WO2024103128A1

WO2024103128A1 - Buiding method and panel

Info

Publication number: WO2024103128A1
Application number: PCT/AU2023/051175
Authority: WO
Inventors: Peter Cocciardi
Original assignee: Cocciardi Nominees Pty Ltd
Priority date: 2022-11-18
Filing date: 2023-11-17
Publication date: 2024-05-23

Abstract

A building (160) made according to a method utilising a single size module panel (n00) Multiples of the panel (n00) are used for all of the external walls (162) of the particular building (160). Multiples of the panel (n00) are used for all of the internal walls (164) of the building (160). All of the panels (n00) are located within the footprint of a roof of the building. Multiples of the panels (n00) may be used as floor panels supported by floor joists of the building (160). Multiples of the panels (n00) may be used as ceiling panels supported by a roof frame of the building (160). Multiples of the panels (n00) may be used as roof panels supported by a roof truss of the building (160). Multiples of the panel (n00) are used for all of the walls, floors, and ceiling and/or roof, of the building (160).

Description

BU I D I N G M ETH OD AN D PAN EL

FIELD OF INVENTION

This invention relates to a method for constructing a building. More particularly, this invention relates to a method for prefabrication of small building elements and components and constructing a building.

BACKGROUND ART

The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion should not be assumed to relate to what is commonly or well known by the person skilled in the art, but to assist in the inventive process undertaken by the inventor(s) and in the understanding of the invention.

Applicant observes major issues in the traditional stick build method of building that has been the mainstay for decades. On review of this process, Applicant concluded that offsite prefabrication provides a manufacturing advantage - a first building block in the inventive process. However, offsite prefabrication brings with it significant problems and inefficiencies according to existing methods.

The accepted "prefabrication" solution is to simply build large elements of a house. These elements can be a large wall section, floor sections, roof sections or large assembled sections of a house that have floors, walls and roof as part of the element. These elements are transported to site and then lifted into place by crane due to their size and mass. There are some advantages to this building method over conventional stick-built construction. These large sections can be preassembled off site, usually in a factory so that weather and light are mitigated factors. They use the same basic materials and building trades in prefabrication off site. However, such methods do not enable mass-production of building elements, but rather lend themselves to bespoke production.

Extensive off-site manufacturing and assembly is not in itself unusual. There are many forms of prefabricated buildings. Off site manufacture may significantly reduce the "time-waste" in having multiple materials delivered, managed, processed, some wasted or resulting in waste onsite, and finally installed by various trades within the same building part.

Traditional construction of wet areas built on site have caused the most number of defects on site and can constitute the most trade labour-intensive and costly rooms of any build.

Prefabrication may include the offsite build of transportable wet area modules. These modules represent singularly focused, prefabricated and enclosed, or discrete and self- contained, bathroom or other drop-in, wet area modules. There is a need to improve on this singularly focused solution in a major broadening of the building concept that maximises prefabrication in a way not previously utilised. In a conventional onsite stick build, even when prefabricated wall framing is used, the easy and non-trade dependent integration of wet area infrastructure with other services and modules is not provided in the prior art.

Traditional onsite work requires "tradesman run, site positioned, electrical cabling". Previous prior art building methods require such wiring on domestic builds as virtually all wiring is currently installed on site after the framing is built and standing in its final location. On traditional (prior art) builds, while the general location of the electrical, plumbing and communication services may be known, there is no dimensionally exact reference that can be relied upon for the install onsite or future repair, maintenance or improvement, at any time in the future. Tradesman must investigate and establish the connections and locations of services before commencing repairs and maintenance. In domestic builds, most of the structure and services are built in situ with little, if any, ability to accurately predict, and determine without investigation, where the electrical, plumbing and communication services have been placed. Requisite inspection by local authorities to sign off on electrical and plumbing services onsite causes delays and potential redoing of critical work where faults are identified.

Conventional domestic builds have all the roof and wall framing installed and then the roof is clad to protect against inclement weather and then the walls are clad to achieve a lock-up stage for security.

An object of the present invention is to ameliorate one or more of the aforementioned disadvantages of the prior art or to at least provide a useful alternative thereto.

STATEMENT OF INVENTION

The invention according to one or more aspects is described herebelow and further defined in the independent claims. Some optional and/or preferred features of the invention are described herebelow and further defined in the dependent claims.

Accordingly, the invention provides a manufactured building:

(A) comprising only elements and components prefabricated offsite including:

(a) small building elements including panels and beams that are sized according to a specific unit dimension between 600mm and 2400mm, wherein the width of the panels and the length of the beams are the specific unit dimension or a product of a whole number and the specific unit dimension, the small building elements sized and weighted to be manoeuvred manually by at most two operators and weighing no more than 100kg; and

(b) small building components that are transportable and manoeuvrable by a vehicle capable of carrying and lifting loads up to 5 tonnes and no longer or wider than 7000mm, the building having no components too large or heavy to be transported and manoeuvred by the vehicle; and

(B) the building is comprised of a first and subsequent modules, each module having a footprint with a size between 2000mm - 6000mm in a first horizontal dimension and 3000mm - 15000mm in a second dimension perpendicular to the first dimension, in which the length in each of the first and second dimensions is a product of a whole number and the specific unit dimension.

In another aspect of the same invention, there is provided a method for constructing the building, including the steps of:

(A) prefabricating offsite elements and components of the building including:

(B) constructing the building in stages starting with a first module which is constructed to a stage where it stands alone and then adding subsequent modules, each first and subsequent module having a footprint with a size between 2000mm - 6000mm in a first horizontal dimension and 3000mm - 15000mm in a second dimension perpendicular to the first dimension, in which the length in each of the first and second dimensions is a product of a whole number and the specific unit dimension.

In the prefabrication stage, the method of construction of the building the small building elements such as wall, floor and roof panels, may be prefabricated according to a specific unit dimension in which wall, floor and roof panels are sized as singles of the specific unit dimension, and horizontal or near horizontal beam spans are sized as multiples of the specific unit dimension, the small building elements sized and weighted to be manoeuvred manually by at most two operators and weighing no more than 100kg, and the small building components weighing no more than 3 tonnes and being transportable and manoeuvrable by a small crane truck.

In the modular building aspect of the method of constructing the building, the method may include one or more of the following steps:

I. installing a first floor support in a first module area corresponding to a first footprint of the first module;

II. erecting part of a first wall frame which includes a common wall along a common wall line which is to be shared by the second module; III. installing a first module roof over the first floor supports and a first floor layer immediately over the first floor supports whereby the first module is capable of receiving a large completed and assembled internal furnishing or installation that is too large to enter through an entry of a completed one of the modules on the first floor layer so that the furnishing or installation is out of the weather and may be manoeuvred within the first module if required on completion of all of the walls ("the first walls") of the first module;

IV. installing a second floor support in a second module area corresponding to a second footprint of the second module immediately adjacent the first module;

V. erecting part of a second wall frame for the second module on the second floor support wherein the common wall forms part of both the first and second wall frames and the building structures along the common wall line are shared by the first and second modules; and

VI. installing a second module roof over the second floor support and a second floor layer immediately over the second floor support whereby the second module is capable of receiving a large completed and assembled internal furnishing or installation that is too large to enter through an entry of a completed one of the modules on the second floor layer so that the furnishing or installation is out of the weather and may be manoeuvred within the second module if required on completion of all of the walls ("the second walls") of the second module, wherein the first module is a stand-alone building in and of itself before construction of the second module is commenced and the elements and conmponents used to form the building include nothing larger than the prefabricated small building elements and components.

The invention may provide, in a services aspect, a method for constructing a building comprising at least a first module, the method optionally including one or more of the following steps:

II. erecting part of a first wall frame which includes a common wall along a common wall line which is to be shared by the second module;

III. installing a first module roof over the first floor supports;

IV. at any stage of the build in steps I - III before a first floor layer is applied to the first floor support, running a length of wiring for electrical supply to the building under the floor, intermediate the length there being at least one wire capable of being live extending from under the first floor layer to a predetermined location at a base of the first wall frame; V. completing all of the walls ("the first walls") of the first module with wall panels made in conformity with a specific unit dimension that is the common denominator of the sizing of all horizontally extending building elements of the building, wherein the wiring of the building does not include any wiring above the first floor layer that extends laterally through the wall panels but may extend vertically to terminate at an electrical access point above the base.

The invention for constructing the building may provide, in a sequencing aspect, a method for constructing a building comprising at least a first module, the method optionally including one or more of the following steps:

I. prefabricating small building elements and small building components for the building comprising multiple modules, including a first module and a second module;

II. delivering each small building element and component to a building site for the building when required;

III. preparing the ground of the site for a building area corresponding to a building footprint of the building, including laying down a grid soil stabilisation membrane in readiness for the construction to start, the membrane extending about lm - 2m beyond the building footprint, the membrane providing a a firm, clean and safe working base for mobile scaffold and scissor lifts and a flat and load bearing membrane for foot, vehicle and access platform traffic;

IV. installing a first floor support in a first module area corresponding to a first footprint of the first module;

V. erecting part of a first wall frame which includes a common wall along a common wall line which is to be shared by the second module;

VI. installing a first module roof over the first floor support;

VII. installing second floor supports in a second module area corresponding to a second footprint of the second module; and

VIII. erecting part of a second wall frame for the second module on the second floor supports wherein the common wall forms part of the first and second wall frames and the building elements along the common wall line are shared by the first and second modules, and wherein the first module is a stand-alone building in and of itself before construction of the second module is commenced and the building is made up of only small building elements and components.

The invention may provide, in a 3-D model aspect, a method for constructing the building comprising at least a first module and the building being made up of only small building elements and components, the method optionally including one or more of the following steps: I. providing a single software to develop 3D models of all of the small building elements and components using generative design; and

II. extracting and manipulating the data so that it is compatible with the software used by each of the machines used to manufacture each specific element and component.

The building is preferably a domestic building.

In another aspect, the method for constructing the building may additionally includea method for designing a home in the form of the building, including one or more of the steps of:

(a) determining a manufacturing and installation process that defines an efficient way to build the building in terms of costs of materials, manufacturing and installation costs, and build time on site;

(b) using a 3D computer model to create and adjust a design of the building to suit the process, the 3D model and associated works developed whereby the design of every part within the model is determined by how it will be manufactured, stored, transported, and installed;

(c) the design process including determining a standard size of each of the various elements, how the various materials will be stored and handled during the manufacturing process to minimise waste and time, so full automated manufacturing can be utilised to maximum effect. These steps will be defined under strict OH&S constraints and the model will form an integral part of any SWMS documentation as required by WorkSafe and the like;

(d) automating manufacturing off site the building's floors, walls and ceilings in small, easily transportable, manually carriable, discrete and repeatable building element;

(e) positioning all of the water, power, communication and waste services in prefabricated, finished and assembled service pods so that site running of the services merely involves connection to external supplies and drains;

(f) assembling the building on site to produce a full home.

Preferably, the building includes, and the method for constructing the building utilises, a single size module panel. Multiples of the panel may be used for all walls of a particular building. Multiples of the panel may be used for all walls and floors of a particular building. Multiples of the panel may be used for all walls and ceilings of a particular building. The panel may be serviced ("serviced panel") and the service may include a communication, plumbing and/or electrical line, and a communication, plumbing and/or electrical inlet and outlet. The serviced panel may be adapted to facilitate offsite manufacture and inclusion of a service in the form of communication, plumbing and/or electrical installations in a building. The panel may be unserviced ("unserviced panel") in that it is not adapted to facilitate installation of a service. The unserviced panel may not include a communication, plumbing and/or electrical line, and a communication, plumbing and/or electrical inlet and outlet.

The building may include, and the method for construction may utilise: A plurality of panels including a plurality of prefabricated unserviced panels and at least one serviced panel, each of the unserviced panels and the serviced panel having:

(a) the same pre-set dimensions, including height, width and depth; and

(b) consistent peripheral edges adapted to cooperate in adjacent manner for assembly of a building with another of the plurality of panels, the unserviced panels:

(c) being identical to each other; and the serviced panels incorporating:

(d) an internal communication, plumbing and/or electrical line;

(e) a communication, plumbing and/or electrical inlet and outlet in a pre-set position in or on the serviced panel that is adapted to respectively operably connect an onsite installation supply line and an interior communication, plumbing and/or electrical installation.

PANEL

The panel may be non-load bearing. When used as the panelling for external and/or internal walls of the building, the panels may be fixed relative to a building frame. The building frame may define the key vertical plane features of the building, such as external and internal walls, and partitions. The panel comprises peripheral frame. The peripheral frame may be in the shape of a rectangle whereby the height of the peripheral frame is greater than the space between side vertical members of the peripheral frame.

The peripheral frame may define one or more internally extending lugs or flanges defining a recess for reception and containment of a peripheral edge of an internal panel filler. The lugs may be in the form of spring clips adapted to receive and grasp the peripheral edge. The internally extending flanges may define a groove within which the peripheral edge is adapted to rest. The lugs may be adapted to pivot about a single-axle hinge rotatable about an axis transverse to a plane of the panel filler.

The panels may include accommodation for windows, doors, vents and other wall features suitable for a dwelling.

In respect of services accommodated in the wall panels, services within the wall panels are preferably minimised with an emphasis on services being delivered through and into the building by prefabricated components such as wet area pods, which will be described later, and cabinetry. Where services are required, it is preferable that electrical and drainage services are incorporated into cabinetry as much as possible. Where services must be run within a wall frame, in particular electrical and data services, these may be preinstalled. The wiring and fittings may therefore be preinstalled within the wall panel. They may be connected to the power supply wiring. The power supply wiring is preferably prefixed to and under the subfloor framing. There may nominally be provided a 30mm - 100mm, preferably 50mm, cavity within the subfloor. The cavity may be located directly under secondary joists that allow for the fixing of a prefabricated wiring loom. The primary floor support members are preferably about 100mm - 250mm, preferably 200mm deep. The secondary support members and subfloor insulation are about 100mm - 200mm, preferably about 150mm deep. The electrical and data wiring looms may be installed when a corresponding section of floor is assembled.

The floor cladding panels are about 15mm - 30mm, preferably about 22mm thick, and prefabricated with holes, notches and fixing locations. The fixing locations may be etched or cut prior to being delivered to site in the required sequence to match the install process. All matching holes for the services are preferably already in place and accurately located following prefabrication.

In the case of wiring and data, these services may be brought up through the holes prefabricated in the floor panels and these holes preferably correspond with holes in the bottom horizontal member of the internal and external wall frames. When the wall fames are installed, there is preferably a pre-made corresponding small access notch to the side of the bottom horizontal wall panel member. The internal cladding will be stopped approximately 100mm above the floor layer thereby allowing the wiring element that is prepositioned and fixed within the wall panel to then be connected to the subfloor wiring loom from within the building. Once the wall panel wiring is connected to the power supply sub floor wiring looms, a conventional skirting may be installed thereby covering a 50mm - 150mm, preferably about 100mm, high access zone at the base.

The plumbing services inlet of the panels made according to the invention with plumbing services are in an identical inlet port location in or on the panel with plumbing services.

The plumbing services outlet of the panels made according to the invention with plumbing services are in an identical outlet port location in or on the panel with plumbing services.

The electrical services inlet of the panels made according to the invention with electrical services are in an identical electrical inlet terminal location in or on the panel with electrical services.

The electrical services outlet of the panels made according to the invention with electrical services are in an identical electrical outlet terminal location in or on the panel with electrical services.

The communication services receiver of the panels made according to the invention with communication services are in an identical incoming communication terminal location in or on the panel with communication services.

The communication services outlet of the panels made according to the invention with communication services are in an identical outgoing communication terminal location in or on the panel with communication services.

It is noted that the electrical and communication incoming and outgoing terminals may be reversible, depending on the application, but the operator (architect, worker and/or builder, etc.) may choose to designate which is which for the purposes of predictability in planning.

Therefore, the operator can predict the location of the inlet, outlet, or terminal on any panel made according to the invention.

A mid rail may extend between side posts of the peripheral frame intermediate the respective lengths of the side posts. The mid-rail may provide service ducting. The mid-rail may provide service ducting for electrical lines.

The panel is preferably no more than 100kg in weight, and still more preferably between 40 - 60 kg, whereby a pair of workers, or a single worker with a portable lifting device, can move the panel without motorised assistance.

The panel filler comprises a sheet of substantially lightweight and rigid material, whilst maintaining some capacity to flex. The wall panels, whether internal or external, are preferably constructed so that the strength of the composite action of the frame and boarding (both internal and external) provides a diaphragm bracing effect when the panel is installed.

In conventional builds, diagonal bracing is applied to large wall framing sections in order to provide this bracing effect to the timber or light steel framing. In other instances, plywood may be fixed to the wall framing, again to provide additional bracing to the wall framing. In other conventional builds, such as brick veneer construction, the external brickwork is fixed to the framing by "brick ties". However, these are designed to tie the brickwork to the inner support framing. Therefore the brickwork provides little, if any, lateral stability to the structure.

The new method of construction using a diaphragm bracing effect according to a preferred form of the invention allows for the composite action of the frame and boarding to be incorporated to maximum effect in the panel structure, allowing the building structure to remain stable during a progressive build.

The internal wall panel filler of the core may be an air void, or may preferably include a sound absorbing core such as mineral or rock wool, glass wool or polyester, depending upon fire resistance requirements. Preferably, the panel filler includes a fire retardant expanded polystyrene core (FR-EPS). Pure aluminium foil may be directly laminated to both sides of the core. These panel filler core boards act may as insulation panels remain rigid and stable and provide excellent thermal and acoustic insulation. They are advantageous compared to traditional bats as the latter can sag and move over time and are extremely problematic when trying to install services and conduits.

Preferably, the panel filler has both a high fire-resistant & thermal insulation ratings.

The cladding of the internal panel may include one or more sintered mineral sheets (such as Promatect™ 100 or James Hardie EasyLap™)_. The cladding may include compressed cement sheet or strong fibre cement panel to provide a lot of lateral stability and rigidity to the wall panels.

The classing of the internal panel may also include compressed polymer, plywood, fibreboard and/or foil sheets.

The internal panel cladding may include two or more sheets of the same kind (e.g. sintered mineral, compressed polymer, plywood, fibreboard and/or foil sheets), and/or a combination of any two or more kinds of sheets spaced apart to provide a void filled by panel filler.

The panel cladding may comprise one or more of a kind of sheet, such as a foil layer. The foil layer of the panel may provide in situ a layer on a first side of the panel adapted to be on an external side of the core. The foil layer of the panel may provide in situ a layer on a second side of the panel adapted to be on an internal side of the core. The panel cladding may have spaced foil layers extending in substantially parallel planes. The foil layers may be used to provide internal and external surfaces of the building. An outer surface of either side of the panel, the first and second sides of the core may be adapted to be painted or clad. Advantageously, the outer surfaces of the first and second sides are finished and do not need further treatment or additional surfacing.

The multiples of the panel includes a number of different kinds of the panel, all having the same front profile dimensions, such as a height in millimetres of any specific integer number between 2400 - 4000, preferably 2400 or 2700mm, a width having a factor in multiples of 600mm of either 1200mm, 1800mm or 2400mm in any one building. The thickness or depth of the multiples of the panel may vary, depending on their function in relation to the building. The panel fillers may have a thickness of 20mm - 50mm. The core may be 10 - 15 mm thick. The panel thickness may be any one of 25mm, 30mm, 35mm and 50mm thick. Preferably, the wall panel thickness is between 30 - 50mm to adjust for thermal transfer associated with steel framing as compare to better thermal insulation properties of timber frames, in order to achieve a satisfactorily high energy rating for the building.

The wall panels may include lighting, splash panels and the like. The roof panels may include vents and/or solar panels. The ceiling panels may include lighting installations and/or one or more vents for heating and/or exhaust. The floor panels may include lighting and/or vents.

The communication, plumbing and/or electrical line may include a conduit or ducting.

The roof panels may be attached to the roof frame by pierce fixing to ensure that the roof cladding is secure, even in very high wind weather. The pierce fixing may be carried out to perform a dual purpose of providing a mounting and fixment for solar panels. The pierce fixing may include fasteners that extend through inverted channels or rails that are so fixed to be positioned proud on an upper surface of the roof panel. The channels or rails are adapted to receive complementary engagement means of solar panels, so that the roof panel fixment is also used to mount and secure the solar panels. METHOD

In another aspect, the invention provides:

A method of erecting a dwelling on a building platform using the above described plurality of panels comprising multiples of the single size module panel, wherein the dwelling has walls that are dimensioned to be formed from a single or multiples of the panel and the method includes the steps of:

(i) prefabricating the plurality of panels, including:

(x) preforming a plurality of unserviced panels, each of the unserviced panels being of an identical dimension in terms of height, width and depth to the single size module panel; and

(y) preforming at least one serviced panel, the serviced panel being of an identical dimension in terms of height, width and depth to the single size module panel,

(ii) installing external supply lines onsite for communication, plumbing and/or electrical services;

(iii) laying foundations or constructing a base to form the building platform; and

(iv) erecting walls using only the panels included in the plurality of panels to form the wall panels.

The above-described method may further include the step of constructing floors comprising only the panels included in the plurality of panels. The panels forming the floor may include serviced panels including lines for electricity, fluid (including gas, water and air) flow. The panels forming the floor may include lines and installations for communication, lighting, ducting, vents, and/or temperature regulation.

The above-described method may further include the step of constructing a ceiling consisting only of the panels included in the plurality of panels. The panels forming the ceiling may include serviced panels including lines for electricity for lighting, vents, fans and temperature regulation.

The building may be for affordable, social and/or relief housing. The building may be a domestic dwelling. The building platform may be a fixed site building site. The terms "onsite" and "offsite" refer to the fixed ground site on which the building may be erected. The building platform alternatively refers to a temporary or mobile platform.

In another aspect of the invention, there is provided:

A preferred method of constructing a building on site according to the invention includes the steps of:

(a) making on site a building platform on a footing subframe and stumps, the building platform defining a perimeter; (b) erecting a structural frame around the perimeter of the building, the structural frame consisting of a plurality of columns, each column mounted on a respective on of the stumps using a fixing element;

(c) installing a roof whereby the peripheral structural frame acts to support the roof components, allowing the framing, including both internal and external wall framing, to be non-load bearing; and

(d) installing a plurality of wall panels after the roof has been installed.

SERVICE PODS

The building may incorporate a number of, preferably at least two, prefabricated service pods. The service pods are prefabricated, drop-in modules, typically with wet-area functionality. These service pods may be an ensuite, a combination bathroom/laundry, a butler's pantry and kitchen, or a variety of other combinations. These service pods supply a fully equipped and finished "wet area". The building may incorporate at least 2 bathroom pods.

Into the pod are added any other services that must be managed and distributed throughout the rest of the building. The pods are positioned to be available to service multiple areas of the building. The building preferably include a critical service pod, which may be the bathroom or kitchen that can service multiple areas and optimise the off-site construction for other areas and services required within the building.

BUILDING METHOD

Preparatory to step (a), the method may include pre-mapping the building (160) layout using a 3D model. All services may be accurately determined in the 3D model, enabling significant prefabrication of items such as wiring looms, plumbing and cabinetry assemblies, without the need for site measurements.

The method further includes is progressively building the building in discrete sections. The sections are dimensioned to be a maximum length, being half ofthe full width of the building. The length of each section is aligned with the lateral direction of the building, which length may be half of the total width of the building. The width of each section may the sum of a factor of the width of the panels. Generally the progressive builds will be determined by the location of secondary structural elements that are required to provide additional structural integrity. The location of these structural elements is coordinated to suit the dimensions of the wall panels.

The roof of the building may include steelwork, trusses and on e or more ridge beams. Once the roof for one of the sections is installed, the roof panels for the section may be installed. This process may be repeated for the section and so on until the entire building is completed. In some installs of the building, external walls and the service pods may be installed during the progressive build so as to bring additional structural integrity to the structure of the unfinished building.

The building method preferably involves installation of the roof panels in pairs either side of the ridge (corresponding to the ridge beam). Once the pairs of roof panels have been fixed together using unique and purpose designed fixing brackets, the full width roof portion of the section may then be moved along the building until it reaches its final location and is then fixed into position. This method of erection may allow the entire building footprint or building platform to be completed, and the columns and supporting trusses installed, so that then the rest of the roof may be installed. The internal and external wall frames may then be installed. With the floor, the main wall and roof supporting structure (columns) installed, the external and internal walls in the form of wall framing and the panels are then installed.

Carports and pergolas to have the same roof pitch of 10 degrees.

The invention in one aspect is a method of erecting a building. Preferably, the invention includes a process involving the manufacture of a large number of buildings. The building method may include a prefabrication process. The prefabrication process may facilitate the mass production of a consistent range of building elements and components ready made for installation at a building site. The building method preferably involves the carrying out of a mass production of prefabricated elements and components for the erection of buildings at multiple sites.

The prefabrication process may involve prefabrication of building elements off site in small mass-reproduceable elements. The small building elements may be referred to herein as "micro form". Rather than build large sections as in conventional prefabrication, according to the prefabrication process, the method may involve offsite prefabrication of small sections or small building elements. The meaning of "small" is given in the definitions.

In the prefabrication process, each wall is divided into small panels ("micro-panels") that can be easily made in through mass production. Although building sheets, windows, tiles and the like may be mass produced according to prior methods, in the prefabrication process, the small building elements may be complete ready-to-install wall elements comprising an exterior layer, internals such as core material and electronic or plumbing services, and an interior layer. These small elements may be therefore easily transported. Mass production in the prefabrication process is preferably fully automated with minimal direct labour.

By using small or micro- panels and other small building elements, transport of light-weight and small elements is simplified. Removal from a transport vehicle to an installation location may be effected without the use of a crane or other heavy lifting equipment. Placement and installation is much easier and involves one or two-man labour, compared to heavy lifting and placement of prior art large pre-fabricated building units. The prefabrication aspect utilises a standardized material size or multiples thereof based on a lowest common denominator. The building element sizes are based on a 1200mm, 2400mm, and/or 4800mm modules. A module is a discrete portion of a building made up of multiple modules. The first erected module is capable of standing alone.

The lowest common denominator in this example may be 1200mm. All of the building elements complement each other at such standardised spans and sizes. The floor beams spacing suits a 600mm module floor panel as the flooring is fixed at 600mm centre-to-centre (ctrs), the wall panelling may be provided in 1200 (wide) x 2400 (height) sheets. The roof sheeting may be rolled in a 600mm width.

The modularised construction method of the prefabrication aspect may include a fully automated off-site mass production of the wall and roof panels. All major components of the build are preferably controlled and manufactured by an offsite facility. All data for the specifications for each building component may be provided directly from a dimensionally accurate 3D computer design model.

Because of the accuracy in the prefabrication aspect of the building method, a new and innovative building sequencing aspect according to another aspect of the invention can be utilised. For example, the whole floor is not built in its entirety. Instead, one module of the intended final building is built in its entirety onsite one module at a time. Each module is completed in its entirety before moving on to construction of the next.

Preferably, none of the internal walls of the building are load bearing. Some internal walls are required for bracing to provide lateral stability of an incomplete module, but the use of internal wall panels for bracing does not interfere with the overall sequence of construction of the building. In addition, it allows for the delivery of the fully assembled cabinetry to site. The cabinetry can be placed directly on the floor of the build. The cabinetry can then simply be rolled and installed in the location of the build, as required.

There is preferably no constraint by door sizes, even to some extent ceiling heights, as these elements can be installed later.

The building sequencing aspect represents a completely different way of building compared to the prior art. The prefabrication aspect delivers advanced efficiencies in mass producing small building elements, such as the wall and floor panels. The building sequencing aspect delivers advanced efficiencies through the completion of each module progressively through the build on site. The modules may be discretely built in sequence. The combination of the prefabrication and building sequencing aspects deliver a manufacturing and building method with advanced efficiencies throughout the entire process.

These efficiencies may include:

1. Production of small building elements, including the wall and/or floor panels, on a large scale. For example, an offsite production run of small, discrete building elements may be sufficient to supply the requisite numbers for at least 50 modules.

2. Mass production of small building elements to facilitate stock control and provide cost and time efficiencies.

All small building elements and components are preferably mass produced so that stock control is far easier. The building method is preferably not used to build one-off homes. The room layout, roof slope and building footprint is replicated in the multiple locations The building is simply replicated in multiple various different locations, with adaptions for requirements, legal constraints, terrain and block size accommodated by the module-by- module building process and height-adaptable stumps.

The colour pallet used for the building may be limited to three different choices. .

Preferably, the builder may have a small number of different home designs that utilise the same small building elements that are mass produced by the prefabrication process.

The internal walls are preferably not load bearing and therefore can be installed at any time to suit the overall building sequence. This allows items such as cabinetry to be delivered to site and installed as fully assembled elements. Many of the internal walls may not require additional cladding as the associated cabinetry may be fixed directly to the preferably steel wall framing. The external wall panels may be prefabricated to be fitted with all internal and external cladding, including windows and any services..

The following step by step guide describes the building method according to the building sequencing aspect.

Preliminary Site Works:

When a building site is demolished or otherwise prepared and cleared, the same contractor may be used to excavate for the services.

There is no natural gas or telephone connections in the build, so that the services required may include only: a. Electrical services including 3 phase installation for electric vehicles ("EV") and other 3 phase uses, including instantaneous electric hot water; and b. Plumbing necessities, such as sewerage and storm water.

A site review and safety check for existing hazards (such as gas or water lines) may be conducted before site connections are installed prior to building start. All excavations may be backfilled, with the site then levelled, compacted and allowed to settle. All service points may be accurately surveyed so that they can be included within the 3D construction model.

Complete site survey, soil tests, and replacement of all fences (if acceptable to neighbours) may be carried out as required.

Building started on Site.

A soil stabilisation membrane may be laid down in readiness for the build to start.

The membrane may extend (for example about lm - 2m, or preferably about 1200mm) beyond the building line or footprint. The membrane allows for crane truck deliveries and also provides a firm base for mobile scaffold and scissor lifts. The subfloor membrane (which may be in the form of a diamond grid) may provide a clean and safe working base for mobile scaffold and scissor lifts. The grid soil stabilisation membrane enables the establishment of a flat and load bearing membrane for both foot, vehicle and access platform traffic. All footings are preferably based on a 40 mm thick Diamond Grid mesh that extends at least 1000 mm past the perimeter of the building footprint. Surefoot™ footings are preferred, although the invention envisages the use of any compatible grid-based loadbearing membrane that may be laid directly on prepared flat soil or land. The grid may be installed in accordance with the manufacturer's specifications. Driven pipes for the Surefoot footings may be driven through Diamond Grids.

Installation of a subfloor steelwork utilising Surefoot™ footings may be effected where required for the first module.

Surefoot™ footings do not require concrete and therefore eliminate the need for stump holes and footing inspections by a Building Surveyor.

A first 4800mm long x 12000mm wide bay of subfloor framing may be installed for the first module.

Next may be the squaring up of framing. This may include leveling and the addition of bracing, before installing micro piles for the stump supports.

Installation and fixing to bearers of an electrical wiring loom may be made in the subfloor with access points provided at critical junctures for connection to small building components like discrete prefabricated a wet area pods with preinstalled electrical and plumbing. As shown in FIG. 24b, flooring panels are fitted. Wiring is preferably located and pulled through flooring. The wiring access is through the floor. The electrical wiring and plumbing is not located in the walls or ceiling, except in the wet area pods as described later. However, PoE (Power over Ethernet) connectivity for lighting is provided in the roof or ceiling panels, as later described.

Create a peripheral frame

The frame may be erected to include main upright and/or vertical posts. This may be followed by the installation of perimeter box beams as shown. This involves standing all main support posts, and then installing the perimeter box beams.

One or more internal wall frames may then be installed.

At least one perimeter wall panel may be used to stabilise and brace the main support structure, including the perimeter frame. For added reinforcement, at least one internal wall panel may be used to stabilise and brace the internal walls, and as a consequence, brace and stabilise the main support structure.

To provide rigidity and reinforcement to the internal and perimeter walls during this intermediate stage of the build, advantageously one or more wall panels are preferably installed. These provide a bracing effect, keeping the frame rigid during this intermediate stage before all wall panels can be installed. Therefore, the initial placement of the first and second wall panels is strategic. Preferably, at least a first bracing wall panel is installed in a wall to lie in a first plane in a first direction and a second bracing wall panel is installed in a second wall to lie in a second plane substantially transverse, and preferably perpendicular, to the first plane. The sequence and volume in which bracing perimeter and wall panels are installed is determined by the specific requirements of each individual build. The bracing wall panels may be installed on one or both spaced and parallel side walls and one end wall. Accordingly, the building is braced against lateral wind forces.

Install ceiling joists and internal roof support frames.

Ceiling joists and internal roof support frames may next be installed.

Install roof panels and any remaining perimeter and internal wall panels.

At least one of the roof panels preferably incorporates PoE lighting. The PoE fixtures may be included in at least one roof panel per internal area. An internal area is an interior part of the building bordered by external and/or internal walls. The PoE lighting only requires Cat 6 cabling to be used on site, thereby significantly decreasing install times and lowering costs for supply of power for lighting to the roof panels.

The build may continue with the addition of second and subsequent modules.

The first module may be a section of the building. The second and subsequent modules may be similar to the first module. The second module may be continuous and contiguous with the first module. Modules adjacent to each other share an internal wall common to each (the common wall). The common wall shares foundations, stumps, braces, floor and roof beams along the common wall line of the that common wall.

The first module is preferably discrete and sufficient as a stand-alone building structure, with complete foundation, floor, walls and roof structures. The second module may be added on to the first module as an extension of the first module, sharing the common wall and associated foundation, floor and roof structures on the common wall line. The second module may have no fundamental building elements that are different to those used in the first module, although it may vary due to cabinetry, shelving, etc. Therefore, the same mass fabricated components used to make the first module are preferably replicated in the second module, with the exception of the shared components of the common wall.

The main floor and roof beams transverse to the long sides of the first module may be extended by coaxial beams extending along the same axis as each main transverse beam of the first module. If the second module is to be sandwiched or located between the first module and a subsequent third module, the second and third modules will share a second common wall and associated foundation, floor and roof structures on the second common wall line.

The building preferably includes one or more prefabricated wet areas with electrical wiring, and plumbing lines and fixtures, built in. The location of plumbing inlets and outlets for, for example, water lines and drains, are specific and consistent to line up with predictable complementary incoming and outgoing building fluid line at predetermined access points. The wet areas may be provided in the form of the pods. The wet areas may comprise a series of bathroom, kitchen and laundry pods. Each pod may be delivered to the building site as a complete unit. Each pod preferably has all fittings, piping, wiring, floor coverings, cabinets, and tapware installed.

Each pod is preferably a complete unit with electrical and plumbing inlets and outlets located and complementarily configured to connect to services, such as electrical or plumbing mains or public utility services on site.

The pod units may form the functional centre of the building. Electrical power may be terminated within the pod units. A smart home management system may be incorporated in one or more of the pod units. The PoE lighting systems may terminate at these locations, i.e. within the pods.

All wet areas are preferably incorporated into a prefabricated assembly in the form of the pod units that are built offsite. This negates the need for any onsite building inspections. It significantly improves the consistency and reliability of the build quality, while dramatically reducing time and cost.

In this example including discrete wet area pod units, the next stage of the build may incorporate subfloor supports for the pods.

A final stage of the building includes a garage/utility room and/or a carport. This may involve the installation of steelwork associated with the garage/utility room and/or carport.

Advantageously, all building components may be transported using a small rigid body crane truck. The transport using the truck and the associated prefabrication method and building sequencing system allows these builds to be installed on any prepared block, for example a suburban block. Because of the adaptable stump heights, even sloping blocks can be accommodated. The pods are preferably relatively small and therefore transportable by the small crane truck as they are not regarded as oversize loads and do not require special permits or wide load clearance. They are easily transportable down a normal suburban street.

The fabrication and sequencing building method described above is a revolution in the building sector. To build a home in modules of a specific unit dimension using exclusively smaller prefabricated components, rather than deliver and install fully completed and assembled modules to the building site, is a significant breakthrough. It allows for mass production of the smaller individual wall and roof panels. The pods go to site as a sealed unit.

The specific unit dimension may be a product of a specific sub-unit measure, such as 500mm, 600mm, 1000mm or 1200mm. In the preferred embodiment the specific unit dimension for the module(s) is(are) 2400mm, 3000mm, 3600mm, 4000mm or 4800mm, 5000mm or 6000mm, with 4800mm being most preferred. For a build of a particular building according to the invention, preferably the specific unit dimension is the same and the modules have the same footprint dimensions. The maximum beam lengths extending transverse of the longitudinal side wall axis may therefore be limited to such lengths, for example 2400mm, 3000mm, 3600mm, 4000mm or 4800mm, 5000mm or 6000mm, with 4800mm being most preferred. The length of the units in the direction of the long side wall axis is less strategically important, but must be manageable, for example in the range 6000mm - 12000mm. The purlin spacing is preferably 600 - 1500mm, and most preferably standardised for the inventive system at 1200mm ctrs.

The Applicant envisages that a 300m² home would take between 6 - 10 weeks to complete on site. The prefabrication method allows "JUST IN TIME" (JIT) delivery of small building elements and components. These components include fully assembled cabinetry to be incorporated in the pods. The cabinetry may be installed or placed anywhere in the building. This is not possible in a conventional build because of access constraints. The building method allows fully assembled cabinetry to be delivered and placed directly onto a completed floor of a module and then simply placed where needed as the completion of the remainder of the build continues around the cabinetry. In this manner, completely assembled features that are too large to fit through finish-build access portals, such as doors, can be accommodated in the building. Such features may include large tables and other furniture that may be located within the relevant module before lock-up stage and before the external walls and/or roof are completed.

There are virtually no waste materials on site because all small building elements and components go to site complete and ready to install. There is virtually no need for cutting or trimming. For example, gutters, flashings and downpipes are advantageously completed, prefabricated and cut to size, and ready to simply fit or install on site.

3-D model

The accuracy of the building method, including the prefabrication and build sequencing, allows for the maximum utilisation of prefabricated elements. Items such as feature walls, wine cellars, entertainment units, security systems, air conditioning (A/C) systems, are all incorporated into a dimensionally accurate 3D detailed model. This detailed model may be used to drive all of the prefabrication using Numerical control (NC).

The prefabrication method may be implemented in a purpose designed fabrication and assembly plant. The prefabrication method preferably derives all data necessary to make each of the small building elements and components directly from the 3D model. The 3D model may be built using publicly available commercial software capable of computer aided design (CAD), mechanical CAD (MCAD), and/or Computer Aided Manufacturing (CAM), such as Solidworks™, Fusion™, AutoCAD™.

The 3D model is developed parametrically or, in another term, utilising generative design principles. The model is a result of the parameters set by the fabrication and construction methods adopted. In prior art building methods, the 3D model or building plans set the size of the rooms and the ceiling heights and the general footprint of the building. Then the prior art construction method is required to meet these dimensional constraints.

In the present building method, the parameters set by the prefabrication and construction method dictates the final shape of the building and the rooms within it. By ensuring the 3D model is derived by a set of rigid principles, generative design becomes possible.

Parametric design uses parameters and constraints to solve a design problem, while generative design applies algorithms to those same parameters to generate hundreds or thousands of possible design variations to review and choose from.

Generative design is a method of using Al (artificial intelligence) algorithms to generate and evaluate multiple design alternatives based on input from the user. This design process can take many factors into account, including performance requirements, manufacturing processes, and materials to generate optimized designs.

For example, utilising a particular set of specific unit dimensions relative to, say stock sizes, or panel sizes, can quickly allow 3D "Al" aided generative design modelling to be utilised. The inventive generative design principles may be used to apply the building parameters set by the fabrication and construction to develop 3D models that are the most cost and time efficient for any size block or building type.

The 3D model does not dictate or set the shape and size of the building as is the case in prior art stick build. Rather the 3D model arises as a result of applying the size and shape of the various panels while allowing for the staged building sequencing method. This is unique and revolutionary to the domestic building industry because building using micro panels and staged construction has never been previously employed.

The 3D Model will enable the extraction of all data directly from the model and converted into Numerical Control (NC) data so the various machines can interpret that specific data and manufacture the individual members to exactly match what is 3D modelled. This extraction of data requires specific computer code to be compatible with the data required for the wide range of prefabrication machines that all utilise system specific manufacturing software. For example, the data utilised by the box beam rolling machine needs to ensure that the first section and the second section while they may have differing holing and notching requirements, are still paired in the correct sequence so as to fabricate the dimensionally correct assembled box beam. This data is completely different to the data required for the cabinetry line, the laser cutting and folding line, or the tube processing line.

While all data is contained within the generative designed 3D model, the extraction and manipulation of this data to enable automated manufacturing and assembly is specifically developed as multi-functional extraction software particular to each prefabrication machine. The delivery format may be a simple comma delimited file. Each machine may utilise purpose- written software that exactly meets the need for what that machine produces. This is achieved by feeding the data into the particular prefabrication machine manually or from smaller specific 3D models that only have that type of member or assembly and have used that specific software to create the 3D model.

For example, for a 3D model of just the steel posts, the stumps, the box beams or the cabinetry, each 3D model would normally have been developed using the software that was compatible with what the machine used to fabricate. In the present construction method, a single software is used to develop the 3D model using generative design and then the data is extracted and manipulated to be compatible with the software used by each of the machines to manufacture that specific element. In particular, the method for constructing a domestic building preferably includes a fully coordinated multi discipline Al aided generative design model utilising small building elements or "micro elements".

A prefabrication facility may be provided with various production stations in a prefabrication plant layout designed to carry out the prefabrication method. The prefabrication plant may be adapted to maximise the prefabrication of assembled building frames such as roof trusses for builds.

The facility is preferably adapted to produce all framing, roof sheeting and cabinetry for 300 - 500 300m2 buildings per annum. Assembled and completed building elements are either transported to the building site in JIT fashion or stored offsite. Management of production and stock preferably utilises JIT workflows.

The prefabrication facility preferably utilises automation involving robotic assisted loading, manufacture, assembly and storage processes.

Key qualified tradespeople are preferably used to establish and oversee the manufacturing and preassembly involved in the prefabrication method, thereby reducing official oversight and inspections that may be otherwise required on site.

There are several specific machining areas within the prefabrication plant:

Box Beam Rolling;

Wall frame rolling;

Roof sheet rolling;

Tube processing, (laser);

Cabinetry smart factory;

Coil fed laser cutting;

Plate fed laser cutting; and/or

Robotically fed press brake folding station.

Box Beam Rolling Machine.

A box beam rolling machine may be used to manufacture box beams by rolling and pressing together two complementary channel sections to form a strong box form. Each channel section includes a base wall from which perpendicularly extend spaced arms, namely a long arm and a short tab arm, with a terminal end of each long arm of each section overlaying the short tab arm of the other section to place in mating positions, and seaming to complete the rectangular box section.

The box rolling machine may include the features of uncoiling and levelling the metal sheet, feeding and guiding into the machine, punching holes in predetermined locations, guiding further, roll forming, printing where required, cutting, conveying, overturning, covering or plating, and pushing to mating positions, seaming and running out the finished box beam product.

The box beam rolling machines are preferably purpose built and adapted to be configured to form at one time any one of a number of different sized box beams by cutting the sheet lengthwise to vary the length of the long arm of the channel sections.

Bracketing System

The box beams may be punched or cut to form flanges, apertures or ledges that may be adapted cooperate with complementary engagement and/or support features on the brackets.

In finished form, the box beams may be adapted to be joined by the bracket system comprising the brackets. This bracket system reduces or eliminates the use of fasteners to fix beams to one other.

Fasteners may therefore be totally eliminated or at least sparingly used in the assembly of framework and support structures in the prefabrication and building onsite stages. The brackets are preferably effective to join the beams in T-joints, cross-joints, overlays, and series- or inline-joins, both coaxial and angled, by means of the engagement of the brackets to the profile of the beams and other frame members, and to the complementary engagement features on the beams. This reduces the need to position and form apertures and effect entry of fasteners. The bracketing system reduces time to assemble and install roof frames and sub floor support members, both in the prefabrication stage, and onsite. This reduces assembly times, simplifies construction on site and significantly reduces build costs. The bracketing system furthermore removes the need for welds. Therefore, welding is preferably not used in the method for construction to join metal components to each other. The data used to drive these rolling machines may be extracted directly from the modelling software of the 3D computer model of the various build designs.

Wall Frame Rolling Machine.

The prefabrication method may include the use of a wall frame rolling machine that has specific design elements not generally utilised by other similar prior art machines. Additional punching sets are provided. This may assist the implementation of the build method on site. Most roll framing machines that are used to form wall frames are configured on the assumption that services such as plumbing and electrical are site run, that placement and specifications such as capacity and quantity are determined by experienced tradesman on site as the build progresses. Therefore, most rolling machines allow for additional service holes throughout the frame.

In the preferred embodiment of the building process, the installation of services is simplified and the time and effort reduced by installing all services in the panels and pods during prefabrication.

Roof Sheet Rolling Machine. The preferred building may include roof cover in the form of metal roof sheeting. The roof sheets are preferably first formed in partial longitudinal sections that comprise ridges defining multiple valleys. The valleys may be substantially flat or may be shallowly longitudinally corrugated. The valleys and ridges lie in parallel. Each roof sheet may comprise 2 - 3 valleys. The ridges may be in the form of tall upright folded points in section, or may be folded to be bulbous and to define a keyhole shaped cavity with a downward facing wide and splayed opening. The roof sheet rolling machine produces identical sections that are broad roof sheets sized for metrically measured spans.

The sheet profiles are preferably sized to specifically cover standard coverage roof spans, whereas prior art roof sheet dimensions may be determined according to an outdated imperial measurement system, being generally rolled in sections that are 250, 305, 406, 620, 700, 762 820, 840 and 850mm wide.

The roof sections are rolled in sheets with coverage that exactly match the specific unit dimension in terms of span. There may be at least two sheet profiles. One sheet profile is preferably 300mm wide and the other is preferably 600mm wide. These two sheet profiles may suit all of the builds. A pierce fixing method may be used to ensure that the build satisfies all wind force categories. Both sheet profiles will span the standard of 1200mm that is set for the purlin spaces. The roof panels are integrated with roof-mounted solar panel support grids in the final build.

Tube Processing Laser Machine.

A tube processing laser machine with a tube processing line that is suitable for manufacturing tubes is provided in the prefabrication stage.

The tube processing line has an auto load capacity that enables the loading of a bundle at one time of 20 tubes that are 6000mm long. This machine produces all of the main support posts and steel stumps. The stumps are integrated with their footings so that there is no need to weld these elements. In fact, there is no need to weld any elements in the preferred build. The posts use a unique clamping system that reduces cost, makes assembly very quick, and provides a better surface treatment.

Cabinetry Smart Station

The prefabrication plant further includes a cabinetry fabrication station. This achieves prefabricated construction of fully assembled cabinetry. It completes all processing of a laminated sheet with little or no human involvement. It is adapted to mark, cut, edge, rebate, drill on a fully automated production line. It produces laminated sheets in a variety of dimensions. The sheets are initially produced as 1200mm wide x 2400mm long sheets. It can produce sheets with a thicknesses from 12mm up to 38mm in a variety of sheet types.

This cabinetry fabrication station is adapted to fabricate and preassemble all cabinetry for multiple builds. It can do all wardrobe units, feature wall units, kitchen cabinets, laundry cupboards, bathroom cabinets, feature shelving. Virtually any shelving or cabinet required can be manufactured through this processing line.

The 3D design model produces precisely dimensioned and configured cabinetry to minimise waste and time on site. Coil and Plate fed laser cutting machines, and Robotically fed Press Brake folding station.

These three machines when coupled with the brake press are adapted to cut, fold and bend all of the brackets used in the builds. The extensive use of box beams and SHS steel members while extremely efficient structurally, does present issues in regard to connections. Therefore, the building method utilises the brackets that allow the operator to build quickly on site. The brackets are cost effective, while enhancing the structural capacity of the box shaped members.

It will be appreciated that any of the features described herein can be used in any combination, and that the invention as described in respect of the second aspect may have the specific features referred to above in respect of the invention as described in respect of the first aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

Figure 1 is a side sectional view of part of a building made according to one embodiment of the invention, including exploded views Figs, la - d;

Figs. 2a-5 are schematic front views of various panels made according to an aspect of the invention;

Figure 6 is a side elevation of the panel shown in Fig. 5;

Figure 7 is a top plan view of the panel shown in Fig. 5;

Figures 8a-bare exploded views of the top plan view of the panel shown in Fig. 7;

Figure 9 is a vertical transverse section of two adjacent and abutting side posts of adjacent panels in linear relationship;

Figures 9a-d are various side and plan elevations, and a magnified view of a and end tab, and section profile of a stud frame of a wall panel;

Figure 10 is a floor plan of a building illustrating the elements and components of a building of the type envisaged in accordance with the invention;

Figures 11a is a sectional view of the foundation and stump and support column arrangement of the buildings according to one embodiment shown in Figs. 10, 13(a) and 14(a);

Figures 11(b) - (c) are, respectively, front and side elevations, of a corner post and bracket therefor according to one embodiment of the invention;

Figures 11(d) - (f) are various isometric views of the corner post and bracket therefor shown in Figs. 11(b) - (c);

Figure 11(g) is an isometric view of a corner post and bracket according to a preferred embodiment; Figures 11(h) - (i) are front and side elevations of the corner post and bracket shown in Fig. 11(g);

Figure ll(j) is a top plan view of the corner post and bracket shown in Fig. 11(h);

Figures Ilk - n are isometric, and, front and side elevation views of a corner post and bracket according to another embodiment;;

Fig, llq shows a number of caps for the stumps shown in Figs, llo-p;

Figs, llri-riii show a footing cap and isometric, plan and side elevation views of a footing according to a preferred embodiment;

Figures llo-p are front and side views of a stump and footings according to one embodiment

Figures 12(a) -(d) are cross-sections of box section beams used as bearers, floor joists or supporting beams for a frame of the building according to a preferred embodiment;

Figures 13(a) - (c) are respectively isometric, front elevation and side elevation views of a 3D model of the building according to a particular embodiment;

Figures 14(a) and (b) are, respectively, upper isometric and lower isometric views of a 3D model of a building according to a preferred embodiment;

Figures 15 (a) - (e) are, respectively, right side elevatory, top plan, front elevatory, left side elevatory, and rear elevatory, views, of the 3D model shown in Fig. 14;

Figure 16 is an isometric view of the building shown in Fig. 14(b);

Figures 17(a) and (b) are, respectively, magnified portion of the footing subframe and roof of the building shown in Fig. 16;

Figure 17(c ) is a isometric view of the subfloor immediately under the pods, and the surrounds, and a collection of various magnified views of joins therefor;

Figure 17d shows various isometric, profile, elevatory and flattened views of a double raft ridge bracket according to a preferred embodiment;

Figure 18(a) is a partial isometric view of a ridge beam and rafter assembly according to one embodiment;

Figures 18(b) to (e) are magnified views of portions of a rafter frame shown in Fig. 18(a), including single and double ridge brackets;

Figures 18(g), (f), (h) and (j) are isometric views of, respectively, a stamped blank and the folded form of an improved single ridge line rafter joining bracket shown in use in Fig. 18(f);

Figs. 18(g) and (i) are flattened profile illustrations including a top plan view of a stamped double ridge bracket according to one embodiment;

Figure 19(a) is an in-use isometric view of an improved T-join framing bracket;

Figures 19(b) - 19(d) are lower isometric views of the bracket shown in Fig. 19(a); Figure 19(e) is a isometric view of a blank of the framing bracket shown in Fig. 19(a);

Figures 20(a) and (c) are isometric views of a ridge saddle bracket according to one embodiment;

Figure 20(b) is a flattened view of the ridge saddle bracket shown in Fig. 20(a);

Figure 21 is an isometric view of a ridge beam bracket according to one embodiment;

Figure 22 is an isometric view of another double ridge bracket according to a preferred embodiment;

Figures 23(a) - (c ) are isometric views of an improved mobile panel install frame;

Figure 24 is an isometric view of a preferred embodiment of the invention showing the subfloor and without rafters; and

Figures 25 - 33e are isometric views of the embodimentshown in Fig. 24 in progressive stages of a build according to a preferred sequencing;

Figure 34 is a schematic plan view of a prefabrication plant;

Figures 35ai - aii are schematic plan views of a cabinetry station of the plant shown in Fig. 34;

Figure 35b is a schematic plan view of stud roll forming and sheet roll forming stations of the plant shown in Fig. 34;

Figures 36a-b are section profiles of roofing sheets according to preferred embodiments;

Figure 37a is a schematic plan view of a box roll forming station of the plant shown in Fig. 34;

Figures 37b-c are, respectively, side elevation and top plan views of a wall framing station of the plant shown in Fig. 34;

Figure 38a -b are, respectively, a schematic plan view and an artistic perspective view of plate fed laser cutting and robotically fed brake press stations of the plant shown in Fig. 34;

Figure 39a-b are, respectively, a schematic plan view and an artistic perspective view of a tube processing and assembly station of the plant shown in Fig. 34; and

Figure 40 is a schematic side view of a typical small crane truck.

DETAILED DESCRIPTION OF THE DRAWINGS

Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. In describing the various embodiments of the invention, like features will be referred to using like references, with references for features of each embodiment generally preceded by 1, 2, 3, or followed by a Roman numeric sequence, such as i, ii, iii, etc. or an alphabetical sequence such as a, b, c, relative to the corresponding feature of the first embodiment. For example, a feature 10 of the first embodiment may represented as 110, 210, 310, (or nlO), or 10a, 10b, 10c, (or lOx) or lOi, lOii, lOiii, (or lOr) etc. in second, third and fourth embodiments, respectively.

In the drawings, with reference to the drawings, there is shown components of a building (160) made according to a method utilising a modular panel (nOO) made according to a limited and controlled number of height, width and depth dimension combinations. For example, the height dimensions may be represented by either Hl, H2 or H3. In one jurisdiction for domestic buildings, Hl and H2 may correspond respectively to 2.4m and 2.7m. In another industrial application, Hl may correspond to 3m. The width dimensions may be WR, where R represents that the width may correspond to increments of 600mm, so that the width may be 0.6m, 1.2m, 1.8m etc. The thickness or depth may vary between 25mm - 60mm, and preferably be about 35mm.

Multiples of the panel (nOO) include an external wall panel (800) that is used for all of the external walls (162) that define a perimeter (66) of the particular building (160). The external wall panels (800) are 1200mm wide and 2400mm in height. The layout and dimensions of the building (160) are governed by these dimensions, so that the length of all external walls are multiples of 1200mm and all external walls (162) are no lower than 2400mm. As shown in Fig. 1, the height Hl of the external wall wall (162) ) can be augmented by an a additional upper panel (802) that may provide additional window space, venting or passage for services.

Multiples of the panel (nOO) include an internal wall panel (700) that is used for all of the internal walls (164) of the building (160). All of the panels (nOO) are located within the footprint (166) of the building (160), being the area that the building (160) when installed occupies when viewed from top plan down.

Multiples of the panels (nOO) may be used to form a floor (70) in the form of floor panels supported by floor joists of the building (160). However, the multiples of panel (nOO) are preferably constructed to be non-load bearing against vertical forces when lying in an orientation plane, whereby they are suitable for walls (162,164) and ceilings (182).

Multiples of the panels (nOO) may therefore be used for a roof (180), including as ceiling panels (600) supported by a roof frame of the building (160). The roof frame includes the rafters (181), ridge beam (183) and trusses (184).

Multiples of the panels (nOO) may be used as roof panels (500) supported by a roof truss (184) of the building (160). Multiples of the panel (nOO) are used for all of the walls (162,164), floors (174), and ceiling (182) and/or roof (180), of the building (160).

The multiples of panel (nOO) includes a number of different kinds of panel (nOO), all having the controlled front profile dimensions, such as a height in millimetres of any specific integer number between 2400 - 4000, preferably 2400 or 2700mm, a width having a factor in multiples of 600mm of either 1200mm, 1800mm or 2400mm in any one building (160).

The invention contemplates different panel (nOO) types, including the internal wall (164), external wall (162), roof (180), and optionally the floor (174).

Roof. The roof panels (500) may be set in situ at a pitch in the range of 5 - 15°, more preferably 8 - 12°, and most preferably a pitch of about 10°. The roof panel (500) is preferably be made from 200mm x 50mm box beams. The rafters (181) may be on the form of box rafters and may be set at spacings of 1200mm nominal centres. Cross beams may be 100mm x 50mm at 600mm centres for the ceiling and 1200mm max. centres for the roofing. Smaller spans may be provided at the ridge (183) and eaves due to higher live loads during the fixing of flashings, etc. As best shown in Figs. 1 and lb, the ends (185) of the roofing frames or trusses (184) preferably cantilever in the form of eaves (187) over the building side wall (external wall 162), preferably by about 200mm - 1000mm, and most preferably about 600mm. The spacing between adjacent said trusses (184) may vary. The end pair of trusses are parallel and preferably nominally spaced 1800mm wide. The internal adjacent pairs of trusses (184) may be spaced 2400mm. Advantageously, the trusses (184) form parts of the box rafters. The end box rafters are preferably 1800mm wide. The internal box rafters are preferably 2400mm wide.

However, the trusses (184) are preferably all designed and dimensioned to have the same span across the roof (180). The span is achieved across the roof by linearly aligned pairs of opposed and mirror-image pairs of trusses (184), each single rafter having a span of 13200mm/2 + 600mm for the eave (187), advantageously based on a centrally located ridge line (183). Each roof panel (500) to be installed in the building (160) shown in Fig. 14(a) (shown without roof panels) is approx. 6800mm (13200mm/2) long. Therefore, the roof panels (500) are preferably not limited to dimensions having multiples of 600mm. Because each truss (184) forming part of the roof frame buts up to an adjoining truss (185) as shown in Fig. 18d, every second rafter line (181) is in effect a double 200mm x 50mm rafter abutting each other.

Referring to Figs.l6a-d, around the perimeter (66) of the building (160), the trusses (184) are supported by double vertical members (16) located directly under the rafters (181) to provide maximum load support for the rafters (181) and stability and rigidity relative to the vertical posts (161). The double vertical members (16a) comprise a pair of parallel metal brackets with multiple apertures for fasteners that extend either side of the corresponding linear truss (184a) vertical member, are co-extensive therewith and reinforce the linear truss vertical member. Alternatively, as shown in Fig. 17b, the linear truss (184a) vertical member may be reinforced by short timber studs (16b).

The linear beam perimeter wall framing trusses (184a) are designed to take the initial roof load. In the embodiments shown in Figs. 24 - 33e, the building is similar according to the invention to that shown in Figs. 13a - 17b and 18f, but perimeter wall framing trusses (184) are replaced with box beams of the type and profile shown in Figs. 12a-d. The box beam profiles are made up of first and second sections paired to fabricate a dimensionally correctly assembled box beam.

Using trusses (184) for the perimeter wall framing is adequate, but using box beams instead of trusses (184) simplifies fabrication and construction and is preferred. The wall frames (161a) once fitted, packed and screwed off are able to take a considerable amount of load both vertically down, and also in the case of uplift in higher wind load conditions, vertically upwards. As soon as the wall panels (800) are installed, packed up and fixed, the entire structure comprising the walls (162) and roof (180) becomes one rigid frame or structure. The invention therefore includes, in one aspect, a method of erecting a super-rigid building structure.

The roof panels (500) preferably go to site fully clad with roof sheeting (external cladding 252) on their intended external side. As best explained with reference to the external wall panel (800) shown in Fig. 1, and for which the cross-sectional structure is similar or identical, the roof panels (500) are preferably provided with full insulation and thermal barriers fitted internally in the core (250). The roof panel's (500) intended interior-facing side is preferably clad with sintered cladding sheets (255) such as Promatect™ 100, which comprises autoclaved calcium silicate spheres (synthetic hydrated calcium silicate in spherical form) bound in a mineral matrix. Such internal cladding (255) provides excellent fire performance in most applications. An intended interior building space face of the interior cladding (255) is preferably smooth and ready to form a finished surface, able to receive almost any form of architectural/finish treatment (256). The reverse face (257) that is internally hidden and facing the core (250) is preferably sanded. The interior roof panel cladding (255) is resistant to the effects of moisture and resists deterioration when used in damp or humid conditions. Performance characteristics tend not to be degraded by age or moisture. However, the internal cladding (255) is not designed for use in areas subject to continual damp or high temperatures and is for internal applications only.

All light fittings and associated wiring (e) required to service the roof panels (500) will preferably be installed along the ridge beam (183) immediately prior to install and managed by way of the primary or critical service pod (62).

The frames (n40) of the panels (nOO) may be rectangular. Two adjacent panels (nOO) in a wall or roof system may abut each other in the same plane and be coextensive. The abutting frames (n40) may in effect form double side posts or members (n44) adjacent each other where the two panels (nOO) abut. The cladding (both internal and external) (n56) may span 600mm, so that two cladding sheets (n56) are used to cover the span of a 1200mm wide roof panel (500) in the inventive modular panelised system, thereby requiring no cutting or adapting of the cladding sheets (n56) or the panels (nOO) to size. The roof panels (500), being 1200mm wide, have noggins (542) internally spanning the 600mm gap between the side posts or members (544) and a mid-point stud (543) extending parallel with the side posts or members (n44) between top and bottom rails (n46,n48) of the panel (nOO).

External wall panels

All external wall frames (161a) are installed on site. The external wall panels (800) are fully clad both inside with the mineralised sheeting (255) and externally with some form of external sheeting/cladding (252), such as James Hardie EasyLap™ sheeting. The internal sheeting (255) is extremely strong as is any of the proprietary cladding sheets. This is used to advantage in the present invention in providing an extremely rigid panel (nOO) structure, leading to an extremely rigid building frame, including the wall frame (161a), once all of the wall panels (nOO) are installed.

Therefore, the external panel (nOO) includes a panel frame (n40), a core (250) that may include an air void or panel filler coplanar with a plane in which the panel frame (n40) lies, and an internal and/or external cladding sheet fixed to the frame (n40) whereby the panel (nOO) structure as a whole is extremely rigid. Preferably, the core is filled.

In the prior art, when constructing a building, conventionally the strength and rigidity contributed by a panel or cladding is not taken into account. The prior art frame must be rigid and strong enough to take all of the wind loads and live loads from its roof and also the walls before it is clad, because that is how the loadings and specifications for prior art building structures are calculated. The prior art frame goes up, the roof goes on and the external brickwork or other wall material goes up and is tied or otherwise fixed to the framework, but the framework is there to stabilise the brickwork, not the other way around.

In the build of the present invention, the frame (240) goes up progressively and the service pods (60) are used as massive stabilizing structures. This, combined with rigidity provided to the structure by the clad panels (nOO), results in a very stable building (160) structure. The building (160) may only have the internal panels (nOO), insulation and a weatherproofing paper installed to the external building frame (610). Therefore, the external panels' (nOO) cladding (252) may be fitted on site. However, more preferably, the cladding (252,255) of the panels (nOO) is installed to complete the panel (nOO) during an offsite prefabrication stage.

Internal wall panels.

Preferably, the internal panels (nOO) are fully clad on both sides, insulated (the core (250) is filled) and fully serviced (e,p,c) where required. Therefore, the internal panel (nOO) includes a panel frame (n40), a core (250) that may include an air void or panel filler coplanar with a plane in which the panel frame (n40) lies, and internal cladding sheets fixed to the frame (n40).

Services, such as electrical supply (e) and fittings are fitted within cabinetry assemblies (61) or within the service pods (60). Additional power points, light fittings and the like are preferably not provided in the wall panels (700,800). However, electrical service (e) points are preferably provided at the corners (612) of the building. All internal wall panels (700) are preferably accessible from under the floor (174). We will also be providing empty conduit position within some panels to enable power to be easily installed at some future date simply by drilling a small pilot hole up through the floor.

The internal (700) and external (800) wall panels preferably have a 1200mm sheeting width (corresponding to being dimensioned in factors or increments of 600mm in terms of width). A vertical stud or member (n43) may be incorporated in the frame (n40) at the mid point of the panel's (nOO), or the wall frame (161a) may provide a suitably placed stud for each panel (nOO). The wall frame (161a) preferably has wall studs at 600mm nominal centres. Where the panels (nOO) abut double studs are provided.

The cladding (both internal (255) and external (252)), preferably span a certain width W/2, so that each wall panel (nOO) having a width W has applied to it a pair of side by side W/2 wide cladding sheets (252,255) in the modular panelised system of the invention. In the preferred dimensions, the cladding (both internal (255) and external (252)) span 600mm, so that each 1200mm wide wall panel (nOO) has applied to it a pair of side by side 600mm wide cladding sheets (252,255). Each panel (nOO) preferably includes noggins spaced W/2 from the side posts or members (n44) and extending to the mid-point stud (n43). In the preferred dimensions, each wall panel (nOO) preferably includes noggins at 600mm from the side of the panel (nOO), extending between the side vertical posts or members (n44) and the mid-point vertical stud (n43).

Automated manufacturing using robotic assembly.

The method of assembly of the building (160) on site enables the building (160) to be completed using manual labour. It allows for a progressive build, maximum flexibility in design, and all of the components are relatively light in weight and do not require massive cranes to lift them into place. The building (160) is therefore suitable for locations for which it is hard to access with heavy machinery, as well as economic builds using manual labour and small capacity lifting devices (for example, for the pods (60)).

An advantage of the method of construction of the building (160) according to the present invention is the manufacture and assembly of the components off site during a prefabrication stage. There are many systems around the world that use large, prefabricated wall and roof frames. But the present method is not restricted in this way by LARGE wall and roof frames, or the storage, transport and positioning and installation equipment for such builds needed onsite. Such large componentry requires heavy duty equipment to make, store, transport and/or erect such large and/or heavy componentry on site.

The present method allows an operator-builder to deal with relatively small componentry and modules on site. Small size and weight componentry has a maximum weight and length limit of 100kg and 7m, respectively.

The present method enables the roof frame ((181,183,184) and the wall frame (610) to be quickly and efficiently assembled, fitted off, stored and then transported without the need for large capacity lifting gear. The building (160) is safer to make, and the components are easier to store and transport, and quick and efficient to install, regardless of how large or small the building (160) envelope (66), or irrespective of the size of the building (160).

Applicant believes that this is a major innovation in the prefabrication of domestic and light commercial buildings anywhere in the world.

Offsite prefabrication manufacturing of the frames (181,183,184,610) and the panels (nOO) are largely completed using robots and cobots (collaborative robots) in conjunction with limited manual input. This process is utilised on a 24 / 7 basis allowing mass production of building components on a scale not previously achievable.

In one particular embodiment of the invention, the panel (nOO) has a panel filler or air void (n50) that extends between a panel frame (n40), including a rectangular peripheral frame (n41), the dimensions of which are 2400mm high and 1200mm wide. The panel (nOO) may have a core (250) that is about 20 - 35mm thick of insulation material, but preferably as shown in Figs. 9a-d the thickness is a standard 30mm thick, and framed by framing studs in the form of a channel profile that is about 89mm wide x 38 - 41mm, preferably 41mm, deep, with a 10mm lip. Figs. 9a-d show notching 142 and service holes 144 in a panel frame 141 that assist in making up wall panels 100. A dimple 146 in the side allows a fixing to be inserted that does not protrude into the cladding zone. The side notches 142 allow for the vertical members of the panel framing 141 to interconnect with the horizontal members.

Cladding (252,255) is provided on either side of the core (250). The cladding (252,255) includes a rigid sintered mineral sheet or compressed polymer sheet. This may be sandwiched between foil layers on both the first (external) side (n02) and second (internal) side (n04) of the cladding sheet (256).

The multiples of the panel (nOO) include different types of serviced panels (100) having services (120,e,p,c). The serviced panel (100) may include a communication, plumbing and/or electrical line (122), and a communication (nnc), plumbing (nnp) and/or electrical (nne) inlet (124e,c,p) and outlet (126e,c,p). The serviced panel (100) is suitable for offsite manufacture and for the inclusion of the services in the form of communication, plumbing and/or electrical installations, firstly embedded in the serviced panel (100) manufactured offsite, and subsequently installed in situ in the building (160). However, preferably services (e,p,c) and fittings (lights, outlets, etc.) are fitted within cabinetry assemblies (61), within the service pods (60) and/or advantageously at the building corners (612). However, the cabinetry assemblies are fully assembled and may be placed in the building where required.

The wiring or wireless receiver/transmitters of the electrical and communication services (e) may be located in, on or adjacent to a mid-rail (n42) of the frame (n40) extending between a pair of spaced posts or side members (n44) of the frame (n40). The frame (n40) includes top and bottom rails (n46,n48) that bridge the respective ends of the posts or side members (n44). In large span panels (for example, 1200mm wide), the frame (n40) may include a midpoint post or stud (n43) extending between the top and bottom rails (n46,n48). The mid-point post (n43) is preferably braced by lateral noggins in the form of the mid-rail (n42). There may be more than one level of noggins (n42) extending laterally between side posts (n44) as shown in Fig. 1. The panel frame (n40) preferably comprises the peripheral rectangular frame (n41) and cross-shaped bracing in the form of the mid-point post (n43) and the mid-rail (n42). Alternatively, the frame (n40) may simply comprise the rectangular peripheral frame to which is attached the cladding (252,255) which, in any case, still provides strong rigidity to the overall panel (nOO) structure and hence the frames (181,183,184,610).

The multiples of the panel (nOO) include unserviced panels (200) that do not include installed services (120,e,p,c). The unserviced panel (200) does not include a communication, plumbing and/or electrical line, or a communication, plumbing and/or electrical inlet and outlet.

The multiples of the panel (nOO) include panels in the form of a windowed panel (300). The windowed panel (300) includes a window (360) set in the panel filler (350). The window (360) may be set in the frame (240) defined by the top rail (346), side posts (344) and the mid rail (342) and the panel filler (350) may extend only between the side posts (344), the bottom rail (348) and the mid rail (342). The widowed panel (300) may include a window that extends substantially the full length of the side posts (344) in a floor to ceiling arrangement.

The multiple of panels (nOO) includes a door panel (400) including a wide single door (460) hinged to one side post 444 acting as a door jam. The multiple of panels (nOO) may include a double door panel (450). Although the door wing (460) is 1200mm wide and 2000mm high, the panel (nOO) being 1200mm wide can accommodate double doors that are each about 565mm wide. Alternatively, the double doors (452) are each 1130mm wide and the rectangular frame 540 is square-shaped, whereby all of the multiple of panels (450) of the particular building incorporating 2400mm wide panels (450) may all be of those dimensions: 2400mm high x 2400mm wide, or having dimensions made up of multiples of W/2, such as 600mm.

With particular reference to Figs. 5 - 9, there is shown an unserviced panel (200) having a frame (240) and side posts (244a, b) that in cross-section are in the form of opposed recesses (254) or RHS. The side posts (244a, b) may include the shallow internally facing recesses (254) into which a peripheral edge (253) of the panel filler (250) is received in the frame (240) during manufacture offsite. Adjacent side posts (244b, 244a) of adjacent panels (200) can be joined linearly to form the external wall (162) (which takes the form of a long wall) by being back-to- back abutted to each other, aligned in the same plane and clamped together by joining brackets.

With specific reference to Fig. 10a, there is shown the building (160) having external walls (162), internal walls (164) and an encapsulating footprint (166) indicated by the peripheral broken line. In this embodiment, he building (160) is a plane rectangular shape in plan, having dimensions of about 10m x 11m. The dimensions of the building (160) are entirely determined by the limited number of combinations dictated by the width W of each of the multiple of panels (nOO) which is invariably a sum of factor W/2 or W/3, for example 600mm, so that panels having a width of 1200mm or 1800mm are provided.

The services (120) are ideally run down a continuous wall (I), utilising serviced panels (100), as shown extending either side of a corridor (168) extending internally the length of the building (160). The floor plan ideally includes all wet areas (kitchen (K), laundry (L), bathroom (WC) requiring plumbing (p) to be located in a common zone. Electrical (e) and communications (c) services are advantageously run down a continuous internal wall (I) containing the bedrooms (B1,B2) and a dining room (D). These serviced panels (100,400) also include door panels (400), whereby the service conduits extend laterally above the jam of the door (460) through a core void or the panel filler (n50). Accordingly, the mid rail (442) extends above the door (460) between the spaced side posts (444) to connect the electrical and communications services (e,c) along the internal wall (I).

The multiple of panels (nOO) includes a plurality of panels (nOO) including a plurality of prefabricated unserviced panels (200) and at least one serviced panel (100), each of the unserviced panels (200) and the serviced panel (100) having:

(a) the same pre-set dimensions, including height (e.g. 2400mm), width (e.g. 1200mm) and depth (e.g. 25mm - 35mm); and

(b) consistent peripheral edges (n44a,b) adapted to cooperate in adjacent manner for assembly of a building (160) with another of the plurality of panels (nOO), the unserviced panels (200):

(c) being identical to each other; and the serviced panels (100) incorporating:

(d) an internal communication (c ), plumbing (p) and/or electrical (e ) line;

(e) a communication, plumbing and/or electrical inlet (n24c,p,e) and outlet (n26c,p,e) in a pre-set position in or on the serviced panel (100) that is adapted to respectively operably connect an onsite installation supply line and an interior communication, plumbing and/or electrical installation, such as an oven, hot plate, exhaust fan or air conditioner, or a sink, toilet or washing machine, or electrical or communication sockets servicing a computer, fridge or television, etc.

A method embodiment of the invention includes:

A method of erecting a dwelling (160) on a building platform (170 - see Figs. 10b and 13b) using the above described plurality of panels (nOO) comprising multiples of the controlled size module panel (nOO), wherein the dwelling (160) has walls (162,164) that are dimensioned to be formed from a single or multiples of the panel (nOO) and the method includes the steps of:

(i) prefabricating the plurality of panels (nOO), including:

(x) preforming a plurality of unserviced panels (200), each of the unserviced panels (200) being of an identical dimension (1200mm x 2400mm x (89mm plus cladding)) in terms of height, width and depth to the controlled size module panel (nOO);

(y) preforming at least one serviced panel (100), the serviced panel (100) being of controlled dimension in terms of height, width and depth to the module panel (nOO); and

(z) all panels having a width W, where W is the sum of multiples of 600mm,

(ii) installing external supply lines onsite for communication (c), plumbing (p) and/or electrical (e) services;

(ii) laying foundations (172) or constructing a base to form the building platform (170);

(iii) erecting walls (162,164) using only the panels (nOO) included in the plurality of panels (nOO) to form the walls (162,164).

The above-described method may further include the step of constructing floors (170) comprising only the panels (nOO) included in the plurality of panels (nOO). The panels (nOO) forming the floor (174) may include serviced panels (100) including lines for electricity (e), and fluid ((p) including gas, water and air) flow. The panels (nOO) forming the floor (174) may include lines and installations for communication, lighting, ducting, vents, and/or temperature regulation. However, preferably, the floor (174) comprises standard flooring panels, such as particle board rated for load bearing.

The above-described method may further include the step of constructing a ceiling (182) consisting only of the panels (nOO) included in the plurality of panels (nOO). The panels (nOO) forming the ceiling (182) may include serviced panels (100) including lines for electricity for lighting, vents, fans and temperature regulation.

The building may include modular units or pods (60) that are adapted to be dropped into or on to the floor (174) to provide ready-made function rooms or wet areas, such as the kitchen (K), bathroom (WC) and laundry (L). The pods (60) may include factory-installed floor (174) panelling.

The overall dimensions of the building (160) is set by the specific dimensions of the panel (nOO) and is governed by the constraint that in any of the 2 lateral dimensions, the length is the sum of multiples of W/2. For example, the panels (200) for the external cladding of the external walls (162) is set to increments of width of 600mm, 1200mm and 2400mm dimensions. This limits the possible shapes and sizes of the building, and its layout. The available wall lengths, and hall and room dimensions, are determined by the available increments set by the panel (nOO) dimensions.

The building platform (170) including the foundations and flooring (70) do not include concrete slabs or concrete footings. Each building (160) made according to the invention stands on an array of adjustable stumps (176) in turn attached to metal plate footings of which the brand Surefoot™ is an example. The stumps (176) are preferably steel stumps. A footing subframe (171) is also preferably made of steel material. The footing subframe (171) may be bolted onto the metal footings (173). The steel stumps (176) are sat directly onto the diamond grid which in turn is laid on a lightly compacted soil base. The main load paths correspond to the supporting columns( 161) and these stumps (176) sit on the sure foot footings (173) which are a footing that uses micro piles rather than a concrete base. This is a major breakaway from conventional subfloor construction.

A soil preparation membrane is laid on top of the cleared site over the building footprint and extending therebeyond by at least lm. The membrane allows for small crane truck (see Fig. 40) deliveries and also provides a firm base for mobile scaffold and scissor lifts. The subfloor membrane (which is in the form of a diamond grid) provides a clean and safe working base. The grid soil stabilisation membrane enables the establishment of a flat and load bearing membrane. All footings are preferably based on a 40 mm thick Diamond Grid mesh that extends at least 1000 mm past the perimeter of the building footprint. Surefoot™ footings are preferred, although the invention envisages the use of any compatible gridbased load-bearing membrane that may be laid directly on prepared flat soil or land. The grid may be installed in accordance with the manufacturer's specifications. Driven pipes for the Surefoot footings may be driven through Diamond Grids.

The spacing (S) of the stumps and metal footings (173) is preferably determined by the specific unit dimensions of the panels (nOO) or standard load-bearing flooring sheets used to form the floor (174). Preferably, the spacing (S) is preferably based on 2400mm cross centres, set into 4800mm wide modules. The floor (174) comprises a subfloor (175) that uses high tensile steel box sections (177a-d) (refer to examples in Figs. 12a-d for sectional views.

The spacing (S) of the footings (173) is preferably based on 2.4 metre cross centres, set into 4.8 metre modules. The floor (174) comprises a subfloor (175) that uses high tensile steel box sections (177a-d) (refer to examples in Figs. 12a-d) for sectional views of bearers and joists (177). The subfloor (175) includes main bearers (177c-d) that have support brackets thereon.

The subfloor (175) sets a Top of Steel (TOS) elevation. The bearers and joists (177) are fixed using a unique fixing bracket (178). The bracket (178) is C-shaped. This flooring arrangement (70) minimises the overall depth of the sub floor (175) support structure without any compromise to strength.

The subfloor (175) utilises the fixing bracket (178) that (has the potential to) remove(s) the need for screw fixing the joists (177a-b) to the support brackets on the bearers (177c-d). This dramatically reduces the time required to assemble and fix the subfloor (175) framing.

The floor (174) TOS is set a minimum of +800mm off nominated ground level so as to provide a minimum ground clearance of 600mm under floor. This allows for easy access to and connection of all services (p,e,c). Preferably, however, the minimum underfloor clearance is 450mm (plus 200mm for a support beam) so TOS (top of steel or surface) is set at minimum 650mm above the diamond grid membrane. This is so that the access ramps required to meet the coding for government imposed regulations such as is provided under the Australian the National Disability Insurance Scheme (NDIS) etc are kept to the minimum length.

The subfloor (175) structure is then covered in flooring (70), The flooring may be in the form of flooring sheets. The flooring sheets preferably include plywood sheets (72). The plywood sheets (72) may comprise 19 - 21mm thick sheets, preferably 21mm thick. The thickness and accompanying strength and flex resistance of the flooring sheets (72) enables the floor (174) sheeting to accommodate maximum lateral support spacings of 600mm. Structural -grade plywood sheets (72) made using plantation pine, having Low formaldehyde emission, Super E0 < 3mg/L as tested to AS/NZS 2098.11 and FSC certified have the following bending and sheer-strength capacity:

In the prior art, flooring is typically comprised of 19mm - 22mm chipboard that is supported at 450mm centres and can also span 600mm.

The 21mm plywood flooring sheets (72) are supplied in 1200 x 2400mm lipped and grooved sheets. These sheets (72) fit perfectly with wet modules in the form of service pods (60). The pods (60) are ideally 4.8m in length, and optionally 1200, 2400, 3600 or 4800 mm in width. Therefore, there is zero waste from panel (72) offcuts, with the length and width of the pods being multiples of the dimensions of the sheets (72). Utilizing the pods (60) in the form of 4.8 metre modules minimises wastage of the sheets (72), reduces building layout options leading to more efficient and economical layouts that lend themselves to efficient and repeatable offsite production of key components.

Where M is the narrowest width of a piece of the sheeting (72) and therefore the lowest common denominator of the building's (160) dimensions, the house frame support structure including the building platform (170) is broken down into two sections (each N x M) in terms of the building's (160) width, together forming a building width 2 x N x M, where N is an integer, preferably in the range 4 - 20. Preferably N = 8 and M = 600mm. N and M are not arbitrary figures or values, but are determined by the preferred weight of individual building elements, such as sheets (72) and module panels (nOO) easily carriable by one ortwo workers, depending on load-lifting limits in the relevant jurisdiction. The house frame support structure including the building platform (170) is broken down into two 4.8 metre sections in terms of the building's (160) width, together forming a building width of 9.6m. The upper structure forming the roof (180) incorporates a full span truss (184) for lateral support of the building.

The trusses (184) are supported on square box steel (SHS) and rectangular hollow steel (RHS) section columns. The columns (161) are mounted to the building platform (170) by means of a purpose designed column fixing element (163). The columns (161) are mounted to the top of the stumps (176). The stumps (176) are specifically designed adjustable stumps (176). The fixing element (163) and the adjustability of the stumps (176) enabling these columns (161) to be installed using the fixing element (163) without any fasteners, screws, bolts or other fixings protruding into the plane and space of the adjacent wall panel units (nOO). These fixing elements (163) is a unique fixing system. It is not used in a domestic building.

All builds incorporate at least two prefabricated "Bathroom pods" (WC). These bathroom pods (WC) may be an ensuite, a combination bathroom/laundry, a butler's pantry and kitchen, or a variety of other combinations. These service pods (60) supply a fully equipped and finished "wet area". These areas have traditionally caused the most numbers of defects on site and are the most trade labour intensive and most costly rooms of any build. "Bathroom pods" are not in themselves a unique product as they have been used extensively on large scale projects in the past. However, the present building method expands these pods into a Building Service Pod. To Applicant's knowledge, this has not been done previously on any build.

Into the pod (60) are added any other services (p,e,c) that must be managed and distributed throughout the rest of the building (160). The pods (60) are positioned to be available to service multiple areas of the building (160).

The bathroom pod (WC) is configured to supply external services on a first internal wall (165) that can provide electrical services (e), and water and waste services (p) for the adjoining butler's pantry (b) or kitchen (K). On a second wall (167), the bathroom pod (WC) is configured to provide water, electrical and waste service (p,e) for the laundry (L). A third service wall (169) of the bathroom pod (WC) is configured to provide services (e) in the form of light fittings, power outlets and switches for the doors (400), lights and other appliances.

The building (160) therefore includes a critical service pod (62), which may be the bathroom (WC) or kitchen (K), in a new building method that is designed to improve on the singularly focused prefabricated enclosed or discrete and self-contained bathroom or other drop-in, wet area module, of the prior art. The bathroom pod (WC) or kitchen pod (K) can service multiple areas and optimise the off-site construction for other areas and services (e,c,p) required within the building (160).

The building includes an electrical box (64) that includes a fuse box and safety switches for the entire building (160), communication services (c) in the form of a smart home operating system. The electrical box (64) is preferably housed in a bench or cupboards (61), the cabinetry therefor incorporated during offsite prefabrication of the critical service pod (62). This enhancement of what has traditionally been a singular focused solution is a major broadening of the building concept and maximises prefabrication in a way not previously utilised. It allows the build to minimise or at times totally remove any site running of water and waste drainage except for the primary connections.

Preferably, all of the internal walls (164) are incorporated in the prefabricated module panel (nOO) elements while keeping the maximum transportable width dimension of the panels (nOO) to 2400mm.

Preferably, utilising just three fully serviced prefabricated pods (K,WC,L) allows the entire inside of the building to be provided with all cupboards and wardrobes for the bedrooms (Bn) in place on the reverse face of the prefabricated pods (K,WC,L). All ensuites and bathrooms (WC) are fitted. The laundry (L) services (p,e) along with all cabinetry and bench tops, are fitted. All service connections (e,c,p), including those for the kitchen (K) are incorporated.

The accuracy and consistency in predictability of placement and positioning of these service and housing elements (e,c,p,61,64) determine the predictable positioning of other internal elements, such as kitchen cupboards together with all appliances (electrical outlets, fans and air conditioners, exhaust hoods, cooking appliances, for example), to be prefabricated, whereby each service pod (60) installed as a single finished element on site. This level of accuracy is not possible with a conventional onsite stick build, even when prefabricated wall forming is used.

The building (160) layout whereby the services are housed in the walls (164,165,167,169) of the service pods (60) also means that, unlike the prior art, it is not necessary to include the electrical and other services (e,c,p) in the wall framing of a building. By positioning the electrical services (e), such as light fittings, switches and power outlets within the prefabricated cabinetry of the benches or cupboards (61), there is no need for a more traditional onsite work of "tradesman run, site positioned electrical cabling". One or two relatively simple under bench (61) connections (e) replaces the prior art build process and electrical infrastructure involving days of site work and excessive untraced wiring cables.

The invention further includes a method of building including pre-mapping the building (160) layout using a 3D model ( (see Figs. 14a - 18f). All services (e,c,p) are accurately determined in the 3D model (200), enabling significant prefabrication of items such as wiring looms.

Every wall stud, pipe, electrical conduit, and light fitting, etc., is accurately located within the 3D model (200). This level of detail is not utilised on domestic builds because most of the work is built in situ with little, if any, ability to accurately predict, and determine without investigation, where the electrical, plumbing and communication services have been placed. A preferred method of constructing a building (160,660) on site according to the invention includes the steps of:

(e) making on site a building platform (170) on a footing subframe (171) and stumps (176), the building platform (170) defining a perimeter (166);

(f) erecting a structural frame (610) around the perimeter (166) of the building (160,660), the structural frame (610) consisting of a plurality of columns (161), each column mounted on the stumps (176) using a fixing element (163);

(g) installing a roof (180) whereby the peripheral structural frame (610) acts to support the roof components (180,680), allowing the framing (610), including both internal and external wall framing, to be non-load bearing; and

(h) installing a plurality of wall panels (nOO) after the roof (180) has been installed.

Conventional domestic builds have all the roof and wall framing installed and then the roof is clad and then the walls are clad.

The main support structure of the building (160) is the perimeter (n66) of the rectangular plan (refer to Figs. 10 and 15(b)) of the building (160). The columns 161 are made of mild steel. The columns (161) support the roof (180) and its roof frame (183). The roof frame (183) includes the roof trusses (184). The roof trusses are gable-shaped. The roof trusses (184) are fabricated from high tensile, lightweight framing. The roof trusses (184) span the width of the building (160). The roof truss structural elements (184) are set at a maximum of 4.8 metre centres, whereby to span the side columns (161) that are spaced twice that length (9.6m). The fabricated gable shaped trusses (184) support a large composite ridge beam (183). The ridge beam (180) comprises two 250mm x 50mm box beams (see Fig. 12(d)) fixed together to form an integral combination beam element 250mm deep x 100mm wide.

Along the side of the building (160) there are placed 5 of the columns (161) of the perimeter (66,166) structure. The columns (161) are either 89mm x 89mm x 5 mild steel SHS or a 200mm x 50mm high tensile steel box beam (see Fig. 12(c)). The columns (161) are set at nominally 4.8 metre centres. These columns (161) are mounted using the unique, purpose designed fixing brackets (760) at their base (161a). Such an arrangement integrates seamlessly into a purpose designed stump (176) and metal footing (173) combination.

The stump mounted post brackets (760) extend from a top of the stump (176). In Figs, lib - f, therefore is shown a non-corner stump (176a) and post bracket (760a). The top (76a) of the stump (176) includes a horizontal spacer plate (76b) vertically adjustably spaced from a body (76c) of the stump (176) to accommodate varying levels of the ground on which the stump (176) is located. At least one small post, and preferably a pair of small posts, (76d) extend(s) upwardly from the spacer plate (76b) and support a base (76e) of the bracket (760a). The small post(s) (76d) is/are eccentrically, off-centre or non centrally located atop the spacer plate (76b). The bracket (760a) comprises a pair of side walls (76f) that are coextensive and spaced laterally from each other and, with the base (76e), define a channel (76g) therebetween whereby to accommodate a structural floor beam. The side walls (76f) may have a lower edge (76h) that is shorter than a vertically spaced upper edge (76i), although the upper wall (761) may be stepped as shown in Figs, lib - f. An upper portion (76j) of the bracket (760a) is cantilevered to hang outside a footprint (17) of the stump body (76c). The cantilevered edges (76k) of the side walls (76f) are inclined inwardly from the upper portion (76j) toward the stump top (76a). Mounted immediately above at least a portion of the cantilevered upper portion (76j) is a post-supporting sub-bracket (76L). The sub-bracket (76L) has a sub-bracket base (76m) adapted to straddle the top edges of the walls (76f) and a pair of laterally spaced side plates (76n) that, together with the sub-bracket base (76m), define a wall post receiving channel (76o). The wall post receiving channel (76o) may also be suitable to receive a bottom edge of a panel (nOO).

In Figs, llg-j, there is shown another stump mounted post bracket (760b). The structure of this bracket (760b) is similar to that of bracket (760a) and like features should be referenced with like reference numerals. In terms of differences of bracket (76b) compared (76a), the lower edge of the side walls is longer than the corresponding upper edge and edges of the side walls are inclined inwardly upwardly. The bracket (760b) is wholly contained within the footprint of the stump body and the upper walls terminate at their spaced opposed upper edges with a small rectangular or square upper sub-bracket base that caps the entirety of the upper wall edges. The sub-bracket base supports a short square sectioned hollow and upstanding stub adapted to receive the corresponding foot of a vertical post (161a) or panel (nOO).

As best seen in Figs, llh-i, the small posts (76di) of bracket 760b are laterally off-centre and, consequently, the stump mounted post bracket (760) is also oriented to one side of the stump top (76a i) . This eccentricity allows for another beam to be accommodated on the outside of the bracket (760b) in a space immediately under a portion of the upstanding stub sub-bracket (76Lii). The bracket (760b) is suitable and adapted for corner stumps (176c) located at the corners (612) of the building (160) where a pair of perpendicularly extending beams of equal height meet and are supported at the corner (612).

As best seen in Figs. llL-m, the small posts (76dii) of bracket (760c) are centrally located along a centreline of the external stump ((176b). As shown in Figs. 16b-d, the stump (176b) is advantageously located to support an external wall (162) of the building (160). The bracket (760c) is adapted to support a single beam of the floor (174) or subfloor (175).

Turning to Figs. 18a-j, there is shown ridge brackets made according to one embodiment of the invention. A shown in Figs. 18g and 18i, the single (80a) and double (80b) ridge brackets may be formed from sheet steel, stamped or laser cut to shape with appropriate apertures, and folded along fold lines (82a-b). A single fold line (82a) defines a join line between a pair of complementary half sections (84a, b). Each complementary section (84a, b) has a central portion (86a, b) and a pair of mirror image wings (85a-d) extending either side of the central portion (86a, b). The opposed wings (85a, c) and (85b, d) each diverge away from each other as they extend from their respective central portions (86a, b) in the blank form. However, when the central portions (86a, b) are marginally rotated relative to each other about an axis extending through the join line (82a), the opposed divergent edges of the wings (85a-d) come together as shown in Figs. 18h,j. A complementary tab or tongue (87a-b,c-d) of each wing (85a-d) is received in a complementary slot or recess (88a-b,c-d) to provide a bracket (80a, b) adapted to join an abutting pair of serially aligned rafters (181), or a double pair of rafters (181) as shown in Figs. 18a, f. where the abutting rafters are angled relative to one another at their joint apex. The ends (89) of the brackets (80a-b) are folded to rest and be fastened to one or two ridge beams (183).

In Figs. 19(a)-(e ), there is shown a framing bracket (90) formed from a blank (90a) for joining beam T-sections in the floor and subfloor assemblies (174,175), as best seen in Fig. 19(a). The bracket (90) defines a channel (92) closed at one end and having a base (91), a pair of long spaced and parallel side walls (93) extending perpendicularly from the base (91), and an end plate (94) adapted to close one end of the otherwise open channel (92). The bracket (90) further has a pair of internally facing barbs (95) in the side walls (93) and a pair of internally directed barbs (96) at the entrance (97) to the channel (92). The channel (92) and barbs (95,96) are adapted to secure a free end of a T-butted beam (177 as the beam end enters the channel (92) from above, the barbs (95,96) catching and gripping the external surface of the beam (177) in a T-section position with a bearer.

A ridge bracket saddle and a ridge beam bracket are also shown in Figs. 20(b) - 22.

In Figs. 23(a) - (c), there is shown a panel install frame trolley (30) comprising a frame (36) mounting a support wall (31) to rest the panel (nOO) against, a short ground- level lip (32) fronting an underside skid (33) to facilitate the slotting of the bottom edge of the panel into position, and a pair of rear trolley wheels (34) for manoeuvrability, the trolley operable by manipulations of a rearwardly extending handle (35).

The roof (180) comprises a system of 450mm deep trusses that span the 4.8 metres between the supporting columns (161). The trusses (184) are fabricated from high tensile lightweight framing and are fixed at their respective ends (185) to the main structural support columns or posts (161). In the preferred embodiment shown in Figs. 24 and 27a-b, the building includes box beams (284) of the dimension profile 200mm x 20mm instead of trusses (184).

The combination of perimeter support steel with columns (161) at 4.8 metre centres combined with a ridge beam (183) fixed between gable shaped roof trusses (184) provide the support required for the prefabricated fully clad roofing panels (500). One method of installing the roof panels (500) that does require heavy lifting machinery involves utilizing an on-site crane truck that lifts and places the roof panels (500) into their final location on the roof frame as part of a progressive build. The building (160) is progressively built in discrete sections (NxM). The sections are dimensioned to be a maximum length, being half of the full width of the building (160). The length of each section is aligned with the lateral direction of the building and is about 6500mm, being half of the total width of the rectangular-shaped building (160), which total is about 13200mm. The width of each section may the sum of a factor of 1200mm, but advantageously is 4.8 metres.

The width of the pods (60) is dependent on a transport limitation in that the transport vehicle can take wide loads up to 2400mm. The pods (60) may be any transportable length having a factor of 1200mm, and preferably have a maximum length of 6000mm, although a pos with a length up to 7000mm would be achievable as it would be manageable by a small crane truck. Once the steelwork and ridge beam in the section are installed, the roof panels (500) for the section will be installed.

This process is then repeated for the next 4.8 metre section and so on until the entire building (160) is completed. In some installs of the building (160), the external walls (162) and the service pods (60) will be installed during the progressive build so as to bring additional structural integrity to the structure of the unfinished building.

The building method preferably involves installation of the roof panels (500) in a progressive build. The small crane truck may be backed up to the first 4800 section whereby it simply drops the roof panels (500) into place. They are located using M12 studs that drop into prepunched holes in the ridge beams (183) and perimeter beams (284), therefore preventing any lateral movement of the roof panels (500) prior to fitting the ridge brackets (80a-b). The roof panels (500) are restrained from sliding off the ridge beam (183) by the shear capacity of the M12 pins which is more than 50 times the capacity required, so that any chance of lateral movement of the roof panels (500) is negated..

The columns (161) and supporting trusses (184) may then be installed, and then the rest of the roof (180) installed. The internal and external wall (162,164) frames are then installed. This method significantly reduces the construction time on site. With the floor (70), the main wall and roof supporting structure (columns 161) installed, the external (164) and internal walls (162) in the form of wall framing and the panels (nOO) are then installed.

The external panels (nOO) are manufactured using lightweight steel framing profiles (see Figs. 12a - e). The panels (nOO) are nominally 1200mm wide and either 2400 or 2700mm high. They are clad on their inside face, have internal insulation fitted in their core (n50), and have a weatherproof external cladding sheet fitted to their external face. This allows these panels (nOO) to be mass produced and sent to site on a pallet and then installed. Installation preferably includes the panels (nOO) being received into a receiving channel at their top and trapped in position using retaining angles at their base.

Preferably, the external wall panels (nOO) are clad on both their external and internal face and go to site as a complete unit. These wall panels (nOO) are designed to have minimum services installed. In those instances where an A/C unit must be fitted, any of the service lines (e,p) required will be fitted into the panel (nOO) prior to delivery to site. This will include any plumbing or power services (p,e) so that there is no requirement for these services (p,c,e) to be site run, except to a single point on the subfloor (175).

The ceilings (182) may be a nominal height from the floor (174) of 2400mm or 2700mm, or may be raked to a minimum height of 2850mm for living and dining areas (D). Preferably, the ceilings (182) are 2400mm in all bedrooms (Bn), and all pods (60), including the bathroom and ensuite (WC), kitchen (K) and laundry (L) pods. A height of 2700mm is an achievable option for the non-dining areas (Bn,WC,L, K), but due to the consequent heights required of the panels (nOO), such a ceiling height does not allow the same efficiencies in the use of materials as a uniform ceiling (182) height of 2400mm.

However, preferably the ceilings (182) over the living and dining areas (D) are raked. Raking ceilings are approx. 2850mm - 3000mm, preferably 2900mm at the lowest point on the inside of the walls (162).

The internal panels will also be fully clad and meet all requirements regarding insulation and fireproofing. It is envisaged that these internal panels will be fixed to the ceiling joists and underside of the gable trusses using a similar system of receiving channel at the top and locating angles at the base.

Other design points for this building (160) and the building method are as follows:

External wall panels (nOO) can be supplied with a width of 2400 mm to include an 1800 wide window assembly. All windows should ideally start +750mm from FFL and be only 1200mm high.

Total building width should not exceed 13.2 Metres as each rafter span is then only approx. 6.5metres

The Gable roof slope should be 10 deg with nominal 600mm eaves at the ends and sides of the building. Appliances, such as lights and ceiling fans are ideally mounted on the ridge beam (183).

Ideally Bedroom windows at either 600mm or 1800mm wide (all 1200 high) at + 750 from FFL in bedrooms.

Living areas can have full depth windows if required but again in those preferred widths.

All serviced wet areas should be adjoining and nothing wider than 2400 so as to be easily transported.

For a standard master ensuite prefer 1800 or 2400 x 2400 if possible and a shared bathroom with double basin 2400 or 3600 x 2400.

Similar with laundries, 1800 x 2400 and Kitchens need the sink, fridge and dishwasher on an adjoining pod wall.

So long as one dimension of these service pods is 2400 the other can vary but preferably in multiples of 1200.

The NDIS ensuites can be 4200 x 2400 wide as these require much larger open areas.

The wet area pods act as a service pod: Ensuite pod may service the laundry and kitchen.

All power points / light fittings are serviced from these pods.

In kitchen, there is no preferably plumbing or sinks to any island benches. Draws and cupboards only. Where additional services are required, these are supplied from the subfloor.

Power points for the remainder of the kitchen are situated on the sides or within the cupboards.

Built in robes to adjoining bedrooms on the same wall (stepped side by side).

Preliminary Site Works:

When a building site is demolished or otherwise prepared and cleared, the same contractor is used to excavate for the services.

There is no natural gas or telephone connections in the build, so that the services required include: c. Electrical services including 3 phase installation for electric vehicles ("EV") and other 3 phase uses, including instantaneous electric hot water; and d. Plumbing necessities, such as sewerage and storm water.

A site review and safety check for existing hazards (such as gas or water lines) is conducted before site connections are installed prior to building start. All excavations are backfilled, the site is then levelled, compacted and allowed to settle. All service points are accurately surveyed so that they can be included within a 3D construction model. Complete site survey, soil tests, and replace all fences (if acceptable to neighbours).

Building started on Site.

Lay down a soil stabilisation membrane in readiness for build to start.

The membrane extends (for example about 1200mm) beyond the building line or footprint. The membrane allows for crane truck deliveries and also provides a firm base for mobile scaffold and scissor lifts. The subfloor membrane (diamond grid) provides a clean and safe working base for mobile scaffold and scissor lifts.

Install the first module of subfloor steelwork utilising Surefoot™ footings where required.

Surefoot™ footings do not require concrete therefore eliminating stump holes and footing inspections by Building Surveyor.

Erect first 4800mm long x 12000mm wide bay of subfloor framing, corresponding to the first module forming part of the building. Figs. 24-26 show the erection of the subfloor with stumps, support beams, braces, joists and blocking in place.

Square up framing, level and add bracing before installing micro piles for the stump supports. Install electrical wiring loom and fix to bearers. As shown in FIG. 26, fit flooring panels. Ensure wiring is located and pulled through flooring. Create a peripheral frame

As shown in Fig. 27a, the frame comprising main upright and/or vertical posts is erected next. This is followed by the installation of perimeter box beams as shown. This involves standing all main support posts, and then installing the perimeter box beams.

One or more internal wall frames may then be installed.

At least one perimeter wall panel is used to stabilise and brace the main support structure, including the perimeter frame. For added reinforcement, at least one internal wall panel is used to stabilise and brace the internal walls, and as a consequence, brace and stabilise the main support structure.

To provide rigidity and reinforcement to the internal and perimeter walls, wall panels are therefore installed. These provide a bracing effect, keeping the frame rigid during this intermediate stage before all wall panels can be installed. Therefore, the initial placement of the first and second wall panels installed is strategic. At least a first bracing wall panel is installed in a wall to lie in a first plane in a first direction DI and a second bracing wall panel is installed in a second wall to lie in a second plane substantially transverse and perpendicular, to the first plane.

The sequence and volume in which bracing perimeter and wall panels are installed is determined by the specific requirements of each individual build. In the present example shown in Fig. 27b, the bracing wall panels are installed on two spaced and parallel side walls and one end wall. Accordingly, the building is braced against lateral wind forces having a vector of direction DI and/or a direction transverse thereto.

Install ceiling joists and internal roof support frames. In Fig. 28, there is shown the progress of the build of the first module in which ceiling joists and internal roof support frames are installed.

Install roof panels and any remaining perimeter and internal wall panels.

At least some of the roof panels in each internal area of the building incorporate PoE (Power over Ethernet) lighting. The PoE fixtures are included in at least one roof panel per internal area. An internal area is an interior part of the building bordered by external and/or internal walls. The PoE lighting only requires Cat 6 cabling to be used on site, thereby significantly decreasing install times and lowering costs for supply of power for lighting to the roof panels. The build continue with the addition of second and subsequent modules, each having a standard width of 4800mm to conform the specific unit dimension. In the present example, the specific unit dimension is 4800mm.

The first module is a first-erected section of the building. The second and subsequent modules are similar to the first module. The second module may be continuous and contiguous with the first module. Modules adjacent to each other share an internal wall common to each (the common wall). The common wall shares foundations, stumps, braces, floor and roof beams along the common wall line of the that common wall for the adjacent modules.

As shown in Fig. 28, the first module is discrete and sufficient as a stand-alone building structure, with complete foundation, floor, walls and roof structures. Figs. 29 - 31 show that the second module is added on to the first module as an extension of the first module, sharing the common wall and associated foundation, floor and roof structures on the common wall line. The second module has no building elements that are different to those used in the first module. Therefore, the same mass fabricated components used to make the first module are replicated in the second module, with the exception of the shared components of the common wall.

The main floor and roof beams transverse to the long sides of the first module are extended by coaxial beams extending along the same axis as each main transverse beam of the first module. The second module is sandwiched or located between the first module and a subsequent third module. The second and third modules share a second common wall and associated foundation, floor and roof structures on the second common wall line.

In a further example of the building, the building includes prefabricated wet areas with plumbing lines and fixtures built in. The location of plumbing inlets and outlets for water lines and drains are specific and consistent in each wet area so that they line up with predictable complementary incoming and outgoing building fluid lines. The wet areas are provided in the form of pods. The wet areas comprise a series of bathroom and laundry pods. Each pod is delivered to the building site as a complete unit. Each pod has all fittings, piping, wiring, floor coverings, cabinets, and tapware installed. The series of pods may include a kitchen pod.

Each pod is a complete unit with electrical and plumbing inlets and outlets located and complementarily configured to connect to services, such as electrical or plumbing mains or public utility services on site. The pod units form the functional centre of the building. Electrical power is terminated within the pod units. A smart home management system is incorporated in the pod units. The PoE lighting systems terminate at these locations, i.e. within the pods.

In a POE lighting system, each light fitting has, in effect, its own IP address. These individual fittings are connected to a hub that can manage a multiple of fittings, for example 6 individual fittings. The hubs are connected to a central control module. The central control module runs and can be used to operate the system. Movement senses, light senses etc may also be used to activate an individual or collective of light fittings, but all of these individual items ultimately get managed by the central control module. The central control module can be paired with a smart phone. Devices such as A/c and security systems can also be integrated and managed by a master control module. The POE system is mounted into the pod at the prefabrication stage and then a series of large hubs accept the cat 6 cables coming from the smaller hubs. Accordingly, it is a plug and play system similar to data cable points in a commercial or domestic build for pc connectivity.

All wet areas are incorporated into a prefabricated assembly in the form of the pod units that are built offsite.

In this example including discrete wet area pod units, the next stage of the build incorporates subfloor supports for the pods as shown in Fig. 32a. Figs. 32a-e show the installation and placement of a pair of wet area pods on the wet area sub-floor supports.

A final stage of a building incorporates a garage/utility room and/or a carport. This involves the installation of the steelwork associated with the garage/utility room and/or carport, as illustrated in Figs. 33a - e. A facade may be added to a front (street-side) of the building to improve street appeal.

All building components are transported using a small rigid body crane truck of the type illustrated in FIG. 40. The transport using the truck and the associated prefabrication method and building sequencing system allows these builds to be installed on any prepared block. Because of the adaptable stump heights, even sloping blocks can be accommodated. The pods are preferably relatively small and therefore transportable by the small crane truck as they are not regarded as oversize loads and do not require special permits or wide load clearance. They are easily transportable down a normal suburban street.

The fabrication and sequencing building method described above is a revolution in the building sector. The building in the form of a house is made in modules of a standard width of 4800mm, which is a specific unit dimension according to the preferred embodiment. The embodiment uses exclusively smaller prefabricated components and delivers and installs fully completed and assembled modules to site. It allows for mass production of the smaller individual wall and roof panels. The pods go to site as a sealed unit.

The specific unit dimension for the module(s) is(are) 4800mm. The specific unit dimension is the same for each of the modules which in turn have the same footprint dimensions. The length of the subsequent modules could be less than their preceding adjacent module so that the common wall is at least as long as the subsequent module. The maximum beam lengths extending transverse of the longitudinal side wall axis may therefore be limited to such lengths, for example 2400mm or 4800mm. The length of the units in the direction of the long side wall axis is less strategically important, but must be manageable, for example in the range 6000mm - 12000mm. The purlin spacing is standardised for the preferred embodiment at 1200mm C2C.

Referring to Fig. 33e, the building comprises 5 modules of 4800mm x a nominal 13200mm wide for a total footprint of 316.8m² + the garage extending this build to approx. 324m². The build including landscaping may be completed in 8 - 12 weeks, with ongoing efficiencies reducing this build time to closer to 8 weeks. Each 4.8m x 13.2m module should take a week to complete, leaving 3 weeks for finishing trades such as painting, rendering and external works. , The prefabrication method allows "JUST IN TIME" delivery of small building elements and components. These components include fully assembled cabinetry to be incorporated in the pods or, in fact, wherever required in the building. In this manner, completely assembled features that are too large to fit through finish-build access portals such as doors can be accommodated in the building. Such features include large tables and other furniture that may be located within the relevant module before lock-up stage and before the external walls and/or roof are completed, for example at the stage shown in Fig. 28 with the roof installed for weather proofing.

There are virtually no waste materials on site because all small building elements and components go to site complete and ready to install. There is no need for cutting or trimming. For example, gutters, flashings and downpipes are completed, prefabricated and cut to size, and ready to simply fit or install on site.

The accuracy of the building method, including the prefabrication and build sequencing, allows for the maximum utilisation of prefabricated elements. Items such as feature walls, wine cellars, entertainment units, security systems, air conditioning (A/C) systems, are all incorporated into a dimensionally accurate 3D detailed model. This detailed model is used to drive all of the prefabrication using Numerical control (NC).

The prefabrication method is implemented in a purposed designed fabrication and assembly plant. The prefabrication method derives all data necessary to make each of the small building elements and components directly from the 3D model. The 3D model may be built using publicly available commercial software capable of computer aided design (CAD), mechanical CAD (MCAD), and/or Computer Aided Manufacturing (CAM), such as Solidworks™, Fusion™, AutoCAD™.

A layout shown in Fig. 34 (and substations shown in magnified view in Figs. 35ai,aii,35b,37,38a and 39a) illustrates a facility with various production stations in a prefabrication.

The facility can produce all framing, roof sheeting and cabinetry for 300 - 500 x 300m2 builds per annum. Assembled and completed building elements are either transported to the building site in JIT fashion or stored offsite. Management of production and stock utilises "Just in Time" (JIT) workflows. Of course, refinement of building tolerances, increased efficiency of assembly sequences, storage and transport systems as well as refinement and streamlining of on-site construction is an ongoing process.

The facility utilises automation involving robotic assisted loading, manufacture, assembly and storage processes.

Key qualified tradespeople are preferably used to establish and oversee the manufacturing and preassembly involved in the prefabrication method, reducing official oversight and inspections that are required on site.

There are several specific machining areas within the plant. ii. Box Beam Rolling (see Fig. 37a); iii. Wall frame rolling (see Figs. 37b-c); iv. Roof sheet rolling (see Fig. 35b); v. Tube processing, (laser) (see Figs. 39a-b); vi. Cabinetry smart factory (see Fig. 35ai - aii); vii. Coil fed laser cutting; viii. Plate fed laser cutting (see Fig. 38a-b); and ix. Robotically fed press brake folding station (see Fig. 38a-b).

Box Beam Rolling Machine.

A box beam rolling machine is shown in Fig. 37a that is used to manufacture box beams as depicted in Figs. 12a-d by rolling and pressing together two complementary channel sections to form a strong box form. Each channel section includes a base wall from which perpendicularly extend spaced arms, namely a long arm and a short tab arm, with a terminal end of each long arm of each section overlaying the short tab arm of the other section to place in mating positions, and seaming to complete the rectangular box section.

The box rolling machine includes the features of uncoiling and levelling the metal sheet, feeding and guiding into the machine, punching holes in predetermined locations, guiding further, roll forming, printing where required, cutting, conveying, overturning, covering or plating, and pushing to mating positions, seaming and running out the finished box beam product.

The box beam rolling machines are purpose built and adapted to be configured to form at one time any one of a number of different sized box beams as depicted in Figs 12a-d by cutting the sheet lengthwise to vary the length of the long arm of the channel sections.

Bracketing System

The box beams are punched or cut to form flanges, apertures or ledges adapted cooperate with complementary engagement and/or support features on the brackets shown in Figs. 18a-j and 19a-e. In finished form, the box beams are adapted to be joined by the bracket system comprising the brackets. This bracket system reduces or eliminates the use of fasteners to fix beams to one other as shown in Fig. 19a.

Fasteners are therefore totally eliminated or at least sparingly used in assembly of framework and support structures in the prefabrication and building onsite stages. The brackets are effective to join the beams in T-joints, cross-joints, overlays, and series- or inline-joins, both coaxial and angled, by means of the engagement of the brackets to the profile of the beams and other frame members, and to the complementary engagement features on the beams. This reduces the need to position and form apertures and effect entry of fasteners. The bracketing system reduces time to assemble and install roof frames and sub floor support members, both in the prefabrication stage, and onsite. This reduces assembly times, simplifies construction on site and significantly reduces build costs.

3-D model

The data used to drive these rolling machines is extracted directly from the modelling software of the 3D computer model of the various build designs.

Wall Frame Rolling Machine.

The prefabrication method includes the use of a wall frame rolling machine that has specific design elements not generally utilised by other similar prior art machines. Additional punching sets are provided. This assists the implementation of the build method on site.

Most roll framing machines that are used to form wall frames are configured on the assumption that services such as plumbing and electrical are site run, that placement and specifications such as capacity and quantity are determined by experienced tradesman on site as the build progresses. Therefore, most rolling machines allow for additional service holes throughout the frame.

The preferred building includes roof cover in the form of metal roof sheeting. The roof sheets are first formed in partial longitudinal sections that comprise ridges defining 2 - 3 valleys. The roof sheet sections are shown in Figs. 36a-b. The valleys may be substantially flat or may be shallowly longitudinally corrugated. The valleys lie in parallel. The roof sheet rolling machine produces identical sections that are broad roof sheets sized for metrically measured spans.

The roof sheet profiles are sized to specifically cover standard coverage roof spans. The roof sections are rolled in sheets with coverage that exactly match the specific unit dimension of 4800mm in terms of span, i.e. the width of the roof sections are a product of the standard 1200mm spacing. There are two sheet profiles. One that is 300mm wide and the other that is 600mm wide. These two sheet profiles suit all of the builds, including the 1200mm and 4800mm spacings and spans. A pierce fixing method is used ensure that the build satisfies all wind categories. Both sheet profiles will span the preferable standard of 1200mm set for the purlin spaces. This may be integrated with roof-mounted solar panel support grids in the final build. The roof panels (500) are attached to the roof frame by pierce fixing to ensure that the roof cladding is secure, even in very high wind weather. The pierce fixing is carried out to perform a dual purpose of providing a mounting and fixment for solar panels. The pierce fixing includes fasteners that extend through inverted channels or rails that are so fixed to be positioned proud on an upper surface of the roof panel. The channels or rails are adapted to receive complementary engagement means of solar panels, so that the roof panel fixment is also used to mount and secure the solar panels. The roof panels therefore incorporate the solar panel fixing channels as part of their mounting assembly. Obviously, solar panels will not cover the entire roof, but the pierce fixing is still effected at these locations. Therefore, for consistency, all roof panels (500) are pierce fixed. Therefore, higher wind load certification is achieved so that the same assembly can be used in higher wind load locations without the need to alter the assembly programming or method.

Tube Processing Laser Machine.

A tube processing laser machine with a tube processing line that suitable for manufacturing tubes is provided in the prefabrication stage and is shown in FIG. 39a-b.

The tube processing line has an auto load capacity that enables the loading of a bundle of at least 10, and preferably at least 20 tubes that are 6000mm long. This machine can produce all of the main support posts and steel stumps 176. The stumps 176 are preferably integrated with their footings so that there is no need to weld these elements. In fact, there is no need to weld any elements in the build according to the invention. The posts use a unique clamping system that reduces cost, makes assembly very quick, and provides a better surface treatment.

Cabinetry Smart Station

The prefabrication plant further includes a cabinetry fabrication station as shown in Figs. 34, and 35ai-aii. It can complete all processing of a laminated sheet with no human involvement. It can mark, cut, edge, rebate, drill on a fully automated production line. It can produce laminated sheets in a variety of dimensions. Preferably, the sheets are initially produced as 1200mm wide x 2400mm long sheets. It can process sheet thicknesses from 12mm up to 38mm in thickness in a variety of sheet types.

This cabinetry fabrication station can fabricate and preassemble all cabinetry for multiple builds. It can do all wardrobe units, feature wall units, kitchen cabinets, laundry cupboards, bathroom cabinets, feature shelving. Virtually any shelving or cabinet required can be manufactured through this processing line.

The 3D design model can produce precisely dimensions and configured cabinetry to minimise waste and time on site.

Coil and Plate fed laser cutting and Robotically fed Press Brake folding stations.

These three machines illustrated in Figs. 38a-b, when coupled with the brake press, can cut, fold and bend all of the brackets used in the builds. The extensive use of box beams and SHS steel members while extremely efficient structurally, does present issues in regard to connections. Therefore, in accordance with the invention, there have been developed unique plate brackets that allow the operator to build quickly on site. The brackets are cost effective while enhancing the structural capacity of the box shaped members.

DEFINITIONS, DICTIONARY AND EXPLANATIONS

Throughout the specification and claims the word "comprise" and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word "comprise" and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.

Whilst the principles of this building method and components therefor has broad application to buildings in general, a reference to the word "building" in this specification is generally a reference to a domestic dwelling, such as a house or unit, including a dwelling for public housing, including housing for the disabled, including those with visibility, mobility or intellectual challenges.

The term "small building element" in this specification means a manufactured item being a subunit of a building that is portable, weighs less than 100kg and is manually moveable by at most one or two workers. Examples are beams, panels and posts. Small building components are components such as wet area pods that are transportable and manipulatable onsite by a small crane truck.

The term "lowest common denominator" in this specification is a standard width of a small building element, such as 1200mm for a floor or wall panel. The repetition in singles or multiples of this dimension in the sizing of the small building elements, such as the floor and/or wall panels, enables the easy design of the building in multiples of the lowest common denominator.

The term "module" in this specification means a discrete building sub-unit that, when completely assembled, has a minimum footprint having a length and width that is the product of a single or multiple of the lowest common dimension denominator. For example, the module may have a footprint with a length or width of 4800mm based on a lowest common denominator of 1200mm.

The term "mass produced" in this specification means the production of sufficient numbers of the small building element to supply enough small building elements for fifty or more modules.

In the present specification, the term "integral" means formed of one body in a single process. In particular, the term "integrally formed" means formed of the one body without postforming attachment of separately formed component parts. That is, "integrally formed" and the similar term "unitarily formed" mean formed in a single forming process and do not include post-forming attachment of component parts by means of fastener or other component fixing substances or methods.

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, which will usually be apparent from the context.

It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention. The features and components of each of the embodiments of the invention described in the detailed description and/or depicted in the accompanying drawings may be interchangeable as required, with regard to functional equivalency and compatibility. A feature or component described with reference to one but not all embodiments, if functionally and dimensionally compatible as an addition with another embodiment herein described, or substitutable with a corresponding feature or component of that other embodiment in relation to which it has not been expressly described, should be read as a potential addition or substitution to that other embodiment and as being within the scope of the invention. Furthermore, in considering a feature or component that is described in relation a particular embodiment but may be omitted from the embodiment without losing the functionality characterising the invention and without departing from the scope of the invention, unless the context and expressions used in describing the embodiment imputes that the feature or component is essential to the invention as broadly described, the omittable feature or component may be read as not being included in the embodiment.

Claims

The claims:

1. A method for constructing the building, including the steps of:

(A) prefabricating offsite elements and components of the building including:

2. The method as claimed in Claim 1, wherein prefabrication is completed in a single prefabrication plant at a single site that is adapted to supply small building elements and small building components to a multiple of separate building sites where additional buildings like the building are to be built.

3. The method as claimed in Claim 2, wherein the prefabrication plant is adapted to supply all building elements and components for at least 300 building sites per annum.

4. The method as claimed in Claim 2, wherein the prefabrication plant includes a station to perform the following: i. box beam rolling by rolling and pressing together two complementary channel sections to form a strong box form, each channel section including a base wall from which perpendicularly extend spaced arms, namely a long arm and a short tab arm, with a terminal end of each long arm of each section overlaying the short tab arm of the other section to place in mating positions, and seaming to complete the rectangular box section.

5. The method as claimed in Claim 2, including the step of manufacturing all small building elements and components at the prefabrication plant according to a detailed 3-D model of the building.

6. The method as claimed in Claim 1, wherein the method includes the steps of: i. installing a first floor support in a first module area corresponding to a first footprint of the first module ii. installing a first subfloor and a first floor layer on the first floor support; and ill. installing all electrical and plumbing services in or under the first subfloor and providing access to the services at the first floor layer level at predetermined locations. The method as claimed in Claim 4, including joining the box beams together onsite using a set of specialised brackets that engage with no welds. The method as claimed in Claim 4, including joining the box beams together onsite without the use of fasteners. The method as claimed in Claim 1, including the step of preparing the ground of the site for a building area corresponding to a building footprint of the building, including laying down a grid soil stabilisation membrane in readiness for the construction to start, the membrane covering the building footprint and extending about lm - 2m beyond the building footprint, the membrane providing a a firm, clean and safe working base for mobile scaffold and scissor lifts and a flat and load bearing membrane for foot, vehicle and access platform traffic A manufactured building:

(A) comprising only elements and components prefabricated offsite including: