GB2588833A

GB2588833A - Structural insulated panel for a modular building

Info

Publication number: GB2588833A
Application number: GB1916408.6A
Authority: GB
Inventors: Fishenden Peter
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-11-11
Filing date: 2019-11-11
Publication date: 2021-05-12
Also published as: GB201916408D0

Abstract

A structural insulated panel, SIP, 102 for a modular building 100 comprises a first structural board 202, a second structural board 204, with an insulating core 201 sandwiched between them. The SIP has a groove arrangement 210 for receiving a support 200. The groove arrangement extends along an edge of the SIP and has a first side wall 404 on the first structural board and a second side wall on the insulating core so the groove arrangement is spaced from the second structural board by the insulating core 403. The groove arrangement may comprise two parallel grooves extending along the entire periphery of the SIP. The structural boards may be magnesium oxide wallboards. The insulating core may comprise expanded polystyrene foam. The insulating core may have a conduit for accommodating an electrical wire. The support may have a C or U or H cross section. Also claimed is an SIP construction comprising first and second SIPs with an intumescent layer between them. The intumescent layer may be hard or soft char. Also claimed is an SIP construction comprising an SIP and a concrete base separated by a compliant layer comprising a plastic lumber. The support may be steel.

Description

I

Structural Insulated Panel for a Modular Building

Field of the Disclosure

The present disclosure relates to a Structural Insulated Panel (SIP) for use in modular building construction. The SIP is particularly, but not exclusively, applicable to use with a steel support.

Background to the Disclosure

It is known to provide Structural Insulated Panels (SIPs) for use in modular building construction. Modem Methods of Construction (MMCs) using SIPs are quick and efficient ways of constructing buildings. Generally, SIPs comprise an insulating core sandwiched between two structural outer boards, typically made from Oriented Strand Board (OSB). The structural outer boards add strength and the insulating core provides insulation.

The SIPs are often set in a timber frame. Such timber frames are easy to erect on site using conventional methods and cheap materials, but they have drawbacks such as poor defence against moisture and fire. It is generally known to use metal frames instead of timber frames to overcome the moisture and fire issues. However, no satisfactory method of combining such metal frames with conventional SIPs is available. Rather, the high thermal conductivity of metal frames causes thermal bridging through conventional SIPs. Thermal bridging involves an area or component of an object that has a higher thermal conductivity than the surrounding materials creating a path of least thermal resistance. In a SIP mounted to a metal frame, this results in an overall reduction in the thermal resistance of the insulated panel at the location of the metal frame, which in turn results in much greater heat transfer through the SIP at that location. This heat transfer tends to cause ghosting on the outer surface of the SIP, because resulting localised temperature differences cause condensation to form on parts of the structural board facing the inside of the building near the frame. The area of increased condensation causes dust and dirt from inside the building to collect on the surface of the structural board, and the appearance of a "ghost" of the metal frame on the surface.

The present disclosure seeks, amongst other things, to overcome this problem.

Summary of the Disclosure

According to a first aspect of the disclosure, there is provided a structural insulated panel for a modular building, the structural insulated panel comprising: a first structural board; a second structural board; an insulating core sandwiched between the first structural board and the second structural board; and a groove arrangement for receiving a support, the groove arrangement extending along an edge of the structural insulated panel and having a first side wall on the first structural board and a second side wall on the insulating core such that the groove arrangement is spaced apart from the second structural board by the insulating core.

Optionally, the groove arrangement is provided in the insulating core. It may extend along an entire edge of the structural insulated panel, and preferably around the entire periphery of the structural insulated panel.

Optionally, the groove arrangement comprises two grooves that are parallel to one another. The two grooves may be separated from one another by a surface that is recessed from an opening of the groove arrangement.

Optionally, the first structural board and the second structural board are Magnesium Oxide Wallboards. They may each be between approximately 9mm and approximately 20mm thick.

Optionally, the insulating core comprises Expanded Polystyrene Foam, EPS, Extruded Polystyrene Foam, XPS, polyisocyanurate foam, polyurethane foam or Honeycomb Sandwich Composite, HSC. It may be between approximately 70mm and approximately 500mm thick.

Optionally, at least one conduit for accommodating an electrical wire is disposed within the insulating core. The conduit may be between 20mm and 50mm wide, e.g. in diameter.

According to a further aspect of the disclosure, there is provided a structural insulated panel assembly comprising the structural insulated panel described above, and the support.

Optionally, the support provides a frame around the structural insulated panel. The support may comprise: a sole plate member; a first side member; a second side member; and a top member.

Optionally, the sole plate member and/or the top member are attachable to the first side member and/or the second side member. The sole plate member and/or the top member may have a recess for receiving the first side member and/or the second side member.

Optionally, the support comprises means for securing the sole plate member, the first side member, the second side member and the top member to one another, preferably wherein the means comprises holes in the support for receiving support bolts.

Optionally, the structural insulated panel assembly further comprises a joist bracket for supporting a joist, wherein the joist bracket is coupleable to either the first side member or the second side member.

Optionally, the support extends into the groove arrangement.

Optionally, the structural insulated panel assembly further comprises a layer of insulation between the support and the insulating core, preferably wherein the layer of insulation is applied as a liquid foam to fill in any gaps between the support and the insulating core.

Optionally, the support has a C cross section. It may be less than approximately 5mm thick.

Optionally, the support is metal. It may be steel, preferably cold pressed steel.

Optionally, the structural insulated panel assembly comprises a covering, wherein the covering is applied to the second structural board. The covering may be a silicone render, a brick slip or a cladding.

According to a further aspect, there is provided a structural insulated panel construction comprising a first structural insulated panel assembly as described above located adjacent to a second structural insulated panel assembly as described above.

Optionally, the structural insulated panel construction has an intumescent layer disposed between the first structural insulated panel assembly and the second structural insulated panel assembly.

According to a further aspect, there is provided a structural insulated panel construction comprising: a first structural insulated panel assembly having a structural insulated panel and a support; a second structural insulated panel assembly having a structural insulated panel and a support; and an intumescent layer, wherein the intumescent layer is disposed between the first structural insulated panel assembly and the second structural insulated panel assembly.

Optionally, the intumescent layer is provided between the first structural board of the first insulated panel assembly and the first structural board of the second insulated panel assembly.

Optionally, the intumescent layer is a strip that is approximately 10mm wide and approximately 4mm thick.

Optionally, the intumescent layer material is either soft char or hard char.

Optionally, the structural insulated panel construction comprises a compliant layer for separating the sole plate member of the support from the a concrete base. The compliant layer may be a plastic lumber, preferably High Density Polyethylene, HDPE, Polyvinyl Chloride, PVC, Polypropylene, PP, Acrylonitrile Butadiene Styrene, ABS, Polystyrene, PS, or Polylactic Acid, PLA.

According to a further aspect of the disclosure, there is provided a structural insulated panel construction comprising: a structural insulated panel assembly having a structural insulated panel and a support; and a compliant layer for separating a sole plate member of the support from a concrete base, wherein the compliant layer is a plastic lumber, preferably High Density Polyethylene, HDPE, Polyvinyl Chloride, PVC, Polypropylene, PP, Acrylonitrile Butadiene Styrene, ABS, Polystyrene, PS, or Polylactic Acid, PLA.

Optionally, the sole plate of the structural insulated panel assembly is coupled to the compliant layer.

Optionally, the compliant layer is between approximately 20 mm and approximately 80 mm thick.

Preferred Embodiments of the disclosure are described below, by way of example only, with reference to the accompanying drawings.

Brief Description of the Drawings

Figure 1 is a schematic illustration of a modular building according to a first embodiment of the disclosure.

Figure 2a is a schematic perspective view of a Structural Insulated Panel (SIP) assembly of the modular building in an exploded state.

Figure 2b is a schematic perspective view of a support of the SIP assembly, where a first side member joins a sole plate member, in an exploded state.

Figure 3 is a schematic perspective view of the SIP assembly in an assembled state.

Figure 4 is a schematic cross sectional view of the SIP assembly, showing the support in a groove arrangement of the SIP.

Figure 5 is a schematic perspective view of a SIP construction comprising two SIP assemblies being joined to one another in line.

Figure 6 is a schematic cross-sectional view of the SIP construction, showing an in-line join between the two SIP assemblies.

Figure 7 is a schematic cross-sectional view of an alternative SIP construction, showing an angled join between the two SIP assemblies.

Figure 8 is a schematic cross-sectional view of the SIP construction incorporating a joist bracket and a compliant layer.

Figure 9 is a schematic cross-sectional view of a variant of the SIP construction further comprising a silicone render covering.

Figure 10 is a schematic cross-sectional view of a variant of the SIP construction further comprising a brick slip covering.

Figure 11 is a schematic cross-sectional view of a variant of the SIP construction further comprising a cladding covering.

Figure 12 is a schematic cross-sectional view of a variant of the SIP having a conduit.

Figure 13 is an illustration of a method of modular construction using the SIP assembly.

Detailed Description of the Embodiments

Referring to Figure 1, a modular building 100 comprises a plurality of structural insulated panels (SIPs) 102. The SIPs 102 provide walls 104 of the modular building 100. The SIPs 102 are arranged side by side, on top of one another or at angles to one another, and are joined together at their edges to provide the walls 104 in a desired configuration, e.g. shape and dimensions. In the illustrated embodiment, each wall 104 of the modular building 100 comprises four identical SIPs 102: two side by side on a first level and two side by side on a second level. The second level is on top of the first level and all the SIPs 102 of the wall 104 are "in line" with one another, e.g. provide a planar structure for the wall 104. The SIPs 102 of each wall 104 are joined at one edge to the SIPs 102 of another wall 104, so that the modular building 100 has an enclosed structure. Preferably, the enclosed structure is substantially airtight. It will be appreciated that the modular building 100 shown in Figure 1 is simplified for the purposes of clarity. Any real modular building 100 is likely to comprise many more SIPs 102 of different shapes and sizes, to accommodate irregular architectural designs and features such as windows and doors. However, the basic principles of construction illustrated by the modular building 100 shown in Figure 1 remain generally the same.

One of the SIPs 102 is shown in Figure 2a, alongside a support 200. The support 200 is preferably used as the primary load bearing component of the building 100 The SIPs 102 are hung on the support 200 and provide some additional load bearing capacity.

Figure 2b is a view of a part of the support 200, showing that a first side member 222 of the support 200 can be mounted in a recess in the sole plate member 220 of the support 200.

A SIP assembly 300 comprising the SIP 102 shown in Figure 2 mounted to the support 200 is shown in Figure 3.

The SIP 102 comprises an insulating core 201 sandwiched between two structural boards -a first structural board 202 and a second structural board 204. The SIP 102 is generally planar or flat. For example, the SIP 102 extends much further in two dimensions, e.g. its width and height, than in a third dimension, e.g. its depth. In this embodiment, the first structural board 202 and the second structural board 204 are substantially identical to one another, that is they are made of the same material and of the same dimensions. However, this is not essential, and in other embodiments the first structural board 202 and the second structural board 204 are made of different materials to one another and have different thicknesses. Usually, the first structural board 202 and the second structural board 204 are stronger than the insulating core 201, such that it is primarily the first structural board 202 and the second structural board 204 that provide the SIP 102 with structural integrity. Similarly, the insulating core 201 usually has lower thermal conductivity than the first structural board 202 and the second structural board 204, such that it is primarily the insulating core 201 that provides the SIP 102 with its thermal insulating properties.

The SIP 102 has a groove arrangement 210. The groove arrangement 210 is located at the edge, e.g. around the periphery, of the SIP 102. In the illustrated embodiment, the groove arrangement 210 extends all the way around the edge of the SIP 102, e.g. around the entire periphery. The groove arrangement 210 is located between the first structural board 202 and the second structural board 204. It is provided in the insulating core 201, more specifically where the insulating core 201 is exposed at the edges of the SIP 102, between the first structural board 202 and the second structural board 204. The groove arrangement 210 faces in directions generally parallel to the plane of the SIP 102, e.g. radially with respect to the normal of the plane of the SIP 102.

The groove arrangement 210 accommodates the support 200. In the illustrated embodiment, the support 200 comprises a sole plate member 220, a top member 221, first side member 222 and a second side member 223. The sole plate member 220, top member 221, first side member 222 and second side member 223 of the support 200 are attachable to one another to provide a frame. In the illustrated embodiment, the frame is generally rectangular and of similar dimensions to the periphery of the SIP 102. As such, the frame can be accommodated in the groove arrangement 210 and extends all the way around the periphery of the SIP 102 when the SIP 102 is mounted to the support 200. However, it is not essential that the support 200 extends all the way around the SIP 102, and in other embodiments the sole plate member 220, top member 221, first side member 222 and a second side member 223 are not joined to one another, but there are instead gaps between them; only sole plate member 220 and the top member 221 are provided; only the first side member 222 and second side member 223 are provided; or even just one of the sole plate member 220, top member 221, first side member 222 and second side member 223 are provided (meaning that the support 200 comprises just that/those components). However, in the preferred embodiment, it remains the case that overall the support 200 provides a frame, and that the support 200 is the primary load bearing structure of the building 100. It is just that some elements of the illustrated support 200 can be omitted whilst still achieving this overall aim.

The support 200 extends into the SIP 102. More specifically, when the SIP 102 is mounted to the support 200, the support 200 is located in the groove arrangement 210 and, in this position, is substantially between the first structural board 202 and the second structural board 204. The combination of the SIP 102 and the support 200, with the SIP 102 mounted to the support 200, is referred to as the SIP assembly 300, as illustrated in Figure 3. The coupling of the support 200 to the SIP 102 improves the overall strength of assembly 300 compared to the SIP 102 alone.

The support 200 shown in Figures 2a and 2b has a C cross-section, but it is also possible for the support 200 to have an H cross-section, a box cross-section or a circular cross-section. Bearing in mind the orientation in which the support 200 is used, the first side member 222 and the second side member 223 might be described as having a C cross section, and the sole plate member 220 and the top member 221 might be described as having a U cross section, but in actuality the profile of the cross sections of each of the members 220, 221, 222, 223 of the support 200 is generally the same.

The first side member 222 and the second side member 223 are each attachable to the sole plate member 220 and the top member 221. In this embodiment, the sole plate member 220 has a recess for receiving the first side member 222 and/or the second side member 223. Likewise, the top member 221 has a recess for receiving the first side member 222 and/or the second side member 223. In this embodiment, the recess is provided for by the inner profile of the C cross section of the sole plate member 220 and the top member 221. As can be seen more clearly in Figure 2b, the first side member 222 and the second side member 223 are narrower than the recesses of the sole plate member 220 and top member 221, such that flanges of the sole plate member 220 overlap the first side member 222 and the second side member 223. In order to facilitate this, ends 224 of the first side member 222 have a reduced width. Effectively, the ends 224 of the first side member 222 and second side member 223 form tabs or plugs, each of which fits into the recess or "socket" provided by the sole plate member 220 and top member 221. Figure 2b specifically illustrates the first side member 222 fitting into the sole plate member 220; however, the feature shown in Figure 2b is also applicable for the other three corner joints in the support 200. The support 200 in this embodiment is made from steel and is manufactured by cold pressing. The support 200 is preferably less than approximately 5mm thick to reduce the overall mass and to ease the cold press manufacturing.

As shown most clearly in Figure 4, the groove arrangement 210 comprises a first side wall 404 on the first structural board 202 and a second side wall 405 on the insulating core 403, such that the groove arrangement 210 is spaced apart from the second structural board 204 by the insulating core 201. The support 200 extends into the groove arrangement 210. In the part of the SIP assembly 300 illustrated in Figure 4, it is the first side member 222 of the support that is shown in cross section, at a location of screws 406, 408 for securing the SIP 102 to the support. However, since the profiles of the sole plate member 220, top member 221, first side member 222 and second side member 223 are generally uniform along their length (except at the ends 224 of the first and second side members 222, 223), the cross section shown in Figure 4 generally applies to the entire periphery of the SIP 102 (other than that the screws 406, 408 may not be present, and that the sole plate member 220, top member 221, first side member 222 and second side member 223 overlap one another where they are joined together). In general, as shown in Figure 3, the groove arrangement 210 extends along the entire edge of the SIP 102, and preferably around the entire periphery of the SIP 102.

It will be seen that the support 200 abuts the first side wall 404 of the groove arrangement 210. It is preferable that the support 200 is in contact with the first structural board 202, as shown in Figure 3, as this increases the strength of the SIP assembly 300. More specifically, the firm join between the support 200 and the first structural board provides a strong and rigid structure.

It is preferable for assembly reasons that the groove arrangement 210 comprises two grooves that are parallel to one another. This is because the embodiment shown in Figure 4 comprises a support 200 that has a C or U cross section. In this embodiment, the first side member 222 and the second side member 223 has a C cross section and the sole plate member 220 and the top member 221 has a U cross section. In the illustrated embodiment, the two grooves are separated from one another by a surface that is recessed from an opening of the groove arrangement 210. This allows the support to be fully accommodated by the SIP 102, within the groove arrangement 210. Indeed, when the SIP 102 is mounted to the support 200, the periphery of the SIP 102, provided by the edges of the first and second structural boards 202, 204 and the insulating core 201, can be roughly flush with the outermost surface of the frame provided by the support 200.

It is preferable that the insulating core 201 is made in one piece and groove arrangement 210 is cut into the insulating core 201. The groove arrangement 210 may be cut into the insulating core 201 using a routing tool. Figure 4 shows that the insulating core 201 may also be in four distinct sections. This results from the insulating core being manufactured by four sections of material being joined to one another.

The insulating core 201 is preferably made from Expanded Polystyrene Foam, EPS, Extruded Polystyrene Foam, XPS, polyisocyanurate foam, polyurethane foam or Honeycomb Sandwich Composite, HSC. All of these materials are known for having good heat transfer resistance. It is also preferable that the insulating core 201 is between approximately 70mm and approximately 500mm thick. In this embodiment, the insulating core 201 is PU foam wherein the thickness is approximately 151mm and the density is approximately 38kg/m3.

The first structural board 202 and the second structural board 204 are preferably Magnesium Oxide Wallboard. Magnesium Oxide Wallboard has good fire and water resistance and is eco-friendly to recycle while still having good structural properties. It is also preferable that the first structural board 202 and the second structural board 204 are between 9mm and 50mm thick.

In this embodiment, the first structural board 202 and the second structural board 204 are Multi Pro, Multi-Pro XS, or Multi-Rend MOO wallboards wherein the thickness is approximately 12mm, the height is approximately 2400mm and the width is approximately 1200mm.

The insulating core 201 is the largest provider of thermal resistance, although the first structural board 202 and the second structural board 204 also provide some additional thermal resistance. Theoretically, if all of the layers of the SIP 102 have the same cross-sectional area then the total thermal resistance in parallel is found by the following equation. 1 1

Rtota/ -1 1 1. k2. k3 R., R2 R3 L, L2 L3 Where the thermal resistance of each layer is Rn, the thermal conductivity of each layer is kn, the thickness of each layer is L, and the cross-sectional area is A. R"tat is known as the 'R' value for the SIP 102, given in the unit m2K/W.

The amount of heat transfer per unit area and temperature difference is found by the following equation.

Rtotat U is known as the U' value of the SIP 102, given in the unit W/m2K. The amount of heat transfer is found by the following equation.

A(T, -T2) Rtotat The table below shows the thermal resistance values of each layer and 'U' value for this embodiment.

Part Thickness (mm) Thermal Conductivity (W/mK) Thermal Resistance (m2K1W) Outside surface resistance 0.040 Silicone render 901 1.5 0.870 0.002 Basecoat for silicone render 5.0 0.470 0.011 Second structural board 204 12.0 0.307 0.039 Insulating core 201 150.0 0.025 6.000 First structural board 202 12.0 0.307 0.039 u -Q = U A(T, T2) Inside surface resistance 0.130 U-Value 0.16W/m2K The steel support 200 has a very high thermal conductivity and can be susceptible to a process called thermal bridging. Thermal bridging is where an area or component of an object which has a higher thermal conductivity than the surrounding materials and creates a path of least thermal resistance. This results in an overall reduction in the thermal resistance of the insulated panel which results in a greater heat loss from the building. Additionally, a process called ghosting occurs where the increased heat transfer causes condensation to form on the inner structural board. This damp area causes dust and dirt from inside the building to collect on the inner structural board causing the ghosting appearance. To reduce the thermal bridging in this embodiment, shown in Figure 4, the support 200 is located closer to the first structural board 202 than the second structural board 204 and the support is separated from the second structural board 204 by the insulating core 201. The outside of the building 100 is generally colder than the inside; therefore, the cold heat transfer has to travel through the insulating core 201 to reach the support 200 and the first structural board 202.

In this embodiment, the inner flange of the support 200 is coupled tight against the first structural board 202 using 40mm galvanised screws 406 spaced 200mm apart from one another both vertically and horizontally. It is also possible for there to be a thin layer of insulating core 201 sandwiched between the support 200 and the first structural board 202, as long as the strength of the SIP assembly 300 is not significantly reduced. The outer flange of the support 200 is coupled to, and offset from, the second structural board 204 by 100mm galvanised screws 408 also spaced 200mm apart both vertically and horizontally. Space within the groove arrangement 210, between the support 200 and the insulating core 201 and first structural board is filled with an insulating layer 407. In other words, with the support 200 mated to the groove arrangement 210, a gap remains between the two, and this gap is filled with the insulating layer 407. In this embodiment, the insulating layer 407 is applied as a liquid foam. The liquid foam 407 is preferably Expanded Polystyrene Foam, EPS, Extruded Polystyrene Foam, XPS, polyisocyanurate foam or polyurethane foam.

The SIP construction 500, shown in Figure 5, comprises a first SIP assembly 300 located adjacent to a second SIP assembly 300. In the particular embodiment shown in Figure 5, the soleplate member 220 of the first SIP assembly 300 is the same part as the soleplate member 220 of the second SIP assembly 300. Additionally, the top member 221 of the first SIP assembly 300 is the same part as the top member 221 of the second structural panel assembly 300. In other words, the first and second SIP assemblies 300 share a sole plate member 220 and a top member 221in the SIP construction 500 Figures 5 and 6 show an end to end joint which is used along the length of a wall in the building 100. The first SIP assembly 300 and the second SIP assembly 300 are coupled to one another using joining means, in this embodiment 50mm galvanised screws inserted through holes (not shown) in the first side member 222 and second side member 223.

An intumescent layer 601 is shown in Figure 6 between the first structural board 202of the first SIP assembly 300 and the first structural board 202of the second SIP assembly 300. The intumescent layer 601 comprised a substance that swells as a result of heat exposure. This improves the fire safety of the building 100, as, in the event of a fire or significantly increased heat, any gaps between the first SIP assembly 300 and the second SIP assembly 300 are filled by the expanding intumescent layer 601. The intumescent layer 601 is made from soft char or hard char. Soft char is commonly produced by a chemical reaction of three main components. ammonium polyphosphate, pentaerythritol and melamine. Hard chars are produced with sodium silicates and graphite. The intumescent layer 601 is provided in a strip and is preferably between 1mm and 20mm thick. In this embodiment, the intumescent layer 601 is approximately lOmm wide and approximately 4mm thick.

Figure 6 shows a gap between the second structural board 204 of the first SIP assembly 300 and the second structural board 204 of the second SIP assembly 300. The gap is required by the manufacturer to allow for expansion of the second structural boards 204. The gap is preferably 4mm and can be filled with a soft sealant or foam according to the manufacturer's instructions.

A first SIP assembly 300 can also be joined to a second SIP assembly 300 to create an alternative SIP construction 500, as shown in Figure 7. In particular, Figure 7 shows a corner joint which is used in the corner of the building 100. The first SIP assembly 300 and the second SIP assembly 300 are coupled using joining means, in this embodiment 50mm galvanised screws.

In order to build a structurally sound modular building 100 the foundation must be level and square. However, in reality, the concrete base 801 on which the building is constructed, is rarely level and square. A compliant layer 802 is shown in Figure 8, which separates the sole plate member 220 of the support 200 from the concrete base 801. The compliant layer 802 allows flexibility in the tolerances so that the sole plate member 220 is not deformed by the uneven concrete base 801. The compliant layer 802 is preferably made from a plastic lumber such as High Density Polyethylene, HDPE, Polyvinyl Chloride, PVC, Polypropylene, PP, Acrylonitrile Butadiene Styrene, ABS, Polystyrene, PS, or Polylactic Acid, PLA. The plastic lumber is commonly made from recycled plastic which is eco-friendly. The compliant layer 802 is preferably between approximately 20mm and approximately 80mm thick. In this embodiment, the compliant layer 802 is approximately 50mm thick and is approximately 150mm wide and as long as the sole plate member 220. The compliant layer 802 is narrower than the sole plate member 220 to allow rain to run off the sides of the sole plate member 220. In this embodiment, the compliant layer 802 is approximately 25mm narrower. Holes, e.g. of approximately 10mm diameter, are drilled in the concrete base 801 to accept rawlplugs and through the compliant layer 802 to accept screws. The sole plate member 220 is coupled to the compliant layer 802 using joining means, in this embodiment 90mm galvanised screws spaced 300mm apart both vertically and horizontally. The 90mm galvanised screws pass through the complaint layer 802 to the concrete base 801 and into the rawlplugs to couple the compliant layer 802 to the concrete base 801. It is also possible for an additional layer, a damp proof course 803, to separate the compliant layer 802 and the sole plate member 220. The damp proof course 803 reduces the moisture passing through the floor of the building 100.

The SIP assembly 300 is used to hang joists (not shown), which are used to create flooring systems over a plurality of floors. In this embodiment, the building 100 is a two storey structure comprising a ground floor, a first floor and a first floor ceiling. A flooring system is required for at least the first floor and first floor ceiling. Figure 8 shows the joist bracket 804 coupled to either the first side member 222 or the second side member 223. The joist bracket 804 is made from the same steel as the support 200 and is coupled to the SIP assembly 300 using joining means, in this embodiment 50mm galvanised screws.

The second structural board 204 is exposed to the outside environment which can result in damage and deterioration to the second structural board 204. To overcome this, the SIP assembly 300 further comprises a covering that is applied to the second structural board 204.

One embodiment is that the covering comprises a render 901, as shown in Figure 9. Firstly, a primer is applied to the second structural board 202 with a paint brush or similar device. The primer is a render primer, such as Unigrund, Jubosilcolor silicone, Siliconeprimer or Vezakrilprimer. Secondly, base coat is applied comprising a mesh layer, such as Jubizol Glass Reinforcement Mesh. Thirdly, a once the base coat has dried, a second layer of primer is applied. Fourthly, once the primer has dried, the render 901 is applied using a trowel or similar device, to a preferable thickness of between 2mm to 4mm. Fifthly, the trowel is used to flatten the render 901 to a preferable thickness of 1mm to 2mm. The render 901 is a silicone render 901 such as Jubizol Silicone Finish S 1.5 or 2.0. The render 901 is characterised by high hardness, good water vapour permeability, high water repellence and resistance to ultraviolet rays. In particular, the Jubizol Silicone Finish S 1.5 or 2.0 has a water vapour permeability coefficient (EN ISO 7783-2) of less than 60 (class V1 -high water vapour permeability) and a water absorption (EN 1062-3) of less than 0.02 kg/m2h0.5 (class V3 -low water absorption).

Another embodiment is that the covering comprises a brick slip 1001, as shown in Figure 10. Firstly, an adhesive is applied to the second structural board 204 with a paint brush or similar device. Second, once the adhesive has dried, the brick slip 1001 is applied by hand or by a jig device to ensure the pattern is evenly spaced.

A further embodiment is that the covering comprises a cladding 1101, as shown in Figure 11. Firstly, substantially horizontal battens are attached fixedly to the second structural board 204 at a preferably approximately 400mm vertical spacing. Secondly, the top ends of the cladding panels are attached fixedly to the battens starting from the lowest batten upwards. This allows the cladding panel to flap over cladding panel below, as shown in Figure 11.

The first structural board 202 may further comprise a covering. This covering may be a paint which aims to improve the interior finish of the building 100.

It will be appreciated that the presence of the intumescent layer 601 between the first structural board 202 of one SIP assembly 102 and the first structural board 202 of an adjacent SIP assembly 300 may cause there to be a gap between the second structural board 202 of the one SIP assembly 102 and the second structural board 202 of the adjacent SIP assembly 300. The gap is for the expansion of the first structural boards 202 and can be filled with sealant or insulating foam 407 in accordance with the manufacturer's instructions.

The SIP 102 in the embodiment shown in Figure 12 further comprises a conduit 12W, wherein the conduit 12W comprises electrical services. The conduit 12W is preferably fitted in the factory during manufacture of the SIP 102, however, it is also possible for the conduit 1201 to be fitted onsite or at another location. It is preferable that the conduit 1201 is disposed vertically into the insulating core 201 of the SIP 102 and spaced horizontally at 400mm apart. The conduit 12W preferably has a width, e.g. a diameter, between approximately 20mm and approximately 50mm. In this embodiment, the diameter is the conduit 1201 is 32mm. If the SIP 102 further comprises a window then the SIP 102 may not be able to comprise a conduit 1201. If the window is in the same horizontal position as the conduit 1201 then the window may interfere with the path of the conduit 1201, in which case the conduit 1201 would not be fitted at that horizontal location.

The construction method of the building 100 is shown in six stages in Figure 13. Figure 13a shows the concrete base 801 which is provided on the ground. Although care is taken in the construction of the concrete base 801, in reality, it is rarely level and square.

Figure 13b shows the compliant layer 802 provided to separate the sole plate member 220 from the concrete base 801. The compliant layer 802 is preferably made from a plastic lumber such as High Density Polyethylene, HDPE, Polyvinyl Chloride, PVC, Polypropylene, PP, Acrylonitrile Butadiene Styrene, ABS, Polystyrene, PS, or Polylacfic Acid, PLA. The plastic lumber is commonly made from recycled plastic which is eco-friendly. The compliant layer 802 is preferably between 20mm and 80mm thick. In this embodiment the compliant layer 802 is 50mm thick and is 150mm wide and as long as the sole plate member 220.

Figure 13c shows compliant layer 802 sandwiched between the sole plate member 220 and the concrete base 801. The compliant layer 802 allows flexibility in the tolerances so that the sole plate member 220 is not deformed by the uneven concrete base 801. The compliant layer 802 is approximately 25mm narrower than the sole plate member 220 to allow rain to run off the sides of the sole plate member 220. The holes are drilled in the concrete base 801 and through the compliant layer 802. The sole plate member 220 is then coupled to the compliant layer 802 using 90mm galvanised screws. The 90mm galvanised screws pass through the complaint layer 802 to the concrete base 509 and into the rawlplugs to couple the compliant layer 802 to the concrete base 801.

Figure 13d shows the first SIP 102 in position on the building 100 floorplan. The SIP 102 is positioned onto the sole plate member 220 in the desired position so that the flanges of the sole plate member 220 extend into the groove arrangement 210 of the SIP 102. The insulating layer 407 is then applied as the liquid foam to fill in any gaps between the sole plate member 220 and the insulating core 201.

The inner flange of the sole plate member 220 is coupled tight against the first structural board 402 of the SIP 102 using the 50mm galvanised screws 406 spaced approximately 200mm apart both vertically and horizontally. The outer flange of the sole plate member 220 is coupled to, and offset from, the second structural board 204 of the SIP 102 by the 100mm galvanised screws 408 also spaced approximately 200mm apart both vertically and horizontally.

The first side member 222 and the second side member 223 are positioned onto SIP 102 in the desired position so that the flanges of the first side member 222 and the second side member 223 extend into the groove arrangement 210 of the SIP 102. Additionally, the first side member 222 and the second side member 223 extend into the recess in the sole plate member 223. The insulating layer 407 between the first side member 222 and the second side member 223 and the insulating core 401 is then applied as the liquid foam to fill in any gaps between the first side member 222 and the second side member 223 and the insulating core 201.

The inner flange of the first side member 222 and the second side member 223 is coupled tight against the first structural board 202 of the SIP 102 using 40mm galvanised screws 406 spaced 200mm apart both vertically and horizontally. The outer flange of the first side member 222 and the second side member 223 is coupled to, and offset from, the second structural board 204 of the SIP 102 by the 100mm galvanised screws 408 also spaced approximately 200mm apart both vertically and horizontally.

The top member 221 is fitted after the other support 200 members. The top member 221 is positioned onto the SIP 102 in the desired position so that the flanges of the top member 221 extend into the groove arrangement 210 of the SIP 102. Additionally, the first side member 222 and the second side member 223 extend into the recess in the top member 221. The insulating layer 407 between the top member 221 and the insulating core 401 is then applied as the liquid foam to fill in any gaps between the top member 221 and the insulating core 201.

The inner flange of the top member 221 is coupled tight against the first structural board 202 of the SIP 102 using 40mm galvanised screws 406 spaced 200mm apart both vertically and horizontally. The outer flange of the top member 221 is coupled to, and offset from, the second structural board 204 of the SIP 102 by the 100mm galvanised screws 408 also spaced approximately 200mm apart both vertically and horizontally.

Figure 13e shows the second SIP 102 in position on the building 100 floorplan. This forms the SIP construction 500 comprising the first SIP assembly 300 located adjacent to the second SIP assembly 300, and the intumescent layer 601 disposed between the first structural board 402 of the first SIP assembly 300 and the first structural board 402 of the second SIP assembly 300.

A first SIP assembly 300 is joined to a second SIP assembly 300 to create a SIP construction 500. In particular, Figure 13e shows an end to end joint which is used along the length of a wall 104 in the building 100. The first SIP assembly 300 and the second SIP assembly 300 are coupled using 50mm galvanised screws.

Figure 13f shows the completed wall 104 assembly for the ground floor of the building 100. In this embodiment, the building 100 comprised six SIPs 102. The building 100 was specifically arranged as two SIPs 102 long by one SIP 102 wide. A first SIP assembly 300 is joined to a second SIP assembly 300 to create a SIP construction 500.

In this embodiment, the SIP 102 is fire-tested and achieved a resistance time in excess of 60 minutes from a United Kingdom Accreditation Service, UKAS, approved fire testing facility.

In this embodiment, the SIP 102, of 175mm thick and using a Badische Anilin und Soda Fabrik, BASF, Elastopor coating, can achieve an R value of 6.25 per 25mm and a typical U value of 0.17W/mK.

The illustrated embodiment, and the alternative embodiments that are described, only represent examples of how the ideas and concepts of the present disclosure can be implemented. Those skilled in the art will recognize that other embodiments for carrying out or practicing the ideas and concepts of the present disclosure are also possible. Modifications to illustrated embodiment, and to the alternative embodiments that are described, are possible without departing from the scope of the present disclosure as defined by the accompanying claims.

Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a nonexclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

Reference numerals appearing in the claims are by way of illustration only and shall have no limiting effect on the scope of the claims.

Each feature disclosed in the description, and, where appropriate, the claims and drawings may be provided independently or in any appropriate combination.

Claims

Claims 1. A structural insulated panel for a modular building, the structural insulated panel comprising: a first structural board; a second structural board, an insulating core sandwiched between the first structural board and the second structural board; and a groove arrangement for receiving a support, the groove arrangement extending along an edge of the structural insulated panel and having a first side wall on the first structural board and a second side wall on the insulating core such that the groove arrangement is spaced apart from the second structural board by the insulating core.
2. A structural insulated panel according to claim 1, wherein the groove arrangement is provided in the insulating core.
3. A structural insulated panel according to claim 1 or claim 2, wherein the groove arrangement extends along an entire edge of the structural insulated panel, and preferably around the entire periphery of the structural insulated panel.
4. A structural insulated panel according any one of the preceding claims, wherein the groove arrangement comprises two grooves that are parallel to one another.
5. A structural insulated panel according to claim 4, wherein the two grooves are separated from one another by a surface that is recessed from an opening of the groove arrangement.
6. A structural insulated panel according to any one of the preceding claims, wherein the first structural board and the second structural board are Magnesium Oxide Wallboards.
7. A structural insulated panel according to any one of the preceding claims, wherein the first structural board and second structural board are each between 9mm and 20mm thick.
8. A structural insulated panel according to any one of the preceding claims, wherein the insulating core comprises Expanded Polystyrene Foam, EPS, Extruded Polystyrene Foam, XPS, polyisocyanurate foam, polyurethane foam or Honeycomb Sandwich Composite, HSC.
9. A structural insulated panel according to any one of the preceding claims, wherein the insulating core is between 70mm and 500mm thick.
10. A structural insulated panel according to any one of the preceding claims, wherein at least one conduit for accommodating an electrical wire is disposed within the insulating core.
11. A structural insulated panel according to any one of the preceding claims, wherein the conduit is between 20mm and 50mm in diameter.
12. A structural insulated panel assembly comprising the structural insulated panel according to any one of the preceding claims and the support.
13. A structural insulated panel assembly according to claim 12, wherein the support provides a frame around the structural insulated panel, preferably wherein the support comprises: a sole plate member; a first side member; a second side member; and a top member.
14. A structural insulated panel assembly according to claim 13, wherein the sole plate member is attachable to the first side member and/or the second side member, preferably wherein the sole plate member has a recess for receiving the first side member and/or the second side member.
15. A structural insulated panel assembly according to claim 13 or claim 14, wherein the top member is attachable to the first side member and/or the second side member, preferably wherein the top member has a recess for receiving the first side member and/or the second side member.
16. A structural insulated panel assembly according to claim 14 or claim 15, wherein the support comprises means for securing the sole plate member, the first side member, the second side member and the top member to one another, preferably wherein the means comprises holes in the support for receiving support bolts.
17. A structural insulated panel assembly according to any one of claims 13 to 16, further comprising a joist bracket for supporting a joist, wherein the joist bracket is coupled to either the first side member or the second side member.
18. A structural insulated panel assembly according to any one of claims 12 to 17, wherein the support extends into the groove arrangement.
19. A structural insulated panel assembly according to any one of claims 12 to 18, further comprising a layer of insulation between the support and the insulating core, preferably wherein the layer of insulation is applied as a liquid foam to fill in any gaps between the support and the insulating core.
20. A structural insulated panel assembly according to any one of claims 12 to 19, wherein the support has a C cross section
21. A structural insulated panel assembly according to any one of claims 12 to 20, wherein the support is less than 5mm thick.
22. A structural insulated panel assembly according to any one of claims 12 to 21, wherein the support is metal, preferably wherein the support is steel, and more preferably wherein support is cold pressed steel.
23. A structural insulated panel assembly according to any one of claims 12 to 22, comprising a covering, wherein the covering is applied to the second structural board
24. A structural insulated panel assembly according to claim 23, wherein the covering is a silicone render, a brick slip or a cladding.
25. A structural insulated panel construction comprising a first structural insulated panel assembly according to any one of claims 12 to 24 located adjacent to a second structural insulated panel assembly according to any one of claims 12 to 24.
26. A structural insulated panel construction according to claim 25, having an intumescent layer disposed between the first structural insulated panel assembly and the second structural insulated panel assembly.
27. A structural insulated panel construction comprising a first structural insulated panel assembly having a structural insulated panel and a support; a second structural insulated panel assembly having a structural insulated panel and a support; and an intumescent layer, wherein the intumescent layer is disposed between the first structural insulated panel assembly and the second structural insulated panel assembly.
28. A structural insulated panel construction according claim 26 or claim 27, wherein the intumescent layer is disposed between the first structural board of the first structural insulated panel assembly and the first structural board of the second structural insulated panel assembly.
29. A structural insulated panel construction according to any one of claims 26 to 28, wherein the intumescent layer material is either soft char or hard char.
30. A structural insulated panel construction of any one of the preceding claims, comprising a compliant layer for separating a/the sole plate member of the support from the a concrete base.
31. A structural insulated panel construction of claim 30, wherein the compliant layer is a plastic lumber, preferably High Density Polyethylene, HDPE, Polyvinyl Chloride, PVC, Polypropylene, PP, Acrylonitrile Butadiene Styrene, ABS, Polystyrene, PS, or Polylactic Acid, PLA.
32. A structural insulated panel construction comprising: a structural insulated panel assembly having a structural insulated panel and a support; and a compliant layer for separating a sole plate member of the support from a concrete base, wherein the compliant layer is a plastic lumber, preferably High Density Polyethylene, HDPE, Polyvinyl Chloride, PVC, Polypropylene, PP, Acrylonitrile Butadiene Styrene, ABS, Polystyrene, PS, or Polylactic Acid, PLA.
33. A structural insulated panel construction according to any one of claims 30 to 32, wherein the sole plate of the structural insulated panel assembly is coupled to the compliant layer.
34. A structural insulated panel construction according to any one of claims 30 to 33, wherein the compliant layer is between 20 mm and 80 mm thick.