WO2012129601A1

WO2012129601A1 - Building system

Info

Publication number: WO2012129601A1
Application number: PCT/AU2012/000318
Authority: WO
Inventors: Mark Tanner
Original assignee: Blue Arc International Pty Ltd
Priority date: 2011-03-30
Filing date: 2012-03-28
Publication date: 2012-10-04
Also published as: AU2012234909A1

Abstract

A building construction system including a number of beams and posts defining a building frame, a plurality of pre-fabricated panels, each panel including a number of C-shaped frame members connected to define a panel frame, the frame being connectable to at least one of the building frame and other panels to form a building structure, in use at least one sheet coupled to the panel frame to define a panel face.

Description

BUILDING SYSTEM

Background of the Invention

[0001] The present invention relates to a building construction system and a method of constructing a building.

Description of the Prior Art

[0002] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0003] It is known to provide construction systems to allow for rapid construction of buildings. However, many of these require significant skilled labour for their construction, which in turn can make construction of such buildings difficult and expensive in regions where there are skilled labour shortages.

[0004] One attempt to address this can be found in AU-780586 describes a transportable building comprising upper and lower rectangular frames 10,11 of metal interconnected by upright metal frame members 14, a floor supported by the lower frame, a roof supported by the upper frame and removable interlocking side panels 15 extending between the upper and lower frames 10,11. The side panels 15 are each of the same size and are slidable within their own plane to enable each panel to be disengaged from the or each adjacent panel. Side panels are provided having doors, windows, electrical and ablution facilities. The framework of the building makes it easy to transport, particularly if the dimensions of the framework match those of conventional shipping containers. The interlocking side panels 15 are removable and as such any of the different types of panel can be positioned at any desired location or one or more panels can be omitted if two buildings are to be interconnected.

[0005] However, such transportable buildings are of a limited size to allow transport and consequently allow for little flexibility in the form of the final building. Summary of the Present Invention

[0006] In a first broad form the present invention seeks to provide a building construction system including:

a) a number of beams and posts defining a building frame;

b) a plurality of pre-fabricated panels, each panel including:

i) a number of C-shaped frame members connected to define a panel frame, the frame being connectable to at least one of the building frame and other panels to form a building structure, in use; and,

ii) at least one sheet coupled to the panel frame to define a panel face.

[0007] Typically the panels include at least one of:

a) floor panels;

b) wall panels;

c) roof panels; and,

d) ceiling panels.

[0008] Typically the frame members include parallel spaced apart joists connected to trimmers at either end to form a frame.

[0009] Typically the frame members are at least one of 0.5mm and 1.0mm thick lightweight steel members.

[0010] Typically the frame members are connected using at least one of:

a) welds;

b) rivets; '

c) bolts; and,

d) screws.

[0011] Typically at least some of the panels include two sheets attached to opposing sides of the panel frame.

[0012] Typically at least some wall panels include a foam tap between the panel frame and at least one sheet to thereby thermally isolate the at least one sheet from the panel frame. [0013] Typically a flashing is inserted between the at least sheet and frame where adjacent wall panels meet.

[0014] Typically the system includes a number of panel brackets for connecting the panel frame to at least one of the building frame and other panel frames.

[0015] Typically the panels are connected to at least one of the building frame and other panels using at least one of bolts and screws.

[0016] Typically the system includes a number of right angled wall panel brackets for coupling the wall panels to the building floor.

[0017] Typically the system includes a number of straps, the straps being for at least one of: a) coupling to the frame members to thereby tension the panel frame; and

b) interconnecting the panels frames and the building frame.

[0018] Typically the building frame includes a post and beam steel sub frame for single or double story buildings, the sub frame including beam grid with post supports.

[0019] Typically the building frame includes a clear span beam grid with post supports for multiple story buildings.

[0020] Typically the sheets include at least one of:

a) linings;

b) insulations;

c) claddings;

d) powder coated metal roof sheeting;

e) gypsum board; and,

f) cement board.

[0021] Typically the system is used to construct a module, the module including:

a) beams defining a module frame; and,

b) a number of panels attached to at least one of the module frame and other panels. [0022] Typically the module frame includes a ceiling frame and vertical supports, the vertical supports extending beyond the ceiling frame.

[0023] Typically the module is pre-fabricated with floor, ceiling, wall, and roof panels are fixed, as required.

[0024] Typically the beams and posts are interconnected using shipping container corner castings.

[0025] Typically the shipping container corner castings provide lifting points for modules.

[0026] In a second broad form the present invention seeks to provide a method of constructing a building, the method including:

a) constructing a building frame including a number of beams and interconnected posts;

b) attaching a plurality of pre-fabricated panels to the building frame, each panel including:

i) a number of ^"C^shaped rame members connected to define a panel frame, the frame being connectable to at least one of the building frame and other panels to form a building structure, in use; and,

ii) at least one sheet coupled to the panel frame to define a panel face.

[0027] Typically the method includes attaching a panel to at least one of the building frame and another panel using at least one of bolts and screws.

[0028] Typically the method includes attaching a panel to at least one of the building frame and another panel using a number of panel brackets.

[0029] In a third broad form the present invention provides a building module including: a) a floor including a floor frame having one or more floor panels mounted thereon; b) a roof including a roof frame having one or more roof panels and one or more ceiling panels mounted on opposing faces;

c) a number of posts interconnecting the floor and roof frames; d) a number of channels mounted to at least one of the floor and roof, the channels before for supporting one or more wall panels.

[0030] Typically the wall panels include:

a) a number of C-shaped frame members connected to define a panel frame, the frame being connectable to at least one of the building frame and other panels to form a building structure, in use; and,

b) at least one sheet coupled to the panel frame to define a panel face.

[0031] Typically at least one of the roof and floor frames include shipping container corner castings.

[0032] Typically the floor at least one first floor panel and at least one overlying second floor panel, the overlying panel including a cut away so that the first floor panel is exposed in a region of the floor.

[0033] Typically the channels are mounted in at least one of:

a) a gap between floor panels; and,

b) a gap between the floor panels and edges of the floor frame.

[0034] In a fourth broad form the present invention provides a method of constructing a building module, the method including:

a) constructing a floor including a floor frame having one or more floor panels mounted thereon;

b) constructing a roof including a roof frame having one or more roof panels and one or more ceiling panels mounted on opposing faces;

c) connecting the floor and roof frames using a number of posts;

d) mounting a number of channels mounted to at least one of the floor and roof; and, e) providing one or more walls supported in the channels.

Brief Description of the Drawings

[0035] An example of the present invention will now be described with reference to the accompanying drawings, in which: - [0036] Figure 1 A is a schematic side view of an example of two interconnected panels;

[0037] Figure IB is a cross-sectional view of one of the panels of Figure 1 A;

[0038] Figure 1C is a schematic perspective view showing the interconnection of frame members of the panel of Figure 1A;

[0039] Figure ID is a partial cross-sectional view showing two interconnected panels;

[0040] Figure 2A and Figure 2B are schematic side and plan views of an example of a partially constructed floor of building;

[0041] Figure 2C is a schematic perspective view of the floor of the partially constructed building of Figures 2A and 2B;

[0042] Figure 2D is a schematic cross-sectional view of an example of the connection of a post to a floor panel;

[0043] Figure 2E is a schematic end view of the connection of Figure 2D;

[0044] Figure 2F is a schematic cross-sectional view of a second example of a connection of a post to a floor;

[0045] Figure 3 A is a schematic perspective view of an example of a partially constructed building including walls;

[0046] Figure 3B is a schematic cross-sectional view of an example of the connection of a wall panel to a floor;

[0047] Figure 3C is a schematic cross-sectional view of a second example of a wall panel connected to a floor;

[0048] Figure 3D is a schematic cross-section view of a third example of a wall panel connected to a floor;

[0049] Figure 3E is a schematic perspective view of a fourth example of a wall panel connected to a floor, when the panel includes first and second sheets prior to connection;

[0050] Figure 3F is a schematic cross-sectional view of the connection of Figure 3E;

[0051] Figure 3G is a schematic perspective view of an example of a partially constructed building including internal walls;

[0052] Figure 3H is a schematic side view of an example of a wall panel incorporating straps;

[0053] Figure 31 is a schematic side view of an example of the interconnection of the straps to the wall panel; [0054] Figure 4A is a schematic perspective view of an example of a partially constructed building including ceiling panels;

[0055] Figure 4B is a schematic perspective view of a partially constructed building including upper wall panels;

[0056] Figure 4C is a schematic perspective view of a partially constructed building including a roof;

[0057] Figure 4D is a schematic cross-sectional view of an example of the connection of a roof panel to a building;

[0058] Figure 4E is a schematic cross-sectional view of a second example of the connection of a roof panel to a building.

[0059] Figure 5 A is a schematic perspective view of an example of a frame for a multi-storey building;

[0060] Figure 5B is a schematic perspective view of a joining plate used to interconnect beams in the frame of Figure 5 A;

[0061] Figure 5C is a schematic perspective view of a second example of a joining plate;

[0062] Figure 5D is a schematic perspective view of a third example of a joining plate;

[0063] Figures 6A to 6J are schematic perspective views of the construction of first and second examples of building modules;

[0064] Figure 6K is a schematic plan view of a module showing a roof member;

[0065] Figure 6L is a schematic perspective view of the frame of Figure 5A incorporating a building module;

[0066] Figures 7A to 7H are schematic diagrams of a third example of a building module; and,

[0067] Figures 8A to 8C are schematic diagrams of an example of the use of building , modules in constructing a building.

Detailed Description of the Preferred Embodiments

[0068] An example of a panel for use in constructing a building will now be described with reference to Figures 1 A to ID. [00691 For the purpose of this example, the panel will be described as a generic panel. In practice, however, different panels may be provided for, but not limited to, floor panels, wall panels, ceiling panels and roof panels. In general, the panels may be constructed in substantially similar manner although different sheet materials may be used for respective panels as will be described in more detail below.

[0070] In this example, each panel 100 is formed from a number of frame members 111, 112, 113 connected to form a frame 1 0. In this example, the frame members include substantially parallel spaced apart joists 111 held in place by trimmers 112 positioned at either end. Additionally optional noggin 113 can be used for interconnecting the joists 1 1 1 as shown.

[0071] In addition, a first sheet 1 14 and an optional second sheet 115 may be provided on opposing sides of the panel frame 110. The second sheet 1 15 is typically only used on wall panels, and accordingly, floor, ceiling and roof panels typically include only a first sheet 114. The sheets 114, 115 can be coupled to the frame 110 in any appropriate manner, such as by gluing, the use of tek screws, or the like. The number of sheets used and the sheet material will depend upon the intended use of the panel. Thus, the sheets may be formed from cement fibre sheets, gypsum, insulating sheets, or the like.

[0072] In another example, the panels 100 include a foam tap positioned between the frame 110 and one of the sheets 114, 115. This operates to thermally isolate the sheet 1 14, 115 from the frame 1 10, thereby assisting in insulating the building.

[0073] In general, the frame members are made of 0.5mm or 1.0mm thick lightweight steel or equivalent having a generally C-shaped cross-section. The frame members used will typically depend on the intended usage or location of the building, so for example, 1.0mm steel may be used in areas at risk of cyclones or other extreme weather. The frame members can be interconnected by deforming a flange 118 to allow another frame member to be inserted therein. This allows the trimmers 1 12 and optionally noggin 1 13 to be connected to the joists 1 1 1. Additionally, the frame members may be further connected using welding, rivets, bolts, screws or the like. In situations where noggin 1 13 is to be attached to a "rear" side of a joist 111, this is achieved by attaching an end plate 116 to the noggin 113 and then joist 111 using tek screws 117.

[0074] Panels may be interconnected in a number of manners. In one example, panels are interconnected through the use of tek screws 1 18, or the like, inserted into the frames 1 10 of adjacent panels 100A, 100B, as shown in Figure ID. It will be appreciated that in order to achieve this easily, this is typically best performed if the panel includes only a single sheet, allowing access to the frame 110. However, alternative connection mechanisms may be used if the panels are fabricated with two sheets in place as will be described in more detail below.

[0075] The use of lightweight steel for the frame members allows the panels to be transported in a constructed state, allowing the panels to be prefabricated in a factory. The completed panels can then be manually lifted into place, allowing the panels to be interconnected to each other and/or a building frame, thereby forming the building structure.

[0076] An example of the use of the panels in constructing a building will now be described with reference to Figures 2A to 2F.

[0077] In this example, the building floor is constructed by laying a building frame 200, which in this example is formed from beams 201 and support posts 202. The support posts may be positioned on any appropriate surface, such as a concrete base, or the like. In this example, a number of beams are arranged in a parallel spaced apart arrangement, as shown in plan view in Figure 2B. Additional cross beams may be provided as shown at 203 interconnecting the beams 201, although for one or two story houses, this is typically not required. In any event, floor panels 210 can be positioned and attached to the frame 200 thereby creating the floor of the building. The beams and posts may be connected in any appropriate manner, such as through the use of welding or the like. Additional structural elements 220, such as roof supports of the like may also be added at this stage.

[0078] The floor panels 210 are typically connected to the beams 201, and optionally the posts 202, for additional structural integrity. In one example, this is achieved through the use of bolts 230 that attach to a plate 231 connected to the posts 202, pass through the beams 201, and attach to a washer 232 provided in the floor panel 210. This holds the floor securely in place relative to the posts 201 which are in turn anchored to the ground, thereby ensuring the structural integrity of the resulting building. As shown in Figure 2F, tek screws 233 may additionally, be used to interconnect adjacent floor panels 210, and to connect the floor panels 210 to the beams 201. Again, the tek screws 233 are inserted through the frame 1 10 of the panels 210, so that the frame 110 provides structural support.

[0079] It will be appreciated that insertion of the bolts 230 requires access to the frame 110 of the floor panel 210, but in any event, the floor panels 210 typically only include a single .sheet 114, so access to the frame 110 is available.

[0080] In one example, the floor panels 210 are 3 x 1.2 m panels, although other sizes can be used.

[0081] Once the floor has been constructed, wall panels can then be attached to the floor to form walls of the building, as shown for example in Figure 3 A.

[0082] In this example, the wall panels 300 are attached to the floor panels 210, using tek screws 301, with the floor panels 210 in turn being connected to the building frame 200.

[0083] The manner in which the wall panels are connected will vary depending upon the implementation. Thus, for example, the wall panel may be affixed directly to the floor panel using tek screws as shown, for example, at 310 in Figure 3B. As shown in this example, the beam 201 can additionally be attached to a plate 320 which is held in place to the post 202 via bolts 321. In this example, the beam 201 is also attached to the floor panel 210 using tek screws 322. It will be appreciated that this highlights that tek screws or bolts may be used to interconnect the floor panels 210 and beams 201, and in a similar manner bolts 302 or tek screws 301 can be used to interconnect the wall panels 300 to the floor panels 210 as shown in Figures 3C and 3D.

[0084] In examples in which tek screws or bolts are used, these are typically placed through the frame 110 of the respective panels. Typically, this requires access to the frames 110 and is therefore typically performed before a second sheet 115 is provided on the panel. This is particularly important in the case of wall panels because typically two sheets must always be used for the panel. As a result, if only a single sheet is present when the panel is put in place in the constructed building, then the second sheet must be fitted to the panel subsequently. This requires the use of additional skilled labour.

[0085] Accordingly, in one example, both 1 14, 115 sheets are provided on the panel in a prefabrication process at a factory or similar. The panels are then interconnected using brackets shown in Figures 3E and 3F. In this example, a right angle bracket 330 is provided which connects to the wall panel and floor panel via tek screws 331. In addition to this, wall brackets 340 are provided which are connected to adjacent wall panels using tek screws 341.

[0086] To allow the brackets 330 to be correctly positioned on the wall and floor panels 210, 300, the sheets 114, 115 may be provided with recesses or openings to receive the brackets 330, 340. This has the added benefits that the brackets can lie flash with, or below, the surface of the sheets 114, 1 15 with additional filler being provided to cover the brackets as required. This allows the brackets 330, 340 to be attached to the wall and floor panels 300, 210, whilst two sheets 114, 115 are in place, thereby making the construction process easier.

[0087] In one example, where adjacent panels 100 abut, a flashing can also be inserted into a gap between the frame and sheet 114, 115, particularly if a foam tap is utilised as described above. This can assist in interconnecting the panels 100, as well as acting to seal any gap between the wall panels 100, thereby prevent ingress of contaminants between adjacent panels 100.

[0088] It will be appreciated that the wall panels 300 can be. used to form internal walls as well as external walls, as shown in Figure 3G. In this example, different sheets may be used for internal as opposed to external walls.

[0089] In one example, the steel support members used to form the panel frame may be formed of lightweight steel. Typically, such material would be unsuitable for use in regions subject to extreme weather, such as cyclones or hurricanes. Accordingly, to provide additional strength and rigidity, the wall panels 300 may incorporate support straps 360, as shown in Figures 3F and 3H. The support straps are typically formed from steel band or the like, which are fixed to the opposing corners of the panel frame 110, and optionally to frame members extending across the frame, as shown at 362 in Figure 3H. The straps are typically fixed to the frame 110 using tek screws 361, or the like, prior to application of the first and second sheets 114, 115. The straps 360 are typically tensioned during attachment, thereby pre-loading the frame members, which in turn adds to the strength and rigidity of the resulting panel, allowing it to be used in a wider range of conditions.

[0090] Wall panels typically have a size in the region of 2.4m x 1.2m, although alternative sizes can be used as appropriate. It will be appreciated that in addition to forming the wall panels with a sheet 114, 115, such as a fibre cement sheet, the wall panels 300 can also be constructed to receive or include other components, such as windows, doorways or the like. In this instance, the configuration of the frame 1 10 can be modified to support the components, as well as providing openings in the sheets 114, 115 for positioning of the components.

[0091] The wall panels may also be filled for example with a lightweight material such as aerated concrete. This can provide additional structural integrity to the wall panel, whilst maintaining a lightweight configuration to allow for easy manipulation of the wall panels during building construction.

[0092] After the walls have been constructed, ceiling panels 400 can then be added to the building to form a ceiling as shown in Figure 4A. Once the ceiling panels have been attached, additional upper wall panels 410 can be affixed, allowing a raised roof 420 to be attached to the building as shown in Figure 4C.

[0093] In one example, the roof 420 is made of one or more roof panels 421, with an optional overlying roof member 422, including an insulating material such as polystyrene sandwiched between C90 steel roof sheets. This can be attached to the roof panels 421 via roof screws 422, or the like. However, this is not essential and alternatively the roof panels can be of any suitable construction.

[0094] In any event, in this example, the roof panels 421 are coupled to the ceiling panel 410 and wall panel 300 via a strap 430. The strap 430 is coupled to the wall panel and roof panel 420 via tek screws 431, whilst tek screws 441 are used to connect the ceiling panel 410 to the wall panel 300 and roof panels 421 , respectively.

[009SJ It will be appreciated that the use of the strap 430 to couple the roof panels 421 to the ceiling panel 410 and/or wall panel 300 allows for a degree of flexibility in the relative angle between the roof 420 and the ceiling panels 410, thereby allowing a sloped roof to be easily provided. In addition to this, the strap 430 can be arranged under tension, thereby providing a strong structural connection between roof 420 and the remainder of the building.

[0096] Having a sloped roof means that roof 420 is higher relative to the ceiling panels 410 at some locations. Accordingly, in this example, braces 450 may be coupled to the ceiling panels 410 via tek screws 451, and to the roof panels 420 via tek screws 452 as shown. In addition to this, the upper wall panels 410 may also be provided to support the roof panels 420, with the upper walls panels being coupled to the roof panels 421 and bracing 450, via joists 460, and to the wall and ceiling panels 310, 410 via bracing 460 and tek screws 461 as shown.

[0097] The above described system is useful for constructing one and two storey buildings. In particular, the structural strength provided by the C-section lightweight steel frames within the wall, ceiling, roof and floor panels provides the building with sufficient structural integrity for low-rise scenarios. However, if it is desired to provide multi-storey buildings of three levels or above, additional structural support is typically required. In order to achieve this, a multi-storey frame is typically constructed using a clear span beam grid, an example of which will now be described with reference to Figure 5A.

[0098] In this example, the building frame 500 is formed from a number of beams 501 coupled to support posts 502. In use, floor, ceiling and wall panels may be attached directly to the frame 500 thereby allowing a building to be constructed in a manner similar to that described above. In this example, floor panels 510 only are shown.

[0099] The frame 500 typically involves interconnecting a number of beams and posts and this can be achieved using joining plates as shown in Figure 5B. [0100] In this example, two posts 501A, 501B are provided, coupled to respective beams 502A, 502B via standard shipping container corner castings 503A, 503B, which are known shipping container components. The posts and beams 501 A, 50 IB, 502A, 502B may form part of a building similar to that described above, or can be part of a module arrangement, described in more detail below. The posts and beams 501A, 501B, 502A, 502B are typically welded to the corner castings 503A, 503B to allow the posts and beams to be interconnected. In addition, the corner castings 503A, 503B include apertures, allowing the corner castings 503A, 503B to provide a standard lifting point for modules, as will be described in more detail below.

[0101] In any event, the posts 501A, 501B are interconnected via a joining plate 530. The joining plate 530 includes a plate body 531 having casting guides 532 extending outwardly therefrom, which are designed to be inserted into apertures 504 of the shipping container corner castings 503A, 503B, thereby aligning the corner castings 503A, 503B. The plate body 531 also includes apertures 534 allowing bolts 535 to be inserted therethrough, with the bolts can being coupled to the posts 502, thereby coupling the posts 502 to the joining plate 530 and each other.

[0102] Shims plates 536 or packers may also be provided between the plate body 531 and the shipping castings 503A, 503B, allowing the relative separation of the posts 501A, 501B to be ^' adjusted. This can be used to ensure that the building frame and/or modules are level when constructed, as well as to space apart stacked modules to allow services to be provided therebetween.

[0103] This allows the frame to be readily and easily constructed on site through simple bolting together of posts 502 and beams 501. As shown in Figures 5C and 5D the joining plates 530 can be adapted to receive any number of posts 502 or beams 501 through the provision of appropriate numbers of post supports 532. This will therefore not be described in any further detail.

[0104] The above described system can also be used to construct individual building modules, which are self-contained building units that can be incorporated into a building. The modules 520 can be pre-fabricated off-site, allowing these to be installed as part of the building with minimal effort.

[0105] Examples of building modules will now be described with reference to Figures 6 A to 6J. In these examples, the building modules 600 typically include a module frame 610 formed from a number of beams and posts 61 1, 612. The beams and posts may be interconnected in any suitable manner, such as by using shipping container corner castings described above with respect to Figures 5 A to 5D.

[0106] Once a module frame 610 has been constructed panels can be attached to the frame 610 using the techniques described above. Thus, for example, floor panels 620 can be attached to the frame 610 as shown in Figures 6C and 6D. As an alternative, the floor panels can provide a formwork to allow a concrete floor to be provided thereon.

[0107] Wall panels 630 may then be connected to the module frame 610 and/or floor panels 620 as shown in Figures 6E and 6F. Ceiling panels 640 are then generally attached to the module frame 610 to form a substantially enclosed structure. It should be noted that for the purpose of these figures the sheets are not included in the panels for clarity only.

[0108] In the examples shown in Figures 61 and 65, the support posts provided at the corners of the module frame 610 can extend above the level of the ceiling panels 640, as shown at 612.1.

[0109] The extension portions 612.1 can be used to provide a space between modules so that if modules are stacked utilities or ducting can be provided in the cavity between the ceiling panels. 640 of a lower module and the floor panels 610 of an upper module 600. Alternatively, ducting or other services can simply be mounted between the floor panels of an upper module, and the ceiling or roof panels of a lower module, in the event that the extension portions 612.1 are not provided. As a further alternative, stacked modules can be spaced by the inclusions of packing plates positioned between the modules, for example as part of the joining plate connection described above. [0110] The extension portions 612.1 can also be used as lifting points, to allow the constructed module to be lifted by crane onto a boat or truck for transport, and subsequently to allow the module to be lifted from the truck and positioned in the building. However, this is not essential and alternative arrangements can be used. For example, in the event that the modules include standard shipping container corner castings to interconnected the posts and beams 61 1, 612, then the corner castings can be used as lifting points. This is particularly advantageous as this allows the modules to be lifted in the same manner as shipping containers, thereby simplifying the transportation process. In one particula example, the modules are sized constructed in such a manner as to allow them to be certified as shipping containers, thereby allowing them to be used to transport other components for use in constructing a building.

[0111] In a further example, a roof member ma be provided on the modules 600, as shown for example in Figure 6K. The roof member 650 is sloped in the direction of the arrows 651 to allow water to drain via a drain point 652, for example when the module is in a stand alone configuration, or during transport or building construction.

[0112] It will be appreciated that the modules can form a stand alone building structure, or can be incorporated into a larger building structure, as shown for example in Figure 6L. Thus, buildings can be constructed from a combination of modules and/or panels mounted to a frame as described above.

[0113] It will also be understood that the building modules, which are self-contained building units that can be incorporated into a building, can be pre-fabricated off-site, allowing these to be installed as part of the building with minimal effort.

[0114] A third example of a building module will now be described with reference to Figures 7A to 7H.

[0115] In this example, the building module 700 includes a floor including a floor frame 71 1 having one or more floor panels 721, mounted thereon. A roof is provided including a roof frame 712 having one or more roof panels 722.1 and one or more ceiling panels (not shown) mounted on opposing faces. The roof is supported relative to the floor by a number of posts 713 interconnecting the floor and roof frames 711, 712. A number of channels 731 are provided on at least one of the floor and roof, the channels being for supporting one or more walls. Whilst any suitable wall material can be used, in one example, the walls are formed from wall panels, described above for example with respect to Figures 1A to ID.

[0116] An example of the construction of the building module will now be described in more detail.

[0117] In this example, the building module 700 includes floor and roof frames 711, 712 formed from elongate first beams 711.1, 712.1, held in a spaced apart arrangement by laterally extending second beams 71 1.2, 712.2. Corner connectors 71 1.3 may be provided at corners 71 1.3, 712.3 of the frame 71 1, 712 for connecting respective first and second beams 711.1, 712.1; 712.1, 712.2. The floor and roof frames 711, 712 may further include shipping container corner castings 711.4, 712.4, mounted at corners of the frames 71 1, 712, to allow the frames 711, 712, and the completed building module, to be easily transported as will be appreciated by a person skilled in the art.

[0118] Once the floor and roof frames 711, 712 have been created they are typically provided with any required panelling, or other surfacing. In this example, the floor frame 711 has two first floor panels 721.1 with two overlying second floor panels 721.2, which define the floor for first and second rooms. It will be appreciated that in the event that the building module is to define a single room, single first and second floor panels may be used. In this example, the overlying panels are cut away so that the first floor panel 721.1 is exposed in a region of the floor. In one example the first panel 721.1 is a water resistant panel and this can therefore define the floor of a wet area such as a bathroom. In contrast the second floor panels 721.2 may be any sort of suitable flooring material such as chipboard or the like.

[0119] The floor panels 721.1, 721.2, are typically separated by a gap 721.3 and are set back from edges of the floor frame 71 1 to provide an edge gap 721.4, to receive wall channels, as will be described in more detail below.

[0120] In the case of the roof frame 712 this is typically covered with a roof panel 722.1, such as corrugated steel or the like, and ceiling panels on an opposing face (not shown). The floor and ceiling panels can be panels similar to those described above and in particular including first and second sheets of material mounted to a frame formed from a number of interconnected C-shaped frame members. However, this is not essential and alternatively these can be formed from any suitable materials, such as panels of chipboard, timber, fibre cement sheets, or the like, depending on the intended application and desired final appearance of the building module.

[0121] As shown in Figure 7C the floor frame and roof frame 71 1, 712 are typically held in the spaced apart arrangements by posts 713. During construction it is typical to form the floor and roof frames 711, 712 and then cover these with any appropriate panels before the frames are interconnected via the posts 713. This makes the manufacturing process easier in particular allowing the floor and roof frames 711, 712 to be independently manipulated when panels are fitted.

[0122] Whilst the posts 713 may be connected in any suitable manner, in one example, the posts are connected to the floor and roof frames 711, 712 via respective brackets 713.1, 713.2. The brackets can be welded or otherwise affixed to the frames 711, 712. The brackets 713.1, 713.2 include respective mounting plates 713.3, 713.4 which can be bolted to corresponding mounting plates 713.5, 713.6 provided on the posts 713. This allows the floor and roof frames 711 , 712 to be easily connected to the support posts 713.

[0123] Following this, a number of channels 731, 732, 733 can be fitted. The channels are provided in the gap 721.3 between the floor panels, and in the gap 721.4 around the frame edges, and corresponding channels can also be provided on the roof. The channels 731, 732, 733 are utilised to support internal and external walls of the building module as shown at 741 and 742 in Figures 7F and 7G respectively. Once completed internal fittings, such as a bed 751, shower unit 752, toilet 753 and sink 754 can be fitted as shown in Figures 7H. It will be appreciated that this allows a completed structure to be provided, ready for transport and installation.

[0124] The above described system modules can also be used to construct individual building modules, which are self-contained building units that can be incorporated into a building. The modules 700 can be pre-fabricated off-site, allowing these to be installed as part of the building with minimal effort. Alternatively the modules 700 can be constructed on-site, using relatively simple construction techniques, thereby allowing multiple modules to be constructed rapidly and easily.

[0125] An example of a building utilising a building module will now be described with reference to Figures 8A to 8C.

[0126] In this example, the building is typically formed from a number of support posts 811 mounted in the ground 801. A building frame 810 is attached to the support posts, which in one example is formed from elongate frame members, such as RHS beams, optionally interconnected with lateral spacing members. Following this, building modules 700, or alternatively modules 600, can be mounted on the frame 810. In one example, this is achieved by providing shipping container corner castings on the frame 810, which couple to corresponding castings on the building modules 700, for example as described above with respect to Figures 5B to 5D. Once the building modules have been installed additional fittings 820 can be provided such as balconies stairs or the like. It will be appreciated that this approach can be used with pre-assembled modules, similar to those shown in Figures 6A to 6K, or modules 700 constructed onsite, as described above with respect to Figures 7A to 7H.

[0127] The above described arrangements allow for buildings to be constructed rapidly and with minimal on-site skilled labour. For example, the frame and panels can be pre-fabricated off-site, for example at a manufacturing plant, then being transported to the construction site in a substantially flat packed arrangement. This allows the quantity of building components to be easily transported to site for construction.

[0128] Once on-site, the building frame can be installed, with the panels being subsequently attached. As the panels are formed from lightweight materials, these can typically be lifted into position with minimal labour. The panels are then simply attached to the building frame and /or other panels, for example using tek screws. In one example, sheets may then need to be attached to the panels, although in other examples, this can be avoided by the use of appropriate mounting brackets.

[0129] In either case, it will be appreciated that the process of constructing the building structure can be performed using unskilled labour, whilst allowing a significant degree of. flexibility in the final design of the building. This therefore allows buildings to be constructed in areas where there are skilled labour shortages, whilst avoiding the disadvantages to pre-configured transportable buildings, which typically all have the same design.

[0130] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS :

1) A building construction system including:

a) a number of beams and posts defining a building frame;

b) a plurality of pre-fabricated panels, each panel including:

ii) at least one sheet coupled to the panel frame to define a panel face.

2) A system according to claim 1, wherein the panels include at least one of:

a) floor panels;

b) wall panels;

c) roof panels; and,

d) ceiling panels.

3) A system according to claim 1 or claim 2, wherein the frame members include parallel spaced apart joists connected to trimmers at either end to form a frame.

4) A system according to claim 3, wherein the frame members are 0.5mm and 1.0mm thick lightweight steel members.

5) A system according any one of the claims 1 to 4, wherein the frame members are connected using at least one of:

a) welds;

b) rivets;

c) bolts; and,

d) screws.

6) A system according to any one of the claims 1 to 5, wherein at least some of the panels include two sheets attached to opposing sides of the panel frame.

7) A system according to any one of the claims 1 to 6, wherein at least some wall panels include a foam tap between the panel frame and at least one sheet to thereby thermally isolate the at least one sheet from the panel frame.

8) A system according to claim 7, wherein a flashing is inserted between the at least sheet and frame where adjacent wall panels meet. 9) A system according to any one of the claims 1 to 8, wherein the system includes a number of panel brackets for connecting the panel frame to at least one of the building frame and other panel frames.

10) A system according to any one of the claims 1 to 9, wherein the panels are connected to at least one of the building frame and other panels using at least one of bolts and screws.

1 1) A system according to claim 10, wherein the system includes a number of right angled wall panel brackets for coupling the wall panels to the building floor.

12) A system according to any one of the claims 1 to 1 1, wherein the system includes a number of straps, the straps being for at least one of:

a) coupling to the frame members to thereby tension the panel frame; and

b) interconnecting the panels frames and the building frame.

13) A system according to any one of the claims 1 to 12, wherein the building frame includes a post and beam steel sub frame for single or double story buildings, the sub frame including beam grid with post supports.

14) A system according to any one of the claims 1 to 12, wherein the building frame includes a clear span beam grid with post supports for multiple story buildings.

15) A system according to any one of the claims 1 to 14, wherein the sheets include at least one of:

a) linings;

b) insulations;

c) claddings;

d) powder coated metal roof sheeting;

e) gypsum board; and,

f) cement board.

16) A system according to any one of the claims 1 to 15, wherein the system is used to construct a module, the module including:

a) beams defining a module frame; and,

b) a number of panels attached to at least one of the module frame and other panels.

17) A system according to claim 16, wherein the module frame includes a ceiling frame and vertical supports, the vertical supports extending beyond the ceiling frame. 18) A system according to claim 16 or claim 17, wherein the module is pre- fabricated with floor, ceiling, wall, and roof panels are fixed, as required.

19) A system according to any one of the claims 1 to 17, wherein the beams and posts are interconnected using shipping container corner castings.

20) A system according to claim 19, wherein the shipping container corner castings provide lifting points for modules.

21 ) A method of constructing a building, the method including:

a) constructing a building frame including a number of beams and interconnected posts; b) attaching a plurality of pre-fabricated panels to the building frame, each panel including:

ii) at least one sheet coupled to the panel frame to define a panel face.

22) A method according to claim 21, wherein the method includes attaching a panel to at least one of the building frame and another panel using at least one of bolts and screws.

23) A method according to claim 21 or claim 22, wherein the method includes attaching a panel to at least one of the building frame and another panel using a number of panel brackets.

24) A building module including:

a) a floor including a floor frame having one or more floor panels mounted thereon; b) a roof including a roof frame having one or more roof panels and one or more ceiling panels mounted on opposing faces;

c) a number of posts interconnecting the floor and roof frames;

d) a number of channels mounted to at least one of the floor and roof, the channels before for supporting one or more wall panels.

25) A building module according to claim 24, wherein the wall panels include:

b) at least one sheet coupled to the panel frame to define a panel face. 26) A building module according to claim 24 or claim 25, wherein at least one of the roof and floor frames include shipping container corner castings.

27) A building module according to any one of the claims 24 to 26, wherein the floor at least one first floor panel and at least one overlying second floor panel, the overlying panel including a cut away so that the first floor panel is exposed in a region of the floor.

28) A building module according to any one of the claims 24 to 27, wherein the channels are mounted in at least one of:

a) a gap between floor panels; and,

b) a gap between the floor panels and edges of the floor frame.

29) A method of constructing a building module, the method including:

c) connecting the floor and roof frames using a number of posts;