condominiums, and a variety of other building types, including basements, retaining walls, acoustic walls and multi storey structures.

Background

[0003] There are several problems in the global building construction industry, such as increasing environmental impact due to growing demand and production of energy, increases in cost of energy consumption, mandatory compliance to new and tougher building energy codes and legislation, increasing impact of climate change and natural disasters, including cyclones, tsunamis and bush fires, all of which are predicted to continue to grow into the future.

[0004] A significant source of energy consumption is in the heating and cooling of buildings and one way to combat the increasing cost and environmental impact of energy production is to make buildings more thermally efficient so that they use energy more efficiently.

[0005] Accordingly, buildings of the future need to be super strong to withstand the vagaries of nature and highly thermally energy efficient, whilst maintaining exceptional occupant comfort.

[0006] Conventional building technologies tend not to be energy efficient and not to comply to increasingly stringent energy codes and legislation. [0007] Super insulation is an approach to building design and construction that dramatically reduces heat loss (and gain) by using much higher levels of insulation and air tightness than is conventional. Super insulation is one of the key elements of the passive house design approach.

[0008] A super insulated building is intended to reduce heating needs very significantly, and may be heated predominantly by intrinsic heat sources (waste heat generated by appliances and body heat of occupants) with only a very small amount of actively generated backup heat being required to maintain occupant comfort. In addition to requiring little or no actively generated heat to moderate the temperature of the building interior, a super insulated building also takes longer to cool in the event of an extended power failure during cold weather, for example after a severe ice storm disrupts electric transmission, because heat loss is much less than normal buildings, without compromising on thermal storage capacity.

[0009] The additional cost of super insulation is offset by a reduction in size and capital cost of heating and cooling systems required for a building, along with drastic reductions in ongoing heating and cooling energy consumption and costs.

[0010] The human body perceives temperature in several ways. Air temperature, air movement, and room surface temperatures all affect how we feel in a space. A super-insulated building shell addresses comfort by limiting the movement of air and increasing room surface temperatures at a given room air temperature. Meticulous efforts to increase insulation and reduce air leakage within the building envelope facilitate occupants feeling much more comfortable within the building and a reduction in energy usage/operating costs.

[0011] Heat losses through external walls account for more than 40% of the total heat losses in buildings. Therefore, improving thermal insulation of external walls is a highly effective way to save energy. In low-energy buildings, the entire building envelope can be super insulated. The building envelope consists of all the building elements that separate the building interior from the exterior environment. A major purpose of superinsulation is to provide a comfortable indoor climate, irrespective of the outdoor climate which is affected by the weather. However, restricting heat flow in any building, irrespective of the climate, can improve its energy efficiency. In summary, quality super insulation can facilitate affordable energy savings. [0012] For the past century, reinforced concrete has been the preferred choice for constructing buildings because of its very high structural strength, which results in solid, strong and durable building structures that are better suited to withstand severe cyclonic weather conditions and have superior ability to withstand bush fires and other natural disasters. However, people often perceive concrete to be a cold unfriendly material, and concrete buildings to be uncomfortable to live in because they get very cold in the winter and very hot in the summer. Accordingly, people perceive concrete buildings to be expensive to heat and cool.

[0013] One way to improve the energy efficiency and comfort levels of a concrete building is to super insulate its concrete walls, which dramatically improves the thermal performance of the building and makes it highly energy efficient by reducing energy consumption required for heating and cooling.

[0014] Passive House standards typically require sufficient insulation to achieve a U- Value of 0.11 W/(m ² K) or an equivalent R- Value of R 9.

[0015] Currently available concrete wall systems are not able to meet the Passive House standards because they are unable to achieve the required insulation thickness. Moreover, poor design of currently available concrete wall systems creates thermal bridges, which disadvantageously allow heat energy to bypass the insulation and pass through the wall, again preventing compliance with Passive House standards. Thermal bridges can also cause condensation, which can lead to mold growth and moisture damage. Elimination of thermal bridges is therefore critical to maintaining building air quality and durability, as well as to achieving the necessary levels of super insulation required for Passive House compliance.

[0016] There are very few modular systems available for forming of super insulated structural concrete walls. Accordingly, builders tend to form super insulated structural concrete walls using conventional poured in place methods with removable formwork, which is subsequently stripped to allow insulation to be installed, or with stay in place insulated concrete form systems commonly known as ICFs. Both these options have severe technical and commercial drawbacks and are very labour intensive and expensive. [0017] In conventional poured-in-place construction with removable formwork, a crew erects spaced apart inner and outer forms of plywood, steel, or aluminum that define a cavity therebetween for receiving wet concrete. After placing rebar in the cavity to reinforce the wall, the crew pours concrete inside the cavity. Once the concrete hardens, the crew strips the forms to leave the reinforced concrete walls. Insulation is then mechanically attached to the walls as a secondary operation by using construction anchors, which is a very time consuming and labour intensive process. The installation of insulation is also prone to defects, such as gaps and thermal bridging, which limit the overall insulation performance of the wall. Some systems use plastic anchors to secure the insulation to the concrete wall, but none of the commercially available plastic anchors are long enough or structurally strong enough to secure insulation of the thickness required to meet Passive House standards. Another disadvantage with conventional systems is that there is no provision for attaching external cladding to the insulation. Accordingly, builders have to install timer batons on the exterior of the insulation and affix the batons using long metal screws extending through the insulation and into the concrete core. These screws act as thermal bridges, which result in the

disadvantages mentioned above.

[0018] Known ICFs are made of foam insulation and, unlike removable forms, are designed to stay in place as a permanent part of the wall assembly. ICFs typically comprise expanded polystyrene foam sheets with a thickness of about 50mm (2 inches). The ICF sheets on each side of the forming cavity are held together by plastic or metal ties and are stacked and interlocked one on top of the other, almost like children's building blocks. The internal and external ICF layers therefore provide a total insulation thickness of only 100mm (4 inches), providing a total R- Value of only R3, which is well below the insulation thickness of 350mm (14 inches) required to provide an R- Value of R9 to meet Passive House standards. The use of metal ties also introduces thermal bridges, which result in the disadvantages mentioned above. Another disadvantage of ICFs is that it is not possible to leave the interior side of the concrete core free of insulation, which can provide enhanced thermal performance in certain

circumstances, and which facilitates installing fiber cement, magnesium oxide, calcium silicate or other dry wall material sheets on the interior side of the concrete core. Another drawback with ICFs is that they use shape moulded expanded polystyrene beads, which have very poor thermal, fire and structural ratings and do not meet the high performance criteria for buildings of the future. The shape moulding process does not allow the use of different types of high performance sheet based insulation materials, such as extruded polystyrene, polyurethane, polyisocyanurate (PIR) or phenolic insulation materials. Another drawback is the presence of a large number of joints, both horizontal and vertical, in the insulation, which result in leakage of air and thermal energy and reduce the overall insulation value of the building, as well as allowing water and moisture ingress. Another drawback is that it is difficult to build corners in any desired angles with ICFs, and builders often have to resort to manual forming to build corners, which is both time consuming and expensive. Another drawback with ICFs is that they are not strong enough for the attachment of heavy weight external cladding such as bricks, stone, fiber cement or similar heavy weight materials, and do not have any structural system which can transfer the weight of the heavy exterior cladding to the concrete core without forming a thermal bridge. Some known ICFs have plastic webs for the attachment of external cladding using screws. However, the webs do not have enough screw pull out resistance to handle negative wind pressure in high winds and cyclone conditions, and the screws also loosen over time, which leads to sagging of the external cladding. Another drawback with known ICFs is that they are not suitable for extended fire rating situations and cannot be used in egress paths or other high risk areas of buildings. Another problem with known ICFs is water seeping through exterior stucco or render finishes and remaining embedded in the external insulation layer for extended periods of time, causing long term condensation and mould growth problems. Another drawback with many known ICFs is that they require external covering and finishing on site, which is very labour intensive and expensive. Another drawback with many known ICFs is that the internal and external insulation layers are installed prior to the installation of steel reinforcement for the concrete core, which makes it virtually impossible to tie the vertical reinforcement to the starter bars, which can seriously compromise the structural integrity of the wall, and to check and inspect the reinforcement prior to pouring the concrete core. Another drawback with known ICFs is that concrete footings for the wall need to be manually formed, which in not only very labour intensive and expensive but also makes it very difficult to level the wall with the footings. Moreover, providing adequate structural connection between known ICF walls and their footings can be very difficult and time consuming.

[0019] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application. Summary

[0020] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0021] In a first aspect, there is provided a frame member for interconnecting an outer insulation layer and an inner layer in an insulated structural concrete wall in which the outer and inner layers and the frame member extend substantially the full height of the wall, said frame member comprising:

an elongate outer member defining a longitudinal axis and adapted to have the outer insulation layer connected thereto;

an elongate inner member substantially parallel to the outer member and adapted to have the inner layer connected thereto;

a plurality of tie members each having a first end for connection to the inner member and a second end for connection to the outer member, the tie members extending in a transverse direction between the outer and inner members at longitudinally spaced apart locations to interlock the outer and inner members together in a spaced apart, substantially parallel relationship, wherein at least one opening is defined between the tie members and the outer and inner members, the at least one opening being sized to permit flow therethrough of uncured concrete poured between the outer and inner layers to form a concrete core;

at least one outer anchor associated with the outer member for securing the outer layer relative to the outer member;

at least one inner anchor associated with the inner member for securing the inner layer relative to the inner member substantially parallel to the outer layer;

wherein the at least one outer anchor is configured to facilitate connection of outer thermally insulating layers of various thicknesses, including thicknesses of at least 300mm (12 inches), to the outer member to permit tailoring of insulation performance to site requirements.

[0022] The at least one outer anchor may be adjustable in the transverse direction to facilitate the connection of outer thermally insulating layers of various thicknesses. The at least one outer anchor may comprise a longitudinally extending outer flange that is connectable to the outer member and that defines an anchor surface extending substantially perpendicular to a plane defined by the tie members for engaging the outer layer. Projections may extend from the outer flange to space the flange from the outer layer to facilitate air circulating between the outer layer and the outer flange. The outer flange may comprise a structural spine, which may be formed from metal, and a thermally insulative capping, which may be formed from a plastics material, extending over the spine. Alternatively, the at least one outer anchor may comprise a plurality of longitudinally spaced apart anchor heads that are connectable to the outer member and that each define an anchor surface extending substantially perpendicular to a plane defined by the tie members for engaging the outer layer. The anchor heads may comprise a textured outer surface to facilitate the application of exterior finishes, such as render or stucco, on the outer layer. A plurality of longitudinally spaced apart connectors, such as pins or bolts, oriented in the transverse direction may connect the outer flange or anchor heads to the outer member. The connectors may be adjustable in the transverse direction, for example by being threadedly connected relative to the tie members. The connectors may be thermally insulative and may, for example, comprise a structural core, which may be formed from metal, and a thermally insulative sheath, which may be formed from a plastics material. A plurality of longitudinally spaced apart brick ties may be connectable to the outer anchor to facilitate the attachment of exterior brick cladding over the outer layer.

[0023] In another embodiment, the at least one outer anchor may comprise a longitudinally extending outer flange that is fixed relative to the tie members and that defines an anchor surface extending substantially perpendicularly to a plane defined by the tie members and spaced at a predetermined distance in the transverse direction from the second ends thereof for engaging the outer layer. The outer member may comprise a longitudinally extending web extending between the second ends of the tie members and the outer flange of the outer anchor. The web may have a plurality of openings therethrough.

[0024] The outer member may comprise a longitudinally extending inner flange located at the second end of the tie members and oriented substantially perpendicular to a plane defined by the tie members for engaging an inner surface of the outer insulation layer. [0025] A pin may be engageable in openings in the web of the outer member to facilitate securing a noggin to the web and/or to define a slot between the pin and the inner flange and/or the outer anchor.

[0026] The at least one inner anchor may configured in any one of the ways disclosed above with respect to the at least one outer anchor to facilitate connection of inner layers of various thicknesses to the inner member. Alternatively, the at least one inner anchor may comprise a longitudinally extending flange that is fixed relative to the tie members and that defines an anchor surface extending substantially perpendicularly to a plane defined by the tie members and spaced at a predetermined distance in the transverse direction from the first ends thereof for engaging an inner layer with a thickness less than that of the outer layer. The inner member may comprise a longitudinally extending web extending between the first ends of the tie members and the outer flange of the inner anchor. The web may have a plurality of openings therethrough.

[0027] The inner member may comprise a longitudinally extending inner flange located at the first end of the tie members and oriented substantially perpendicular to a plane defined by the tie members for engaging an inner surface of the inner layer.

[0028] A pin may be engageable in an openings in the web of the inner member to facilitate securing a noggin to the web and/or to define a slot between the pin and the inner flange and/or the inner anchor.

[0029] The tie members may comprise at least one locating formation for locating reinforcement for the concrete core. A plurality of the locating formations may be provided. The locating formations may be provided on both longitudinal sides of the tie members. Clips may be provided for securing the reinforcement in the locating formations. The clips may be formed as an integral part of the tie members and may snap-lockingly secure the

reinforcement. The tie members may be removably connected to the inner and/or outer member. For example, the tie members may snap-lockingly engage the inner and outer members.

[0030] The frame member may be formed from a plurality of frame member modules connected together longitudinally. Coupling formations may be provided at longitudinal ends of the frame member modules to facilitate their interconnection. The coupling formations may provide for snap locking engagement between modules. The coupling formations may lock when properly engaged to prevent manual disconnection without a special tool, such as a screwdriver. The coupling formations may be configured to facilitate visual confirmation of proper coupling between modules.

[0031] In a second aspect, there is provided a frame member for interconnecting an outer insulation layer and an inner layer in an insulated structural concrete wall in which the outer and inner layers and the frame member extend substantially the full height of the wall, said frame member comprising:

an elongate outer member defining a longitudinal axis and adapted to have the outer insulation layer connected thereto;

an elongate inner member substantially parallel to the outer member and adapted to have the inner layer connected thereto;

a plurality of tie members each having a first end for connection to the inner member and a second end for connection to the outer member, the tie members extending in a transverse direction between the outer and inner members at longitudinally spaced apart locations to interlock the outer and inner members together in a spaced apart, substantially parallel relationship, wherein at least one opening is defined between the tie members and the outer and inner members, the at least one opening being sized to permit flow therethrough of uncured concrete poured between the outer and inner layers to form a concrete core;

at least one outer anchor associated with the outer member for securing the outer layer relative to the outer member;

at least one inner anchor associated with the inner member for securing the inner layer relative to the inner member substantially parallel to the outer layer;

wherein the at least one outer anchor is adjustable in the transverse direction to facilitate the connection of outer thermally insulating layers of various thicknesses to the outer member to permit tailoring of insulation performance to site requirements.

[0032] The frame member of the second aspect may further comprise any of the other features defined above with respect to the first aspect, apart from the feature of the at least one outer anchor comprising a longitudinally extending outer flange that is fixed relative to the tie members and that defines an anchor surface extending substantially perpendicularly to a plane defined by the tie members and spaced at a predetermined distance in the transverse direction from the second ends thereof for engaging the outer layer.

[0033] In a third aspect, there is provided a system for constructing an insulated concrete structure, the system comprising:

an outer layer;

an inner layer spaced apart from and substantially parallel to the outer layer; and a plurality of spaced apart frame members as defined in the first or second aspect above extending between the outer layer and the inner layer to interlock the outer and inner layers together and maintain a space therebetween for receiving uncured concrete to form a concrete core of a wall of the structure in which the outer layer, the inner layer and the frame members extend substantially the full height of the wall.

[0034] Cross ties may extend between the spaced apart frame members to secure the frame members together. At least some of the cross ties may be provided at different longitudinal positions to others of the cross ties. If the cross ties do not extend along a length of the wall, a plurality of partially overlapping cross ties may in combination extend along the full length of the wall. The cross ties may engage the tie members of the frame members. The cross ties may be substantially parallel with the inner and outer layers and may be provided at both the first and the second ends of the tie members. The cross ties may take the form of a comb or rack.

[0035] The outer layer may be a thermally insulating layer formed from a plurality of sheets that together extend along the full length of the wall. The outer layer may have a thickness of at least 300mm (12 inches). The outer layer may comprise two or more layers of thermally insulating sheets. Joins between the sheets in each of the two or more layers may be staggered to inhibit air and heat energy leakage through the wall. Pre drilled holes may extend through the two or more sheets to facilitate installation of a said connector therethrough for connecting a transversely adjustable outer anchor to the outer member to secure the sheets to the inner member. Drainage channels may be provided in the outer layer to facilitate drainage of moisture that may penetrate into the outer layer.

[0036] An elongate corner securing member may be connected to an end of the outer layer of the wall to facilitate its secure connection to the end of the outer layer of an adjoining wall to form a corner therebetween. The corner securing member may comprise an outer corner securing element having a pair of elongate elements oriented relative to each other at a desired angle of the corner. The pair of elongate elements may be hingedly connected to one another to accommodate a range of desired corner angles. In some embodiments, at least one bracket may be connected to an inner side of one of the pair of elongate elements for engaging the end of the outer layer of the wall and at least one bracket may be connected to an inner side of the other of the pair of elongate elements for engaging the end of the outer layer of the adjoining wall. In other embodiments, the corner securing member may comprise an inner corner securing element spaced inwardly of the outer corner securing element, the inner corner securing element comprising pair of elongate elements oriented relative to each other at a desired angle of the corner, wherein the ends of the outer layers of the wall and an adjoining wall are is securable in the space between the inner and outer corner securing elements. The pair of elongate elements of the inner corner securing element may be hingedly connected to one another to accommodate a range of desired corner angles. The spacing between the inner and outer corner securing elements may be adjustable to facilitate securing corners in outer layers of various thicknesses. The cross ties of the adjoining walls may engage the corner securing member. The corner securing member may be formed from a plurality of corner securing member modules connected together longitudinally. Coupling formations may be provided at longitudinal ends of the corner securing member modules to facilitate their interconnection. The coupling formations may provide for snap locking engagement between modules. The coupling formations may lock when properly engaged to prevent manual disconnection without a special tool, such as a screwdriver. The coupling formations may be configured to facilitate visual confirmation of proper coupling between modules.

[0037] The inner layer may be an insulating layer for moderating transmission of heat energy from the concrete core.

[0038] A footing member may be connectable to a longitudinal end of the frame member to facilitate forming a concrete footing for the wall and to facilitate integrating the wall and footing, said footing member comprising:

an elongate outer member that extends parallel to the longitudinal axis when the footing member is connected to the frame member, the outer member of the footing member adapted to have an outer layer connected thereto; an elongate inner member substantially parallel to the outer member and adapted to have an inner layer connected thereto;

a plurality of tie members each having a first end for connection to the inner member and a second end for connection to the outer member, the tie members extending in a transverse direction between the outer and inner members at longitudinally spaced apart locations to interlock the outer and inner members together in a spaced apart, substantially parallel relationship, wherein at least one opening is defined between the tie members and the outer and inner members, the at least one opening being sized to permit flow therethrough of uncured concrete poured between the outer and inner layers to form a concrete core of the footing;

at least one outer anchor associated with the outer member for securing the outer layer relative to the outer member; and

at least one inner anchor associated with the inner member for securing the inner layer relative to the inner member substantially parallel to the outer layer.

[0039] The tie members of the footing member may comprise at least one locating formation for locating reinforcement for the concrete core of the footing. A plurality of the locating formations may be provided. The locating formations may be provided on both longitudinal sides of the tie members. Clips may be provided for securing the reinforcement in the locating formations. The clips may be formed as an integral part of the tie members and may snap- lockingly secure the reinforcement. The tie members may be removably connected to the inner and/or outer member of the footing member. For example, the tie members may snap- lockingly engage the inner and outer members.

[0040] One or more coupling formations may be provided at a longitudinal end of the footing member to facilitate its interconnection with the frame member. The coupling formations may provide for snap locking engagement between the footing member and the frame member. The coupling formations may lock when properly engaged to prevent manual disconnection without a special tool, such as a screwdriver. The coupling formations may be configured to facilitate visual confirmation of proper coupling. The footing member may comprise a plurality of spaced apart coupling formations to engage with a plurality of corresponding coupling formations of the frame member. The footing member may comprise more coupling formations than the frame member to facilitate the frame member being connected to the footing member at a desired position on the footing member. [0041] The footing member may be formed from a plurality of footing member modules connected together longitudinally. Coupling formations may be provided at longitudinal ends of the footing member modules to facilitate their interconnection. The coupling formations may provide for snap locking engagement between footing member modules. The coupling formations may lock when properly engaged to prevent manual disconnection of the footing member modules without a special tool, such as a screwdriver. The coupling formations may be configured to facilitate visual confirmation of proper coupling between footing member modules.

[0042] Cross ties and/or corner securing members similar to those disclosed above with respect to the frame member, may also be used with the footing member.

[0043] In a fourth aspect, there is provided a system for constructing a concrete structure, the system comprising:

at least four interconnected wall frames for at least four respective walls, each of the wall frames extending substantially the full height of the respective wall and comprising:

a plurality of frame members spaced apart along the length of the respective wall, each of the frame members comprising:

an elongate outer member defining a longitudinal axis and adapted to have an outer layer connected thereto;

an elongate inner member substantially parallel to the outer member and adapted to have an inner layer connected thereto;

a plurality of tie members each having a first end for connection to the inner member and a second end for connection to the outer member, the tie members extending in a transverse direction between the outer and inner members at longitudinally spaced apart locations to interlock the outer and inner members together in a spaced apart, substantially parallel relationship, wherein at least one opening is defined between the tie members and the outer and inner members, the at least one opening being sized to permit flow therethrough of uncured concrete poured between the outer and inner layers to form a concrete core;

at least one outer anchor associated with the outer member for securing the outer layer relative to the outer member;

at least one inner anchor associated with the inner member for securing the inner layer relative to the inner member substantially parallel to the outer layer; cross ties extending between the spaced apart frame members to secure the frame members together;

at least one corner securing member connecting the ends of adjoining said walls of the structure to form a corner therebetween and resist relative movement between the walls when the concrete core is poured.

[0044] Each wall may comprise an outer layer connected to the outer members of the frame members of that wall. Each wall may comprise an inner layer connected to the inner members of the frame members of that wall.

[0045] The frame members of at least one of the wall frames may be frame members as defined in the first or second aspect above. The frame members of at least one of the wall frames may be frame members having a fixed outer anchor. The frame members of at least one of the wall frames may be frame members having an adjustable outer anchor to configure the at least one wall frame for use with outer layers of different thicknesses.

[0046] The system may further comprise any of the other features defined above with respect to the first, second and third aspects.

Brief Description of Drawings

[0047] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of an embodiment of a system for forming a modular super insulated concrete structure;

Figure 2 is a perspective view of the system of Figure 1, with the outer and interior insulation modules removed to show how the various system components can be mixed and matched and assembled together;

Figure 3 is a perspective view of a fixed frame member module of the system of Figure 1 for receiving a single thicker outer insulating layer and a single thinner inner insulating layer;

Figure 3 a is an enlarged perspective view of part of the frame member module of

Figure 3; Figure 3b is an enlarged perspective view of reinforcement clips of the frame member module of Figure 3;

Figure 3c is an enlarged perspective view of an interface between the inner member and the tie member of the frame member module of Figure 3;

Figure 3d-3g are enlarged perspective views showing how coupling formations on longitudinal ends of the frame member module of Figure 3 can be used to connect several frame member modules together to form a longer frame member;

Figure 4 is a perspective view of a single variable frame member module of the system of Figure 1 for receiving multiple layers of outer insulation defining a thicker outer insulating layer along with a single thinner inner insulating layer;

Figure 4a is an enlarged perspective view of part of the frame member module of Figure 4, shown with its baton module and adjusting bolt removed;

Figure 5 is a perspective view of a double variable frame member module of the system of Figure 1 for receiving multiple layers of outer and inner insulation defining thicker outer and inner insulating layers;

Figure 5a is an enlarged perspective view of part of the frame member module of Figure 5, shown with its baton module and adjusting bolt removed;

Figure 6 is a perspective view of a fixed corner securing module for use in walls of the system of Figure 1 comprising the fixed frame member modules of Figure 3;

Figure 6a is an enlarged perspective view of the corner securing module of Figure 6;

Figure 7 is a perspective view of a variable corner securing module for use in walls of the system of Figure 1 comprising the variable frame member modules of Figures 4 and 5;

Figure 8 is a perspective view of a lateral cross tie for interconnecting the frame member modules is each of the walls of the system of Figure 1 ;

Figure 9 is an enlarged partial perspective view of the lateral cross tie snap-lockingly engaged with a tie member of the fixed frame member module of Figure 3;

Figure 10 is a perspective view of an insulated composite bolt for the single and double variable frame member modules of Figures 4 and 5;

Figure 11 is sectional view of the composite bolt of Figure 10;

Figure 12 is a perspective front view of an insulated composite baton for the single and double variable frame member modules of Figures 4 and 5;

Figure 13 is a perspective rear view of the composite baton of Figure 12; Figure 14 is an enlarged perspective view of coupling formations of the thermally insulative capping of the composite baton of Figure 12 for joining several lengths of the capping together to facilitate forming a longer baton;

Figure 15 is a perspective front view of a render washer for use on a wall of the system of Figure 1 to which stucco or a render based exterior finish is to be applied;

Figure 15a is a perspective rear view of the render washer of Figure 15;

Figure 16 is a perspective view of a brick tie module for use on a wall of the system of Figure 1 to which heavy exterior brick cladding is to be applied;

Figure 17 is a perspective view of a thick single layer insulation module primarily for use with fixed frame member module of Figure 3;

Figure 18 is a perspective view of a thin single layer inner insulation module primarily for use with the fixed frame member module of Figure 3;

Figure 19 is a perspective view of a thick outer insulation render module primarily for use with the fixed frame member module of Figure 3 on a wall of the system of Figure 1 to which a stucco or render based exterior finish is to be applied;

Figure 20 is a perspective view of an extra thick multiple layer insulation module for use with the single or double variable frame member modules of Figure 4 and 5;

Figure 21 is a perspective view of an extruded dry wall module for use with the fixed frame member module of Figure 3 or the single variable frame member module of Figure 4;

Figure 22 is a perspective view of a removable form plate module for use with the fixed frame member module of Figure 3 or the single variable frame member module of Figure 4;

Figure 23 is a perspective view of a form clip for positively engaging and holding the form plate module of Figure 22;

Figure 24 is a perspective view of a form wedge for positively engaging and holding the form plate module of Figure 22;

Figure 25 is a perspective view of several fixed frame member modules of Figure 3, a fixed corner module of Figure 6 and lateral cross ties of Figure 8 assembled together to create a modular wall frame assembly ready for the installation of the desired outer and inner layers;

Figure 26 is a perspective view of the modular wall frame assembly of Figure 25 with an outer layer of insulation render modules of Figure 19 and an inner layer of thin insulation modules of Figure 18; Figure 27 is a perspective view of the modular wall frame assembly of Figure 25 with a single outer layer of the thick insulation modules of Figure 17 and an inner layer of the removable form plate modules of Figure 22 held in place by the form clip modules of Figure 23 and the form wedges of Figure 24;

Figure 28 is a perspective view of several single variable frame member modules of Figure 4, a variable corner module of Figure 7 and lateral cross ties of Figure 8 assembled together to create a modular wall frame assembly ready for the installation of the desired outer and inner layers;

Figure 29 is an interior perspective view of the modular wall frame assembly of Figure 28 with an outer layer of insulation modules of Figure 20 and an inner layer of the extruded dry wall modules of Figure 21;

Figure 30 is an exterior perspective view of the assembly of Figure 29, also showing baton modules of Figure 12, render washer modules of Figure 15 and brick tie modules of Figure 16, for attaching various exterior finishes, such as external cladding, external siding, render and stucco based external finishes, or heavy external brick cladding;

Figure 31 is a perspective view of several double variable frame member modules of Figure 5 supporting an outer layer of the thick insulation modules of Figure 20;

Figure 32 is a perspective view of a footing module for the creation of super insulated structural concrete walls with integral structural concrete footings;

Figure 33 is a perspective view of the footing stud module of Figure 32 shown connected to a frame member formed from two of the fixed frame member modules of Figure 3;

Figure 34 is a perspective view of an alternative embodiment of an insulated composite bolt for the single and double variable frame member modules of Figures 4 and 5;

Figure 35 is a perspective front view of an alternative embodiment of an insulated composite baton for the single and double variable frame member modules of Figures 4 and 5;

Figure 36 is a perspective view of an alternative embodiment of a single variable frame member module of the system of Figure 1 for receiving multiple layers of outer insulation defining a thicker outer insulating layer along with a single thinner inner insulating layer; and

Figures 37a-37d are perspective views of an alternative embodiment of a fixed frame member module of the system of Figure 1 for receiving a single thicker outer insulating layer and a single thinner inner insulating layer. Description of Embodiments

[0048] Referring to the drawings, and initially to Figures 1 and 2, there is shown a perspective view of a system 100 for forming a modular super insulated concrete structure comprising walls formed using different embodiments of frame members according to the present disclosure. Walls 100a- lOOd comprise either "fixed" frame member modules

30,"single variable" frame member modules 30' or "double variable" frame member modules 30", depending on the desired insulation performance of the wall, as will be discussed in more detail below. Lateral cross ties 40 extend between the frame member modules 30, 30', 30" of each wall to secure the frame member modules together. The corners between walls lOOa-lOOd are secured by either "fixed" corner securing modules 33 or "variable" corner securing modules 33'. The system 100 also includes insulated composite bolts 41, insulated baton modules 42, render washers 43, brick ties 44, thick single layer insulation modules 20, thin single layer insulation modules 21, thick insulation render modules 22, extra thick multilayer insulation modules 23, extruded drywall modules 25, removable form plate modules 27, removable form clips 46, removable form wedges 47 and footing modules 30" '. The various components of the system 100 can be mixed and matched to create a tailored insulated structural concrete structure.

[0049] Accordingly, the presently disclosed system 100 gives architects, engineers, builders and owners the freedom to mix and match components to construct a super insulated thermal mass concrete structure that best suits their design and site climatic conditions and increases the energy efficiency of the structure at an economical cost.

[0050] As shown in Figures 1, 2, 25 and 26, wall 100a comprises a thicker outer layer comprising insulation render modules 22 and a thinner inner layer comprising insulation modules 21 which are spaced apart from each other, interlocked and maintained substantially parallel by a plurality of laterally spaced apart fixed frame member modules 30. The frame member modules 30 are secured together by lateral cross ties 40, which are provided at various longitudinal positions in the wall 100a. If individual cross ties 40 do not extend the full length of the wall 100a, a plurality of partially cross ties 40 are overlapped and in combination extend along the full length of the wall. Uncured concrete is poured into the space 15 between the outer 22 and inner layers 21 to form a concrete core. [0051] As shown in Figures 1, 2, 25 and 27, wall 100b comprises a thicker outer layer comprising insulation modules 20 and an inner layer comprising removable form plate modules 27 which are spaced apart from each other, interlocked and maintained substantially parallel by a plurality of laterally spaced apart fixed frame member modules 30. The frame member modules 30 are secured together by lateral cross ties 40, which are provided at various longitudinal positions in the wall 100b. If individual cross ties 40 do not extend the full length of the wall 100b, a plurality of partially cross ties 40 are overlapped and in combination extend along the full length of the wall. As shown in Figure 27, removable form clips 46 and removable form wedges 47 secure the form plate modules 27 to the frame member modules 30. Uncured concrete is poured into the space 15 between the outer 20 and inner 27 layers to create a concrete core.

[0052] As shown in Figures 1, 2 and 28-30, wall 100c comprises a thicker outer layer comprising multi layer insulation modules 23 and an inner layer comprising extruded drywall modules 25 which are spaced apart from each other, interlocked and maintained substantially parallel by a plurality of laterally spaced apart single variable frame members modules 30' . The frame member modules 30' are secured together by lateral cross ties 40, which are provided at various longitudinal positions in the wall 100c. If individual cross ties 40 do not extend the full length of the wall 100c, a plurality of partially cross ties 40 are overlapped and in combination extend along the full length of the wall. Uncured concrete is poured into a space 15 between the outer 23 and inner 25 layers to form a concrete core.

[0053] As shown in Figures 1, 2 and 31, wall lOOd comprises a thicker outer layer and a thicker inner layer, both comprising multi layer insulation modules 23, which are spaced apart from each other, interlocked and maintained substantially parallel by a plurality of laterally spaced apart double variable frame member modules 30" . The frame member modules 30" are secured together by lateral cross ties 40, which are provided at various longitudinal positions in the wall lOOd. If individual cross ties 40 do not extend the full length of the wall lOOd, a plurality of partially cross ties 40 are overlapped and in combination extend along the full length of the wall. Uncured concrete is poured into a space 15 between the outer and inner layers 23 to form a concrete core.

[0054] As shown in Figures 1 and 2, corners between walls 100a and 100b, and walls 100a and lOOd are secured with fixed corner securing modules 33, and corners between walls 100b and 100c, and walls 100c and lOOd are secured with variable corner securing modules 33'. Features of the corner securing modules 33, 33' will be discussed in more detail below.

[0055] Figure 3 shows fixed frame member modules 30 used in walls 100a and 100b. The frame member modules 30 comprise an elongate outer member 30a defining a longitudinal axis A and an elongate inner member 30b extending substantially parallel to the outer member 30a. A plurality of tie members 30c extend transversely between the outer and inner members 30a, 30b at longitudinally spaced apart locations to interlock the outer and inner members together in a spaced apart, substantially parallel relationship. Each of the tie members 30c has a first end for connection to the inner member 30b and a second end for connection to the outer member 30b. Openings 50 are defined between the tie members 30c and the outer and inner members 30a, 30b, the openings being sized to permit flow therethrough of uncured concrete poured between the outer and inner layers of walls 100a, 100b.

[0056] The outer and inner members 30a, 30b each comprise spaced apart outer 30al, 30b 1 and inner 30a3, 30b3 flanges interconnected by a web 30a2, 30b2. The length of the web 30a2 of the outer member 30a matches the thickness of insulation modules 20 and corresponds to a depth of the slots 22al in insulation render modules 22. The length of the web 30b2 of the inner member 30b matches the thickness of insulation modules 21. Large longitudinally oriented rectangular apertures 30a5, 30b5 and small transversely oriented rectangular apertures 30a6, 30b6 are provided in the webs 30a2, 30b2 at longitudinally spaced apart locations. A plurality of oval shaped stepped hubs 30a7, 30b7 extend inwardly from the flanges 30a3, 30b3 and are engageable by the associated end of the tie members 30c. The hubs 30a7, 30b7 also serve as engagement points for lateral cross ties 40 which extend between and interconnect the laterally spaced apart frame member modules 30 in walls 100a, 100b. The step in the hubs 30a7, 30b7 prevents the lateral cross ties 40 from sliding off the hubs onto the tie members 30c. Strengthening ribs 30a28, 30b28 are provided to strengthen the joints between tie members 30c and flanges 30a3, 30b3.A plurality of small circular holes 30a8, 30b8 are also provided in the webs 30a2, 30b2 to receive thermally insulated nails, screws or pins for engaging the ends of insulation modules 20 or insulation modules 22 secured to the outer member 30a or insulation modules 21 secured to the inner member 30b, respectively. The outer and inner members 30a, 30b are also provided with marking lines 30al 1, 30b 11 at regular intervals of 25mm (1 inch) to facilitate easy and accurate trimming of the outer and inner members to a desired length. [0057] Coupling formations, in the form of bottom 30a9, 30b9, 30a26, 30b26 and top 30al0, 30b 10 connectors, are formed on opposite longitudinal ends of the outer flanges 30al, 30b 1 and webs 30a2, 30b2 to facilitate several frame member modules 30 being joined together to form a unitary frame member with a desired height. Whilst the features and functionality of the top and bottom connectors 30a9, 30b9, 30al0, 30b 10, 30a26, 30b26 will be described with reference to Figures 3d-3g, which show only the connectors 30b9, 30b 10, 30b26 associated with the inner member 30b, it is to be understood that the connectors 30a9, 30al0, 30a26 associated with the outer member 30a have corresponding features with corresponding functionality.

[0058] Bottom connector 30b9 has an outer flexible tab 30b 11 and an inner flexible tab 30b 12 that engage on either side of the web 30b2 of an adjoining frame member module 30. Lateral slots 30bl3 and 30bl4 are provided in tabs 30bl l and 30bl2, respectively. Chamfered lips 30bl5 and 30bl6 are provided on tabs 30bl l, 30bl2, respectively, to facilitate the engagement of a small flat head screwdriver under the tabs 30b 11, 30b 12 for disengaging the top and bottom connectors 30b9, 30bl0. Top connector 30bl0 has an outer fixed tab 30bl8 and an inner fixed tab 30b 19 corresponding to and engageable by the inner and outer tabs 30bl2, 30bl l of the bottom connector 30b9. Lateral locking ribs 30b20 and 30b21 are provided on tabs 30b 18 and 30b 19, respectively, to snap-lockingly engage the slots 30b 13 and 30bl4 of tabs 30bl l and 30bl2. Tabs 30bl8 and 30bl9 are provided with chamfered outer edges 30b22 and 30b23, respectively, to facilitate the engagement of a small flat head screwdriver between tabs 30bl 1 and 30bl9 and between tabs 30bl2 and 30bl8 for

disengaging connectors 30b9, 30b 10. A notch 30b24 is provided on an inner side of flange 30b 1 adjacent tab 30b 18 to facilitate engagement of a small flat head screwdriver with the chamfered lip 30bl6 of tab 30bl2 for disengaging connectors 30b9, 30bl0. A similar notch 30b25 is provided on an outer side of flange 30bl adjacent tab 30bl9 to facilitate engagement of a small flat head screwdriver with the chamfered lip 30b 15 of tab 30b 11 for disengaging connectors 30b9, 30b 10.

[0059] Bottom connector 30b26 comprises a pair of laterally offset projections 30b 27 that extend longitudinally from the bottom end of the web 30b2 to engage with recesses 30b29 on either side of the top end of the web 30b2 of an adjoining frame member module 30. [0060] As shown in Figures 3d-3g, connectors 30b9, 30b 10 of adjoining frame member modules 30 are engaged by aligning bottom connectors 30b9, 30b26 with top connector 30b 10 and the upper end of web 30b2, respectively, and pressing the adjoining modules 30 together longitudinally. This causes tabs 30b 11 and 30b 12 of the bottom connector 30b9 to flex and slots 30bl3, 30bl4 to snap-lock over ribs 30b21, 30b22 of the top connector 30bl0, and causes projections 30b27 of bottom connector 30b26 to engage with recesses 30b29 on either side of the web 30b2, thereby to securely connect the frame member modules 30 together. As shown in Figures 3f and 3g, interlocking of slots 30b 13, 30b 14 with ribs 30b21, 30b22 is visible to the human eye to allow visually confirmation of proper joining of the frame member modules 30 prior to installation. Snap-locking of slots 30bl3, 30bl4 with ribs 30b21, 30b22 is also audible to the human ear to provide audible confirmation of proper joining of the frame member modules 30 prior to installation. It will be appreciated that the connectors 30a9, 30b9, 30al0, 30b 10, 30a26, 30b26 provide a strong and secure locking system restraining relative movement between adjoining frame member modules 30 in all three axes.

[0061] Referring to Figures 3-3c, the tie members 30c comprise webs 30cl with a plurality of U-shaped reinforcement snap clips 30c2 formed therein for securely positioning and supporting horizontally oriented steel reinforcement for the concrete core poured in the space 15 between the inner and outer layers of walls lOOa-lOOd. In other embodiments, the clips 30c2 may be of different shapes and/or sizes and/or may be provided at different longitudinal positions to facilitate a tailored arrangement of the steel reinforcement. In the illustrated embodiment, the clips 30c2 are provided on both top and bottom sides of the webs 30c 1 to facilitate reversibility of a frame member formed from the frame member modules 30 and/or to allow steel reinforcement to be supported on the top of the webs 30c 1 and/or slung from underneath. The webs 30c 1 are also be provided with a plurality of small circular holes 30c6, which serve as convenient attachment point for wires, clips, ties and similar fasteners for temporary securing of building accessories such as window and door bucks, lintels, wall anchors and the like. As shown in Figure 3b, the clips 30c2 comprise pairs of spaced apart, substantially parallel thin and flexible fingers 30c3 defining slot 30c4 with a profiled base therebetween. The fingers 30c3 terminate in gripping formations 30c5 for captively engaging the steel reinforcement in the slots 30c4. [0062] In wall 100a, the T-shaped slots 22a 1 of insulation render modules 22 are slidably engaged with the outer flanges 30al, as shown in Figures 1 and 26, such that the outer flanges 30al act as anchors for retaining the insulation render modules 22. In wall 100b, the insulation modules 20 are slidably engaged between the outer 30al and inner 30a3 flanges, as shown in Figures 1 and 27, such that the outer flanges 30al act as anchors for retaining the insulation modules 20.

[0063] In wall 100b, removable form plate modules 27 are installed between the inner 30b3 and outer 30b 1 flanges of the inner member 30b for the formation of walls with bare concrete on the inner side, as shown in Figures 1 and 27. The form plate modules 27 are anchored against the inner flanges 30b3 by removable form clips 46 and removable form wedges 47. As such, the inner flanges 30b3 act as anchors for retaining the form plate modules 27. Opposite ends of the form clips 46 are engaged in the apertures 30b5 of adjacent frame member modules 30, with clips defined between prongs 46b snap-lockingly engaging webs 30b2 of adjoining frame member modules 30 to cross brace the form plate modules 27 to prevent the form plate modules bulging due to the weight of uncured concrete poured in the space 15 . Tapered pins 47a of the form wedges 47 are engaged with the apertures 30b6, such that the heads 47b of the form wedges positively engage and hold lateral sides of the form plate modules 27 in a secure and tight position against the inner flanges 30b3. Similar apertures 30a5 and 30a6 are also provided in the web 30a2 to facilitate installing form plate modules 27 instead of insulation modules on the outer side of the wall. It will be appreciated that the removable form plate modules 27, form clips 46 and form wedges 47 are not intended to permanently stay in place and only act as a temporary formwork for the forming and pouring of the concrete core. After the concrete core has cured, the form plate modules 27 can easily be removed by removing the form clips 46 and form wedges 47. If desired, parts of the frame member modules 30 extending from concrete core can be trimmed to provide a bare concrete wall with a smooth finish. However, in some embodiments, the form plate modules 27 may be made from mineral based materials, such as fiber cement, magnesium oxide, calcium silicate, or similar, and may be left in place to form a built in services cavity with moderated thermal mass effect.

[0064] Outer flanges 30al, 30bl of the frame member module 30 are also slidably engageable in T-shaped slots 25a of extruded drywall modules 25 in a similar manner as shown in Figures 1 and 29 with respect to frame member module 30', such that the outer flanges 30al, 30bl act as anchors for retaining the extruded drywall modules 25.

[0065] Figures 4 and 4a show a single variable frame member module 30' used in wall 100c. Frame member module 30' has many features in common with frame member 30, where corresponding reference numerals indicate corresponding features with corresponding functionality. In frame member module 30', however, the outer flange 30al and web 30a2 are replaced by an outer flange in the form of insulated baton module 42 and adjustable insulated bolts 41. Adjustment of the bolts allows a space between in inner flange 30a3 and the baton module 42 to be increased to receive a thick multi layer insulation module 23 therein. A plurality of apertures 30al2 are provided in the inner flange 30a3 at positions aligning with the tie members 30c. Apertures 30al2 are formed by superimposing a pair of horizontal tapered slots 30al3 and 30al4, which negates the requirement for sliding cores on an injection moulding machine used to form the frame member modules 30'. The bolts 41 extend through the apertures 30al2 and threadedly engage female threaded half tie nuts 30c8 formed on alternate sides of the tie members 30c. The alternating arrangement of half tie nuts 30c8 again negates the requirement for sliding cores on the injection moulding machine. Tightening of the bolts 41 anchors insulation modules 23 between flange 30a3 and baton module 42. In alternative embodiments, as shown in Figures 28-30, the baton module may be replaced by a plurality of longitudinally spaced apart anchor heads, in the form of render washers 43 or brick tie modules 44, each of which is secured against the outside of insulation modules 23 by an insulated bolt 41.

[0066] Figure 5 and 5a show a double variable frame member module 30" used in wall lOOd. Frame member module 30" has many features in common with frame member 30', where corresponding reference numerals indicate corresponding features with corresponding functionality. In frame member module 30", however, along with the outer flange 30al and web 30a2, the outer flange 30b 1 and web 30b2 are also replaced by an outer flange in the form of insulated baton module 42 and adjustable insulated bolts 41, and a plurality of apertures 30bl2, formed by tapered slots 30bl3, 30bl4, are also provided in the inner flange 30b3 at positions aligning with the tie members 30c. Accordingly, thick multi layer insulation modules 23 can be installed on both sides of frame member module 30". [0067] Frame member modules 30, 30', 30" may be moulded or fabricated from a light weight but strong and inexpensive plastics material, such as recycled polypropylene, polyethylene, polystyrene, abs, or similar.

[0068] Figures 6 and 6a show a fixed corner securing module 33 for securing corners between walls 100a and 100b, and walls 100a and lOOd. The corner securing module 33 comprises a pair of elongate and substantially parallel outer flanges 33a and 33b. Flanges 33a, 33b are hingedly connected by a continuous integral hinge 33c having an axis perpendicular to the longitudinal axis of the flanges. The hinge 33c is adapted to flex to adopt a desired corner angle. A plurality of longitudinally spaced apart C-shaped brackets 33al and 33bl are connected to the flanges 33 a, 33b and define channels 33a2 and 33b2 for securely engaging an end of insulation modules 20 or insulation render modules 22, as shown in Figure 1. The longitudinal spacing between brackets 33al, 33b 1 matches the longitudinal spacing between the tie members 30c of the frame member modules 30, 30', 30" . The brackets 33al, 33bl can also engage insulation modules 23 if an appropriately positioned longitudinal slot is formed in the end of insulation modules 23, as shown in Figure 1. Returning to Figures 6 and 6a, hubs 33a3 and 33b3 extend from brackets 33al and 33b 1 for snap-locking engagement by lateral cross ties 40 to align and secure the corner modules 33 to the associated frame member modules 30, 30', 30" . Coupling formations, in the form of bottom connectors 33a4, 33b4 and top connectors 33a5, 33b5, are provided at opposite longitudinal ends of the flanges 33a and 33b to facilitate joining several modules 33 together to provide a unitary corner member with a desired height. Bottom connectors 33a4, 33b4 comprise flexible tabs 33a6, 33b6 having lateral ribs 33a7, 33b7 thereon. Top connectors 33a5, 33b5 comprise recesses 33a8, 33b8 complementary to and engageable by the tabs 33a6, 33b6, such that lateral slots or cutouts 33a9, 33b9 in the recesses 33a8, 33b8 are snap-lockingly engageable by the lateral ribs 33a7, 33b7. The flat face top connectors 33a4, 33b4 are inserted into the recessed flanges 33a8, 33b8 of the bottom connectors 33a5, 33b5 which causes the flexible webs 33a6, 33b6 and the angled protrusions 33a7, 33b7 to flex and lock into the horizontal engagement slots 33a9, 33b9 to mechanically join the fixed corner modules 33.

[0069] Figure 7 shows a variable corner securing module 33' for securing corners between walls 100b and 100c, and walls 100c and lOOd. Corner securing module 33' has a number of features in common with corner securing module 33, where corresponding reference numerals indicate corresponding features with corresponding functionality. In variable corner securing module 33', however, brackets 33al, 33bl are replaced by a pair of elongate and substantially parallel inner flanges 33d and 33e, which are spaced apart from and extend parallel to outer flanges 33a, 33b. Flanges 33d, 33e are hingedly connected by a continuous integral hinge 33f having an axis perpendicular to the longitudinal axis of the flanges 33d and 33e. The hinge 33f is adapted to flex to adopt a desired corner angle. Groups of laterally spaced apart apertures 33alO and 33b 10 are provided in the outer flanges 33a, 33b at longitudinally spaced apart positions. Corresponding laterally extending slots 33dl and 33el are provided in the inner flanges 33d and 33e. The longitudinal spacing between the groups of apertures 33alO and 33blO and corresponding slots 33dl and 33el matches the longitudinal spacing between the tie members 30c of the frame member modules 30, 30', 30" . The outer flanges 33a, 33b and inner flanges 33d, 33e are bolted together using insulated bolts 41 that can be installed through the apertures 33al0 and 33bl0 and slots 33dl and 33el and secured by an insulated nut 47. The nut 47 can be adjusted to securely engage the end of an insulation module 23, as shown in Figure 1. The nuts 47 may be configured for snap-locking engagement by lateral cross ties 40 to align and secure the corner modules 33' to the associated frame member modules 30, 30', 30" .

[0070] Corner securing modules 33, 33' may be moulded, extruded or fabricated from a light weight but strong and inexpensive plastics material, such as recycled polypropylene, polyethylene, polystyrene, abs, or similar.

[0071] A spine, comprising a high strength thin sheet steel reinforcement channel 33g, 33h, may be secured to the outer flanges 33 a, 33b for additional structural and screw pull out strength, along with enhanced fire resistance in extended fire rating situations. Longitudinal ribs 33i, 33j on the outer flanges 33a, 33b space the spine from the insulation module 23 to inhibit conduction of heat to the insulation module 23 and concrete core, and to allow air flow and moisture drainage between the outer flange and insulation module 23 to inhibit condensation and mould growth.

[0072] Figure 8 is a perspective view of a lateral cross tie 40 used to interconnect frame member modules 30, 30', 30". The lateral cross tie 40 comprises an elongate spine 40a with a plurality of regularly spaced apart prongs 40b extending therefrom. Clips are defined between the prongs 40b. The clips are alignable and snap-lockingly engageable with hubs 30a7, 30b7 of frame member modules 30, 30' and hubs 33a3, 33b3 of corner stud modules 33. A plurality of apertures 40c may be provided in the spine 40a for receiving screw fasteners to further increase the rigidity of the system 100 if required. Figure 9 is a perspective close up view of cross tie 40 snap-locked with hub 30a7 of frame member module 30. Cross tie 40 may be moulded or fabricated from a light weight but strong and inexpensive plastics material, such as recycled polypropylene, polyethylene, polystyrene, abs, or similar.

[0073] Figures 10 and 11 show an insulated threaded bolt 41 used with frame member modules 30', 30" to secure baton modules 42, render washers 43, brick tie modules 44 and/or corner securing modules 33', such as shown in walls 100c and lOOd in Figure 1. The insulated bolt 41 comprises a threaded shaft with a structural core 41a formed from high strength steel and a thermally insulative sheath 41b of plastics material formed around the core 41a. The sheath may be formed from a thermally insulative high performance composite material, such as a fibre glass reinforced plastics material or an oriented fibre glass polyester material. In other embodiments, the whole bolt 41 may be moulded or fabricated from a thermally insulative high performance composite material, such as a fibre glass reinforced plastics material or an oriented fibre glass polyester material. The shaft is engageable with the nuts 30c8, 47 of frame member modules 30', 30" and corner securing module 33' respectively. A circular head 41c is provided at one end of the bolt shaft. In some embodiments, the circular head 41c may take the form of a removable nut threadedly engaged with the bolt shaft.

[0074] Figures 12-14 show an insulated baton module 42 used with frame member modules 30', 30" and insulation modules 23, such as shown in walls 100c and lOOd in Figure 1. The baton module 42 comprises a thermally insulative elongate flange 42a with a plurality of spaced apart circular recesses 42b therein that are sized to match the heads 41c of insulated bolts 41. A plurality of projections 42c extend from opposite sides of the flange 42a to assist in thermally isolating the baton module 42 from the insulation module 23. Openings 42h are also defined between the projections 42c to facilitate the circulation of air to between insulation module 23 and the baton module 42 to inhibit the formation of mould. Marking lines 42f are provided at regular intervals on an outer side of the flange 42a to facilitate easy and accurate trimming of the baton module 42 to a desired length. The baton module 42 includes bottom 42gl and top 42g2 connectors to facilitate connection of several baton modules 42 to form an integrated baton of a desired length. The bottom and top connectors have the same configuration as connectors 33a4, 33a5 of corner modules 33. The baton module 42 may be moulded, extruded or fabricated from a thermally insulative high performance composite material, such as a fibre glass reinforced plastics material or a wood reinforced plastics material. Alternatively, as best seen in Figure 13, the flange 42a and projections 42c may be moulded, extruded or fabricated from a thermally insulative material and reinforced by a structural spine, in the form of a high strength thin sheet steel or fibreglass reinforcement channel 42d that extends the length of the flange and is secured between the projections 42c. The spine 42d has apertures 42e therein that align with the recesses 42b. In some embodiments, the circular recesses 42b may be in the shape of a key hole with built in retaining clips to facilitate easy site assembly and removal of the insulated baton module 42.

[0075] Figure 15 and 15a show a render washer 43 for use with frame members 30', 30" and insulation modules 23, such as shown in wall 100c of Figure 1. The render washer module 43 comprises a thermally insulated flat washer 43a with a circular recess 43b in its outer surface having a rim that is sized to be engaged by the head 41c of insulated bolt 41. The render washer modules 43 and is provided with a tapered or "feathered" peripheral rim 43c, a textured outer surface 43d, and a plurality of circular and conical recesses or openings 43e to facilitate the adhesion of stucco or render based exterior finishes on insulation modules 23 anchored with the render washer modules 43. The inner surface of render washer module 43 comprises a tapered circular hub 43f and a plurality of radial flanges 43g that penetrate the insulation module 23to facilitate level and flush engagement of the render washer module 43 with the insulation module 23. The render washer module 43 may be moulded from a general purpose plastics material. In some embodiments, the circular recesses 43b may be in the shape of a key hole with built in retaining clips to facilitate easy site assembly and removal of the render washer 43.

[0076] Figure 16 shows a brick tie module 44 for use with frame members 30', 30" and insulation modules 23, such as shown in wall 100c in Figure 1, to secure exterior brick cladding to the wall. The brick tie module 44 comprises a thermally insulative flat washer 44a with a circular recess 44b in its outer surface having a rim that is sized to be engaged by the head 41c of insulated bolt 41. Spaced apart mounts 44c are provided on the washer 44a. A galvanized high tensile bent steel wire hook 44e is engageable with the mounts 44c and extends substantially perpendicular to a plane defined by the washer 44a. The hook 44e is adapted to be embedded in mortar between horizontal layers of the exterior brick cladding and provides enough flexibility for the expansion and contraction of the brick work. The brick tie module 44 may be moulded from a thermally insulative high performance composite material, such as a fibre glass reinforced plastics material or a fibre glass reinforced polyester. In some embodiments, the circular recesses 44b may be in the shape of a key hole with built in retaining clips to facilitate easy site assembly and removal of the brick tie module 44.

[0077] Figure 17 shows a thick outer insulation module 20 for slidably engaging between the outer and inner flanges 30al, 30a3 of laterally spaced apart frame members 30. Insulation module 20 comprises a plain rectangular sheet of rigid insulation 20a having a thickness of at least 100mm (4 inches).

[0078] Figure 18 shows a thin inner insulation module 21 for slidably engaging between the outer and inner flanges 31al, 31a3 of laterally spaced apart frame members 30. Insulation module 21 comprises a plain rectangular sheet of rigid insulation 21a having a thickness of at least 50mm (2 inches).

[0079] Figure 19 shows a thick outer insulation render module 22. Module 22 comprises a plain rectangular sheet of rigid insulation 22a having a thickness of at least 150mm (6 inches). The insulation 22a has slots 22al therein for slidably receiving flanges 30al of frame members 30, such that the flanges 30al do not interfere with the application of stucco and render based exterior finishes. Vertical slots 22a2 are also formed in the insulation 22a and act as drainage channels for the drainage of water or condensate, which may seep through the stucco or render based exterior finishes, to inhibit condensation and mould growth.

[0080] Figure 20 shows a multiple layer insulation module 23 for use with the single or double variable frame members 31, 32. Insulation module 23 comprises several layers of plain rectangular sheets of rigid insulation 23a providing a total insulation thickness of from

100mm to 300mm (4 to 12 inches) or more. The insulation layers 23a are laterally offset from each other to inhibit air flow through module 23. The sheets 23 a are pre-drilled with a regular pattern of holes 23b for receiving insulated bolts 41 used with frame member 30' and 30".

[0081] The insulation in modules 20, 21, 22 and 23 may be any very high r-value rigid sheet based insulation, such as expanded polystyrene, extruded polystyrene, polyisocyanurate (PIR), polyurethane, phenolic, aerogel or any other type of rigid insulation. [0082] The present inventor has found that a U- Value of 0.11 W/(m ² K) or an equivalent R- Value of R 9 can be achieved using a thickness of external building insulation as shown in the table below, consisting only of the material specified:

Insulation Thermal Conductivity Insulation Thickness

Material (W/mK) mm required for

U=0.11W/(m ² K)

EPS Expanded 0.039 W/mK 350mm (14 Inches) Polystyrene

XPS Extruded 0.033 W/mK 300mm (12 Inches) Polystyrene

Polyisocyanurate 0.022 W/mK 200mm (8 Inches) (PIR)

[0083] Figure 21 shows an extruded drywall module 25 for use with frame member modules 30, 30' . Module 25 includes T-slots 25a for slidably receiving the outer flanges 30al, 30bl of frame members 30, 30'. T-slots 25a also act as drainage channels for the drainage of water or condensate that may otherwise cause condensation and mould growth. Module 25 may be formed from mineral based dry wall materials, such as fiber cement, magnesium oxide, calcium silicate, or similar, which are extruded or fabricated to form a twin layer drywall sheet 25a. Extruded drywall modules 25 and insulation modules 20 may be installed as a composite inner or outer layer on frame member modules 30, 30' by inserting insulation modules 20 between flanges 30aland 30a3, and/or between flanges 30bl and 30b3 and slidably engaging extruded drywall modules 25 with flanges 30al and/or 30b 1, such that extruded drywall modules 25 protect insulation modules 20 and also act as an exterior cladding. The extruded drywall modules 25 may also be provided with built-in extruded ducts 25b that can act as a services cavity to facilitate installation of cables and pipes for electrical, communication, plumbing and gas services.

[0084] Figure 22 shows a removable form plate module 27 in the form of a grid plate panel for use with frame member modules 30, 30' to act as a temporary formwork for uncured concrete. Module 27 comprises a matrix of square ribs 27a to further enhance its strength and rigidity. Module 27 may be moulded from a light weight but strong and inexpensive plastics material, such as recycled polypropylene or polyethylene. Alternatively the form plate module 27 may be made from mineral based materials, such as fiber cement, magnesium oxide, calcium silicate, or similar, and may be left in place to form a built-in services cavity with moderated thermal mass effect.

[0085] Figure 23 shows a removable form clip 46 for use with the removable form plate module 27. The form clip comprises an elongate spine 46a. Opposite ends of form clip 46 are sized to fit into rectangular apertures 30a5, 30b5 in the webs 30a2, 30b2 of frame member modules 30, 30' . The form clip 46 takes the form of a comb or rack, having a plurality of regularly spaced prongs 46b extending from the spine 46a and defining clips therebetween. Teeth 46c are formed on the clips. The outermost of the clips are snap-lockingly engageable with webs 30a2, 30b2 of frame member modules 30, 30' when the ends of the form clip 46 are inserted into the rectangular apertures 30a5, 30b5 of the frame member modules. The form clip 46 may be moulded from a light weight but strong and flexible plastics material, such as recycled polypropylene or polyethylene.

[0086] Figure 24 shows a removable form wedge 47 for use with the removable form plate module 27, such as shown in wall 100b in Figures 1 and 27. Form wedge 47 comprises a spaced apart pair of tapered pins 47a, which are interconnected by a head 47b. The pins 47a can be aligned with and hammered into the apertures 30a6, 30b6 in the webs 30a2, 30b2 of frame member modules 30, 30' to anchor the removable form plate module 27 against the inner flanges 30a3, 30b3. Form wedges 47 may be moulded from a light weight but strong plastics material, such as recycled polypropylene or polyethylene.

[0087] Figure 32 shows a footing member module 30" ' engageable with frame member modules 30, 30', 30" to facilitate forming an integrated footing and wall frame assembly as shown in Figure 33. Footing module 30" ' is similar in concept to frame member module 30, where corresponding reference numerals indicate corresponding features with corresponding functionality. Footing module 30" ' is about one third the height and about three times the width of frame member modules 30, 30', 30". Footing module 30"' includes a plurality of pairs of top and bottom connectors 30a9, 30al0, 30b9, 30b 10, each of which pairs is selectively snap-lockingly engageable with the top and bottom connectors of the frame member module 30, 30', 30", to allow adjustment of the position of the frame member modules 30, 30', 30" on the footing module 30" '. Footing module 30" ' is adapted to receive an outer layer of insulation modules 21 and an inner layer of insulation modules 21, which act as built-in footing edge insulation to create a super insulated concrete footing to inhibit migration of heat from a structure's foundations and also to inhibit frost rise.

[0088] Figure 34 shows an alternative embodiment of an insulated threaded bolt 41 ' that can be used instead of insulated threaded bolt 41 of Figure 10. Like bolt 41, bolt 41 ' comprises a threaded shaft with a structural core formed from high strength steel and a thermally insulative sheath 41b of plastics material formed around the core. Bolt 41 ', however, has flexible serrated "threads" 41d that allow bolt 41 ' to be push-fitted in place using a hammer, thereby saving on assembly time. The bolt 41 ' also has an integral circular head with built-in twin recesses 41e for engaging twin T-slots 42i of the extruded baton module 42' of Figure 35.

[0089] Figure 35 shows an alternative embodiment of an insulated baton module 42' that can be used instead of insulated baton module 42 of Figure 12. Baton module 42' has built-in extruded twin T-slots 42i which engage with the twin recesses 41e on the head 41e of the insulated threaded bolt 41 ' of Figure 34. The baton module 42' may be extruded from a thermally insulative high performance composite material, such as a fibre glass reinforced plastics material or a wood reinforced plastics material and may also be provided with additional side T-slots 42j for engaging small clips and ties which may be used in

construction. In some embodiments, the baton module 42' may additionally be reinforced with a structural spine in the form of a high strength thin sheet steel or fibreglass

reinforcement channel.

[0090] Figure 36 is a perspective view of an alternative embodiment of a single variable frame member module 30"" for use in the system of Figure 1. Frame member module 30"" has many features in common with the single variable stud module 30' of Figure 4, where corresponding reference numerals indicate corresponding features with corresponding functionality. In frame member module 30" ", however, the insulated threaded bolt 41 is replaced by the threaded bolt 41 ' of Figure 34 and the insulated baton module 42 is replaced by the insulated baton module 42' of Figure 35. The single variable frame member module 30"" also has an additional small T-flange 30bl2 that projects from the outer flange 30bl and that can be used for engaging thin drywall sheets and inner linings. [0091] Figures 37a-37d show an alternative embodiment of a fixed frame member module 30 for use in the system of Figure 1. Frame member module 30 has many features in common with the single variable stud module 30 of Figures 3 and 3g, where corresponding reference numerals indicate corresponding features with corresponding functionality. In frame member module 30 , however, the coupling formations 30a9, 30b9, 30a26, 30b26, 30al0, 30b 10 are replaced with coupling formations 30a9 ^* , 30b9 ^* , 30a26 ^* , 30b26 ^* , 30al0 ^* , 30b 10 ^* , 30a27 ^* , 30b27 ^* . Coupling formations 30a9 ^* , 30b9 ^* , 30al0 ^* , 30b 10 ^* are relatively similar to coupling formations 30a9, 30b9, 30al0, 30b 10, apart from being shorter, tongue and groove engagement being provided between coupling formations 30b9 and 30b 10 , and between coupling formations 30a9 and 30al0 , and the lateral locking ribs 30b20 and 30b21 and slots 30bl3 and 30bl4 being omitted. Instead, interconnection between adjoining modules is provided primarily by coupling formations 30a26 , 30b26 , 30a27 , 30b27 , which are substantially identical to coupling formations 33a4, 33b4, 33a5, 33b5 of the corner securing modules 33, and operate in the same manner. Also, in frame member module 30*, the web 30c 1 of the tie members 30c is provided with a strengthening rib 30c50*. It will be appreciated that interconnection by coupling formations 30a26 , 30b26 , 30a27 , 30b27 facilitates relatively simple assembly and disassembly of the frame member modules 30 by hand, without the need for tools. Also, moulding of the frame members 30 is simplified due to the coupling formations 30a26 , 30b26 , 30a27 , 30b27 being located in the line of opening of the mould for the frame members. Whilst not illustrated, it will be appreciated that coupling formations 30a9, 30b9, 30al0, 30bl0, 30b26 of modules 30', 30", 30"' can also be substituted with the respective coupling formation 30a9 ^* , 30b9 ^* , 30al0 ^* , 30b 10 ^* , 30a26 ^* , 30b26 ^* .

[0092] It will be appreciated that when a plurality of wall frames, each formed from frame member modules 30, 30', 30", 30" " or 30 interconnected by cross ties 40, are connected with corner securing modules 33, 33' as shown in Figure 2, a self-reinforcing and self- standing interlocked grid frame assembly 200 is defined. When inner and outer layers are installed in each of the wall frames, as shown in Figure 1, stability is even further enhanced. Accordingly, the need for stabilisation using external stays or props during pouring of a concrete core in space 15, as is common in prior art systems, is eliminated or at least greatly reduced. [0093] It will also be appreciated that the single and double variable frame member modules 30', 30", 30"' facilitate the use of different thicknesses and/or types of insulation on the outside and inside of the concrete core, which facilitates optimisation of the solar passive design of a building based on the solar orientation of individual walls and the external climate. Examples of such optimisation are discussed below.

[0094] In wall 100a, a majority of the total insulation thickness is shifted to the outside of the wall, due to the combination of thicker insulation module 20 on the outside with thinner insulation module 21 on the inside, to reduce heat energy transmission to the concrete core of the wall from the exterior environment. The provision of the thinner insulation module 21 moderate transfer of heat from the concrete core to the interior of the structure. This configuration may be used on walls with good solar orientation (e.g. southern walls in the Northern Hemisphere and northern walls in the Southern Hemisphere) in extreme climates.

[0095] In wall 100b, the total insulation thickness is provided on the outside of the wall to reduce heat energy transmission to the concrete core of the wall from the exterior

environment. This configuration may be used on walls with good solar orientation (e.g.

southern walls in the Northern Hemisphere and northern walls in the Southern Hemisphere) in non-extreme climates, or on walls with poor (e.g. northern walls in the Northern Hemisphere and southern walls in the Southern Hemisphere) or moderate (e.g. eastern or westers walls) solar orientation in more extreme climates, where moderation of transfer of heat from the concrete core to the interior of the structure is not required.

[0096] In wall 100c, a dual external insulation layer is provided on the outside of the wall, with no insulation layer provided on the inside, to reduce heat energy transmission to the concrete core of the wall from the exterior environment. This configuration may be used on walls with good solar orientation (e.g. southern walls in the Northern Hemisphere and northern walls in the Southern Hemisphere) in more extreme climates, or on other walls in highly extreme climates, where moderation of transfer of heat from the concrete core to the interior of the structure is not required.

[0097] In wall lOOd, dual insulation layers are provided on both the outside and inside of the wall, to reduce heat energy transmission to the concrete core of the wall from the exterior environment and moderate the transfer of heat from the concrete core to the interior of the structure. This configuration may be used in highly extreme climates.

[0098] It will be appreciated that the present system 100 facilitates construction of a composite structure that takes advantage of the exceptional structural strength and thermal mass of concrete and the heat insulating effect of thermal insulation to provide a structure that is both structurally strong and exceptionally energy efficient. The system 100 also simplifies construction and reduces construction costs by using the insulation layers as formwork for the concrete core and reducing the need for props or stays to support the walls during curing of the concrete core by interconnecting the various components of the system 100. The components of the system 100 have also been designed for economical manufacture.

[0099] The elimination of thermal bridging by use of insulated bolts 41, 41 ', insulated baton modules 42, 42', insulated render washers 43 and insulated brick ties 44, along with a reduction in gaps in the outer and inner layers formed by insulation modules 20-23, which provides added protection from rain and wind, facilitates an increase in the overall r-value of a structure and increases the thermal mass capacity of the concrete core by better isolating it from extremes in exterior temperature and other weather conditions.

[0100] The embodiments of super insulated structural concrete walls disclosed above with reference to the drawings have a number of advantages as follows:

Strength: The reinforced concrete core provides great structural strength and impact resistance against cyclones, high winds and other natural disasters, ensuring building occupants are safe and secure in almost any situation.

Energy Efficiency: The continuous outer and inner layers of insulation virtually eliminate air gaps, which greatly reduces air infiltration into a building. The thermally insulative bolts 41, 41 ', baton modules 42, 42', render washers 43 and brick ties 44 prevent thermal bridging. Accordingly, presently illustrated system 100 facilitates providing high r-value super insulation to a building. The excellent insulation design, combined with the thermal mass properties of the concrete core, facilitate thermal energy being stored in the concrete core and released to the building interior, moderated by an inner insulation layer if necessary, to optimise the energy performance of the building by regulating the temperature of the building interior and thereby greatly reducing energy usage costs that may otherwise be required for heating or cooling. The energy efficiency benefits of insulated thermal mass concrete wall systems are discussed in more detail in the Applicant's earlier International Patent Publication No. WO 2011/134008, the disclosure of which is incorporated herein by reference.

Ability to Mix and Match: The ability to mix and match various components of the system 100 gives architects, engineers, builders and owners the freedom to construct a super insulated thermal mass concrete structure that best suits their design and site climatic conditions, and facilitates providing the structure with an excellent energy efficiency at an economical cost. For example, the system 100 facilitates the use of different thicknesses and/or types of insulation on the outside and inside of the concrete core, which facilitates optimisation of the solar passive design of a building based on the solar orientation of individual walls and the external climate.

Fire Resistance: The steel reinforced concrete core is non combustible, providing very high fire resistance and improving safety for building occupants. The materials used in insulation modules 20-23 are non toxic and have fire retardant properties.

Acoustic Performance: The reinforced concrete core, along with the layers of super insulation, together act as an effective sound barrier and filter out unwanted noise, dampen sound vibrations from unwanted outside noise, thereby improving occupant comfort.

Ease of construction: The modular design of the presently disclosed system facilitates economical manufacture and erection on site. Ease of construction is also facilitated by reducing or eliminating the need for stays or props to stabilise the wall during pouring and curing of the concrete core.

[0101] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.