AU2019204861A1

AU2019204861A1 - Hinged Roof Module

Info

Publication number: AU2019204861A1
Application number: AU2019204861A
Authority: AU
Inventors: Ryan BAXTER
Original assignee: CSR Building Products Ltd
Current assignee: CSR Building Products Ltd
Priority date: 2018-07-06
Filing date: 2019-07-05
Publication date: 2020-01-23

Abstract

Abstract 5 A prefabricated roof module comprising a ceiling subassembly and a rafter subassembly is transformable between a flat pack configuration for ease of transportation and an inclined in-use configuration for forming the roof or roof support of a building in which 10 the ceiling subassembly comprises a multitude of spaced apart substantially parallel ceiling framework members hingedly connected at one respective ends collectively to respective one ends of spaced apart substantially parallel rafter members forming the rafter subassembly. Different 15 length webs movably attached to either the ceiling framework members or the rafter framework members at spaced apart locations extend between the ceiling subassembly and the rafter subassembly to support the rafter subassembly in the inclined in use configuration to 20 form the roof or roof support of the building. The advantage of the roof module is that after being manufactured in an off-site manufacturing facility, the module can be lifted into position and transformed into the inclined in use configuration to save time and money 25 during construction of the building. 11503789_1 (GHMatters) P108934.AU.1 5/07/19 14 32 35 35 -16 , 32 <12 14 FIGURE 10 -12 FIGURE 11 2

Description

HINGED ROOF MODULE

FIELD

The present description relates to prefabricated building products and to the manufacture of such prefabricated building products.

In one form the present description relates to building products in the form of modules or assemblies which contain various components interconnected to one another to form the building product, and to methods of manufacturing the modules or assemblies from the various components and installing the modules or assemblies in the form of the building products to construct building structures .

In one form the present description relates to modules or assemblies which can be converted or transformed between two different configurations, one configuration being suitable for transporting the modules or assemblies from one location to another location, and the other configuration being an in use configuration corresponding to the completed and installed configuration of the module or assembly on or within the building structure .

Embodiments of the present description find particular application as a roof module or assembly for use in constructing a building structure which module or assembly is manufactured in a manufacturing facility for transportation to a building site when in a first configuration, being a collapsed or retracted or flat configuration, and after location within the building structure in the first configuration, the roof module or assembly is able to be transformed so as to be lifted to

11503789_1 (GHMatters) P108934.AU.1 5/07/19 adopt an expanded or in use configuration for forming the roof or part of the support structure of the roof of the building structure.

Although specific embodiments of the roof module or assembly made from a variety of different components will be specifically described in the present description, including ways of transforming the roof module or assembly between different configurations, it is to be noted that the scope of protection is not restricted to the described embodiments or methods, but rather the scope of protection is more extensive so as to include other forms, modifications and variations of the module or assembly, and of the components from which the various modules or assemblies are manufactured, and the use of the various forms of the module or assembly in applications other than specifically described.

BACKGROUND

There is an increasing demand to develop innovative building products, and their manufacture and/or use in constructing building structures, in order to reduce costs associated with producing the building products themselves, and their installation in building structures in order to also reduce the cost associated with constructing the building structures. One of the activities which contribute to the high cost of constructing a building structure is the cost of the labour component of using experience and skilled tradespersons at the building site to construct the building structure. Although there have been previous attempts at reducing the labour costs of construction by having prefabricated building products made in a factory for transportation to a building site, such attempts have not been always entirely satisfactory due in part to the prefabricated products still requiring the services of

11503789_1 (GHMatters) P108934.AU.1 5/07/19 experienced and skilled tradespersons on site to install the prefabricated products at the building site, usually requiring more or less customisation of the pre-fabricated product to correctly and/or functionally fit the building product at the specific location within the building structure. Therefore, there is a need for innovative prefabricated building products which are adapted to be more efficiently and/or more readily installed by less experienced and skilled personnel at the building site by requiring less customisation or adaption to the specific location within the building structure, in order to reduce the overall cost of construction of the building.

Accordingly, it is an aim of the present description to provide an innovative building product which is adapted for ease of installation.

Accordingly, it is an aim of the present description to provide a method of manufacturing a building product which is adapted to be more readily and/or efficiently installed within a building structure, and typically at a lower cost.

Accordingly, it is an aim of the present description to provide an innovative method of installing a building product within a building structure allowing installation of the building product by less skilled and/or experienced tradespersons, and typically taking a reduced amount of time .

SUMMARY

According to one form of the present invention there is provided a roof module transformable between a first configuration and a second configuration, the roof module for forming a roof structure of a building,

11503789_1 (GHMatters) P108934.AU.1 5/07/19 the roof module comprising:

a ceiling subassembly including individual ceiling elements interconnected to one another to form the ceiling subassembly, a rafter subassembly including individual rafter elements interconnected to one another to form the rafter subassembly and interconnecting elements movably connected to selected rafter elements of the rafter subassembly, the ceiling subassembly and the rafter subassembly being movable with respect to one another for facilitating transformation of the roof module between the first configuration and the second configuration, the individual rafter elements and the individual interconnecting elements being movable in unison when the rafter subassembly moves from the first configuration to the second configuration, the interconnecting elements being movable with respect to the selected rafter elements between a first position and a second position in response to movement of the rafter subassembly with respect to the ceiling subassembly from the first configuration to the second configuration, the first position adopted by the interconnecting elements corresponding to the first configuration of the roof module and the second position adopted by the interconnecting elements corresponding to the second configuration of the roof module, and when in the second position the interconnecting elements maintain the rafter subassembly in the second configuration with respect to the ceiling subassembly to form the roof structure of the building in which the roof module is installed.

According to one form of the present invention there is provided a method of installing a roof module on or within a building to form a roof structure of the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 building, the roof module comprising:

a ceiling subassembly including ceiling elements interconnected to one another to form the ceiling subassembly, a rafter subassembly including rafter elements interconnected to one another to form the rafter subassembly and movable interconnecting elements movably connected to selected rafter elements of the rafter subassembly, the ceiling subassembly and the rafter subassembly being movable with respect to one another to convert the roof module between a first configuration and a second configuration, the interconnecting elements being movable between a first position and a second position when the rafter subassembly moves in unison with respect to the ceiling subassembly from the first configuration to the second configuration, the first position adopted by the interconnecting elements corresponding to the first configuration of the roof module and the second position adopted by the interconnecting elements corresponding to the second configuration of the roof module, wherein movement of the interconnecting elements of the rafter subassembly from the first position to the second position is in response to movement of the rafter subassembly from the first configuration to the second configuration, and the interconnecting elements when in the second position maintain the rafter subassembly in the second configuration with respect to the ceiling subassembly for enabling the roof module to remain in the second configuration, the method comprising the steps of: locating the roof module when in the first configuration at a required location on or within the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 building, attaching the roof module to the building to maintain the ceiling subassembly fixedly in place, moving the rafter subassembly with respect to the ceiling subassembly so that the roof module adopts the second configuration, moving the interconnecting elements of the rafter subassembly from the respective first positions to the respective second position, and fixedly locating the interconnecting elements to the ceiling subassembly when the rafter subassembly is in the second position to maintain the roof module in the second configuration to form a support for the roof of the building.

According to one form of the present invention there is provided a method of manufacturing a roof module for forming a roof structure of a building, the method comprising the steps of:

forming a ceiling subassembly of ceiling elements interconnected to one another to form the ceiling subassembly, forming a rafter subassembly of rafter elements interconnected to one another to form the rafter subassembly and interconnecting elements movably connected to selected rafter elements of the rafter subassembly, connecting the ceiling subassembly and the rafter subassembly together to form the roof module, the ceiling subassembly and the rafter subassembly being movable with respect to one another for facilitating conversion of the roof module between a first configuration and a second configuration, and the rafter elements and the interconnecting elements being movable in unison in response to movement of the rafter subassembly with respect to the ceiling subassembly from the first configuration to the second configuration, the interconnecting elements being movable with

11503789_1 (GHMatters) P108934.AU.1 5/07/19 respect to the selected framework elements between a first position and a second position in response to movement of the rafter subassembly with respect to the ceiling subassembly, the first position adopted by the interconnecting elements corresponding to the first configuration of the roof module and the second position adopted by the interconnecting elements corresponding to the second configuration of the roof module, wherein when in the second position the interconnecting elements maintain the rafter subassembly in the second configuration with respect to the ceiling subassembly to form the roof structure of the building having the roof module .

BRIEF DESCRIPTION OF EMBODIMENTS

In one form the roof module/assembly is a roof cassette. In one form the roof cassette is a selfcontained module or assembly containing substantially all of the components required to form the roof or a supporting structure for the roof of a building, typically in the form of a domestic dwelling, such as a house, residential unit or similar.

In one form the ceiling subassembly is an interconnected array of individual framework elements forming a ceiling or part of a ceiling of the building . Typically, the individual framework elements of the ceiling subassembly are ceiling framework elements, preferably ceiling joists, for forming the ceiling of the building structure or supports for the ceiling of the building. In one form the ceiling joists are aligned with one another to form a substantially planar structure collectively. More typically, the ceiling joists are aligned to be substantially parallel to each other.

11503789_1 (GHMatters) P108934.AU.1 5/07/19

In one form the rafter subassembly is an interconnected array of individual framework elements or members forming the roof or roof support of the building structure, typically the support for the roof covering or outer skin or weatherproofing membrane of the roof of the building or the like. Typically, the individual framework elements or members of the rafter subassembly are roof elements or members, typically roof joists or rafters for supporting the weatherproof, weather resistant, outer covering, membrane, facade, cladding or similar of the roof, such as for example, metal roofing panels, galvanised iron sheets, tiles, strips or similar.

In one form the ceiling subassembly and rafter subassembly are hinged to one another, typically hinged through suitable fasteners, such as for example screws, pins, bolts, pegs, or the like, preferably Tek screws or similar, more preferably No. 14 type 17 screws having a length of 70 mm for use with 35 mm thick components, or a length of 90 mm for use with 45 mm thick components.

In one form the ceiling joists remain stationary after the roof module is located and securely fastened or anchored in position on top of the building structure, typically on top of the load bearing walls of the building structure .

In one form the rafters are movable, typically movable with respect to the ceiling joists which remain stationary during transformation of the roof module from the first configuration to the second configuration as the rafters move. In one form the rafters have a first end which is movably connected or hinged to a ceiling joist allowing relative pivoting movement of the rafter with respect to the ceiling joist, and a second end which is movable so as to be spaced apart from the ceiling joist to

11503789_1 (GHMatters) P108934.AU.1 5/07/19 which the first end is movably attached. Respective one ends of the individual rafters are moveable with respect to the fixed respective ends of the stationary ceiling joists. Typically, the rafter sub assembly is moved with respect to the ceiling subassembly by one end of the rafter sub assembly being lifted by a suitable lifting device, such as for example, a crane, hoist, or similar.

In one form the first configuration of the roof module is a flat or planar configuration, a collapsed configuration, a retracted configuration, or a transport configuration suitable for transportation from one location to another location, typically transportation by road vehicles, from the manufacturing facility at which the roof module is pre-fabricated to the building site at which the roof module is installed in or on the building.

In the flat configuration individual rafters are oriented in side by side spaced apart relationship with each other and with individual ceiling joists so as to occupy a minimum volume. In one form respective ends of individual ceiling joists are connected to respective ends of individual rafters allowing displacement of the other ends of the rafters from the ceiling joists during installation and/or transformation of the roof module for forming the roof of the building.

In one form the second configuration is an expanded configuration, an inclined configuration, a sloping configuration, a support configuration, an installed configuration or an in use configuration in which the plane of the rafters is inclined to the plane of the ceiling joists, typically angularly inclined so as to form an inclined or sloping support structure for the roof of the building and/or the roof of the building. In one form the angularly inclined support structure is a skillion roof or similar, or a support structure for a skillion

11503789_1 (GHMatters) P108934.AU.1 5/07/19 roof .

In one form the interconnecting elements of the rafter subassembly are webs, props, supports, stubs, studs, noggins, battens, girts, purlins or the like. Preferably, the interconnecting elements are lengths of timber, typically a set of webs, more typically a set of webs having different lengths. The webs are located at spaced apart locations along the length of the rafter, typically at irregularly spaced apart intervals. In forms, the different lengths of the individual timber webs are in accordance with the different location of where the webs are connected to the individual respective rafters. It is to be noted that the length of the individual timber webs and the locations of the individual timber webs are arranged and selected so that the webs collectively support the rafter at the required angle of inclination.

In one form the ceiling subassembly includes one or more mounts facilitating attachment of the interconnecting elements to the ceiling joists. The mounts can be connected to the ceiling joists at the manufacturing facility or can be attached at the building site. Although the mounts can have any convenient or desirable form, one form is a mounting block, typically in the form of a block or short length of timber, preferably of a generally rectilinear shape, such as for example a rectangular prism or parallelepiped. A preferred form of timber is LVL or is a suitable grade of a suitable softwood, such as for example, pine or similar, including Pinus Radiata. Preferably, the mounting block is located on the side of the ceiling joist opposite to the side on which the rafter is located aligned against the ceiling joist in side-byside parallel relationship thereto.

In one form the rafter subassembly includes a covering for forming the roof of the building, typically

11503789_1 (GHMatters) P108934.AU.1 5/07/19 the outer upper surface of the roof. The covering can be made from any suitable or convenient material, and be of any suitable or convenient type, style, form, size, thickness, material or the like. One preferred form of covering includes boards, sheets, panels, strips, lengths, decking or similar, such as for example sheets or panels of oriented strand board (OSB) or other engineered timber or wood product in the form of boards, panels, sheets or similar. Another form of covering includes metal decking or metal sheets or a metal skin. Preferably, the covering includes two or more layers of different materials. One form of a combination of different materials includes Enviroseal sarking over OSB, preferably by wrapping the Enviroseal sarking over the OSB for weather tightness, more preferably 6 mm OSB3 stapled at 150 mm c/c to rafters with the Enviroseal over to provide weather tightness when installed. It is to be noted that such combinations also provide rafter bracing thereby eliminating the need for separate additional wind bracing of the type usually provided by metal braces, metal ties or steel strips or other suitable reinforcing in some embodiments.

Forms of the roof module are provided with covering to improve or enhance the weather resistance, waterproofing, weather tightness or similar of the roof. Forms of the covering include membranes, films, sheets, decking, panels or similar.

In forms of the roof module, the length of the individual rafters is less than, equal to or greater than the length of the corresponding ceiling joist to which the rafter is movably connected. Preferably, the length of the individual rafters is greater than the length of the corresponding ceiling joists. More preferably, the overshoot of the length of the rafter as compared to the length of the ceiling joist is in accordance with the amount of inclination of the sloping roof so that the ends

11503789_1 (GHMatters) P108934.AU.1 5/07/19 of the rafters extend beyond the line of the ends of the ceiling joists. It is to be noted that the relationship between the lengths of the rafters as compared to the lengths of the ceiling joists is determined by the amount of overhang of the eaves of the roof or roof structure of the building in accordance with the final position of the module and/or the design of the building.

In forms of the installed roof module, the ceiling joists collectively are substantially horizontal so as to support a horizontal ceiling of the building structure, typically attached to the underside or under surface collectively of the ceiling joists, whereas the rafters collectively are substantially inclined to the ceiling joists to provide support for the outer covering of the inclined roof, typically in the form of a skillion roof.

In forms of the roof module, the ceiling joists are collectively planar or form a planar support surface. In forms of the roof module, the rafters collectively form a planar support surface for supporting the outer covering of the roof, albeit an inclined planar surface.

In forms of the installed roof module when in the second configuration or expanded, sloping or in use configuration, the webs are oriented to extend substantially vertically between the horizontal ceiling joists at the lower ends thereof, collectively, and the inclined rafters at the upper ends thereof, collectively.

Forms of the rafter subassembly optionally include reinforcement or a reinforcing element or member or device. Although the reinforcement, or multiple reinforcements, if provided, can have any suitable or desirable form or be of any suitable or desirable shape, type, style, size, length or the like, it is to be noted that one preferred form of the reinforcement is a brace,

11503789_1 (GHMatters) P108934.AU.1 5/07/19 more typically a cross brace. Preferably, the reinforcement is bracing. More preferably, the bracing is an elongate strip or length of metal having a suitable or convenient shape or profile. Preferably, the bracing includes Speedwell braces arranged in a suitable pattern or array, such as for example, in a generally cruciform shape, crisscross pattern, overlapping pattern, superposed array or zigzag array. It is to be noted that reinforcement, typically in the form of steel wind bracing or tie is not usually required for the rafters when the modules are braced with the OSB. In forms, the end vertical webs are braced on site in accordance with the relevant regulation or prescription of the Building Code of Australia (BCA), such as for example, in accordance with AS4440 to tie the rafter bracing of the module to the top plate.

Forms of the rafter subassembly include multiple elongate braces extending obliquely from one side of the subassembly to the opposite side of the subassembly in a criss-cross pattern or overlapping array where individual braces overlap adjacent braces in order to impart rigidity and strength to the subassembly.

It is to be noted that any form of suitable or desirable external covering of the roof can be used in the construction of the building structure, such as for example, metal panels, metal sheets, metal decking, tiles, shingles, slates, or the like.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the roof module of the present description will now be described and illustrated more fully by way of example only with reference to the accompanying drawings in which

11503789_1 (GHMatters) P108934.AU.1 5/07/19

Figure 1 is a schematic form of a ceiling joist,

Figure 2 is a schematic form of a rafter,

Figure 3 is a schematic form of the rafter of figure side elevation view of one side elevation view of one side elevation view of the having webs depending down therefrom shown in an inclined or in use configuration,

Figure 4 is a schematic side elevation view of the form of the rafter of figure 2 in which the webs are folded in parallel alignment with the rafter for forming a transport or flat configuration,

Figure 5 is a schematic side elevation view of one form of roof module shown in a lifted or in-use configuration,

Figure 6 is a schematic top plan view of another form of roof module in a flat or transport configuration,

	Figure	7	is	a schematic plan	view of further	form of
roof	module	in	a	flat or transport	configuration,
	Figure	8	is	a schematic plan	view of further	form of
roof	module	in	a	flat or transport	configuration,
	Figure	9	is	a schematic side	elevation view	of the
roof	module	of	figure 8 in a flat	or transport

configuration,

Figure 10 is a schematic side elevation view of the roof module of figure 6 in a lifted or in-use configuration,

Figure 11 is a schematic side elevation view of one

11503789_1 (GHMatters) P108934.AU.1 5/07/19 form of building structure having the roof module of figure 6 in the lifted configuration installed in use at the top of a building forming a support for a skillion roof,

Figure 12 is a schematic partial fragmentary top plan view of one form of a ceiling cassette layout having a covering on the upper surface thereof,

Figure 13 is a schematic side elevation view of section SS of the ceiling cassette of figure 12,

Figure 14 is an enlarged schematic section view of detail B of figure 13,

Figure 15 is an enlarged schematic elevation view of detail section TT of figure 13,

Figure 16 is a schematic side view of detail A in the form of a packer of the cassette of figure 12.

SPECIFIC EMBODIMENT

Forms of the roof module, their manufacture and their use and installation in forming the roof of a suitable building structure will now be described with reference to the accompanying drawings.

One form of building structure, generally denoted as 2, has an inclined roof, in the form of skillion roof 4 installed upon a wall structure defining separate rooms 6 of building 2. A wall structure defining separate rooms is typically a load bearing wall 8. Skillion roof 4 is formed by one form of a roof module, generally denoted as 10.

One form of roof module 10, includes as the main parts, a ceiling joist subassembly and a rafter

11503789_1 (GHMatters) P108934.AU.1 5/07/19 subassembly movably interconnected to one another to allow the roof module to move between a first configuration being a flat, retracted or collapsed configuration, typically as transported in a transport configuration, and a second configuration being in an expanded, inclined or supporting configuration, typically as installed in an inuse configuration. The ceiling joist subassembly and the rafter subassembly are both generally rectilinear, such as, being in the form of a generally rectangular array in the form of a grid of longitudinal and transverse framework elements or members arranged substantially perpendicularly to one another.

One form of the ceiling subassembly, generally denoted as 12, includes a multitude of longitudinally extending individual ceiling framework members in the form of ceiling joists 14 arranged in regularly spaced apart substantially parallel relationship to one another extending longitudinally of the subassembly from one end or transverse side of ceiling subassembly 12 to the opposite end or transverse side of ceiling subassembly 12 in parallel relationship to the longitudinal sides of subassembly 12 so as to extend in spaced apart intervals from one longitudinal side of the subassembly to the opposite longitudinal side of the subassembly, as shown more particularly in figures 6, 7 and 8.

In one form each ceiling joist 14 is of a length in accordance with the length of the roof of the building structure upon which the roof module is to be installed so that the one roof module spans the required length and area of the building to form the roof. However, it is to be noted that 2 or more roof modules may be located in side-by-side relationship or in end to end relationship or both depending upon the area of the roof. Typically, joist 14 is of a generally square or rectangular profile or cross-section. Preferably, ceiling joist 14 is a timber

11503789_1 (GHMatters) P108934.AU.1 5/07/19 joist or is a length of laminated veneer lumber (LVL) or other suitable engineered timber or wood product. However, it is to be noted that joist 14 can be made from any suitable or convenient material and be of any suitable or convenient shape, size, profile, style, length or the like .

Typically, one overall length of joist 14 is 11,670 mm, and joists 14 are located at 600 mm centres. Joist 14 can be a single length of LVL or can be multiple lengths of LVL or other suitable timber interconnected in end to end relationship collinearly to form the joist. It is to be noted that the lengths of individual ceiling joists can be in the range from about 3 m to about 20 m.

Ceiling subassembly 12 includes cross members or elements in the form of plates, preferably top plates, and more preferably ribbon plates 16, extending between the opposite respective outer joists 14 forming the longitudinally extending sides, ends or edges of subassembly 12. Ribbon plates 16 are generally square or rectangular in cross-section or profile. Again, the length of ribbon plate 16 is in accordance with the width of roof module 10 so as to span the width of the roof module, and to extend beyond the location of one of the outer longitudinal side joists, such as for example, as shown in figure 7.

Although ribbon plate 16 can have any suitable or convenient size or length, a typical ribbon plate 16 is a length of 90x35 mm MGP10 (Machined Graded Pine) or MGP12 or LVL or similar engineered wood product. Typically, the ribbon plates are 90 x 35 MGP10 when the load bearing walls are 90 mm wide or are 70 x 35 MGP10 when the walls are 70 mm wide, whilst the lengths correspond to the width of the module, placed at required and available loadbearing wall locations in accordance with the design of

11503789_1 (GHMatters) P108934.AU.1 5/07/19

2019204861 05 Jul 2019 the building.

It is to be noted that ribbon plate 16 can be made from any suitable or convenient material. Also, it is to be noted that each ribbon plate 16 is a single length or comprises two or more lengths of timber interconnected together collinearly in end to end relationship to one another to extend from one longitudinal side to the opposite longitudinal side of roof module 10. Although ribbon plates 16 can be of any suitable or convenient length, a typical lengths is 2700 mm. In use, ribbon plates 16 are located within module 10 in accordance with the location of load bearing walls forming the walls of the rooms of the building structure upon which the roof module is to be installed. Typically, ribbon plates 16 are located at variable centres to one another in accordance with the size of the individual room defined between the load-bearing walls of the building structure. Typical spacing include 3850 mm, 2610 mm and 4850 mm.

One form of the rafter subassembly, generally denoted as 30, will now be described.

Rafter subassembly 30 includes a multitude of longitudinally extending individual rafters 32 arranged in regularly spaced apart substantially parallel relationship to one another extending longitudinally of the subassembly from one end or transverse side of rafter subassembly 30 to the opposite end or transverse side of rafter subassembly 30 in parallel relationship to the longitudinal sides of subassembly 30 so as to extend in spaced apart intervals from one longitudinal side of the subassembly to the opposite longitudinal side of the subassembly, as shown more particularly in figures 6, 7 and 8.

In one form each rafter 32 is of a length in

11503789_1 (GHMatters) P108934.AU.1 5/07/19

2019204861 05 Jul 2019 accordance with the length of the roof of the building structure upon which the roof module is to be installed so that the one roof module spans at the required length and area of the building to form the roof. Typically, rafter

32 is of a generally square or rectangular profile or cross-section. Preferably, rafter 32 is a length of timber or is a length of laminated veneer lumber (LVL) or other engineered timber or wood product or the like. However, it is to be noted that rafter 32 can be made from any suitable or convenient material and be of any suitable or convenient shape, size, profile, style, length or the like. In one form the rafters and ceiling joists are Machined Graded Pine or LVL, usually 35mm thick, or alternatively 45 mm thick, with depths that vary, such as for example, being typically 90 mm, 120 mm, 140 mm or 190 mm. Additionally, the rafters and ceiling joists are designed from first principle to suit the specific spacing of the load bearing wall locations and relevant roof and ceiling loads of the particular building structure into which the module is to be installed. Further, it is to be noted that components made from pine longer than 6 m are nail plate joined whereas components made from LVL longer than 12 m are nail plate joined.

Typically, one overall length of rafter 32 is 11,945 mm, and rafters 32 are located at 600 mm centres from one another. Each rafter 32 can be a single length of LVL or can be multiple lengths of LVL or other suitable timber interconnected in end to end relationship collinearly to form the rafter.

Rafter subassembly 30 also includes multiple interconnecting elements for movably interconnecting ceiling joist subassembly 12 and rafter subassembly 30 to 35 one another. In one form the interconnecting elements include webs 34, props, stops, spacers, struts or similar movably connected at spaced apart locations along the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 length of selected rafters 32. In one form each rafter 32 is provided with a set of webs 34 located at spaced apart different locations along the longitudinal length thereof and at different centres, as shown more particularly in figures 3, 5 and 10. In one form each rafter 32 is provided with three individual webs 34 with one web being located at, or towards or near to one end of rafter 32, being the heel end of the rafter, and a second web being towards one side of about the midpoint of the rafter, and a third web being located towards the other side of about the midpoint of the rafter, particularly as shown in figures 3, 5, 7 and 10.

It is to be noted that web 34 can be made from any suitable or convenient material and be of any suitable or convenient shape, size, profile, style, length or the like. Preferably, web 34 is a timber web or is a length of laminated veneer lumber (LVL) or other engineered timber or wood product. The length of individual webs 34 is in accordance with a combination of the precise location of each individual web and the angle of inclination of rafter assembly 30 when in the lifted or in use configuration for forming the skillion roof of the building structure.

Typically each web has a square or rectangular crosssection or profile and is a length of 90x35 mm MGP10 (Machined Graded Pine) or MGP12 or LVL or similar engineered wood product. In one form the hinged webs are typically 90 x 35 MGP10 and are arranged to be supported on rafter props 37. Rafter props 37 are pre-cut and supplied with the module to be side-placed under the rafters, between the hinged webs and ceiling joists, which are also typically 90 x 35 MGP10 and have the same thickness as the rafters. Further, it is to be noted that the hinged webs and rafter props are nail-laminated on site .

11503789_1 (GHMatters) P108934.AU.1 5/07/19

It is to be noted that the length of web 34 located at or towards the heel of roof module 10 is short or relatively the shortest of the lengths of the various individual different length webs whereas the web located at or towards the toe of roof module 10 is long or relatively the longest of the lengths of the various different length individual webs. Further, it is to be noted that the lengths, including the ratio of relative lengths of the webs, typically of the one set of webs, is in accordance with the angle of inclination of the skillion roof being formed from the roof module.

In one form of roof module 10 it is to be noted that webs 34 are located on individual rafters 32 at locations in alignment with the location of ribbon plates 16 of ceiling assembly 12. Further, it is to be noted that the location of ribbon plates 16 is in accordance with the location of the dividing walls within building structure

2. More typically, the hinged webs 34 are located to be directly over the ribbon plates to transfer the vertical loads of the rafters to the correct locations of the load bearing walls.

Rafter subassembly 30 further includes reinforcement, typically in the form of bracing for enhancing the strength and rigidity thereof. One form of the bracing includes individual braces or struts, typically elongate braces 35. Preferably, the elongate braces include SPEEDBRACE strips. In one form the braces 35 are arranged in a generally zig zag or crossing over or criss-cross pattern collectively over individual rafters 32, as shown more particularly in figure 8. However, it is to be noted that individual braces 35 can be arranged in any suitable or convenient pattern or configuration, and that braces 35 can have any suitable or convenient form, type, style, size, shape or the like.

11503789_1 (GHMatters) P108934.AU.1 5/07/19

In roof module 10 respective individual joists 14 and corresponding individual rafters 32 are arranged to extend longitudinally along the length of the module as pairs in side by side relationship to one another. The respective ends of joist 14 and rafter 32 of the one pair are hingedly connected together by a suitable fastener, such as for example, a Tek screw or similar allowing pivoting movement of the rafter with respect to the joist to allow rafter subassembly 30 to pivotally move from the flat horizontal transport configuration to the inclined lifted in use configuration upon lifting of the toe end of rafter subassembly 30. It is to be noted that all of the components of rafter subassembly 30 move in unison as rafter subassembly 30 is lifted.

Roof module 10 is provided with lifting fittings or fixtures. In one form the lifting fitting or fixture is in the form of a lifting trimmer 36 and a lifting bracket 38. Typically, the lifting trimmer 36 is in the form of a length of timber or LVL, more typically a length of 90x35 mm MGP10 timber, and even more typically arranged to extend transversely of roof module 10 between the outer ceiling joist 14 or outer rafter 34 along one longitudinal side of roof module 10 and the other outer ceiling joist 14 or outer rafter 34, respectively, along the opposite longitudinal side of roof module 10. It is to be noted that in one form the lifting trimmers are typically 90 x 35 LVL14. Further, it is to be noted that the thickness of the lifting trimmers is less than or equal to the thickness of the roofing battens if the trimmers are to be remain on the module permanently. In one form the lifting bracket is an LTB bracket, such as a Pryda engineered lifting bracket product, such as for example, as shown more particularly in Figures 12 to 16. If required a packer 40 or shim is provided with the lifting bracket 38. In one form packer 40 or shim is provided with a slot 42 or slit or elongate opening. In one form the packer is a

11503789_1 (GHMatters) P108934.AU.1 5/07/19 horseshoe packer. One form of a 10 mm horseshoe packer for use with a screw in bolt 44 facilitates lifting of the cassette is illustrated in figures 13 to 16. It is to be noted that the LTB brackets 38 are used for lifting floor cassettes, such as for example the Pryda floor cassette, by having the chains or lifting sling of the crane or hoist provided with lifting clutches that fit onto the protrusion of bolts 44 for being released on site remotely. It is to be noted that one form of the lifting arrangement is shown in figures 12 to 16.

In one form lifting bracket 38 is fixedly connected to trimmer 36.

In one form lifting trimmer 36 is fixedly connected to ceiling joists 14 or to rafters 34 or to both ceiling joists 14 and rafters 34. Preferably, lifting trimmers 36 are connected to rafters 34 only so that roof module 10 can be lifted into position using trimmers 36 and brackets 38 when rafters 34 are securely attached to ceiling joists 14, and also rafter module 30 can be hingedly lifted from the lowered flat transport configuration to the upper lifted in use sloping configuration b with y the lifting device, typically in the form of a hoist or crane, since rafter subassembly 30 is hingedly connected to ceiling joist subassembly 12.

Bracket 38 in one form is provided with an eye or eyelet or similar for receiving therethrough a flexible lifting sling or similar for lifting roof module 10 into the final position on top of the walls of building 2, and/or rafter assembly 30 from the flat horizontal transport configuration to the inclined lifted in use configuration.

11503789_1 (GHMatters) P108934.AU.1 5/07/19

Manufacture of flat roof cassette assembly

One method of manufacturing a typical flat roof cassette assembly in the form of a roof module/assembly will now be described.

Ribbon plates 16 which have been pre-cut to the required length are located into position on a suitable substrate or support surface provided within the manufacturing facility, typically a factory. One form of the suitable substrate or support surface is a pedestal jig arranged so that ribbon plates 16 extend in a substantially transverse direction with respect to the longitudinal direction or lengthwise extending direction of module 10. The required number of individual rafters 32 which had been previously pre-cut to the desired length, and the corresponding required number of individual ceiling joists 14 which had been previously pre-cut to the desired length, are located in position in pairs at the required spacing apart so as to extend in the lengthwise extending direction or longitudinally on top of the transversely extending ribbon plates.

Within the one pair, the end of rafter 32 is connected to the end of the corresponding ceiling joist 14 by a suitable screw to pivotally connect rafter 32 to joist 14 at the heel end of module 10 so as to allow pivotal movement of rafter subassembly 30 with respect to ceiling joist subassembly 12. After each pair of rafter and ceiling joist is pivotally or hingedly connected to one another the individual transverse ribbon plates 16 are fixedly screwed to the rafters and/or ceiling joists or both from underneath module 10.

After pre-cutting to the required individual lengths, each of webs 34 are fastened to a corresponding rafter 32 on the opposite side to the location of the corresponding

11503789_1 (GHMatters) P108934.AU.1 5/07/19 ceiling joist of the pair to facilitate pivoting movement of web 34 to rafter 32 as rafter subassembly 30 is lifted to adopt the lifted inclined configuration. Thus, as rafter subassembly 30 is lifted to adopt an inclined position corresponding to the second configuration, webs 34 hinge downwardly so that the respective lower ends of webs 34 are located near to ceiling joist 14 enabling the lower ends of webs 34 to be fixedly attached to ceiling joists 14 at the required location so that webs 34 extend substantially vertically. When webs 34 are fixedly attached to joists 14 rafters 32 and rafter subassembly 30 are maintained in the required inclined configuration to form the roof of building 2 or to support the roof covering of building 2.

Bracing 35 in the form of individual elongate bracing strips of metal are fixedly attached to the upper surface of rafters 32 collectively to form wind bracing for increasing the strength and rigidity of the roof module.

It is to be noted that the flat roof cassette assembly or roof module is manufactured in the flat horizontal configuration in the factory so that the roof module is in a flat configuration suitable for transporting as a flat pack.

Installation of the flat roof cassette assembly

After manufacture in the manufacturing facility, such as a factory, each wall section, including all loadbearing walls and all non-load bearing walls, of the building structure being assembled at the building site, is loaded onto a suitable vehicle for transportation to the building site from the manufacturing factory.

The flat roof cassette assembly forming the roof module of the building structure, in which the roof module

11503789_1 (GHMatters) P108934.AU.1 5/07/19 includes rafters, ceiling joists, vertical webs, braces, props, OSB covering and ribbon plates all interconnected to one another to form the roof module, after being manufactured in the manufacturing facility as described previously, is loaded onto the transport vehicle together with the wall sections before transportation to the building site. It is to be noted that, preferably, the wall sections are loaded on top of the flat cassette or flat roof module for ease of transportation, and/or for being in the correct order for unloading at the building site where installation of the individual wall sections occurs before installation of the roof module.

At the building site the wall sections are unloaded first and hoisted into their respective final positions in accordance with the style and type of building structure, using a suitable lifting device, typically in the form of a crane. Then, the roof module is unloaded from the transport vehicle and hoisted into position so as to be located on top of the now assembled vertical wall sections with the ribbon plates lowermost or underneath the roof module resting upon the vertical load bearing wall sections .

The ribbon plates are fixedly fastened to the load bearing walls by suitable fasteners, in the form of Tek screws, typically at 900 mm spacing to securely anchor the roof module to the load bearing walls.

After attaching a suitable lifting device, fitting, or fixture, such as for example, a lifting sling to the lifting brackets of the roof module, the toe end of the rafter subassembly is lifted to the required height to form the inclined roof at the desired angle of inclination .

Mounting blocks having the same thickness as the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 individual rafters are fixedly attached to the side of the respective corresponding ceiling joists of each of the pairs of joists and rafters. The webs are rotated about their respective pivot axis formed by the fasteners for attaching the webs to the rafters, from the original position of the webs corresponding to the flat configuration in which the webs are substantially aligned with the corresponding rafter to a substantially vertical position extending between the now inclined rafter and the horizontal ceiling joist corresponding to the expanded inuse configuration. The crane is operated to lower the now vertical webs so that their respective lower ends rest upon the corresponding ribbon plate whereupon the lower ends of the now vertical webs are nailed or otherwise fastened to the corresponding ceiling joist mounting blocks to complete installation of the roof module.

Thereafter, the outer weather resistant covering in whatever form is required, such as for example, metal sheets, corrugated steel, tiles, decking, metal panels or similar, is fixedly attached to the upper surface of the rafters collectively. Optionally, battens can be attached to the rafters depending upon the type of roof treatment or covering.

ADVANTAGES

One or other of the embodiments of the roof module of the present description have one or other of the following advantages .

Faster manufacture of wall frames, eliminating the need for manual fixing of the ribbon plates to the wall frames at the building site.

Faster roof installation and erection at the building site is possible as compared to the time taken for

11503789_1 (GHMatters) P108934.AU.1 5/07/19 constructing a conventional roof.

A reduction in cost of the components used in the manufacture of the roof module.

A reduction in the cost of labour required in the manufacture of the roof module.

A reduction in the effort required for manufacturing roof structures.

A decrease in the time taken for manufacturing roof structures .

A saving in the cost of transporting the materials required to construct a roof structure as the roof modules of the present description are less bulky than conventional roof trusses used in the construction of roof structures .

A reduction in the space required at the building site for storage of building products and components for use in the construction of the building structure using the roof modules.

Increased efficiency in unloading transport vehicles and hoisting roof modules into position as compared to conventional roof trusses.

Reduction in the amount of finishing required after the roof modules are located in the correct position for forming the roof of the building structure due to no additional fixing of rafters or ceiling joists being required on-site to securely anchor the roof structure to the building and no additional wind bracing or installation of ties being required.

Claims

The Claims defining the invention are as follows:

1. A roof module transformable between a first configuration and a second configuration, the roof module for forming a roof structure of a building, the roof module comprising:

a ceiling subassembly including individual ceiling elements interconnected to one another to form the ceiling subassembly, a rafter subassembly including individual rafter elements interconnected to one another to form the rafter subassembly and interconnecting elements movably connected to selected rafter elements of the rafter subassembly, the ceiling subassembly and the rafter subassembly being movable with respect to one another for facilitating transformation of the roof module between the first configuration and the second configuration, the individual rafter elements and the individual interconnecting elements being movable in unison when the rafter subassembly moves from the first configuration to the second configuration, the interconnecting elements being movable with respect to the selected rafter elements between a first position and a second position in response to movement of the rafter subassembly with respect to the ceiling subassembly from the first configuration to the second configuration, the first position adopted by the interconnecting elements corresponding to the first configuration of the roof module and the second position adopted by the interconnecting elements corresponding to the second configuration of the roof module, and when in the second position the interconnecting

11503789_1 (GHMatters) P108934.AU.1 5/07/19 elements maintain the rafter subassembly in the second configuration with respect to the ceiling subassembly to form the roof structure of the building in which the roof module is installed.
2. A method of installing a roof module on or within a building to form a roof structure of the building, the roof module comprising:

a ceiling subassembly including ceiling elements interconnected to one another to form the ceiling subassembly, a rafter subassembly including rafter elements interconnected to one another to form the rafter subassembly and movable interconnecting elements movably connected to selected rafter elements of the rafter subassembly, the ceiling subassembly and the rafter subassembly being movable with respect to one another to convert the roof module between a first configuration and a second configuration, the interconnecting elements being movable between a first position and a second position when the rafter subassembly moves in unison with respect to the ceiling subassembly from the first configuration to the second configuration, the first position adopted by the interconnecting elements corresponding to the first configuration of the roof module and the second position adopted by the interconnecting elements corresponding to the second configuration of the roof module, wherein movement of the interconnecting elements of the rafter subassembly from the first position to the second position is in response to movement of the rafter subassembly from the first configuration to the second configuration, and the interconnecting elements when in the second

11503789_1 (GHMatters) P108934.AU.1 5/07/19 position maintain the rafter subassembly in the second configuration with respect to the ceiling subassembly for enabling the roof module to remain in the second configuration, the method comprising the steps of:

locating the roof module when in the first configuration at a required location on or within the building, attaching the roof module to the building to maintain the ceiling subassembly fixedly in place, moving the rafter subassembly with respect to the ceiling subassembly so that the roof module adopts the second configuration, moving the interconnecting elements of the rafter subassembly from the respective first positions to the respective second position, and fixedly locating the interconnecting elements to the ceiling subassembly when the rafter subassembly is in the second position to maintain the roof module in the second configuration to form a support for the roof of the building.
3. A method of manufacturing a roof module for forming a roof structure of a building, the method comprising the steps of:

forming a ceiling subassembly of ceiling elements interconnected to one another to form the ceiling subassembly, forming a rafter subassembly of rafter elements interconnected to one another to form the rafter subassembly and interconnecting elements movably connected to selected rafter elements of the rafter subassembly, connecting the ceiling subassembly and the rafter subassembly together to form the roof module, the ceiling subassembly and the rafter subassembly being movable with respect to one another for facilitating conversion of the roof module between a first configuration and a second configuration, and

11503789_1 (GHMatters) P108934.AU.1 5/07/19 the rafter elements and the interconnecting elements being movable in unison in response to movement of the rafter subassembly with respect to the ceiling subassembly from the first configuration to the second configuration, the interconnecting elements being movable with respect to the selected framework elements between a first position and a second position in response to movement of the rafter subassembly with respect to the ceiling subassembly, the first position adopted by the interconnecting elements corresponding to the first configuration of the roof module and the second position adopted by the interconnecting elements corresponding to the second configuration of the roof module, wherein when in the second position the interconnecting elements maintain the rafter subassembly in the second configuration with respect to the ceiling subassembly to form the roof structure of the building having the roof module .
4. A roof module or a method according to any preceding claim in which the module is a roof cassette wherein the roof cassette is a self-contained module or assembly containing substantially all of the components required to form the roof or a supporting structure for the roof of a building.
5. A roof module or a method according to any preceding claim in which the ceiling subassembly of the roof module is an interconnected array of individual framework elements forming a ceiling or part of a ceiling of the building in which the framework elements are ceiling framework elements, preferably in the form of ceiling joists, for forming the ceiling of the building or for supporting for the ceiling of the building.

11503789_1 (GHMatters) P108934.AU.1 5/07/19
6. A roof module or a method according to any preceding claim in which the ceiling joists are aligned with one another in substantially parallel spaced apart relationship to each other to form a substantially planar structure collectively.
7. A roof module or a method according to any preceding claim in which the rafter subassembly is an interconnected array of individual framework elements or members forming the roof or roof support of the building structure, or the support for the roof covering or outer skin or weatherproofing membrane of the roof of the building or the like.
8. A roof module or a method according to any preceding claim in which the individual framework elements or members of the rafter subassembly are roof elements or members, typically roof joists or rafters for supporting the weatherproof, weather resistant, outer covering, membrane, facade, cladding or similar of the roof, such as for example, metal roofing panels, galvanised iron sheets, steel decking, tiles, strips or similar.
9. A roof module or a method according to any preceding claim in which the ceiling subassembly and rafter subassembly are hinged to one another, typically hinged through suitable fasteners, such as for example screws, pins, bolts, pegs, or the like, preferably Tek screws including No. 14 type 17 screws having a length of 70 mm for use with 35 mm thick components, or a length of 90 mm for use with 45 mm thick components.
10. A roof module or a method according to any preceding claim in which the ceiling joists remain stationary after the roof module is located and securely fastened or anchored in position on top of the building structure, including on top of the load bearing walls of the building

11503789_1 (GHMatters) P108934.AU.1 5/07/19

2019204861 05 Jul 2019 structure .
11. A roof module or method according to any preceding claim in which the rafters are movable, typically movable

5 with respect to the ceiling joists which remain stationary during transformation of the roof module from the first configuration to the second configuration as the rafters move wherein the rafters have a first end which is movably connected or hinged to a ceiling joist allowing relative

10 pivoting movement of the rafter with respect to the ceiling joist, and a second end which is movable so as to be spaced apart from the ceiling joist to which the first end is movably attached so that respective one ends of the individual rafters are moveable with respect to the fixed

15 respective ends of the stationary ceiling joists.
12. A roof module or method according to any preceding claim in which the first configuration of the roof module is a flat or planar configuration, a collapsed

20 configuration, a retracted configuration, or a transport configuration suitable for transportation from one location to another location, typically transportation by road vehicles, from the manufacturing facility at which the roof module is pre-fabricated to the building site at

25 which the roof module is installed in or on the building.
13. A roof module or method according to any preceding claim in which in the flat configuration individual rafters are oriented in side by side spaced apart

30 relationship with each other and with individual ceiling joists so as to occupy a minimum volume.
14. A roof module or method according to any preceding claim in which the second configuration is an expanded

35 configuration, an inclined configuration, a sloping configuration, a support configuration, an installed configuration or an in use configuration in which the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 plane of the rafters is inclined to the plane of the ceiling joists, typically angularly inclined so as to form an inclined or sloping support structure for the roof of the building and/or the roof of the building wherein the angularly inclined support structure is a skillion roof or similar, or a support structure for a skillion roof.
15. A roof module or method according to any preceding claim in which the interconnecting elements of the rafter subassembly are webs, props, supports, stubs, studs, noggins, battens, girts, purlins or the like including lengths of timber, typically a set of webs, more typically a set of webs having different lengths.
16. A roof module or method according to any preceding claim in which the webs are located at spaced apart locations along the length of the rafter, typically at irregularly spaced apart intervals.
17. A roof module or method according to any preceding claim in which the different lengths of the individual timber webs are in accordance with the different locations of where the webs are connected to the individual respective rafters so that the length of the individual timber webs and the locations of the individual timber webs are arranged and selected so that the webs collectively support the rafter at the required angle of inclination .
18. A roof module or method according to any preceding claim in which the ceiling subassembly includes one or more mounts facilitating attachment of the interconnecting elements to the ceiling joists wherein the mounts are connected to the ceiling joists at the manufacturing facility or can be attached at the building site and wherein the mounts include a mounting block, typically in the form of a block or short length of timber wherein the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 mounting block is located on the side of the ceiling joist opposite to the side on which the rafter is aligned against the ceiling joist in side-by-side parallel relationship there to.
19. A roof module or method according to any preceding claim in which the rafter subassembly includes a covering for forming the roof of the building, typically the outer upper surface of the roof wherein the covering includes boards, sheets, panels, strips, lengths or similar, such as for example sheets or panels of oriented strand board (OSB) or other engineered timber or wood product in the form of boards, panels, sheets, decking or similar.
20. A roof module or method according to any preceding claim in which the covering comprises one or more layers of different materials, including a combination of different materials in which one combination is Enviroseal sarking over OSB, for weather tightness.
21. A roof module or method according to any preceding claim in which the combination of Enviroseal over OSB is 6 mm OSB3 stapled at 150 mm c/c to rafters with the Enviroseal over to provide weather tightness when installed by wrapping the sarking over the OSB and/or roof rafters or roof framework members or elements.
22. A roof module or method according to any preceding claim in which the roof module further comprises a covering to improve or enhance the weather resistance, waterproofing, weather tightness or similar of the roof, including membranes, films, sheets, decking, panels or similar .
23. A roof module or method according to any preceding claim in which the length of the individual rafters is less than, equal to or greater than the length of the

11503789_1 (GHMatters) P108934.AU.1 5/07/19 corresponding ceiling joist to which the rafter is movably connected, including the length of the individual rafters being greater than the length of the corresponding ceiling joists by an overshoot or overhang wherein the overshoot or overhang of the length of the rafter as compared to the length of the ceiling joist is in accordance with the amount of inclination of the sloping roof so that the ends of the rafters extend beyond the line of the ends of the ceiling joists.
24. A roof module or method according to any preceding claim in which the ceiling joists collectively are substantially horizontal so as to support a horizontal ceiling of the building structure, typically attached to the underside or under surface collectively of the ceiling joists, whereas the rafters collectively are substantially inclined to the ceiling joists to provide support for the outer covering of the inclined roof to form a skillion roof .
25. A roof module or method according to any preceding claim in which the webs of the roof module when the roof module is installed and in the second configuration or in the expanded, sloping or in use configuration, are oriented to extend substantially vertically between the horizontal ceiling joists at the lower ends thereof, collectively, and the inclined rafters at the upper ends thereof, collectively.
26. A roof module or method according to any preceding claim in which the roof module further comprises reinforcement or a reinforcing element or member or device in which the reinforcement is a brace, a cross brace in the form of a strip or length of metal having a suitable or convenient shape or profile including Speedwell braces arranged in a suitable pattern or array, such as for example, in a generally cruciform shape, crisscross

11503789_1 (GHMatters) P108934.AU.1 5/07/19 pattern, overlapping pattern, superposed array or zigzag array.
27. A roof module or method according to any preceding claim in which the rafter subassembly includes multiple elongate braces extending obliquely from one side of the subassembly to the opposite side of the subassembly in a criss-cross pattern or overlapping array where individual braces overlap adjacent braces in order to impart rigidity and strength to the subassembly.
28. A roof module or method according to any preceding claim in which the webs are located on individual rafters at locations in alignment with the location of ribbon plates of ceiling assembly wherein the location of the ribbon plates is in accordance with the location of the dividing walls within the building structure, including the hinged webs being located to form directly over the ribbon plates to transfer the vertical loads of the rafters to the correct locations of the load bearing walls .
29. A roof module substantially as hereinbefore described with reference to the accompanying drawings.
30. A method of manufacturing a roof module substantially as hereinbefore described with reference to the accompanying drawings .
31. A method of installing a roof module on or in a building structure substantially as hereinbefore described with reference to the accompanying drawings.