NZ513817A - Method of manufacturing a modular structure with rows of four columns spaced apart predetermined distances - Google Patents

Abstract

A method of erecting a modular building structure includes: erecting a row of first, second, third and fourth columns into the ground in a straight line, with the spacing between first/second and third fourth being a first standard distance, and the spacing between the second/third columns being a second standard distance. A further row of four columns are then placed alongside the first row in parallel formation with the line between each of the numbered columns of the first and second row being perpendicular to the line of the first row., with the second row being spaced a third standard distance from the first row. The second standard distance is twice the first standard distance, and the third standard distance is either the first or second distance.

Description

PATENTS FORM NO. 5 Fee No. 4: $250.00 PATENTS ACT 1953 COMPLETE SPECIFICATION After Provisional No: 513817 Dated: 28 February 2003 METHOD OF MANUFACTURING A MODULAR STRUCTURE WE CRYSTAL HOMES LIMITED, a New Zealand company of 11 Cargill Street, Papakura, New Zealand, hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: Intellectual Property Office of N.Z. - 7 OCT 2004 RECEIVED James & Wells Ref: 26614 METHOD OF MANUFACTURING A MODULAR STRUCTURE TECHNICAL FIELD This invention relates to a method of manufacturing a modular structure. Preferably the present invention may allow a modular structure to be built using a series of 5 support poles on which roofing elements are attached and cantilevered. Such a modular design of support poles and roofing elements may be extended, and scaled up or down depending on the size of the structure required.

BACKGROUND ART In some areas there is significant demand for housing and other types of structures. 10 In some applications, it is preferable for buildings to be constructed as quickly and as inexpensively as possible.

In the case of domestic housing, for example, the design or floor plan of the house will dictate how much construction work will be involved and the complexity of the job to be completed. Using existing building techniques the first step of 15 construction completed is the excavation of foundations and the pouring of a concrete slab or base upon which the house is to be built. Once the floor has been poured, construction workers must wait until the concrete has set and is sufficiently hard or strong enough to be built upon.

This step introduces a significant delay in the building process. Furthermore, as the 20 concrete pad or floor is exposed to the sky it is subject to rainfall, which in turn increases the concrete's drying and curing time.

A supporting framework is next erected on the concrete pad once it has cured. Only after the sidewalls or framing has been erected can a roof be put in place over the Intellectual Property Office of N.Z - 7 OCT 2004 r e n e i v f= n & Wells ref: 26614 building site, thereby allowing the structure to be worked on in all weathers, with a degree of protection being provided for the materials under the roof.

As discussed above, the need to wait for the floor of the structure to harden sufficiently before proceeding with other building activity can significantly increase 5 construction times. Furthermore, the bases of these types of structures are secured directly to the ground, leaving them vulnerable to the adverse effects of surface flooding.

In most instances a unique or customised design is also implemented to build the structure required. This in turn forces the construction workers to complete a series 10 of unique jobs, as opposed to, for example, a much faster assembly line production method. These types of structure also rely on large amounts of materials being incorporated into the sidewall framing of the house to support the weight of the roof applied. As this framing is used to form load bearing walls, high quality materials need to be used, some times in large quantities.

An improved method of manufacturing a structure and the resulting structure itself that addressed any or all of the above problems would be of advantage. A method of manufacturing a modular design structure quickly and inexpensively, which exhibited a high degree of strength and structural integrity, would also be of advantage.

All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of 25 prior art publications are referred to herein, this reference does not constitute an Intellectual Property Office of N.Z. - 7 OCT 2004 RECEIVED- & Veils ref: 26614 admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

It is acknowledged that the term 'comprise' may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term 'comprise' shall have an inclusive meaning - i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements. This rationale will also be used when the term 'comprised' or 'comprising' is used in relation to one or more steps in a method or process.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF INVENTION According to one aspect of the present invention there is provided a method of manufacturing or constructing a structure, characterised by the steps of: (a) fixing a first support column into the ground on which the structure is to be constructed, and (b) fixing a second support column into the ground displaced a standard distance from the first support column, and (c) fixing a third support column into the ground substantially in line with the first and second support columns, said third support column being displaced further from a different distance from the second support column, and Intellectual Property Office of N.Z. - 7 OCT 2m 4 James & Wells ref: 26614 (d) fixing a fourth support column into the ground substantially in line the first, second and third support columns, said fourth support column being displaced the standard distance from the third support column.

According to a further aspect of the present invention there is provided a method of 5 manufacturing a structure substantially as described above further characterised by the steps of (e) fixing a second set of four support columns into the ground, wherein the first support column of the second set is displaced the standard distance from the original first support column in a direction substantially perpendicular to the orientation of the line of first support columns formed, and (f) fixing the second, third and fourth support columns of the second set of support columns in the ground substantially as described above and wherein said second set is substantially parallel to said first line of said support columns.

According to further aspect of the present invention there is provided a method of manufacturing a structure substantially as described above wherein said different distance is substantially twice the standard distance.

According to yet another aspect of the present invention there is provided a method of manufacturing a structure substantially as described further characterised by fixing subsequent sets of four support columns into the ground until the plurality of sets of support columns define the area of the structure to be manufactured.

According to yet another aspect of the present invention there is provided a method of manufacturing a structure substantially as described above further characterised by the additional steps of Intellectual Property Office of N.Z. - 7 OCT 20Q1* ;received? ;James & Wells ref: 26614 ;0) ;attaching a first rafter to the first and second support columns of a set, with one end of the rafter attached to the first support column and the middle of the rafter attached to the second column to cantilever the first rafter, and ;(ii) attaching a second rafter to the third and fourth support columns of the set, 5 with one end of the rafter being attached to the fourth support column and the middle of the rafter being attached to the third support column, and ;(iii) fixing together the free cantilevered ends of the rafters. ;According to yet another aspect of the present invention there is provided a method of manufacturing a structure substantially as described above further characterised 10 by the additional step of ;(iv) applying said first and second rafter pairs substantially as described above to all other sets of support columns fixed into the ground of the building site. ;According to yet another aspect of the present invention there is provided a method of manufacturing a structure substantially as described above further characterised 15 by the additional step of ;(v) applying a roof covering or cladding material over the plurality of first and second rafter pairs to cover the area of ground enclosed by the support columns. ;According to further aspect of the present invention there is provided a method of 20 manufacturing a structure substantially as described above wherein one or more rafters may be combined to form a single rafter. ;According to further aspect of the present invention there is provided a method of manufacturing a structure substantially as described above wherein said support columns are wood, composite materials, metal or metal allova. -—-—— ;mteSlectual Property ;Office of N.Z. ;- 7 OCT 2004 ;REctivrtr ;According to further aspect of the present invention there is provided a method of manufacturing a structure substantially as described above wherein fixing a support column into the ground is by driving the support column into the ground with force. ;According to further aspect of the present invention there is provided a method of 5 manufacturing a structure substantially as described above wherein fixing a support column into the ground is by securing the support column into the ground using concrete. ;According to further aspect of the present invention there is provided a method of manufacturing a structure substantially as described above wherein a rafter ;10 attachment means is a combination of one or more of the following: ;(a) checking the rafter into the top of the support pole, ;(b) nailing, gluing or bolting into place ;According to further aspect of the present invention there is provided a structure manufactured by a method substantially as herein before described. ;15 The present invention is adapted to provide a method of constructing or manufacturing structures. Preferably the present invention may be used to provide for example low cost, strong housing which can be erected quickly. Reference throughout this specification will also be made to the present invention being used to construct housing, but those skilled in the art should appreciate that other types of 20 structures may also be formed in accordance with the present invention if required. For example, the present invention may be used in any instance where a low cost structure needs to be built quickly. ;As a first stage of the construction method a plurality of support columns are fixed into the surface of the ground of the site on which the building is to be constructed. 25 The placement and orientation of the support columns will then define the perimeter or footprint of the resulting structure. ;Intellectual Property Office of N.Z. ;- 7 OCT 200<| ;REC ;ames & Wells ref: 26614 ;A standard distance as used in accordance with the present invention as understood by a skilled reader as referring to a distance to be used as a unit of measurement, chosen for ease of assembly and for cost effectiveness. ;It will also be understood by those skilled in the art that in order to construct an 5 inexpensive structure the standard distance may generally conform to the standard dimensions to sheets of cladding materials as produced by building material manufacturers from time to time. ;In preferred embodiments the first distance equates to a first standard distance. ;In preferred embodiments the second distance equates to substantially twice the first 10 distance. ;In preferred embodiments the third distance equates to either: the first standard distance or a second standard distance. ;A support column as used in accordance with the present invention may be formed from any substantially straight length of material with sufficient load bearing 15 qualities to ;Intellectual Property Office of N.Z. ;- 7 OCT 2004 ;RECEIVED ;7a James k Weils rel: 20614 ;allow it to be used within the structure to be formed. Preferably the support columns used are orientated substantially vertically. ;In a further preferred embodiment a number of wooden poles or large posts may be used as the support columns required. Wooden poles form a relatively inexpensive building material which exhibits strong load bearing characteristics and which can also be treated with a range of chemicals to preserve the pole from degradation through exposure to the elements. ;Reference throughout this specification will also be made to the support columns employed in conjunction with the present invention being wooden support poles. However, those skilled in the art should appreciate that other forms of support columns such as, for example, square cross section wooden columns or steel I columns may also be used in conjunction with the present invention if required. ;The poles employed are preferably used in a load bearing capacity to support the weight of the roof of the structure to be formed. The length of the poles employed will therefore be determined by the eventual height of the structure required. ;In a preferred embodiment the support poles may be fixed to the ground by being located within a hole or trench dug to a set depth with the end of the pole being concreted in place within the trench. The depth of the trench or hole used may vary depending on the size of the structure to be formed and the underlying soil structure or soil conditions within the ground of the building site. ;In a preferred embodiment once the first support column is located in place on the building site a second support column may be fixed into the ground at a standard distance or displacement from the first support column. The standard distance used ;Intellectual Property Office of (M.Z. ;- 7 OCT 2004 ;8 ;between the first and second support columns will in turn determine the overall width of the structure to be formed. ;Once the first and second support columns are in place the third and fourth support columns of a set of four columns can then be located within the ground. The third 5 support column may be orientated in line with the first and second support columns and may be displaced twice the distance between the first and second support columns from the second support column. This will position the third support column twice the standard distance from the second support column and three times the standard distance from the first support column. The fourth support column is 10 preferably also located in line with the first, second and third support columns and is displaced the standard distance from the third support column. ;This methodology executed in accordance with the present invention will place a set of four support poles substantially in line with one another to define a single line or orientation for the set. The displacement or spacing between the poles may be 15 determined or set by the length of the standard distance selected, which will place a pair of poles of the set on opposite sides of an open central area within the line defined. ;Preferably a structure formed in accordance with the present invention may employ a plurality of sets of support columns substantially as described above. Preferably 20 sets of four support columns are fixed into the ground of the building site to define the area or footprint of the structure to be formed. The number of support column sets used will be determined by the length of the building to be formed, whereas the width of the building will be defined by the standard distance applied between the spaced apart support columns of a set. ;Intellectual Property Office of N.Z. ;- 7 OCT 2004 ;REC D ;20 ;In a further preferred embodiment once the first set of support columns are fixed in place the first of a second set of support columns be fixed into the ground with an orientation which is substantially perpendicular to the line of orientation on which the first set of support columns run. The first support column of the second set may also be displaced the standard distance from the first support column of the first set, thereby using the second set of support columns to extend the length of the structure to be formed. As discussed above a plurality of sets of support columns may be employed to determine or fix the length of the structure to be formed. ;This configuration of the invention gives the resulting structure and method of manufacture employed a substantially modular format. Simply by determining the size and length of the structure to be formed an appropriate standard distance for the spacings between the support poles may be calculated, as can the number of sets of support poles to be used to achieve the required length of the structure. More or less sets of support columns may be used, or greater or smaller standard distances may be employed to adjust or modify the dimensions of the structure yet still retain the same modular configuration and construction methodology. ;This configuration of the invention substantially simplifies the building construction method. As the dimensions between support poles is a standard value throughout the structure, pre-formed building components with set dimensions may be employed to accelerate the building process. These building components may be manufactured in large quantities due to the fact that large numbers of modular structures can be built which are able to receive and use these components. Furthermore, the standardisation of the spacings between support poles also allows the follow on construction work to be standardised and broken down into a number of small, simple tasks. This allows unskilled labour to be quickly trained to assist in the building process to complete a small number of repetitive tasks on a structure. ;Intellectual Property Office of N.Z. ;10 ;- 7 OCT fflft ;Wells ref: 26614 ;10 ;15 ;20 ;In a preferred embodiment the present invention may also include or employ the use of a spacing clamp. A spacing clamp may be formed from a pair of pole connectors located at opposite ends of the clamp with an adjustable length column making up the main body of the clamp. The length of the clamp body may be adjusted to ensure that connectors attached to two adjacent poles set the distance between these poles to the standard distance to be used in the construction of a building. ;In use, a builder may determine the standard distance they wish to use between the support poles involved and may adjust the length of the clamp to fit to this distance. The first of the support poles may then be fixed in place in the ground and one end of the clamp attached to same. A hole or trench may next be dug underneath the free connector of the clamp and a second support pole to be attached to the second connector of the claim and placed within the hole dug. In this way the clamp can be used to accurately control the distance between the support poles employed. ;In a further preferred embodiment two or more spacing claims may also be used when support poles are located in the ground. Multiple spacing clamps may be used to secure the lower, middle and upper areas of the support poles with respect to one another with the number of support camps employed being determined by the length or height of the poles. For example, in a further preferred embodiment only a pair of support clamps may be employed when a support pole is located in place. ;The use of a spacing clamp or clamps substantially improves the speed at which poles can be located in place. As the orientation and spacing of all the poles with respect to one another is done almost automatically by the clamps employed only the placement of the first pole needs to be completed carefully and slowly. Once the first support pole employed is in place, the remaining poles to be used can be quickly located. ;Intellectual Property Office of N.Z. ;- 7 OCT 2004 ;D C (O ;BBSS gSCDt 8 ;m sl, ;>614 ;11 ;Preferably once the support poles are fixed at the required locations within the ground, rafters may be connected to these posts. In a further preferred embodiment a pair of first and second rafters may be connected to the four support poles making up a single set of support poles. The first of this pair of rafters may be connected to the first and second support columns of the set whereas the second of the pair of rafters may be connected to the third and fourth support columns of the set. ;Those skilled in the art should appreciate that any number of different methods may be employed to connect rafters to support poles. For example, in a preferred embodiment a central groove or channel may be formed in the top of each support pole with a width complementary to the width of the rafter to be connected. The rafters may be checked into the top of the support poles and nailed, glued or bolted in place. Those skilled in the art should appreciate that numerous different types of connection schemes may be employed in conjunction with the present invention and therefore reference to the above only throughout this specification should in no way be seen as limiting. ;In a further preferred embodiment the first of the rafters connected may have one end attached to the first support column and the middle of the rafter connected to the second support column. In addition, the second of the pair of rafters connected may have one of its ends attached to the fourth support column, and the middle of the rafter attached to the third support column. This configuration of support poles and rafters will cantilever the rafters with respect to the support poles and place or orientate the free ends of the rafters in towards the centre of the line of poles. ;However, in an alternative embodiment the rafters employed may not be positioned symmetrically to meet the centre of the structure formed substantially as described above. For example, in one alternative embodiment the first of the rafters may have one end attached to the first support column but the rafter may be of an extended ;12 ;James & Wells ref: 26614 ;length so that the second support column is not attached to the middle of the rafter. The free end of the first rafter may extend out past the middle of the line of support poles. In such an embodiment a second rafter may again have one end attached to the fourth support column while the second rafter is of a shorter length than the first rafter to therefore allow it to abut the extended free end of the first rafter. This configuration of the invention will give the roof a substantially offset configuration, as opposed to the central 'in-line' configuration discussed above. ;In a further preferred embodiment the size and length of the rafters may be selected so that their free cantilevered ends abut one another. A further connector or attachment system may also be employed to lock and fix in place the free ends of the rafters together. ;This configuration of the invention allows a strong roof to be formed within the building constructed. By cantilevering each of the pair of rafters employed the free or unsupported ends of these rafters may abut one another, and therefore support one another without the use of any other additional supporting elements. ;Preferably a pair of rafters may be provided for each set of support columns sunk into the ground of the building site. The combination of the rafter pairs and pole sets will create a structural framework for the building and form all the load bearing or strengthening elements it requires. Once the rafters are put in place a surface or roofing cladding may be installed on the top of the structure's framework to give a covering for the area of ground on which the structure has to be sited. Once the roof cladding or covering is in place the inner areas of the building will be protected from rainfall, and therefore construction of any remaining components of the structure need not be delayed through adverse weather conditions. ;Intellectual Property ;Office of N.Z. ;-tticrm ;13 ;Once the basic structural framework of the building has been constructed from the poles and rafters discussed above the exterior roofing surface and exterior sidewalls of the structure may then be formed, as can the interior floor plan of the building. As the load bearing elements of the building are formed from the rafters and support posts discussed above, those skilled in the art should appreciate that any number of different types of roofing materials, exterior wall claddings or interior finishing materials may be used in numerous different embodiments of the present invention. A degree of customisation of the look and internal layout of the building can be applied at this stage depending on the requirements of the eventual user of the structure. ;For example, in one instance pre-formed walls panels may be employed to form the interior or exterior walls of the structure. These wall panels may have fixed sizes or dimensions allowing them to be easily installed within the standard distance displacements between the support poles of the structure. ;Furthermore, the present invention need not necessarily be limited to constructing single storey or single level structures. For example in some embodiments the length or height of the support poles used may be increased to allow the volume they define to be broken up into several different levels of the same structure. In some instances the ground floor of a structure may be used as a garaging and storage area and the upper levels of the structure may be used as a living area. ;In some embodiments the roof of the structure formed may not be created from fixed covering elements or cladding. For example in one embodiment portions of the roof may be pivoted or moved up or down to form either the outer edges of the structure's roof or alternatively a covering or protective component for the side walls of the structure. In such instances the space between the first and second, and third and fourth support columns may be employed as an exterior veranda or deck ;14 ;James & Wells ref: 26614 ;and the roof covering over these areas may be pivoted downwards to create a protective cover or shield for the outer side walls. A number of separate elements of the roof may pivot down between the first and second support poles and the first rafter and the third and fourth support poles and the second rafter to protect the side 5 walls of a structure. ;This configuration of the invention may be employed in areas where strong winds or storms are expected. The outer edges of the roof may be pivoted down to protect side walls and windows in the event of a storm, cyclone or any other high energy weather system. ;10 The present invention may allow strong buildings to be constructed with inexpensive materials. By employing an array of support poles with cantilevered rafters a strong structure is provided which minimises the amount of materials required to form the load bearing elements of the structure. ;Due to the simple design employed such buildings may also be constructed quickly 15 and potentially with unskilled labour. ;Furthermore, by using support poles the living area of a house (for example) may be elevated above the ground and therefore provide protection from surface flooding. In addition, without the need to site the building on a concrete pad or floor this can allow access to the sub-floor of the structure to run plumbing, gas fittings or wiring 20 cablest. ;BRIEF DESCRIPTION OF DRAWINGS ;Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which: ;15 ;Figures la and lb show front views of a partially complete and fully complete structure formed in accordance with a preferred embodiment of the present invention; and ;Figure 2 shows a top view of the structure shown with respect to ;5 Figure la, and ;Figure 3 shows a number of different structure floor plans which may be implemented using the present invention, and ;Figure 4 shows a front view of yet another structure formed in accordance with a preferred embodiment of the present 10 invention, and ;Figure 5a to 5c show a number of views of a spacing clamp preferably used in the construction method of the present invention. ;Figures 6a to 6d show a number of steps executed in the construction of the fully complete structure, and ;15 Figures 7a,7b show side cross section views of a structure formed in accordance with a further embodiment of the present invention. ;BEST MODES FOR CARRYING OUT THE INVENTION ;Figures la and lb show front views of a partially complete and fully complete 20 structure formed in accordance with a preferred embodiment of the present invention. Figure 2 shows a top cross section view of the structure shown with respect to Figure la. ;Intellectual Property Office of N.Z. ;- 7 COT 200*i received 16 James & Wells ref: 26614 The structure includes a plurality of support columns, shown in this embodiment as support posts 1. As can be seen from Figure 2 numerous sets support posts 1 are orientated along a single line to form a set 2 of four support posts. Figures la and lb show a single set of support posts at the front of the structure.

When the structure shown is initially constructed, the first support post la had one of its ends placed within a pre-dug hole or trench within the ground. The first support pole is then concreted into place and the second support pole is positioned at the location shown, at a standard distance 3 from the first support pole la.

Once the second support pole lb had been concreted in place the third support pole 10 lc is placed in a hole or trench in line with the first and second support poles at a distance twice the standard distance from the first support pole lb and three times the standard distance from the first support pole la.

Once the third support pole had been concreted in place the fourth support pole Id is placed in a foundation hole or trench in line with the other support poles at a 15 location displaced by the standard distance 3 from the third support pole.

The standard distance selected between the first and second and third and fourth support poles, and twice the standard distance between the second and third support poles defines the total width of the structure formed.

The length of the structure is then defined by the number of individual sets 2 of four 20 support poles employed within the structure. As can be seen from Figure 2 the length of the structure is determined in this instance by the six sets of support poles employed.

Once the first set of support poles is in place the first support pole of the second set is placed the standard distance 3 away from the first support pole of the first set at an angle substantially perpendicular to the line of < 17 - 7 OCT 20M ^ A et 6614 (shown by reference arrow 4). Subsequently, the second, third and fourth support poles of the second set can then be placed in position using substantially the same method as employed to install the first set of support poles.

Once the plurality of support poles 1 are fixed in place a set of rafters 5 are connected to the top of the support poles. A pair of rafters 5a and 5b, are applied for each set 2 of support poles.

The first of the pair of rafters 5a has one end connected to the top of the first support pole and the centre of the rafter connected to the top of the second support pole lb. Conversely, the second rafter 5b has one end attached to the top of the fourth support pole Id with the middle of the rafter attached to the top of the third support pole lc. In the instance shown support poles may be connected to rafters through a central groove formed into the top of each pole with a complementary shaped profile to the rafter. The rafter may be slotted into such a groove and also bolted in place for security.

This arrangement of rafters cantilevers each of the rafter pairs and places their free ends in contact with each other at point 6. The abutting rafter ends apply a balancing force to each other eliminating the need for an additional support component to be placed beneath the cantilevered ends of the rafters.

As can be seen from Figure lb once the load bearing rafters and support poles are in place an exterior cladding can be applied between the support poles to form the external walls of the structure. Decorative finishing touches such as an external deck may also be formed underneath a roofing cladding applied to the rafters 5.

As can be appreciated by those skilled in the art the length and width of the structure may be scaled up or down simply by providing more or less sets of support poles and by increasing or decreasing the standard distance 3 used to determine distance between support poles. This gives a resulting structure a consistent and modular 18 James & Wells ref: 26614 design allowing it to be assembled quickly by workers familiar with the construction steps required to complete the building. Furthermore as the load bearing or strength forming elements of the structure are provided by the support poles and rafters so any other materials incorporated into the building need not necessarily perform a 5 load bearing role.

Figure 3 illustrates how the modular design discussed above may be used to form 14 different structures with varying internal floor plans and lengths.

Figure 4 also illustrates the adaptability of the building system discussed which allows multi tier or multi storey buildings to be constructed. For example, in the 10 embodiment shown with respect to Figure 4 storage and car garaging areas may be provided in the lower regions, living areas may be provided in the upper central area and a viewing and recreation deck may be provided at the upper outer sides of the structure.

Figures 5a to 5c show portions of a spacing clamp 7 which may be used in preferred 15 embodiments of the present invention. The spacing clamp 7 includes an extendible length central body 8 which may telescope in or out to adjust the overall length of the clamp. At either end are provided pole connectors 9 which in use are adapted to encircle and clamp in place a support pole.

The spacing clamp may be used to ensure that support poles accurately position with respect to one another at the standard distance 3 discussed above. One of the pole clamps 9 may initially be secured around a pole already in the ground and then a second pole may be placed within the second 'free' pole connector. As the length of the body 8 is fixed to correspond to the standard distance selected the second pole will then be correctly displaced from the first support pole.

Figures 6a to 6d show four consecutive steps in the construction of a structure. As shown in step 6a the support columns and rafters employed may initially be located 19 James & Wells ref: 26614 in place. In step 6b portions of the wall exterior cladding and roof framework are in place. In step 6c further wall cladding and roof coverings are shown installed, whereas step 6d shows the fully complete structure.

Figures 7 a and 7b show sides views of a structure formed in accordance with yet 5 another embodiment of the present invention. In both instances the structure employs a pivoting roof section in both a single level (Figure 7a) and double level (Figure 7b) structure.

As shown with respect to these diagrams the outer edges of the roof is formed into a number of portions that can pivot between the outer support poles of the structure. 10 A hinging connector 10 connects the pivoting roof elements directly to the structure and allows them to pivot up between the two positions shown to cover a deck area, or form a protective cover for the side walls of the structure.

Retention systems 11 and 12 are also employed in this embodiment with the upper retention system 11 formed from a locking pin located through the first support 15 poles and portions of the pivoting section of the roof. Alternatively this component may be formed from a spring loaded pin system which can be pushed out of the way when the roof element is to be dropped but will then spring back into its normal extended position.

A lower retention system 12 may also be employed to securely fix in place the roof 20 elements when lowered to cover the side walls of the structure. Again a suitable locking pin arrangement may be employed to form such a lower retention system.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.

Intellectual Property Office of N.Z. - 7 OCT 2004 FfE C i \i tz i V t James & Wells ref: 26614

Claims (12)

WHAT WE CLAIM IS:

1. A method of manufacturing a modular building structure, characterised by the steps of: (a) fixing a first support column substantially vertically into the ground; and (b) fixing a second support column substantially vertically into the ground and displaced a first standard distance from the first support column; and (c) fixing a third support column substantially vertically into the ground so that is forms a substantially straight line with the first and second support columns, said third support column being displaced a second standard distance from the second support column; and (d) fixing a fourth support column substantially vertically into the ground substantially in line with the first, second and third support columns, said fourth support column being displaced the first standard distance from the third support column to create a first set of support columns; (e) fixing a second set of four support columns substantially vertically into the ground, wherein the support columns of the second set of columns are each displaced either: the first standard distance, or a third standard distance, from the first set of support columns in a direction substantially perpendicular to the orientation of the line of first set of support columns formed; and (f) fixing individual support columns of the second set of support columns in the ground so as to be substantially aligned with the first set of support columns and aligned with each other so as to form a substantially straight line; and Intellectual Property Office ef N.Z. 23 AUG 2005 RECEIVED 21 James & Wells ref: 26614 4 (g) optionally adding a further set or sets of support columns substantially pursuant to steps e) and f) with respect to the last affixed set of support columns; wherein the second standard distance equates to substantially twice the first standard distance; and the third standard distance equates to either the first standard distance or the second standard distance.

2. A method of manufacturing a structure as claimed in any one of the preceding claims further characterised by fixing subsequent sets of four support columns into the ground to define the area of the structure to be manufactured.

3. A method of manufacturing a structure as claimed in any one of the preceding claims further characterised by the additional steps of: (i) attaching a first rafter to the first and second support columns of a set, with one end of the rafter attached to the first support column and the middle of the rafter attached to the second column to cantilever the first rafter, and (ii) attaching a second rafter to the third and fourth support columns of the set, with one end of the rafter being attached to the fourth support column and the middle of the rafter being attached to the third support column, and (iii) fixing together the free cantilevered ends of the rafters.

4. A method of manufacturing a structure as claimed in claim 3 further characterised by the additional step of: (iv) applying said first and second rafter pairs substantially as described above to all other sets of support columns fixed into the ground of the building site. Intellectual Property Office of N.Z. 14 SEP 2005 RECEIVED 22 James & Wells ref: 26614

5. A method of manufacturing a structure as claimed in claim 3 or claim 4 further characterised by the additional step of: (v) applying a roof covering or cladding material over the plurality of first and second rafter pairs to cover the area of ground enclosed by the support columns.

6. A method of manufacturing a structure as claimed in any one of claims 3 to 5 wherein one or more rafters may be combined to form a single rafter.

7. A method of manufacturing a structure as claimed in any one of the preceding claims wherein said support columns are wood, composite materials, metal or metal alloys.

8. A method of manufacturing a structure as claimed in any one of claims 3 to 6 wherein said rafters are wood, composite materials, metal or metal alloys.

9. A method of manufacturing a structure as claimed in any one of the preceding claims wherein fixing a support column into the ground is by driving the support column into the ground with force.

10. A method of manufacturing a structure as claimed in any one of the preceding claims wherein fixing a support column into the ground is by securing the support column into the ground using concrete.

11. A method of manufacturing a structure as claimed in any one of claims 3 to 6 wherein a rafter attachment means is a combination of one or more of the following: (a) checking the rafter into the top of the support pole, (b) nailing, gluing or bolting into place

12. A method substantially as hereinbefore described and with reference to any one of the accompanying drawings. fnttltotuaf Prcffitrty Offie# if nT 23 AUG 2005 23 James & Wells ref: 26614 A structure manufactured by a method as claimed in any one of claims 1 to 12. CRYSTAL HOMES LIMITED by their Attorneys JAMES & WELLS 24 James & Wells ref: 26614