Top-to-bottom construction system

Abstract

Disclosed is a nesting element for use in a hollow pile. The nesting element is configured to be retained at an opening defined in a wall of the pile. The nesting element comprises a surface that is configured such that, in use, the surface substantially conforms to an internal profile at a transverse cross-section of the pile. Also disclosed are a pile system that employs one or more nesting elements in one or more respective piles, and an installation system for installing the pile system into the ground. Additionally, a method of constructing a retaining wall using the pile system and installation system is disclosed.

1 - 41 . (canceled) 
     
     
         42 . A nesting element for use in a hollow pile, the nesting element being configured to be retained at an opening defined in a side wall of the pile, the nesting element comprising a surface that is configured such that, in use, the surface substantially conforms to an internal profile at a transverse cross-section of the pile. 
     
     
         43 . A nesting element as claimed in  claim 42 , wherein the surface extends generally orthogonally from a flange, and wherein the flange is configured to be arranged against an interior or exterior surface of the hollow pile to be retained thereat in use. 
     
     
         44 . A nesting element as claimed in  claim 43 , wherein the nesting element further comprises at least one side wall that extends from the surface in a direction opposite to the flange. 
     
     
         45 . A nesting element as claimed in  claim 44 , wherein the at least one side wall is configured to locate adjacent to an interior surface of the hollow pile in use. 
     
     
         46 . A nesting element as claimed in  claim 42 , wherein the nesting element is configured to support one or more reinforcing bars that in-use extend vertically through the pile. 
     
     
         47 . A nesting element as claimed in  claim 46 , wherein the surface is provided with one or more holes therethrough, each sized for a respective one of the one or more reinforcing bars, to support the rods at the surface, and to maintain a spacing between adjacent rods. 
     
     
         48 . A nesting element as claimed in  claim 42 , wherein, when the hollow pile comprises a sheet pile having a rectangular box section extending for its length, the nesting element is correspondingly dimensioned to nest in the rectangular box section. 
     
     
         49 . A nesting element as claimed in  claim 48 , wherein the surface defines an in-use upper surface of the nesting element, with the nesting element comprising two opposing side walls that each extend downwardly in use from respective opposing side edges of the upper surface, and a rear wall that extends downwardly in use from a rear edge of the upper surface. 
     
     
         50 . A nesting element as claimed in  claim 48 , wherein the nesting element is open at least two sides thereof, with the two open sides being adjacent to one another; wherein a first of the two open sides is arranged to open outwardly of the sheet pile at the wall opening in use, and a second of the two open sides is arranged to open downwardly in the sheet pile in use. 
     
     
         51 . A pile system comprising:
 a hollow pile that has at least one opening defined in a side wall of the pile; and   a nesting element that is configured such that it is able to be retained at the at least one opening of the hollow pile, the nesting element comprising a surface that is configured such that, in use, the surface substantially conforms to an internal profile at a transverse cross-section of the pile.   
     
     
         52 . A pile system as claimed in  claim 51 , wherein the hollow pile has a plurality of openings defined in and spaced out along the wall of the pile, with each opening being located to correspond to an adjacent floor level in use of the pile, and with a nesting element being provided for each opening. 
     
     
         53 . A pile system as claimed in  claim 51 , the system comprising a plurality of hollow piles, wherein each of the hollow piles are configured to be connected to each other along their length whereby, when the hollow piles are connected together, they are thereby able to form a substantially self-supporting wall. 
     
     
         54 . A pile system as claimed in  claim 53 , wherein each of the hollow piles comprises at least one male clutch and at least one corresponding female clutch, the male clutch projecting from a side wall of the hollow pile to extend longitudinally along the length of the side wall, and the female clutch being formed at a side wall of the hollow pile to extend longitudinally along the length of the side wall, the male and female clutches able to be aligned on adjacent piles whereby, when the hollow piles are connected together in-use via their clutches, they are thereby able to form a substantially smooth face along the wall. 
     
     
         55 . A pile system as claimed in  claim 54 , wherein the male clutch is formed to project from an intermediate location along the side wall or is formed along a distal end of the side wall, and wherein the female clutch is respectively formed within the side wall at an intermediate location along the side wall or is formed along a distal end of the side wall. 
     
     
         56 . A pile system as claimed in  claim 55 , wherein a rebate is provided within and along the length of the or each female clutch such that, in use, a sealing bead may be inserted into the rebate in use. 
     
     
         57 . A pile system as claimed in  claim 56 , wherein, when the hollow piles have been connected together to form the wall, the system is configured to have a cementitious material poured into the connected piles at an open upper end of each of the hollow piles. 
     
     
         58 . A pile system as claimed in  claim 57 , wherein, prior to pouring the cementitious material into the open upper end of each of the hollow piles, the system is configured to receive reinforcing vertically through each of the hollow piles. 
     
     
         59 . A method of constructing a retaining wall, the method comprising:
 driving into ground a first mandrel having an elongate tubular internal profile that is correspondingly dimensioned to an external profile of a hollow pile;   removing ground from within an interior of the first mandrel;   driving into the ground a second mandrel that comprises an elongate channel having opposing elongate side walls that are connected to one another by a rear wall, each side wall being configured to connect with a side wall of an adjacent first mandrel to be guided thereby;   removing ground from within an interior of the second mandrel;   locating a hollow pile as defined in claim  10  within the first mandrel.   removing the first mandrel from the ground;   locating a hollow pile as defined in claim  10  within the second mandrel such that the hollow pile connects to the adjacent hollow pile that was located within the first mandrel;   removing the second mandrel from the ground; and   pouring a cementitious material into the hollow pile at an in-use open upper end thereof, with the cementitious material flowing down inside the pile until it reaches a surface of an in-use uppermost nesting element located at a respective wall opening.   
     
     
         60 . A method as claimed in  claim 59 , wherein the retaining wall is constructed along a perimeter of a construction site and a slab of cementitious material is formed at the ground of the construction site perimeter, optionally with one or more slab support columns having first been formed into the ground, the method further comprising:
 excavating the ground under the slab down to a level that aligns with a line of nesting elements arranged in the hollow piles of the retaining wall at the site perimeter, the line of nesting elements being at a level that corresponds to a next floor slab; and   pouring the next floor slab at the excavated ground level, the cementitious material being able to flow in through each of the pile wall and nesting element openings and into the respective hollow pile, so as to fill up the pile, either to a surface of a next lower nesting element, or to a base of the hollow pile.   
     
     
         61 . A method as claimed in  claim 60 , wherein the method comprises as required, excavating ground under the next floor slab and pouring a further floor slab, with steps similar to those as set forth in claim  19  being repeated until a final base floor slab is formed at a lowermost level corresponding to a base of the retaining wall.