Reinforced modular steel-concrete structures

Abstract

A construction element is provided. The construction element comprises a base panel and two generally orthogonal sidewall panels, which together define a U-shaped channel having an interior cavity. At least one panel includes at least one panel opening sized to allow a reinforcing or stabilizing material to pass into the interior cavity. The construction element further comprises at least one support plate (70) having first and second ends secured to respective corresponding sidewall panels and extending generally orthogonal to the sidewall panels across the channel to support the sidewall panels.

Description

[Technical Field]

[0001] The present invention relates to the field of reinforced modular structures, such as base mats, foundations, floors, walls and roofs, which are formed from a number of individual structural elements which combine together to form the structure. [Background technology]

[0002] When building large structures, it is beneficial to reduce labor costs and minimize construction time. This is particularly relevant in the construction of nuclear power plants, where such efficiencies are necessary for nuclear power to become a more viable and realistic alternative fuel source to fossil fuels or other less powerful alternative sources.

[0003] Nuclear power plants and other sensitive structures, including nuclear waste processing and / or storage facilities, must withstand natural phenomena such as earthquakes and hurricane-force winds and contain large overpressures. This requires significant reinforcement of the built structures. Known reinforcement means employ complex and expensive assemblies of laminated flat steel plates braced at intervals by separate internal grids of stiffening members and / or tie bars and / or shear studs. The assembly of these currently available solutions requires highly specialized and skilled labor, which is itself expensive and difficult to procure. Therefore, there is a need for a simpler, more efficient, and more cost-effective means of providing structural reinforcement to the nuclear and other industries.

[0004] One solution proposed by the applicant can be found in Patent Document 1 (WO 2013 / 117892). Patent Document 1 discloses a construction component comprising a modular assembly of multiple building reinforcements, each formed from two L-shaped elements to define a U-shaped channel. The base panel of one U-shaped channel is secured along the distal edges of both sidewall panels of an adjacent U-shaped channel to form a lid that closes the open top of the adjacent U-shaped channel. In this way, multiple reinforcements are secured to each other to form a component that can be a wall, ceiling, or floor. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2013 / 117892 Brochure Summary of the Invention [Problem to be solved by the invention]

[0006] When such components are brought together, such as when forming a joint between a wall and a supporting floor, the weight of the wall components will be loaded onto the floor, causing one or more of the side wall panels that form the floor component to bend or buckle.

[0007] Another potential problem with such components occurs when they are filled with concrete. Air pockets can become trapped within individual elements as the concrete fills the interior spaces defined by the elements. These air pockets can become weak spots in the structure.

[0008] Fastening of elements is typically accomplished using welding, adhesives, and / or mechanical fasteners to form modular assemblies. While this configuration is an undoubted improvement over the complex and expensive assemblies previously used, the formed components must still be attached to one another on-site using one of these same fastening methods to form the resulting building or other structure. This means that forming a building or other structure from a large number of these reinforced components can still be a time-consuming process. The need to fasten components on-site using welding, adhesives, or mechanical fasteners limits the versatility of the system, meaning that it may not be able to meet specific design requirements.

[0009] It is an object of the present invention to obviate or mitigate one or more of these disadvantages of reinforced modular structures. [Means for solving the problem]

[0010] According to a first aspect of the present invention there is provided a construction element comprising: a base panel and two generally orthogonal sidewall panels that together define a U-shaped channel having an interior cavity, at least one of said panels including at least one panel opening sized to permit passage of a reinforcing or stabilizing material into said interior cavity; at least one support plate having first and second ends secured to respective side wall panels and extending across the channel generally perpendicular to the side wall panels to support the side wall panels; Equipped with.

[0011] Preferably, said at least one support plate comprises at least one support plate dimensioned to allow reinforcement or stabilising material to pass through said support plate.

[0012] Preferably, at least one of the side wall panels includes a vent hole to allow air to pass from the interior to the exterior of the element, the vent hole may be tapered to have a larger diameter at the exterior surface of the side wall panel than at the interior surface of the side wall panel.

[0013] According to a second aspect of the present invention there is provided a construction element comprising: 1. A construction element comprising a base panel and two substantially orthogonal sidewall panels that together define a U-shaped channel having an interior cavity, at least one of said panels including at least one panel opening dimensioned to allow passage of a reinforcing or stabilizing material into said interior cavity, At least one of the sidewall panels includes a vent that allows air to pass from the interior to the exterior of the element.

[0014] Preferably, the vent is tapered to have a larger diameter at the outer surface of the side wall panel than at the inner surface of the side wall panel.

[0015] Preferably, the construction elements are made from steel sheets having a thickness between 6 mm and 25 mm.

[0016] The construction element may be formed from two separate L-shaped sections joined together to form the U-shaped channel. The two separate L-shaped sections may be shaped to define the at least one panel opening when joined together. The two separate L-shaped sections may be joined together by welding, adhesive, or mechanical fastening.

[0017] Preferably, the interior surface of at least one of the base panel and the side wall panel includes a plurality of shear studs that project into the interior cavity.

[0018] According to a third aspect of the present invention there is provided a construction component comprising a modular assembly of a plurality of construction elements according to the first and second aspects of the present invention, wherein the base panel of one construction element is fastened along distal edges of side wall panels on either side of an adjacent construction element to form the construction component.

[0019] The construction component further comprises at least one tension duct adapted to receive a tension tendon, said at least one tension duct being capable of passing through said at least one panel opening in each construction element along the length of said component.

[0020] According to a fourth aspect of the present invention there is provided a method of forming an L-shaped or T-shaped joint from a first construction element and a second construction element of the first aspect, the method comprising: determining first and second abutment points where the ends of the two side wall panels of the first construction element abut against the side wall panels of the second construction element when forming the joint; fastening a pair of support plates across the channel of the second construction element at the first abutment location and the second abutment location; bringing the first and second construction elements together so that the two side wall panels of the first construction element are substantially flush with the support plates corresponding to each of the second construction elements; and securing the first construction element and the second construction element to one another; Equipped with.

[0021] The step of securing may include welding, gluing or mechanically fastening the components involved together.

[0022] According to a fifth aspect of the present invention there is provided a construction component comprising a modular assembly of a plurality of construction elements attached to one another to form a substantially planar component, each construction element comprising a plurality of panels which together define an internal cavity, at least one of said panels including at least one panel opening dimensioned to allow the passage of reinforcing or stabilising material into said internal cavity, said component further comprising at least one tension duct adapted to receive a tension tendon, said at least one duct passing through said at least one panel opening in each construction element along a length of said component.

[0023] The construction component may further comprise a tension tendon disposed within each duct, the tendon being selected from the group consisting of a wire, a multi-wire strand, and a bar. The tendon may include a first fastener and a second fastener at each end thereof, the fasteners being connectable to another construction component and / or a concrete surface.

[0024] According to a sixth aspect of the present invention there is provided a method of constructing a structure, the method comprising: forming a construction component according to the fifth aspect of the invention; filling the internal cavities of a plurality of the construction elements with concrete; and tensioning the tension tendons after the concrete has hardened; Equipped with.

[0025] According to a seventh aspect of the present invention there is provided a method of constructing a structure, the method comprising: forming at least two construction components according to the fifth aspect of the invention; arranging the two components to define the structure; anchoring a first end and a second end of each tension tendon to an outer surface of the at least two components; initially tensioning the tendon to secure the at least two components together; filling the internal cavities of the at least two construction components with concrete; and further tensioning the tendon after the concrete has hardened; Equipped with.

[0026] The structure may be a four-sided structure and the method may include: forming four construction components according to the fifth aspect of the invention; arranging the four components to define a base, first and second side walls, and a top of a structure; placing tension tendons in at least one duct in the base component and the top component; anchoring first and second ends of each tension tendon to outer surfaces of the first and second side walls; initially tensioning the tendons to secure the base and roof to the first and second side walls; filling the internal cavities of the plurality of construction components with concrete; and further tensioning the tendon after the concrete has hardened; Equipped with.

[0027] The step of disposing the component may include employing one or more temporary supports to temporarily hold the component in place, and the method further comprises removing the temporary supports after the locking step.

[0028] According to an eighth aspect of the present invention there is provided a method of constructing a structure, the method comprising: forming one or more construction components according to the fifth aspect of the invention; disposing the one or more components on a foundation to define a central core of the structure; anchoring a first end and a second end of each tension tendon to the foundation and an upper surface of the or each component; initially tensioning the tendons to secure the or each component to the foundation; placing one or more support posts adjacent to the central core; attaching one or more support beams between the support columns and the core; filling the internal cavities of the one or more construction components with concrete; and further tensioning the tendon after the concrete has hardened; Equipped with. [Brief explanation of the drawings]

[0029] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 shows a planar plate with fold lines and apertures from which construction elements are formed. [Figure 2] 2 shows a two-dimensional planar plate section representing one half of the construction element of FIG. 1; [Figure 3] 2 shows an alternative two-dimensional planar plate section representing one half of the construction element of FIG. 1; [Figure 4a] 1 shows one of two different three-dimensional construction elements. [Figure 4b] 1 shows the other of two different three-dimensional construction elements. [Figure 4c] This refers to a construction element that combines a series of individual construction elements by fastening them together. [Figure 5] 1 is a cross-sectional view of a construction component formed from construction elements. [Figure 6a] 1 shows one stage in the process of filling a construction component with concrete. [Figure 6b] 1 shows one stage in the process of filling a construction component with concrete. [Figure 6c] 1 shows one stage in the process of filling a construction component with concrete. [Figure 6d] Shows one of the stages in the process of filling a construction component with concrete. [Figure 7a] 1 shows a perspective view of a joint formed from construction components. [Figure 7b] 1 shows a side view of a joint formed from construction components. [Figure 7c] 1 shows an end view of a joint formed from construction components. [Figure 8a] 1 shows a perspective view of an alternative joint formed from construction components. [Figure 8b] 10 shows a top view of an alternative joint formed from construction components. [Figure 8c] 10A-10C show end views of alternative joints formed from construction components. [Figure 9a] 4c shows a schematic illustration of a method for constructing a reinforced building component by use of the construction component shown in FIG. [Figure 9b] 4c shows a schematic illustration of a method for constructing a reinforced building component by use of the construction component shown in FIG. [Figure 9c] 4c shows a schematic illustration of a method for constructing a reinforced building component by use of the construction component shown in FIG. [Figure 10a] 4c shows a schematic illustration of a method for constructing a reinforced tunnel by using construction components shown in FIG. [Figure 10b] 4c shows a schematic illustration of a method for constructing a reinforced tunnel by using construction components shown in FIG. [Figure 10c] 4c shows a schematic illustration of a method for constructing a reinforced tunnel by using construction components shown in FIG. [Figure 11a]4c shows a schematic illustration of a method for constructing a building having a reinforcing core formed using the construction components shown in FIG. 4c. [Figure 11b] 4c shows a schematic illustration of a method for constructing a building having a reinforcing core formed using the construction components shown in FIG. 4c. [Figure 11c] 4c shows a schematic illustration of a method for constructing a building having a reinforcing core formed using the construction components shown in FIG. 4c. DETAILED DESCRIPTION OF THE INVENTION

[0030] FIG. 1 shows a construction element in a two-dimensional pre-assembled state prior to formation into a three-dimensional construction element. The construction element consists of a rectangular metal plate 10 subdivided by two straight, parallel fold lines 12a, 12b that define three equal-sized panels 14, 16, 18. Each panel lies in a common plane. The plate is made of metal. Most preferably, the plate is formed from flat stainless steel or carbon steel. Each fold line 12a, 12b has a line of weakness formed by scratching, stamping, or partially cutting into the surface of the metal plate. The central panel 14 has a row of equally spaced circular openings 14a along its length. The diameter of the openings 14a can be at least 50% of the width of the central panel 14 between the fold lines 12a, 12b.

[0031] Figure 2 shows an alternative two-dimensional planar plate section representing one half of the construction element of Figure 1. The plate section is shaped with a series of spaced apart semi-circular recesses 15 located along one edge of the panel 14.

[0032] 3 shows a further alternative two-dimensional planar plate portion, also forming one half of a construction element (not shown), which is shaped with a series of spaced apart hexagonal recesses 15h located along one edge of the panel 14.

[0033] FIG. 4a shows a three-dimensional construction element formed from a two-dimensional metal plate 10 similar to that shown in FIG. 1. The sidewall panels 16, 18 have been forced to bend along fold lines 12a, 12b from an initial common panel and deformed to extend perpendicular to the base panel 14. The three-dimensional construction element therefore adopts a U-channel shape, whereby the sidewall panels 16, 18 face each other and rise generally parallel from the base panel 14 to define the U-channel. In the particular embodiment illustrated in FIG. 4a, an array of shear studs 20 is welded to the inward-facing surfaces of the sidewall panels 16, 18. These shear studs may be Nelson® studs, which have enlarged heads relative to their shank width.

[0034] The plate preferably has a thickness in the range of 6 to 25 mm, and more preferably is a steel plate. Particularly when forming elements from plates of this thickness, it has been found that the process of manufacturing a three-dimensional, three-panel construction element is simpler by joining two L-shaped two-panel halves together. For example, two of the planar plate sections shown in FIG. 2 can be forced to bend along their corresponding fold lines 12a so that each panel 14 extends perpendicular to panel 16. The two L-shaped panels can then be oriented so that their semicircular recesses 15 align to form a circular opening 14a, for example, by welding the edge portions midway between the openings 14a. Naturally, this method of manufacturing a U-shaped channel is more practical than forming two bends in a single three-panel construction element using a mechanical press. Another advantage is that the two planar plate halves can be manufactured from different grades of steel, such as stainless steel and carbon steel, respectively.

[0035] The above process can also be adapted to use pairs of planar plate sections as shown in Figure 3. The advantage of using planar plates with hexagonal recesses 15 is that it completely eliminates the waste of metal plate material when cutting from the base metal plate during manufacturing.

[0036] Figure 4b shows an alternative three-dimensional construction element formed from a two-dimensional metal plate 10 (not shown). The sidewall panels 16, 18 have been modified from the initial common panel to define the same U-channel as shown in Figure 4a. However, the opening 16a is provided in the sidewall panel 16 rather than the base panel 12.

[0037] Figure 4c shows a reinforced building component consisting of three construction elements according to Figure 4a and one construction element according to Figure 4b. Typically, the construction elements are oriented so that they stand on their ends and their panels 14, 16, 18 extend vertically. The individual construction elements are aligned in the same orientation so that they are fastened together in series, for example, by welding the distal edges 16d, 18d of one U-shaped channel to the outer edge of the base panel 14 of the other U-shaped channel. In doing so, the adjacent sidewall panels 16, 18 present a substantially planar outer surface of the double-skin assembly, and each base panel 14 closes the open top of the U-shaped channel to which it is fastened.

[0038] When fastened together in this manner, the openings 14a align to define an interior passageway through the interior of the construction assembly between the opposing side walls 16, 18. Ducts 30 may be provided within the building components such that the ducts 30 extend longitudinally through the passageway defined by the aligned openings 14a along the length of the components.

[0039] The construction element of Figure 4b may act as a "corner" element that helps to change the direction of the interior passage by 90°.

[0040] The exact shape, size, and location of the openings 14a, 16a in the construction elements described above are not critical, provided that they allow the selected reinforcement, stabilization material, and / or ducts to pass through. The size of the openings is further selected with respect to the required residual strength of the construction element panels and the elimination or reduction of stress sources. For example, concrete with a coarse aggregate filler may require larger open holes than fiber-filled resin.

[0041] Figure 5 shows a cross-section of a building component formed from a plurality of construction elements of the type illustrated in Figures 4a and 4b, where the attached elements have been filled with concrete 32. At least one element has been modified to include a weep hole or vent 40 in one side wall panel 18.

[0042] 6a-d show how weep holes 40 are utilized in the process of filling multiple elements with concrete. FIG. 6a shows how air is forced out of the element from the interior through weep holes 40 as concrete flows into the element through openings in the panel. Weep holes 40 taper outward from the inner surface 17 of panel 18 to the outer surface 19. In other words, weep holes 40 have a larger diameter at outer surface 19 than at inner surface 17. Allowing air to escape from the element in this manner ensures that the element is completely filled with concrete without air pockets or bubbles present within the element.

[0043] Figure 6b shows the element completely filled with concrete 32, as described above. After the concrete 32 has completely hardened, a hole 42 is drilled into the concrete through the weep hole 40. A ceramic plug 44 is then placed into the hole 42, as shown in Figure 6c. Finally, a weld 46 is placed over the plug 44 in the weep hole 40, as shown in Figure 6d. The weld 46 seals the panel 18, ensuring that nothing can leak from the element through the weep hole 40.

[0044] Figures 7a-c show a joint formed between two building components formed as described above. In this embodiment, a T-shaped joint is formed between a horizontal component (e.g., a foundation or floor) 50 and a vertical component (e.g., a wall) 60. The elements that are attached to each other to form the horizontal component 50 and the vertical component 60 are substantially the same as those shown in Figures 4-c.

[0045] During the design process for the structure of which the components 50 and 60 form a part, the exact configuration and positioning of the various components is pre-established. This means that bulkhead support plates can be attached to some or all of the elements that join two components together to provide additional strength at the joints. In the embodiment shown in FIG. 7, pairs of bulkhead plates 70 are welded to the U-shaped channels of each horizontal component 50. The bulkhead plates 70 are attached to the horizontal components at the longitudinal points where the vertical components 60 abut their corresponding side walls. Thus, the bulkhead plates 70 are generally flush with the side walls of the first vertical component 60, providing additional strength and support for the horizontal component 50 element below the vertical component 60. One or both bulkhead plates in each pair can have openings for concrete flow, as shown, or one or both can be solid. These bulkhead plates can also be installed anywhere in a building component where reinforcement is needed. For example, if a wall component is to be fitted with heavy equipment, a bulkhead plate may be fitted into a channel in one or more elements of the wall component in the area where the equipment is to be fitted.

[0046] Figures 8a-c show an alternative joint that can be formed between two building components of the type described above. In this embodiment, a T-shaped joint is formed between a pair of horizontal and vertical components 50', 60'. The elements that are attached to each other to form the horizontal and vertical components 50', 60' are substantially identical to those shown in Figures 4-c. This joint differs from that shown in Figure 7 in that the vertical component 60' is sandwiched between a pair of horizontal components 50', rather than resting on a single horizontal component.

[0047] As with the joint in Figure 7, the exact placement and positioning of the various components is established in advance during the design phase. This means that bulkhead support plates can be attached to some or all of the elements joining two components together to provide additional strength to the joint. In the embodiment shown in Figure 8, pairs of bulkhead plates 70' are welded to the U-shaped channels of each element of the vertical component 60'. The bulkhead plates 70' are attached to the vertical components at the longitudinal points where the elements of the horizontal component 50' rest against the vertical component 60'. Thus, the bulkhead plates 70' are generally flush with the sidewalls of the first element of the horizontal component 50', providing additional strength and lateral support for the vertical component 60'. One or both bulkhead plates in each pair can have openings for concrete flow, or one or both can be non-opening. In the embodiment shown, the lower plate in the pair does not have openings, while the upper plate does.

[0048] Figures 9a-c show schematically how a building component of the type shown in Figure 4c may be employed. In the illustrated embodiment, a replacement bridge span 100 is formed from a plurality of construction elements of the type shown in Figures 4a and 4b fastened in series by welding adjacent elements together as described above. At least one duct extends from one end of the span 100 to the other through openings 14a, 16a. One or more tension tendons or bars 102 may be inserted into the duct at the manufacturing site, or may otherwise be inserted after the component is transported to the required installation site.

[0049] The span 100 is constructed in an off-site manufacturing facility, then transported to the work site where it is installed as shown schematically in Figure 9a. Once in place, concrete is poured into the span 100, and the openings 14a, 16a in the elements allow the concrete to flow into and through each element, ultimately filling the interior of the span, as shown in Figure 9b.

[0050] After the concrete has hardened, one or more tendons or bars within the span's ducts are tensioned by pulling on the ends of the tendons or bars with anchorages 104 secured to either side of the hardened concrete core. This is shown in Figure 9c. The large force required to tension the tendons or bars 102 after the tendons are "locked off" with the anchorages 104 results in a large permanent compression of the concrete. The method of locking the anchorages onto the ends of the tendons or bars depends on the tendon / bar configuration, with the most common systems being "button head" anchorages (for wire tendons), split wedge anchorages (for stand tendons), and threaded anchorages (for bars).

[0051] Figures 10a-c schematically illustrate the construction of a reinforced tunnel using building components described elsewhere herein. Initially, as shown in Figure 10a, floor, wall, and roof components 110, 120, 130 are brought to the site and installed as needed. Each of the components 110, 120, 130 is formed from a series of building elements to reach its final form, as shown in Figure 4c. A series of temporary supports 200 are installed to hold the components 110, 120, 130 in place.

[0052] 10b, tendons or bars 102 are placed into ducts that penetrate the floor and roof components 110, 130, and the ends of the tendons / bars are then anchored to the exterior surface of the wall component 120. The tendons / bars 102 are then tensioned so that the components 110, 120, 130 are held tightly together and the temporary support 200 can be removed.

[0053] In the final installation stage shown in Figure 10c, each of the floor, wall, and roof components 110, 120, 130 is filled with concrete. After the concrete has hardened to the required extent, the tendons / bars 102 are further tensioned to post-tension the concrete. After post-tensioning is complete, the outer areas of the tunnel are backfilled to cover the tunnel.

[0054] Another construction application is shown schematically in Figures 11a-c. In this application, a reinforced core for a building is formed. As shown in Figure 11a, the first step involves bringing a prefabricated core 300 to the site and placing the core 300 on a foundation 310. The foundation 310 can be formed from concrete or can be formed from multiple building elements into a building component of the type described herein. The core 300 is formed from one or more building components of the type shown in Figure 4c. The core 300 can be a core wall formed from a single component, or alternatively, it can be a core box made from a floor component, four wall components, and a roof component. However, many components are used, each having at least one duct passing through it, as shown in Figure 4c.

[0055] In step 2 of the process, shown in Figure 11b, tendons or bars 102 are placed within the ducts of the vertical wall components. The tendons or bars 102 are anchored at their lower ends to the foundation 310 and at their upper ends to the top surface of the roof or wall component. The tendons / bars 102 are tensioned to secure and stabilize the core 300 on the foundation 310.

[0056] As shown in FIG. 11c, additional core components 300' can be placed on top of the first core 300 to bulk out the height of the core structure. Each additional story is attached to the story below by tendons / bars 102 that pass through vertical ducts in the vertical components of that new story. The lower ends of the tendons / bars 102 anchor to the first core component 300, while the upper ends anchor to the roof component or the top surface of the new story. After the core structure is formed, an outer framework of beams 320 and columns 330 can be formed and attached to the core structure 300, 300'. The core stabilizes the beams and columns 320, 330, allowing construction to continue on and around the beams and columns.

[0057] Once completed, the core 300, 300' is filled with concrete for added strength, stiffness, and fire resistance. After the concrete has hardened, additional post-tensioning is added if necessary.

[0058] By providing bulkhead support plates at predetermined locations within the elements, the completed components can be brought together to form L- or T-shaped joints without any risk of bowing or buckling of one or more elements. By providing one or more vent holes in the element panels, air can easily escape from the element as concrete flows into the interior volume. This ensures the absence of trapped air pockets and associated structural weaknesses within the completed component.

[0059] When employing tension ducts and associated tendons, the present invention provides a versatile, lightweight modular construction system that can be used to form reinforced structural walls, partitions, extended support surfaces, floors, ceilings, and roofs, among others. This system allows for rapid assembly of planned construction, yet is flexible enough to allow for improvised on-site modifications to meet unforeseen challenges. The modular design also allows for existing construction work to be filled with insulating resins and the like, without requiring special training or significant changes in work practices to introduce these secondary construction materials. In more complex structures, modular assemblies can be fastened vertically to other modular assemblies to form a modular construction system with layers, floors, and stories of modular assemblies. In this way, a completed structure can be formed with many different stories, with floors, ceilings, and walls all in place. Additionally, the modular assembly can be provided with additional structural elements such as those forming fixtures, conduits, ducts, wiring for electrical circuits, staircases, etc., so that such elements are available on each floor of the final structure, requiring only minimal final construction on site.

[0060] Tension ducts and tendons allow the formed reinforcement components to be attached to one another without welding, adhesives, or a large number of mechanical fasteners. This means that building or other structures can be constructed from these reinforcement components more quickly and cheaply than with current methods. This also provides a versatile building system that can be adapted to changing design requirements.

[0061] Although each element in the illustrated embodiment is shown as rectangular, the elements can have other shapes. For example, a pair of sidewall panels that make up an element can both be shorter at one end than at the other end, meaning that the sidewall panels are tapered or angled. This can allow the element to have a generally triangular shape, which is useful, for example, when aiming to create a circular reinforcement component.

[0062] Alternatively, the sidewall panels can be of a generally constant height, but one sidewall panel in the pair can be shorter than the other sidewall panel on the other side of the U-shaped channel. In other words, this is when the goal is to create a U-shaped channel from the ends of elements where one side of the channel is shorter than the other. This configuration means that when a series of such elements are attached in series as described herein, they will define a curve, thus forming a curved building component, such as a curved exterior wall of a containment structure.

[0063] If a bulkhead support plate is provided, it may have approximately the same surface area as the channel in the U-shaped element to be installed, so that when the elements are assembled to form a wall, floor, etc., the free edge of the plate that is not attached to the joining channel can be attached to the base panel of an adjacent element.

[0064] These and other modifications and improvements may be incorporated without departing from the scope of the present invention.

Claims

1. A construction element comprising: the construction element is formed by a planar metal plate defined by two parallel fold lines into three panels of equal size, or by first and second planar metal plates each defined by one fold line into two panels, the panels are deformed from an initial common plane by bending along respective fold lines such that the construction element is a base panel and two generally orthogonal sidewall panels that together define a U-shaped channel having an interior cavity, at least one of the panels including at least one panel opening dimensioned to permit passage of a reinforcing or stabilizing material into the interior cavity; The construction element further comprises at least one support plate disposed within the U-shaped channel, the at least one support plate having first and second ends secured to respective side wall panels and extending across the channel generally perpendicular to both the base panel and the side wall panels to support the side wall panels.

2. 10. The construction element according to claim 1, wherein said at least one support plate comprises at least one support plate dimensioned to allow reinforcement or stabilization material to pass through said support plate.

3. 3. A construction element according to claim 1 or 2, wherein at least one of the side wall panels comprises ventilation holes allowing air to pass from the interior to the exterior of the element.

4. 4. A construction element according to claim 3, wherein the vent holes are tapered to have a larger diameter at the outer surface of the side wall panel than at the inner surface of the side wall panel.

5. A construction element according to any one of claims 1 to 4, made from steel sheets having a thickness between 6 mm and 25 mm.

6. 6. A construction element according to any one of claims 1 to 5, wherein the element is formed from the first and second planar metal plates deformed into two separate L-shaped sections which are joined together to form the U-shaped channel.

7. 7. A construction element according to claim 6, wherein the two separate L-shaped sections, when joined together, are shaped to define the at least one panel opening.

8. 8. A construction element according to claim 6 or 7, wherein the two separate L-shaped sections are joined together by welding, gluing or mechanical fastening.

9. A construction element according to any one of the preceding claims, wherein the inner surface of at least one of the base panel and the side wall panel comprises a plurality of shear studs projecting into the internal cavity.

10. 10. A construction component comprising a modular assembly of a plurality of construction elements according to any one of claims 1 to 9, wherein the base panel of one construction element is fastened along the distal edges of side wall panels on either side of an adjacent construction element to form the construction component.

11. 11. The construction component of claim 10, further comprising at least one tension duct adapted to receive a tension tendon, said at least one tension duct passing through said at least one panel opening in each construction element along the length of said component.

12. A method for forming an L-shaped or T-shaped joint from a first construction element and a second construction element according to any one of claims 1 to 4 and 5 to 9, comprising: determining first and second abutment points where the ends of the two side wall panels of the first construction element abut against the side wall panels of the second construction element when forming the joint; fastening a pair of support plates across the channel of the second construction element at the first abutment location and the second abutment location; bringing the first and second construction elements together so that the two side wall panels of the first construction element are substantially flush with the support plates corresponding to each of the second construction elements; and securing the first construction element and the second construction element to one another; A method comprising:

13. 13. The method of claim 12, wherein the step of securing comprises welding, gluing or mechanically fastening the components involved together.

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