IMPROVED MODULAR WALL CONSTRUCTION FIELD OF THE INVENTION

The invention relates to the modular construction of walls in the building industry. It is particularly suitable for use within the housing industry. The improved construction is suitable for use in relation to both load-bearing and non load-bearing walls. BACKGROUND TO THE INVENTION

The use of prefabricated panels to form structural walls of buildings such as houses, shops, schools, factories, fences and the like has several advantages over other construction methods. Principally, these advantages are gained by moving labour intensive fabrication work away from a building site into an efficient factory environment. This greatly reduces the time required to be spent by builders on the site.

Traditionally, to make such a system cost effective, the panels are fabricated in large sizes and are consequently extremely heavy. Machinery such as cranes is required both in the factory and on site to move, handle, place and erect the panels. Secondary processes of connection and alignment further add to the cost of construction.

Using such panels, a high degree of direct supervision and/or a highly skilled work force is required to efficiently and safely construct a wall of acceptable quality and standard.

A construction method addressing these issues is described in the International Patent Application PCT/AU98/00652, the contents of which are hereby incorporated herein by reference. The method proposes a modular construction system which is fast and economical for construction of single and multi-story structures. The method reduces the dependency on skilled labour, cranes, scaffolding, and elaborate construction tools and fasteners during the construction of both load bearing and non load bearing walls.

Specifically, the system proposes a method for constructing a wall from discrete modules. In a preferred form, the modules are of three types: T-shaped first modulesTT-shaped second modules and L-shaped end modules. The wall is constructed firstly by aligning a desired number of first modules between two end modules, such that the flanges of each module combine to form a substantially

continuous outer surface. The webs of successive first modules are connected by steel tie rods. This structure, including one face of the wall, is then able to support a second face of the wall. In its preferred form the tie rods provide a frame on which second modules can be hung, with the flanges of the second modules forming a second substantially continuous outer surface opposed to the first outer surface. The spaces in between webs of the first and second modules provide a cavity wall space in which pipes, electrical conduits and other building services can be provided.

In practice, it has been found that the structural behaviour of a wall constructed from these modules is influenced by many aspects of the wall design. These include the shape and configuration of the modules, particularly the cross- sectional shape of the first modules, the manner in which they are connected together to form a supporting structure for the second modules, and the type of connection means used to connect the first modules together. These factors have substantial influence on the distribution of forces in the wall, for example in the tie rods, on the ultimate strength capacity, and on the cost of the wall. In particular, the response of the wall to different lateral wind loading conditions varies greatly as the wall design factors are varied.

Some difficulties have arisen when using T-shaped modules to build a wall, as described in the above mentioned patent application, for use in cyclone- prone areas. When subjected to powerful winds, lateral forces acting perpendicular to the plane of wall and racking forces acting on top of the wall along the plane of the same wall induce substantial bending in the tie rod connection means connecting the first modules together. The forces also result in high localized stresses in the first and end modules at the connection point. As a result, high localised stresses can be created in the webs of modules adjacent the connection point. These stresses can be sufficiently high to cause failure of the web.

In practice, the possibility of high racking forces in cyclone-prone areas has necessitated the use of larger, more rigid tie rods. This adds significantly to the cost of the construction, and also creates a variable which complicates the supply of panels in modular form. Even when using larger rods, the resistance to bending of the rods still provides a limit to the strength of the modular wall.

The present invention seeks to improve on the building construction of PCT/AU98/00652, by providing a structure which is more readily resistant to high strength winds.

SUMMARY OF THE INVENTION In accordance with a first aspect of the invention there is provided a method of construction of a wall from a plurality of primary modules and at least one secondary module, each primary module having an outer face portion and two side portions, each secondary module having an outer face portion and at least one mounting portion, the method including the steps of: aligning at least two primary modules together such that their outer face portions both form part of a first face of the wall, with a first side portion of a first primary module abutting a second side portion of a second primary module; connecting the first side portion of the first primary module to the second side portion of the second primary module such that the first and second primary modules are constrained to move together; and mounting a secondary module onto the wall such that the outer face portion of the secondary module forms at least part of a second face of the wall, wherein the at least one mounting portion of the secondary module engages with a primary module to restrain movement in at least one direction of the secondary module.

It will be seen that the connected primary modules, including the first face of the wall, provide a support structure for the secondary modules and the second face of the wall. The connected primary modules are thus the principal load bearing elements. Advantageously, the transmission of forces between adjoining primary modules is carried by a connection means connecting abutting side portions. Racking forces applied to a wall are transmitted through this connection means primarily as shear forces, rather than inducing bending as in the prior art.

In one form of the invention the primary modules are provided with a mounting support, such that the mounting portion of the secondary module engages with at least one mounting support.

In one embodiment of the invention secondary modules are provided in at least two forms: intermediate secondary modules and end secondary modules.

Intermediate secondary modules can be formed in similar fashion to primary modules, with an outer face and two side portions, the mounting portion being contained within the side portions. In this way, a wall can be constructed with the side portions of an intermediate secondary module each being located within cavities of adjoining primary modules, such that the outer face of the secondary module effectively covers the abutting side portions of the primary module.

In this arrangement end secondary modules may be formed, effectively, as half intermediate modules, having an outer face and a single side portion which includes a mounting portion. Such an arrangement simplifies both manufacture of the modules and construction of the wall.

Preferably both the primary modules and intermediate secondary modules are substantially "C" shaped in cross section, with the outer face portion forming the web and the side portions forming the flanges of the "C" shape. The end secondary modules are thus substantially "L" shaped in cross section. As the cross sectional shape of each of these modules is similar, they can be produced using a single mould with various modifications.

The connection means connecting abutting side portions of primary modules may comprise bolts passing through aligned holes in the side portions, or a dowel and screw arrangement. In a preferred construction, the connection means comprises horizontal keys which pass through aligned, rectangular holes in the side portions and are secured in position by vertically applied securing wedges. Advantageously, this increases the bearing area of the connection means, and the area through which shear forces act due to racking forces on the wall, thus dissipating the shear force. This reduces the localised stresses within the modules. The shear force is further dissipated by the inclusion of additional keys, which may be spaced vertically along the side portions. The inclusion of additional keys further increases the load capacity of the wall. In a preferred form, the keys each have an enlarged head which bears against one side portion, with the vertical wedge bearing against the other side portion. The mounting support may extend across each primary module, from the first side portion to the second side portion. The mounting support may be at least one rod receivable within apertures in the side portions. Preferably, the mounting support comprises two parallel, vertically spaced rods across each primary

module. The apertures may extend through the side portions, such that a rod may be inserted from outside the primary module. The apertures of abutting side portions may be aligned, such that a rod may span more than one primary module. Alternatively, mounting supports may be pre-fitted to primary modules prior to alignment either in the factory during manufacturing or on site.

The mounting portion of the secondary modules preferably comprises slots within the side portions which extend diagonally upwardly within the side portions.

This allows each secondary module to be hung over the mounting supports. In this way the weight of the secondary module assists in maintaining it in position, without necessarily requiring the use of additional fasteners.

Preferably, the mounting portion is positioned such that a gap is provided between a first module and second module.

In an alternative form of the invention, the secondary modules may comprise cladding sheets or panelling which is connected to the primary modules.

The cladding sheets or panelling may be connected to a mounting support within the primary modules, such as a plurality of mounting brackets, or may be connected directly to the primary modules, for instance by screwed fasteners.

Mounting brackets used in this form of the invention may be comprise rigid brackets arranged to span each primary module, for instance by use of a connection means such as horizontal keys, or by bolting. In another form of the invention the mounting brackets may comprise U-shaped brackets which grasp about abutting side portions.

The brackets are preferably positioned such that a gap is provided between the cladding or panelling and the abutting side portions of the first modules.

The invention results in a structure largely without mortared joints. As a result, the likelihood of failure during events such as an earthquake is greatly reduced. It will be appreciated that the wall can form part of a building, a fence or other structure.

In a preferred form of the invention, corner primary modules may also be provided, in which an outer edge of a side portion extends from an outer corner of

the module at an acute angle. In this way two corner primary modules can be abutted to form a corner of a building. The corner may be further strengthened by the use of a corner bracket. In its simplest form the acute angle will be 45°, allowing the abutting modules to form a 90° corner. The corner primary modules may be connected to adjacent primary modules by the connection means described above. They may alternatiely be connected to secondary modules, for instance by locating mounting rods through aligned second apertures.

Doors and windows may be provided within a wall formed according to the invention. For doors, the invention envisages the use of packing members connected to primary modules about the door. The packing members can provide support for a door frame, which can be adjusted into a square configuration before concrete or similar bonding material is applied to fix it in position.

For both doors and windows smaller primary and secondary modules can be mounted above the door or window. In the case of windows additional small modules can be mounted beneath the window.

It will be appreciated that the primary and secondary modules can be made from any suitable materials. Such materials include reinforced concrete, fibre reinforced concrete, fibre reinforced geopolymer concrete, fibre reinforced polymer concrete, polymer concrete, fibre reinforced gypsum, metal, treated foams materials, and timber, in addition to other suitable building materials. The modules could have a composite construction whereby an end wall is made from a first material and the side portions from another material, for instance the end wall could be concrete with metal side portions. Advantageously, these materials enable the construction of a module which is sufficiently lightweight to be conveniently handled by one or two workers.

Other forms of the invention are envisaged. For instance, primary modules could comprise a web having a more than two flanges, to produce, for example, an "E" shaped cross section. This could allow for larger primary modules, potentially allowing faster erection of a wall but also requiring greater weight transporting and handling capacity, such as the use of cranes.

The invention can be used to create a multi-story structure. Where an intermediate floor is located internally of the outer structure, lower primary

modules can be connected to upper primary modules using shear connectors, either connected along side portions of the primary modules of within channels across primary modules. Where the intermediate floor extends out within the structure, a higher wall can be bolted directly to the intermediate floor. In accordance with another aspect of the invention there is provided a method of construction of a column from a two primary modules and at least two secondary module, each primary module having an outer face portion and two side portions, each secondary module having an outer face portion and at least one mounting portion, the method including the steps of: aligning at least two primary modules together such that their outer face portions abut each other, with a first side portion of a first primary module and a second side portion of a second primary module forming a side face of the column; connecting the outer face portion of the first primary module to the outer face portion of the second primary module such that the first and second primary modules are constrained to move together; mounting a secondary module onto each of the primary modules such that the outer face portion of the secondary module forms at least part of a face of the column, wherein the at least one mounting portion of each secondary module engages with a primary module to restrain movement of the secondary module in at least one direction.

BRIEF DESCRIPTION OF THE DRAWINGS It will be convenient to further describe the invention with reference to the accompanying drawings which illustrate preferred embodiments of the modular wall construction of the present invention. Other embodiments are possible, and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:

Figure 1a is a side view of a primary module for use in a wall construction in accordance with the present invention;

Figure 1 b is a cross sectional view of the primary module of Figure 1a;

Figure 2a is a side view of an intermediate secondary module for use in conjunction with the primary module of Figure 1 ;

Figure 2b is a cross sectional view of the intermediate secondary module of Figure 2a; Figure 3a is a side view of an end secondary module for use in conjunction with the primary module of Figure 1 ;

Figure 3b is a cross sectional view of the end secondary module of Figure 3a;

Figure 4a is an enlarged side view of a portion of a secondary module such as that of Figures 2 or 3;

Figure 4b is an enlarged side view of a first portion of the primary module of Figure 1a;

Figure 4c is an enlarged side view of a second portion of the primary module of Figure 1a; Figure 5a is a side view of a corner primary module for use in a wall construction in accordance with the present invention;

Figure 5b is a cross sectional view of the corner primary module of Figure 5a;

Figure 6a is a side view of a primary angle for use in a wall construction in accordance with the present invention;

Figure 6b is a cross sectional view of the primary angle of Figure 6a;

Figure 7a is a side view of an alternative secondary module for use in particular applications of the wall construction of the present invention;

Figure 7b is a cross sectional view of the alternative secondary module of Figure 7a;

Figure 8a is a side view of a packing member for use within a wall construction in accordance with the present invention;

Figure 8b is a cross sectional view of the packing member of Figure 8a;

Figure 9a is a plan view of key for use in a wall construction in accordance with the present invention;

Figure 9b is a side view of the key of Figure 9a;

Figure 9c is a side view of a bolt which may be used as an alternative to the key of Figure 9a;

Figure 9d is a side view of a rod for use in a wall construction in accordance with the present invention;

Figure 9e is an end view of the rod of Figure 9d

Figure 9f is a side view securing wedge for use in conjunction with the key of Figure 9a;

Figure 9g is a roof bolt for use in a wall construction in accordance with the present invention;

Figure 10a is a perspective of a mounting bracket for use in an alternative secondary module in accordance with the present invention; Figure 10b is a perspective of a corner mounting bracket for use in a further alternative secondary module in accordance with the present invention;

Figure 10c is a perspective of a U-shaped mounting bracket for use in yet another alternative secondary module in accordance with the present invention;

Figure 10d is a perspective of an alternative mounting bracket to be used as an alternative to the mounting bracket of Figure 10c;

Figure 11a is a front corner bracket for use in a wall construction in accordance with the present invention;

Figure 11 b is a second corner bracket for use in a wall construction in accordance with the present invention; Figure 11c is a column floor bracket for use in a wall construction in accordance with the present invention;

Figure 11d is a floor bracket for use in a wall construction in accordance with the present invention.

Figure 12a is an enlarged plan view of a portion of a wall constructed in accordance with the present invention;

Figure 12b is a front elevation of the portion of the wall of Figure 12a;

Figure 13a is a plan view of an external corner of a building constructed in accordance with the present invention;

Figure 13b is a front elevation of a portion of a wall in the building of Figure 13a;

Figure 14a is a plan view of an internal corner of a building constructed in accordance with the present invention;

Figure 14b is a front elevation of a portion of a wall in the building of Figure 14a;

Figure 15a is a front elevation of a column formed in accordance with an embodiment of the present invention; Figure 15b is a cross sectional plan view of the column of Figure 15a;

Figure 16a is a front elevation of a column formed in accordance with an alternative embodiment of the present invention;

Figure 16b is a cross sectional plan view of the column of Figure 16a;

Figure 17a is a cross sectional plan view of a wall constructed in accordance with a second embodiment of the present invention;

Figure 17b is a front elevation of the wall of Figure 17a;

Figure 18a is a cross sectional plan view of a wall constructed in accordance with a third embodiment of the present invention;

Figure 18b is a front elevation of the wall of Figure 18a; Figure 19a is a cross sectional plan view of an external corner of a building constructed with walls of Figure 17a;

Figure 19b is a part front elevation of the external corner of Figure 19a;

Figure 20a is a plan view of an alternative embodiment of an external corner of a building constructed in accordance with the present invention; Figure 20b is a part front elevation of a portion of a wall in the building of

Figure 20a;

Figure 21a is a first shear member for use in joining walls constructed in accordance with the present invention;

Figure 21b is a second shear member for use in joining walls constructed in accordance with the present invention;

Figure 22a is a first embodiment of a pier formed in accordance with the present invention;

Figure 22b is a second embodiment of a pier formed in accordance with the present invention; Figure 23a is a plan view of an alternative corner within a building constructed in accordance with the present invention;

Figure 23b is a front elevation of a portion of a wall in the building of Figure 23a;

Figure 24a is a plan cross section of a first embodiment of a multi-story structure built in accordance with the present invention;

Figure 24b is a cross sectional elevation of the structure of Figure 24a;

Figure 25a is a plan cross section of a second embodiment of a multi-story structure built in accordance with the present invention;

Figure 25b is a cross sectional elevation of the structure of Figure 25a;

Figure 26 is a plan cross section of an internal wall built in accordance with an embodiment of the present invention;

Figure 27a is an elevation of a capping member for use in the structure of Figure 25a;

Figure 27b is a cross section of the capping member of Figure 27a;

Figure 27c is an elevation of a lintel for use in a wall built according to the present invention;

Figure 27d is a cross section of lintel of Figure 27c; Figure 28a is an elevation of a door frame for use within a wall built according to the present invention;

Figure 28b is a side view of the door frame of Figure 28a;

Figure 28c is a tie for use in conjunction with the door frameof Figure 28a;

Figure 28d is a cross sectional view of the doorframe of Figure 28a; Figure 28e is a cross section of the door frame of Figure 28a with the tie of

Figure 28c attached;

Figure 29a is an elevation of an alternative door frame for use within a wall built according to the present invention;

Figure 29b is a side view of the door frame of Figure 29a; Figure 29c is a tie for use in conjunction with the door frame of Figure 29a;

Figure 29d is a cross sectional view of the door frame of Figure 29a;

Figure 29e is a cross section of the door frame of Figure 29a with the tie of Figure 29c attached;

Figure 30 is a front elevation of a portion of a wall in accordance with the present invention including the door frame of Figure 28a;

Figure 31a is a cross section plan view of a portion of the wall of Figure 30;

Figure 31 b is a cross sectional side view of a portion of the wall of Figure 30;

Figure 32a is a plan cross section of a third embodiment of a multi-story structure built in accordance with the present invention;

Figure 32b is a cross sectional elevation of the structure of Figure 32a;

Figure 33 is a cross sectional elevation of a fourth embodiment of a multi- story structure built in accordance with the present invention;

Figure 34a is an elevation of a window for use within a wall built according to the present invention;

Figure 34b is a cross-section of a top portion of the window of Figure 34a;

Figure 34c is a cross-section of a bottom porion of the window of Figure 34a;

Figure 34d is a cross-section of a side portion of the window of Figure 34a;

Figure 35 is an elevation of a wall built according to the present invention including the window of Figure 34; and

Figure 36 is a side cross section through a portion of the wall of Figure 35. DESCRIPTION OF PREFERRED EMBODIMENT(S)

Referring to the figures, there is shown in Figure 12 a wall 10 constructed from a plurality of primary modules 12 and secondary modules 14, together with various other components as will be described below.

A primary module 12 is shown in Figures 1a and 1b. The primary module 12 is elongate, and substantially C shaped in cross section. In a typical embodiment of the invention the primary module 12 has a height (shown as length in Figure 1a) of about 2700mm, a width of 250mm and a depth of 125mm. It will be understood that these dimensions are illustrative only, and that primary modules 12 may be of any suitable dimensions. The primary module 12 consists of a rear wall 16 having an outer face portion 18; and two side portions: a first side portion 20 and a second side portion 22. The side portions 20, 22 protrude from either end of the rear wall away from the outer face portion 18 in a direction substantially perpendicular to the outer face portion 18. External corners of 90° are formed between the outer face portion 18 and respective outer faces of each of the side portions 20, 22.

Internal corners 24 are formed between inner faces of the side portions 20, 22 and an inner face of the rear wall 16. In the embodiment of the drawings, the

internal corners 24 are bevelled. In an alternative embodiment, the internal corners may be curved.

Each side portion 20, 22 includes a plurality of first apertures 26 and a plurality of second apertures 28. Each of the first apertures 26 is rectangular, with a long edge aligned horizontally, in use, and a short edge aligned vertically. The first apertures 26 are spaced along a vertical span of each side portion 20, 22. Each first aperture may be located centrally between a front most edge of the side portion 20, 22 and the outer face portion 18. In a preferred embodiment, as detailed in Figure 4b, the first apertures 26 are arranged closer to the outer face portion 18 than to the front most edge of the side portions 20, 22.

Each of the second apertures 28 is substantially circular, and is located slightly closer to the front most edge of the side portion 20, 22 than to the outer face portion 18. This is shown in more detail in Figure 4c. The second apertures 28 are positioned such that, in use, they are located substantially centrally of a wall 10 as will be described further below. At least one of the second apertures 28 is located towards the top, in use, of the side portion 20, 22. At least one other is located towards the bottom, in use, of the side portion 20, 22.

A secondary module 14, being an intermediate secondary module 30, is shown in figures 2a and 2b. The intermediate secondary module 30 is elongate, and substantially C shaped in cross section. The intermediate secondary module 30 is substantially similar in shape and dimension to the primary module 12.

The intermediate secondary module 30 consists of a rear wall 32 having an outer face portion 34; and two side portions: a first side portion 36 and a second side portion 38. The side portions 36, 38 protrude from either end of the rear wall away from the outer face portion 34 in a direction substantially perpendicular to the outer face portion 34. External corners of 90° are formed between the outer face portion 34 and respective outer faces of the side portions 36, 38.

Internal corners 40 are formed between inner faces of the side portions 36, 38 and an inner face of the rear wall 32. In the embodiment of the drawings, the internal corners 40 are bevelled. In an alternative embodiment, the internal corners may be curved.

In a preferred embodiment, the side portions 36, 38 of the intermediate secondary modules 30 protrude slightly further than the corresponding side portions 20, 22 of the primary modules 12.

The side portions 36, 38 each include a mounting portion in the form of two inclined slots 42. The slots 42 extend upwardly at an incline within the side portions 36, 38 from an opening 44 in the front most edge of the relevant side portion 36, 38, to a rounded end 46 within the side portion 36, 38.

The slots 42 are in the form of bevelled cuts at a particular angle α from the horizontal, for example 60° or 45° as shown in figure 4a. Angle α and the locations of cuts along the webs are selected having regards to the required strength of the module. The bevelled cuts are intersected by a horizontal cut at the opening 44 to form a triangular entry region as shown generally in Figure 2 and in detail in Figure 4a. The size and angle of the slots 42 depend on the height of the wall 10 to be constructed and on the design loading of the same wall 10. In the embodiment shown in the drawings each side portion has two slots

42. The slots 42 are positioned such that, in use, their rounded ends 46 are at about the same level as sets of second apertures 28 in primary modules 12. It will be appreciated that more slots 42 may be provided, should additional mounting portions be required. A secondary module 14, being an end secondary module 50, is shown in figures 3a and 3b. The end secondary module 50 is elongate, and substantially L shaped in cross section. The end secondary module 50 is effectively identical to an intermediate secondary module 30 which has been halved along a central elongate line. The end secondary module 50 consists of a rear wall 52 having an outer face portion 54; and a first side portion 56. The first side portion 56 protrudes from one end of the rear wall 52 away from the outer face portion 54 in a direction substantially perpendicular to the outer face portion 54. An external corner of 90° is formed between the outer face portion 54 and an outer face of the first side portion 56.

An internal corner 60 is formed between inner face of the first side portions 56 and an inner face of the rear wall 52. In the embodiment of the drawings, the

internal corner 60 is bevelled. In an alternative embodiment, the internal comer may be curved.

The first side portion 56 includes a mounting portion in the form of two inclined slots 42, similar in shape and form to those in the intermediate secondary modules 30.

A corner primary module 62 is shown in Figures 5a and 5b. The corner primary module 62 is similar to a primary module 12, but with the first side portion replaced by a mitred side portion 64.

The mitred side portion 64 has an externally facing side face 66 which extends from an outer edge of the outer face portion 18 at an angle of 45°, thus forming an acute external corner. The outer face portion extends to a point almost level with the front most edge of the second side portion 22.

The mitred side portion 64 includes second apertures 28 in equivalent locations to the second apertures 28 within the second side portion 22. The mitred side portion 64 does not have any first apertures 26.

A primary angle 68 is shown in Figures 6a and 6b. The primary angle 68 comprises two elongate flanges 70 disposed at right angles to each other. Each flange 70 is similar in dimension to a first side portion 20 of a primary module 12. Each flange 70 includes a plurality of first apertures 26 in equivalent locations to the first apertures 26 of the side portions 20, 22 of the first module 12; and a plurality of second apertures 28 in equivalent locations to the second apertures 28 of the side portions 20, 22 of the first module 12.

An alternative secondary module 72 is shown in Figures 7a and 7b. The alternative secondary module 72 is elongate, and is T-shaped in cross-section, having a flange 74 and web 76. The flange 74 is equal in width to the rear wall 16 of the first module 12. The web 76 protrudes out from the flange 74 in a similar fashion to the side portions 36, 38 of the intermediate secondary module 30, and has two slots 42, with associated openings 44 and rounded ends 46, in the same positions as in the side portions 36, 38. A packing member 78 for use in conjunction with the primary modules 12 is shown in Figures 8a and 8b. The packing member 78 is an elongate channel, having a web 80 and two flanges 82. The web 80 is of the same width as a wall 10, the formation of which is described below. The web includes a plurality of first

apertures 26 positioned to align, in use, with some of the first apertures 26 of a first module 12. In the embodiment of the drawings the web 80 includes three even spaced first apertures 26.

The flanges 82 are arranged to receive a door frame 168,170. A connection means for use in connection with the primary modules 12 is shown in Figures 9a, 9b and 9f. The connection means includes a flat key 84 and a securing wedge 86.

The flat key 84 includes an enlarged head 88, a body portion 90 extending away from the head 88 and an end region 92 remote from the head 88. The body region 90 is slightly smaller, in cross section, than the first apertures 26 in the primary modules 12, and is arranged to be moveable within the first apertures 26. The enlarged head 88 has width greater than that of the first apertures 26, and thus bears against a side portion 20, 22 of a primary module 12 when the body portion 90 is inserted within a first aperture 26. The body portion 90 of a standard key 84 has a length slightly greater than the combined width of a first side portion 20 and a second side portion 22 of primary modules 12. When two primary modules 12 are placed alongside each other, with the first side portion 20 of one primary module abutting the second side portion 22 of the other side module, the flat key can be inserted within aligned first apertures 26 of the abutting first and second side portions 20, 22, with the enlarged head on one side of the aligned first apertures 26 and the end region 92 extending from the other side of the aligned first apertures 26. Where the key is to be used in other applications, as described below, the length of the body potion 90 may need to be altered accordingly. The end region 92 includes a vertical slot 94 which locates, in use, immediately adjacent a first or second side portion 20, 22 of a primary module 12. The vertical slot 94 is sized to receive the securing wedge 86, which is inserted vertically into the vertical slot 94. When the flat key 84 is inserted into two aligned first apertures 26, the enlarged head 88 bears on the first side portion 20 and the securing wedge 86 bears on the second side portion 22.

In an alternative embodiment of the invention the first apertures 26 may be round, and the connection means may consist of a boit and nut 96 as shown in Figure 9c.

A mounting support in the form of a rod 98 is shown in figures 9d and 9e. The rod 98 is circular in cross section, and is sized to be receivable in the second apertures 28 in a sliding fit. In the embodiment of the drawings the rod 98 is approximately equal in length to the width of the rear wall 16 of a primary module 12. When the rod is inserted into a second aperture 28 from outside a primary module 12, it can be slid through to a corresponding second aperture 28 in an opposite side portion, thus spanning the first module 12. It will be appreciated that in an alternative embodiment the rod 98 may be longer than the width of the rear wall 16, although preferably it will be equal to a multiple of this length. A tie-rod 99 is shown in Figure 9g. The tie-rod 99 includes a bolt 100 fixed by suitable means, such as welding, to a base plate 101. The base plate includes a centrally located aperture 102 of the same dimensions as the first apertures 26 of the primary modules 12.

An alternative mounting support in the form of a mounting bracket 103 is shown in Figure 10a. The mounting bracket 103 is formed from a strip of rigid material, such as steel, and is substantially C-shaped with two side arms 104 separated by a central portion 105. The side arms 104 are substantially parallel, and are spaced such that when one side arm 104 is against an internal wall of a first side portion 20 of a primary module 12, the other side arm 104 is against an internal wall of the second side portion 22 of the primary module 12. The central portion 105 thus spans the primary module 12.

Each of the side arms 104 has a rectangular aperture 106 which is of the same dimensions as the first apertures 26. In use, the mounting bracket 103 is positioned across a primary module 12 such that its rectangular apertures 106 align with a pair of first apertures 26 in the primary module 12.

A corner mounting bracket 108 is shown in Figure 10b. The corner mounting bracket 108 has two connecting portions 110 disposed at right angles to each other, each having a rectangular aperture 106, and two mounting surfaces 112, each being at right angles to an adjacent connecting portion 110 and being parallel to and spaced from the other connecting portion 110. The use of the corner mounting bracket 108 will be described below.

A U-shaped mounting bracket 114 is shown in Figure 10c. The U-shaped bracket 114 has a central spacing portion 116 and two arms 118. The arms are

spaced so as grasp about abutting side portions 20, 22 of adjacent primary modules 12. The spacing portion 118 is sufficiently deep to provide an air gap between sheeting affixed to its outer side and the front most edge of the abutting side portions 20, 22. The U-shaped mounting bracket 114 is preferably formed from a fireproof material, such as a fireproof plastic, compressed fibre-reinforced cement or galvanised steel.

An alternative mounting bracket 119 is shown in Figure 10d. The alternative mounting bracket 119 effectively comprises merely the central spacing portion 116 with no arms 118. A first corner bracket 120 is shown in Figure 11a. The first corner bracket

120 has two perpendicular arms 122, each of which has a central rectangular aperture 106. The rectangular aperture 106 is identical to that of the mounting brackets 103, 108. The first corner bracket 120 is preferably constructed from a strong, rigid material such as steel. A second corner bracket 124 is shown in Figure 11 b. The second corner bracket 124 two perpendicular arms 126, each of which has two round apertures 128 which are vertically spaced. The round apertures 128 are similar in dimension to the second apertures 28 in the primary modules 12. The second corner bracket 120 is preferably constructed from a strong, rigid material such as steel.

A column floor bracket 130 is shown in Figure 11c. The column floor bracket 130 has two perpendicular arms 132, each of which has a central round aperture 128 similar in dimension to that of the second corner bracket 124. The column floor bracket 130 is preferably constructed from a strong, rigid material such as steel.

A standard floor bracket 134 is shown in Figure 11d. The floor bracket 134 has a first arm 136, arranged to locate on a footing of a wall 10, with a centrally located round aperture 128. The floor bracket also has a second arm 138, perpendicular to the first arm 136, which is arranged to locate along a side portion 20, 22 of a primary module 12. The second arm 138 includes a rectangular aperture 106 located near an upper end thereof, arranged to align with a first aperture 26 of the primary module 12. It will be appreciated that the minimum distance between the first apertures 26 and the rear wall 16 of a primary module

12 is determined by the need for a floor bracket 134 to locate outside the internal corner 24.

Figure 21 a shows a first style of shear connector 146 for use in connecting primary modules 12 vertically, in order to create multi-story structures. The connector 146 is formed from a rigid plate, such as a steel plate. The connector

146 has a width greater than the combined width of first and second side portions

20, 22 of the primary modules 12.

The connector 146 has two vertically aligned channels 148, one extending inwardly from each of the top and bottom edges of the _. connector 146. Each of the channels 148 extends through about one third of the height of the connector 146, leaving a central portion 150 of about one third of the height of the connector 146. The channels 148 are each of a similar width to the combined width of first and second side portions 20, 22 of the primary modules 12. The channels 148 each have an enlarged mouth portion 152. Figure 21 b shows a second style of shear connector 154. The second style of connector 154 is also formed from rigid plate, such as a steel plate. The second style of connector 154 is elongate, with a rectangular aperture 106 located adjacent either end. The apertures 106 are spaced such that, in use, one aperture 106 aligns with the lowest first aperture 26 of a top primary module 12 when the other aperture 106 is aligned with the highest first aperture 26 of a bottom primary module 12, the top primary module being directly above the bottom primary module.

Figures 27a and 27b show a capping member 156 for use in certain applications of the wall construction method described herein. The capping member 156 is elongate, and substantially U-shaped in cross section. The U- shape has a base 158 which is substantially equal in width to the side portions

20, 22 of a primary module 12.

Figures 27c and 27d show a lintel 160 which can be used above a window, as described below. The lintel 160 includes a web 162, a front flange 164 extending downwardly from a front edge of the web 162 and a rear flange 166 extending upwardly from a rear edge of the web 162. The web 162 is stepped in size, with a the rear flange 166 and portion of the web 162 adjacent the rear

flange 166 being longer that the front flange 164 and a portion of the web 162 adjacent the front flange 164.

Two alternative door frame embodiments are shown in Figures 28 and 29 respectively. A first door frame 168 is formed from an extrusion shown in Figure 28d, and a second door frame 170 is formed from an extrusion shown in Figure 29d. The first door frame 168 includes an architrave, and is shaped with a several bends along its length. The second door frame 170 has no architrave, and fewer bends.

A tie 174 is shown in Figures 28c and 29c. The tie has two substantially straight connecting portions 176 and a U-shaped extension portion 178. A plurality of ties 174 are spaced along the door frames 168, 170, on the outside of the door frames 168, 170. In a preferred embodiment each side of the door frame has four ties 174. Conveniently, the connecting portions 176 can be affixed within the door frames 168, 170, such as by welding, in such a way that the extension portions 178 can be moved between a transporting position in which the extension portions lie along the door frame 168, 170 and an extended position in which the connecting portions protrude outwardly behind the door frame 168, 170.

The construction of a wall 10 in accordance with a first embodiment of the invention will now be described with reference to Figure 12. The construction of the wall 10 is begun by placing a first primary module 12a at a desired end point of the wall 10. The first primary module 12a is placed such that its outer face portion 18 forms part of a first face 202 of the wall 10. A second primary module 12b is then aligned next to the first primary module 12a, such that their outer face portions 18 form a substantially continuous surface. It will be appreciated that the first side portion 20 of the first primary module 12a abuts the second side portion 22 of the second primary module 12b. As a result both the first apertures 26 and the second apertures 28 of the first side portion 20 align with the respective first apertures 26 and second apertures 28 of the second side portion 22. The first and second primary modules 12a, 12b are connected by use of the connection means. In a desired number of aligned first apertures 26, which may be two as in Figure 12 or, more generally, three, a flat key 84 is inserted and

secured by a securing wedge 86. This constrains the first and second primary modules 12a, 12b to move together.

The first primary module 12a may be bolted to the ground by use of a floor bracket 134. The floor bracket 134 is connected to the first primary module 12a and second primary module 12b via a flat key 84 passing through the aligned rectangular aperture 106 and first aperture 26. The bracket is bolted to the floor, or to footings of the wall, through the round aperture 128. It will be appreciated that a column floor bracket 132 may be used as an alternative, with the bracket 132 being bolted to the primary module 12a. Mounting supports in the form of rods 98 are then inserted into a desired number of aligned second apertures 28. The rods 98 are threaded through the second apertures 28 so as to extend across each of the first and second primary modules 12a, 12b. The number of rods 98 inserted into each primary module 12 is equal to the number of slots 42 in corresponding secondary modules 14. It will be appreciated that the structure thus created, defining the first face

202 of the wall 10, is entirely self supporting. In face, it forms a support structure on which the second face 204 can be constructed. External loads are borne by this structure, passing through the primary modules 12.

An intermediate secondary module 30 can be located on the wall 10. The intermediate secondary module 30 is positioned such that the openings 44 of the slots 42 of the first side portion 36 are located over the rod 98 of the first primary module 12a, and the openings 44 of the slots 42 of the second side portion 38 are located over the rod 98 of the second primary modules 12b. The intermediate secondary module 30 can then be mounted onto the wall by sliding the slots 42 over the rod 98 until the rounded ends 46 locate near the rod 98 and the front most edges of the side portions 36, 38 come into contact with the rear walls 16 of the associated primary modules 12.

As the intermediate secondary module 30 is in an opposite orientation to the primary modules 12, its outer face portion 34 forms part of a second face 204 of the walMO.

It will be appreciated that the weight of the intermediate secondary module 30 assists to maintain it in position over the rods 98. The rods 98 restrain movement of the intermediate secondary module 30 perpendicular to the plane of

the wall faces 202, 204. In order for the intermediate secondary module 30 to be moved, therefore, an upward force must be applied to it.

An end secondary member 50 can be similarly mounted over the rods 98 of the first primary module 12a adjacent the intermediate secondary module 30. The end secondary member 50 is positioned such that the outermost edge of its outer face portion 54 rests against the second side portion 22 of the first primary module 12a, creating a square end for the wall 10.

Further primary modules 12 and intermediate secondary modules 30 can be added in similar fashion to extend the length of the wall. When the final primary module 12 has been added to complete the first side 102 of the wall, a final intermediate secondary module 30 can be mounted, and then a further end secondary module 50 can be mounted to complete another square end. It will be appreciated that this further end secondary module will be a mirror image of the first one. Floor brackets 134 can be added at regular locations, in the manner described above. Tie-rods 99 can also be added to secure a roof structure, and to allow racking forces to be transmitted from the roof structure to the primary modules 12. The tie-rods 99 are connected to primary modules 12 in a similar fashion to floor brackets, being keyed into a first aperture 26 using a key 84 and securing wedge 86. For structural reasons it is considered preferably to locate tie- rods 99 on the same primary modules 12 as floor brackets 134.

As described above, the side portions of the secondary modules 14 extend further than those of the primary modules 12. As a result, a gap 140 is created between the side portions 20, 22 of the primary modules and the rear walls 32 of the secondary modules 30. This gap 140 assists in pressure equalisation within the wall 10, and reduces the propensity for water to be drawn through the wall under a pressure differential. In order to take advantage of this arrangement, the wall 10 should be constructed with the first face 202 as an external wall of a building. Other methods may be employed to reduce the propensity for water to be drawn through a wall 10. These include painting an external face of the wall 10, or providing waterproof sheeting against a surface of the wall 10.

The gap 140 may also allow for insulation to be included. It is also possible to form a wall 10 with gaps 140 also between side portions 36, 38 of secondary modules and rear walls 16 of primary modules. This arrangement may prove beneficial for the installation of insulation, and may also provide a degree of sound-proofing.

It will be appreciated that the length of wall 10 created using this method increases in increments equal to the breadth of the primary modules 12. The overall length of the wall 10 may be a whole number of these increments, or it may include an additional half increment. A half increment is achieved by effectively reversing the orientation of the primary modules 12 and secondary modules 14. This is shown in Figure 26. Before rods 98 are inserted into a primary module 12c, another primary module 12d can be opposed to it, in the position normally held by an intermediate secondary module. The opposed primary module 12d can be moved into position where its second apertures 28 are aligned with the second apertures 28 of the first primary module 12c. Rods 98 can then be inserted within the first primary module 12c, passing through a side portion 20 of the opposed primary module 12d and thus tying the two primary modules together. The wall can extend outwardly on either side of these primary modules 12c, 12d, with the primary modules 12 on one side in the opposite orientation to those on the other.

If a wall is required with a length which is not equal to a whole number of increments, or to 0.5 increments, it becomes necessary to form two wall portions with a gap. The size of the gap will necessarily be smaller than half an increment. This gap can be closed with filling material such as concrete in a known fashion. It will be appreciated that this situation is most likely to occur when constructing internal walls in existing structures, and therefore the filled gap will not be required to support a significant load.

In another embodiment of the invention, the intermediate and end secondary modules 30, 50 can be replaced with alternative secondary modules 72, with the flange of each alternative secondary module 74 spanning an associated primary module 12. This embodiment is more suited for internal walls 10, as in this embodiment no equivalent to gap 140 exists to prevent the ingress of water.

A building can be constructed with walls 10 as described above. There are a number of ways in which corners can be formed, depending on the orientation and location of the corner.

Figure 13a shows an external corner 212 of a building 210. The building has an interior 206 and an exterior 208. The corner 212 is constructed using two corner primary modules 62 as follows.

The structural part (ie the primary modules 12) of a first wall 10a is completed with the final primary module 12 being a corner primary module 62a. This corner primary module 62a is connected to its adjacent primary module 12 along its second side portion 22 using the connection means describe above. The corner primary module has its mitred side portion 64 at the corner 212, with the side face 66 oriented in the direction the second wall 10b is to go.

A second corner primary module 62b can then be brought against the first corner primary module 62a at right angles, with the two side faces 66 bearing against each other.

In order to hold the second comer primary module in position, at least one second corner bracket 124 is introduced about the mitred side portions 64. The second corner bracket is positioned such that one round aperture 128 on each arm 126 is aligned with a second aperture 128 on a respective mitred side portion 64. The second comer bracket 124 can be secured against the first corner primary module 62a by insertion of a rod 98 through that the aligned apertures. It can be further secure by bolting through the other round aperture 128.

The second corner primary module 62b can be secured against the other arm 126 of the second corner bracket 124 in the same way. Further primary modules 12 can then be added to the second wall 10b as required.

It is considered preferable to use three second corner brackets 124. Two of the second corner brackets 124 are located in positions aligned with the slots

42 of second modules 14; and can thus be secured through one aperture 128 by the rod 98. The third corner bracket 124 can be located between the rods 98, and secured by two bolts on each side.

Secondary modules 14 can be added following the completion of the corner 212. It will be appreciated that the corresponding internal corner will be formed by abutting edges of secondary modules 14.

It will be understood that the corner brackets 124 could be replaced with a longitudinal steel angle column extending along the height of the wall, should extra load capacity be required.

Another external corner 214 is shown in Figure 20. The external corner 214 of Figure 20 is similar in construction to the external corner 212 of Figure 13, the difference being the replacement of the one or more second corner brackets 124 with a primary angle 68. It will be appreciated that the primary angle 68 is able to take vertical loads, and therefore the external corner 214 of Figure 20 has more structural strength than the corner 212 of Figure 13. An internal corner 216 of an exterior wall is shown in Figure 14. It is constructed as follows.

The structural part (ie the primary modules 12) of a first wall 10c is completed with the final primary module 12c being located at one side of the internal corner 216. At least one (and preferably three) first corner brackets 120 are then located on the outside of the second side portion 22 of the primary module 12c, with one arm 122 against the second side portion 22 and the other arm 122 facing in the direction of a second wall 10d. The first corner brackets 120 are positioned such that their rectangular apertures 106 are aligned with first apertures 26 in the second side portion 22. The first corner brackets 120 are connected to the primary module 12c using a connection means including keys 84 and wedges 86 as described above.

A first corner primary module 62a can then be prepared for use. It is prepared by bolting at least one (preferably three) second corner bracket(s) 124 to its mitred side portion 64 in the same manner as that discussed above in relation to the external corner 212. The second corner brackets 124 are positioned such that, where appropriate, round apertures 128 are aligned with second apertures 28 to receive rods 98.

The first corner primary module 62a can then be located in position, such that its outer face portion 18 forms part of the internal face of the wall 10c. The first corner primary module 62a is secured in position relative to the primary module 12c by the passing of rods 98 in turn through the second apertures 28 of the second side portion 22 of the primary module 12c; the round apertures 128

and the second apertures 28 of the mitred side portion 64 of the corner primary module 62a.

The second wall 1Od is connected in an analogous fashion. It will be appreciated that the keys 84 connecting the first corner brackets 120 to a first primary module 12d of the second wall 1Od must be located within the first corner brackets 120 before the primary module 12d is put into position, as access may become difficult.

Similarly, a second corner primary module 62b must be located in position and bolted to the second corner brackets 124 before the second primary module 12d can be put into position.

An interior corner 218 is shown in Figure 23. The interior corner 218 can easily be created by bolting a first primary module 12f to a second primary module 12g at right angles, with the bolt(s) passing through the first side portion 20 of the first primary module 12f and the rear wall 16 of the second primary module 12g, such that the first side portion 20 of the second primary module 12g becomes a virtual extension of the outer face portion 18 of the first primary module 12f. Any small gap between the two can be filled by plaster or similar as required.

It is also possible to form a column 220 in accordance with the present invention. Two embodiments of a column 220 are shown, one in Figure 15 and one in figure 16.

The structural part of the column 220 is formed by locating two primary modules 12 back-to-back, and bolting their respective rear walls 16 together. The two primary modules 12 should also be bolted to footings, using column floor brackets 130. Rods 98 can be inserted into each of the primary modules 12.

In the column embodiment of Figure 15, the column 220 is completed by mounting two end secondary modules 50 onto the rods 98 of each primary module 12. In the column embodiment of Figure 16, the column 20 is completed by mounting an alternative secondary module 72 onto the rods 98 of each primary module 12. It will be appreciated that the alternative module 72 is effectively the same as two end secondary module 50 joined flange-to-flange.

Piers 222 can be formed in a similar fashion to columns 220, with the two possible arrangements shown in Figures 22a and 22b. In both cases the

structural part of the pier 222 is created by bolting primary modules 12 back-to- back with primary modules of a wall 10. End secondary modules 50 can be used to complete the pier 222, as in Figure 22a, or alternative secondary modules 72 can be used as in Figure 22b. In an alternative embodiment of the invention, the secondary modules 14 are formed using sheeting, such as plasterboard sheeting, to provide an outer face potion of the secondary modules and thus the second face 204 of the wall 10.

Figure 17 shows one such way of constructing a wall 10 according to this embodiment of the invention. The structural part of the wall 10 is constructed from primary modules 12 in the same fashion as in the first embodiment described above. The secondary modules according to this embodiment are formed using suitable panelling 142, such as timber panelling, connected to mounting brackets 103. It will be appreciated that other panelling or cladding, such as plaster board sheeting, may also be used. The mounting brackets 103 can be affixed within primary modules 12 using keys 84 through aligned rectangular apertures 106 and first aperture 26. The mounting brackets can also be bolted to the side portions 20, 22 of primary modules 12 if they are required at spacings different to that of the first apertures 26. The central portion 105 of each mounting bracket 103 thus protrudes from its associated primary module 12. The panelling 142 can be affixed to the central portion 105 by suitable means, such as screws 144 passing through central apertures in the central portion 105.

The shape of the mounting bracket 103 is such that a gap 140 exists between the side portions 20, 22 of the primary modules 12 and the panelling 142.

Another, similar embodiment is shown in Figure 18. The secondary module is again formed by panelling 142, this time connected to U-shaped mounting brackets 114. The U-shaped mounting brackets 114 are connected at suitable locations about abutting side portions 20, 22. Alternative mounting brackets 119 may be used instead, with the each screw 144 passing through the mounting panelling 42, the mounting bracket 119 and being secured within the side portions 20, 22 of the primary modules 12.

A corner 224 may be formed in accordance with these embodiments using corner mounting brackets 108. An example of such a corner 224 is shown in Figure 19.

The corner 224 is formed by two walls 10e and 1Of ₁ constructed as per the embodiment of Figure 17. The panelling 142 is located on the external faces of the walls 10e and 10f. The structural parts of the two walls 10e and 10f, namely the primary modules 12, are joined by a primary angle 68, using connection means as described above.

A plurality of corner mounting brackets 108 can be located within the primary angle 68, with their connecting portions 110 being connected to the primary angle 68 by keys 84 or by bolting, and their mounting portions 112 being substantially co-planar with the central portions 105 of nearby mounting brackets 103. Panelling 142 can then extend across both mounting portions 112, forming the requisite corner 224. There are several available methods to construct multi-story buildings using the construction method of the present invention. Figure 24 shows a first such method.

In the embodiment of Figure 24 a lower wall 10h is constructed from primary modules 12 and secondary modules 14 as discussed above, with the secondary modules 14 being shorter than the primary modules 12. As a result, a space 180 is created at the top of the second face 204 of the lower wall 10h.

A beam 182, such as a C-channel, is supported by suitable means such as regularly spaced columns 220 along the lower wall 10h. The base of the beam

182 is adjacent the upper end of the secondary modules 14, with a small gap between them to allow for insertion and removal of secondary modules 14. The top of the beam 182 is positioned at a desired height beneath the top of the primary modules12, and provides a support on which a concrete floor 184 can be laid. It will be appreciated that a plurality of beams 182 could be placed in parallel to support the floor 184, if additional support is required. A floor tie 186 is provided passing through a first aperture 26 adjacent the floor 184, and into the floor a84, thus tying the wall 10h to the floor 184.

An upper wall 10i is constructed above the lower wall 10h, and is constructed from primary modules 12 and secondary modules 14, with these

secondary modules extending down beneath the primary modules 12. Each primary module 12 of the upper wall 1Oi is located directly above a corresponding primary module 12 of the lower wall 1Oh, with the two primary modules being connected by second shear connectors 154 as shown in Figure 21b. The second shear connectors run alongside first or second side portions 20, 22, and are connected to the respective side portions by us of keys 84 within the rectangular apertures 106 and aligned first apertures 26. In some applications, it may be necessary to use second shear connectors 154 on either side of abutting side portions 20, 22. Figure 25 shows a second embodiment of a multi-story structure using the wall described above. In this case, the structure is created according to walls of the second embodiment of the invention, as shown in Figure 17.

A lower wall 10j is covered by a capping member 156 as shown in Figure 27a. This provides a surface upon which an end of a concrete floor 184 can be poured. The weight of the floor is thus supported by the primary modules 12 of the lower wall 10j.

An upper wall 101 can then be installed above the floor 184 in the same fashion as a single story structure, with the upper wall 101 being bolted to the floor 184. The cladding or panelling 142 of the upper wall 101 can be extended over the outside of the floor 184 to create a smooth outer face 204 of the structure.

Figure 32 shows a third embodiment of a multi-story structure, similar in many respects to the embodiment of Figure 24. The principle difference is that Figure 32 used the shear connectors 146 of Figure 21a, rather than the shear connectors 154 of Figure 21 b.

In order for the shear connectors 146 to be used, slots must be provided in the side portions 20, 22 of the primary modules 12, the slots being at the depth of half the central portion 150 of the shear connectors 146. This enables a shear connecter 146 to be inserted within the abutting side portions 20, 22, and for primary modules 12 of the upper wall 10i to be then located over the shear connector 146.

It will be appreciated that the shear connectors 146 of Figure 32 do not prevent the action of an uplifting force, but provide a stronger lateral support than those of Figure 24.

Figure 33 shows another embodiment of a multi-story structure, similar to that of Figure 25. In the embodiment of Figure 33 the walls are constructed according to the embodiment of Figure 12, and the floor 184 extends outside the walls 10.

Figures 30 and 31 show the inclusion of a door frame 168, 170 within a wall 10. Referring to Figure 31a, it can be seen that a wall is constructed using the method described above until a final primary module 12 is located in position next to the door arrangement. A packing member 78 is then located next to the first side wall 20 of the final primary module 12, with its web 80 abutting the first side wall 20 such that the first apertures 26 of the packing member 78 align with first apertures 26 of the first side wall 20, allowing the packing member 78 to be connected to the primary module 12 using the key and wedge connecting means described above.

Importantly, the packing member 78 is the height of the door frame 168, 170, and shorter than the primary module 12.

The wall 10 up to the packing member 78 can be completed with intermediate secondary modules 30 and an end secondary module 50. The end secondary module 50 is the same height as the doorframe 168, 170.

The door frame 168, 170 can be located about the flanges of the packing member 78, and adjusted so as to be plumb even if the wall 10 is slightly out of square. This permits a door to be hung without extensive adjustment required. The extension portions 178 of the ties 174 are moved into the extended portion, and thus protrude between the door frame 168, 170 and the web 80 of the packing member 78.

The gap between the door frame 168, 170 and the web 80 of the packing member 78 can then be filled, from the top, by concrete or similar bonding material.

Preferably, floor pins 188 can be located at the base of the gap to further strengthen the bond of the door frame to the structure.

A similar procedure can be followed on the other side of the door frame 168, 170.

Above the doorframe 168, 170, construction of the wall 10 can continue as described above, using primary and secondary modules 12, 14 of a height equal to the height difference between the door frame 168, 170 and the wall 10. These smaller modules located above the door frame as shown in Figure 31 b.

A window 190 can similarly be included within a wall 10. An example of such a window 190 is shown in Figures 34 to 36.

The inclusion of windows differs from doors in two ways. Firstly, windows do not generally extend to the floor, and thus shorter modules 12, 14 are required beneath the window as well as above the window. Secondly, the window can be readily sized to located between modules, and thus packing members 78 are not required.

The window 190 is mounted between a window base 192 and a lintel 160. The window base 192 is similar to the capping member 156, though generally lighter weight as it is not required to bear a similar load. Significantly, the window base 192 has an upstanding potion 194 extending along the length of the window, against which a window frame 196 can be fixed.

The lintel 160 locates within the primary modules 12, and behind the second face 204 of the wall 10. The window frame 196 can be secured to the lintel 160 using an angle bracket 198.

Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.