Elongate structural element, a bracket and an elongate structural section

There is disclosed an elongate structural element (10). The element (10) includes an inner plate (12) having first and second opposing planar surfaces (14, 16). The element (10) further includes first and second outer sections (18, 18′). Each of the outer sections (18, 18′) comprises a central wall (20) having a pair of longitudinal grooves (32, 34). Each of the outer sections (18, 18′) further comprises a pair of side walls (22, 24) extending from the central wall (20) to define a generally U-shaped channel (30). The longitudinal grooves (32, 34) depress into the U-shaped channel (30). Each of the outer sections (18, 18′) further comprises a pair of flanges (26, 28) respectively extending outwardly from the pair of side walls (22, 24). The flanges (26, 28) of the first outer section (18) are attached to the first planar surface (14) of the plate (12) and the flanges (26, 28) of the second outer section (18′) are attached to the second planar surface (16) of the plate (12) such that the U-shaped channels (30) are substantially closed by the inner plate (12) and opposed to each other.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application represents the U.S. National Stage of International Application No. PCT/AU2016/000072, filed Mar. 8, 2016, which is based on, claims priority to, and incorporates herein by reference in its entirety, Australian Patent Application Serial No. 2015900856, filed Mar. 11, 2015, and entitled, “An Elongate Structural Element, A Bracket and an Elongate Structural Section.”

FIELD

The present invention relates to an elongate structural element, a bracket and an elongate structural section.

The present invention has been developed primarily for use in constructing a structural frame of a building (including multi-story buildings) and will be described hereinafter with reference to this application. However, it will be appreciated that the present invention is not limited to this particular field of use and is also suitable for constructing other structures, such as stand-alone facades, bridges, walkways, shelving/racking, structural boxes, fences and artwork displays. It will also be appreciated that the present invention can be used in conjunction with concrete slabs and existing buildings.

BACKGROUND

During the construction of a conventional building, various structural components are assembled together to form a structural frame. Typically, on-site, each individual structural component is cut to size and then connected to each other by welds, bolts, screws, and/or nails. However, this cutting and joining process is quite labour intensive and requires people with considerable skill to carry out. Further, once the structural frame is assembled, it is often difficult or impossible to disassemble the structural frame such that the structural components can be reused. It is also often difficult to connect additional structural components to the assembled structural frame.

Given the ever increasing cost of labour/materials and the increasing demand for buildings, there is a need for structural components that can be easily and quickly assembled together by people with relatively little skill. There is also a need for structural components that can be readily assembled and disassembled so that they can be reused. There is also a need for structural components that, once assembled, allow for additional structural components to be readily connected thereto. There is also a need for structural components to be readily fabricated and prefinished in a factory using robotic technology. There is also a need for structural components that allow or enable buildings to be readily designed and ordered via a web based system. There is also a need for structural components that allow for sustainable building.

OBJECT OF THE INVENTION

It is the object of the present invention to substantially address one or more of the above needs, or at least provide a useful alternative.

SUMMARY OF THE INVENTION

There is disclosed an elongate structural element, including:

an inner plate having first and second opposing planar surfaces; and

first and second outer sections, each of the outer sections comprising:a central wall having a pair of longitudinal grooves;a pair of side walls extending from the central wall to define a generally U-shaped channel, the longitudinal grooves depressing into the U-shaped channel; anda pair of flanges respectively extending outwardly from the pair of side walls,

wherein the flanges of the first outer section are attached to the first planar surface of the plate and the flanges of the second outer section are attached to the second planar surface of the plate such that the U-shaped channels are substantially closed by the inner plate and opposed to each other.

Each of the grooves preferably comprises a profile with an open narrow region and an enlarged end region. Preferably, the profile of each groove is generally keyhole shaped.

The grooves of the first outer section are preferably substantially parallel with each other, and the grooves of the second outer section are substantially parallel with each other.

The grooves of the first outer section are preferably respectively substantially aligned with the grooves of the second outer section.

The grooves of the first outer section are preferably substantially coextensive with each other, and the grooves of the second outer section are substantially coextensive with each other.

Each of the central walls preferably comprises at least one aperture. Preferably, each of the apertures is generally keyhole shaped with a narrowed region and an enlarged region. In each of the keyhole shaped apertures, the narrowed region preferably extends from the enlarged region substantially parallel to a longitudinal axis of the elongate structural element. In each of the keyhole shaped apertures, the narrowed region preferably extends from the enlarged region at an angle with a longitudinal axis of the elongate structural element. The angle is preferably between 0 to 90 degrees. The angle is preferably about 45 degrees. In each of the outer sections, the narrowed regions of the keyhole shaped apertures preferably respectively extend from the enlarged regions of the keyhole shaped apertures in generally the same direction.

Preferably, each of the apertures is generally rectangular in shape.

The first and second outer sections are preferably substantially coterminous with the inner plate.

The flanges of the first outer section and the flanges of the second outer section are preferably respectively attached to the first and second planar surfaces of the inner plate by: rivets, metal glue, seam welding, spot welding, or a combination thereof.

The first and second outer sections are preferably respectively for lied from a sheet of metal, plastic, carbon fiber or a combination thereof.

Preferably, the element is formed by cast extrusion.

The inner plate is preferably formed from a sheet of metal, plastic, carbon fiber or a combination thereof.

The side walls of the first outer section are preferably respectively aligned with the side walls of the second outer section.

The central wall of the first outer section is preferably substantially parallel to the central wall of the second outer section.

The elongate structural element preferably further comprises a plurality of attachment apertures extending through the inner plate and the flanges of the first and second outer sections.

There is also disclosed herein an elongate structural section, including:

a central wall having first and second ends; a pair of side walls extending from the central wall to define a generally U-shaped channel; and

a pair of flanges respectively extending outwardly from the pair of side walls,

wherein the first end has a male portion and the second end has a female portion configured to receive the male portion of a further elongate structural section such that the elongate structural section is longitudinally attached and aligned with the further elongate structural section.

The male portion is preferably trapezoidal in shape. The female portion is preferably a recess corresponding to the shape of the male portion.

The central wall preferably comprises at least one aperture. Preferably, each of the apertures is generally keyhole shaped with a narrowed region and an enlarged region. The narrowed region preferably extends from the enlarged region substantially parallel to a longitudinal axis of the elongate structural section. The narrowed region preferably extends from the enlarged region substantially at an angle with a longitudinal axis of the elongate structural section. The angle is preferably between 0 to 90 degrees. The angle is preferably about 45 degrees.

Preferably, each of the apertures is generally rectangular shaped.

There is also disclosed herein a bracket for connecting a rail to an elongate structural element, the bracket including:

a body configured for attachment to the elongate structural element, the body defining a shoulder for supporting the rail thereon;

a strap configured for wrapping around the rail, the strap having first and second ends, the first end being secured to the body; and

a bolt configured for attaching the second end to the body and also for fixing the location of the body relative to the elongate structural element.

The bolt is preferably further configured for adjusting a distance between the first end and the second end to adjustably apply tension to the strap.

The bracket preferably further comprises a bolt aperture for receiving the bolt therethrough, the bolt aperture extending through at least the second end and the body. Preferably, the bolt aperture also extends through the first end.

The bolt is preferably receivable into an aperture of the elongate structural element.

The strap preferably comprises a sheet-like material. The sheet-like material preferably has a thickness between 0.05 to 0.5 mm. The thickness of the sheet-like material is preferably between 0.125 to 0.33 mm. The sheet-like material is preferably formed from a metal. When the second end is preferably attached to the body by the bolt, the strap defines a rail aperture for holding the rail therein. The rail aperture preferably has a profile substantially corresponding with an outer profile of the rail. The profile of the rail aperture is preferably generally square, rectangular, or circular shaped.

The body preferably comprises a plate and at least one arm member extending outwardly therefrom defining the shoulder. The arm member preferably has a surface for abutment with the rail, the surface being substantially perpendicular to the plate. The arm member is preferably integrally formed with the plate. The plate preferably comprises two end portions and the surface of the arm member is located between the two end portions. The body preferably comprises two of said at it members. The body preferably further comprises at least one protrusion extending from the plate portion and being receivable into another aperture of the elongate structural element for attachment. The protrusion is preferably a slot pin comprising a narrow portion and an enlarged end portion. Preferably, the protrusion comprises a first part extending from the plate and a second part extending from a free end of the first part to define a recess therebetween for receiving a portion of the elongate structural element.

DESCRIPTION OF EMBODIMENTS

FIGS. 1 to 4show an embodiment of an elongate structural element10for constructing a structural frame of a building. The element10includes an inner plate12having first14and second16opposing planar surfaces. The inner plate12is formed from a sheet of steel. It will be appreciated, however, that the inner plate12may also be formed from a sheet of aluminium, plastic, carbon fibre, or a combination thereof.

The element10further includes first18and second18′ outer sections. As best seen inFIG. 3, the first outer section18is formed from a sheet of steel. It will be appreciated, however, that the first outer section18may also be formed from a sheet of aluminium, plastic, carbon fibre, or a combination thereof. The first outer section18is a top hat section that comprises a central wall20, a pair of side walls22,24and a pair of flanges26,28. The side walls22,24respectively extend from the central wall20such that a generally U-shaped channel30is defined. The flanges26,28respectively extend outwardly from the side walls22,24such that the flanges26,28are aligned to each other and perpendicular to the side walls22,24.

The central wall20has a pair of longitudinal grooves32,34that depress into the U-shaped channel30and are coextensive with each other. The grooves32,34extend the length of the element10and are substantially parallel to each other. Each of the grooves32,34comprises a generally keyhole shaped profile with an open narrow region36and an enlarged end region38. The enlarged end regions38of the grooves32,34are located about midway into the U-shaped channel30. The grooves32,34provide the first outer section18with additional strength and rigidity such the element10is able to better bear structural loads and wind loads. The grooves32,34also provide connection points for other building components (e.g. weather proofing membranes, reflective material and metal panels) that are easily engaged with the keyhole profile of the grooves32,34.

Although, in this embodiment, each of enlarged end regions38is substantially circular in shape, it will be appreciated that the enlarged end regions38may be of any suitable shape (e.g., triangular, diamond-shaped etc.) in other embodiments. Also, in other embodiments, the degree in which the grooves32,34depress into the channel30may vary. For example, as shown inFIG. 45, the grooves32,34may substantially depress into the channel30such that the enlarged end regions38are located near the opening of the channel30. Also, as shown inFIG. 46, the grooves32,34may slightly depress into the channel30such that the enlarged end regions38are located near the central wall20.

The central wall20comprises a plurality of generally keyhole shaped apertures40, each with a narrowed region42and an enlarged region44. In each keyhole aperture40, the narrowed region42extends from the enlarged region44at a 45 degree angle to the longitudinal axis of the element10. The narrowed regions42of the keyhole apertures40respectively extend from the enlarged regions44in generally the same direction. The keyhole apertures40are arranged in groups of 4 and the groups are equally spaced along the length of the element10. In each group, the keyhole apertures40are arranged in a generally rectangular shape with a keyhole aperture40in each corner. The central wall20further comprises a plurality of generally circular locating apertures46located generally in the centre of each group of keyhole apertures40.

As shown inFIGS. 4.1 and 4.2, in another embodiment of the element denoted10a, the narrowed regions42extend from the enlarged regions44substantially parallel with the longitudinal axis of the element10. It will be appreciated that, in other embodiments, the narrowed regions42may extend from the enlarged regions44at an angle between 0 to 90 degrees with the longitudinal axis of the element10.

The second outer section18′ is a mirror image of the first outer section18with all the same features. Accordingly, the same reference numerals used for the first outer section18will be used herein to denote like features of the second outer section18′.

As best seen inFIG. 4, the flanges26,28of the first outer section18are attached to the first planar surface14at edges of the inner plate12so that the first outer section18is coterminous with the inner plate12. The flanges26,28of the second outer section18′ are attached to the second planar surface16at the edges of the inner plate12so that the second outer section18is coterminous with the inner plate12. The U-shaped channels30of the first and second outer section18,18′ are substantially closed by the inner plate12in a water-tight manner and opposed to each other. The flanges26,28of the first outer section18and the flanges26,28of the second outer section18′ are respectively attached to the surfaces14,16of the inner plate12by rivets (not shown). It will be appreciated, however, that the flanges26,28of each section18,18′ may also be respectively attached to the surfaces14,16by metal glue, spot welding, seam welding or a combination thereof. In other embodiments, the element10may be formed from a unitary sheet of metal which has been folded in such a way to define the inner plate12and the outer sections18,18′.

As best seen inFIG. 2, the side walls22,24of the first outer section18are respectively aligned with the side walls22,24of the second outer section18′. The grooves32,34of the first outer section18are also respectively aligned with the grooves32,34of the second outer section18′. The central wall20of the first outer section18is also parallel with the central wall20of the second outer section18′.

The element10further includes a plurality of first and second circular connection apertures48,50. Each of the first connection apertures48extend through the flanges26of the first and second outer sections18,18′ and the inner plate12. The first connection apertures48are equally spaced apart along the length of the element10. Each of the second connection apertures50extend through the flanges28of the first and second outer sections18,18′ and the inner plate12. The second connection apertures50are equally spaced apart along the length of the element10. Each rivet used to fix the flanges26,28of the first and second outer sections18,18′ to the surfaces14,16of the inner plate12are located between a pair of first connection apertures48or a pair of second connection apertures50.

It will be appreciated that a plurality of the elements10are connected and assembled together to form the structural frame. It will also be appreciated that each element10is prefabricated to the required length and then delivered to the construction site for assembly of the structural frame. It will also be appreciated that the elements10can be assembled off-site (e.g., in a factory) and then transported to the construction site.

Although the elements10can be connected together in numerous different ways, only the following exemplary connections will be described below:a T-connection (as seen inFIGS. 8 and 9);a corner connection (as seen inFIGS. 11, 12, 14 and 15);a corner T-connection (as seen inFIGS. 16 to 19); anda straight connection (as seen inFIGS. 22 and 23).
The supporting and/or connecting components utilised for the above connections will also be described below.

FIGS. 5 and 5.1show a triangular bracing/support member52formed from a sheet of steel. The bracing/support member52has a main plate54and a pair of flanges56,58respectively extending from a pair of adjacent edges of the main plate54. The flanges56,58are perpendicular to each other and each flange56,58is perpendicular to the main plate54. The main plate54has a plurality of apertures60located substantially adjacent and equally spaced along the adjacent edges. The main plate54also has a plurality of clearance apertures60a. Each clearance aperture60ais located between a pair of apertures60. The main plate54also has a stiffening groove61that extends parallel to a free edge61aof the main plate54. As best seen inFIG. 5.1, the bracing/support member52also has a plurality of bolt nuts61battached to the main plate54such that each bolt nut61bcorresponds to an aperture60.

FIGS. 6 and 7show an end-to-side interconnection spacer62for connecting two elements10in a T-shape. The end-to-side interconnection spacer62is generally cubic in shape and has a first portion63and a second portion64. The first portion63has a profile substantially matching the inner profile of the element10with a transverse slot65such that the first portion63is able to be fittingly received into an end of the element10with an edge of the inner plate12received into the transverse slot65. The second portion64has a profile substantially matching the outer profile of the element10such that the second portion64is flush with the outer profile of the element10when the first portion63is received therein. The second portion64also has a transverse slot65′ for receiving the flanges26and an edge of the inner plate12of another element10. The end-to-side interconnection spacer62also has a pair of flanges69,69′ that extend outwardly from respective sides of the second portion64.

In another embodiment, as shown inFIG. 7.1, the first and second portions63,64of the end-to-side interconnection spacer62can be substantially hollowed to reduce the amount of material required for its manufacture. Also, the transverse slot65′ of the second portion64can be substantially enlarged.

FIGS. 8 and 9show a T-connection59in which two elements10,10′ are connected by the end-to-side interconnection spacer62and supported by two bracing/support members52,52′. In forming the T-connection, the second portion64of the end-to-side interconnection spacer62is engaged with the element10′ such that the flanges26and the inner plate12of the element10′ are received into the transverse slot65′ and the second portion64abuts with the sidewalls22of the element10′. This will also abut the flanges69,69′ against the inner plate16and the flanges26of the element10′. The element10is then engaged with the first portion63of the end-to-side interconnection spacer62such that the first portion63is received into the end of the element10and the inner plate12of the element10is received into the transverse slot65. This will arrange the element10perpendicularly to the element10′. Two bracing/support member52,52′ are then joined to the element10and the element10′. Specifically, the main plate54of the bracing/support member52is abutted against the flange26of the first outer section18of the element10and the flange26of first outer section18of the element10′. It will be appreciated that the clearance apertures60aof the main plate54will accommodate the rivets of the elements10,10′ such that the main plate54can be abutted against the flanges26of the elements10,10′. The flange56of the bracing/support member52is abutted against the side wall22of the first outer section18of the element10and the flange58of the bracing/support member52is abutted against the side wall22of the first outer section18of the element10′. This will respectively align the apertures60of the bracing/support member52with some of the apertures48of the element10and some of the apertures48of the element10′. Also, the main plate54of the bracing/support member52′ is abutted against the flange28of the first outer section18of the element10and the flange26of the first outer section18of the element10′. The flange58of the bracing/support member52′ is abutted against the side wall24of the first outer section18of the element10and the flange56of the bracing/support member52′ is abutted against the side wall22of the first outer section18of the element10′. This will respectively align the apertures60of the bracing/support member52′ with some of the apertures50of the element10and some of the apertures48of the element10′. A plurality of bolts57are then passed through the aligned apertures and screwably secured to the bolt nuts61bof the bracing/support member52,52′. An advantage of the end-to-side interconnection spacer62is that it enables the transfer of load and allows for expansion. Also, the end-to-side interconnection spacer62enables the continuation of waterproofing membranes to be connected to the elements10,10′.

FIG. 10shows a corner interconnection spacer66for connecting two elements10at a corner. The spacer66has a central portion68and a pair of end portions70,72. The end portion70has a profile substantially matching the inner profile of the element10with a transverse slot74such that the end portion70is able to be fittingly received into an end of the element10with an edge of the inner plate12of that element10received into the transverse slot74. The end portion72has the same profile with a transverse slot76such that the end portion72is able to be fittingly received into an end of another element10with an edge of the inner plate of that element10received into the transverse slot76. The central portion68has a profile substantially matching the outer profiles of the elements10such that the central portion68is flush with the outer profiles of the elements10when the end portions70,72are received therein. The central portion68is perpendicularly bent such that the elements10are substantially perpendicular to each other when the end portions70,72are received therein. The corner interconnection spacer66also has a pair of right-angled flanges73that extend outwardly from respective sides of the central portion68.

FIGS. 11 and 12show a corner connection73in which two elements10,10′ are connected by the corner interconnection spacer66and are perpendicularly oriented. In forming the corner connection, the corner interconnection spacer66is engaged with the elements10,10′ such that the end portion70is received into an end of the element10and the end portion72is received into an end of the element10′. Given that the central portion68of the spacer66has the same outer profile as the elements10,10′, each groove32,34of the first and second sections18,18′ of the element10is continuously connected to a respective groove32,34of the first and second section18,18′ of the element10′. Also, the right-angled flanges73are aligned with the inner plates16and the flanges26,28of the elements10,10′.

FIG. 13shows a corner bracket78comprising two top hat sections80,80′ joined together at a right-angle. The section80comprises a central wall84, a pair of side walls86,88and a pair of flanges90,92. The side walls86,88respectively extend from the central wall84such that a generally U-shaped channel94is defined. The flanges90,92respectively extend outwardly from the side walls86,88such that the flanges90,92are aligned to each other and perpendicular to the side walls86,88. Each of the flanges90,92has a plurality of apertures93equally spaced apart. The section80′ is substantially identical to the section80with all the same features. Accordingly, the same reference numerals used for the section80will be used herein to denote like features of the section80′. The corner bracket78further comprises a floor support having a triangular plate98and two rectangular plates100,102. The rectangular plates100,102respectively extend from adjacent edges of the triangular plate98such that the rectangular plates100,102are perpendicular to the triangular plate98and each other. The rectangular pate102is attached to the central wall84of the section80and the rectangular plate100is attached to the central wall84of the section80′.

FIGS. 14 and 15show the corner connection73secured by the corner bracket78. In securing the corner connection73, the U-shaped channel94of the section80receives the central wall20and the side walls22,24of the second outer section18′ of the element10and the flanges90,92respectively abuts with the flanges26,28of the second outer section18′ of the element10. Also, the U-shaped channel94of the section80′ receives the central wall20and the side walls22,24of the second outer section18′ of the element10′ and the flanges90,92respectively abuts with the flanges26,28of the second outer section18′ of the element10′. This will respectively align the apertures93of the corner bracket78with some of the apertures48,50of the elements10,10′. A plurality of bolts79are then passed through the aligned apertures and srewably secured.

FIGS. 16 to 19show a corner T-connection81in which two elements10,10′ are respectively connected to a corner connection of two elements10″,10′″. It will be appreciated that the corner connection will be formed in the same manner as described above. In forming the T-connections, the element10is connected to the element10″ adjacent the central portion68of the corner interconnection spacer66by a T-connection as described above. However, the bracing/support member52′ is not utilised in this T-connection and the end-to-side interconnection spacer62shown inFIG. 7.1is utilised such that the enlarged transverse slot65′ can accommodate the flange90of the corner bracket78. Similarly, the element10′ is connected to the element10′″ adjacent the central portion68of the corner interconnection spacer66by a T-connection as described above. However, the bracing/support member52is not utilised in this T-connection and the end-to-side interconnection spacer62shown inFIG. 7.1is utilised such that the enlarged transverse slot65′ can accommodate the flange90of the corner bracket78. As specifically shown inFIGS. 18, 18.1 and 19, for securement, corner stiffening members96formed from a W-shaped bracket96aand C-shaped bracket96b. The W-shaped bracket96ais abutted against the flanges28of the first outer section18of the element10and the flanges26of the first outer section18of the element10′. The W-shaped bracket96ahas apertures97along its length for alignment with some of the apertures50of the element10and some of the apertures48of the element10′. The C-shaped bracket96bis abutted against the flanges28of the second outer section18′ of the element10and the flanges26of the second outer section18′ of the element10′. The C-shaped bracket96bhas apertures97′ along its length for alignment with some of the apertures50of the element10and some of the apertures48of the element10′. The corner stiffening members96further has a plurality of bolt nuts96cattached to the C-shaped bracket96bsuch that each bolt nut96ccorresponds to an aperture97′. This allows bolts99to be passed through the aligned apertures and screwably secured to the bolt nuts96c.

FIG. 20shows a stiffening rail98formed from a L-shaped steel section. The rail98has a first wall98aand a second wall98bperpendicular to the first wall98a. The first wall98aincludes a plurality of apertures101equally spaced along its length.

FIG. 21shows an end-to-end interconnection spacer104for connecting two elements10. The end-to-end interconnection spacer104has a central portion106and a pair of end portion108,110. The end portion108has a profile substantially matching the inner profile of the element10with a transverse slot112such that the end portion108is able to be fittingly received into an end of the element10with an edge of the inner plate12of that element10received into the transverse slot112. The end portion110has the same profile with a transverse slot114such that the end portion110is able to be fittingly received into an end of another element10with an edge of the inner plate12of that element10received into the transverse slot114. The central portion106has a profile substantially matching the outer profiles of the elements10such that the central portion106is flush with the outer profiles of the elements10when the end portions108,110are received therein. The central portion106is shaped such that the elements10are substantially linearly aligned to each other when the end portions108,110of the end-to-end interconnection spacer104are received therein. The spacer104also has a pair of flanges105that extend outwardly from respective sides of the central portion68.

FIGS. 22 and 23show a straight connection115in which two elements10,10′ are connected by the end-to-end interconnection spacer104and secured by four rails98,98′,98″,98′″. In forming the straight connection, the end-to-end interconnection spacer104is engaged with the element10,10′ such that the end portion108of the spacer104is received into an end of the element10and the end portion110of the spacer104is received into an end of the element10′. The rail98,98′,98″,98′ are then engaged with elements10,10′ and the spacer104such that the apertures101of the rails98,98′,98″,98′″ are respectively aligned with some of the apertures48,50of the elements10,10′ such that bolts107can pass through the aligned apertures and be screwably secured. Given that the central portion106of the spacer104has the same outer profile as the elements10,10′, each groove32,34of the first and second sections18,18′ of the element10is continuously connected to a respective groove32,34of the first and second sections18,18′ of the element10′.

An advantage of the element10is that it is easily and quickly connected with other elements10without the need for highly skilled technicians. As the element10is essentially formed from three pieces of sheet metal, it can be mass manufactured in an easy, quick and cost effective manner. This allows the element10to be readily prefabricated to the required length and delivered to a construction site for assembly.

Another advantage of the element10is that all connections with other elements10′ are not permanent and easily disassembled. Specifically, all connections are secured only by removable bolts that pass through prefabricated apertures (e.g. apertures48,50).

Another advantage of the element10is that, once assembled with other elements10, additional elements10can be easily connected.

Another advantage of the element10is that the grooves32,34of the first and second outer sections18,18′ of the element10provide additional strength and rigidity such that the element10can bear more structural loads. Further, the grooves32,34provide connections points for other building materials, such as weather proofing membranes, reflective material and metal panels.

Another advantage of the element10is that water cannot pass between the U-shaped channel30of the first outer section18and the U-shaped channel30of the second outer section18′. This is particularly useful, when one of the sections18,18′ is exposed to the outside environment and the other section18,18′ is indoors.

FIGS. 24 to 26show an embodiment of a bracket116for connecting a square tube rail118to the element10such that the rail118is perpendicular to the element10. The bracket116includes a body119configured for attachment to the element10. The body119is formed from a unitary piece of steel and comprises a plate120and two arm members122,124. The arm members122,124respectively extend outwardly from the plate120such that a generally U-shaped profile is defined. Each arm member122,124has a surface126that is perpendicular to the plate120and located between ends portions128,130of the plate120. The surfaces126of the arm members122,124define a shoulder for supporting the rail118.

The body119further comprises four button stud slot pins132extending outwardly from the plate120in an opposite direction to the arm members122,124. The slot pins132are arranged in a generally rectangular shape with a slot pin132in each corner. Each slot pin132has a narrow portion134and an enlarged end portion136. The plate120comprises a circular threaded aperture138located generally in the centre below the surfaces126of the arm members122,124.

The bracket116further includes a strap140configured for wrapping around the rail118. The strap140is formed from a minimum 20 mm wide steel ribbon that has thickness between 0.125 to 0.33 mm so as to be substantially flexible. As best seen inFIG. 26, the strap140is plastically bent in four areas to define, in a closed configuration, a generally square shaped aperture141for the rail118. The aperture141has a profile substantially corresponding with an outer profile of the rail118. It will also be appreciated that the strap140is biased to the closed configuration. The strap140has a first end142with a circular aperture144and a second end146with a circular aperture148. In the closed configuration, the circular aperture144and the circular aperture148are substantially aligned and the first end142is spaced from the second end146. The first end142is secured to the body119between the arm members122,124and below the surfaces126by a pressure plate150such that the first end142is sandwiched between the pressure plate150and the plate120and the aperture144is substantially aligned with the aperture138. The pressure plate150has a circular aperture151substantially aligned with the aperture144. The bracket116further includes a pair of pressure plates152,154that are attached to the second end146so that the second end146is sandwiched therebetween. Each of the pressure plates152,154has a circular aperture153,155that is substantially aligned with the aperture148of the second end146.

The bracket116further includes a threaded bolt156configured for attaching the second end146to the plate120. The bolt156is also configured for fixing the location of the plate120relative to the element10. The bolt156is sequentially passed through the apertures153,148,155with its head located to face outwardly.

It will be appreciated that, in other embodiments, the body119and strap140may be formed from any other suitable material such as plastic or aluminium. It will be appreciated that the strap140may have a thickness between 0.05 to 0.5 mm.

The operation of securing the rail118to the element10by the bracket116will now be described.

As shown inFIGS. 27 to 29, the slot pins132of the bracket116are inserted and locked into a group of keyhole apertures40of the first outer section18of the element10. Specifically, the enlarged end portion136of each slot pin132is inserted into the enlarged region44of a respective keyhole aperture40. The bracket116is then moved so that the narrowed portions134of the slot pins132are received into the narrowed regions42of the keyhole apertures40. This will lock the bracket116such that lateral movement in relation to the element10is prevented. Also, this will substantially align the apertures138,144,148,151,153,155with a locating aperture46of the element10.

As best seen inFIGS. 30 to 32, the strap140is then flexed into an open configuration allowing the rail118to be placed and supported on the shoulder (i.e. abutted on the surfaces126of the arm members122,124). As best seen inFIGS. 33 and 34, the strap140is then allowed to move into the closed configuration such that the rail118is within the aperture141and substantially wrapped by the strap140. The bolt156is then sequentially passed through the apertures151,144,138. As best seen inFIG. 25, the bolt156will protrude from the plate120and therefore pass through the locating aperture46of the element10such that the location of the bracket116in relation to the element10is fixed. In order to adjust the tension applied on the strap140and therefore adjust the constriction on the rail118, the bolt156is rotated and engaged with the threaded aperture138of the plate120to adjust the distance between the first end142and second end144.

An advantage of the bracket116is that the rail118can be easily connected to the element10without the need for highly skilled technicians.

Another advantage of the bracket116is that all connections with the element10and the rail118are not permanent and easily disconnected. Therefore, the bracket116, the element10and the rail118can be readily reused.

Another advantage of the bracket116is that the strap140is substantially thin such that it does not interfere with other components attached to the rail118.

It will be appreciated that, in other embodiments, the bracket116may be for connecting a rectangular or circular tube rail to the element10. In such embodiments, the strap140would be configured to define a rectangular or circular shaped aperture141to correspond to that rail.

FIG. 35shows an embodiment of an elongate structural section160for renovating an existing building and/or installing a facade to a building wall. The section160is formed from a sheet of steel with a thickness of 1 mm. It will be appreciated, however, that the section160may be formed from a sheet of aluminium, plastic, carbon fibre, or a combination thereof. It will also be appreciated that, in other embodiments, the thickness of the section160may be formed from a sheet with a thickness of 1.6 mm or 2 mm. The section160is a top hat section that comprises a central wall162, a pair of side walls164,166, and a pair of flanges168,170. The side walls164,166respectively extend from the central wall162such that a generally U-shaped channel172is defined. The flanges168,170respectively extend outwardly from the side walls164,166such that the flanges168,170are aligned to each other and perpendicular to the side walls164,166.

The central wall162has first174and second ends176. The first end174has a male portion178that is substantially trapezoidal in shape. The second end176has a female portion180in the form of a recess that corresponds to the shape of the male portion178. As shown inFIG. 36, the female portion180of the section160is able to fittingly receive the male portion178of another section160′ such that the section160is longitudinally attached and aligned with the section160′. This allows a plurality of sections160to be easily interconnected in longitudinal alignment without the need for skilled technicians.

The central wall162comprises a plurality of generally keyhole shaped apertures182, each with a narrowed region184and an enlarged region186. In each keyhole aperture182, the narrowed region184extends from the enlarged region186parallel to the longitudinal axis of the section160. The narrowed regions184of the keyhole apertures182respectively extend from the enlarged regions186in generally the same direction towards the second end176. The keyhole apertures182are arranged in groups of 4 and the groups are equally spaced along the length of the section160. In each group, the keyhole apertures182are arranged in a generally rectangular shape with a keyhole aperture182in each corner. The central wall162further comprises a plurality of generally circular locating apertures188located generally in the centre of each group of keyhole apertures182.

It will be appreciated that, in other embodiments, the narrowed regions184may respectively extend from the enlarged regions186at an angled between 0 to 90 degrees with the longitudinal axis of the section160.

The section160further includes a plurality of first and second circular apertures190,192. Each of the first apertures190extend through the flange168and are equally spaced apart along the length of the section160. Each of the second apertures192extend through the flange170and are equally spaced apart along the length of the section160.

The operation of securing the bracket116to the section160will now be described.

As shown inFIGS. 37 to 39, the slot pins132of the bracket116are inserted and locked into a group of keyhole apertures182of section160. Specifically, the enlarged end portion136of each slot pin132is inserted into the enlarged region186of a respective keyhole aperture182. The bracket116is then moved so that the narrowed portions134of the slot pins132are received into the narrowed regions184of the keyhole apertures182. This will lock the bracket116such that lateral movement in relation to the section160is prevented. Also, this will substantially align the apertures138,144,148,151,153,155with a locating aperture188of the section160such that the bolt156can be received therethrough.

FIGS. 40 to 44show another embodiment of an elongate structural element10b. With the exception of the differences described below, it will be appreciated that this embodiment of the elongate structural element10bis substantially similar to the embodiment of the elongate structural element10as described above. Accordingly, reference numerals used to denote components of the elongate structural element10will also be used to denote like components of the elongate structural element10b, with only the corresponding alphabetic reference being changed. For example, the reference number18bwill denote a first outer section of the elongate structural element10b.

In this embodiment, instead of being keyhole shaped, each of the apertures40bof the elongate structural element10bis substantially rectangular in shape with an arcuate side194b.

FIGS. 47 to 51show another embodiment of a bracket116a. With the exception of the differences described below, it will be appreciated that this embodiment of the bracket116ais substantially similar to the embodiment of the bracket116as described above. Accordingly, reference numerals used to denote components of the bracket116will also be used to denote like components of the bracket116a, with only the corresponding alphabetic reference being changed. For example, the reference number140awill denote a strap of the bracket116a.

In this embodiment, the bracket116ais for connecting a square tube rail (not shown) to the element10bsuch that the rail is perpendicular to the element10b. The body119aof the bracket116ais formed by cast metal or cast plastic. Instead of comprising four button stud slot pins132as seen in bracket116, the bracket116acomprises four protrusions196aarranged in a generally rectangular shape with one protrusion196ain each corner. As best seen inFIGS. 49 and 50, each protrusion196ahas a first part198aextending outwardly from the plate120ain an opposite direction to the arm member122a,124aand a second part200aextending downwardly from a free end of the first part198a. In each protrusion196a, the first part198aand the second part200adefine a recess202atherebetween.

As best seen inFIGS. 52 to 54, the periphery of each protrusion196agenerally corresponds to the shape of an aperture40bof the element10b. To connect the bracket116ato the element10b, the protrusions196aof the bracket116bare inserted into a group of apertures40bof the element10bas shown inFIGS. 52 and 53. Then, as best seen inFIG. 54, the bracket116ais longitudinally moved in relation to the element10btowards the arcuate sides194bof the apertures40bsuch that portions of the central wall20bare received within the recesses202adefined by the protrusions196a. This will lock the bracket116asuch that lateral movement in relation to the element10is substantially prevented.

As best seen inFIGS. 48 and 51, the first end142aof the strap140ais secured to the body119aabove the aperture138aby screws204aand the pressure plate150a. The pressure plates152a,154aare attached to the second end146aso that the second end146ais sandwiched therebetween. Each of the pressure plates152a,154ahas an aperture153a,155athat is substantially aligned with the aperture148aof the second end146asuch that the bolt156ais able to pass therethrough. In the closed configuration as seen inFIG. 47, the bolt156apasses through the apertures153a,148a,155aand the threaded aperture138aof the plate120a.

Although the invention has been described with reference to particular embodiments, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.