Patent Description:
The invention has been developed primarily for use in/with single or multilevel building structure and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

Conventional methods of constructing cavity walls of a single storey or multi-level building are often time-consuming and labour intensive. Typically, to construct a wall conventionally using masonry units such as bricks or concrete blocks requires much on-site labour and ordering of bulk raw materials on site. These raw materials must be stored on site until they are used up during the building process. In addition, a substantial amount of time and resources are typically required for vertical lifting and loading of materials when constructing high rise buildings. In addition, a substantial amount of effort and labour is required for installing scaffolding for safe access to these cavity walls on multiple story constructions.

Prefabricated walls offer the convenience of pre-fabricating wall panels in a factory controlled environment and then transporting these panels to the site, lifting them up to the desired level and securing them to the side of the building. They also do not require large amount of raw materials to be present and handled by workers on site which reduces occupational health and safety risk to the workers on-site. Less workers are also required to transport and install prefabricated walls. Thus, construction using prefabricated walls is more time efficient over conventional construction processes. This in turn increases the chances of the project being completed in time.

However, one of the inherent challenges in using pre-fabricating walls are that wall panels must be sufficiently secured and robust during transport, lifting and installation, especially for higher levels of high-rise buildings. There is also the risk that the wall panels will break during transportation. During transportation, handling and installation, panels may be subject to bending forces, which creates tension stresses in the panel. Panels are typically designed for handling compressive stressors and not tension stresses, and this can result in the panels becoming easily damaged or broken.

A brick wall panel is typically desired over concrete outer walls for aesthetic purposes. However, typically brick walls are ill-equipped to withstand loading that the walls may experience during transport such as tensile and bending loads.

Also, as prefabricated walls are constructed as a whole in a factory controlled environment, for example using traditional brick and mortar and/or concrete, they must be completed before transportation. Hence, after the walls have been constructed, there is less opportunity to modify the prefabricated wall to accommodate, for example, reinforcement members or in-wall and through-wall elements.

Other challenges include being able to easily configure walls for different purposes such as different loading conditions for example, at different levels of a building. Also, if pre fabricated walls have a complicated bespoke design, then lifting and transporting the particular panel must be configured to suit the physical and mechanical characteristics of the particular design. This can be an expensive process, especially if skilled labour is used to construct these walls.

In the specification, any reference to the term "masonry" shall be deemed to include clay, stone such as mobile, granite, travertine, and limestone; or concrete, , including without limitation, conventional concrete masonry units such as hollow stretcher blocks, autoclaved aerated concrete blocks, bricks, or any other mineral, rock or similar material that may be used for cladding on a building structure.

The present invention seeks to provide a prefabricated wall and a method of manufacturing a prefabricated wall, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

<CIT> details an invention focused on improving the manufacture of brick wall panels through a novel vibrating mortar plow. This plow has parallel fins designed to fit into mortar spaces between bricks, ensuring even mortar distribution and preventing air pockets. The brick wall panels feature cantilevering connectors, allowing them to be directly attached to a building structure or connected to a backing layer to form composite panels. This innovation enhances the quality and efficiency of brick wall panel production and provides flexible mounting options, resulting in more robust constructions and faster installation.

According to a first aspect of the present invention, there is provided a prefabricated wall assembly as defined in claim <NUM> for constructing a wall of a building. According to a further aspect of the invention; there is provided a method of manufacturing a prefabricated wall assembly as defined in claim <NUM>.

In the first aspect, the invention may be said to consist in a prefabricated wall assembly including:.

In one embodiment, the prefabricated wall assembly further includes at least one or more support brackets on which the prefabricated wall assembly may be supported by a building structure.

In one embodiment, the prefabricated wall assembly further includes a wall connector arrangement configured for securely engaging a prefabricated wall assembly with an adjacent similar prefabricated wall assembly.

In one embodiment, the prefabricated wall assembly further includes slinging formations associated with one or both selected from the outer frame assembly and the inner frame assembly, the slinging formations being configured for slinging of the prefabricated wall assembly during installation of the prefabricated wall assembly on a building structure.

In one embodiment, the slinging formations are configured for being received into complementary recesses in an adjacent similar prefabricated wall assembly as the wall connector arrangement.

In one embodiment, the connecting assemblies include a thermal barrier layer.

In the further aspect, the invention may be said to consist in a method of manufacturing a prefabricated wall assembly, the method comprising the steps of:.

The step of manufacturing the prefabricated wall assembly may include the step of:.

In one embodiment, the rigid vertical members are rigid side members.

The invention will now be described, by way of example only, with reference to the accompanying drawings. Here <FIG> concern an aspect not according to the invention but which is useful for understanding the invention. In the drawings:.

It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

A first embodiment of a prefabricated masonry panel assembly <NUM> not according to the invention is depicted with reference to figures <FIG>. A prefabricated wall panel assembly <NUM> in accordance with one embodiment of the present disclosure is positioned and installed between an upper building structure <NUM> and a lower building structure <NUM> which together define a level of a building.

The prefabricated masonry panel assembly <NUM> can be used to construct the outer walls of a single level building or a multi-level building.

The prefabricated masonry panel assembly <NUM> includes a panel <NUM> formed from masonry units (such as a type of brick) laid using mortar. In this embodiment, a standard clay brick comprising three "cores" or holes which extend through the entire the thickness of each brick, are used (not shown). Each core is substantially cylindrical. In this embodiment, each core has a diameter of <NUM>. It is envisaged that in other embodiments, other types of masonry units can be used. However, an advantage of this prefabricated masonry panel assembly is that conventional bricks which are readily available, can be used.

The brick panel <NUM> can be formed by laying individual blocks of bricks which can be stacked to form a brick panel. Each panel <NUM> includes several horizontal layers or courses of laid brick. As shown in <FIG> and <FIG>, for example, each course is horizontally offset relative to a vertically adjacent course.

The bricks in each course are positioned relative to bricks of a vertically adjacent course such that cores of vertically adjacent bricks are aligned to provide at least one continuous longitudinally extending aperture extending from the top surface to the bottom surface of each block. Thus, each block can have a plurality of continuous apertures along the breadth of the block, each aperture extending from a top surface of the block to the bottom surface of the block. In the illustrated embodiment, each block has five continuous apertures. When the blocks are stacked vertically, each continuous aperture in each block is contiguous with a corresponding continuous aperture in a vertically adjacent block. This results in apertures extending continuously through each panel from the top surface <NUM> of each brick panel <NUM> to the bottom surface <NUM> of each brick panel <NUM> for housing a rod (not shown).

In other embodiments, the brick panel can also have a thickness (T) of more than one brick.

In the illustrated embodiment, each block has a width or breadth that is equal to the width or breadth of the panel.

Typically, each brick has at least one hole extending through the brick. In the present embodiment, it is not necessary for each laid brick to be filled with settable material such as concrete as it is laid. Typically, each hole is filled to stiffen each brick and in turn, to stiffen a wall formed of the laid bricks, for example. In the present system, each brick does not have to be filled with concrete or mortar. An advantage of this is that a robot such as the SAM construction robot can quickly and efficiently lay the bricks in each block, especially in an off site environment. This reduces the need for costly human labour and is more efficient. Using a robot can also reduce workplace health and safety risk associated with employing human construction workers to lay bricks. An advantage of using blocks of bricks is that an entire panel of bricks does not need to be constructed at once. Another advantage of this is that reinforcement members can be horizontally positioned between blocks of bricks that have been laid by the robot, for example.

Alternatively, when bricks are laid manually, the brick laying process is made more efficient and less variable (i.e. the blocks will have more uniform stress distribution across each block under loading) if the holes in each brick do not need to be filled. Less mortar is also required to assemble each block of laid bricks.

<FIG> illustrates a side view of a portion of the brick panel <NUM> of the present embodiment. In this embodiment, each block <NUM> includes <NUM> courses or rows of bricks. The laid brick panel <NUM> can be reinforced using reinforcing members (not shown) at bed joints <NUM> to stiffen and strengthen the brick panel. Reinforcing members at bed joints may be in the form of wire tracks that run in parallel between each row or course of bricks, or any other suitable form of reinforcement. Also, other reinforcing members can be used to connect adjacent blocks and to reinforce joints between adjacent blocks of bricks. For example, an elongate rod such as a helix bar can be used to join adjacent blocks of bricks within the panel. It is envisaged that other types of reinforcement members can be used to reinforce and connect adjacent blocks such as re-bars.

A bed joint <NUM> is preferably positioned between adjacent blocks <NUM> (i.e. after every five rows) to connect and simultaneously reinforce adjacent blocks <NUM>. The panel <NUM> shown in <FIG> has a thickness or width of one brick. It is envisaged that in other embodiments, the thickness or width of the panel can be the thickness of more than one laid brick to achieve a desired strength or other parameter.

The type, number and spacing of reinforcement members each brick panel <NUM> can be varied.

<FIG> shows a side view of the prefabricated wall assembly <NUM> installed between an upper building structure <NUM> and a lower building structure <NUM> of a level of a multi-level building.

The assembly <NUM> also includes a first support <NUM> attached to a top end of the brick panel <NUM>, as shown in <FIG> and <FIG>.

The first support is shown as a first angle bracket <NUM> defines an internal angle that is positioned and installed to abut over an inner edge of a top of the brick panel <NUM>. The first angle bracket <NUM> has a first flange <NUM> and a second flange <NUM> perpendicular to the first flange <NUM>. The first flange <NUM> is flush with the top surface of the brick panel <NUM>. The first angle bracket <NUM> is installed such that the second flange <NUM> depends or extends downwardly from the top surface of the brick panel <NUM>. The first angle bracket <NUM> extends along substantially the entire top surface of the brick panel <NUM>. The blocks <NUM> of the upper course of the brick panel include an extended portion <NUM> for hiding the first support for better aesthetics from outside of the brick panel <NUM>, so that an oversize gap is not shown between adjacent installed masonry panels.

The assembly <NUM> also includes a second support <NUM> attached to and configured to support the bottom end of the brick panel <NUM>. As shown in <FIG>, the second support <NUM> is a strip of metal <NUM>. The second support <NUM> preferably extends along the entire width of the brick panel.

The assembly <NUM> further includes at least one tensioning and/or torqueing fastener <NUM> configured to fasten the first support <NUM> and the second support <NUM> to the brick panel <NUM> and to apply a clamping force to compress the brick panel <NUM> between the first support <NUM> and the second support <NUM>. In the embodiment illustrated in <FIG>, the torqueing fastener <NUM> comprises a threaded rod <NUM> and at least one torqueing member <NUM> coupled to the threaded rod <NUM> at one or both ends of the rod <NUM>. In an alternative embodiment (not shown), it is envisaged that the rod <NUM> may be permanently secured one of the support members at one end, for example by welding, and threaded at an opposed end.

As mentioned previously, the brick panel <NUM> has <NUM> continuous apertures extending through an entire height of the brick panel <NUM>. Each of the first and second support members (<NUM>, <NUM>) also have at least one aperture or hole extending through each of the first flange <NUM> of the first support, and the second support <NUM>. Each of the holes in each of the first <NUM> and second support <NUM> members is aligned or concentric with each of the longitudinally extending continuous apertures in the brick panel <NUM> such that each threaded rod <NUM> can simultaneously extend through the respective holes in each of the supports and also, through the entire height of the brick panel <NUM>.

In the embodiment illustrated in <FIG>, the torqueing member <NUM> are provided as torqueing nuts <NUM> or a threaded nut including an internal thread complementing the thread of the rod. There is a first torqueing nut <NUM> coupled to a first end of the rod when the rod is inserted within the brick panel <NUM>. The first torqueing nut <NUM>, in use, is also located above the first flange <NUM>. There is a second torqueing nut <NUM> coupled to the second end of the rod <NUM>. The prefabricated wall assembly of claim <NUM> , wherein the torqueing member is a threaded nut.

In this embodiment, the prefabricated wall panel assembly <NUM> also includes a second angle bracket <NUM> configured to connect the brick panel <NUM> to the lower structure <NUM> of the building. <FIG> shows that the second angle bracket <NUM> is located three courses or rows of masonry units above the bottom of the brick panel <NUM> and is attached to the top of the lower building structure. This is so that the outer side of the floor of the level is concealed and/or covered by the brick wall <NUM>. The height of the structure <NUM> in the current embodiment corresponds to three blocks.

As shown in <FIG>, a first flange <NUM> of the second angle bracket <NUM> is located between and attached to adjacent vertical blocks of the brick panel <NUM>. A second flange <NUM> of the second angle bracket <NUM> is located adjacent the lower structure <NUM> of the building. In this case, the structure <NUM> of the building includes a concrete slab to which the prefabricated brick panel assembly is attached.

The second angle bracket <NUM> is installed such that the second flange <NUM> of the second angle bracket <NUM> preferably extends upwardly. However, in alternative embodiments, it is envisaged that the second flange <NUM> could extend downwardly. The second flange <NUM> of the second angle bracket <NUM> extends parallel to an inner side of the brick panel (i.e. a side of the brick panel that will be located internal to the building after the prefabricated brick panel assembly is installed).

After a threaded rod <NUM> is inserted into each of the continuously extending apertures (not shown), one or both of the torqueing nuts <NUM> can be rotatably coupled to each end of the rod. Further rotating of applying torque to one or both of the torqueing nuts <NUM> creates tension within each of the threaded rods which, in turn applies a clamping force to the first and second support (<NUM>, <NUM>) and the brick panel <NUM>. Each of the first support and the second support (<NUM>, <NUM>) restrain the brick panel <NUM> and reinforce the ends of the brick panel <NUM> to prevent crumbling of bricks located at either end of each brick panel <NUM>.

Having rods <NUM> within the brick panel <NUM> is advantageous as when the clamping force is applied, the brick panel <NUM> will not tend to buckle under any bending force as it is restrained by each of the rods. As each of the rods extend through the entire height of the panel <NUM>, the clamping force or preload is relatively evenly distributed along the entire height of the panel. In this way, a clamping arrangement and/or tensioning arrangement is provided by the torqueing nuts, first and second supports and threaded rod acting in concert to compress the brick panel.

Advantageously, after the panel <NUM> has been sufficiently compressed to achieve the desired stiffness across the entire panel, the rods <NUM> being located inside the brick panel <NUM> also act as reinforcing members to internally reinforce the brick panel. The stiffened and strengthened brick panel <NUM> can be transported using suitable machinery to the installation site.

Stiffening the panel reduces the likelihood that the brick panel will warp and be damaged in use. Bricks are porous and typically, have a low tensile strength. Bricks have a relatively high compressive strength and so, are able to be compressed to a significant extent without breaking. The torqueing fastener and/or clamping arrangement holds the entire brick panel including all reinforcing members together during transport. Pre-compressing the brick panel <NUM> therefore requires the pre-compression to be overcome before the bricks and/or mortar move into a state of tension, thereby helping to prevent the bricks being damaged or the panel <NUM> coming apart.

Other types of masonry units made of clay or concrete or other similar materials have similar characteristics. By reinforcing and compressing the brick panel <NUM>, the brick panel <NUM> is able to better withstand tensile, compressive, bending, torqueing and shear loading during transport.

<FIG> depicts a top view of the prefabricated masonry panel assembly <NUM> after it has been installed.

<FIG> depicts a bottom view of the prefabricated masonry panel assembly <NUM> after it has been installed.

Both figures illustrate that five torqueing fasteners <NUM> were used to compress the brick panel <NUM> in this embodiment. It is envisaged that in other embodiments, the prefabricated wall assembly <NUM> can include more or less than five torqueing fasteners.

The diameter, gauge of thread of each rod, number of fasteners, and spacing of fasteners can be varied to achieve the desired mechanical characteristics of the wall.

As shown in each of <FIG> and <FIG>, the assembly also includes a restraining arrangement <NUM> to restrain the walls against lateral loads caused by wind at higher levels of the building, and assist with slab deflections. The restraining arrangement <NUM> includes a first part <NUM> including a first protrusion or plate <NUM> configured to be connected to an underside of the upper structure <NUM> of the building to extend substantially vertically.

The restraint or restraining arrangement <NUM> also includes a second part <NUM> including two protrusions in the form of plates <NUM> projecting perpendicularly to and inwardly (towards the inside of the building) from preferably the second flange <NUM> of the first angle bracket. Each projecting plate <NUM> includes a slot (not shown) that is sized to receive the first plate <NUM> of the first part <NUM> within the slots of the plates <NUM>. <FIG> shows the first plate <NUM> received within and through the slots.

The vertically oriented first plate <NUM> of the first part <NUM> is preferably substantially rectangular and has a length, a width and a thickness. When attached to the building structure, the first plate <NUM> extends vertically downwards through the slots provided in each of the two projecting plates <NUM>. The first plate <NUM> of the first part <NUM> extends perpendicularly downwards relative to the two projecting plates <NUM> and through the slots of each of the two projecting plates <NUM>. The first plate <NUM> also extends in a direction parallel to the brick wall panel <NUM>.

Each slot (not shown) in plates <NUM> has a length that is slightly greater than the width of the first plate <NUM> and a width that is slightly greater than the thickness of the first plate <NUM> so that the first plate can pass through the slots. The two plates <NUM> act to contain the first plate <NUM> within the slots, while allowing relative vertical movement of the first plate <NUM>.

Therefore, when the wall is laterally loaded for example, by wind, the first plate <NUM> restrains the wall <NUM> and prevents the wall <NUM> from moving laterally.

This prevents at least the top of the wall from being pulled off the side of the building by wind, while allowing for movement between the building structure and the panel assembly <NUM>, due to, for example thermal stresses or the like.

As can be seen in <FIG>, each of the slots is oriented such that each slot extends longitudinally along the length of each plate <NUM>. The first plate <NUM> is oriented such that it is parallel to the brick panel <NUM>. This means that the entire width of the first plate <NUM> extends along the panel to strengthen the panel in the direction in which the wind will act to suck the panel off the building. Hence, in this orientation of the first plate <NUM> there is a greater amount of material to counteract the forces of the wind on the installed wall in use.

The dimensions, type of material and mechanical properties of the plates can be varied depending on the magnitude of the forces the wall will be subjected to at least level of the building, for example. In other embodiments, the number of restraints along each wall can be selected to sufficiently counteract the magnitude of the external forces, in use.

In the embodiment illustrated in <FIG>, there are two restraints or restraining arrangement <NUM> against lateral loading that are spaced from each other along the top of the wall.

In other embodiments, there may be more than two restraints <NUM> spaced from each other along the top of the wall.

As mentioned above, the first plate <NUM> is vertically moveable within the slots. Building structures typically include materials that contract or expand (both vertically and laterally) as a result of a change in temperature. Hence, the brick wall assembly <NUM> must be configured to adjust to accommodate for these vertical changes to prevent the brick wall and/or structure being mechanically stressed by these vertical changes. Repeated stressing can cause the wall and/or building structure to be damaged.

The dimensions and relative positions of each of the first vertically extending plate <NUM> and two laterally extending plates <NUM> can be selected to accommodate for predicted vertical movement of the wall relative to the structure during the life of the building.

Conventionally, wall ties are used to tether an outer wall to an inner wall along the height of the wall to restrain the wall against lateral wind loading. This requires wall ties to be inserted during construction of the wall. Advantageously, the present prefabricated wall assembly <NUM> does not require there to be an internal wall and the top restraint and bottom restraint are both preferably configured to be sufficiently strong to withstand any external and internal forces on the wall that may act to detach the wall from the building.

As mentioned above, the second angle bracket <NUM> is installed such that the second flange <NUM> of the second angle bracket <NUM> extends upwardly and parallel to an inner surface of the wall panel <NUM>. The second flange <NUM> provides a structure for attachment of one or more brackets <NUM> through which the brick panel assembly <NUM> can be attached to the lower building structure <NUM> to create a wall or cladding of the building. In the illustrated embodiment shown in <FIG>, there are two brackets spaced from each other, each connecting the brick panel assembly <NUM> to the building structure.

To assemble the illustrated prefabricated brick panel <NUM>, blocks <NUM> of laid bricks are created. Threaded holes can be drilled through each block <NUM> for insertion of reinforcement. Each block <NUM> spans substantially the entire width of the wall. Each block <NUM> is connected to another block <NUM> at a bed joint <NUM> via a suitable joining material. Bed joints <NUM> are installed every five courses or rows between adjacent blocks throughout the entire height of the brick wall, while ensuring that the holes for each fastener are not covered. While the blocks are being assembled, the second angle bracket <NUM> is secured to the brick panel <NUM>.

Holes corresponding to the position in which threaded rods are to be inserted are then made in the first flange <NUM> of the first support member <NUM> i.e. first angle bracket including the two projecting plates <NUM> as part of the restraining arrangement <NUM>. The holes may be threaded. The first angle bracket <NUM> including two projecting plates <NUM> can be of unitary construction, or can be assembled and connected, for example by welding. Holes corresponding to the position in which threaded rods are to be inserted are then made in the second support member <NUM> which is an elongated plate. The holes may be threaded.

Each rod <NUM> is then inserted into and through the brick panel <NUM> and the second support member <NUM> in the correct place. A torqueing nut <NUM> is fastened onto the bottom of the rod <NUM> by screwing the nut <NUM> on to the threaded ends of the rod <NUM>. It is envisaged that the torquing nut <NUM> will initially be tightened by hand.

The first support member <NUM> is installed over the top of the rod in the correct place, and then another torqueing nut <NUM> is secured onto the top of the rod <NUM>. It is envisaged that the torquing nut <NUM> will initially be tightened by hand.

The torqueing nuts <NUM> at the bottom face of the panel <NUM> are then clamped to haul them still, while the torqueing nuts <NUM> at the top of the brick panel are then tightened to evenly compress the brick panel <NUM> to achieve a desired stiffness for safe transport of the wall.

Installation of the prefabricated wall assembly <NUM> between an upper building structure <NUM> and a lower building structure <NUM> is now described. A plurality of brackets <NUM> are fixedly attached to the second flange <NUM> of the second angle bracket <NUM> at selected points along the second angle bracket <NUM>. Alternatively, the brackets <NUM> can be attached to the second flange <NUM> before the assembly <NUM> is transported.

The prefabricated wall assembly <NUM> can be strapped or otherwise secured and transported to the installation site to be installed on a building structure of a building that is being constructed.

On-site, while the prefabricated wall assembly <NUM> is held in place, each of the brackets <NUM> attached to the second angle bracket <NUM> are connected to the lower building structure <NUM> by fastening each bracket <NUM> to the lower building structures using at least one suitable bolt <NUM>. As can be seen from <FIG>, each bolt <NUM> is inserted deep into the concrete of the building structure. The bracket can then be grouted underneath and an adjustment screw <NUM> positioned horizontally along the bracket <NUM> between the bolt <NUM> and
the second angle bracket <NUM> to adjust for tolerances and to ensure that the wall is at the right level.

The first part <NUM> of the restraining arrangement <NUM> is then provided. As shown in <FIG> this includes a flat base <NUM> and the plate <NUM> of the first part, extending from the flat base <NUM>. The bottom of the plate <NUM> is aligned with the slots of the plates <NUM> of the second part <NUM> and the plate <NUM> is inserted into the slots.

The base <NUM> is then bolted to an underside of the upper building structure <NUM> using a suitably sized connector in the form of an anchor bolt <NUM> as shown in <FIG>.

As mentioned previously, the prefabricated masonry panel <NUM> is also suitable for domestic buildings as an external masonry wall. For a domestic building, each prefabricated masonry panel is positioned as an external wall adjacent and parallel to and connected to an inner wall. The inner wall is spaced from the external wall by a desired distance to allow for airflow. In a preferred embodiment (not shown), this distance is <NUM>. In other embodiments, the distance may be greater than <NUM> or less than <NUM>.

In an embodiment suitable for domestic buildings (not shown), the prefabricated masonry panel assembly includes wall ties such as helical rods, extending perpendicularly to an inner surface of the wall. A first end of each wall tie is secured within the brick panel while the second end is fixed to an internal wall. Multiple wall ties can be arranged at intervals along a height and a width of the wall to secure the outer wall to the inner wall.

In such an embodiment, the prefabricated masonry panel assembly may not include brackets to fix the bottom of the wall to a lower building structure. However, any of the first support <NUM>, second support <NUM>, bracket <NUM>, and restraining arrangement <NUM> could also be used for a residential construction.

For domestic buildings, the internal wall can be constructed in a factory controlled environment or otherwise off-site, and then attached to the prefabricated masonry panel assembly. The internal wall and the connected prefabricated masonry panel assembly can be transported together to the installation site and installed.

An advantage of the prefabricated masonry panel described above, is that many parts are not required to assemble the prefabricated wall assembly <NUM>. Hence, it is relatively easy to assemble and therefore, there is less opportunity for human error during assembly.

Another advantage is that less raw material is required on site, less labour is required to construct buildings. There is less chance of a prefabricated wall breaking during transport, lifting and installation and so there is less chance of there being wastage of materials especially, an entire prefabricated wall. The overall cost of construction can also be reduced as less labourers are required on-site, less OHS risk is posed to the labourers on-site and if robots are used to construct blocks, less labourers are required to construct each prefabricated wall. Furthermore, as walls do not have to be constructed on-site, less on-site time is required to construct a building and long delays due to bad weather can be avoided.

The embodiments described above also provide a modular system whereby, blocks and reinforcement and other elements such as number of fasteners or brackets etc. can be selected to design a panel having desired mechanical characteristics. As prefabricated walls do not have to be designed from scratch and a large number of different types of materials are not required, each prefabricated wall can be made less expensive than a bespoke designed prefabricated wall.

The number of options for types of reinforcement and dimensions of blocks and types of masonry units, for example, can be provided to a user to pre-select to quickly and cost-effectively design a wall with well-known or highly predictable mechanical characteristics. In this way, the design process can be streamlined and greater quality control over prefabricated walls can be provided.

A second embodiment, according to the invention, of a prefabricated wall assembly <NUM>, and a building structure <NUM> constructed using the prefabricated wall assembly <NUM>, is shown in <FIG>. The building structure <NUM> shown include columns <NUM> and floor slabs <NUM>. The prefabricated wall assembly <NUM> includes an outer panel assembly <NUM> and an inner panel assembly <NUM>. The outer panel assembly <NUM> and inner panel assembly <NUM> are rigidly connected to each other by connectors or panel connecting arrangement <NUM>.

The outer panel assembly <NUM> in this embodiment is shown in the form of masonry panel <NUM> (shown schematically with hatching) comprising a plurality of masonry units or bricks <NUM> arranged in a wall formation, and a securing arrangement <NUM> configured for pre compressed the masonry units to haul them together. The securing arrangement <NUM> includes a tensioning mechanism <NUM>.

The inner panel assembly <NUM> includes an inner insulation panel <NUM> composed of an insulation layer <NUM> that is framed by a frame <NUM>.

It is envisaged that the prefabricated wall assembly could be provided in a variety of different forms. For example, as shown in <FIG>, the prefabricated wall assembly includes an inner panel assembly <NUM>.

The masonry panel <NUM> is planar in configuration and defines a pair of rectangular opposed major faces <NUM>, with minor faces <NUM> extending between the major faces. The minor faces <NUM> define a top surface <NUM> and a bottom surface <NUM>. In the embodiment shown, the masonry panel is made up of a plurality of masonry units <NUM> such as bricks, or another other suitable unit. It will be appreciated by person skilled in the art that a wide variety of masonry type units and materials could be used. The masonry units <NUM> can be arranged into blocks <NUM> that may be made up of one or more rows or courses of masonry units <NUM>. Blocks <NUM> of masonry units <NUM> can be connected to adjacent similar blocks at bed joints (not shown).

As shown in detail in <FIG> and <FIG>, and in more detail in <FIG> and <NUM>, the securing arrangement <NUM> includes a first compression or support member <NUM> in the form of first angle bracket <NUM>. First angle bracket <NUM> includes first flange <NUM> that is intended to extend vertically in operation when the prefabricated wall assembly <NUM> is attached to a building structure, and second flange <NUM> that is intended to extend horizontally in operation. Second flange <NUM> includes a plurality of apertures <NUM> extending along its length. The securing arrangement <NUM> further includes a second compression or support member <NUM> in the form of second angle bracket <NUM>. Second angle bracket <NUM> mirrors first angle bracket <NUM> in that it includes a first flange <NUM> and second flange <NUM>, with second flange <NUM> including a plurality of apertures (not shown) along its length. Both of the first compression member <NUM> and second compression member <NUM> are configured for compressing opposed sides of the masonry panel <NUM>.

The tensioning mechanism <NUM> is configured for pulling the first compression member <NUM> and second compression member <NUM> towards each other to thereby pre-compress the masonry panel <NUM>. The tensioning mechanism <NUM> includes a tensioning elongate member <NUM> in the form of a preferably galvanised rigid rod <NUM>. The rigid rod <NUM> includes threaded end at each end. The rigid rod <NUM> is configured to extend through the masonry panel <NUM> via apertures in the masonry units <NUM>, and be tensioned by fasteners, in the form of screws <NUM>, extending through apertures 2214in the first compression member <NUM> and similar apertures (not shown) in the second compression member <NUM>. The screws <NUM> are threaded with a complementary internal thread which fits over the threaded rods <NUM>. As screws <NUM> are tightened, this tensions the rigid rod <NUM> to pull the first compression member <NUM> and the second compression member towards each other to compress the masonry panel <NUM> between them.

As shown in <FIG>, <FIG> and <FIG> include glass panes <NUM> supported by window frames <NUM> may be seated on the prefabricated panel assemblies. It is envisaged that a sealing sheet or flashing will extend underneath the windowpane outwardly over the outer edge of the masonry panel <NUM>. It is envisaged that a differently sized prefabricated wall assemblies <NUM> will be provided, depending on whether windows are required or not. For example, the prefabricated wall assembly 2000a on the left-hand side shown in <FIG>, <FIG> and <FIG> will extend from one floor to the same relative level on the next floor. The smaller masonry panels 2100b shown in <FIG>, <FIG> and <FIG> will be used to extend from the top of the window pane on one level to the bottom of the window pane on a vertically adjacent level. Another smaller prefabricated wall assembly 2000c is shown in <FIG>, and is used for making up the difference in height between the top of a prefabricated wall assembly 2000b and the bottom of a windowpane. The smaller prefabricated wall assembly 2000c is mounted on top of the larger prefabricated wall assembly 2000b, with the.

In an alternative embodiment (not shown) is envisaged that the prefabricated panel assemblies may include built-in window frames with or without glass panes. However, this would require the window frames to be compressed together with the masonry units, and is not preferred.

By providing an outer panel assembly <NUM> connected to an inner panel assembly <NUM> that are rigidly connected to each other and supportable by a wide variety of brackets as will be discussed below, it is possible to reduce the stresses on windows and window frames.

It will be appreciated by persons skilled in the art that a wide variety of alternative securing arrangements and tensioning mechanisms could be used.

In an alternative embodiment (not shown), it is envisaged that the tensioning member need not be rigid and could be a flexible member such a steel cable.

As mentioned previously, the prefabricated wall assembly includes an inner panel <NUM>. The inner panel <NUM> is substantially rectangular in shape, and includes a rectangular planar insulation layer <NUM> and a waterproof vapour layer <NUM>.

The planar insulation layer <NUM> defines a pair of major faces <NUM> and four minor faces <NUM> connecting the major faces at edges <NUM>. The planar insulation layer <NUM> is surrounded by a frame <NUM> that preferably encloses the edges <NUM> and minor faces <NUM> of the insulation layer <NUM>. In <FIG> a vertically aligned plate <NUM> is welded to an inwardly facing surface of the uppermost edge member <NUM> of frame <NUM>, the vertically aligned plate <NUM> extending above the edge member <NUM>. In <FIG>, the channel shaped edge members <NUM> are disposed in opposite orientation to the edge members <NUM> in <FIG>. In <FIG>, a preferably steel sealing plate <NUM> is provided that extends between the two panels from in front of the first angle bracket <NUM> to behind the inner insulation panel <NUM>, where it extends vertically in a similar fashion to the vertically aligned plate <NUM> of <FIG>.

The frame <NUM> is composed of four parallel flange channel (PFC) edge members <NUM> that are preferably U-shaped in cross-section, and are either welded or bolted together
at their ends to form a rectangular shape corresponding to the insulation layer <NUM>. In this way, the general shape of the inner panel <NUM> is also rectangular, and substantially coincides with the shape and dimensions of the masonry panel <NUM>. The waterproof vapour layer <NUM> is shown in <FIG> and <FIG> as being inside the insulation layer <NUM>, however in alternative embodiments, it is envisaged that the waterproof vapour layer could be disposed outside of the insulation layer, or both inside and outside.

<FIG> shows a similar view to <FIG>, but with a slightly different sealing arrangement, in that sealing plate <NUM> is provided as flashing for sealing the windowsill. In the embodiment shown in <FIG>, the window frame can be seen to be bolted or otherwise anchored into rigid edge member <NUM>.

The inner panel <NUM> can also include a layer of plasterboard lining <NUM> connected to the insulation layer <NUM> by top hat members <NUM>, although it is preferable that this is installed on site due to the frangible nature of the plasterboard lining. When installing the plasterboard lining on site, the screw lengths for securing the plasterboard to the top hat members <NUM> will have a suitable end so that they do not pierce the vapour barrier It is envisaged that, due to the fragility of the plasterboard lining, the plasterboard lining layer <NUM> would typically be installed once the prefabricated wall assembly <NUM> has been attached to the building structure on site, and would not be installed site for transport to the construction site.

The inner panel <NUM> is spaced from the masonry panel <NUM> to allow for airflow and equal pressurisation between the masonry panel <NUM> and inner panel <NUM>, thereby allowing for any water, such as from rain, that has ingressed inside of the masonry panel <NUM> to dry.

The inner panel <NUM> and masonry panel <NUM> are disposed with their major faces in alignment with each other, and are connected to each other along their top edges, and preferably along the bottom edges as well, by a panel connecting arrangement <NUM>. The panel connecting arrangement <NUM> includes a securing arrangement <NUM> in the form of a screw and nut assembly, and a thermal barrier <NUM>. The thermal barrier <NUM> is preferably in the shape of an elongate rectangular planar strip, and is composed of a material that is heat resistant, such as cementitious material; a fireproof plastic; carbon fibre, basalt fiber; or any other suitable material. The thermal barrier <NUM> functions to reduce thermal bridging between the outer panel assembly and the inner panel assembly, for example in the event of a fire or the like.

As shown in <FIG> and <FIG>, the first vertical flange <NUM> of the first compression member <NUM> includes an aperture (not shown) for receiving the screw <NUM> from a screw and nut assembly <NUM>. In an alternative embodiment, a bolt and nut assembly could be used.

The thermal barrier also includes spaced apertures along its length that coincide with the size and spacing of apertures along the length of the first vertical flange <NUM>. Similarly, the outer wall of the U-shaped edge members <NUM> along an upper edge and lower edge of the frame <NUM> also includes spaced apertures along its length for receiving screws <NUM>. Along an upper edge of the masonry panel <NUM> and frame <NUM>, screws <NUM> extend through corresponding spaced apertures in first vertical flange <NUM> , thermal barrier <NUM> and the upper edge member <NUM>, and are fastened by complementary nuts <NUM>.

Similarly, along a lower edge of the masonry panel <NUM> and frame <NUM>, screws <NUM> extend through corresponding spaced apertures in the first flange <NUM>, thermal barrier <NUM> and lower edge member <NUM> to be secured with complementary nuts <NUM>. In this way, the masonry panel <NUM> and the inner panel <NUM> are held in parallel alignment with each other, and spaced from each other.

As shown in <FIG>, it is further envisaged that side angle brackets <NUM> can be provided for supporting the sides of the masonry panel <NUM>. The side angle brackets <NUM> are preferably not connected to the first compression member <NUM> and/or second compression member <NUM> as this would interfere with the compressive loading by the tensioning mechanism <NUM>. Instead, the side angle brackets <NUM> are preferably bolted to the frame <NUM>, preferably with a thermal barrier <NUM> extending between the side angle brackets <NUM> and the frame <NUM> in the same way as described above.

As shown in <FIG> , the prefabricated wall assembly can further include a pivot arm <NUM> located to each side of the frame <NUM>. The pivot arm <NUM> includes an arm member <NUM> that is pivotably connected to a fastening bracket <NUM> that is adapted to be secured to building structures <NUM> , <NUM>. The arm member <NUM> and fastening bracket <NUM> are connected at hinge <NUM>. Similarly, another fastening bracket <NUM> is secured to frame <NUM> and connected to an opposed end of arm member <NUM> at hinge <NUM>. The pivot arm <NUM> secures the prefabricated wall assembly <NUM> to the building structure while still allowing for movement of the prefabricated wall assembly <NUM> due to thermal stresses and/or strains.

The prefabricated wall assembly can also include a structural support bracket <NUM> (shown in <FIG>, <FIG> and <FIG>) that is configured for attachment to the structure of a building. The wind loading bracket <NUM> includes a pair of plates <NUM>, <NUM> extending at <NUM>° to each other. One of the plates <NUM> includes a pair of apertures <NUM> for securely mounting the bracket <NUM> to a building structure by anchor bolts <NUM>, preferably in a horizontal alignment. The other plate <NUM> extends vertically and parallel with the inner panel. The vertically extending plate <NUM> includes a slot (not shown) that extends vertically in operation.

Wind loading bracket <NUM> is adapted for supporting the prefabricated wall assembly against wind loading forces generated by wind loading.

The wind loading bracket <NUM> is secured to the frame <NUM> by a nut and bolt arrangement <NUM> (shown in <FIG>). The bolt is movable within the vertical slot in the vertical plates <NUM>, to allow for relative movement between the frame <NUM>, and the building structure on which the wind loading bracket <NUM> is securely mounted. In alternative embodiments it could be secured by other means such as by using fasteners such as screws, bolts or rivets, or by any other suitable means. The wind loading bracket <NUM> is configured for being secured to a building structure such as a concrete slab <NUM> or column <NUM> preferably by an anchor bolt or similar arrangement that can be sunk into, for example a concrete floor slab.

The fabric prefabricated wall assembly <NUM> can also include a dead and wind loading bracket <NUM> (as shown in <FIG>, <FIG> and <FIG>) that is designed for supporting the dead weight of the prefabricated wall assembly <NUM>, as well as against wind loading forces. The dead and wind loading bracket <NUM> is in the form of a flat plate <NUM> with a pair of mounting apertures <NUM> for securely mounting the plates to a horizontal building structure surface such as a floor slab, preferably using anchor bolts <NUM> or the like. The dead and wind loading bracket <NUM> does not allow for any vertical play between the building structure and the prefabricated wall assembly <NUM> likely wind loading bracket <NUM>. The dead and wind loading bracket <NUM> is securely mounted to the frame <NUM>, preferably by welding, however alternative securing arrangement such as using fasteners such as screws, bolts or rivets are envisaged.

Further, the prefabricated wall assembly <NUM> is configured for attachment to adjacent similar prefabricated wall assemblies <NUM> by means of a wall connector arrangement <NUM>. The wall connector arrangement <NUM> includes a rectangular protrusion <NUM> (shown in <FIG> and <FIG>) that extends outwardly, and preferably upwardly, from an upper edge member <NUM> of frame <NUM>. The rectangular protrusion <NUM> is securely connected to the frame <NUM> and preferably includes an aperture <NUM> to act as slinging formations by which the prefabricated wall assembly <NUM> can be rigged for transport to and from the construction site, as well as by which the prefabricated wall assembly <NUM> can be lifted or slung into place on site.

The rectangular protrusion <NUM> is receivable into a slot (not shown) in the lower edge member <NUM> of frame <NUM> in a sliding fashion. It is envisage that, on site, a prefabricated wall assembly <NUM> will be slung into position above a pre-installed similar prefabricated wall assembly, and lowered until the rectangular protrusion of the lower prefabricated wall assembly <NUM> is received into the slot, as a spigot and socket assembly <NUM> (shown in <FIG>). The rectangular protrusion may be welded onto the frame <NUM> of the adjacent prefabricated wall assembly <NUM> in order to be secured in place.

The prefabricated wall assembly <NUM> further includes sealing formations, preferably in the form of gaskets <NUM> for sealing around an outer periphery of the frame <NUM>. One upper gasket <NUM>, preferably in the form of rubber, silicon or plastic liners mounted to aluminium carriers or tracks, is provided disposed along the length of an outer surface of the vertically aligned plate <NUM>, for abutment with an inner edge of the lowest edge member <NUM> of a similar prefabricated panel assembly <NUM> located above. This prevents water from flowing in from outside between horizontal gaps between the adjacent prefabricated panel assemblies <NUM>. Further, side gaskets <NUM> are provided (shown in <FIG>) for sealing the vertical gap between adjacent similar prefabricated panel assemblies <NUM> laid side to side. It is further envisaged that a waterproof sealing sheet <NUM>, preferably composed of tough waterproof material such as silicone, and preferably embedded in sealant, may be provided to seal the top of the prefabricated panel assembly <NUM> where it abuts with a similar prefabricated panel assembly <NUM> lying next to it. Such a waterproof sealing sheet <NUM> is shown in broken lines in <FIG>.

In this way, a prefabricated panel assembly <NUM> may be provided that can be mostly assembled off-site and slung into position on the frame of a building structure, and which allows for movement due to thermal stresses, water ingress and air movement , while also providing for the required levels of water tightness.

During manufacture, it is envisaged that, in order to manufacture the prefabricated wall assembly, initially an inner frame assembly similar to those described above will be constructed. The lower support/compression member will then be connected to the inner frame assembly, preferably by a panel connecting arrangement as described above. Tensioning members are then inserted into the lower support/compression member. Side support members will be securely connected to the lower support with fasteners.

Layers of masonry units will then be constructed onto the lower support/compression member, building onto the tensioning members, preferably using settable material such as mortar between the masonry units. Connector clips will be built in between the layers of masonry units at bed joints towards the side edges of the masonry panel, and preferably extend towards the inner frame assembly from the masonry panel.

Side support members will be engaged with the connector clips as they are built into the masonry panel. Upper support/compression member will then be laid on top of the masonry panel, and loosely connected to the side support members to hold the panel in alignment. Fasteners will be loosely attached to the top of the tensioning members to hold the upper support and lower support together. The settable material will then be allowed to cure, completing the masonry panel.

The tensioning members are then tensioned to compress the masonry units between the upper support and the lower support.

At this stage, the fasteners of the adjustment mechanism will be tightened to create a rigid outer panel frame. The upper support will then be securely connected to the inner frame assembly.

Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may do so.

Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others.

Claim 1:
A prefabricated wall assembly (<NUM>, <NUM>) comprising:
a. an outer frame assembly connected to a masonry panel assembly, the masonry panel assembly comprising a plurality of masonry units (<NUM>) compressed into at least one masonry panel;
b. an inner frame assembly attached to an insulation panel (<NUM>);
c. the masonry panel and the insulation panel (<NUM>) being spaced at a distance from each other by an air gap;
d. the inner frame assembly and the outer frame assembly being securely connected to each other at one or more connecting assemblies;
e. the prefabricated wall assembly being configured for being connected to the outside of a building structure as cladding.