The present invention relates to construction elements in both their pre-assembly
(2D) and post-assembly (3D) conditions and particularly, but not exclusively, to the
provision of a modular construction assembly comprising a plurality of construction
elements fastened together to form walls, floors and ceilings. The invention may be
used in isolation or in conjunction with steel frame construction methods currently
forming the core components of steel framed buildings.
Background to the Invention
When building large structures it is beneficial to reduce labour costs and minimise
build times. This is particularly relevant to the construction of nuclear power plants
where such efficiencies are necessary to allow nuclear power to become a more
viable and realistic alternative fuel source to fossil fuels or other low capacity
alternative sources.
Nuclear power plants and other sensitive structures including nuclear waste
processing and/or storage facilities are required to withstand natural events such as
earthquakes and hurricane force winds, and to contain large over-pressures. This
necessitates substantial reinforcement of the building structure. Known
reinforcement means employ a complex and expensive assembly of layered planar
steel plates braced apart by a separate internal lattice of stiffening members and/or
tie bars and/or shear studs, examples of which are shown in Figs l a and lb. A
highly specialised and skilled work force - which itself is expensive and difficult to
source - is required to assemble those presently available solutions.
Consequently, there exists a need for a simpler, more efficient and more costeffective
means of providing structural reinforcements to the nuclear and other
industries.
Summary of the Invention
According to a first aspect of the present invention there is provided a construction
element in a pre-assembly condition comprising a metallic sheet sub-divided by one
or more fold lines into panels to define a multi-panelled sheet wherein each panel
lies in a common plane; at least one of the panels being deformable along said one
or more fold lines out of said common plane to form an assembled threedimensional
construction element for adjoining to another three-dimensional
construction element; and wherein at least one panel is provided with an opening
dimensioned to allow the passage of a reinforcement or stabilising material through
the assembled three-dimensional construction element.
In a non-limiting example, the metallic sheet is rectangular in shape and formed
from a steel plate having a thickness of between 6mm and 25mm. However, wall
thicknesses can be scaled according to individual requirements.
Optionally, the fold lines are each straight and mutually parallel.
In a non-limiting example, the fold lines each lie parallel to the opposing edges of the
sheet such that all panels are rectangular in shape.
Optionally, the opening extends across the full width of the at least one panel
between two fold lines.
Optionally, the opening is circular in shape.
Alternatively, the opening is oval, elliptical or hexagonal in shape.
Optionally, the major axis of the oval or elliptical opening extends perpendicularly
with respect to each fold line.
By providing circular, oval or elliptical openings which extend across the full width
of a panel to the, or each, fold line, regions of concentrated stress (also known as
stress raisers) are reduced or eliminated. Oval openings have been found to be the
best at reducing stress concentrations at the point where the opening meets the
sidewall panels.
Optionally, the metallic sheet is sub-divided into only three panels.
Optionally, each panel has the same surface area.
Such an arrangement allows the sheet to be deformed into a symmetrical U-shaped
channel shape whereby both sidewall panels have the same shape and size as the
base panel.
Alternatively, at least one panel has a different surface area than the other panels.
In a non-limiting example, one sidewall panel is made smaller than the other
sidewall panel so as to provide an asymmetrical U-shaped channel shape.
Optionally, each fold line is defined by a line of weakness formed by scoring,
stamping or partially cutting the planar sheet.
Creating lines of weakness assists with the folding of the construction element into
its three-dimensional assembled condition whilst reducing the costs associated with
storage and transportation of the constructions elements whilst they are in their
pre-assembly condition. The fold lines are located at predetermined positions
depending on the intended final shape of the construction elements.
According to a second aspect of the present invention there is provided a threedimensional
construction element assembled from the multi-panelled sheet of the
first aspect.
Optionally, the planes of adjacent panels are mutually perpendicular.
Optionally, the fold lines separating adjacent panels define curved adjoining edges.
The curved adjoining edges are a consequence of the folding process which is
typically carried out by a mechanical press. Typically, the radius of curvature of the
curved edges is small relative to the width dimension of each panel.
Optionally, the element comprises only a base panel and two sidewall panels which
together define a U-shaped channel.
In a non-limiting example, a flooring module is constructed from a series of Ushaped
channels fastened together, each having base panels measuring
approximately 200mm in width and sidewall panels measuring approximately
200mm in height. Shear studs may be welded to one or more of the inner surfaces
of the U-shaped channel. The studs may have a shank diameter of approximately
6mm. Nelson® studs having an enlarged head are preferred. In an alternative nonlimiting
example, a wall module designed for aircraft impact resistance is
constructed from a series of U-shaped channels fastened together, each having base
panels measuring approximately 900mm in width, sidewall panels measuring
approximately 900mm in height and Nelson® studs having a shank diameter of
19mm. Importantly, tie bars are never required since the base panel of all U-shaped
channels acts as an integral tie bar. The total length of a floor, wall or ceiling module
constructed from a series of fastened U-shaped channel members can vary
depending upon individual requirements. Module lengths of 12m are readily
achievable.
Optionally, distal edges of both sidewall panels comprise inwardly extending flange
portions serving to reduce the spacing between their distal ends.
Optionally, the flange portions extend inwardly at an acute angle relative to the
plane of each sidewall panel.
Optionally, the acute angle falls within the range of 30 - 60 degrees.
Optionally, the base panel and at least one of the two sidewall panels is provided
with an opening dimensioned to allow the passage of a reinforcement or stabilising
material.
Such an arrangement is particularly suitable for use in a flooring layer assembly
whereby the openings in each sidewall panel allow for the vertical passage of, for
example, concrete and the openings in each base panel allow for its horizontal
passage along the entire flooring layer assembly.
According to a third aspect of the present invention there is provided a modular
construction assembly comprising a plurality of three-dimensional construction
elements according to the second aspect connected together to form a wall, ceiling
or floor.
Optionally, adjacent three-dimensional construction elements are fastened together
by welding and/or bonding and/or mechanical fasteners.
In this way complex shaped modular construction assemblies can be built from
selected three-dimensional construction elements. In addition, a number of
modular construction assemblies can be fastened together to make larger
structures. The assembled construction elements and the modular construction
assemblies themselves can be fastened to pre-existing structures such as floors or
supports by welding and/or bonding and/or mechanical fasteners.
Optionally, each three-dimensional construction element comprises only a base
panel and two sidewall panels which together define a U-shaped channel; wherein
the base panel of one U-shaped channel is fastened along distal edges of both
sidewall panels of its adjacent U-channel so as to form a lid closing the open top of
the adjacent U-shaped channel.
In a non-limiting example, the construction elements are fastened together in a way
which either presents a continuous planar sidewall surface (if both sidewall panels
have the same surface area) or a multi-faceted surface (if one sidewall panel has a
larger surface area than the other). When the construction assembly of the
invention is to be used in combination with a steel frame construction system,
interfacing U-sections could be formed by welding sidewall plates onto the flanges
of a universal beam, universal column or cellular beam (c.f. WESTOK products EP 0
324 206 Al).
Optionally, the base panel of one U-shaped channel is fastened along distal edges of
flanges on both sidewall panels of an adjacent U-channel so as to form a lid closing
the open top of the adjacent U-shaped channel, and thereby defining outwardly
facing recesses lying between the respective sidewall panels of adjacent U-shaped
channels.
Optionally, each recess is covered by a metallic plate fastened between a
sidewall/flange junction of one U-shaped channel and the base/sidewall fold line of
an adjacent U-shaped panel.
Optionally, each covered recess defines a drainage channel.
In a non-limiting example, the fastening together of the adjacent U-shaped channels
is performed by a first external weld within the recess before it is covered by the
metallic plate. A second external weld which fastens the metallic plate creates a
double barrier.
Optionally, the assembly is reinforced and/or stabilised by the introduction of
reinforcement or stabilising material into the volumes defined by the base, sidewalls
and lid of adjacent three-dimensional construction elements.
The ingress of, for example, radioactive material through the second external weld
can be accommodated and dissipated within the vertical drainage channel thus
avoiding seepage of radioactive material into the stabilising and/or reinforcement
material contained within each U-shaped channel.
Optionally, the reinforcement or stabilising material is selected from concrete, resin,
asphalt and particulate aggregate.
In a non-limiting example, the particulate aggregate may include sand, gravel,
rubble or soil.
Brief Description of the Drawings
The invention will now be described, by way of example only, with reference to the
accompanying drawings in which:
Figure l a shows a prior art assembly of steel plates braced apart by a complex
stiffening network; and
Figure l b shows an alternative prior art assembly of steel plates braced apart by
separate tie bars.
Figure 2a shows a planar sheet having fold lines and apertures in accordance with
an embodiment of the invention;
Figure 2b shows a two-dimensional planar sheet portion which represents one half
of the construction element of Figure 2a .
Figure 2c shows an alternative two-dimensional planar sheet portion having a
single fold line and an edge comprising a series of alternate semi-circular recesses
and projections;
Figures 3a-c show two different three-dimensional construction elements and a
construction assembly comprising a series of four individual construction elements
fastened together;
Figures 4a-c show two alternative three-dimensional construction elements and a
construction assembly comprising a series of eight individual construction elements
fastened together;
Figures 5a and 5b show a further alternative three-dimensional construction
element and a construction assembly comprising two individual construction
elements fastened together;
Figures 6a and 6b show a yet further alternative three-dimensional construction
element and a construction assembly comprising thirteen individual construction
elements fastened together;
Figure 7a shows a construction assembly comprising two individual construction
elements of Figure 5a fastened together to define a covered recess along the line of
their connection;
Figure 7b shows the covered recess of Figure 7a in greater detail;
Figure 8a shows a construction element having sidewalls of different heights and
surface areas;
Figure 8b shows a construction assembly comprising four individual construction
elements of Figure 8a fastened together;
Figure 9a shows a construction element having openings in both its base panel and
one of its sidewall panels;
Figure 9b shows a construction assembly comprising thirty two individual
construction elements of Figure 9a fastened together to form a floor or ceiling unit;
and
Figure 10 shows a modular construction comprising three different construction
assemblies connected together to form a wall structure.
Detailed Description of the Invention
Figure 2a shows a construction element in a two-dimensional pre-assembly
condition before it is formed into a three-dimensional construction element. The
construction element comprises a rectangular metallic sheet 10 subdivided by two
straight, parallel fold lines 12a, 12b to define three panels 14, 16, 18 of equal
dimensions. Each panel lies in a common plane. The material of the sheet may be
plate stainless steel or carbon steel. Each fold line 12a, 12b comprises a line of
weakness formed by scoring, stamping or partially cutting into the surface of the
metallic sheet. The central panel 14 is provided with circular openings 14a equally
spaced in a line along its length. The diameter of the openings 14a is at least 50% of
the width of the central panel 14 between the fold lines 12a, 12b.
Figure 2b shows an alternative two-dimensional planar sheet portion which
represents one half of the construction element of Figure 2a. The sheet portion is
shaped such that it comprises a series of spaced semi-circular recesses 1 located
along one edge of the panel 14.
Figure 2c shows a further alternative two-dimensional planar sheet portion which
also forms one half of a construction element (not shown). The sheet portion is
shaped such that comprises a series of spaced hexagonal recesses 15h located along
one edge of the panel 14.
Figure 3a shows a three-dimensional construction element formed from a twodimensional
metallic sheet 10 similar to that shown in Figure 2a. Sidewall panels
16, 18 have been deformed out of their initial common plane by forcible bending
along their fold lines 12a, 12b so as to extend perpendicularly with respect to the
base panel 14. The three-dimensional construction element therefore adopts a Uchannel
shape whereby the sidewall panels 16, 18 are opposed, substantially
parallel and standing upright from the base panel 14 to define the U-channel. In the
particular embodiment illustrated in Figure 3a, an array of shear studs 20 are
welded to the inwardly facing surfaces of the sidewall panels 16, 18. The shear
studs may be Nelson® studs having heads which are enlarged relative to their
shank widths.
In practice it has been found that, the process of manufacturing a three-dimensional
three-panel construction element is made simpler by joining together two L-shaped
two-panel halves. For example, two of the planar sheet portions shown in Figure 2b
may be forcibly bent along their respective fold lines 12a so that each panel 14
extends perpendicularly with respect to its panel 16. The two L-shaped panels may
then be orientated such that their semi-circular recesses 15 are aligned to form
circular openings 14a and then fastened together by, for example, welding the edge
portions lying intermediate each opening 14a. It will be appreciated that this
method of manufacturing the U-shaped channels is more practicable than forming
two bends in a single three-panel construction element using a mechanical press. A
further advantage is the two planar sheet halves can be manufactured from different
grades of steel, e.g. stainless steel and carbon steel respectively.
The above process can also be employed using pairs of planar sheet portions as
shown in Figure 2c. The advantage of using planar sheet halves having hexagonal
recesses 1 is that wastage of the metallic sheet material can be entirely eliminated
during their manufacture when they are cut from a blank metallic sheet.
Figure 3b shows an alternative three-dimensional construction element formed
from a two-dimensional metallic sheet 10 (not shown). Sidewall panels 16, 18 have
been deformed out of their initial common plane so as to define the same U-channel
shape as shown in Figure 3a . However, the openings 16a are provided in a sidewall
panel 16 rather than in the base panel 12.
Figure 3c shows a construction assembly comprising three construction elements
according to Figure 3a and one of the construction elements of Figure 3b. Typically,
the construction elements are orientated such that they stand on their end and their
panels 14, 16, 18 extend vertically. The individual construction elements are
identically orientated and aligned so as to be fastened together in series by, for
example, welding the distal edges 16d, 18d of one U-channel to the outer edges of
the base panel 14 of another U-channel. In doing so, the adjoined sidewall panels
16, 18 present substantially planar exterior surfaces of a double-skinned assembly,
and each base panel 14 closes the open top of the U-channel to which it is fastened.
The exact manner of the connection between adjacent U-channels is described in
more detail below. When fastened together in this way the openings 14a are aligned
to define an internal passage through the interior of the construction assembly
between its opposing sidewalls 16, 18. The construction element of Figure 3b may
act as a 'corner' element serving to change the direction of the internal passage by
90 degrees.
Figure 4a shows a three-dimensional construction element having a single circular
opening 14a formed centrally in its base panel 14 but spaced from the fold lines 12a,
12b. The opposing free edges 14d of the base panel 14 are each arcuate in shape
across their full width between the opposing fold lines 12a, 12b.
Figure 4b shows a three-dimensional construction element similar to that of Figure
4a. However, the lower edge of the base panel 14 extends in a straight line between
two sidewall panels 14, 16 of reduced height. An end plate 22 is fastened to the
construction element by, for example, welding it to the free edges of the base panel
14 and the two sidewall panels 16, 18 to close off one end of the U-channel. The end
plate 22 is over-sized in the lateral direction such that two flanges 24 extend
outwardly at right angles relative to the sidewall panels 16, 18. Openings may be
provided in the flanges 24 to allow the end plates 22 to be mechanically fastened to
a floor or other structure.
Figure 4c shows a construction assembly comprising six construction elements
according to Figure 4b beneath two construction elements of Figure 4a. The
individual construction elements in each row are fastened together in series by, for
example, welding the distal edges 16d, 18d of one U-channel to the base panel 14 of
another U-channel so that the adjoined sidewall panels 16 and the adjoined sidewall
panels 18 present substantially planar exterior surfaces. The end plates 22 of the
lower row of six construction elements combine to form a contiguous end support
panel. The other two construction elements forming the upper row are fastened
together in the same manner as described above with reference to Figure 3c. The
two rows are fastened together by, for example, welding along edges of the sidewall
panels 16, 18 extending perpendicularly with respect to the bases 14.
In the particular embodiment shown in Figure 4c, the height of the sidewall panels
16, 18 of each individual construction element in the lower row is equal to one third
of the height of each individual construction element in the upper row. This
provides additional strength at the lower row. Once the assembled upper row of
construction elements is mounted onto the assembled lower row, the arcuate free
edges 14d of each base panel 14 on each upper row construction element align with
a like arcuate free edge 14d of a base panel 14 of the lower row construction
element to create an additional row of openings 14e. The openings 14e extend fully
across the gap between the opposing sets of adjoined sidewall panels 16, 18. By
creating a full width arcuate free edge 14d, all straight free edges of the base panel
are removed. It will be appreciated that this arrangement eliminates the need for
any fastening together of base panels 14 to be performed from within the U-shaped
channels since all parts of the arcuate free edges 14d of adjoining base panels 14
remain spaced apart when rows of construction assemblies are mounted one on top
of the other. It is very advantageous to be able to perform all fastening together, e.g.
by welding, from the outside of each assembled row of U-shaped channels.
Furthermore, since individual rows of construction assemblies are pre-assembled,
only a horizontal weld is required to fasten together adjacent rows. The full width
arcuate free edges 14d also serve to eliminate or reduce stress concentrations
where the arcuate free edges 14d meet each sidewall panel 16, 18.
Figure 5a shows a three-dimensional construction element having two elliptical
openings 14a formed in its base panel 14. The elliptical openings extend across the
full width of the base panel 14 between its fold lines 12a, 12b. The opposing free
edges 14d of the base panel 14 are each arcuate in shape and also extend across the
full width of the base panel between its opposing fold lines 12a, 12b. Figure 5b
shows a construction assembly comprising two construction elements according to
Figure 5a fastened together in series. The arcuate shape of the opposing free edges
14d is a half-ellipse such that they may form further elliptical openings when
multiple rows of connected elements are stacked one on top of the other as
described above with respect to Figure 4c. By employing full-width opposing free
edges 14d, all fastening can be perfomed from the outside of each assembled row of
U-shaped channels as noted above.
Figure 6a shows a three-dimensional construction element having two oval
openings 14a formed in its base panel 14. The oval openings extend across the full
width of the base panel 14 between its fold lines 12a, 12b. The opposing free edges
14d of the base panel 14 are each arcuate in shape and also extend across the full
width of the base panel between its opposing fold lines 12a, 12b. Figure 6b shows a
construction assembly comprising thirteen construction elements according to
Figure 6a fastened together in series. The arcuate shape of the opposing free edges
14d is a half-oval such that they may form further oval openings when multiple
rows of connected elements are stacked one on top of the other as described above
with respect to Figure 4c. Again, by employing full-width opposing free edges 14d,
all fastening can be perfomed from the outside of each assembled row of U-shaped
channels as noted above.
Figure 7a shows a non-limiting example of how individual U-channel construction
elements may be fastened together in series. The sidewall panel 16 extends away
from its base panel 14 and terminates in a distal edge 16d extending along its full
length parallel to the plane of the base panel 14. The distal edge 16d is located on a
flange 30 which extends inwardly towards the opposing sidewall panel 18 at a 45
degree angle. As can be seen in Figures 7a and 7b, the width of the flange 30 is
narrow relative to the total height of the sidewall panel 16. Typically, the width of
the flange 30 will be less than 10% of the height of the sidewall panel 16. As is
shown more clearly in Figure 7b, the distal edge 16d has a chamfered 45 degree
angle so as to mate with the plane of a base panel 14 of another U-channel
construction element inwardly of its curved fold line 12a. The inward angle of the
flange 30 creates an elongate concavity or recess between adjoining sidewall panels
16. The chamfered distal edge 16d is fastened to the adjoining base panel 14 by
welding from the exterior. Subsequently, a covering plate 32 is partially inserted
into the recess and welded - from the exterior - to the flange 30 of one U-channel
and the curved fold line 12a of the adjoining U-channel respectively. A drainage
channel 34 is created behind the covering plate 32. Although not illustrated in the
figures, the other sidewall panel 18 is connected to the curved fold line 12b of the
adjoining U-channel in the same manner. Such an arrangement may be particularly
beneficial if the construction assembly is to form the wall of, for example, a spent
fuel pool. In particular, if any leakage occurs through the exterior (wet) face of the
wall assembly, liquids are accommodated and dissipated within the vertical
drainage channel 34 thus avoiding seepage of radioactive material into the
stabilising and/or reinforcement material contained within each U-shaped channel.
Figure 8a shows that by varying the spacing of the fold lines 12a, 12b in metallic
sheet 10 asymmetric U-channel shapes are created. Since the height of sidewall
panel 16 is less that the height of sidewall panel 18, a series of such construction
elements fastened together curves in the direction of the smaller sidewall panel 16
as shown in Figure 8b. The average radius of curvature of the curved assembly can
be varied by changing the relative dimensions of the sidewall panels 16, 18.
Asymmetric U-channel shapes can also be manufactured from two differently
dimensioned L-shaped panel portions in a similar manner to that described above
with respect to Figures 2b and 2c.
Figure 9a shows a U-channel construction element whereby both the base panel 14
and one sidewall panel 16 are provided with a central circular opening 14a, 16a.
Two Nelson® studs 20 extend from either side of the circular opening 16a, and from
the opposing sidewall panel 18. All three panels 14, 16, 18 are square. The Uchannels
may be aligned and fastened together to form a construction assembly as
shown in Figure 9b. Such an arrangement may be particularly suitable for use as a
floor assembly. This is because concrete can be introduced through the upper
horizontal openings 16a and spread horizontally through the vertical openings 14a
formed in each base panel 14. Once the concrete sets around the Nelson® studs 20
a composite deck is formed having a large span capacity suitable for flooring
assemblies. Instead of being constructed from 32 separate square construction
elements, the floor assembly could instead comprise of four elongate construction
elements each having sixteen circular openings 14a, 16a.
The exact shape, size and position of the openings 14a, 16a in all of the construction
elements described above is not critical, provided that the selected reinforcement or
stabilising material is able to pass through. The sizes of the openings are also
selected having regard to the required residual strength of the panels of the
construction element, and the elimination or reduction of stress raisers. For
example a concrete with coarse aggregate filler may require larger apertures than a
fibre-filled resin.
It will be appreciated that the apparatus of the present invention provides a
versatile lightweight modular construction system capable of being used to form
reinforced structural walls (see Figure 10), partitions, extended support surfaces,
floors, ceilings and roofs etc. The system enables rapid assembly of a planned
construction but is flexible enough to accommodate ad hoc on site changes to meet
unforeseen challenges. The modular design also accommodates existing
construction practice for pouring concrete, filling with insulation resins etc. without
requiring any special training or substantial changes in work practices for installing
those secondary construction materials. In more complex structures modular
assemblies can be fastened vertically to other modular assemblies in order to form a
modular construction system having tiers, floors or levels of modular assemblies. In
this way complete structures can be formed having a number of different levels with
floors, ceiling and walls all in place. In addition the modular assemblies may be
provided with utilities, conduits, ducts, wiring for electrical circuitry and additional
structural elements such as to form stairs or the like so that such elements are
available on each level of the final structure so that only minimal final construction
is required on site.
An advantage of the present invention is that it can be used in the construction of
large structures but it can also be used or is applicable to Fastrak® construction
methods, such as the core walls of steel framed buildings. However, it should be
understood that its use is not limited to such and it can be used in a wide range of
applications, building and construction methods all of which will be understood by a
person skilled in the art.
CLAIMS
1 . A construction element in a pre-assembly condition comprising a metallic
sheet (10) sub-divided by one or more fold lines (12a, 12b) into panels (14, 16, 18)
to define a multi-panelled sheet wherein each panel lies in a common plane; at least
one of the panels being deformable along said one or more fold lines out of said
common plane to form an assembled three-dimensional construction element for
adjoining to another three-dimensional construction element; and wherein at least
one panel (14) is provided with an opening (14a) dimensioned to allow the passage
of a reinforcement or stabilising material through the assembled three-dimensional
construction element.
2 . A pre-assembly construction element according to claim 1, wherein the fold
lines (12a, 12b) are each straight and mutually parallel.
3 . A pre-assembly construction element according to claim 2, wherein the
opening (14a) extends across the full width of the at least one panel (14) between
two fold lines (12a, 12b).
4 . A pre-assembly construction element according to any preceding claim,
wherein the opening (14a) is circular in shape.
5 . A pre-assembly construction element according to any preceding claim,
wherein the opening (14a) is oval, elliptical or hexagonal in shape.
6 . A pre-assembly construction element according to claim 5, wherein the
major axis of the elliptical opening (14a) extends perpendicularly with respect to
each fold line (12a, 12b).
7 . A pre-assembly construction element according to any preceding claim,
wherein the metallic sheet (10) is sub-divided into only three panels (14, 16, 18).
8 . A pre-assembly construction element according to any preceding claim,
wherein each panel (14, 16, 18) has the same surface area.
9 . A pre-assembly construction element according to any of claims 1 to 7,
wherein at least one panel has a different surface area than the other panels.
10. A pre-assembly construction element according to any preceding claim,
wherein each fold line (12a, 12b) is defined by a line of weakness formed by scoring,
stamping or partially cutting the planar sheet.
11. A three-dimensional construction element assembled from the multipanelled
sheet of any of claims 1 to 10.
12. A three-dimensional construction element according to claim 11, wherein
the planes of adjacent panels are mutually perpendicular.
13. A three-dimensional construction element according to claim 12, wherein
the fold lines separating adjacent panels define curved adjoining edges.
14. A three-dimensional construction element according to claim 12 or 13
wherein the element comprises only a base panel (14) and two sidewall panels (16,
18) which together define a U-shaped channel.
15. A three-dimensional construction element according to claim 14, wherein
distal edges (16d) of both sidewall panels (16, 18) comprise inwardly extending
flange portions (30) serving to reduce the spacing between their distal ends
16. A three-dimensional construction element according to claim 15, wherein
the flange portions (30) extend inwardly at an acute angle relative to the plane of
each sidewall panel (16, 18).
17. A three-dimensional construction element according to claim 16, wherein
the acute angle falls within the range of 30 - 60 degrees.
18. A three-dimensional construction element according to any of claims 14 to
17, wherein the base panel (14) and at least one of the two sidewall panels (16, 18)
is provided with an opening (14a, 16a) dimensioned to allow the passage of a
reinforcement or stabilising material.
19. A modular construction assembly comprising a plurality of threedimensional
construction elements according to any one of claims 11 to 18
connected together to form a wall, ceiling or floor.
20. A modular construction assembly according to claim 19, wherein adjacent
three-dimensional construction elements are fastened together by welding and/or
bonding and/or mechanical fasteners.
21. Amodular construction assembly according to claim 20, wherein each threedimensional
construction element comprises only a base panel (14) and two
sidewall panels (16, 18) which together define a U-shaped channel; and wherein the
base panel of one U-shaped channel is fastened along distal edges of both sidewall
panels of its adjacent U-channel so as to form a lid closing the open top of the
adjacent U-shaped channel.
22. Amodular construction assembly according to claim 21 when dependent on
any of claims 15 to 18, wherein the base panel (14) of one U-shaped channel is
fastened along distal edges of the flanges (30) on both sidewall panels (16, 18) of an
adjacent U-channel so as to form a lid closing the open top of the adjacent U-shaped
channel, and thereby defining outwardly facing recesses lying between the
respective sidewall panels of adjacent U-shaped channels.
23. Amodular construction assembly according to claim 22, wherein each recess
is covered by a metallic plate (32) fastened between a sidewall/flange junction of
one U-shaped channel and the base/sidewall fold line of an adjacent U-shaped panel.
24. A modular construction assembly according to claim 23, wherein each
covered recess defines a drainage channel (34).
25. A modular construction assembly according to any of claims 19 to 24,
wherein the assembly is reinforced and/or stabilised by the introduction of
reinforcement or stabilising material into the volumes defined by the base, sidewalls
and lid of adjacent three-dimensional construction elements.
26. A modular construction assembly according to claim 25, wherein the
reinforcement or stabilising material is selected from concrete, resin, asphalt and
particulate aggregate.