AU2018100859B4 - Modular cassettes, panels and kits for constructing residential structures - Google Patents

Abstract

A prefabricated module as part of a domestic structure, comprising at least one board of rectangular shape having sufficient structural strength to meet domestic loading requirements, and a support frame fixedly coupled to the board, wherein a plurality of the prefabricated modules can be assembled as part of a kit for assembling a domestic structure.

Description

“Modular cassettes, panels and kits for constructing residential structures”

Technical Field [0001] The described embodiments relate generally to prefabricated components and kits using modular structures for residential structures and methods of their use or assembly. Particular embodiments relate to modular cassettes and panels suitable for use as various structural elements of at least part of a residential structure.

Background [0002] Construction of residential buildings is a complex process requiring the coordination and management of various materials, equipment, activities, and personnel. Along with potential safety issues, this can be time-consuming and/or expensive.

[0003] Specialist heavy equipment, such as large cranes, is often required for the construction process. Due to cost, such equipment is hired and therefore may not always be available. Access to site can be an inconvenience particularly in residential areas. It is desirable to minimise the amount of hire time.

[0004] Coordination and management of the construction process is a significant contributor to the time and cost of the project. Specialist tradespeople need to be on site at the correct time to synchronise their work activities with other specialist tradespeople on other aspects of the project.

[0005] The timing and progress of certain work activities may also be affected by adverse weather events.

[0006] The use of varying room sizes and arrangements requires custom structural elements for each area of the building, which adds complexity to the project.

[0007] Obtaining permits and certification of built structures can be a time-consuming and/or expensive process, particularly if designs vary across projects.

[0008] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0009] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

Summary [0009a] Some embodiments relate to an assembled domestic structure, comprising: an array of footing elements; a grid of horizontal structural floor members fixedly supported on the footing elements; and a plurality of prefabricated modules supported by the horizontal structural floor members, each prefabricated module comprising: a first board of rectangular shape having sufficient structural strength to meet domestic floor loading requirements; and a support frame fixedly coupled to the board, the support frame having a same length and width as the board and comprising first and second oppositely disposed end beams, first and second oppositely disposed side beams, and at least one intermediate beam extending from the first end beam to the second end beam, where each of the first and second end beams and the first and second side beams is formed of at least one metal section; wherein the length of each of the prefabricated modules is about 3.6m and the width of each of the prefabricated modules is about 1.8m; wherein the horizontal structural floor members define spaces therebetween to receive one or more of the prefabricated modules and comprise support means to support the one or more prefabricated modules when received in the spaces; wherein the structure further comprises columns to support a roof and a plurality of wall panels of uniform size disposed between the columns; and the structure further comprises the roof, wherein the roof comprises a grid of horizontal structural roof members and a plurality of the prefabricated modules received in spaces defined between the horizontal structural roof members, and further comprises roof sheeting spaced above the roof members.

[0009b] Some embodiments relate to a kit for assembling a domestic structure, comprising: an array of footing elements; a plurality of horizontal structural floor members to be assembled in a floor grid to be fixedly supported on the footing elements; and a plurality of prefabricated modules to be supported by the structural floor members, each prefabricated module comprising: a first board of rectangular shape having sufficient structural strength to meet domestic floor loading requirements; and a support frame fixedly coupled to the board, the support frame having a same length and width as the board and comprising first and second oppositely disposed end beams, first and second oppositely disposed side beams, and at least one intermediate beam extending from the first end beam to the second end beam, where each of the first and second end beams and the first and second side beams is formed of at least one metal section; wherein the length of each of the prefabricated modules is about 3.6m and the width of each of the prefabricated modules is about 1.8m; wherein the horizontal structural floor members, when assembled into the floor grid, define floor spaces therebetween to receive one or more of the prefabricated modules in each floor space and comprise support means to support the one or more prefabricated modules when received in the spaces; wherein the kit further comprises: a plurality of columns to connect to the horizontal structural floor members to support a roof; a plurality of wall panels of uniform size to be disposed between the columns; a plurality of horizontal structural roof members to be assembled in a roof grid to be fixedly supported on the columns; and a further plurality of the prefabricated modules; wherein the horizontal structural roof members, when assembled into the roof grid, define roof spaces therebetween to receive one or more of the further plurality of prefabricated modules in each roof space and comprise support means to support the further plurality of prefabricated modules when received in the spaces.

[0010] Some embodiments relate to a prefabricated module as part of a domestic structure, comprising: a first board of rectangular shape having sufficient structural strength to meet domestic floor loading requirements; and a support frame fixedly coupled to the board, the support frame having a same length and width as the board and comprising first and second oppositely disposed end beams, first and second oppositely disposed side beams, and at least one intermediate beam extending from the first end beam to the second end beam, where each of the first and second end beams and the first and second side beams is formed of at least one metal section or purlin.

[0011] The length of the module may be about 3.6m and the width of the module is about 1.8m. A thickness of the board may be about 20mm. The board may be formed of a cement comprising magnesium oxide. The at least one section or purlin may be formed of a steel material having a thickness of around 2mm. The module may further comprise a second board fixedly coupled to the support frame on an opposite side of the support frame from the first board.

[0012] Some embodiments relate to an assembled domestic structure, comprising: an array of footing elements; a grid of horizontal structural floor members fixedly supported on the footing elements; and a plurality of any of the modules described above or herein; wherein the horizontal structural floor members define spaces therebetween to receive one or more of the modules and comprise support means to support the one or more modules when received in the spaces.

[0013] The structure may further comprise columns to support a roof and a plurality of wall panels disposed between the columns.

[0014] The structure may further comprise the roof, wherein the roof comprises a grid of horizontal structural roof members and a plurality of the modules received in spaces defined between the horizontal structural roof members, and further comprising roof sheeting spaced above the roof members.

[0015] The wall panel may comprise a support frame fixedly coupled to a first wall board, the support frame having a same length and width as the first wall board and comprising first and second oppositely disposed end studs, first and second oppositely disposed side studs, and at least one intermediate stud extending from the first end stud to the second end stud, where each of the first and second end studs and the first and second side studs is formed of at least one metal section.

[0016] The wall may further comprise a second wall board fixedly coupled to the support frame on an opposite side of the support frame from the first wall board.

[0017] The width of the panel may be about 1.2m, and the length of the panel may be about 2.4m or about 2.7m according to some embodiments.

[0018] Some embodiments relate to a kit for assembling a domestic structure, comprising: an array of footing elements; a plurality of horizontal structural floor members to be assembled in a floor grid to be fixedly supported on the footing elements; and a plurality of any of the modules described above or herein; wherein the horizontal structural floor members, when assembled into the floor grid, define spaces therebetween to receive one or more of the modules and comprise support means to support the one or more modules when received in the spaces.

[0019] The kit may further comprise a plurality of columns to connect to the horizontal structural floor members to support a roof and a plurality of wall panels to be disposed between the columns.

[0020] The kit may further comprise: a plurality of horizontal structural roof members to be assembled in a roof grid to be fixedly supported on the columns; a further plurality of any of the modules described herein; wherein the horizontal structural roof members, when assembled into the roof grid, define spaces therebetween to receive one or more of the further plurality of modules and comprise support means to support the one or more modules when received in the spaces.

[0021] Individual modules can be positioned in different orientations relative to each other. The support structure may be formed by at least one type of extruded metallic material.

[0022] Some embodiments relate to a method of erecting a module assembly from a package kit, comprising: positioning at least one module as described above or herein to be supported in relation to a support structure.

[0023] The positioning may comprise positioning two of the modules adjacent to each other along a component of the support structure.

[0024] Some embodiments relate to a method of manufacturing a module, the method comprising: fixedly coupling various constituent parts to form a body, together having a length, a width, and a depth, a first end, an opposite second end, a first side, an opposite second side, a first major face defined by a surface extending from the first end to the second end and from the first side to the second side, and a second major face opposite the first major face, and minor faces located at and defined by the surfaces extending between the perimeters of the two major faces; forming the major faces and minor faces to feature a plurality of mounting formations to facilitate mounting of the module to supporting structure; and forming the minor faces to be geometrically oriented such that they may be coupled with the corresponding minor face of another body of the same type; [0025] Some embodiments relate to a residential structure comprising a plurality of any of the modules described above.

[0026] A body of the module may comprise means to contain or support ancillary devices such as insulation, electrical cabling, and/or plumbing; such means may include but are not limited to a cavity and/or attachment brackets. The means to contain ancillary devices may comprise recesses created by the orientation of the beams.

[0027] At least the side beams may comprise mounting formations including male and/or female connectors. The length of the module may be between about 2m and 4m. The width may be between about lm and 2m. A depth of the module may be between about 150mm and 300mm. The beams may be formed by at least one type of extruded metallic material.

Brief Description of Drawings [0028] Embodiments are described in further detail below, by way of example, with reference to the accompanying drawings, in which: [0029] Figure 1A is an exploded perspective view of a cassette according to some embodiments; [0030] Figure IB is an inverse view of the assembled cassette of Figure 1A; [0031] Figure 2 is a perspective view of two of the assembled cassettes of Figure 1A; [0032] Figure 3 is an exploded view of the assembled cassettes of Figure IB and adjacent supporting structural members according to some embodiments; [0033] Figure 4 is a perspective view of the footing system; [0034] Figure 5 is a perspective view of two instances of the assembled cassettes and their adjacent supporting structural members of Figure 3, located on the footing system of Figure 4. Additional structural members in the form of columns for support of another embodiment of the cassette are shown; [0035] Figure 6A is an exploded perspective view of a wall panel according to some embodiments; [0036] Figure 6B is a partially exploded perspective view of a wall panel according to some embodiments; [0037] Figure 6C is a perspective view of the assembled wall panel of Figure 6 A; [0038] Figure 7 is a perspective view showing a general arrangement of multiple panels of Figures 6A and 6B mounted to each other and to supporting structure, with applicable apertures forming a window in a wall; [0039] Figure 8 is a perspective view of the general arrangement of Figure 7 together with a roof structure comprised of additional cassettes of another embodiment related to Figure 1 A; [0040] Figure 9 is a general perspective view of a complete assembly of various embodiments; [0041] Figure 10 is a plan view of the footing system on which the support structure is based; [0042] Figures 11A and 11B provide section views of two configurations of adjacent supporting structural members according to some embodiments; [0043] Figure 12A is a section view at the location marked on Figure 10, and is a connection detail for the roof cassettes and floor cassettes to the structural columns showing the assembled cassette, structural column, and associated connection details; [0044] Figure 12B is a section view at the located marked on Figure 10, and is a connection detail for the roof cassettes and floor cassettes to the structural columns showing the assembled cassette, structural column, and associated connection details; [0045] Figure 13 is a section view at the location marked on Figure 10, and is a connection detail for the floor cassette to the structural column showing the assembled cassette, structural column, and associated connection details; [0046] Figure 14 is a section view at the location marked on Figure 10, and is a connection detail for the structural column to the support structure main beam of configuration in Figure 11B, and also shows connection details for the assembled cassette to the support structure main beam; [0047] Figure 15 is a section view at the location marked on Figure 10, and is a connection detail for the structural column to the support structure main beam of configuration in Figure 11A and also shows connection details for the assembled cassette to this support structure main beam; [0048] Figure 16 is a plan section view showing how panels of Figures 6A and/or 6B according to some embodiments can be mounted to a mounting structure; [0049] Figure 16 is a plan section view showing the internal structure of panels of Figures 6A and/or 6B according to some embodiments; [0050] Figure 17 is an elevation view of Figure 7, and shows typical dimensions and connections; [0051] Figure 18 is an assembly detail of Figure 8 for the roof cassettes and secondary structures including roof sheeting, fascia, gutters, and siphonic drainage systems; [0052] Figure 19A is section view at the location marked on Figure 10; and [0053] Figure 19B is a section view at the location marked on Figure 10.

Detailed Description [0054] The described prefabricated modules function as part of a package comprising cassettes, panels, and support structure which can be used to form at least part of a residential structure, for example. When used together with support structures, the described cassettes and panels can extend across a large area, horizontally as well as vertically. This system enables a modular approach to design and construction of a residential structure which can reduce overall design and construction time and cost.

[0055] The prefabricated cassette and panel modules reduce the time on site required of specialist tradespersons and equipment hire.

[0056] The described cassettes and panels are fabricated and assembled off-site in a controlled environment from materials described herein. Standardisation of parts means fabrication and assembly can be performed in a timely manner, and the individual cassettes and panel modules provide for a lighter and more easily transportable form than prefabricated residential structures of the prior art.

[0057] Formation of the cassettes and panels with components made from standard materials and sections available in the industry permits the replacement of individual components.

[0058] Bathroom and/or kitchen units may be supplied as prefabricated “pod” units which interface directly with the cassette and panel modules, and support structure.

[0059] The described cassettes and panels are or can include modules of several pre-determined sizes, for example to suit various load requirements in accordance with the applicable international and Australian Standards, and building codes. Cassettes denote floor and roof embodiments, while panels denote wall embodiments. Modules denote the general concept of prefabricated cassettes and panels.

[0060] The described cassettes and panels are formed by fixedly coupling various constituent parts together to create a lightweight body with stiffness and rigidity in the desired loading planes.

FLOOR CASSETTES

[0061] Referring now to Figures 1A and IB, a floor cassette 100 according to some embodiments will now be described in further detail. Floor cassette 100 comprises a first end 101 with first end face 104, an opposite second end 101a with second end face 104a, a first side 102 with first side face 104b, an opposite second side 102a with second side face 104c, a first major face 103, and a second major face 103a. The first end face 104 is parallel to the second end face 104a, and the first side face 104b is parallel to the second side face 104c. The end faces 104 and 104a are perpendicular to the side faces 104b and 104c. Collectively, the faces 104, 104a, 104b, and 104c may also be referred to as “minor faces”. The minor faces 104, 104a, 104b, and 104c may be contoured to facilitate positioning adjacent to the corresponding minor faces of another cassette 100 or with the support structure main beams 120a. The first major face 103 has a level surface which provides an extended uniform surface when two cassettes 100 are positioned adjacently. The second major face 103a is on the opposite side to the first major face, and in conjunction with the stiffening members 121, defines a plurality of surface variations on the inverse of cassette 100. The exposed surfaces of the stiffening members 103b are parallel to 103a. There may also be a plurality of mounting formations on the major and minor faces to facilitate mounting of the cassette 100 to the supporting structure main beams 120a.

[0062] A frame 120 is created by fixedly coupling various stiffening members 121. These members 121 span the length and width of cassette 100 at a designated spacing. One embodiment of 120 is illustrated in Figure IB, where there are four equally-spaced stiffening members along the length (121a) of cassette 100, and a further two stiffening members along the width (121b), although the number and spacing of stiffening members 121a and 121b may vary across different embodiments. The designated spacing is intended to reduce the loaded span of the board 110 and provide rigidity to the overall structure of the cassette 100 or panel 150.

[0063] For floor cassettes 100, stiffening members 121 are or comprise elongate sections, typically comprising “Boxspan” B20020 steel sections with a cross section measuring 200mm x 50mm and section wall thickness 2mm, or steel sections such as the “Hopley HJ 200” open web joist section, although these are examples only and are not intended to be limiting. In other known embodiments, for example panel 150, stiffening members 121 can be 75mm deep steel studs (133). The use of steel does not preclude stiffening members 121 being made from alternative materials comprising timber, aluminium, or plastic, such as a polyolefin material, for example. In some embodiments, the cross-sectional size and shape of the stiffening members may vary, to suit the load and span requirements. The lengths of stiffening members 121 are to be sized to achieve the required overall cassette or panel dimensions, and fixedly coupled by means of removable connectors, such as brackets and “Tek” screws provided by the supplier, although this is intended to be illustrative and not restrictive.

[0064] A board 110 is fixedly coupled to the frame 120 as shown in Figures 1A and IB. The combination of board 110 and frame 120 defines a series of recesses and cavities 105 in between the stiffening members 121. These recesses and cavities 105 may be used to accommodate secondary features such as insulation 132, wiring harness 130, and other services 131. Typical wiring 130 may include electrical and data cabling. Typical services 131 may include water, gas, and sewage piping. Removable connectors such as nuts and bolts may be used to attach the board 110 to the frame 120, and the secondary features to the board or frame. Different connectors may be used in different embodiments and their specification is intended to be illustrative and not restrictive.

[0065] As illustrated in Figure 2, individual floor cassettes 100 have a typical length of about 3600mm, a typical width of about 1800mm, and a typical depth of about 220mm, although some small variation to these dimensions may occur during manufacturing and assembly. Example dimensions given in the Figures are expressed generally in millimetres for distances or degrees for angles. These dimensions may vary in different embodiments and are intended to be illustrative, not restrictive.

SUPPORT STRUCTURE

[0066] Figure 3 shows the main members 120a of the support structure. These are elongate sections, typically comprising steel rectangular hollow section (RHS) with cross section measuring 200mm x 100mm and have a section wall thickness of 4mm. These act as main structural beams for the roof and floor. The beam size and shape used for the floor may not be the same size and shape used for the roof. In some embodiments, the cross-sectional size and shape of the main members 120a may vary, to suit the load and span requirements. For example, steel “I” or “H” beams may be used for the roof or floor. In other embodiments, the main structural beams may comprise alternative materials to steel, for example timber, aluminium, or plastic such as a polyolefin material. Members 120a are available in different configurations depending on the number of cassettes to be supported (Figure 11A and 1 IB). Members 120a are positioned adjacent and parallel with end faces 104 and 104a of cassette 100.

[0067] With reference to Figures 7, 9, 10, and 13, member 120b is positioned adjacent and parallel to side faces 104b and 104c of cassette 100. Member 120b may be or comprise an elongate folded steel section of cross section about 200mm deep and about 25mm wide, for example, or of similar dimensions, such that adequate support and connection for the wall panel 150 is provided. In some embodiments, the material and the cross-sectional size and shape of member 120b may vary to suit the load and span requirements.

FOOTING SYSTEM

[0068] Figure 4 is a perspective view of the layout of the footing system 106 with indicative dimensions. The footing systems used may be or comprise a third-party proprietary product, for example the “Mega Anchor Footing” or “Sure Foot” system, installed at 3700mm centres directly beneath columns 114.However, footing installation at other locations may be necessary depending on site requirements, and so 3700mm centres may not be used in some embodiments.

[0069] Separate bathroom and kitchen “Pod” modules may be fitted to add user amenity. Pods for bathrooms (107) and kitchens (108) are assembled on a standard floor cassette at an off-site factory, together with all required fixtures and fittings, finishes and sealing, electric and water services and similar. The pods are fully finished ready for installation on-site and connected by plugs through standard off-the-shelf plug and play assemblies. Example systems are electric systems by CMS Electron, hot and cold water systems by Sharkbite, and drainage systems by Geberit.

[0070] Figure 5 is a perspective view of the positioning of the cassettes 100 in relation to the support structure members 120a and support structure columns 114. Figures 12A, 12B, 13 to 15 are section views of the floor cassette 100 in position with support structure. The board 110 is nominally an inert material, such as magnesium oxide board, for example. Other board materials may be used in other embodiments, and the use of magnesium oxide board does not preclude use of alternative board materials. In some embodiments, the board 110 may comprise a composite material or composite structure, such as sandwich panels comprising metal or plastic or timber layers combined with layers of other metal, plastic and/or wood materials. The thickness of board 110 is nominally about 20mm, although this may vary across other embodiments, may vary depending on the board material used, and is intended to be illustrative, not restrictive. The cassettes and panels are attached to columns 114 and main beams 120a by means of a bracket 115 and a nut and bolt arrangement 116. Similar forms of connection to 115 may include, but are not limited to, cleats 115a, top hats 115b, and plates 115c.

WALL PANELS

[0071] Figures 6A, 6B, and 6C show a further modular cassette or panel embodiment 150. Embodiment 150 is typically used as a divider or wall, and is henceforth referred to as a panel. As both major sides of panel 150 are visible and accessible, an additional board 110 is placed on the exposed faces of the stiffening members (103b) for cosmetic, safety, and functional purposes. This sandwiches the frame 120 between two boards 110. The internal cavity of panels 150 may contain insulation 132 and modularised connectable electrical cables 130. Inserts or cut outs, as illustrated in Figures 6B and 7, may be formed in boards 110 to accommodate windows and doors and their ancillary components.

[0072] Referring further to Figures 6A, 6B, and 6C, a wall panel 150 according to some embodiments is described in further detail. Wall panel 150 comprises a first end 151 with first end face 151a, an opposite second end 152 with second end face 152a, a first side 153 with first side face 153a, an opposite second side 154 with second side face 154a, a first major face 155, and a second major face 156. The first end face 151a is parallel to the second end face 152a, and the first side face 153a is parallel to the second side face 154a. The end faces 151a and 152a are perpendicular to the side faces 153a and 154a. Collectively, the faces 151a, 152a, 153a, and 154a may also be referred to as “minor faces”. The minor faces may be contoured to facilitate positioning adjacent to the corresponding minor faces of another wall panel 150, the supporting structure main beams 120a, or the support structure 114. The first major face 155 is a level surface which provides an extended uniform surface when two panels 150 are positioned adjacently. The second major face 156 is on the opposite side to the first major face and is similar to 155 in providing an extended uniform surface. There may also be a plurality of mounting formations on the major and minor faces to facilitate mounting of the panel to the supporting structure main beams 120a, or the support structure columns 114, using connections 115, 115a, 115b, and/or 115c as illustrated in Figures 12 to 17. Wall panels 150 have a width 1200mm and depth 90mm, although this may vary in different embodiments. The height of the panel may be 2400mm or 2700mm depending on the floor-to-ceiling height desired. In some embodiments, the height of the panel may be between 2000mm and 4000mm.

[0073] With reference to Figures 7 and 17, multiple wall panels 150 may be positioned end-to end in a line along members of the support structure. Adjacent wall panels are butted, and the joints sealed externally and internally to form an air gap with a pre-compressed impregnated resin joint sealing tape 117. The sealing tape expands into the joint to fully seal the joint but enables ease of removal for alterations or additions. A suitable sealing tape product is Tremco Illmod 600, for example.

[0074] Figure 16 is a section of the wall panel 150 and shows the construction of the panel and connection of the panel to vertical support structure 114, which may include vertical members, such as columns or stanchions. The frame 120 of panel 150 is a standard steel frame of similar form, manufacture, function, and configuration to the frame used for cassette 100. However, in the instance of panel 150, steel studs (133) measuring 75mm in width are used for the stiffening members 121. In some embodiments, stiffening members 121 may comprise an elongate section of varying size and material to satisfy loading requirements. Stiffening members 121 may be oriented along the length and width of the panel as per configuration for cassette 100. There may also be stiffening members located inboard, however their exact number and configuration may not be identical to that used in cassette 100. The panel is fixed to support structure 114 via steel stud 133.

[0075] With reference to Figure 16, the vertical members of the support structure 114 comprise node points which may include a steel square hollow section (SHS) column with cross section measuring 100mm x 100mm, and height 2400mm or 2700mm to correspond with wall panel 150. Section wall thickness of the column is nominally 2mm, although the thickness may vary depending on whether a second storey is supported. These columns transfer loads into the footing system 102. Support structure 114 attaches to main beams 120a by means of a cleat arrangement 115a. In some embodiments, the node points may comprise alternative materials and dimensions to satisfy loading requirements.

ROOF CASSETTES

[0076] Figures 8, 18, and 19 show alternative cassette embodiment 140. Cassette 140 is formed using cassette 100 as a starting point. Secondary structure in the form of graded battens and/or purlins 122 are positioned on the exposed faces of the stiffening members (103b), and are oriented parallel to stiffening members 121b. Roof sheeting 123 is subsequently fixedly coupled to the battens and purlins. Further additional secondary structure includes gutters 134, fascia 135, flashing 136, ceiling lining 137, and the siphonic drainage system 138. Cassette 140 is based on cassette 100 and therefore both cassettes are identical in form, manufacture, and configuration prior to the addition of any secondary structures.

[0077] Gutter 134 as shown in Figure 18 may typically be a box section with a cross section measuring 200mm x 150mm, fabricated from PVC “grey grade” to minimise the effects of thermal expansion/contraction and UV damage. It may also be possible to use steel, aluminium, or another plastic as an alternative material.

[0078] Figure 18 is a section view showing a typical arrangement of the roof sheeting 123, gutter 134, fascia 135, flashing 136, ceiling lining 137, and siphonic drainage system 138 relative to the roof cassette 140, support structure members 121a, and wall panel 150. Typical connection details for the roof cassette 140, support structure members 121a, and wall panel 150 are illustrated in Figures 12A and 12B, and feature connections by means of brackets 115 and a nut and bolt arrangement 116. Dimensions indicated are intended to be illustrative, not restrictive.

[0079] Figure 9 is a perspective view of the assembled residential structure with floor cassettes 100, wall panels 150, roof cassettes 140, and support structure members 120a and columns 114. Figure 19A is a section view showing the positioning of graded battens and/or purlins 122 to which the roof sheeting 123 is attached. Typical purlin sections are “z purlins”, although this is intended to be illustrative, not restrictive. Figure 19B is another section view from an alternative angle.

Claims (5)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

   1. An assembled domestic structure, comprising: an array of footing elements; a grid of horizontal structural floor members fixedly supported on the footing elements; and a plurality of prefabricated modules supported by the horizontal structural floor members, each prefabricated module comprising: a first board of rectangular shape having sufficient structural strength to meet domestic floor loading requirements; and a support frame fixedly coupled to the board, the support frame having a same length and width as the board and comprising first and second oppositely disposed end beams, first and second oppositely disposed side beams, and at least one intermediate beam extending from the first end beam to the second end beam, where each of the first and second end beams and the first and second side beams is formed of at least one metal section; wherein the length of each of the prefabricated modules is about 3.6m and the width of each of the prefabricated modules is about 1.8m; wherein the horizontal structural floor members define spaces therebetween to receive one or more of the prefabricated modules and comprise support means to support the one or more prefabricated modules when received in the spaces; wherein the structure further comprises columns to support a roof and a plurality of wall panels of uniform size disposed between the columns; and the structure further comprises the roof, wherein the roof comprises a grid of horizontal structural roof members and a plurality of the prefabricated modules received in spaces defined between the horizontal structural roof members, and further comprises roof sheeting spaced above the roof members.
2. 2. A kit for assembling a domestic structure, comprising: an array of footing elements; a plurality of horizontal structural floor members to be assembled in a floor grid to be fixedly supported on the footing elements; and a plurality of prefabricated modules to be supported by the structural floor members, each prefabricated module comprising: a first board of rectangular shape having sufficient structural strength to meet domestic floor loading requirements; and a support frame fixedly coupled to the board, the support frame having a same length and width as the board and comprising first and second oppositely disposed end beams, first and second oppositely disposed side beams, and at least one intermediate beam extending from the first end beam to the second end beam, where each of the first and second end beams and the first and second side beams is formed of at least one metal section; wherein the length of each of the prefabricated modules is about 3.6m and the width of each of the prefabricated modules is about 1.8m; wherein the horizontal structural floor members, when assembled into the floor grid, define floor spaces therebetween to receive one or more of the prefabricated modules in each floor space and comprise support means to support the one or more prefabricated modules when received in the spaces; wherein the kit further comprises: a plurality of columns to connect to the horizontal structural floor members to support a roof; a plurality of wall panels of uniform size to be disposed between the columns; a plurality of horizontal structural roof members to be assembled in a roof grid to be fixedly supported on the columns; and a further plurality of the prefabricated modules; wherein the horizontal structural roof members, when assembled into the roof grid, define roof spaces therebetween to receive one or more of the further plurality of prefabricated modules in each roof space and comprise support means to support the further plurality of prefabricated modules when received in the spaces.
3. 3. The structure of claim 1 or the kit of claim 2, wherein each of the plurality of prefabricated modules and/or each of the further plurality of prefabricated modules further comprises a second board fixedly coupled to the support frame of the prefabricated module on an opposite side of the support frame from the first board.
4. 4. The structure of claim 1 or claim 3 or the kit of claim 2 or claim 3, wherein each wall panel comprises a support frame fixedly coupled to a first wall board, the support frame having a same length and width as the first wall board and comprising first and second oppositely disposed end studs, first and second oppositely disposed side studs, and at least one intermediate stud extending from the first end stud to the second end stud, wherein each of the first and second end studs and the first and second side studs is formed of at least one metal section, wherein each wall panel further comprises a second wall board fixedly coupled to the support frame on an opposite side of the support frame from the first wall board, wherein each wall panel is configured to be load bearing.
5. 5. The structure of any one of claims 1, 3 and 4 or the kit of any one of claims 2 to 4, wherein the width of each wall panel is about 1.2m, and the length of the panel is about 2.4m or about 2.7m.