AU2009201244A1 - Apparatus and method for constructing a building - Google Patents

Description

Pcrspc APPARATUS AND METHOD FOR CONSTRUCTING A BUILDING FIELD OF INVENTION This invention relates to an apparatus and method for constructing a building and a method for using the apparatus. More particularly, the invention relates to a modular 5 building component a inethod of constructing a building incorporating the component. 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 does not 10 relate to what is commonly or well known by the person skilled in the art, but assists in the understanding of the inventive step of the present invention of which the identification of pertinent prior art proposals is but one part. Domestic and commercial buildings are traditionally built from building materials brought to a building site. Each stage of building requires the attendance of specialist 15 tradesman, such as plumbers and electricians. Building regulations must be complied with so that construction can be halted at critical stages until certain steps are completed. Qualified tradesman such as carpenters, electricians, plumbers, cabinet makers, plasterers, tilers and painters must also be sequentially or concurrently coordinated to achieve as efficient and economical construction as possible. 20 However, non-attendance or delays associated with each specialty can compound organisational problems for the building supervisor. Tradesman scheduled to attend site for carrying out their specialty are unable to perform before completion of an . earlier feature in the building procedure. Another problem with building construction on site is weather damage, theft, 25 vandalism or accidental damage of building materials, particularly expensive items such as electrical and plumbing installations associated with wet areas. Such items may need to be left on site unattended, uninstalled and/or unsecured whilst delayed stages are completed. 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 IN VENTION 5 Accordingly, in one aspect of the invention there is provided: a transportable core for a wet area of a building including: an attachment for attaching a lifting mechanism; at least one electrical or plumbed installation; and at least one removable protective solid covering secured to the core to form a i transportable and securely storable module. The covering may be secured to the core by the attachment. The covering and the attachment may be releasable from the core only by unlocking the attachment. The core may include a lower support structure below the installation, an upper structure above the installation and a vertical structure extending between and fixed to 1s the upper and lower structures. In another aspect, the invention provides: a method for assembling a module containing a transportable core including, in no particular order, the steps of: assembling on a lower support structure a wet area for a building; 20 erecting on the lower structure a vertical structure to support an upper structure; installing at least one electrical or plumbed installation in or on the core; securing to the core at least one removable protective solid covering to form a transportable and securely storable module; and fixing an attachment to the module for attaching a lifting mechanism. 25 'the method for assembling a module may include the further step of: using the attachment to secure the covering to the core. in yet another aspect, the invention provides: 2 a method for forming a building incorporating a core for a wet area and at least one electrical or plumbed installation, the method including the steps of: laying a foundation and floor support for a lower support structure of the core; lifting a module incorporating the core by an attachment for attaching a lifting 5 mechanism, the module having at least one removable protective solid covering secured to the core to make the module transportable and securely storable; locating the module at a predetermined location on the floor support; releasing the lifting mechanism from the attachment; erecting the building to lock-up stage incorporating the module and preparing a 10 connection in the building to connect the installation to the building; unlocking the covering from the core to expose the core for use; and connecting the installation to the building. The method for forming a building may include the additional step of: removing the covering and the attachment from the building. 1s In the method for fonning a building, the step of unlocking the covering may include unlocking the attachment. in the method or core as described above, the lower structure may be rectangular in plan. The covering may include four substantially vertical walls and a roof panel. The roof panel may be secured by anchoring a locking mechanism to the lower 20 structure for transport or storage. 'Tbhe locking mechanism may comprise an elongate member extending substantially from the lower structure to the upper structure. The elongate member may be a threaded rod. The attachment may be secured to the module by a lockable nut that also secures the covering to the modulc. In another aspect, the invention provides: 25 a method for building a module as described above or as follows, including using the attachment to secure the covering to the core. In yet another aspect, the invention provides: a method for fonming a building incorporating a core as described above or as follows. 3 MODULE The term core refers to discrete building sub-units having electrical or plumbing installations that require the specialist trade input. The module includes the covering and attachment, whereas the term core is used to refer to the completed wet area unit s without the covering or attachment. The module may be prefabricated off-site and shipped to a building site 1or ready installation. The core may be used as a complete installation for suitable discrete wet areas. The wet areas may include kitchen, laundry, bathroom, ensuite and spa areas. Preferably the cores are prethbricated off site to achieve efficiency and economy in 10 utilising the services of the various trades required to build and assemble the cores. For example, the off site manufacturing installation may include tradesmen permanently employed on site and organised to build the cores in a coordinated and predictable manner according to predetermined schedules. Alternatively, according to predictable schedules, the various tradesmen may be organised to.attend at specific is and predictable times during different stages of the assembly/building process. The off site manufacturing plant may include a factory and the modules may be assembled using an assembly line process. For example, the progressively built modules may be mounted on a rail system and moved from one location to another within the factory for each stage of the building process. The assembly line may 2o include stations equipped for carpentry, welding, cabinet making, white goods installation, plumbing installations, electrical wiring, tiling, plastering and/or painting or other surface finishing. The installations may include white goods installations such as a fridge, stove, microwave, waste disposal unit, water dispenser or cooler, dish washer, rangehood, 25 exhaust fan, air conditioner, television, radio, sound system, intercom, light fittings, hand or hair dryer, towel rail, toilet, bath, basin, spa heater, hot water heater and the like. 4 Preferably the core includes at least one connection for connecting the electrical or plumbed installation to an external supply or waste facility, such as mains electricity; a local electrical generation plant, such as a solar electricity generator; waste or sewerage outlet; and/or a mains or tank water supply. Preferably the connection is s located in a predetermined position on the core to allow easy connection to the supply or waste service on site. For example, the connection may be located at a specific position on. the core for direct connection to a corresponding fitting prepared on site. The drainage portal's location will depend on the type of installation. For example, a portal for a shower or bath drainage outlet will generally be located in the floor or at 10 the lower most edge of a side or end wall, whereas the drainage for a more elevated basin may be effectively located in a wall of the core above floor level. The modules are preferably completed in the factory, each as a total and discrete unit inclusive of all fittings and ready for use once connected to onsite plumbing and/or electrical installations. The factory manufacture of cores better allows for improved 1s quality control and may make obtaining approval by the relevant building authority easier, by completing the construction of the core, including electricals and plumbing, in a regulated environment prior to delivery to the building site. The core may have any one of a number of floor plans. For example, the floor plan of the core may be circular, oval or polygonal, for example where the core is a spa. The 20 core may be L-shaped, for example, to suit the architect's design for a kitchen area. I however, for case of manufacture of floor structures and for transport, the floor plan of the core will nonnally be rectangular, including square, subject to transport requirements and local regulations for the transport of large or wide loads. OFF SITE 25 Prefabrication of many of the other construction components for the building may assist in improving efficiency and economy of the overall construction. Preferably, construction components, such as wall frames, roof trusses, pre-cut roof sheets, wardrobes and pre-hung doors are prefabricated ofT-site for ready installation on site. 5 This hybrid construction method may reduce building costs and construction time. More over, construction time may be substantially reduced with factory and onsite assembly running in parallel. TRANSPORT 5 Transportation of the module from the prefabrication plant to the building site may be achieved by suitable vehicular transport, such as rail or road means. Preferably, modules will be transported by trucks. At either end, i.e. departure or delivery, cranes may be provided to perform the lifting and on site manoeuvring and placement of the module. 10 Depending on the transport restrictions in particular jurisdictions, the module dimensions will be generally limited to maximum widths, heights and lengths. For example, in the state of Victoria, Australia, road transportation between the hours of 9am and 4pm without escort imposes certain dimensional restrictions. At such times, modules are limited to a width of 3.5m, a height of 3m and a length determined by the 15 practical constraints of the transport vehicle. Otherwise, special permits may be obtained for transportation of modules of greater or irregular dimensions. Of course, depending on the capacity and availability of the lifling equipment, restrictions on the overall weight of the module may apply. ATTACHMENT 20 The attachment may include any suitable means for enabling the modules to be loaded on to a transport vehicle, unloaded from the vehicle, delivered to site and installed on the building site. For exiunple, the module may include lower slots in its base to receive the lines of a forklilf or similar lilting device. Preferably, the attachment includes one or more hooks or eyelets engageable to a 25 cable crane hook. The attachment may be located in an upper region of the module. The attachment preferably includes multiple pairs of hooks or eyelets fixed to the modules at the top of the module. For example, the module may include three or four 6 releasable attachment hooks or eyelets, each-attachment located at a corner of the module. 'The attachment is preferably anchored at a point on the module that is sufficiently strong to support part or the whole of the module's weight. The anchor point may be reinforced. 5 In a particularly preferred embodiment, the module includes a frame that extends around the top edges of the module and is easily disassembled once the covering is unsecured. '[he top frame may be secured to a base structure supporting the floor of the core. The base may form part of the module. The upper frame may be connected to the base by one or more elongate members,.such as poles, posts or rods. 10 Preferably, the upper framc is connected to the base by elongate rods. Preferably, the vertical rods are high tension rods capable of supporting a large linear weight. Preferably, the connection rods are fixed directly to the attachmrent so that substantially linear upward tensional force is applied to the connection rod. Preferably, the attachment, including rods is removed from the core, when the 1s covering is to be removed from the core. I OWKR STRUCTURE The lower structure may extend along a side of the core. Preferably, the lower structure includes the base. The lower structure may include a framc comprising support beams and floor joists. The support beams may be made of a metal alloy, 20 such as steel or cast iron. The lower structure may include a floor structure including joists and a floor surface such as floor boards, plywood panels or other 1loor surfaces known to the building industry. As the cores are generally for wet areas, the floor surface may be tiled or covered with linoleum, but may be carpeted or otherwise covered or the like. 25 UPPKR STRUCTURE The upper structure may include a ceiling and frame therefor. Preferably, the upper structure presents a generally planar internal (down-facing) surface. Fittings, such as exhaust fans and light fittings, may be exposed on the top side of the ceiling or may 7 be enclosed in a false ceiling. Covering the upper structure may be a removable roof panel forming part of the removable covering. The protective roof pane! may be secured to the upper frame. VERTICAL STRUCTURE 5 The vertical structure may include one or more vertical or substantially vertical walls extending between the lower and upper structures. The installations, such as basins, cabinets, and the like, may be secured to the vertical structure. Preferably, the vertical structure includes a nwber of walls, in a rectangular floor plan optimally four walls, and may include one or more pre-hung doors with corresponding door openings, if 10 one of the walls is to be an external wall in the completed building, the external wall may have a window for natural light. COVERING The removable covering may include an integral member covering exposed areas of the core, for example in the form of a monocoque shcll. Preferably, the covering 15 comprises one or more panels. The covering may include a roof cover, as mentioned above, and one or more side and end wall covers. Preferably, the core has a rectangular floor plan and the covering includes four wall panels and the roof panel. The covering may be made from any suitable protective material. The covering should be sufficiently strong to give protection against likely causes of damage, such 20 as weather, physical buffering during fabrication and on site, or would-be vandals. Thc covering is preferably secured by locking means to resist tampering by a thief. Preferably, the covering is made from sheet metal, such as corrugated metal sheeting; metal skinned, polystyrene core, sandwich panels; or checker plate steel sheets. Checker plate steel or iron plating may be preferred where the environment is likely to 25 be particularly hostile and weight restrictions do not prohibit the heavier panelling. One or more walls or the roof panel may be adapted to fnm a protective layer for the core and to remain in place following installation on site. However, preferably, the covering is fully removable and reusable on another core. 8 In use, the covering may remain in place on the module until lockup stage of the building. Accordingly, the covering may provide a shcl within which the core is protected until the potential for damage or theft has been removed. Accordingly, the module is preferably dropped into position on the building foundations on-site and the 5 covering is retained thereon until the building is completed around the module to lockup stage. Only then, preferably, the covering is removed from the core and the covering returned to the pre-fabrication factory for use on newly manufactured cores. BRIIF I)ESCR IPTION OF THE DRAWINGS Preferred features of the present invention will now be described with particular 10 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 the drawings: Figure Ia is a plan view of a building according to a first embodiment; Figure lb is a plan view of a bathroom module according to another aspect of 15 the invention, the module being incorporated into die; Figure 1c is a side elevation sectional view of the bathroom module shown in Figure b; Figure Id is an end elevation sectional view of the ensuite powder room/kitchen module shown in Figures lb and Ic; 20 Figure 2a is a plan view of a lower structure of the ensuite powder room/kitchen module shown in Figures lb-Id; Figure 2h is a side elevation of the lower structure shown in Figure 2a; Figure 3 is a plan view of the bathroom/shower module shown in Figure la; Figure 4a is an end sectional view of a portion of the lower structure shown in 25 Figures 2a and 2b; 9 Figure 4b is a plan view of a corner of the lower structure shown in Figure 2a showing greater detail; Figure 4c is a section view C-C of the corner section shown in Figure 4e; Figure 4d is a section view D-D of the corner section shown in Figure 4 e; 5 Figure 4e is a plan view of a corner section of the core; Figure 5a is an end view of a corner portion of the lower structure shown in Figure 2a; Figure 5b is an end sectional view of the corner portion shown in Figure 5a, but further including a stiffening plate; 10 Figure Se is a side elevation of the corner portion shown in Figure 5b; Figure 5d is a phn view of the stiffening plate shown in Figures 5b and 5c; Figure 5c is an end sectional view.of a portion of the corner section shown in Figure 5b, further showing a weld nut; Figure 6a is a plan view of the upper structure of the ensuite powder 15 room/kitchen module shown in Figure 1b; Figure 6b is a side elevation of the bathroom/shower nodule shown in Figure 3a Figure 7a is a front elevation of an attachment eyelet; Figure 7b is side view of the eyelet shown in Figure 7a; 20 Figure 7c is a side view of the lower end of the lilting rod shown in Figure 7a; Figure 7d is an end sectional view of a module including a covering; Figure 7e is an end sectional view of the module shown in Figure 7c; 10 Figure 8a is an end sectional view of a lower structure of an island module in situ; Figure 8b is an end sectional view of a lower structure of a module in place having an external wall; 5 Figure 9a is an end sectional view of a lower corner of a module in place having a floor mounted on beams; Figure 9b is an end sectional view similar to that shown in Figure 9a; Figure 9c is an end sectional view of a lower corner of a module in place having the floor mounted on joists; 10 Figure 9d is an end sectional view of a lower corner of a module similar to that shown in Figure 9c; Figure 10 is a plan view a building according to another embodiment showing schematically the electronic wiring thereof; Figures 11 a and 11 b are similar to corresponding Figs. 7d and 7e but show 15 different shaped roof sheeting edges 64 and gutter channels 73; and Figure 12 shows top and bottom plates for use as washers in the embodiment shown Figure 1 la and 11 b. DETAILED DESCRIPTION OF THE DRAWINGS The plan view of a building, shown in Fig. I follows standard architectural blueprint 20 conventions. There is shown a building 1 made from a hybrid construction derived from a combination of factory and onsite construction. The building 1 includes three discrete cores 10, 20, 30, corresponding to wet areas of the building 1. The cores include a combination ensuite/powder room/kitchen core 10, a second bathroom/shower core 20 and a laundry/W.C. core 30. The cores 10, 20, 30 enable 25 the construction process to take less time and to limit wastage of building materials 11 during construction. Standard materials, products, appliances may be purchased and installed in bulk to eliminate wastage where possible. The ceiling heights may be standardised, for example, at between 2400 - 3000mm, and preferably 2700mm, so that the cores 10, 20, 30 can be installed without further 5 work required on the wall linings and without the requirement to cut the wall linings to fit in situ, compared to traditional building procedure in which plasterboard may be required to be cut in lengths. The cores may be completely finished in the factory in a controlled environment, packaged as protected and covered modules and then delivered to site. 1o Independent of the construction and installation of the cores 10, 20, 30, prefabrication of other construction components for site assembly enable construction to be completed in less time taken to build a traditional structure. For example, wall frames, roof trusses, pre-cut roof sheets, wardrobes and pre-hung doors may all be prepared off site and installed with little augmentation onsite. 1s Accordingly, the hybrid construction method of the present invention will typically result in significant reductions in building costs and construction time. This is achieved inter alia by construction in both the off site factory and on site concurrently. Figures l b and 1c show the combination core 10 in which the plumbing services are 20 shared through a common wall 11 between a kitchen section 12 and a bathroom section 13. The walls 11, 14 may be made from traditional wall materials, for example, including a timber or metal frame clad with plaster or particle board lining. Doorways 15 are formed during assembly at the prefabrication plant and all doors and fittings are installed at that time. The core 10 includes features such as a pantry 16a, 25 linen press 16b' sink 16c, hot plates 16d, wall oven and microwave 16e, toilet 16f, small hand wash basin 16g, vanity basin 16h, shower 16i, exhaust fan 16j and wall vent 16k, -all mounted onto a single lower support structure 40, including joists 43 and floor platform 44, or to the walls 11, 14, 12 The ensuite powder room/kitchen core 10 is mounted on the lower support platform 40. The lower support includes three equi-length C section galvanised channel bearers 42 extending across the width of the core 10. Welded to the ends of the lateral bearers 42 are longitudinal bearers 41 made from the same C section channel 5 as for bearers 42. Mounted astride the bearers 42 arc longitudinal parallel joists 43 extending the full length of the core 10. The joists 43 arc preferably hardwood for long service and the floor surface 44 is completed by waterproof plywood panels 44. Preferably, the flooring is covered with a waterproof layer of tiles sealed with suitable grouping. lxtcnding on the sides of the core 10 between upper end corners 19 and a 10 mid-position 45 on the support platform 40 are a pair of braces 18 in V-formation to strengthen the structure of the core 10 during transit. On installation in situ, the braces 18 may be removed. Figure Id shows another view of the core 10 showing a section f-f of Figure lb. The longitudinal bearers 41 welded to the lateral bearers 42 are shown, together with the 15 joists 43 and plywood flooring 44 completing the lower structure 40. Also shown in Figure Id are cabinets 161 and drawer units 16m. The core 10 includes a ceiling 17 comprising a standard height, low-weight bearing frame clad by fibre-cement sheets such as Villaboard"M supplied by James IHardie Australia Pty Ltd. particle board or another suitable cladding with sufficient structural rigidity. 20 .1'urning to Figurc 2a, the core 10 shows the lower structure 40 in which the four ends of the longitudinal bearers 41 each include a hole 46 for receiving the threaded rod of an attachment device as will be described later. Figure 2b shows another perspective of the lower structure 40 and Figure 3 shows an end view of the lower structure 40. In Figure 4a, there is shown in morc detail a longitudinal bearer 41 supporting a joist 25 43 via a bracket 48 welded to a top arm of the longitudinal bearer 41, the joist secured' to the L or channel-shaped bracket 48 by fasteners, such as coach bolts 49. In Figure 4b a plan view of a corner of the lower structure 40 shows the longitudinal bearer 41 welded in perpendicular relationship to a lateral bearer 42. The upper ann 13 50 of the longitudinal bearer 41 includes the aperture 46 extending completely through to receive an attachment rod as best shown in Figure 7d below. In Figure 5a, the weld connection 52 betwcn the longitudinal bearer 41 and the lateral bearer 42 is clearly shown. Referring to Figure 4e, there is shown a corner section that is typical 5 of cach of the corners of a rectangular core such as core 10. Sections C-C and D-D of Figure 4e are shown in Figures 4c and 4d, respectively. To strengthen the structure of the end beam 41 and mounting point of an attachment 80 (described in greater detail with reference to Figures 6b to 7e and I 1a and 1 1b), vertical reinforcement plates 54, 55 are welded to the corners thereby minimizing twisting of the bearer 41 and beam 10 42 during the lifting of the core 10. At each corner, it can be scene that advantageously a pair of opposed vertical stiffening plates 54, 55 are welded to the end beam 42 and bearer 41 therchy mitigating torsional forces as upward force is. applied force is applied through the attachment 80 to the horizontal plate 52 and longitudinal bearer's 41 upper arm and, in turn, through to the vertical stiffening 15 plates 54, 55 welded. In Figure 5b the underside surface of the longitudinal bearer's 41 upper arm 50 has welded to it a horizontal stiffening plate 52 through which a bore 51 extends, as also shown in Figure Sc. Also shown in Figure Se is a threaded bore provided by welding a nut 53 in registration with the aperture 46. 20 Figure 5d shows the shape of the stiffening plate 52 in plan. Figure 5c shows the upper portion of the longitudinal bearer 41, including the bore 51, in this case a 1 8mm diameter bore. The weld nut 53 is internally threaded to receive a 16mm threaded rod 85 (described later) Turning to figure 6a, there is shown the top of a module I Oa incorporating the core 10 2s in plan wherein the module 10a is prepared for transport or exposed storage on site. The upper structure 60 includes a removable upper covering in the form of corrugated steel roof sheet 61. The removable sheet 61 is optionally secured in place by a pair of diagonally crossed braces 62 joined intermediate their lengths with nut-bolt fastening means 63. The removable sheet 61 is held about its edges by two longitudinal lengths 14 of channel edging 64 and two end lengths of channel edging 65. Although shown extending longitudinally, the roof sheets 61 may be advantageously aligned laterally so that a single sheet 61 can be laid transversally extending the full width of the core 10a. 5 'The corners of the roof sheet 61 and ends of the braces 62 are received within the channel sections 64, 65. T1he channel sections 65 may vary in shape and dimension as shown in Figure I la to more closely confonn to the sectional shape and dimension of the roof sheets 61. The abutting vertical channel sections at each corner (see below) are retained in place by an L-shaped corner section 74 at each corner. The channel io sections and roof sheet 61 are secured in place by an attachment 80 including an elongate rod 85 and locking nut arrangement 81. The attachment 80 will be described in detail below. Tn Figure 6b the module 10a is shown in side view. As with the roof sheet 61, each side and end includes a substantially planar, vertical panel, such as corrugated steel 1s sheeting 70 held in its vertical plane by a pair of diagonally crossed braces 71 joined intermediate their lengths by a nut and bolt fastening means 72 and secured at their ends by further fastening means by L-section corner strips 74. The edges of the wall panels 70 are retained within channel sectioned stainless steel lengths 73, both upper, lower and side edges. Adjacent vertical channel sections 73 at cach corner arc 20 retained in place by vertical 1, scctioned cornerlengths 74. As shown in Figure 1 lb, the channel section. 73 shape can vary in shape and dimension to more closely conform to the sectional shape and dimensions of the corrugated wall sheeting 70. Referring to Figures 7a and 7c, the attachment means 80 is provided in the form of an cyclet or lifting lug 81 having a loop section 82 and apcrturc base 83. In the transport 25 or safe-storage form, the module 10a is clad with the protective covering of the roof and wall sheets 61, 70, the sheets 61, 70 held in place by the channel sections 64, 65 and 73 and further secured by extending an elongate lifting rod 85 through the aperture base 83, threaded into the aperture 46 in the lower structure by threading into the welded nut 53 and locking the upper end of the rod 85 within the lifting lug 81 by 15 means of a threaded locking nit 86 and washer 87 combination. Figure 7b shows the lifling lug 81 in side sectional view. Referring now to Figures 7d and 7c, the attachment means 80 extends from the lifting lug 81 down the length of each corner of the module 10a through the floor 44 and a floor joists 43 of the lower structure and through the longitudinal bearer 41. Accordingly, the steel roof shect 61 and wall sheets 70 provide a protective cover for the enclosed core 10 shown in the drawings with reference to vertical studs 14a and ceiling panels 17. The channel sections 73 trap the walls 70 in their planar vertical orientation and the roof channel sections 65, 64 trap the roof sheet 61 in its horizontal to planar orientation. The channel section 64 is open ended to allow egress of water at the ends of the channel to resist weather damage. The vertical corner angles 74 have an apertured square plate 88 welded to their respective top edges and the base 83 of the lug 81 sits on the top of the plate 88. In Figure 12 there is shown a pair of top and bottom plates 88a and 88b. The top 15 plate 88a is welded to the top of a corner angle 74a and the bottom plate 88b is welded to the bottom of the corner angle 74a as shown in Figure 1 a and Figure 12. The top and bottom plates 88a, 88b have central open ended slots 46a, 46b, rather than apertures so that the corner angles can be easily removed from the core 1 Oa, once the locking nut 86a is loosened whereby to loosen the lifting lug 8 Ia. 20 The corrugated steel roofing panels 61 a are trapped in roof sheeting edges. 64a. In contrast to the roof sheeting edges 64 shown in Figure 7d, the roof sheeting edges 64a are more vertically compact to more effectively trap the corrugated sheeting edges in the roof sheeting edges 64a. The side wall corrugated sheeting panels 70a are trapped within top downwardly 25 depending channel 73a and upwardly extending lower channel 73b. The channels 73a, 73b are squarer in transverse section whereby to more closely fit the side corrugated sheeting panels 70a whereby to minimise play thereof. The lifting rod 85a is 16mm in diameter compared to the 12mm diameter of the lilting 16 rod 85 shown in Figure 7d and is suitable for higher loads than the smaller diameter lifting rod 85. Referring to Figure 8a, there is shown a concrete slab 90 poured lor the building 1, including a thickened slab beam 91 having a formed recess 113 for reception of the s module 10a so that the remaining core 10 will be in place in the building as an island surrounded by the remainder of the building 1. A alternatively, other traditional Ibundation types may be employed, such as timber floor structures, so that the module 10 may rest on floor boards or the like. As the skilled person will appreciate, it is necessary to provide a structurally sound base and 10 this may be determined by the overall weight and weight distribution of the module 10. The slab 90 preferably comprises 100mm reinforced concrete slab with a mesh top. Before roof and wall structures are erected on the building 1, the module 1Oa is preferably hoisted from the transport vehicle or from the site on which it has been. 1s stored onsite and lifled into place by a crane or other suitable lifting device using the lugs 81 as attachments for the crane hooks. However, the walls and other parts of the building may be erected before instaling the module 10, depending on vertical accessibility to the slab 90 base on which the module IOa will rest and the control/capacity of the crane and operator. 20 Turning to Figure 8b, there is shown an installation similar to that shown in Figure 8a, but the module 10a is installed along an external edge 3 of the building 1. For example, with reference to Figure 1 a, the laundry/W.C. module 30 may be suitably installed at such a location. The concrete slab 93 includes a thickened slab beam 94, reinforcing mesh 95 and N 12 size support bars 96. 26 As shown in greater detail in Figure 9a, the externally edged module 30a enclosing core 30 includes a'longitudinal bearer 41 that rests on the concrete slab 93 within the recess 97 specifically provided or the module 30a, so that the floor 44 of the module 30a is flush and at the same height as the concrete floor 98 of the building I adjacent 17 to the module 30a. Although the mass of a core will be substantial and unlikely to shill in the short term, the core 30 is prevented from shifting by bolting the corcs 10,20,30 down in. the recesses 97,113 using masonry anchors. Back filling with concrete or gravel into the recess of the channel of the longitudinal bearer 41 may also 5 provide secondary stability. On site a floor-linc facia 110 is first attached to the floor 44 and depends down therefrom until just below the intended lccl of the back filled ground externally adjacent to the module 30a. Once the lockup stage of the building 1 is reached, the protective paneling 61, 70 is removed by dismantling the attachment 80 and custom orb cladding I11 is inserted I into the lower longitudinal channel section 73a which is retained as part of the core 30. A. rubber packing strip 112 can be inserted at the base of the cladding 111 to provide a weather seal. Once the module 30 has been manoeuvred into place, the lifting rod 85 may be unscrewed from the nut 53 and removed for return and reuse at the prefabrication factory. is In Figure 9b, there is shown the internal core installed as an island core 10 within the building 1. The longitudinal bearer 41 is manoeuvred into place in a recess 11.3 in the slab, so that the floor 44 lies level with the concrete floor 98 of the building 1. Figure 9c shows a minor variation on the core 30 shown in Figure 9a, wherein the core 30 floor 44 is supported by floor joists 43 secured to the longitudinal hearer 41 20 by a welded bracket 48, The ground level cladding I 10 is attached to the particle board floor panel 44, or more preferably to the floor joists 43 and then back fill with concrete or screenings is used to fill in the space in and around the channel of the longitudinal bearer 41 to secure the module 30 into place and to counteract any tendency for long-term shifting. 25 Figure 9d shows a minor variation on both Figures 9b and 9c, in that the module l0a is shown installed in a recess 113 formed in the concrete slab 90. The recess 113 is made to a sufficient depth to rccive the module 10 a to the level of floor height of floor 44, wherein the floor panels 44 are supported on floor joists 43.

In Figure 10, the electrical wiring of a building 2 is shown in which the core 10 is connected to a modem, router or loom to the electrical mains of the building 2, the .connection positions having been predetermined. The module construction in the off site factory may be described. as follows. The 5 cores 10, 20, 30 may be manufactured starting with the erection of the frames and base, including the studs 14a and lower structure 40. Depending on regulations, the frame may be inspected by an authority at this stage. The plumbing and electrical preliminary work can be commenced, followed by the lining of the walls 11, 14 and ceiling 17, as well as the floor 44. Fixtures, such as showers, basins, toilets and the 10 like, may be installed. Tiling of walls, shower units and the floor may then be carried out, followed by painting of wall and ceiling surfaces as required. The final electrical fit oil of the core 10, 20, 30 can then be completed. The final step prior to removal from the factory is the covering of the core 10, 20, 30 with the roof 61 and wall 70 sheets, locked in place by the attachment arrangement 80 as previously described, to 15 form the modules 1 Oa,20a,30a. At this stage, the module 10, 20, 30 is secure and resistant to damage, vandalism or theft of component parts. The module 10, 20, 30 may then be loaded onto a transport vehicle using crane hooks to engage with the lifting lugs 81. The module 10, 20, 30 can be transported to the building site and unloaded using a crane on site directly into the prepared recess 97,113. 20 The construction sequence on site may be described as follows. The site may be prepared as necessary, for example by scraping to level the site and to remove unwanted rubble, dangerous items and the like. The soil may be treated for termites or other potential infestations, followed by slab preparations. At this stage a pre-slab inspection may be carried out by the relevant building authority for the particular 25 jurisdiction. The slab 90,93 may then be prepared with reinforcing in place, poured, and formed, followed by a curing time. At this stage, preferably the modules 10, 20, 30 are delivered to the site and immediately unloaded from the transport and bolted in position. The cores 10,20,30 are bolted down in the recesses 97,113 using masonry anchors. 19 The wall frames, roof trusses arrive on site for assembly to commence and be completed. At this stage, frame inspection of the building 1, 2 may be carried out by the relevant building regulation authority. Windows, doors, external cladding and all other building materials may then be added and finished for lock up completion. In a this connection, it is preferable that the protective covers are only removed when lock up is complete. This prevents access to the cores 10, 20, 30 whilst the building 1, 2 remains unsecured. Once the covering is removed, all services to the cores 10, 20, 30 and the primary building 1, 2 commence, including the connection of plumbing and electrical services to the cores 10, 20, 30. In this regard, the cores 10, 20, 30 include 10 specifically located access points for these services that are calculated to correspond to predetermined connection points pre-installed in the building 1, 2, so that connection of these services is a simple matter. When the core 10 is an island surrounded by floor support, such as a slab 90, the access points are typically provided in sleeves extending through the slab 90 or other wall of the recess 113 and 1s present at a terminal end in the recess 113 wall, positioned for easy connection to a connection extending from the core 10. Where the core 30 has an external side or end, the services can be supplied at the external wall. The internal cladding (e.g. plastering), internal fit off and internal and external painting of the building 1, 2 may be carried out and completed and the site cleaned for 20 hand over. A final inspection by the relevant authority may then be carried out to complete the building process. Through-out the specification and claims the word "comprise" and its derivatives is intended to have an inclusive rather than exclusive meaning unless the context requires otherwise. 25 Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and arc based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the upper structure uppermost. 20 Tt 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. 21

Claims (15)

1. A transportable core for a wet area of a building including: an attachment for attaching a lifting mechanism; at least one electrical or plumbed installation; and 5 at least one removable protective solid covering secured to said core to form a transportable and securely storable module.

2. A transportable core according to claim 1, wherein said covering is secured to said core by the attachment.

3. A transportable core according to claim I or 2, wherein said covering and said 10 attachment are releasable from said core only by unlocking the attachment.

4. A transportable core according to any one of claims 1 to 3, wherein said core includes a lower support structure below said installation, an tipper structure above said installation and a vertical structure extending between and fixed to said upper and lower structures. 1s

5. A method for assembling a module containing a transportable core including, in no particular order, the steps of: assembling on a lower support structure a wet area for a building; erecting on said lower structure a vertical structure to support an upper structure; 20 installing at least one electrical or plumbed installation in or on said core; securing to said core at least one removable protective solid covering to form a transportable and securely storable module; and fixing an attachment to said module for attaching a lilling mechanism.

6. A method according to claim 5, including the further step of: 25 using said attachment to secure said covering to the core.

7. A method for Ibrining a building incorporating a core for a wet area and at least one electrical or plumbed installation, said method including the steps of: 22 laying a foundation and floor support for a lower support structure of said core; lifting a module incorporating said core by an attachment for attaching a lifting mechanism, said module having at least one removable protective solid covering secured to said core to make said module transportable and securely 5 storable; locating said module at a predetermined location on said floor support; releasing said lifting mechanism froin said attachment; erecting said building to lock-up stage incorporating said module and preparing a connection in said building to connect said installation to said building; 10 unlocking said covering from said core to expose said core for usc; and connecting said installation to said building;

8. A method according claim 7, including the step of: removing said covering and said attachment from said building.

9. A method according claim 7, wherein the step of unlocking said covering 15 includes unlocking said attachment.

10. A method or core according to any one of the previous claims, wherein said lower structure is rectangular in plan.

11. A method or core according to any one of claims I - 9, wherein said covering includes four substantially vertical walls and a roof paneL 20

12. A method or core according to claim 10, wherein said roof panel is secured by anchoring a locking mechanism to said lower structure for transport or storage.

13. A method or core according to claim 12, wherein said locking mechanism comprises an elongate member extending substantially from said lower structure to said upper structure. 25

14. A method or core according to claim 13, wherein said elongate member is a threaded rod. 23

15. A method or core according to any one of claims I - 14, wherein said attachment is secured to said module by a lockable nut that also secures said covering to said module 24