AU2021221627A1 - Building components, a building structure formed therefrom and a method of construction thereof - Google Patents

Building components, a building structure formed therefrom and a method of construction thereof Download PDF

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Publication number
AU2021221627A1
AU2021221627A1 AU2021221627A AU2021221627A AU2021221627A1 AU 2021221627 A1 AU2021221627 A1 AU 2021221627A1 AU 2021221627 A AU2021221627 A AU 2021221627A AU 2021221627 A AU2021221627 A AU 2021221627A AU 2021221627 A1 AU2021221627 A1 AU 2021221627A1
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AU
Australia
Prior art keywords
wall
beams
building
floor
panel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
AU2021221627A
Inventor
Simon Pratt
Pin ZHENG
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Quantum Buildings Pty Ltd
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Quantum Buildings Pty Ltd
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Filing date
Publication date
Priority claimed from AU2020903926A external-priority patent/AU2020903926A0/en
Application filed by Quantum Buildings Pty Ltd filed Critical Quantum Buildings Pty Ltd
Publication of AU2021221627A1 publication Critical patent/AU2021221627A1/en
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34321—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/026—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of prefabricated modules, e.g. box-like or cell-like units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34326—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by longitudinal elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E04B1/6137—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface the connection made by formlocking
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E04B1/6141—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface the connection made by an additional locking key
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7448—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with separate framed panels without intermediary posts, extending from floor to ceiling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/024—Sectional false floors, e.g. computer floors
    • E04F15/02447—Supporting structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/024—Sectional false floors, e.g. computer floors
    • E04F15/02447—Supporting structures
    • E04F15/02464—Height adjustable elements for supporting the panels or a panel-supporting framework
    • E04F15/0247—Screw jacks
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/005—Modulation co-ordination
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34317—Set of building elements forming a self-contained package for transport before assembly
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34869—Elements for special technical purposes, e.g. with a sanitary equipment
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/14—Load-carrying floor structures formed substantially of prefabricated units with beams or girders laid in two directions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • General Engineering & Computer Science (AREA)
  • Load-Bearing And Curtain Walls (AREA)
  • Buildings Adapted To Withstand Abnormal External Influences (AREA)

Abstract

An adjustable post for use in a floor support system of a building, comprising: (a) a head jack for supporting the floor and a base jack disposed on the top 5 of a footing at ground base level beneath the floor to be built, and (b) an adjustable threaded shaft between the base and head jacks, configured to operate as a turnbuckle. 2/16 12 6 10 o 8 4 Figure 3

Description

2/16
12
6
o 8
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Figure 3
P10408.AU Specification - 25/08/2021
Building components, a building structure formed therefrom and a method of construction thereof
Field of the invention The present invention relates to building components, a building structure formed from those components, and a method of constructing the building structure.
Background Existing construction methods and building components used to erect buildings such as residential homes suffer a range of shortcomings. In at least Australia, housing construction is burdened by regulations, inefficient construction methodologies, legislation, rigid financing requirements, a relatively high number of litigation cases and so on which have the effect of stifling building and construction innovations which may otherwise: - reduce construction periods, and costs, and OHS hazards; - improve the quality, dimensional and/or precision level of the workmanship and construction - improve on-site labour management and productivity; - improve construction efficiencies; - facilitate less complex installation requirements; and - enhance the flexibility, creativity and simplicity with which houses can be designed and constructed.
The modular construction of houses attempts to address these issues, whereby various sections of the house to be built are prefabricated off-site. The prefabricated sections are then transported on-site and craned into position, connected, assembled, and finished off to form a complete house.
However, the design of modular houses can be rather restrictive, owning to limitations such as road conditions, regulations and capacity, truck size, site access, and
P10408.AU Specification - 25/08/2021
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crane capacity. Moreover, additional costs associated with crane usage, additional built-in structures necessary for transport and lifting operations and transport damage reduce the cost-effectiveness of modular house construction in many cases.
There is a need to address the above, and/or at least provide a useful alternative.
Summary According to a first aspect of the present invention, there is provided an adjustable post for use in a floor support system of a building, comprising: (a) a head jack for supporting the floor and a base jack disposed on the top of a footing at Ground Base Level (GBL) beneath the floor to be built, and (b) an adjustable threaded shaft between the base and head jacks, configured to operate as a turnbuckle.
In embodiments of the invention, various structurally certified lengths and steel strengths, of the adjustable post, will be specified and provided, according to the site ground conditions and the configuration of the floor system for any one specific house layout.
In embodiments of the invention, the support head jack and the base jack, are aligned with a vertical axis, to form an always adjustable structural support to the floor system.
In embodiments of the invention, the height of the head support bracket above the footing at Ground Base Level (GBL) is adjustable.
In embodiments of the invention, the central shaft is screwthreadingly engaged with the support head bracket and base bracket, to effect height adjustment thereof.
P10408.AU Specification - 25/08/2021
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According to a second aspect of the present invention, there is provided a panel for forming part of a frame of a building structure, comprising: (a) an opposed pair of longitudinally extending beams; (b) spaced apart transverse joists interconnecting the beams; and (c) an expanded polystyrene (EPS) insulation layer underlying the joists.
In embodiments of the invention, the beams comprise structural channels configured to receive ends of the joists and EPS insulation layer.
In embodiments of the invention, the beams of adjacent panels are secured together such that a cross-section thereof is substantially in the form of an I-beam.
In embodiments of the invention, the joists and/or beams comprise access openings to allow egress of services lines such as electrical or water sevices trough the frame.
In embodiments of the invention, the panel is configured to form the floor and/or roof panels of the building frame.
According to a third aspect of the present invention, there is provided a wall panel for forming a wall structure of a building comprising: (a) an external wall layer; (b) an internal wall layer; and (c) a spaced apart and opposed pair of substantially parallel and vertically extending beams sandwiched between the wall layers, the beams being configured to connect to the beams of adjacent wall panels so as to form the wall structure of the building.
In embodiments of the invention, the wall layers comprise EPS layers and the beams comprise structural beams.
In embodiments of the invention, when viewed from above:
P10408.AU Specification - 25/08/2021
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(a) one of the beams is inwardly offset from first lateral edges of the wall layers such that a vertical slot is defined between the layers and the beam; and (b) the other of the beams is outwardly offset from second lateral edges of the wall layers such that the beam protrudes outwardly from between the wall layers, wherein in use, the protruding beam of a first wall panel is inserted into the slot of a second wall panel to connect the two panels vertically.
In embodiments of the invention, the wall panel further comprises one or more noggings between wall panel beams, wherein the end of each nogging comprises flanges for receiving and securing to a beam.
In embodiments of the invention, the lateral flanges of at least one nogging protrude into the slot so as to be configured to be secured to the protruding beam of an adjacent wall panel.
In embodiments of the invention: (a) one of the opposed beams comprises one or more outwardly extending flaps; and (b) the other of the opposed beams comprises one or more respective openings configured to releasably receive a respective flap of an adjacent wall panel.
According to a fourth aspect of the present invention, there is provided a building structure supported by adjustable posts according to a first aspect of the invention, having floor and roof panels according to a second aspect of the invention, and wall panels according to third aspect of the invention.
In embodiments of the invention, the building structure further comprises one or more self-contained kitchen and/or wet area modules supported by the adjustable posts.
According to a fifth aspect of the present invention, there is provided a method of constructing a building structure according a fourth aspect of the invention, comprising:
P10408.AU Specification - 25/08/2021
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proceeding the installation, an appropriate footing system is to be installed, selected by the Structural Engineer, with the footing heads finished to a specified GBL (a) commencing installation of adjustable posts according to a first aspect of the invention configured for supporting self-contained kitchen and/or wet area hubs; (b) installing the or each hub so as to be supported by the installed footings with adjustable posts; (c) completing installation of the footing system by installing the remaining adjustable posts for the building structure; (d) constructing a floor structure using panels according to a second aspect of the invention; (e) constructing a wall structure using wall panels according to a third aspect of the invention; and (f) constructing a roof structure using panels according to a second aspect of the invention.
Brief description of the drawings In order that the invention may be more easily understood, an embodiment will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a top perspective view of a frame and self-contained hubs of an incomplete building structure formed from building components embodying the present invention; Figure 2 is a partially transparent front perspective view of an incomplete building structure formed from building components embodying the present invention; Figure 3 is a partially transparent front view of an incomplete building structure formed from building components embodying the present invention; Figure 4 is a perspective view of an external corner adjustable post (leg) building component according to embodiments of the present invention; Figure 5 is a perspective view of an internal adjustable post at a junction of 4 floor panels;
P10408.AU Specification - 25/08/2021
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Figure 6 is a partially transparent top perspective view of a floor structure of an incomplete building structure formed from building components embodying the present invention; Figure 7 is a front perspective view of a floor panel building component according to embodiments of the present invention; Figure 8 is a close-up side view of a lower edge of an incomplete building structure showing engagement between the footing, floor panel and wall panel building components embodying the present invention; Figure 9 is a close-up front view showing engagement between a footing and adjacent floor panel building components according to embodiments of the present invention; Figure 10(a) is a side perspective view of an incomplete building structure with a range of wall panel building components according to embodiments of the present invention; Figure 10(b) is a cross-sectional front view of a range of differently dimensioned wall panel building components according to embodiments of the present invention; Figure 11(a) is a top perspective cross-sectional view of two wall panel building components according to embodiments of the present invention; Figure 11(b) is a top cross-sectional view of a wall panel building component according to embodiments of the present invention; Figure 12 is a partially transparent perspective view of two wall panel building components according to embodiments of the present invention; Figure 13(a) is a close-up cross-sectional front view of two adjacent wall panel building components according to embodiments of the present invention, prior to being installed together; Figure 13(b) is a close-up cross-sectional front view of the wall panel building components of Figure 13(a) installed together; Figure 14(a) is an exploded front perspective view of a wall panel building component according to embodiments of the present invention; Figure 14(b) is an exploded front perspective view of a wall panel building component according to embodiments of the present invention;
P10408.AU Specification - 25/08/2021
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Figure 15 is a close-up front perspective view of a wall panel frame according to embodiments of the present invention; Figure 16(a) is a side perspective view of a roof panel building component according to embodiments of the present invention; Figure 16(b) is a cross-sectional end view of a roof panel building component according to embodiments of the present invention; Figure 17 is a close-up side view showing engagement between a roof panel building component and a wall panel building component according to embodiments of the present invention; and Figure 18 is a partially transparent internal perspective view showing engagement between roof panel and wall panel building components according to embodiments of the present invention.
Detailed description Figures 1 to 3 show partially complete residential building structures 2 formed from building components according to embodiments of the present invention. The building components include the following: * adjustable posts (legs) 4 for supporting the aboveground building structure 2; • self-contained kitchens and/or wet areas hubs 6; * floor panels 8 which form a floor structure of the building structure 2; * wall panels 10 which form a wall structure of the building structure 2; and * roof panels 12 which form a roof structure of the building structure 2.
These relatively light-weight building components may be mass-produced off-site, then transported and installed on-site with less effort and time without the need for cranes and other specialized machinery and equipment. The self-contained wet area and kitchen hubs 6 can be lifted and installed using forklifts, though cranes may optionally be used. The building components are described below with reference to the Figures.
Building support components
P10408.AU Specification - 25/08/2021
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Figures 4 and 5 show views of an adjustable post (leg) building component 4 configured to form a support system that underlies and connects the aboveground building structure 2 to footings. The support 4 comprises a head jack 16 , a base jack 14, with a connecting threaded shaft 20 or'turnbuckle'. The base jack 14 of the support 4 is fixed to the top of the in-gound footings at the GBL, and the head jack 16 is fixed to the frame of the floor panel system 2.
The support 4 comprises a support head jack 16 and a base jack 14 for securing to and supporting the floor structure of the building by being fixed to and bearing upon the top of the inground footing at GBL. The support head jack 16 shown in Figures 4 and 5 comprises a "T" bracket 17 for receiving edges of the flooring structure, as will be described with reference to Figure 8. Supports 4 configured to underlie and support flat surfaces of the flooring structure are configured with a flat support head 16 (e.g., not a "T" bracket 17), as will be described with reference to Figure 9.
In the depicted embodiment, the support head jack 16 is supported by a central shaft 20 and base jack 14 connected by a screwed shaft 18 as an adjustable turnbuckle. In preferred embodiments of the support 4, a height of the support head 16 above the base jack 14 is adjustable to allow the height of the support head 16 to be finetuned to securely abut against and receive the floor structure which it is to support and ensure floor levelling precision. To this end, and with reference to Figure 5, the pipe 18 is threaded such that an upper end thereof is configured to receive a lower end of a threaded shaft 20, and the support head jack 16 comprises a downwardly extending and threaded pipe 22 configured to receive an upper end of threaded shaft 20. In this way, the central shaft 18 and the support head jack 16 are screwthreadingly engaged to effect rough-in or fine adjustment of the height of the support head jack 16 above the footing and base jack 14.
Self-contained wet area and kitchen building components (Hubs) Figures 1, 2, 3 and 10 show embodiments of self-contained kitchens and/or wet area building components 6 according to embodiments of the invention (henceforth also referred to as Hubs 6). The Hubs 6 are prefabricated and contain the wet areas of the
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house (e.g. kitchen, bathrooms, powder rooms, laundry etc). The Hubs are completely constructed in a factory environment, including their walls, insulation, linings, wet area amenities, cabinetry and finish off. Services and features such as plumbing, waterproofing, wall tiling, vanities, joinery and kitchen and bathroom facilities are all installed in the Hub 6 off-site. The prefabricated Hub 6 can then be transported on-site and craned or forklifted into position to be supported by the adjustable posts (legs) 4 (see Figure 10). Standardized Hubs are designed and built to fit within the dimensions of internal high-cube containers. This facilitates ease of transport, cranage, and protection from damage during transport.
Existing bathroom pods produced by local manufacturers do not form part of a complete building methodology. In contrast, the present Hubs 6, either as standardized or non-standardized, are built in a factory environment so as to be transported and installed as part of a complete building methodology which comprises the other building components disclosed herein.
In terms of the installation procedure, the adjustable posts (legs) 4 for supporting the Hubs 6 should be installed on the footings first. Next, the Hubs 6 can be placed on those adjustable posts (legs) 4. Then, the remaining adjustable posts (legs) 4 of the overall house can be installed.
Floor panel building components After the adjustable posts (legs) system and Hubs 6 have been installed, the floor structure of the building can be formed from floor panel building components 8 embodying the present invention. Figures 2, 3, 6, 8 and 9 show floor panel building components 8 installed in place and supported by the adjustable posts (legs) system 4.
With reference to Figures 7 to 9, the floor panel 8 comprises a pair of spaced apart and opposed structural beams or bearers 36 having a Light Gauge Steel (LGS) C-shaped cross-section. The beams 36 are oriented such that the C-shaped channels 38 thereof face one another. A series of longitudinally spaced transverse floor joists 40 are disposed
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between the C-shaped channels 38 and interconnect the beams 36. A layer of expanded polystyrene (EPS) 42 underlies the joists 40 and is similarly disposed between and interconnects the beams 36. Since the joists 40 and EPS 42 are contained within the height of the C-shaped channels 38, the overall floor thickness of the present floor panels 8 can be significantly less than conventional bearer and joist floor systems.
As shown in Figures 8 and 9, the ends of the joists 40 are adjacent to if not flush against an upper flange surface 44 of the C-shaped channel 36. Similarly, the EPS layer 42 is adjacent to if not flush against a lower surface 46 of the C-shaped channel 38. Advantageously, the EPS layer 42 acts as thermal insulation and also provides a vapour barrier.
With reference to Figure 9, when installed, the beams 36 of adjacent floor panels 8 are secured to one another to form, in cross-section, an I-section beam. The footing 4 in Figure 9 comprises a flat support head 16(a) or "T" support head 16(b) configured to secure against and support the lower flange 46 of the I-section beam (i.e. the two lower flanges 46 of the C-shaped channels 38 of the adjacent floor panels 8).
Figure 8 shows a close up of a lower perimeter of the building structure 2 to illustrate how the adjustable post 4, floor panel 8, square hollow section RHS steel or timber edge beam 48 and wall panel 10 (to be discussed) are secured together. As shown, the C-section beams 38 which define the perimeter of the building structure 2 are screw fixed to a RHS Steel or timber edge beam 48. The RHS Steel or timber edge beam 48 is in turn fixed to the upright face 34 of the angle bracket 17 of the footing 4. The steel SHS or timber edge beam 48 is also screw fixed to a bottom of the wall panel 10 to achieve a complete structural 'tie down'. In this way, the perimeter of the floor is strengthened, improving both load and deflection resistance, and no straps or conventional tie-downs are necessary. Figure 8 also shows a floorboard 50 covering the floor panel 8, with a protective steel Z-Flashing plate screw 52 fixed to the floorboard 50 and to the outer edge of the steel SHS or timber edge beam 48.
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After the floor panels 8 are installed, services (mainly electrical and mechanical cabling) are to be installed within the depth of the cavity created by the panel frame before covering the floor panels 8 with floorboards 50. Advantageously, the floor joists 40 are provided with through-holes 54 for convenient service access and installation. It is envisaged that the bearers 38 may also be provided with such through-holes for service access. Advantageously, a clearance between the floor structure and natural ground therebeneath also provides service access.
The present standardised floor panels 8 can be mass-manufactured off-site and transported and installed on-site. The floor panels 8 are dimensioned and configured to be of lightweight construction and can be manually handled and installed by two people without needing lifting equipment.
It is envisaged that the floor panels 8 are to be made according to a limited range of dimensions; if the building structure 2 requires differently-sized floor panels, the mass produced floor panels 8 can be supplemented by a small number of infill floor panels 56 either custom-made in a factory or'stick-built'on-site from the relevant supplied materials, as shown in Figure 6.
Wall panel building components After floorboards 50 and the flashing bottom plates 52 are installed around the floor perimeter, wall panel building components 10 may then be installed to define a wall structure of the building 2. Figures 10 to 15 show wall panel building components 10 according to embodiments of the present invention.
Referring to Figures 11, 12 and 14, each wall panel 10 comprises an opposed pair of structural beams 60 sandwiched between two layers of EPS 62. A first EPS layer 62(a) defines the external side of the building structure 2 and is ready for rendering or cladding. The second EPS layer 62(b) may be lined with a breathable reflective foil facing the beam and defines an internal side of the building structure 2 and is ready to be finished with conventional plasterboard or other internal wall linings. The external EPS 62(a) layer is
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preferably thicker than the internal EPS layer 62(b), and the configuration of layers 62 an LGS frame 78 provides qualities of thermal and acoustic insulation and helps stabilise the wall panel 10 during handling and installation. The EPS layers 62 are glued with a structural, chemical glue and/or screw fixed to the structural beams 60.
With reference to Figures 11(a) and 11(b), the wall panels 10 are configured to fasten together via a tongue and groove mechanism and a flap and slot mechanism. Looking down at the cross-sectional wall panel 10 in Figure 11(b), the left-hand side beam 60 juts out leftwardly from between the two EPS layers 62. This protruding beam defines the "tongue" of the tongue and groove mechanism. Meanwhile, the right-hand side beam 60 is "tucked in" leftwardly between the two EPS layers 62. As such, a space or groove 64 is defined between the two EPS layers 62 and the outer surface of the beam 60. This space 64 defines the "groove" of the tongue and groove mechanism. In other words, although the width of the EPS layers 62 is similar if not identical to the external width between the beams 60, viewed from above, the beams 60 are offset from the EPS layers 62. As such, in fitting adjacent wall panels 10 together, the protruding tongue beam 60 of a first wall panel 10 is inserted into the vertical space or groove 64 of a second wall panel 10, as indicated by Figure 11(a).
With reference to Figures 10(a) and 10(b), the wall panels 10 are made according to a limited range of dimensions and design; if the building structure 2 requires a small number of differently-sized wall panels 10, the mass-produced wall panels 10 can be supplemented by a small number of manufactured infill wall panels or 'stick-built' on-site. The infill panels provide electrical and mechanical cable management. In Figure 10(b), the narrower left-most three wall panels 10a comprise opposed beams 60 interconnected by transverse noggins 66a and diagonal noggins 66b; the fourth wall panel 10b from the left comprises opposed beams 60 interconnected by one or more transverse noggins 66a. The wider and right-most two wall panels 10c in Figure 10(b) comprise a third and central beam 68 between the opposed end beams 60, the central beam 68 being interconnected to the end beams 60 via noggins 66.
P10408.AU Specification - 25/08/2021 - 13
Figure 12 shows two of the wider wall panels 10 side by side. In addition to the aforementioned tongue and groove mechanism, the beams 60 have complementary flap and slot engagement features to help facilitate installation of the wall panels 10. With reference also to Figures 11(a), 13(a) and 13(b), one outer beam 60 in the groove of a wall panel 10 comprises vertically spaced apart flaps 70, and the other outer beam 60 of the wall panel 10 comprises corresponding vertically spaced apart slots or openings 72 for receiving respective flaps 72. The flaps 70 of one wall panel 10 clip in through a "lift and drop" manner with the respective openings 72 of an adjacent wall panel 10 during installation and help lock the panels 10 in position before additional structural securing means can be implemented. The bottom of the connection slots will be used to give access to allow the bottom frame of the wall panel to be screw fixed into the floor edge beam below. To get access this will be done before the following wall panel is installed.
Figures 14 and 15 illustrate additional means for securing adjacent wall panels 10 together. Figure 14(a) shows an exploded view of a wall panel 10c. The internal frame 78 thereof comprises a central beam 68 interconnected to a pair of opposed outer beams 60 via upper and lower joists 80 and central noggings 66a.
Figure 14(b) shows an exploded view of a wall panel 10a. The internal frame 78 thereof comprises a pair of outer beams 60, upper and lower joists 80, horizontal noggins 66a, and diagonal noggins 66b.
Wall panel 10a acts to support higher concentration loads in lieu of an external wall structural post and resists horizontal loads such as wind or earthquake loads in lieu of a conventional lateral braces.
LGS truss frame 78 without EPS layers can also be engaged as an internal load bearing wall or post.
Figure 15 shows a close-up of noggings 66a which facilitate the securing of one wall panel 10 to another. In the depicted embodiment, the noggings 66a are formed from LGS
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channels similar to those which form the beam 60. At each end of the nogging 66a, a top and bottom face 84 thereof is cut away such that the top and bottom faces 84 abut against the respective beams 60, 68. The sides of each end of the nogging 66a define flanges 86 which can be fixed to the respective vertical beams 60, 68 using a punch/stamping jointing method or conventional threaded fasteners. In Figure 15, the left-hand side nogging is disposed towards the side of the wall panel 10 where the groove 64 is (see Figure 11(b)). As such, the side flanges 86 of this nogging 66a protrude into the groove 64 and are configured for being fixed to the vertical tongue beam 60 of an adjacent wall panel 10. For example, the flanges 86 may be screw fixed to structurally join the wall panels 10 together.
Referring back to Figure 8, the wall panels 10 are also screwed fixed to the bottom flashing plates 52. Top flashing plates (not shown) are also screw fixed along an upper end of the wall panels 10. The flashing plate acts as water barriers and an important part of the tie-down mechanism, while also helping to ensure the wall panels 10 are installed in a straight and accurate alignment. The bottom flashing plates 52 also help spread the load from the wall panels 10 above and functions as a positioning element to facilitate installation of the wall panels 10. Additionally, a top timber wall plate 76 (see Figures 17 and 18) is fastened between roof panel 12 and wall panel 10 by a hold-down bracket 112 along the top of the installed wall panels 10.
Roof panel building components After the wall panels 10, top flashing plate and top timber wall plate 76 are installed, roof panel building components 12 may then be installed to define a roof structure of the building 2. Figures 16 to 18 show roof panel building components 12 according to embodiments of the present invention.
It is envisaged that the roof panels 12 are to be made according to a limited range of dimensions; if the building structure 2 requires differently-sized roof panels, infill panels can be custom-made in a factory environment or constructed in-situ on site from the relevant supplied materials on-site.
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Figures 16(a) and 16(b) show a roof panel building component 12 according to embodiments of the invention. The composition and configuration of the roof panel 12 is similar to that of the floor panel 8. The roof panel building component 12 is also made from a pair of opposed structural beams (i.e. rafters) 100 having LGS C-shaped cross-sectional channels 102 between which transverse joists 104 and an EPS layer 106 are disposed. In the embodiment depicted in Figure 16(b), the EPS layer 106 is thicker than the joist 104 and is preferably vertically spaced from the joist 104. The spacing 108 allows for condensation and access for services such as electrical cable management.
The installation of roof panels 12 next to one another to form the roof structure is also not dissimilar to the installation of adjacent floor panels 8. In this regard, the adjacent C-channel beams 100 of two roof panels 12 are screw fixed together to form an I-section beam. With reference to Figure 17, to install a roof panel 12, the lower flange 110 of each C-shaped channel 102 is fixed to the upper timber top wall plate 76 installed along the top of the wall panels 10. To this end, the lower face 110 of the C-shaped channel 102 can be screw fixed to the top timber wall plate 76 via a hold-down bracket 112 indicated in Figures 17 and 18, thereby interconnecting the roof panels 12 to the wall panels 10.
The present roof panels 12 are relatively light such that they can be handled and lifted into position by two or more people without needing additional lifting assistance. Due to the simple linear construction of the roof panels 12, with no conventional truss required, a roof space can be formed and utilised as an attic, a loft room, a storage space etc. Chamfered, high, or cathedral ceilings with skylights are accommodated by the present roof panels 12. The joists 104 and/or opposed rafters 100 of the roof panels 12 are also provided with service access openings 114 for easy installation and access of cabling and the like.
Owing to the aforementioned building components 4, 6, 8, 10, 12, a significant proportion of a building structure 2 can be mass prefabricated off-site in factory environments and conditions due to the repetitive modular nature of the panel system. This allows much of the components of the building structure 2 to be strictly quality controlled and error proofed. This in turn can reduce manufacturing and construction costs through
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repetition and reduced material wastage. The prefabricated components can then be transported and installed relatively quickly on-site with little need for specialist equipment and machinery on site. The remaining construction work can therefore mostly be carried out in indoor conditions after building structure 2 is constructed. The reduced construction time also translates to reduced costs, OHS hazards during construction, and risk of on-site vandalism and theft.
Many modifications of the above embodiments will be apparent to those skilled in the art without departing from the scope of the present invention. For example, other means for adjusting a height of the support head jack16, wall panels on other footing or floor system, roof panels on other walling system, any adaptable dimension of kitchen or wet area are considered within the scope of the present specification.
In embodiments of the invention, the framing (e.g. beams, joists, noggings etc.) of the floor, wall and roof panels is formed from light gauge steel (LGS). For insulation and condensation protection purposes, the floor, wall and roof panels are formed from EPS with a layer of breathable sarking. Of course, framing formed from other materials is also within the scope of the present specification.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims (1)

  1. P10408.AU Specification - 25/08/2021
    - 17
    CLAIMS:
    1. An adjustable post for use in a floor support system of a building, comprising: (a) a head jack for supporting the floor and a base jack disposed on the top of a footing at ground base level beneath the floor to be built, and (b) an adjustable threaded shaft between the base and head jacks, configured to operate as a turnbuckle.
    2. The adjustable post of claim 1, wherein the support head jack and the base jack, are aligned with a vertical axis, to form an always adjustable structural support to the floor system.
    3. The adjustable post of any one of the preceding claims, wherein the height of the support head jack above the ground base level (GBS) is adjustable.
    4. The adjustable post of claim 3, wherein the shaft is screwthreadingly engaged with the support head jack and base jack, to effect permanent (turnbuckle) height adjustment thereof.
    5. A panel for forming part of a frame of a building structure, comprising: (a) an opposed pair of longitudinally extending beams; (b) spaced apart transverse joists interconnecting the beams; and (c) an expanded polystyrene (EPS) layer underlying the joists.
    6. The panel of claim 5, wherein the beams comprise structural channels configured to receive ends of the joists and EPS layer.
    7. The panel of claim 6, wherein in use, the beams of adjacent panels are secured together such that a cross-section thereof is substantially in the form of an I-beam.
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    8. The panel of any one of claims 5 to 7, wherein the joists and/or beams comprise service access openings.
    9. The panel of any one of claims 5 to 8, being configured to form the floor and/or roof panels of the building frame.
    10. A wall panel for forming a wall structure of a building comprising: (a) an external wall layer; (b) an internal wall layer; and (c) a spaced apart and opposed pair of substantially parallel and vertically extending beams sandwiched between the wall layers, the beams being configured to connect to the beams of adjacent wall panels so as to form the wall structure of the building.
    11. The wall panel of claim 10, wherein the wall layers comprise EPS layers and the beams comprise structural beams.
    12. The wall panel of claim 10 or 11, wherein, when viewed from above: (a) one of the beams is inwardly offset from first lateral edges of the wall layers such that a vertical slot is defined between the layers and the beam; and (b) the other of the beams is outwardly offset from second lateral edges of the wall layers such that the beam protrudes outwardly from between the wall layers, wherein in use, the protruding beam of a first wall panel is inserted into the slot of a second wall panel to connect the two panels.
    13. The wall panel of any one of claims 10 to 12, further comprising one or more noggings between wall panel beams, wherein the end of each nogging comprises flanges for receiving and securing to a beam.
    14. The wall panel of claim 13 as appended to claim 12, wherein the lateral flanges of at least one nogging protrude into the slot so as to be configured to be secured to the protruding beam of an adjacent wall panel.
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    15. The wall panel of any one of claims 10 to 14, wherein: (a) one of the opposed beams comprises one or more outwardly extending flaps; and (b) the other of the opposed beams comprises one or more respective openings configured to releasably receive a respective flap of an adjacent wall panel.
    16. A building structure supported by footings according to any one of claims 1 to 4, having floor and roof panels according to any one of claims 5 to 9, and wall panels according to any one of claims 10 to 15.
    17. The building structure of claim 16, further comprising one or more self-contained kitchen and/or wet area Hubs supported by the adjustable posts.
    25. A method of constructing a building structure according to claim 23 or 24, wherein the kitchen and other wet areas are separated from the remaining dry areas of the house and focused into service hubs which are prefabricated off-site, comprising the steps of: (a) commencing installation of a structural support system by installing adjustable posts according to any one of claims 1 to 4 configured for supporting self contained kitchen and/or wet area Hubs; (b) installing the or each Hub so as to be supported by the installed adjustable posts; (c) completing installation of the structural support system by installing the remaining adjustable posts required for the building structure; (d) constructing a floor structure using panels according to any one of claims 5 to 9; (e) constructing a wall structure using wall panels according to any one of claims 10 to 15; and (d) constructing a roof structure using panels according to any one of claims 5 to 9.
AU2021221627A 2020-10-29 2021-08-25 Building components, a building structure formed therefrom and a method of construction thereof Pending AU2021221627A1 (en)

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GB2628044A (en) * 2021-01-06 2024-09-11 Merit Group Services Ltd Modular building construction system
EP4311891A1 (en) * 2022-07-26 2024-01-31 Nicolae Tiberiu Giolgau Giolgau Industrialised construction system and manufacturing process and assembly of said industrialised construction system
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US20080263968A1 (en) * 2007-04-25 2008-10-30 Day Mark O Prefabricated rapid response accommodation structure
AU2012234909A1 (en) * 2011-03-30 2013-11-14 Blue Arc Australia Pty Ltd Building system
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