Patent Publication Number: US-2012042587-A1

Title: Load bearing member

Description:
The present invention relates to normally rigid members including: structural components such as beams, columns and the like; and connecting components such as mechanical fasteners. In particular, but not exclusively, the invention relates to apparatus having an improved performance during dynamic loading, such as destructive vibrations and movements created during earthquakes; and a method of limiting damage to both the integrity of a structure and its non-structural elements due to relative displacement or acceleration forces or dynamic loading. 
     During construction of any structure within the built environment, for facilities such as buildings, bridges, platforms and the like, it is common to rigidly connect structural components using compression fixings or welding. However, seismic wave propagation (expressed as Rayleigh, Love, Primary or Secondary waves) and the associated movements of an earthquake or explosion can cause severe shock waves and intense vibrations which affect base structural components at the foundation of the structure and, in turn, can adversely affect any other structural components which are directly or indirectly rigidly connected to the base components. These types of disturbance can cause damage to, or even the collapse of, the structure. 
     Also, non-structural components of buildings, such as electrical plant, HVAC equipment, windows, ceilings, and external cladding are typically rigidly connected to the building. These non-structural components typically represent around seventy percent of a building value, and the contents of the building can be many times the value of the building. Damage to these non-structural components in an earthquake can result in enormous financial loss, significant business interruption and loss of essential post earthquake services as well as, directly or indirectly, risk to life and injury. Damage surveys of earthquakes have shown that, in many cases, buildings which have only suffered minor structural damage have been rendered uninhabitable and hazardous to life owing to the failure of mechanical and electrical systems and damage to the architectural elements. For all these reasons, the preservation of non-structural components may be equal in importance to maintaining the integrity of the building structure. 
     Non-structural elements such as cladding may be damaged during an earthquake due to two distinct mechanisms, namely, relative displacement or acceleration. In particular, it is common for facade elements of the structure to be distorted and shaken free from the exterior surface of the structure. This can be, directly or indirectly, a hazard or risk to life. 
     It is therefore desirable to structurally isolate non-structural components of buildings to prevent or reduce damage, such as caused by earthquakes. One method of doing this is to provide a flexible, rather than rigid, means of connecting non-structural components to structural components of a structure such as a building. 
     It may also be desirable to provide flexible means of connecting structural components to dampen or decrease the transmission of vibrations during a severe event such as an earthquake. However, such flexible connecting means can be impractical during construction or normal conditions of service for a number of reasons. For instance, construction requires predictable, fixed tolerances which may not be achievable using flexible connectors. Also, a structure with excessive flexibility may at least be perceived to be unsafe. Furthermore, the flexible connector may be a compression fixing but the flexibility of the connector may hinder fastening of the connector. For instance, in a connector with a torsional flexibility, the flexibility will act as biasing means during fastening which will bias the connector in an unfastening direction. It is desirable to provide a means of connecting structural components which provides compressive rigidity during normal in service conditions and dynamic flexibility during excessive dynamic loading conditions. 
     The human body has a mechanism for resisting and reducing damage from unexpected forces and this relies upon the elastic properties of the tendon. For example there are certain configurations of bones and joints within the skeletal frame that provide axial rigidity in normal circumstances but also precipitate the tendons to stretch in response to non-axial loads. 
     Compression fasteners or tension elements for resisting lateral loads form part of many structural systems. However, to overcome existing design, engineering and building constraints and performance limitations, it is desirable to create a means of mechanical anchor, with tendon like responsiveness, that uses passive embedded, tension potential and elastic deformation in the dynamic way proposed. 
     There are also a number of problems with existing technology relating to facade systems for buildings. Current cladding systems, such as precast concrete panels with decorative elements, are extremely heavy to manoeuvre and align accurately. They can require extremely large manufacturing premises as each panel has to be laid flat during manufacture. The panels can also take upwards of two weeks to cure before they can be handled with specialist lifting equipment. 
     Timber or steel frame components, sheathing boards and cladding all vary in dimension and tolerances and have to be altered to create compatible components. Off-site construction methods rely on components being transported to site economically. This can be problematic due to the weight, size and structural integrity of these components. 
     Also, existing insulating brick cladding panels are not structural and, in the event of seismic activity, can become dislodged as they do not allow for the movement involved. 
     Lightweight construction techniques such as timber frame and metal section rely on cladding systems to provide aesthetics to the structure. These cladding systems do not currently provide a homogonous ‘through wall’ solution. Timber construction relies on the framework to be boarded with structural timber-based sheeting products such as plywood which are costly, heavy, and can absorb moisture making them dimensionally or structurally unstable. Alternatively, cement based particle boards can be used but these are heavy and costly. 
     Current cladding methods typically rely solely on chemical fixing of decorative elements which can fail on site, especially if installation conditions are variable. 
     According to a first aspect of the present invention there is provided a load bearing member comprising:
         a first rigid portion adapted to bear a load until the load reaches a predetermined load and thereafter have a reduced or substantially no load bearing capacity; and   a second flexible portion adapted to bear the load after the predetermined load is reached,   wherein the first rigid portion and the second flexible portion cooperate to bear the load such that the load bearing member is enabled to transform from rigidly to flexibly bearing the load when the predetermined load is reached.       

     The term “flexible” is intended to cover any means that allows the second portion to deflect in one or more directions under loading. This includes but is not limited to: a property, such as an elasticity, viscoelasticity or plasticity, of a material forming the second portion; or a geometric configuration that promotes bending, buckling, stretching, compression or rotation of the second portion; or a mechanical arrangement. 
     The first rigid portion may be adapted to fail at the predetermined load. The first rigid portion may include a weakening feature adapted to fail at the predetermined load. Failure at the predetermined load may be due to a material forming the first rigid portion reaching a failure value. The failure may be due to fracture or plastic collapse or elastic buckling of the material. The weakening feature may be adapted to respond more to particular types of loading and less to other types of loading. 
     The weakening feature may be provided at a predetermined axial location. A weakening feature may be provided at a plurality of predetermined axial locations. 
     Alternatively, the load bearing member may include switching means and load sensing means and the load bearing member is adapted to switch from the first rigid portion to the second flexible portion for bearing the load when the predetermined load is reached. The load bearing member may be adapted to switch from the second flexible portion to the first rigid portion for bearing the load when the load falls below the predetermined load. 
     The first and second portions may be configured to bear a load in parallel. The first rigid portion may be arranged to bear the majority of the load prior to the predetermined load is reached. 
     The second flexible portion may be provided as an inner core of the structural member and the first rigid portion may substantially surround the inner core. 
     The first rigid portion may be provided as a hollow tubular member. The second flexible portion may be provided as an inner wire or the like provided within the tubular member. The second flexible portion may be provided with anchor points at each end of the inner wire. 
     Alternatively, the second flexible portion may be formed by removing material from a solid member to form a waist portion. The first rigid portion may be provided as a collar member provided around the waist portion. 
     The first rigid portion and second flexible portion may be provided as an insert for retrofitting to a conventional structural member. 
     The load bearing member may comprise a beam, column, bracket, hanger, strut, axle, cable, pipe, pipe joint, or the like. 
     Alternatively, the load bearing member may comprise a compression fastener such as a bolt, nut, rawlplug screw, washer, nail, clamp or the like. 
     The load bearing member may comprise a fastener and include a washer member. The washer member may comprise a resilient material, such as rubber. The washer member may include a recess or cavity adapted to allow displacement of the second flexible portion. The cavity may contain a gas such as air. The washer may include an aperture having an entrance for the fastener and an exit spaced apart from the entrance and the entrance may be oversized relative to the fastener. 
     The load bearing member may include a sleeve member. The sleeve member may include a joint portion at a location corresponding to the predetermined axial location. The joint portion may be flexible. The joint portion may comprise a concertina member. Alternatively, the joint portion may be rigid until the predetermined load is reached and thereafter flexible. The joint portion may be adapted to fail at the predetermined load. 
     The load bearing member may include transformation indicating means adapted to indicate when the load bearing member has transformed from rigidly to flexibly bearing the load. The transformation indicating means may comprise colour coding or movement of a flag member from a first position to a second position. 
     A testing device may be provided for determining whether the load bearing member has transformed from rigidly to flexibly bearing the load. The testing device may cooperate with the transformation indicating means. Alternatively, the testing device may be adapted to investigate the state of the first rigid portion. 
     The load bearing member may be formed from any suitable material, such as steel, aluminium, plastic or composite. The first rigid portion may be formed from a first material and the second flexible portion from a second different material. The first material may be selected for its failure characteristics. The second material may be selected for its flexibility and/or strength. 
     The compression fastener may be adapted for fastening a facade, such as a brick or stone slip system, or any other type of decorative or non decorative element to a structure such as a building. 
     The load bearing member may form part of the facade of a building. The facade may comprise a plurality of facade elements, such as brick or stone slips, which are attached to a support which is fastened to an exterior surface of the building using a plurality of fasteners. One or more of the fasteners may comprise the first rigid portion and the second flexible portion. 
     The support may be configured to cover a substantial portion of the exterior surface. 
     The facade may include a matrix material interposing the support and the exterior surface. The matrix material may comprise a first layer of compressible material, such as foam, and a second layer of rigid material. The second layer may include a plurality of cavities. The second layer may be a honeycomb material. According to a second aspect of the present invention there is provided a method of supporting a load within a structure using a load bearing member, the method comprising:
         providing the load bearing member with a first rigid portion adapted to have a load bearing capacity until a predetermined load is reached and thereafter have a reduced or substantially no load bearing capacity; and   providing the load bearing member with a second flexible portion adapted to bear the load after the predetermined load is reached.       

     The method may include adapting the first rigid portion to fail at the predetermined load. The method may include selecting a material forming the first rigid portion which will reach a failure value at the predetermined load. The method may include configuring the first rigid portion to fracture, plastically collapse or elastically buckle at the predetermined load. 
     The method may include providing the second flexible portion as an inner core of the structural member and the first rigid portion as substantially surrounding the inner core. 
     The method may include providing the first rigid portion as a hollow tubular member and the second flexible portion as an inner wire or the like provided within the tubular member. The method may include providing anchor points at each end of the inner wire. 
     Alternatively, the method may include forming the second flexible portion by removing material from a solid member to form a waist portion and providing the first rigid portion as a collar member around the waist portion. 
     The method may include retrofitting the first rigid portion and second flexible portion to a conventional structural member. 
     The method may comprise supporting a plurality of facade elements provided on the exterior surface of a building. The facade elements may be attached to a support which is fastened to an exterior surface of the building using a plurality of fasteners. One or more of the fasteners may comprise the first rigid portion and the second flexible portion. 
     The method may include interposing a matrix material between the support and the exterior surface. The matrix material may comprise a first layer of compressible material, such as foam, and a second layer of rigid material. The second layer may include a plurality of cavities. The second layer may be a honeycomb material. 
     According to a third aspect of the present invention there is provided a facade system which is installable on the exterior surface of a structure, the facade system comprising:
         a plurality of facade elements;   a support for supporting the facade elements and which is attachable to the exterior surface using a plurality of fasteners; and   a matrix material interposing the facade elements and the exterior surface, wherein the matrix material comprises a first layer of compressible material and a second layer of rigid material.       

     The first layer may comprise a foam material. 
     The second layer may include a plurality of cavities. The second layer may be a honeycomb material. 
     The matrix material may interpose the support. Alternatively, the matrix material may be adapted to provide the support. 
     One or more of the fasteners may comprise a first rigid portion and a second flexible portion. 
     The first rigid portion may be adapted to fail at the predetermined load. Failure at the predetermined load may be due to a material forming the first rigid portion reaching a failure value. 
    
    
     
       Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which: 
         FIG. 1  is a side view of a fastener according to a first embodiment of the invention; 
         FIG. 2  is a cross sectional side view of the fastener of  FIG. 1 ; 
         FIG. 3  is a cross sectional end view of the fastener of  FIG. 1 ; 
         FIG. 4  is a cross sectional side view of a fastener according to a second embodiment of the invention; 
         FIG. 5  is a side view of the fastener of  FIG. 1  fastening a panel to a wall of a building; and 
         FIG. 6  is a perspective view showing a number of variations of washers that can be used with a fastener according to the invention. 
     
    
    
       FIGS. 1 to 3  show a load bearing member which in this embodiment is in the form of a bolt  10 . The bolt  10  has a first rigid portion comprising a shaft  12  having a hollow portion  14 . The shaft  12  includes a weakening feature in the form of fracture lines  16  at a distance  100  from the head  18  of the bolt  10 . The bolt will be subject of various types of loading such as tension, shear and torsion, and torque will be applied to fasten the bolt  10 . The number, depth and direction of the fracture lines  16  are selected so that the shaft  12  will catastrophically fail at a predetermined load. Therefore, the shaft  12  is adapted to bear a load until the load reaches a predetermined load and thereafter will have no load bearing capacity. Also, the direction of the fracture lines  16  can be selected to promote failure from a particular type of loading. For instance, in  FIG. 1 , the fracture lines  16  are normal to the longitudinal axis of the bolt  10 . Therefore, tensile and shear loads are more likely to cause fracture than, say, torsional loads. Such loads are more commonly produced during the dynamic loading associated with wave propagation and seismic movement from earthquakes. This feature also minimises the likelihood of undesirable catastrophic failure during fastening of the bolt  10 . 
     A second flexible portion in the form of a connector wire  20  is provided within the hollow portion  14  between two anchor points. The wire is selected to sustain a load which exceeds the intended in service loading demands and therefore a greater load than the predetermined load. Therefore, like a performance enhancing tendon, the wire  20  will bear the load after the predetermined load is reached. 
     The hollow portion  14  of the bolt  10  is particularly suitable for resisting bending loads since the material is offset from the centreline of the shaft  12 . The wire  20  will be flexible during bending as it is positioned at the centreline. A wire has an elasticity which allows a degree of elongation during tensile loading. To increase the possible displacement in this direction, the wire  20  may be provided with some slackness. 
     It can be seen that the hollow portion  14  and the wire  20  are configured to bear the load in parallel. However, the hollow portion  14  will bear the majority of the load prior to the predetermined load being reached. 
       FIG. 4  shows an alternative embodiment of the load bearing member, still in the form of a bolt  10  and like features are given like reference numerals. 
     A waist portion  22  is formed by removing material from a convention bolt shaft which effectively acts as the flexible wire of the first embodiment due to its reduced diameter. A collar  24  is provided around the waist portion  22  which is formed from a brittle material. The brittle material is selected to fail at the predetermined load and thereafter the waist portion  22  will bear all of the loading. 
     In an alternative embodiment, which can be based on the first or the second embodiments, the first rigid portion and second flexible portion can be provided as an insert for retrofitting to a conventional bolt. 
     There are many other ways of forming the load bearing member. The flexible portion could be cast in to the rigid portion. Or the flexible portion could be mounted at the exterior or around the rigid portion, such as a spring member coiled around the flexible portion and having an end attached to the rigid portion on both sides of the fracture lines  16 . 
       FIG. 5  shows the bolt  10  of the first embodiment fastening a facade panel  110  to a wall  112  of a building. The location of the fracture lines  16  is predetermined so that they are located at the interface of the panel  110  and wall  112 . This is important as, if the fracture lines  16  are located within the wall then the wall could restrict flexibility, whereas if the fracture lines  16  are located within the panel then the panel could be damaged or vibrations could be propagated from the wall to the panel. 
     A range of bolts  10  of the invention can be provided with the fracture lines  16  at a variety of locations to correspond to different standard or non-standard thickness of panels or elements. For standard panels, the fracture lines  16  simply have to be located at a distance from the head  18  which corresponds to the thickness of the panel being used. For non-standard panels, packer elements, such as washers or straps, can be provided between the head  18  and the panel to ensure that the fracture lines  16  are located at the interface. 
     Post-installation adjustment means can be provided. In particular, the bolt  10  can be adjusted so that the fracture lines are at the interface. 
     In certain situations, more than one panel may be being fastened to the wall  112 . The bolt  10  can be adapted to have fracture lines  16  at more than one location along its shaft  12 , with each location corresponding to an interface of the panels or of a panel and the wall  112 . Such a bolt  10  could also be useful for cavity walls. 
     During normal conditions, the bolt  10  acts as a conventional bolt supporting static loading from the weight of the panelling. The hollow portion  14  will support the majority of this static loading. During an earthquake, the wall  112 , which is directly or indirectly rigidly connected to structural components at the ground, will vibrate which will exert dynamic loading on the bolt  10 . When this dynamic loading reaches the predetermined load, the hollow portion  14  will fracture and the wire  20  will then take up the loading. The wire provides the dynamic flexibility and inherent strength required. Therefore, the panel  110  will still be fastened to the building but in a more flexible manner which accommodates relative displacement between the panel  110  and the wall  112 . 
     The bolt  10  can be configured such that, after the hollow portion  14  has fractured, a portion of the hollow portion  14  is sacrificed or released. The remaining portions can provide a failsafe retaining capability. 
     A washer may be provided which is formed from a resilient material such as rubber. This increases the flexibility of the bolt  10  both before and after the predetermined load has been reached. And by allowing a greater relative displacement, the washer can also increase the predetermined load which may be desirable. The washer can comprise two rigid plates which sandwich a rubber material, with an aperture through the washer for receiving the bolt  10 . The rubber material allows relative lateral displacement of the two plates during dynamic loading. The aperture at the outer plate (adjacent to the head  18 ) can be made to be oversized relative to the bolt outer diameter to accommodate pivoting of the bolt  10  relative to the outer plate (the side walls of the aperture will not restrain the bolt  10  from pivoting). Alternatively, the aperture at the inner plate can be oversized. 
     The washer can also include a recess or cavity to allow greater displacement of the wire  20  after the predetermined load has been reached. The recess provides a volume of space allowing unrestrained movement of the bolt  10  other than at the outer plate. The recess also, by removing material from the washer, allows greater deformation of the washer caused by dynamic movement of the bolt  10 . In the case of the washer having a cavity, this cavity can be filled with a gas such as air. This arrangement does not interfere with dynamic movement of the bolt  10  but assists in the washer returning to its non-deformed state. 
     Examples of such washers are given in  FIG. 6  which shows washers both with and without the recess. As shown in certain examples, the washer can be adapted for a single bolt or for many and can even be provided as a full panel. Also, the washer can be adapted to fit to a corner of the building. 
     It is common, when fastening a fastener to a substrate, to use a sleeve inserted into the substrate for receiving the fastener. The sleeve protects the fastener from corrosion. The load bearing member according to the invention can include a sleeve which has a joint portion at a location corresponding to the predetermined axial location of the fracture lines  16 . The joint portion can be flexible such as being formed as a concertina member which allows bending, compression and elongation, or the joint portion can be rigid until failure at the predetermined load and thereafter flexible. In an alternative embodiment, the sleeve can be adapted to provide the second flexible portion of the load bearing member. 
     The load bearing member can be provided with transformation indicating means to indicate when the load bearing member has transformed from rigidly to flexibly bearing the load. This may comprise colour coding in which the colour appears or changes when the load bearing member has transformed. Or a flag member could be provided which changes from a first position to a second position when the load bearing member has transformed. Or a sensor may be embedded which detects the transformation and sends a signal to a visual or auditory alarm device. The alarm device can be provided at the load bearing member or may be remote. 
     A testing device may be provided for determining whether the load bearing member has transformed. The testing device may cooperate with the transformation indicating means. Alternatively, the testing device may be adapted to investigate the state of the first rigid portion, such as by testing the flexibility of the load bearing member. 
     While the foregoing description relates to a bolt, it can be appreciated that the invention can apply to any fastener such as a nut, screw, rawlplug, washer, nail, clamp or the like. 
     However, it should also be appreciated that the invention may relate to a structural component (a structural part of the building) such as a beam, column or bracket, or it may relate to an insert for such a component. 
     Considering again  FIG. 5 , the flexible connector is particularly suitable for attaching a facade system to a building. To further inhibit damage to the facade, the facade can include a matrix material interposing the support for facade elements (not shown) and the exterior surface. The matrix material can comprise a first layer of compressible material, such as foam, and a second layer of rigid material. 
     The foam layer has a mesh layer either side bonded on to it using an adhesive. The foam layer allows greater relative displacement but is relatively structurally weak. The second layer, being rigid, is stronger. The second layer can be a honeycomb material which includes a number of cavities. These act to absorb vibrations and so limit the propagation of vibrations to the facade elements. 
     The embodiment also increases the in-plane shear performance of the facade and its attached elements by enhancing the ability to resist seismic shear forces. This ability to improve and maintain vertical resistance after sustaining significant in-plane shears is due to the embodiment capability to deliver a secure and an elastic response upon demand. Therefore a decrease or loss of in-plane shear strength and stiffness in the facade or (conceivable) out-of-plane structural failure can to some extent be abridged by this embodiment. 
       FIG. 7  shows another embodiment of a façade system according to the invention. 
     Fixings  30  are used to fix the façade system to a structural member of the building. These fixings  30  can be a load bearing member, such as the bolt  10 , according to the first aspect of the invention. 
     Façade elements  32  are bonded, using an adhesive layer  34  to a mesh layer  36 . The adhesive layer  34  provides pressure and/or chemical and/or heat bonding of the façade elements  32 . The adhesive, in liquid form, expands under pressure within a moulding press to achieve homogonous bonding throughout. This layer  34  also prevents water absorption and provides a thermal break between the external façade elements  32  and the internal structure of the building. 
     The mesh layer  36  comprises a rigid or flexible material which is encapsulated within the adhesive layer  34 . The mesh layer  36  can also provide for spacing and/or support of the façade elements  32  during the bonding process. The mesh  36  can be flat or profiled for reinforcing the overall panel. The mesh  36  incorporates alignment markers to facilitate the alignment of the mesh relative to the mould casing and/or façade elements  32 . The mesh can be made up from a series of plates, strips or as one continuous sheet. 
     Connection between panels is provided by members  38  which can either be incorporated into the mesh material or provided as separate elements such as plates, strips, tabs or the like. The connection system locates the mesh  36  and fixing points. It can comprise locating members on the perimeter of the mesh  36 . These members  38  can interlock the edges of the mesh or the whole panel. When mesh elements and/or whole panels are locked together, a homogonous mesh across a defined section of the building structure is created. Where two panels connect, the façade elements  32  (which are pre-bonded together under pressure by the adhesive layer  34 ) are inserted between the locking interface. This covers the join between panels and masks the fixings which are exposed at the locking interface. Each panel can have an exposed area measuring half the size of a façade element  32  so that, when the panels are brought together, a full façade element can be inserted into the exposed area. 
     Inserts  40  can be incorporated into the mesh material or can be provided as a separate element. The insert  40  locates the mesh  36  within the mould and positions the mesh  36  relative to the fixing points which are dispersed between façade elements  32 . The insert  40  spreads the load of the fixing preventing the head of the fixing from pulling through the surface and damaging the adhesive layer  32 . 
     A binding element  42  in the form of a sheet material is bonded to the adhesive layer  32  during the pressure bonding process. The binding element acts as a medium between the adhesive layer  32  and a second adhesive layer  44 . This medium facilitates a strong, keyed bond between the two adhesive layers. The second adhesive layer  44  bonds the adhesive layer  32  to a drainable/non drainable honeycomb board  46 . By chemically bonding these elements, a strong, rigid, light weight, homogonous panel is created. 
     The drainable/non drainable honeycomb board  46  can be made up from a combination of materials such as fibreglass, metals, magnesium oxide board and the like. The boards  46  can be vented or unvented and can inhibit or allow the passage of moisture. The board  46  has the ability to create a drainable cavity which is a standard requirement for many types of construction under current building regulations. As a result, the honeycomb board  46  bypasses the need for a separate cavity within wall. 
     Steel or timber frames  48  are used to create a rigid, light weight structure. The frame can use proprietary fixings or load bearing members according to the first aspect of the invention. 
     The complete walling system can be mounted in such a way that they can either be attached to the main sub-structure or isolated from the main structure and able to move independently under specific circumstances such as seismic shock. Isolation from the main structure compensates and protects the overall cladding configuration from the effects of love waves and other forces. The frame sections are insulated on the internal side of the wall allowing for soft or rigid insulation to be used. 
     The facade of the invention provides a holistic solution, rather than an elemental solution, for the external or internal use of walling. The core of the system is created in specifically designed moulds which bond (under pressure) the façade elements  32  to a reinforcing mesh  36 . This creates a highly robust and lightweight component. This component is then bonded to a drainable/non-drainable honeycomb board  46 . At this stage a rigid panel is created which can then be attached mechanically to frame members. 
     The system can be manufactured in flat panels and/or in corner panels which are used for external/internal building corners and reveals. 
     The panels are lightweight and strong and structurally stable enabling them to be lifted and transported easily. Due to their light weight, the panels can be aligned and fixed to the frame members with ease. Full wall panels can be assembled quickly as pressure bonding and chemical bonding processes take hours rather than weeks to cure. 
     The components of the panels are pre-matched to ensure that all fixings, structural members and façade elements align and interact in a modular fashion. Whole wall systems can be manufactured off-site enabling reduced build schedules with less dependency on weather conditions or wet trades. A complete, homogonous through wall solution can be achieved with both external and internal wall finishes being applied onto structural framework off-site. 
     The use of flexible fixings provides flexibility throughout the homogonous structure which enables the decorative elements to remain isolated from any shock. 
     Honeycomb board technology combines moisture resistance, light weight, strength, stability and drainable/non-drainable options which create the opportunity to avoid heavy, costly, moisture absorbing sheeting materials. Authentic brick finishes can be achieved off-site and in a factory controlled environment. The panels provide accurate brick spacing over large areas with the security of chemical and mechanical fixing. 
     Whilst specific embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the present invention.