AU2011201797A1 - Prefabricated Room Assembly - Google Patents

Abstract

A substantially complete room module (10) including: a frame (12) comprising: first (28) and second (30) pluralities of interconnected generally 5 horizontal members (16); and, a plurality of upright members (14) disposed at least at corner regions of the room module (10) and being connected to the first (28) and second (30) pluralities of interconnected generally horizontal members (16), thereby spacing the first (28) plurality of interconnected horizontal members (16) from the second (30) plurality of interconnected 10 horizontal members (16); and, a door frame (24), rigidly connected to the frame, for receiving a door; wall, floor and ceiling panelling (18,20,22) respectively forming the walls, floor and ceiling of the room module (10), which panelling (18,20,22) is supported by the frame (12); wherein the room module (10) is assembled offsite to a substantially complete state.

Description

P/00/001 Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) TO BE COMPLETED BY APPLICANT Name of Applicant: CULLEY, Brian Malcolm Actual Inventor: CULLEY, Brian Malcolm Address for Service: EKM patent & trade marks Level 1, 38-40 Garden Street South Yarra Victoria 3141 Australia Invention Title: Prefabricated Room Assembly Details of Associated Provisional Patent Application No.: 2010901643 The following statement is a full description of this invention, including the best method of performing it known to us: -2 PREFABRICATED ROOM ASSEMBLY TECHNICAL FIELD The present invention relates to prefabricated room assemblies for 5 buildings, and associated methods of construction and installation of same, and relates particularly, though not exclusively, to a prefabricated room assembly in the form of a complete bathroom, ensuite, kitchen or laundry manufactured off-site, wherein the assembly is subsequently transported to and installed at a building site. It can be particularly suited to use in multi 10 level buildings or hotel buildings. BACKGROUND ART Any discussion of documents, devices, acts or knowledge in this specification is included to explain the context of the invention. It should not 15 be taken as an admission that any of the material forms a part of the prior art base or the common general knowledge in the relevant art in Australia or elsewhere on or before the priority date of the disclosure herein. It is generally known in the building industry that bathrooms are one of the most complex and/or difficult areas of a multi level apartment or hotel 20 building to construct. This is due to the fact that there are usually a number of different tradesmen, approximately eight to ten, who need to work on approximately twenty-five separate activities such as tiling, flooring, plastering, plumbing, ventilation, painting and installation of bathroom fittings in a small space. 25 As a result, all work must be co-ordinated to allow tradesmen for each particular activity access to the bathroom in sequence. For example, a builder may firstly have access to construct internal walls, followed by necessary multiple activities by plumbers, plasterers, carpenters, electricians, tillers, painters, cleaners, etc. Because the co-ordination of many tradesmen 30 is required, delays often occur which subsequently cause or add to a delay in the completion of a building resulting in additional costs or losses to the building developer or owner. 20/04/2011, SAW103878.cap.spc, 2 -3 In addition, given the number of tradesmen going in and out of the bathroom, there is a high likelihood of damage to fittings, flooring and tiles as tools may be dropped or fittings knocked. Replacement or repair of such items adds further cost to the project. 5 Furthermore, if fittings for a room have relatively large dimensions (i.e. shower screens and cabinets) when compared with the dimensions of the surrounding halls and doorways, it can be difficult to move those fittings into position for installation. Accordingly, a need exists for prefabricated room assemblies which 10 are manufactured off-site, wherein a completed room, such as a bathroom, ensuite, toilet, kitchen or laundry, can be provided according to required specifications, which may include finished walls and ceilings, door frames, tiled surfaces, flooring, ventilation, plumbing, fire sprinklers and/or smoke detection devices, light fittings, taps, toilets, showers and/or baths, vanity 15 units, mirrors, sinks, screens, built-in cooking appliances and other fittings and accessories. A need also exists for a method of construction and installation of prefabricated room assemblies in the form of, for example, a complete bathroom, ensuite, toilet, kitchen or laundry in a building. 20 DISCLOSURE OF THE INVENTION According to one aspect of the present invention there is provided a substantially complete room module comprising: a frame comprising: first and second pluralities of interconnected generally horizontal members; and, a plurality of upright members disposed at least at corner regions of the room 25 module and being connected to the first and second pluralities of interconnected generally horizontal members, thereby spacing the first plurality of interconnected horizontal members from the second plurality of interconnected horizontal members; and, a door frame, rigidly connected to the frame, for receiving a door; wall, floor and ceiling panelling respectively 30 forming the walls, floor and ceiling of the room module, which panelling is supported by the frame, wherein the room module is assembled offsite to a substantially complete state. 20/04/2011, SAW103878.cap.spc, 3 -4 Preferably the upright members are disposed, in use, exclusively at corner regions of the room module. In this context, the word 'exclusively' is intended to confer the idea that the frame includes no wall studs or nogging. Preferably the substantially complete room module further includes 5 cladding disposed between at least two of the upright members and secured to at least one of the frame and/or the wall panelling, the cladding including channels, or projections, to which wall cladding of adjacent rooms can be secured once the room module is installed, wherein the channels or projections provide external cavities for concealing service connections, 10 fittings or the like. Preferably at least one of the wall, floor and ceiling panelling is formed from a magnesium oxide material. According to a further aspect of the present invention there is provided a frame for a room module comprising: first and second pluralities of 15 interconnected generally horizontal members; and, a plurality of upright members disposed, in use, at least at corner regions of the room module and being connected to the first and second pluralities of interconnected generally horizontal members, thereby spacing the first plurality of interconnected horizontal members from the second plurality of interconnected horizontal 20 members, wherein a wall, floor and ceiling of the room module are able to be supported by the frame. Preferably the upright members are disposed, in use, exclusively at corner regions of the room module. In this context, the word 'exclusively' is intended to confer the idea that the frame includes no wall studs or nogging. 25 Preferably the frame in accordance with any one of the preceding paragraphs is constructed of a metal or alloy material, more particularly steel or aluminium. According to yet a further aspect of the present invention there is provided a method for manufacturing a frame according to the preceding 30 paragraph, the method including the step of welding the members of the metal or alloy frame together to form a substantially rigid structure. 20/04/2011, SAW103878.cap.spc, 4 -5 According to yet a further aspect of the present invention there is provided a method of constructing a multi level building incorporating prefabricated substantially complete room modules, the method including the steps of: (i) pouring a slab; (ii) positioning at least one prefabricated room 5 module on the slab; (iii) pouring a further slab directly above the previously poured slab having the at least one prefabricated room module positioned thereon; (iv) positioning at least one prefabricated room module on the slab poured at step (iii); and, repeating steps (iii) & (iv) for all levels of the multi level building. 10 The method of constructing a multi level building according to the preceding paragraph, utilising prefabricated substantially complete room modules as described above. These and other essential or preferred features of the present invention will be apparent from the description that now follows. 15 ADVANTAGES OF THE INVENTION The offsite manufacture of a bathroom room assembly, as opposed to its onsite manufacture in a multi level building, can provide improved work efficiencies and a greater degree of control. By way of example, offsite 20 construction of bathroom room assemblies may provide, but is not limited to, the following advantages: a significant time saving of up to approximately 20% in the completion of any multi level building, with a consequent financial saving of approximately 2.5% - 3.0% of the project cost; greater control and the ability to achieve and maintain a better quality of finish by tradesmen 25 working in a factory environment; less exposure of the completed work to damage by other tradesmen; less time required to correct defects in a factory environment when compared with onsite construction; avoids the need to transport materials and equipment to site, and the need to store such items, thereby reducing overall installation costs; reduces the risk of theft of 30 uninstalled materials and equipment; and, reduces labour time and cost (i.e. workers do not need to travel through the building for breaks or to gather more materials). 20/04/2011, SAW103878.cap.spc, 5 -6 For example, the cost saving in building an apartment building of approximately 30 floors and 300 bathrooms with an overall construction cost of about $120,000,000.00 would be approximately $3,600,000.00. The approximate overall reduction in construction and commissioning time of the 5 project would be about 4.5 months (around 20%), when compared with building the bathrooms onsite. The bathroom room assembly can be made to any desired standard to accommodate hotels of any star rating and are particularly suited to use in multi level apartment buildings and hotels. 10 Although the description herein will generally be provided with respect to bathrooms, it will be understood that other rooms, such as those mentioned above, may also be provided without venturing outside the scope of the present invention. 15 BRIEF DESCRIPTION OF THE DRAWINGS In order that the invention may be more clearly understood and put into practical effect there shall now be described in detail preferred embodiments of prefabricated room assemblies, and methods of construction and installation of same, in accordance with the invention. The ensuing 20 description is given by way of non-limiting example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective cutaway view of a bathroom room module made in accordance with a preferred embodiment of the present invention, the room module shown ready for installation; 25 Figure 2 is a perspective view of an exemplary frame member suitable for use with a room module made in accordance with the present invention, such as the bathroom room module shown in Figure 1; Figures 3A and 3B are partial cross-sectional views of preferred room modules, each showing preferred floor structures; 30 Figure 4 is a partial cross-sectional view of a further preferred room module, this time showing an alternative preferred floor structure; 20/04/2011, SAW103878.cap.spc, 6 -7 Figure 5 is a partial cross-sectional view of a preferred room module installed in a set down (i.e. counter-sunk) region in the floor of a building; Figure 6 is a partial cross-sectional view of a preferred room module, showing an embodiment of a ceiling structure; and, 5 Figure 7 is a perspective view of a completed preferred room module, shown prior to installation in a building. MODES FOR CARRYING OUT THE INVENTION A prefabricated room assembly, for example, a bathroom as shown in 10 Figure 1, comprises a room module 10 including a frame 12, which is preferably constructed of a suitable metal or alloy material such as steel or aluminium. Frame 12 includes upright members 14 disposed at corner regions of module 10, and generally horizontal members 16 connecting to the upright members 14. Module 10 further includes wall, floor and ceiling 15 panelling 18, 20 and 22, supported by frame 12, which respectively form the walls, floor and ceiling of module 10. Module 10 also includes at least one door frame 24 rigidly connected to frame 12, for accommodating any suitable door, as for example a swinging or sliding door. In the present case, module 10 further includes fittings 26 which are 20 dependent on the intended use of module 10 once installed. For example, in the case of the preferred bathroom room module 10 shown in Figure 1, fittings 26 may include: taps, toilets, showers and/or baths, vanity units, mirrors, sinks, shower screens, etc. Of course, should module 10 be a room other than a bathroom, such as, for example, a kitchen or laundry, fittings 26 25 will vary as required to suit that room type. Members 14, 16, of frame 12, will generally be welded or otherwise joined together (depending on the type of material used to construct frame 12). In particular, where metal is used to construct frame 12, same can be selected such that frame 12 is sufficiently rigid so as to substantially avoid 30 buckling or deformation which might damage fittings 26, or panelling 18, 20, 22, whilst module 10 is being transported and installed. Therefore, modules 20/04/2011, SAW103878.cap.spc, 7 -8 10 are assembled offsite until they are in a substantially complete state, and are then able to be transported to site and installed when appropriate. As afforded by the rigidity of frame 12, module 10 may be (if required) installed within around 24 to 48 hours of a floor slab being poured. This can 5 offer a significant time saving, up to an estimated 20% in cases of multi level apartment buildings, as, with particular regard to bathrooms, the skills of a number of different trades-people are required and they are thus rooms in which significant project delays can be caused. With regard to members 14, 16 of frame 12, horizontal members 16 10 serve to support all of panelling 18, 20, 22 and can be divided into two groups. Firstly, a floor group 28, comprising a plurality of interconnected, generally horizontal members 16, supports floor panelling 20 of module 10. Secondly, a roof group 30, comprising a plurality of interconnected, generally horizontal members 16, supports ceiling panelling 22 and may also provide 15 lifting points 32 to allow positioning of module 10 by, for example, a crane or the likes. Lifting points 32 may instead be provided on upright members 14, which members 14 serve to separate the roof group 30 of member 16 from the floor group 28 of members 16, and may provide additional support for wall panelling 18. 20 It should be noted that frame 12 shown in the present embodiment does not include walls studs or nogging - instead, upright members 14 are provided exclusively at corner regions of module 10. If frame 12 included wall studs and/or nogging, then the positioning of penetrations through the wall 18 (i.e. for receipt of plumbing and/or cabling) would need to take into 25 account the positions of those wall studs and/or nogging. The absence of such wall features can thus provide greater flexibility in the positioning of penetrations, with a consequent flexibility in the positioning of fittings 26. In spite of the foregoing, it may occasionally be necessary to include one or more upright members 16 at points intermediate the corner regions of 30 module 10, particularly for longer modules 10. As frame 12 does not include wall studs or nogging, ceiling 22, floor 20 and, in particular, wall panelling 18 should have sufficient rigidity so as to 20/04/2011, SAW103878.cap.spc, 8 -9 contribute, along with frame 12, to the structural integrity of module 10. Rigidity is of utmost importance as wall movements and flexion, particularly during transportation of modules 10, have a tendency to damage fittings 26 and plumbing (not shown). 5 In Figure 2 there is shown a preferred frame 12 which is suitable for use with module 10 shown in Figure 1. Frame 12 comprises a floor group 28, a roof group 30 and a plurality of upright members 14. Peripheral horizontal members 34 of the floor group 28 of frame 12 will generally act as the floor bearers and joists 36 are then welded (or otherwise joined) directly 10 to those bearers 34. For structural rigidity, frame 12 is preferably constructed from rectangular hollow section (RHS) and square hollow section (SHS) steel. In this regard, a floor group 28 suitable for most applications comprises four 75mmx75mm SHS, or 100mmx50mm RHS, bearers 34 joined at their 15 corners at right-angles, and 65mmx35mm RHS, or 50mmx50mm SHS, parallel joists 36. This arrangement for floor group 28 is particularly useful when combined with 75mmx75mm SHS vertical members 14 and a roof group 30 comprising four 75mmx50mm RHS horizontal members 38 joined at their corners at right-angles. As door frame 24 need not be as rigid as 20 frame 12, door frame 24 is preferably formed from pressed metal and welded to frame 12. It will be appreciated that the dimensions of members 14, 16, the types of material used, and the thickness of that material (i.e. 2mm or 3mm) may be adapted to suit rooms of different sizes. Lifting points 32 are a series of lugs provided at the corners of module 25 10 and are arranged to be engaged by slings or chains attached to a crane hook, or the likes, to allow module 10 to be lifted, or otherwise moved, into position. Lifting points 32 are, in the present case, welded to upright members 14, though they may alternatively be attached or integrally formed with another frame member 14, 16, at any suitable location. As an 30 alternative to lugs, any suitable means may be employed at lifting points 32, such as sockets for shackle hoops or simply a protrusion about which a chain link can be received. A skilled person will appreciate many such alternative 20/04/2011, SAW103878.cap.spc, 9 - 10 arrangements, and as such the present invention should not be construed as limited to the specific examples provided. Lifting points 32 may also be configured to assist with tying module 10 to a transport vehicle. For example, if lifting points 32 are lugs, they may be 5 engaged by tie-downs to secure module 10 to a truck. Conveniently, lifting points 32 can preferably be installed upon construction of frame 12 and remain in place even after module 10 has been positioned in a building. The design of wall, floor and ceiling panelling 18, 20, 22 will depend on preferences and function. For example, for a module 10 installed in a set 10 down region 42 of a slab of a building 62 (as shown in Figure 5), a floor assembly 44 may comprise a tile layer 46 (see Figure 3A) adhered to a screed 48 poured onto a layer of cement sheeting 50. In a preferred embodiment, tile layer 46 comprises porcelain tiles of around 6mm thickness, the screed 48 may be approximately 20mm to 30mm thick and include a fall 15 to an outlet 52 of, for example, a shower or central drain, and the cement sheeting 50 comprises around a 19mm Scyon@ layer or 16mm magnesium oxide board layer. A particular advantage of floor assembly 44, as shown in Figure 3A, is that floor assembly 44 drops away from level towards outlet 52 (i.e. the floor 29 of the wet areas, such as shower areas, do not sit above the 20 floor 20 of the surrounding bathroom, but instead neatly drop away therefrom). However, it will be apparent to the skilled person that many variations in floor assembly 44 configuration may be made without falling outside the scope of the present invention. For example, modules 10, as shown in Figure 3B, may include floor assemblies 44i in which the wet areas 25 53i include a lip 53ii and are at least partially raised above floor assembly 44i. In situations where, for example, module 10 is to be installed on a slab of a building 62 which includes a very deep set down 42, does not include a poured slab, or does not provide a thermal/noise insulating effect, it may be advantageous to provide module 10 with a thicker floor assembly 44 which 30 has an inherent insulating capability. As shown in Figure 4, such a floor assembly 44 may consist of base panelling 54, struts 56, insulation 58 and floor panelling 20. In this example, base panelling 54 may again comprise 20/04/2011, SAW103878.cap.spc, 10 - 11 cement sheeting and simply serve to support floor assembly 44 on joists 36. As is shown, struts 56 may be secured at opposite ends to both floor panelling 20 and base panelling 54, thereby maintaining a gap between floor panelling 20 and base panelling 54, into which gap insulation 58 can be laid. 5 Due to this preferred construction, struts 56 also reduce flexion in floor panelling 20 when, for example, floor assembly 44 is supporting the weight of a person. Insulation 58 provides a thermal and noise insulating effect. It is also preferably non-flammable to avoid ignition when penetrations 60 are being cut into floor assembly 44. 10 In any of the embodiments described above, floor panelling 20 preferably comprises one or more of: a compressed cement sheet (50, i.e. T&G@ compressed cement sheet); tongue-in-groove floor-panels; tiles (46) adhered to sheeting (50); magnesium oxide boards or sheeting (50); or moulded flooring which is particularly useful in cases where multiple units 10 15 are being constructed to the same specifications. As opposed to simply designing module 10 to fit a particular space in a building 62, building 62 itself (as shown in Figure 5) may be configured to receive module 10. For example, a set down region 42 as previously discussed may be provided, which region 42 is of a predetermined depth so 20 that when module 10 is received therein, the surface of floor panelling 20 is level with the surrounding flooring 64 of building 62. In addition, the thickness of floor assembly 44 may be adjusted to suit the set down 42 by, for example, using thicker tiles 46 or screed layer 48. Now turning to wall panelling 18 - wall panelling 18 preferably consists 25 of a sandwich panel comprising an interior sheeting 66 and an exterior skin 68 between which a filler or insulating layer 70 is disposed. Interior sheeting 66 is preferably rigid, but must still allow for accurate penetration and easy adhesion of tiles and/or other internal wall cladding (72). It is also preferable that interior sheeting 66 be able to sustain transverse loads such as a sheet 30 of tiles 72. In this regard, it is has been found that a sanded fibre cement sheet (such as Villaboard@ - which is impact resistant, though easy to fix fittings to) is particularly suitable. Exterior skin 68 is preferably able to be 20/04/2011, SAW103878.cap.spc, 11 - 12 quickly fixed to horizontal members 16. It should also be easy to cut, impact resistant, provide some structural rigidity and, along with filler or insulating layer 70, absorb point loads. In this regard, it has been found that steel sheeting (such as Colorbond@) is quite suitable. In addition to the above 5 described desirable attributes of an external skin 68, Colorbond@ also provides a degree of waterproofing which can be advantageous in circumstances where module 10 is exposed to poor weather. Finally, filler or insulating layer 70 is chosen to provide any desired properties (i.e. thermal/noise insulation) and is preferably made from polystyrene. 10 Having regard to the foregoing, wall panelling 18 comprising a sandwich panel which consists of: an interior Villaboard@ or magnesium oxide sheet 66 of around 6mm; a filler or insulating layer 70 of around 44mm; and, an exterior Colorbond@ skin 68 of around 0.4mm; has been found suitable for most applications. This results in a preferred sandwich wall panel 15 having an overall thickness of approximately 50mm. In addition to wall panelling 18 of module 10, wall cladding 76 (i.e. plasterboard - see, for example, Figure 5) of adjacent rooms must be taken into consideration when designing module 10. As discussed above, frame 12 preferably contains no wall studs or nogging which would otherwise provide 20 anchor points for adjoining wall cladding 76. To address this potential deficiency, a further sheet of external cladding 74 (see Figure 1) is preferably fixed to module 10 to provide a structure to which adjoining wall cladding 76 of neighbouring rooms can be secured. In addition, as a preferred metal skin 68 is desirable for the reasons provided above, it would also be desirable that 25 external cladding 74 be manufactured from metal to allow ease of coupling (i.e. by pop riveting, etc) with skin 68. In this regard, external cladding 74 such as Trimdeck@ or Monoclad@ has been found very suitable, as it is both manufactured from metal and includes intermittent channels or projections 78 (see Figure 1) which act as ribs for attachment of wall cladding 76 of adjacent 30 rooms. In addition, cabling and plumbing of module 10 can be positioned between these channels 78 in a similar manner to that permitted by studded walls. 20/04/2011, SAW103878.cap.spc, 12 - 13 By using an additional external cladding 74, provided with channels or projections 78, such as that shown in Figure 1, a module 10 results which is conveniently provided with external cavities for the provision of cabling, plumbing, or the likes. It is considered that this preferred arrangement of a 5 module 10 with external cavities is very advantageous for multi level buildings. In respect of ceiling panelling 22, as best seen in Figure 6, any suitable ceiling panelling 22 may be used. However, a suspended plasterboard ceiling 80, or a ceiling comprising a series of furring channels 10 with internal panelling affixed thereto (not shown), is preferred as they are light-weight and wiring, etc, can be concealed behind them. In the case of a suspended ceiling, as is shown in Figure 6, plasterboard 80 is preferably fixed by flexible members 82 to a substrate 84 which preferably comprises a skin 86 and an insulating layer 88. It has been found that a 75mm 15 polystyrene panel 88 sandwiched between a pair of 0.6mm Colorbond@ sheets 86 is particularly suitable for most applications. In particular, this form of sandwich panel can, for most module 10 sizes, support the weight of a tradesperson and thus provide a safe work platform and avoid any significant deflection which could otherwise damage module 10. 20 To ensure correct levelling is achieved upon installation of module 10, bearing plates 90 (as shown in Figure 6) may be welded, or otherwise affixed/coupled, to the corners of frame 12. In practice, bearing plates 90 ideally would bed down onto a pre-prepared, surveyed, bearing pad, (not shown) provided in a set down region 42 of a building 62, upon installation. 25 With regard to installation, a completed module 10, as shown in Figure 7, need only be connected to utilities in order to be rendered functional. Module 10 is fitted offsite with all necessary components which provide that functionality, which components may include, but are not limited to: a junction box 92; general purpose outlet 94; hot and cold water pipes 96; exhaust fan 30 ducting 98; down light connections 100; a fan switch 102; and, sprinklers (not shown) where appropriate. 20/04/2011, SAW103878.cap.spc, 13 -14 It will be appreciated that certain components of module 10 (for example, lifting points 32, external cladding 74, etc) are not shown in Figure 7 in order to simplify the drawing. Similarly, although not shown, modules 10 may include additional components that may be necessary or preferred in 5 order to simplify the installation process. For example, although not shown, modules 10 could include a series of rods (which may be threaded) comprising formwork projecting upwards from respective corners of module 10 that could be used to assist with aligning further modules 10 positioned on a floor directly thereabove. In this way, such formwork could project through 10 the slab laid above modules 10, so that subsequent modules can be readily aligned on above floors of a building 62 using the projecting portions of the rods. Should such formwork be used, lifting points 32 may be disposed at end portions of those rods instead of being disposed adjacent the corners of module 10 as shown in the drawings. Accordingly, the present invention 15 should be construed as including within its scope such variations in design that may not be shown in the drawings. Module 10 described above is ideally suited to an integral structural design that can accommodate a set down 42 of between approximately 60mm to 115mm, more preferably a set down 42 of between 66mm to 70mm, 20 in a concrete slab of a building 62, for receipt of a completed room module 10 (e.g. a bathroom room module 10 as shown in Figure 1). Thus, it may be that a completed room module 10 can be delivered and installed on site within 24 to 48 hours of pouring the abovementioned slab. Once installed, the slab of the floor above (for multi level buildings 62) can be formed and 25 poured, and the procedure repeats itself, though various embodiments may be suitable for use in single level and domestic buildings which may/may not include a slab. Construction and Installation Modules 10 are preferably assembled offsite and a plurality of 30 modules 10 can be simultaneously constructed in an assembly line manner. After assembly, modules 10 can be moved to site and into position using any appropriate means. For example, modules 10 can be dimensioned such that 20/04/2011, SAW103878.cap.spc, 14 - 15 they fit onto a flat-bed truck or modified rig and thereby be transported to site. They can then be moved into position by a crane, or the likes. In assembling and installing a preferred bathroom module 10, trade contractors of various types may be required. The typical steps performed by 5 such people may include: (a) welding frame 12 to support module 10, and attaching a door frame 24 thereto; (b) cutting floor panelling 20 and fixing same to joists 36 (i.e. by gluing and/or screw fixing); (c) cutting floor waste penetrations 60 to allow plumbing to connect from fittings 26 within module 10 to external sewerage systems, etc; (d) cutting wall panelling 18, fitting and 10 securing same to frame 12 (i.e. by pop riveting and/or screw fixing) - this may include the use of purpose made aluminium extrusions, or the likes; (e) drilling/cutting all penetrations (not shown) for electrical and plumbing installations in wall panelling 18 - electrical and plumbing installations can include, but are not limited to: exhaust and ceiling fans, taps, shower 15 assemblies, sanitary fittings, light fittings and switches, power outlets and heaters; (f) building all remaining wall panels 18 (i.e. internal cladding) and recesses to suit specified requirements for module 10 - these panels and recesses may include, for example, a box in which a bath tub will sit, sauna panelling, dado or wainscot finishing, and partitioning to section off portions 20 of the room; (g) connecting waste outlets for the bath, shower, toilet, basin, floor waste and hot/cold water supply, to floor penetrations 60; (h) installing wiring for later attachment to fittings 26 - it is preferred that fittings 26 are not installed at this stage due to the potential for damage whilst other works are being completed; (i) installation of exhaust fan and sprinkler (rough-in); (j) 25 suspending false plasterboard or magnesium oxide ceiling 80, or ceiling comprising furring channels with internal cladding affixed thereto, installing flush square cut joints to corners or provide cornices as specified; (k) painting ceiling and wall panelling 18, 22 with sealer and applying a first coat of top coat colour thereto; (1) providing screeds 48 to falls as required, depending 30 on fittings 26 in module 10 (i.e. shower areas); (m) applying waterproofing membrane to walls 18 and floor 20 wet areas; (n) installing vanity units, toilets and cisterns - i.e. fittings 26; (o) installing wall 72 and floor 46 tiles; (p) 20/04/2011, SAW103878.cap.spc, 15 - 16 applying grout to tiled areas and silicon to wet area surface intersections; (q) installing shower screens and mirrors - i.e. further fittings 26; (r) fit taps and remaining fittings 26 and pressure test system; (s) installing light fittings, switches, remaining fans and other fittings 26, and installing a junction box 92 5 on the roof or other appropriate position; (t) fitting remaining fittings/finishings 26 (i.e. timber doors, towel rails, hooks and door stops); (u) applying the final top coat; (v) cleaning module 10; (w) conducting a quality insurance inspection; and, (x) moving module 10 into position - this step may involve: a forklift or crane operator moving module 10 onto a vehicle and from the 10 vehicle to its final position; a truck or float operator transporting module 10 to site; and, a rigger for attaching the crane to module 10 and module 10 to the truck. Offsite assembly of modules 10 can be particularly useful for steps such as (k), (1), (n), (p) and (r) outlined above, in which curing and drying time 15 is required before module 10 is available for further work. Trade contractors can work on other modules 10 while awaiting completion of the curing and drying processes. This ensures that individual trade contractors are utilised for a greater proportion of their time than might otherwise be achievable if modules 10 were constructed in situ, thus reducing labour costs. 20 There are additional advantages provided by constructing modules 10 offsite. In a factory setting, including, but not limited to: the environment is easier to control and is thus safer; equipment does not need to be moved long distances, into elevators or up flights of stairs; similar processes can be undertaken sequentially, improving task efficiency and reducing overall 25 project time and carrying costs (i.e. interest); materials need not be stored for long periods or in specific storage areas on site; due to improved accessibility to the area around the module, defects can be corrected rapidly whereas, under onsite construction conditions, defects lists can take months to correct; and, fittings 26 can be installed at the latest possible time during the 30 assembly process and are thus not as exposed to foot and tooling traffic as might be the case in multi level buildings 62. 20/04/2011, SAW103878.cap.spc, 16 -17 Finally, subdivisions and buildings 62 are susceptible to break-in during construction even after new appliances and fittings 26 have been installed. The factory environment ensures that such appliances and fittings 26 are locked safely away for a large proportion of the construction cycle. 5 Wherever it is herein specified that various components are attached, for example by welding, it will be appreciated that any other appropriate method of attachment may be employed (i.e. bolting, adhesion or pop riveting, etc) without departing from the spirit and scope of the present invention. 10 In addition, specified wall, floor and roof panelling 18, 20, 22 may be replaced with other suitable panelling. For example, the Scyon@ cement sheeting 50 or panelling 18, 20, 22 may be replaced with a magnesium oxide material which itself may be provided as tongue-in-groove panels, rather than sheeting, and/or as a panel with a honeycomb structure, and/or be semi 15 structural in nature so as to improve the rigidity of module 10. Depending on the application and size of module 10, panelling 18, 20, 22 may also be moulded or sprayed into a desired shape. Wall, floor and roof panelling 18, 20, 22 may also be modified to suit any application. For example, floor panelling 20 may be fixed directly to 20 joists 36 and bearers 34, if appropriate to do so, without the need for a screed 48 or layer of cement sheeting 50. Finally, dimensions provided are only exemplary in nature. The dimensions of materials used for any particular module 10 will depend on design constraints, among other considerations. In addition, individual 25 features are not drawn to scale relative to each other. For example, flooring features 20, 54, 56 and 58 in Figure 4 may have different relative dimensions such that, for example, panelling 54 is the same width as insulation layer 58 in practice. While this invention has been described in connection with specific 30 embodiments thereof, it will be understood that it is capable of further modification(s). The present invention is intended to cover any variations, uses or adaptations of the invention following in general, the principles of the 20/04/2011, SAW103878.cap.spc, 17 - 18 invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth. 5 As the present invention may be embodied in several forms without departing from the spirit of the essential characteristics of the invention, it should be understood that the above described embodiments are not to limit the present invention unless otherwise specified, but rather should be construed broadly within the spirit and scope of the invention as defined in 10 the attached claims. Various modifications and equivalent arrangements are intended to be included within the spirit and scope of the invention. Therefore, the specific embodiments are to be understood to be illustrative of the many ways in which the principles of the present invention may be practiced. 15 Where the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification, they are to be interpreted as specifying the presence of the stated features, integers, steps or components referred to, but not to preclude the presence or addition of one or more other features, integers, steps, components to be grouped therewith. 20/04/2011, SAW103878.cap.spc, 18

Claims (13)

1. A substantially complete room module comprising: 5 a frame comprising: first and second pluralities of interconnected generally horizontal members; and, a plurality of upright members disposed at least at corner regions of the room module and being connected to the first and second pluralities of 10 interconnected generally horizontal members, thereby spacing the first plurality of interconnected horizontal members from the second plurality of interconnected horizontal members; and, a door frame, rigidly connected to the frame, for receiving a door; wall, floor and ceiling panelling respectively forming the walls, floor 15 and ceiling of the room module, which panelling is supported by the frame; wherein the room module is assembled offsite to a substantially complete state.

2. The substantially complete room module according to claim 1, wherein 20 the upright members are disposed, in use, exclusively at corner regions of the room module.

3. The substantially complete room module according to claim 1 or claim 2, further including cladding disposed between at least two of the upright 25 members and secured to at least one of the frame and/or the wall panelling, the cladding including channels, or projections, to which wall cladding of adjacent rooms can be secured once the room module is installed, wherein the channels or projections provide external cavities for concealing service connections, fittings or the like. 30

4. The substantially complete room module according to any one of the preceding claims, wherein at least one of the wall, floor and ceiling panelling is formed from a magnesium oxide material. 20/04/2011, SAW103878.cap.spc, 19 - 20

5. A frame for a room module comprising: first and second pluralities of interconnected generally horizontal members; and, a plurality of upright members disposed, in use, at least at corner 5 regions of the room module and being connected to the first and second pluralities of interconnected generally horizontal members, thereby spacing the first plurality of interconnected horizontal members from the second plurality of interconnected horizontal members, wherein a wall, floor and ceiling of the room module are able to be 10 supported by the frame.

6. The frame according to claim 5, wherein the upright members are disposed, in use, exclusively at corner regions of the room module. 15

7. The frame of the substantially complete room module according to any one of claims 1 to 4, or the frame according to claim 5 or claim 6, constructed of a metal or alloy material.

8. A method for manufacturing a frame according to claim 7, the method 20 including the step of welding the members of the metal or alloy frame together to form a substantially rigid structure.

9. A method of constructing a multi level building incorporating prefabricated substantially complete room modules, the method including the 25 steps of: (i) pouring a slab; (ii) positioning at least one prefabricated room module on the slab; (iii) pouring a further slab directly above the previously poured slab having the at least one prefabricated room module positioned thereon; (iv) positioning at least one prefabricated room module on the slab poured at step (iii); and, repeating steps (iii) & (iv) for all levels of the multi 30 level building. 20/04/2011, SAW103878.cap.spc, 20 - 21

10. The method of constructing a multi level building according to claim 9, utilising prefabricated substantially complete room modules according to any one of claims 1 to 4. 5

11. A frame, substantially as hereinbefore described with reference to the accompanying drawings and/or examples.

12. A substantially complete room module, substantially as hereinbefore described with reference to the accompanying drawings and/or examples. 10

13. A method for manufacturing a frame for a room module, substantially as hereinbefore described with reference to the accompanying drawings and/or examples. 20/04/2011, SAW103878.cap.spc, 21