GB2382596A

GB2382596A - Lightweight modular roof

Info

Publication number: GB2382596A
Application number: GB0128713A
Authority: GB
Inventors: Kenneth Michael Everitt
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-11-30
Filing date: 2001-11-30
Publication date: 2003-06-04
Also published as: GB0128713D0

Abstract

A roof section is fabricated from panels cut from sheets of flat panel material. The panels are assembled into a three-dimensional structure and bonded using an adhesive to form the three-dimensional structure. Rigid cross members, which may be cold formed metal beams, may be bonded to the panels. Cladding 600, 601, 605 may be bonded to outer surfaces of the roof section. Each panel may comprise a sheet of bulk foam material having outer skins bonded to it. Each panel may also comprise a channel member overlapping an edge face of the panel and a main face of the panel and bonded to the panel. Various other disclosures are made including a method of joining adjacent panels comprising the steps of abutting edges of the panels and attaching jointing plates to the faces of the panels to cover the join between the panels, a roof section comprising rib members bonded to flat roof panel members and a building panel comprising first and second skins bonded to faces of a bulk foam material sheet.

Description

LIGHTWEIGHT MODULAR ROOF Field of the Invention The present invention relates to building structures, and particularly although not exclusively to roof structures.

Backaround to the Invention Conventional commercial buildings for example of the type used as fast food restaurants are constructed from pre-fabricated roof sections and wall sections, attached to a steel-framed structure. Typically, an on-site installation of such a structure comprises the stages of ; leveling a site area for installation of a concrete foundation; erecting a steel frame, by connecting together an assembly of steel beams; attaching wall panels to the steel frame, Including glass panels and doors; lifting a plurality of pre-fabricated roof sections onto the frame, and securing the roof sections to the frame; and installing interior fitments, and utility services prior to full commissioning of the building.

Important criteria in constructing such commercial buildings are the speed at which the building can be erected on site, and cost of construction. There is pressure to improve the speed of construction, and reduce the cost of construction.

Referring to Fig. 1 herein, there is illustrated schematically in perspective view a prior art commercial building comprising a steel frame, a plurality of wall panels, and a plurality of roof sections. The wall panels and roof are secured to the main steel frame by bolts.

Referring to Fig. 2 herein, there is illustrated schematically, a prior art roof section being lowered into position on top of a main steel frame structure during construction of a building. The prior art roof section comprises a welded steel sub-

frame, capable of being bolted directly to the main steel frame of the building, the sub-frame having a plurality of laterally extending steel beams which, in use extend at an incline to the horizontal, and outwardly away from the main building. A plurality of wooden slat members are secured transverse to the lateral beams, such that they extend along a fall of the roof, and parallel to the main walls of the building in use, the slats providing a securement for fitting of a plurality of conventional lightweight roofing tiles, which cover the roof section. Due to local planning requirements, the external finish of the roof section may be varied by usage of different types of tiles. For example, in some areas, local authorities may specify that slate tiles are used, whilst in other areas, local authorities may specify stone or stone-effect tiles. Consequently, the weight of the roof section is dependant upon the tile finish which is specified by a local authority. With the conventional roof section comprising of steel sub-frame, roof sections typically of the order 20-25m in length, and 1. 5-2. 0m in height are fabricated.

The roof sections are fabricated away from the construction site and transported to the site when required. A single heavy-goods vehicle having a long, flat-bed is used to transport each single roof section to the construction site. For a typical building having a substantially rectangular plan, six individual roof sections are required in order to construct a complete roof, each roof section being bolted to the main steel frame of the building. As a building is to be constructed in as short a time as possible, that is within a few days, typically there are required six articulated trucks each carrying a roof segment, to arrive on site on the same day or within a short period, and there needs to be a large crane on site in order to unload the trucks and lower the roof sections onto the steel frame for fitment to the frame.

Referring to Fig. 3 herein, there is illustrated schematically in perspective view, a single prior art roof section 300 being loaded on to a flat-bed trailer of an articulated truck for transport from a site of manufacture of the roof section, to a construction site. The fabricated roof section is lifted using a lifting frame 300, to

which the roof section 300 is attached, to lift the roof section onto the flat-bed trailer. Because of the geometry of the steel sub-frame of the roof section, only one roof section at a time can be loaded onto a single flat-bed trailer.

Specific implementations according to the present invention aim to address the problem of producing weight reduced roof sections for a modular building, whilst maintaining enough strength to be able to accommodate a wide variety of exterior roofing materials, and all required super loads, i. e. wind, snow, rain and the like.

In addressing this problem, specific implementations must retain rigidity, and strength, and comply with all local safety and building regulations.

Summary of the Invention Specific embodiments of the present invention provide a roof section comprising a plurality of individual composite panels bonded together by an adhesive, rivets, self-tapping screws, or like attachments.

The roof sections may be attached to a known metal frame structure, for a building to create a light weight modular roof structure. The roof sections are of relatively light weight compared to prior art roof sections.

According to a first aspect of the present invention there is provided a method of construction of a roof section of a building, said method comprising the steps of : cutting a plurality of sheets of substantially flat panel material, to form a plurality of shaped panels ; assembling said plurality of shaped panels into a three-dimensional structure and;

bonding said plurality of panels using an adhesive substance to form said three dimensional structure.

According to a second aspect of the present invention there is provided a roof section comprising: a plurality of substantially upright rib members; at least one substantially flat roof panel member; wherein said at least one substantially flat roof panel is rigidly bonded to said first and second rib members.

According to a third aspect of the present invention there is provided a building panel comprising; a bulk foam sheet material having first and second sides; a first skin member; a second skin member; wherein said first skin member is bonded to first side of said foam sheet material and said second skin member is bonded to said second side of said sheet material ; and an edging member bonded around a periphery of said panels.

According to a fourth aspect of the present invention there is provided a method of forming a panel for a roof structure, said method comprising the steps of;

placing first and second skin members in spaced apart relationship from each other such that a cavity is formed there between; introducing a seftable foam material in flowable form into said cavity; allowing said settab) e foam material to set into a solid foam mass, wherein said set-able foam material bonds itself to interior surfaces of said first and second skin members; and bonding an edging member to a periphery of said first and second skin members and said foam material.

Other features and aspects of the present invention are as recited in the claims herein.

Brief Description of the Drawings For a better understanding of the invention and to show how the same may be carried into effect, there will now be described by way of example only, specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which: Fig. 1 illustrates schematically in perspective view a prior art building having a steel frame and cladding structure; Fig. 2 illustrates schematically a prior art section of roofing being lowered onto a steel frame during a construction phase of the building of Fig. 1;

Fig. 3 illustrates schematically the prior art roof section being loaded onto a flat-bed truck for transport to a construction site; Fig. 4 illustrates schematically in perspective view a modular roof section according to a specific embodiment of the present invention; Fig 5. illustrates schematically an exploded view of a carcass of the modular roof section of Fig. 4; Fig 6 illustrates schematically an end-view of a roof section in-situ on a metal frame of a building ; Fig. 7 illustrates schematically in perspective view the modular roof section, without outer roof covering and without wooden slats during a stage of construction.

Fig. 8 illustrates schematically in perspective view, the modular roof section of Fig. 7 showing a rear-side of the roof section; Fig. 9 illustrates schematically in cut-away view construction of a panel component of the roof section of Fig. 4.

Fig. 10 illustrates schematically bonding between components of the panel of Fig. 9; Fig. 11 illustrates schematically a joint between two panels ; Fig. 12 illustrates schematically part of a carcass for a second roofing section, during assembly ;

Fig. 13 illustrates schematically the carcass of the second roofing section viewed from another angle ; Fig. 14 illustrates schematically fixing of first and second roof panels to a rib member; Fig. 15 illustrates schematically a third roof section according to a third specific embodiment of the present invention; Fig. 16 illustrates schematically a rib member comprising the third roof section; Fig. 17 illustrates schematically in plan view a roof structure comprising a plurality of modular roof sections, installed on a building ; Fig. 18 illustrates a first set of calculations for construction of a roof section; and Fig. 19 illustrates schematically a second set of calculations for construction of a roof section; and Fig. 20 illustrates a method of manufacture of a building panel.

Detailed Description of the Best Mode for Carrying Out the Invention There will now be described by way of example the best mode contemplated by the inventors for carrying out the invention. In the following description numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the present invention.

Referring to Fig. 4 herein, there is illustrated schematically in perspective view, a roof section according to a specific embodiment of the present invention. The roof section comprises a plurality of flat panels of composite material, bonded together with adhesive, to form a modular light-weight carcass. The carcass is covered with conventional cladding, lightweight tiles, and conventional fascia board to form a roof section ready for fitment to a steel frame of a building.

Referring to Fig. 5 herein, there is illustrated schematically in exploded view a carcass of the roof section of Fig. 4. The carcass comprises first and second upright rib members 500,501 respectively, each said rib member having one or a plurality of inclined faces 502-505 ; a first inclined roof panel 506, extended between said first and second upright rib members; a second inclined roof panel 507 extended between first and second upright rib members, a capping panel 508 extending between said first and second upright rib members; a fascia panel 509 extending between front tip portions of first and second upright rib members 500, 501 ; a soffit panel 510 extending between the first and second upright rib members, and fixed and at lower edges of said first and second rib members; and a back panel 511 for fitting between rear edges of said first and second rib members.

The upright panels, 500,501 are spaced apart from each other, with the roofing panels, cap panel, fascia panel, soffit panel and back panel extending there between, the whole roof section being rigidly bonded together by an adhesive material, for example a polyethylene adhesive, polyacrylate adhesive or known building adhesive, for example Araldite , such that the bonded panels form a lightweight rigid base module, which can be used as a basis for building a full roof section with further addition of cladding sheets, light-weight tiles and one or more cross members.

Referring to Fig. 6 herein, there is illustrated schematically in cross-sectional view, the roof section of Figs. 4 & 5, together with part of a main structure of a building, onto which the roof section is mounted. The upper and lower roofing panels 507,506 respectively are covered with a ribbed cladding sheets 600,601 respectively, the cladding sheets being stuck to the upper and lower roofing panels by means of adhesive. Mounted on the ribbed cladding sheets, are a plurality of wooded slats 602, spaced apart at distances suitable for mounting conventional light-weight tiles 603. At an upper-ridge of the roof section, there is provided an extruded aluminum, or cold-formed steel capping member 604, which may be fitted retrospectively to the roof section, once a plurality of roof sections are fitted onto a building.

A rear cladding sheet 605 is bonded to back-member 511 using adhesive, the rear cladding sheet having an overhanging lip 606, which overhangs a boundary wall 607 of a flat/interior roof structure 608, built on top of a metal frame of the building. The cladding sheet material may be vacuum formed, for example, vacuum formed polystyrene or other like plastics material.

First and second a metal cross-beam members 609,610 extend between upright panel members, and are bonded thereto using the adhesive. The metal cross-members are cold-formed"C"shaped steel. There is also provided a further "C" metal cross-member 611 at a lower edge of the roof section, which may be used as a cable tray.

The roof section sits upon one or a plurality of upright center columns 611 of a main steel structure of the building, and may be secured thereto by means of bolts passing from the"C"shaped cross-member into a locating plate positioned on top of the upright columns.

Soffit panel 510 is provided with an external cladding sheet 612, to provide a visually appealing cladding finish to the underside of the roof section.

It will be appreciated by a person skilled in the art that the construction system described herein comprising a plurality of composite material panels rigidly fixed together with adhesive, is capable of forming a wide range of shapes and structures, for creation of a roof.

There will now be described construction of a roof section having three upright panels connected by a plurality of cold-formed metal cross-members.

Referring to Fig. 9 herein, there is illustrated schematically in cut-away view, a section through a composite panel member, forming the basic material for construction of the roof modules. The panel comprises a bulk sheet of foam material 900, for example polyurethane foam or a phenolic foam, of thickness in the range 50mm-200mm, bonded on a first side to a first metal sheet skin member 901, and bonded on a second side to a second metal sheet skin member 902; and a coldformed steel"U"or"C"shaped channel edging member 903 bonded to an edge of the sheet material, and to the first and second skin members 901,902 respectively.

Skin members can be formed from different types of sheet material, including plastics materials, or metals for example mild steel, aluminum or the like, and similarly the channel members 903 can be formed from a wide range of materials as will be appreciated by those skilled in the art. In the best-mode, a steel sheet of thickness of the order of 0.5mm is used, although the sheet thickness may vary between 0.2mm and 2. 0mm. The sheet may be painted or otherwise coated.

Referring to Fig. 10 herein, there is illustrated schematically in cross-section part of the panel of Fig. 9, showing bonding of the channel edging member 1000 and a skin member 1001 to the bulk foam material 1002. The panel member is manufactured by sawing a sheet of the foam sheet material into a required shape

using a conventional saw. E. g. a jig-saw hand tool or a bench-saw, and then laying one or a plurality of beads of adhesive 1003 between the foam material, and the channel edging member, and/or between an outer surface of the skin member 1002, and the channel member 1000.

An exposed perimeter of the foam sheet material is covered by the"U"or"C" shaped channel members 1000, by first applying beads of adhesive to the foam and outer faces of the skin sheets 1002, and sliding the channel members over the peripheries of the foam material, such that the channels bond both to the foam material and/or to the outer skins.

The adhesive may be a polyurethane adhesive, such as Lastite@ or Araldite@.

Using the above techniques, panels of a wide variety of shapes can be manufactured.

The panel construction method has the advantage of increased strength compared to a foam sheet material. The skin material, although thin lends rigidity and strength to the interior foam material, by constricting its degrees of freedom under loading, and thereby resulting in a relatively light and strong panel member, which can be formed into a wide variety of shapes, and which can be constructed without the need for heat-treatment or special tools.

In an alternative embodiment, a panel may be formed by introducing a foam in flowable or semi-liquid form between a plurality of skin members spaced apart, optionally, with one or a plurality of substantial"C"or"U"shaped edging members surrounding rims of the sheet skin members. Using this method, the skin members and edging members are held in fixed relationship to each other, forming a cavity therein, and the foam is introduced into the cavity in liquid form. The foam sets into

a solid mass, bonding itself to the interior walls of the skin members and the channels as it sets.

Referring to Fig. 11 herein, there is illustrated schematically joining of first and second panels to form an upright rib member. The panels may or may not include peripheral channel members at the joint. In the joint shown, peripheral channel edging members are not included between panels.

Each panel is cut such as to have a face 1100,1101 respectively which is perpendicular to a main plane formed by a main side of the panel. In other words, in the best mode, the panels are cut at approximately 90 to the main sides of the panels. The panels comprise a sheet of foam material, having first and second skin members bonded thereto. The exposed edge-faces of the panels are bonded together by placing beads of adhesive along those faces and pressing the faces together. In order to strengthen the joint, first and second jointing plates are applied either side of the edge-faces and oppositely facing each other. Between each jointing panel and the skin member of the first and second panel has to be joined is placed one or a plurality of beads of adhesive 1104-1107. The plates are pressed towards each other, and on to the respective skin members of the panels. Holes are drilled through the plates, through the skin member and foam member of the panels, and rivets or bolts 1108, 1109 are passed through the drilled holes and secure the jointing panels to each other, compressing the panels there between.

There will now be described a method of construction of a second roof section, with reference to Fig. 12 and Fig. 13 herein.

Referring to Fig. 12 herein, there is shown in perspective view, a second roof module at a stage during construction. The second roof module comprises a plurality of rib members 1200-1202, each rib member comprising first and second panels joined together by a joint as described with reference to Fig. 11. The ribs are

spaced apart equidistantly, and rigidly held by a plurality of formed metal cross member 1204-1206 as shown.

Due to the light weight of the structure, the structure can be manually assembled he need for cranes or other lifting apparatus, during construction.

A plurality of rib members are spaced apart and held upright on the surface, for example a floor of a workshop, or a jig. Cross members are glued to the rib members, using beads of adhesive extruded from an adhesive gun, or alternatively using adhesive which is piped from a central reservoir to an adhesive application tool, whereby an operator can squeeze a trigger on the tool, to exude adhesive onto the ribs and cross member.

The structure of Figs 12 and 13 which is inverted, for fitment of the cross members 1204-1206 may then be turned over, for fitment of outer roof panels across the ribs, and for fitment of a capping panel.

First and second roof panels extend between the ribs. In the example shown in Figs 12 and 13, a single first roof panel may be used to cover a first, lower fall of the roof section, or alternatively, two individual roof panels may be used to cover the lower fall, where a first lower roof panel extends between a first outer-rib and a central rib, resting upon and bonded to exterior channel faces or edges of the first outer and central rib, and a second lower exterior roofing panel may be placed adjacent at the first lower roof panel, extending between a second outer-rib and the central rib. The central rib is of sufficient width, to support the edges of two separate lower roofing panels, as shown in Fig. 14. Alternatively, the roof panels may abut and be glued to sides of the rib members.

Upper roofing panels are fitted to the upper fall of the roof section, and bonded thereto by adhesive as previously described.

A back panel is fitted to the roofing section. The back panel may comprise a single panel extending a full length of the roof section, or may comprise two separate back panels, each extending between the first and second outer-ribs respectively, and the central rib.

The partially constructed carcass may then be manually lifted and turned over into an inverted position as shown in Figs 12 and 13 again, for fitment of the soffit panels, between the first and second outer-ribs respectively and the central rib, or where a single soffit panel is used, extending across all three ribs.

A fascia panel, which may be fitted as a single fascia panel extending the length of the section, or as two/three separate fascia panels may then be fixed using adhesive and rivets to the ends of the rib.

The structure may then be inverted again so as to be placed the correct way up as in use, for fitment of cladding panels to the upper fall, lower fall, fascia panel and back panel (s) as shown in end view in Fig. 6 herein. Wooden batons are secured to the cladding on the upper and lower falls of the roof section, and lightweight tiles or other external roof covering are then secured to the batons. Securement of the batons to the cladding is by conventional means, for example screws and/or adhesive.

Securement of the cladding to the panels of the roof section is by application of adhesive and pressing the cladding to the panels.

The structure may then be inverted once again, for fitment of cladding to the soffit panels, by gluing the cladding panels to the soffit panels.

It will be appreciated by the persons skilled in the art that there are many variations in the order in which the above processes may be carried out. However, because of the relative light weight of the roof section compared to prior art roof sections, inversion of the roof section is easier and quicker than for an equivalent dimensioned prior art roof section having a steel sub-frame.

Referring to Fig. 14 herein, there is illustrated schematically one method of fixing first and second roof panels to an upper edge of a rib. The rib is of sufficient width that the first and second panels can each be rested on an upwardly facing surface of the rib, and be glued thereto and to each other.

Alternatively, the roof panels may abut a side of the rib, in which case an edge of each roof panel abuts a respective side of the rib and is glued thereto using adhesive.

Referring to Fig. 15 herein, there is illustrated schematically in end-view, a third roof section according to a third specific embodiment of the present invention.

The third roof section comprises first and second upright rib members, 1500 of which only one is shown in Fig. 15, an upper roof panel 1501; a lower roof panel 1502; a fascia panel 1503; a soffit panel 1504; a back panel 1505; and a cap panel 1506.

The rib members of the third roof section comprise first and second panels 1508, 1509 joined by a jointing plate structure 1510 as herein before described with reference to Fig. 11 herein.

A method of construction of the third roof section is substantially as herein before described, by glueing panels together using adhesive.

Referring to Fig. 16 herein, in the third embodiment, each rib member comprises first and second panels 1600,1601 respectively joined by a jointing plate assembly 1602 as described herein before. The rib member comprises a first

substantially flat side 1603, and a second substantially flat side (not shown). A perimeter of the rib is surrounded by a substantially"C"shaped cold-formed or extruded edging strip 1604, which is cut and glued around a peripheral edge of the rib, as a plurality of individual members. A general shape of the rib as viewed in a direction perpendicular to a main side of the rib consists of an elongate arm 1605, an upper edge of which accommodates a lower roof panel, forming a lower roof fall, and an under edge 1607 of which provides mounting for an underside soffit panel 1604, the whole construction forming an overhanging canopy, a more vertically inclined upright angled edge 1604 for fitment of an upper roof panel to provide an upper roof fall, a substantially horizontal upper edge 1608 for supporting a substantially horizontal capping panel, to form an upper ridge of the roofing section; an upright rearward edge 1609, providing a face for mounting a back panel ; and a substantially horizontal base face 1610, for mounting the roof section on to a steel frame of a building. The elongate arm section 1605 extends from a lower region of the substantially truncated triangular upper panel 1600.

As shown in Fig. 15 herein, the base edge of the upper region may be slotted to accommodate first and second cross members, which link a plurality of the ribs in spaced apart relationship, parallel to each other for forming a roof section.

A complete roof section according to the third embodiment may be used as a canopy over entrances, doorways or the like of a building.

Referring to Fig. 17 herein, there is illustrated schematically in plan view, a roof construction in-situ on a building. The roof construction comprises a plurality of individual roof modules 1700,1701 which have been pre-assembled into roofsections, each section comprising a plurality of roof modules.

The size of the roof sections can be varied at manufacture off-site, and selected to the size which provides easiest assembly at the construction site. In the

example of Fig. 17, there are provided six individual roof sections identified 1702- 1707 respectively.

Due to the lightweight materials, each roof section has approximately 30% of the weight of an equivalent prior art roof section.

In the example of the roof construction of Fig. 17, because there is no steel sub-frame, loading of the roof section onto a flat-bed trailer is not restricted by the sub-frame, therefore two or three times as many roof sections can be loaded on to a flat-bed articulated truck, as compared to the prior art roof sections. Therefore to transport the entire set of roof sections for the roof of Fig. 17 requires only two trucks, whereas in the prior art to transport the equivalent steel sub-frame prior art roof sections would require six flat-bed trucks.

Referring to Fig. 20 herein, there is illustrated schematically a method of manufacture of a building panel comprising a polyeurothane or phenolic foam filler introduced in flowable or liquid form into a cavity formed between first and second skin member 2000 enclosed by a plurality of substantially "C" shaped channel edging members, which are riveted, glued or otherwise bonded to the skin members 2000.

The panel can be lifted in-situ onto a building, without having the interior foam material introduced, and the foam material can be introduced once the panel is already placed in-situ on the building, by delivery of the foam in a liquid form through a delivery tube and nozzle 2002,2003.

Benefits of the specific embodiments and methods disclosed herein are the relative lightness and strength of the materials used. As persons skilled in the art will appreciate, structures must be fabricated to have sufficient strength and rigidity

to be able to withstand all environmental conditions which may be encountered by the structure including snow, rain and wind ladings.

In appendix 1 herein, there is illustrated schematically a set of design calculations for a roof section comprising a plurality of individual modules, the modules constructed into sections, as shown in Fig. 15 herein. For a typical roof section as illustrated with reference to Fig. 6 herein. The design calculations are for a roof structure which satisfies British Standards on codes of practice including BS6399 part 1 and part 3 (imposed loading), CP3 (wind loading), BS5268 (structural use of timber) and BS5950 part 5 (structural use of steel work in buildings, cold form sections).

The design calculations are set out in Appendix 1 herein for a design utilising composite panels having glued and riveted connections where applicable Appendix

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Claims

Claims :

1. A method of construction of a roof section of a building, said method comprising the steps of: cutting a plurality of sheets of substantially flat panel material, to form a plurality of shaped panels ; assembling said plurality of shaped panels into a three-dimensional structure and; bonding said plurality of panels using an adhesive substance to form said three dimensional structure.

2. The method as claimed in claim 1, further comprising the step of: bonding a plurality of rigid cross members to said plurality of panels.

3 The method as claimed in claim 2, wherein a said rigid cross-member comprises a cold-formed metal beam.

4. The method as claimed in any one of the preceding claims, further comprising the step of: bonding one or a plurality of cladding sheets, to one or more outwardly facing surfaces of said structure.

5. The method as claimed in any one of the preceding claims, further comprising the step of:

attaching a plurality of tiles to an outwardly facing surface of said structure.

6. The method as claimed in any one of the preceding claims, wherein a said adhesive material is selected from the set : a polyacrylate adhesive; a general purpose building materials adhesive.

7. The method as claimed in any one of the preceding claims, wherein a said panel comprises: a bulk foam sheet material ; a plurality of outer skin-sheets, wherein said plurality of outer-skin sheets are bonded to said bulk foam sheet material using an adhesive.

8. The method as claimed in claim 7, wherein a said panel further comprises; at least one said channel member overlapping an edge-face of said panel and at least one main side of said panel, said channel member being bonded to said foam material and/or said skin-sheet using an adhesive material.

9 A method of joining first and second panel members to form a rib member for a roof structure, said method comprising the steps of : attaching a first said panel member to a second said panel member by: abutting a first edge-face of said first panel member with a second edge-face of said second panel member;

applying adhesive to said first edge-face of said first panel member; aligning said first and second panel members, such that a first outer-surface of said first panel member is aligned substantially parallel with a second outersurface of said second panel member; applying an adhesive material to said first outer surface of said first panel member and said second outer surface of said second panel member; pressing a first jointing plate onto a region of said first outer surface and said second outer surface, said first jointing plate traversing a gap between said first and second panels; applying an adhesive material to a third outer surface of said first panel member and to a fourth outer surface of said second panel member; pressing a second jointing plate onto a region of said third outer surface and onto a region of said fourth outer surface, said second jointing plate traversing said gap between said first and second panels ; forming at least one aperture through said first jointing plates and said first panel member; forming at least one aperture through said first and second jointing plates and said second panel member; passing a fixing member through said first aperture and securing said first and second jointing plates together using said first fixing member, said first panel member sandwiched there between; and

passing a second fixing member through said second aperture, and securing said first and second jointing plates and said second panel member using said second fixing member;

10. A method of producing a building panel, said method comprising the steps of; bonding a first skin-sheet material to a sheet of bulk foam material; bonding a second skin-sheet material to said bulk foam material to form a composite panel member comprising said bulk foam sheet material, said first skin sheet and said second skin sheet; applying an adhesive to at least one end-face of the said bulk foam material ; and fitting a substantially"C"shaped channel member over said end-face of said bulk sheet material and over at least one of said skin-sheets.

11. The method as claimed in claim 10, further comprising the step of: applying an adhesive material to an outer surface of said skin sheet material, for bonding a lip of said substantially"C"shaped channel member to said outersurface of said skin-sheet.

12. A roof section comprising: a plurality of substantially upright rib members; at least one substantially flat roof panel member;

wherein said at least one substantially flat roof panel is rigidly bonded to said first and second rib members.

13. The roof section as claimed in claim 12, further comprising a fascia panel, said fascia panel extending between said first and second rib panels, said fascia panels bonded to said first and second rib panels.

14. The roof section as claimed in claim 12, further comprising: a cap panel, said cap panel extending between respective upper portions of said first and second rib panels, and bonded thereto.

15. The roof section as claimed in any one of claims 12 to 14, further comprising. at least one upright back panel, said back panel extending between rearward facing portions of said first and second rib panels, and bonded to said first and second rib panels.

16. The roof section as claimed in any one of claims 12 to 15, further comprising : a soffit panel, said soffit panel extending between said first and second rib panels, and bonded to an underside of said first and second rib panels.

17. The roof section as claimed any one of claims 12 to 16, further comprising: at least one cladding sheet, said at least one cladding sheet bonded to a said panel.

18. The roof section as claimed in claim 17, wherein said cladding sheet comprises: a plurality of ridges, in use said ridges extending substantially lengthways along a main length of said roof structure.

19. The roof structure as claimed in any one of claims 12 to 18, comprising, a rear cladding sheet bonded to a back member of said roof structure, said rear cladding sheet comprising an overhanging lip which, in use, is adapted to overhang a boundary of a flat roof structure.

20. The roof section as claimed any one of claims 12 to 19, further comprising: a plurality of outer tiles, said plurality of outer tiles bonded to a said cladding sheet.

21. The roof section as claimed in any one of claims 12 to 20, comprising a plurality of cross members extending between said plurality of upright rib members, said plurality of cross members providing means for securement of said roof section for fitting said roof section to a frame of a building.

22. The roof section as claimed in claim 20, wherein a said cross member comprises a substantially "C" shaped metal beam.

23. A building panel comprising; a bulk foam sheet material having first and second sides; a first skin member;

a second skin member, wherein said first skin member is bonded to first side of said foam sheet material and said second skin member is bonded to said second side of said sheet material ; and at least one substantially"C"shaped edging member, said edging member bonded to said foam matenal and/or at least one said skin member using an adhesive material.

24. The panel as claimed in claim 23, wherein said foam material comprises of polyurethane or a phenolic based foam.

25. A method of forming a building panel, said method comprising the steps of; placing first and second skin members in spaced apart relationship from each other such that a cavity is formed there between; introducing a settab ! e foam material in flowable form into said cavity; allowing said seftable foam material to set into a solid foam mass, wherein said settab) e foam material bonds itself to interior surfaces of said first and second skin members.

26. The method as claimed In claim 25, further comprising the step of ; further enclosing said cavity by fitment of a plurality edging members around a periphery of said skin members.

27. The method as claimed in claim 25 or 26 wherein said foam is injected into said cavity.