Wall unit

Abstract

A method of manufacturing a wall unit comprises assembling a set of substantially parallel vertical elongated wall ties having opposite edges which are substantially coplanar on each side of the set. Each wall tie has a plurality of triangular openings distributed along its length with the openings of adjacent wall ties substantially aligned in a horizontal direction. A plurality of reinforcing rods are inserted horizontally through respective sets of aligned openings. Due to the triangular configuration of the openings each rod is deflected under gravity towards, and comes to rest adjacent, an edge of the wall tie. One or more formwork panels are secured to the substantially coplanar edges on each side of the wall ties.

1 . A wall unit comprising:
 a set of substantially parallel elongated wall ties having opposite edges which are substantially coplanar on each side of the set so as to lie in two substantially parallel planes containing said edges,   at least one reinforcing mesh recessed into the wall ties on at least one side of the set by being received in slots in the wall tie edges on that side of the set, and   at least one formwork panel secured to the substantially coplanar edges on each side of the set of wall ties.   
   
   
       2 . The wall unit as claimed in  claim 1 , further including apertures in the wall ties which are aligned in a direction substantially normal to the longitudinal direction of the wall ties, and at least one reinforcing rod extending through the apertures along an edge of a rectangular opening in the set of wall ties. 
   
   
       3 . The wall unit as claimed in  claim 1 , further including at least one reinforcing rod extending substantially parallel to and between adjacent wall ties along an edge of a rectangular opening in the set of wall ties 
   
   
       4 . The wall unit as claimed in  claim 1 , wherein each wall tie has a generally I-shaped cross-section. 
   
   
       5 . The wall unit as claimed in  claim 1 , having a concrete filling in the gap between the formwork panels. 
   
   
       6 . A wall tie for spacing opposite substantially parallel formwork panels in a wall unit, the wall tie comprising:
 an elongated member with substantially parallel opposite flat longitudinal edges for retaining a formwork panel, each edge having a plurality of slots which intermittently interrupt the edge to allow a reinforcing mesh to be recessed into the wall tie clear of the edge.   
   
   
       7 . The wall tie as claimed in  claim 6 , wherein the wall tie has a plurality of apertures distributed along its length between the opposite edges. 
   
   
       8 . The wall tie as claimed in  claim 6 , having a generally I-shaped cross-section. 
   
   
       9 . The wall tie as claimed in  claim 6  formed from one of a metal, polymer or composite material. 
   
   
       10 . The wall tie as claimed in  claim 6  wherein said flat longitudinal edges are arranged to adhesively and/or mechanically retain a formwork panel. 
   
   
       11 . A method of manufacturing a wall unit comprising:
 assembling a set of substantially parallel elongated wall ties having opposite edges which are substantially coplanar on each side of the set so as to lie in two substantially parallel planes containing said edges,   recessing at least one reinforcing mesh into the wall ties on at least one side of the set by inserting the mesh in slots in the wall tie edges on that side of the set, and   securing at least one formwork panel to the substantially coplanar edges on each side of the set of wall ties.   
   
   
       12 . The method as claimed in  claim 11 , wherein the wall ties include apertures which are aligned in a direction substantially normal to the longitudinal direction of the wall ties, the method further includes inserting at least one reinforcing rod through the apertures to lie along an edge of a rectangular opening in the set of wall ties. 
   
   
       13 . The method as claimed in  claim 11 , further including inserting at least one reinforcing rod substantially parallel to and between adjacent wall ties to lie along an edge of a rectangular opening in the set of wall ties. 
   
   
       14 . The method as claimed in  claim 11 , wherein each wall tie has a generally I-shaped cross-section. 
   
   
       15 . The method as claimed in  claim 11 , further including filling the gap between the formwork panels with concrete. 
   
   
       16 . A method of manufacturing a wall unit comprising:
 assembling a set of substantially parallel vertical elongated wall ties having opposite edges which are substantially coplanar on each side of the set, each wall tie having a plurality of openings distributed along its length between its opposite edges with the openings of adjacent wall ties substantially aligned in a horizontal direction,   inserting a plurality of reinforcing rods horizontally through respective sets of aligned openings, the openings being configured such that under gravity each rod is deflected towards, and comes to rest adjacent, an edge of the wall tie, and   securing at least one formwork panel to the substantially coplanar edges on each side of the set of wall ties.   
   
   
       17 . The method claimed in  claim 16 , wherein the openings are triangular and each rod comes to rest at the lowermost angles of the respective set of aligned triangular openings. 
   
   
       18 . The method claimed in  claim 16 , wherein vertically consecutive rods come to rest adjacent alternate edges of the wall ties. 
   
   
       19 . The method claimed in  claim 16 , further including filling the gap between the formwork panels with concrete. 
   
   
       20 . A wall unit made by the method of  claim 16 .