WO2006032078A1 - Modular construction system and method - Google Patents

Abstract

A modular system for the construction of one or more structural elements of a building and a method of construction is described. The modular system uses a plurality of aligned stiff elongate members connected together using a plurality of connectors. Each elongate member has a planar web portion extending between a first arm and a second arm with the first and second arms extending at right angles outwardly from the planar web portion. Once assembled, each structural element comprises a planar first surface which may be of pre-finished quality. The second surface of the structural element is provided with a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members. The open channels are available to receive services, insulation or sound-proofing. A system for post-tensioning the structural elements is also disclosed.

Description

Modular Construction System and Method

Field of the Invention

The present invention relates to a modular system for construction of one or more of the structural elements of a building.

The present invention further relates to a structural element or a building formed using the modular system.

The present invention further relations to a stiff elongate member used in the modular construction system and a method of constructing a building using the modular construction system.

The present application claims priority from Australian provisional patent application number 2004905398 filed on 20 September 2004.

Background to the Invention Using traditional methods of construction, the design of spaces, rooms and amenities is undertaken by a random assembly of incompatible materials and methods of fixing. Typically a combination of materials and methods are used with different tradespeople being required at each of the different stages of construction to perform specialist tasks. For example, the construction of a dwelling generally starts with the layout of services such as plumbing or electrical in advance of the pouring of a concrete slab to form the foundation of the dwelling. Thereafter, the structural walls of the dwelling are constructed, typically using bricks or prefabricated panels.

Brickwork wall construction is a slow and labour intensive process. Mortar must be applied to form the joints as each brick is laid great care is needed to ensure that the horizontal and vertical alignment of the walls is maintained. Non-structural walls of the dwelling may also be constructed using brickwork or timber joinery.

Typically the walls of the dwelling require cladding or plastering to provide substantially flat planar internal wall surfaces. This stage of construction requires the services of yet another different type of tradesperson. In general, roof construction requires the services of carpenters to construct a timber framework for supporting either cement roofing tiles or sheet metal roofing. This stage of construction again requires the co-ordination of the services of two different types of tradesperson.

Prefabricated panels relieve many of the problems associated with traditional building construction methods but are generally produced in such large sizes that an on-site crane is needed to lift and position the pre-fabricated panels in place. A specialist work force is required to efficiently and safely construct a building using such panels and the costs associated with the use of a crane result in such panels generally being used only for the construction of commercial or industrial buildings, not single-person housing.

Modular construction systems have been proposed in the past. U.S. patent application number 09/726,237 discloses a cellular-core structural panel and a building structure incorporation the cellular-core structural panel. The panel incorporates a honeycomb or other cellular core sandwiched between two metal face sheets and surrounded by a metal frame. The frame sides define interlocking protrusions and channels that interlocking joints between panels. Brackets are used to attach the panels to other parts of the structure.

US Patent 6,332,298 discloses a portable building construction system. The building system uses a series of beams, headers, tubular supports, and blocks to create a building frame. Walls, floors, and a roof can then be attached to the frame. US Patent 6,179,211 discloses a demountable wall system. The wall system is designed to be mounted between, but not attached to the floor and ceiling of a building having a plurality of wall sections. The wall system uses upper and lower horizontal members that mount or interface with the floor and ceiling of the building. Between the horizontal members, there are mounted vertical panels and vertical frame members, as well as frame members for mounting a door. US Patent 6,295,778 discloses modular building structures for which the wall sections are constructed from extruded components that stack together and may be connected by fastening panels. US Patent 6,178,714 discloses a modular temporary building with a poured concrete foundation and having regularly spaced holes for vertical block assembly rods. Wall blocks, having corresponding holes are placed on the foundation. Rods are run through the holes in the blocks down to the holes in the foundation. US Patent 6,082,066 discloses another modular building system using an integrated construction panel that has a grid of structural studs. A rigid frame surrounds the grid, where the frame is designed to mate to the frame of an adjacent panel. Each panel has front and rear surfaces that are attached to the frame.

US Patent 3,987,597 also discloses a modular structural assembly and method of construction. The modular structural assembly is formed from a frame assembly and a plurality of rectangular panels which are releasably secured to the frame. Each panel is formed from four struts which are interconnected and a sheet which is stretched over the struts and secured thereto. Each strut includes and outwardly extending flange which is secured to the frame by clips mounted on the frame. The surfaces create and substantially enclosed space, which is substantially filled with closed cell foam. International Patent Application PCT/AU90/00527 (published as WO 91/06725) discloses a modular building system which includes wall panels joined to one another by interleaving a plurality of coaxial tubes aligned along the edges of the panels. While each of the prior art modular construction systems discussed above is meritorious in its own right, there remains a need for an alternative form of modular construction wherein the various structural elements are easy to construct yet robust against extreme weather conditions without needing to erect a separate supporting frame.

It will be clearly understood that, although prior art use and publications are referred to herein, this reference does not constitute an admission that any of these form a part of the common general knowledge in the art in Australia or in any- other country.

In the statement of invention and description of the invention which follow, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Summary of the Invention

According to a first aspect of the present invention there is provided a modular system for the construction of one or more structural elements of a building comprising a plurality of aligned stiff elongate members connected together using a plurality of connectors, each elongate member comprising a planar web portion extending between a first arm and a second arm, the first and second arms extending at right angles outwardly from the planar web portion, each structural element comprising a planar first surface and a second surface comprising a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members, the open channels being provided for receiving services, insulation or sound-proofing. A principle advantage of the present invention is that all of the various structural elements of a building may be formed using elongate members and connectors of essentially the same construction which adds to the ease of construction without the need to erect a supporting frame using other components.

Preferably the length of the first arm is equal to the length of the second arm and the length of the web portion is equal to or greater than twice the length of the first or second arm.

In one embodiment, the length of the elongate members is not less than an anticipated final dimension of the structural element. In another embodiment, the length of the elongate members is less than the anticipated final dimension of the structural element and the structural element is formed from a plurality of rows of structural elements aligned in an end-to-end arrangement, the structural elements within each row aligned in a side-by-side arrangement.

Alignment of the elongate members can be facilitated in a number of different ways. In one embodiment, the elongate members are laid "back to back", such that a first series of elongate members is aligned with a second series of elongate members such that the web portions of the first series of elongate members are facing the web portions of the second series of elongate members and the first and second series of elongate members are connected together using a plurality of first connectors arranged to be received in web slots provided in the web portions of adjacent elongate members. The at least two web slots may be positioned proximate the distal ends of the elongate members to improve stability.

The connectors may take any number of forms. In one embodiment, each first connector comprises a T-shaped shank with a locking slot for receiving a wedge to lock the first connector in position when the wedge is driven into the locking slot. The wedge may comprise a hole for receiving a locking pin to positively lock the position of the wedge relative to the T- shaped shank.

Alternatively, the plurality of elongate members may be arranged in side-by-side alignment to form the structural element and adjacent elongate members are connected together using a plurality of second connectors received within apertures provided in the first and second arms of the elongate members. Each elongate member may comprise at least two arm apertures positioned proximate the distal ends of the elongate member to maximise stability. In one embodiment each second connector comprises a plate with a locking slot for receiving a wedge to lock the second connector in position when the wedge is driven into the locking slot. The wedge may comprise a hole for receiving a locking pin to positively lock the position of the wedge relative to the plate, particularly if vibration is considered to be a problem.

Advantageously, the second connector may further comprise a locating pin for guiding side by side alignment of adjacent elongate members, the elongate members further comprise corresponding locating pin slots for receiving the locating pin of a second connector. In one embodiment, the locating pin extends at right angles to the plane of the plate and the second connector. Equally, the system may further comprise a third connector with a locating pin for guiding perpendicular alignment of adjacent members and/or a fourth connector with a first locating pin for guiding side by side alignment of adjacent members and a second locating pin for guiding perpendicular alignment of adjacent members.

To provide for cladding to be placed over the second surface to cover the open channels after services, insulation or sound¬ proofing has been installed, the modular system may further comprise a plurality of first brackets for bridging the open channels and providing a surface for attaching fixings to the second surface of the structural element. Advantageously, each first bracket may comprise a planar web section extending between a first arm and a second arm, the first and second arms extending at right angles to the planar web section of the bracket, the first and second arms further comprising a slot arranged to receive one of the plurality of connectors used to join the elongate members of the structural element.

In one embodiment, the modular system further comprises a first and a second series of aligned elongate members connected together using a plurality of connectors, the second series of members being positioned adjacent to a first series of members in an offset overlapping arrangement. When this arrangement is used, the outer surfaces of the planar web portions of the first series of members may form an exterior surface of the building and the outer surfaces of the planar web portions of the second series of wall members may form the interior wall surface of the building. Each of the outer surfaces may be of pre-finished quality which overcomes the need to apply some other form of finishing such as cladding.

Advantageously, an alignment aid may be used to position the second series of members relative the first series of members. The alignment aid may be a second bracket shaped to correspond with the size and shape the interior surface of an elongate member.

To facilitate post-tensioning of the structural elements, the connectors may include locating pins for guiding the alignment of adjacent members, the locating pins having a hollow bore to accommodate the passage of a tensioning means therethrough for post-tensioning the structural element. The tensioning means may be a rope, wire, rod or cable. The tensioning means may be used alone or in combination with a ground anchoring system co- operatively associated with the tensioning means to secure the position of the building relative to the ground.

Whilst any number of materials may be used to construct the elongate members, it is considered to be particularly advantageous for the elongate members to be made from geopolymer as described in greater detail in the description of the preferred embodiments. To reduce the costs of building, the planar first surface may have a pre-finished quality.

For sound-proofing and weather-proofing purposes, the structural element may be impervious to fluid flow from the first surface to the second surface and this may be achieved by ensuring the web portion of the elongate members are impervious to fluid flow once adjacent members are connected.

Whilst in the preferred embodiments, each elongate member is U- shaped in cross-section, a W-shaped cross-section may equally be used.

For improved safety, each elongate member may be constructed using a fire retardant material. For improved acoustics, each elongate member is constructed using a sound-proofing material.

In one embodiment, the modular system further comprises services, insulation or sound-proofing which has been routed within the open channels.

According to a second aspect of the present invention there is provided an elongate member for use in the modular construction system of the first aspect. According to a third aspect of the present invention there is provided a connector for use in the modular construction system of the first aspect. According to a fourth aspect of the present invention there is provided a bracket for use in the modular construction system of the first aspect. According to a fifth aspect of the present invention there is provided a method of constructing a building comprising one or more structural elements, the method comprising the steps of: aligning a plurality of stiff elongate members in side by side alignment to form a structural element of the building, each elongate member comprising a planar web portion extending between a first arm and a second arm, the first and second arms extending at right angles outwardly from the planar web portion; connecting adjacent elongate members to each other using a corresponding plurality of connectors, whereby each structural element comprises a planar first surface and a second surface comprising a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members; and, providing services, insulation or sound-proofing within the open channels of the structural element.

When the length of the elongate members is greater than an anticipated final dimension of the structural element and the method may further comprise the step of reducing the size of the elongate members. When the length of the elongate members is less than the anticipated final dimension of the structural element and the method further comprises the step of providing a plurality of rows of structural elements aligned in an end-to-end arrangement, the structural elements within each row being aligned in a side-by-side arrangement.

In one embodiment, the plurality of elongate members are arranged in side-by-side alignment to form the structural element and adjacent elongate members are connected together using a plurality of second connectors received within apertures provided in the first and second arms of the elongate members. Advantageously, the second connectors may further comprise a locating pin for guiding side by side alignment of adjacent elongate members, the elongate members further comprise corresponding locating pin slots for receiving the locating pin of a second connector and the method further comprises the step of aligning the elongate members using the locating pins as a guide.

To assist in cladding over the open channels after services, insulation or sound-proofing has been installed, the method may further comprise the step of installing a plurality of first brackets for bridging the open channels and to provide a surface for attaching fixings to the second surface of the structural element. The first brackets may be installed during the step of sequentially connecting adjacent aligned elongate members together.

In one embodiment, the method further comprises the step of providing a first series of aligned elongate members connected together using a plurality of connectors and a second series of members, the second series of members being positioned adjacent to a first series of members in an offset overlapping arrangement. When this is done, the outer surfaces of the planar web portions of the first series of members form an exterior surface of the building and the outer surfaces of the planar web portions of the second series of wall members form the interior wall surface of the building. The services, insulation or sound-proofing may be installed before positioning the second series of members over the first series of members.

To facilitate post-tensioning the structural elements, the connectors may include locating pins for guiding the alignment of adjacent members, the locating pins having a hollow bore to accommodate the passage of a tensioning means therethrough and the method includes the step of post-tensioning the structural element using the tensioning means. The tensioning means may be a rope, wire, rod or cable. The tensioning means may be used alone or in combination with a ground anchoring system, the method further comprising the step of anchoring the building to the ground using a ground anchoring system co-operatively associated with the tensioning means.

For sustainability, the method may further comprise the step of manufacturing the elongate members by moulding geopolymer.

According to a sixth aspect of the present invention there is provided a tensioning system for post-tensioning one or more structural elements of a building, the structural element comprising a plurality of aligned stiff elongate members connected together using a plurality of connectors, the connectors comprising a plate arranged to be receivable within corresponding apertures provided in the elongate members, the connectors further comprising a locating pin extending outwardly from the plane of a plate for guiding alignment of adjacent elongate members, the locating pin having a hollow bore, the tensioning system comprising a tensioning means threadingly receivable through the hollow bore of the locating means such that application of a pulling force to the tensioning means causes post-tensioning of the structural element.

The locating pins may extend at right angles to the plane of the plate. The locating pins may be arranged to guide side-by-side alignment of adjacent elongate members, be arranged to guide perpendicular alignment of adjacent members or each connector may comprise a first locating pin for guiding side by side alignment of adjacent members and a second locating pin for guiding perpendicular alignment of adjacent members.

In one embodiment, each elongate member comprises a planar web portion extending between a first arm and a second arm, the first and second arms extending at right angles outwardly from the planar web portion. The structural element may thus comprise a planar first surface and a second surface comprising a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members, the open channels being provided for receiving services, insulation or sound-proofing. For maximum stability, adjacent elongate members may comprise at least two connectors positioned proximate the distal ends of the elongate member. To ensure that the connectors remain in position, each connector may further comprise a plate with a locking slot for receiving a wedge to lock the connector in position when the wedge is driven into the locking slot. For greater security, the wedge may comprise a hole for receiving a locking pin to positively lock the position of the wedge relative to the plate.

The tensioning means may be a rope, wire, rod or cable. The tensioning means may be used alone or in combination with a ground anchoring system co-operatively associated with the tensioning means to secure the position of the building relative to the ground.

Brief Description of the Drawings

In order to facilitate a more comprehensive understanding of the nature of the invention, preferred embodiments of the process in accordance with the invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:

Figure Ia is a side view of a foundation-type member showing the position of cross-section A-A which is shown in Figure Ib;

Figure Ib is a sectional view of the member shown in Figure Ia showing the web section and first and second arms of the U-shaped profile as well as the position of the web aperture for receiving a first type of connector;

Figure Ic is an enlarged view of a portion of the member of Figure Ia;

Figure 2a is a side view of a floor-joist member showing the position of cross-section B-B which is shown in Figure 2b; Figure 2b is a sectional view of the member shown in Figure 2a showing the web section and first and second arms of the ϋ-shaped profile as well as the position of the corresponding web aperture for receiving a first type of connector for joining foundation-types members to floor-joist members/ Figure 2c is an enlarged view of a portion of the member of Figure 2a showing the apertures provided for receiving a second type of connector for joining adjacent floor-joist members when in side-by-side arrangement;

Figure 3a is a side view of a floor or ceiling member showing the position of cross-section C-C which is shown in Figure 3b;

Figure 3b is a sectional view through C-C of the member shown in Figure 3a showing the web section and first and second arms of the U-shaped profile as well as the position of the web aperture for receiving a first type of connector;

Figure 4a is a side view of a wall member showing the position of cross-section D-D which is shown in Figure 4b;

Figure 4b is a sectional view through D-D of the member shown in Figure 4a showing the web section and first and second arms of the U-shaped profile as well as the position of the web aperture for receiving a fourth type of connector;

Figure 4c is a sectional view through E-E of the member shown in Figure 4a showing the web section and first and second arms of the U-shaped profile as well as the position of the web aperture for receiving a third type of connector;

Figure 4d an enlarged view of a portion of the member of Figure 4a;

Figures 5a to h is a series of views of an example of a first connector; Figures βa to d is a series of views of an example of a second connector;

Figures 7a to d is a series of views of an example of a third connector;

Figures 8a to d is a series of views of an example of a fourth connector; Figures 9a to c is series of views of an example of a saddle type fifth connector used to straddle the apex of a roof constructed using a plurality of roof members;

Figures 10a to c is a series of views of a first type of bracket used to provide fixing points for cladding or other fixtures for internal walls of a building;

Figures 11a to d is a series of views of a second type of bracket used to provide fixing points for a second series of wall members when such second series of wall members is used to provide the planar internal wall surface of a building;

Figure 12 is half-sectional plan view of one example of a building constructed using the system and method of the present invention for which the members have been used to construct all of the planar surfaces; this figure also shown the position of section Sl-Sl and elevations El-El to E4-E4 of Figures 13 to 17 as well as showing the arrangement of the plurality of members in alignment with each other;

Figure 13 is a side view through section Sl-Sl of Figure 12; Figure 14 shows elevation El-El of Figure 12;

Figure 15 shows elevation E2-E2 of Figure 12;

Figure 16 shows elevation E3-E3 of Figure 12;

Figure 17 shows elevation E4-E4 of Figure 12; and

Figure 18 illustrates an example of a ground anchoring system.

Detailed Description of the Preferred Embodiments of the

Present Invention

Before embodiments of the present invention are described, it is understood that this invention is not limited to the particular type of building or materials of construction described. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs.

Throughout this specification, the term "structural" is used to refer to something that has the ability to span and take forces from one pivot point to another. The term "structural element" is used to refer to the footings, floor joists, floor, walls, and/or roof of a building.

Embodiments of the method and system of the present invention are now described in detail with reference to the drawings in the context of the construction of a building 10, the design of which is shown in Figures 12 to 17. Other designs or types of buildings, including multi-storey buildings are equally possible.

Using the modular system of the present invention, one or more or indeed all of the structural elements of the building 10 may be constructed by aligning and connecting together a plurality of stiff elongate members in such a way that the structural element comprises a first surface 11 which is planar and a second surface 13 comprising a plurality of open channels 12 extending parallel to the longitudinal axis of the aligned elongate members. These open channels 12 are available for routing services or for receiving insulation or sound-proofing after the structural element has been constructed.

Whilst it is considered to be one of the key advantages of the system and method of the present invention that it is possible to define the entire three-dimensional space of a 'building using only the members and connectors described herein, the method and system of the present invention may equally be used to construct only one of the structural elements of the building, such as the floor, the walls or the roof.

The construction of the building 10 of Figures 12 to 17 will now be described in sequence. The first stage of the construction is the preparation of a level site and the marking out of the location of the footings which define the perimeter of the building and the location of at least any load-bearing walls. Footings may also be provided for non-loading bearing walls if desired.

To construct the footings, a plurality of elongate footings-type members 14 shown in Figures Ia to Ic are provided and positioned in alignment with the markings made on the level site. The length of each footings-type member 14 will typically be the full length of the perimeter of the building 10. The perimeter may equally be defined by placing a plurality of footings-type members 14 in an end-to-end arrangement and/or cutting a longer footings-type member 14 to size depending on the starting length of a given member and the design requirements of a particular site.

Each of the elongate members used for construction of the various structural elements that define the three-dimensional space of the house 10 has a U-shaped profile in cross-section, as illustrated in Figure Ib in relation to the footings-type member 14. Each ϋ-shaped profile comprises a planar web portion 16 extending between a first arm 18 and a second arm 20, the first and second arms extending at right angles to the web portion 16. The relative lengths and thicknesses of the web portion 16 and each of the first and second arms 18 and 20, respectively, may vary depending on the design of the building and the anticipated loads, provided only that the first and second arms 18 and 20, respectively, are of the same length. The outer surface of the web portion 16 is planar and may be provided with a pre-finished surface. In this way when a plurality of elongate members is aligned and connected, a first face of the structural element is also planar as described in greater detail below in relation to the method of constructing the walls of the building.

The outer surface of the first and second arms 18 and 20, respectively are planar such that when adjacent members are placed in side-by-side alignment, the outer surface of the first arm of a first member sits flush against the outer surface of the second arm of a second member. The advantage of this is that it helps to ensure that the structural element formed from a plurality of aligned elongate members is weatherproof. This also provides improved acoustical qualities to the building.

A further advantage of each elongate member having a U-shaped profile is that when a structural element such as wall, roof or floor is constructed by aligning and connecting a plurality of the elongate members together, the structural element has a series of open channels 12 for receiving services such as plumbing, gas, telephone, electrical or the like. Advantageously, each of the elongate members is able to be manufactured using a single mould. The members are able to be conveniently handled by one or two people without the need to use a crane depending on the particular materials of construction and the size of a given member. It is to be understood that whilst a "W" shaped profile could equally be used, this shape is considered less advantageous than a "U" shape as each elongate member will weigh more.

If desired, the footings-type members 14 may be connected to each other at the right-angled corners of the perimeter of the building 10 where they meet or simply rest on the site without being connected to each other at this stage.

After the footings of the building 10 have been laid, the floor can then be constructed using similarly shaped elongate floor joist and floor members, 22 and 46 respectively. The floor joists are laid within the perimeter defined by the footings. The function of the floor joists is to act as a support for whatever type of flooring is used in the construction of the building. In this example, the floor itself is constructed using a plurality of elongate ϋ-shaped floor members 24. It is to be understood that the floor could equally be constructed using conventional flooring materials supported by the floor joists if desired .

An example of a suitable floor joist member 22 is shown in Figures 2a to 2c. An example of a suitable floor member 46 is shown in Figures 3a to 3c. Each of the members 22 and 46 has a U-shaped profile as best seen in the cross-sectional views of Figures 2b and 3b. The width of the web portion 16 of the floor joist members 22 as well as the length of the first and second arms 18 and 20, respectively, of the floor members 46 is adjusted such that when the floor is laid over the floor joists, the floor is flush with the level of the footings as best seen in Figure 13. The widths and lengths of the various members are also adjusted in this way for ease of joining of the members to each other.

The web portions 16 of each of the floor joist members 22 and the footings-type members 14 are provided with correspondingly sized and positioned web slots 26 for receiving a first connector 30. Typically each of the members 22 and 14, respectively are provided with at least two such web slots 26 positioned in a spaced apart relationship. For maximum strength, the at least two web slots 26 are positioned proximate the distal ends 24 and 28 of each floor joist member 22 as well as proximate the distal ends 13 and 15 of each footings-type member 14. Additional web slots 26 may be located at intervals along the length of each member 22 and 14 to receive corresponding additional first connectors 30 for additional strength if desired.

An example of a first connector 30 for joining a floor joist member 22 to a footings-type member 14 is illustrated in Figure

5a to 5h. As a first step, one of the floor joist members 22 is placed in abutting contact with a footings-type member 14 in such a way that the web portions 16 of each member are flush with one another as best seen in Figures 5a and 5b. In this arrangement, the first and second arms 18 and 20, respectively of each floor joist member 22 extend outwardly away from the arms 18 and 20 of each footings-type member 14 as illustrated in Figure 13. The web slots 26 of each of the floor joist member 22 and the footings- type member 14 are in alignment.

The first connector 30 comprises a T-shaped shank 32 having a first end 31 and a T-section 40. The first end 31 includes a locking slot 34 shaped to receive a wedge 36. In this example, the wedge 36 takes the form of a metal plate which is straight on one side and tapered on the other side, the tapered side having an included angle not greater than eight degrees. The wedge 36 is provided with one or more optional holes 38 for receiving one or more locking pins (not shown) for positively locking the position of the wedge 36 relative to the T-shaped shank 32 after the wedge 36 has been driven into position.

To connect the floor joist and footings-type members 22 and 14, respectively, together using the first connector 30, the first end 31 of the first connector 30 is inserted through the aligned web slots 26 until the T-section 40 of the shank 32 rests on the web portion 16 of the footings-type member 14. The shank 32 is sufficiently long to pass through the combined thickness of the web portions 16 of both the footings-type member 14 and the floor joist member 22 and extending outwardly therefrom. A washer 44 may then be slid along the shank 32 and brought to rest adjacent to the web portion 16 of the floor joist member 22. The wedge 36 is then driven through the locking slot 34 to lock the floor joist member 22 to the footings-type member 14. The greater the force with which the wedge 36 is driven into the locking slot 34, the greater the pulling force that is exerted to hold the members together.

Additional floor joist members 22 are put in place depending on the design requirements of a particular building and each floor joist member 22 is connected to the footings-type members 14 in an analogous manner. It is to be understood however that not every floor joist member needs to be connected to the footings. The number of first connectors 30 used depends on the particular design requirement of each building and it is considered a matter of routine for a building engineer to determine the number of connectors required.

To construct the floor, a plurality of floor members 46 is laid sequentially in side-by-side alignment over the floor joist members 22. An example of a floor member 46 is illustrated in Figures 3a to 3c. As best seen in Figure 3b, each floor member has a U-shaped profile in cross-section for which like numerals refer to like parts, the only point of difference being that the floor members 46 are not provided with web slots 26. Instead, each of the first and second arms 18 and 20 respectively, of each floor member is provided with at least two arm apertures 52 arranged to receive a second connector 50, an example of which is illustrated in Figures 6a to 6d. The at least two arm apertures 52 are positioned proximate the distal ends 42 and 48 of each floor member 46 for maximum strength. Additional arm apertures 52 may be located at intervals along the length of the each floor member 46 to receive additional second connectors 50 if desired.

The second connectors 50 are used to connect the floor members 46 with the floor joist members 22 as well as assist in aligning the floor members 46 relative to the floor joist members 22. Each second connector 50 comprises a plate 54 having a first end 55 and a second end 57. The first end 55 of the plate 54 is provided with a locking slot 56 for receiving a wedge 58. A tubular shaped locating pin 60 extends at right angles to the plane of the plate 54 at the second end 57 of the second connector 50.

The at least two arm apertures 52 in each of the first and second arms 18 and 20, respectively, of each floor member 46 are arranged to receive the tubular shaped locating pin 60 of the second connector 50. Each floor joist member 22 is provided with correspondingly arranged arm apertures 25 for receiving the plate 54 of a second connector 50.

In use, the first end 55 of a second connector 50 is inserted through the arm aperture 25 of a floor joist member 22. Δ wedge 58 is driven into the locking slot 56 to lock the position of the second connector 50 relative to the floor joist member 22. One or more locking pins (not shown) can be driven into the holes 61 provided in the wedge 58 to hold the wedge 58 in place. The locking pins are used to mitigate the risk of the wedge 58 coming loose due to vibration after construction. A floor member 46 can now be placed in position over the floor joist member 22 using the locating pin 60 of the second connector 50 as a guide to ensure correct alignment of the floor member 46 relative to the floor joist member 22. The locating pin 60 of the second connector 50 is received in one of the arm apertures 52 of the first arm 18' of a first floor member 46' and the second arm 20" of a second floor member 46", as best seen in Figure 6a.

After the floor has been laid, the walls of the building 10 are constructed using similarly shaped wall members 66 shown in Figures 4a to 4d. Typically the walls of the building 10 are constructed by starting at one corner of the building 10 and working across. The length of each wall member 66 is generally the full height of the wall to be constructed (even for multi- storey construction) but may be less than this as required to accommodate the position of, for example, a window or a door as seen in the elevations shown in Figures 15 to 17. Elongate U- shaped members may be used to form the lintels 65 above and or below windows or doors if required. The width of the arms 18 and 20 and web portion 16 of the wall members 66 may be adjusted to suit the thickness of door or window frames used in the building industry as well as the width of fittings associated with plumbing and other services.

The wall members 66 rest on the footings-type members 14 that were put in place at the start of the construction process and may be secured to the footings-type members 14 using a third connector 70 illustrated in Figures 7a to 7d. The third connector 70 has a similar arrangement of parts as the second connector 50, namely a plate 74 having a first end 75 and a second end 77. The first end 75 of the plate 74 is provided with a locking slot 76 for receiving a wedge 78. The wedge 78 may be provided with holes 81 for receiving a locking pin (not shown) to lock the position of the wedge 78 relative to the locking slot. A tubular shaped locating pin 60 extends at right angles to the plane of the plate 74 at the second end 77 of the third connector 70. The locating pin 60 of the second connector 50 is used to align the position of the wall members 66 relative to the footings members 14.

In use, the first end 75 of the plate 74 is inserted through a correspondingly sized and shaped arm aperture 64 provided in each first and second arm 18 and 20 respectively, of each footings- type member 14. A washer 79 may be put in place. The wedge 78 is driven in the locking slot 76 of the third connector 70 to connect the footings-type and wall members 14 and 66 together.

Advantageously the third connector 70 not only joins the wall members 66 to the footings-type members 14 but is also used to align the position of adjacent wall members 66 relative to each other. The locating pins 60 of the third connectors 70 are received within corresponding sized and positioned alignment apertures 72 in each of the first and second arms 18 and 20 respectively, of each wall member 66. The locating pins 60 of each third connector 70 are in this way used to align the position of adjacent wall members 66 at right angles with the footings-type members 14 as best seen in Figure 7a. One of the functions of the third connector is to transfer some of the engineering stresses from the wall to the footings.

It is to be understood that not every wall member 66 need be positively tied to the footings-type members 14. It is considered a matter of routine for a building engineer to assess the number of such connections that are required to provide a required level of strength to the building.

The wall members 66 may be positioned such that the first and second arms 18 and 20 of each wall member 66 extend either inwardly or outwardly of the building 10. It is preferable to position the wall members 66 such that the arms 18 and 20 of each wall member 66 extend towards the inside of the building 10. In this arrangement, two benefits are realised. The outer surface 17 of the planar web portions 16 of the wall members 66 together form the first planar face of the wall. Advantageously, the outer surface of the planar web portions 16 may be pre-finished such that when the first face of the structural element (in this case a wall) is external to the building 10, the first face requires no further finishing. The external wall surface may be rendered or clad if desired to achieve the particular aesthetic appeal required of the building or simply left as is for a low cost option. The surface finish of the outer surface 17 of the planar web portions 16 may be engineered to provide the particular look of the exterior of the building desired.

The second benefit is that when the walls of the building are constructed in this way, the internal walls comprise a plurality of vertically aligned open channels 12 for receiving services such as electricity, gas or water plumbing, telephone, insulation or sound-proofing may be run through these channels.

To construct a wall, a first wall member 66' is positioned, typically in a corner, its alignment relative to the footings is checked and the first wall member 66' is locked into position relative to the footings-type member 14 by passing the locating pin 60 of a third connectors 70 through the arm aperture 72 of the first arm 18 of the first wall member 66' . A second wall member 66" is then positioned adjacent to the first wall member

66' in side by side alignment therewith. The locating pin 60 of the third connector 70 also passes through an arm aperture 72 of the second arm 20 of the second wall member 66".

The first wall member 66' is further connected to the second wall member 66" using a fourth connector 80, an example of which is illustrated in Figures 8a to 8d.

Each fourth connector 80 comprises a plate 82 with locking slots 84 positioned at each of a first end 86 and second end 88, each locking slot 84 arranged to receive one of two wedges 90' and 90". Each of the first and second arms 18 and 20 respectively of each wall member 66 is provided with a plurality of correspondingly shaped rectangular slots 87 at spaced apart locations along the length of each wall member 66, as best seen in Figure 4a, 4b and 4d. Each rectangular slot 87 is arranged to receive the plate 82 of a fourth connectors 80.

In use, the plate 82 of the fourth connector 80 is passed through the aligned rectangular slots 87 of the arms 18 and 20 of adjacent wall members 66. Optional washers 94 are positioned adjacent the first arm 18 of the first wall member 66' and abutting second arm 20 of the second wall member 66". Thereafter each of the wedges 90' and 90" are driven into corresponding locking slots 84 to connect the first and second wall members 66' and 66" together.

With reference to Figures 10a to 10c, the walls of the building 10 may be provided with a plurality of first brackets 100 to provide fixing points for cladding the walls with, for example fibre-cement sheeting. The first brackets 100 may equally be fixing points for windows, doors and the like. The first brackets 100 are typically bent from a thin flat sheet of metal to form a similar U-shape to the U-shaped profile of the wall members. The U-shape is adopted for the first brackets 100 to maximise the size of the open channels 12 within the wall members 66 to reduce obstruction to services. Each U-shaped first bracket 100 has first and second arms 101 and 102, respectively, positioned at distal ends of and extending at right angles outwardly from a planar web section 106.

Conveniently, each arm 101 and 102 of each first bracket 100 is provided with a slot 104 arranged to receive the plate 82 of a fourth connector 80, so that the first bracket 100 may be mounted within a wall member 66 as illustrated in Figure 10a. In this arrangement, the arms 101 and 102 of the first bracket 100 take the place of the washer 94 of the fourth connector 80. The web portion 106 of the first bracket 100 provides a surface for attaching fixings, for example, cladding in the form of plasterboard sheeting, to the walls of the building 10.

In an alternative embodiment of the modular building system of the present invention, the walls may be constructed using two layers of wall members 66. In this embodiment, a first series of wall members 140 is constructed in the manner outlined above. Thereafter, a second series of wall members 150 is constructed adjacent to the first series of wall members 140 in an offset overlapping arrangement, as best seen in Figure 11a. In this arrangement, the outer surfaces 17' of the planar web portions 16' of the first series of wall members 140 forms the exterior wall surface of the building 10 and the outer surfaces 17" of the planar web portions 16" of the second series of wall members 150 form the interior wall surface of the building 10.

In this embodiment, a second bracket 130 (an example of which is illustrated in Figures 11a to lid) is used instead of the first brackets 100. The second brackets 130 are used as an alignment aid during construction of the second series of wall members 150. Each second bracket 130 is bent from a thin flat sheet of metal to form a U-shape that corresponds with the size and shape the inner surface 68 of a wall member 66. The second brackets 130 are made in this way so as to fit snugly within the inner surface 68 of a wall member 66 in such a way that the size of the open channels 12 remains as large as possible to reduce obstruction to services. Each ϋ-shaped second bracket 130 has first and second arms 131 and 132, respectively, positioned at distal ends and extending at right angles outwardly from a planar web section 136. Conveniently, each arm 131 and 132 of each second bracket 130 is provided with a slot 134 shaped to receive the plate 82 of a fourth connector 80. In this arrangement, as illustrated in Figure 11a, the arms 131 and 132 of the second bracket 130 take the place of the washer 94 for the fourth connector 80.

The web portion 136 of the second bracket 130 is further provided with a third arm 152 for aligning the position of the second series of wall members 150. The third arm 152 comprises a plate 154 forming a T-piece with the web portion 136 of the second bracket 130 as seen in Figure lie. A wing portion 156 extends outwardly at right angles from the plate 154 in parallel alignment with the first and second arms 131 and 132 respectively, of the second bracket 130. A locating pin 60 extends at right angles from the wing portion 156 in such a way that the locating pin 60 is in longitudinal parallel alignment with the web portion 136 of the second bracket 130. The arrangement of the plate 154 relative to the web portion 136 has the effect of offsetting the relative height of the bore 62 of the locating pin 60 relative to the slots 134 in the first and second arms 131 and 132 of the second bracket 130 as best seen in Figure Hd.

In use, the first series of wall members 140 are constructed in an analogous fashion as described above. During the construction of the walls of the building 10, a plurality of second brackets 130 is snugly fit within the inner surface 68 of the wall members 66 of the first series of wall members 140. The second brackets 130 are held in position using a corresponding plurality of fourth connectors 80. Services such as electricity, plumbing, gas and telephone can then be installed in the open, channels 12. Thereafter, the first wall member 66 of the second series 150 is put into position using the locating pins 60 of the second brackets 130 as a guide. Each wall member 66 in the second series 150 is provided with arm apertures 72 arranged to receive the tubular locating pins 60 of the second bracket 130. The relative positions of the first and second series of wall members 140 and 150 respectively, are fixed by the size and shape of the various parts of the second bracket 130.

Each wall member 66 in the second series 150 is sequentially located relative to the first series 140 and relative to each other by sliding the locating pins 60 of the second bracket 130 into the arm apertures 72 of each wall member 66 in the second series 150.

The second brackets 130 perform a second function. The length of the arms 131 and 132 of the second brackets 130 are arranged to ensure that, after construction of the second series of wall members 150 is completed, a gap 160 is maintained between the arms 18 and 20 of the first series of wall members 140 and the inner surface 116 of the second series of wall members 150. This gap 160 is maintained to discourage water penetration through the walls due to condensation. The gap 160 acts as a waterproofing cavity for the building 10.

A ceiling and/or a roof may be constructed in an analogous fashion to the way in which the floor was constructed using ceiling and roof members (not shown) of a similar U-shaped profile or using standard industry methods of construction. Figures 13 to 17 illustrate the use of roof members 110 arranged in side by side alignment, the roof members 110 being pitched at an angle so as to meet at the apex 112 of the building 10. With reference to Figure 9a to 9c, a fifth connector 120 is used to straddle the apex 112 of the building 10 so as to connect roof members 110' and 110" on opposite sides of the roof of the building 10. Each fifth connector 120 comprises a bridging portion 122 midway between two wing portions 124 extending at an angle to the bridging portion 122, the angle being dependent on the pitch of the roof. Each wing portion 124 is provided with a locating pin 60 which is slidably receivable in correspondingly shaped and positioned apertures in the arms of the roof members 110.

It is to be understood that the locating pins 60 of the second or third connector and/or the second bracket need not be tubular in shape and may be hollow or solid provided only that the corresponding arm apertures of the various members are of a corresponding size and shape to receive the locating pins.

In a further alternative embodiment described below, it is particularly advantageous for the various locating pins 60 to be hollow to receive a tensioning means 200 in the form of a wire rod or rope to allow post-tensioning of the various structural elements of the building 10. With reference to Figures 6a, 7a and 9a, the bore 62 of each of the locating pins 60 of second, third and fifth connectors 50, 70 and 120, respectively, is hollow to accommodate the passage of a tensioning means therethrough. The tensioning means 200 is used to apply post- tensioning to the structural elements of the building 10 to improve the cyclone rating of the building. The tensioning means 200 typically takes the form of a steel wire, rod or cable that is sequentially threaded through the bore of the hollow locating pins during the construction of the floor, walls and roof respectively.

The use of the tensioning means 200 is hereinafter described in the context of construction of a wall of the building 10. It is to be understood however that the tensioning means 200 could equally be applied to one or more of the other structural elements including the footings, floor joists, floor, ceiling and roof members to provide additional stability, strength and cyclone proofing to the building. The tensioning means 200 is considered particularly advantageous for the roof. When a tensioning means 200 such as a wire rope, is threaded through the bore 62 of the locating pins 60 of the fifth connectors 120 that bridge the apex 112 of the roof, the wire can be used to tie both sides of the roof together or to tie the roof to the wall members 66 or to one or more ground anchors if desired. In this way, a single wire can be used to connect and post-tension a plurality of structural elements. The walls can thus be tied down to the floor joists and/or footings. The number of connectors and brackets can be adjusted for greater post-tensioning capacity depending on the overall desired strength of the building.

Typically one end of the tensioning means 200 is bolted or otherwise mechanically fastened to a member at one end of a structural element, such as one end of a wall. The tensioning means 200 is sequentially threaded through the bore 62 of each locating pin 60 during construction of the wall until the wall has been completed. When the wall has been completed, a pulling force can be applied to one end of the tensioning means 200 to post-tension the walls. The ends of the tensioning means may be bolted or otherwise mechanically fastened to the modules that are located at opposing distal ends of a structural element such as each end of a wall or attached to a ground anchoring system as described below. In this way, post-tensioning of the structural elements can be achieved immediately after construction or at any later stage thereafter if required.

A ground anchoring system 206 may be used alone or in combination with the tensioning system 200 to secure the building 10 to the ground 210. Any suitable ground anchoring system may be used. In the example illustrated in Figure 18, the ground anchoring system 206 comprises a plurality of footings-type members 14 connected together with an extended first connector 30' , the shank 32 of the extended first connector 30' having a variable length depending upon the depth to which the ground anchoring system 206 is required to extend underground. To construct the ground anchoring system 206, a first footings- type member 14' is buried under the ground, typically at a depth of one metre or more depending on the soil conditions of a particular building site. For some soil types it may be necessary for the footings-type member 14' to be cemented in place in the ground. The extended first connector 30' is threaded through the arm apertures 64 of the first arm 18 of the first footings-type member 14'until the T-piece 40 is in abutting contact with the inner surface 19 of the first arm 18' . Thereafter a second footings-type member 14" is placed in position on the level site (as described in greater detail above) . The first end 31 of the first connector 30 is passed through a corresponding arm aperture 64 in the second arm 20" of the second footings-type member 14". The wedge 36 is driven into the locking slot 34 to hold the first extended connector 30 in place.

The particular material of construction of the members used in the various embodiments of the present invention is not critical to working thereof. Accordingly, the members can be constructed of any suitable material including but not limited to fibre cement, concrete, polymers, metal, and/or timber. For sustainability, the preferred material of construction is geopolymers which have load-bearing properties and strength that are comparable to concrete but are manufactured with far less green house gas emissions typically using recycled flyash from coal-fired power stations and with improved fire proofedness compared with traditional building materials. Advantageously, geopolymers can be readily cast to form the members used in the system or method of the present invention and are able to be manufactured with surface finishes that are of sufficient aesthetic appeal that cladding of the visible faces of the walls, floor, ceiling and/or roof need not be conducted. A further advantage of geopolymers is that they are generally more chemical and in particular sulphate resistant than concrete. This allows for mild steel to be used for the tensioning means instead of the more expensive option of using stainless steel. Where reference is made to the use of "metals' in the manufacture of connectors and brackets it should be recognised the options of other materials with comparable physical properties could be used.

Now that the preferred embodiments and illustrative examples of the present invention have been described in detail, the present invention has a number of advantages over the prior art, including the following:

(a) the ability to construct an entire building using members of the same shape greatly simplifies the construction of the building and allows the members to be made using a single mould; (b) the open channels reduce the number of specialist trades that need to be scheduled during the construction of a building;

(c) the connectors are easy to use for connecting any of the structural elements of the building and assist in correct alignment of some of the elements relative to others;

(d) the tensioning system allows for post-tensioning of the building to improve its overall strength; and,

(e) ground anchors may be used either alone or in combination with the tensioning system to further increase the cyclone rating of the building;

(f) the structural elements formed using the elongate members are weatherproof without the need to provide external cladding;

(g) if web slots are not provided in the elongate members, the structural elements formed when the elongate members are aligned and connected together does not allow the passage of fluid from the first face of the structural element to the second face or vice versa;

(h) the structural elements have good acoustic properties;

(i) the elongate members are sufficiently stiff whereby the structural elements are self-supporting, obviating the need for a separate supporting frame;

(j) the modular system is readily adapted for designing a building using three-dimensional co-ordinates using commercially available computer software.

Numerous variations and modifications will suggest themselves to persons skilled in the relevant art, in addition to those already described, without departing from the basic inventive concepts. All such variations and modifications are to be considered within the scope of the present invention, the nature of which is to be determined from the foregoing description and the appended claims.

Claims

Claims defining the invention:

1. A modular system for the construction of one or more structural elements of a building comprising a plurality of aligned stiff elongate members connected together using a plurality of connectors, each elongate member comprising a planar web portion extending between a first arm and a second arm, the first and second arms extending at right angles outwardly from the planar web portion, each structural element comprising a planar first surface and a second surface comprising a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members, the open channels being provided for receiving services, insulation or sound-proofing.

2. The modular system of claim 1 wherein the length of the first arm is equal to the length of the second arm and the length of the web portion is equal to or greater than twice the length of the first or second arm.

3. The modular system of any one of claims 1 or 2 wherein the length of the elongate members is not less than an anticipated final dimension of the structural element.

4. The modular system of claim 1 or 2 wherein the length of the elongate members is less than the anticipated final dimension of the structural element and the structural element is formed from a plurality of rows of structural elements aligned in an end-to-end arrangement, the structural elements within each row aligned in a side-by-side arrangement.

5. The modular system of any one of claims 1 to 4 wherein a first series of elongate members is aligned with a second series of elongate members such that the web portions of the first series of elongate members are facing the web portions of the second series of elongate members and the first and second series of elongate members are connected together using a plurality of first connectors arranged to be received in web slots provided in the web portions of adjacent elongate members.

6. The modular system of claim 5 wherein at least two web slots are positioned proximate the distal ends of the elongate members.

7. The modular system of claim 5 or 6 wherein each first connector comprises a T-shaped shank with a locking slot for receiving a wedge to lock the first connector in position when the wedge is driven into the locking slot.

8. The modular system of claim 7 wherein the wedge comprises a hole for receiving a locking pin to positively lock the position of the wedge relative to the T-shaped shank.

9. The modular system of any claim 1 wherein the plurality of elongate members are arranged in side-by-side alignment to form the structural element and adjacent elongate members are connected together using a plurality of second connectors received within apertures provided in the first and second arms of the elongate members.

10. The modular system of claim 9 wherein each elongate member comprise at least two arm apertures positioned proximate the distal ends of the elongate member.

11. The modular system of claim 10 wherein each second connector comprises a plate with a locking slot for receiving a wedge to lock the second connector in position when the wedge is driven into the locking slot.

12. The modular system of claim 11 wherein the wedge comprises a hole for receiving a locking pin to positively lock the position of the wedge relative to the plate.

13. The modular system of any one of claims 9 to 12 wherein the second connector further comprises a locating pin for guiding side by side alignment of adjacent elongate members, the elongate members further comprise corresponding locating pin slots for receiving the locating pin of a second connector.

14. The modular system of claim 13 wherein the locating pin extends at right angles to the plane of the plate and the second connector.

15. The modular system of any one of claims 1 to 14 further comprising a third connector with a locating pin for guiding perpendicular alignment of adjacent members.

16. The modular system of any one of claims 1 to 15 further comprising a fourth connector with a first locating pin for guiding side by side alignment of adjacent members and a second locating pin for guiding perpendicular alignment of adjacent members.

17. The modular system of any one of claims 1 to 16 further comprising a plurality of first brackets for bridging the open channels and providing a surface for attaching fixings to the second surface of the structural element.

18. The modular system of claim 17 wherein each first bracket comprises a planar web section extending between a first arm and a second arm, the first and second arms extending at right angles to the planar web section of the bracket, the first and second arms further comprising a slot arranged to receive one of the plurality of connectors used to join the elongate members of the structural element.

19. The modular system of any one of claims 1 to 18 further comprising a first and a second series of aligned elongate members connected together using a plurality of connectors, the second series of members being positioned adjacent to a first series of members in an offset overlapping arrangement.

20. The modular system of claim 19 wherein the outer surfaces of the planar web portions of the first series of members form an exterior surface of the building and the outer surfaces of the planar web portions of the second series of wall members form the interior wall surface of the building.

21. The modular system of claim 20 wherein an alignment aid is used to position the second series of members relative the first series of members.

22. The modular system of claim 21 wherein the alignment aid is a second bracket shaped to correspond with the size and shape the interior surface of an elongate member.

23. The modular system of any one of claims 1 to 22 wherein the connectors include locating pins for guiding the alignment of adjacent members, the locating pins having a hollow bore to accommodate the passage of a tensioning means therethrough for post-tensioning the structural element.

24. The construction system of claim 23 wherein the tensioning means is a rope, wire, rod or cable.

25. The modular system of any one of claims 23 or 24 further comprising a ground anchoring system co-operatively associated with the tensioning means to secure the position of the building relative to the ground.

26. The modular system of any one of claims 1 to 25 wherein the elongate members are made from geopolymer.

27. The modular system of any one of claims 1 to 26 wherein the planar first surface has a pre-finished quality.

28. The modular system of any one of claims 1 to 27 wherein the structural element is impervious to fluid flow from the first surface to the second surface.

29. The modular system of any one of claims 1 to 27 wherein each elongate member is W-shaped in cross-section.

30. The modular system of any one of claims 1 to 29 wherein each elongate member is constructed using a fire retardant material.

31. The modular system of any one of claims 1 to 30 wherein each elongate member is constructed using a sound-proofing material.

32. The modular system of any one of claims 1 to 31 further comprising services routed within the open channels.

33. The modular system of any one of claims 1 to 32 further comprising insulation or sound-proofing material arranged within the open channels.

34. An elongate member for use in the modular construction system of any one of claims 1 to 33.

35. A connector for use in the modular construction system of any one of claims 1 to 33.

36. A bracket for use in the modular construction system of any one of claims 1 to 33.

37. A method of constructing a building comprising one or more structural elements, the method comprising the steps of: aligning a plurality of stiff elongate members in side by side alignment to form a structural element of the building, each elongate member comprising a planar web portion extending between a first arm and a second arm, the first and second arms extending at right angles outwardly from the planar web portion; connecting adjacent elongate members to each other using a corresponding plurality of connectors, whereby each structural element comprises a planar first surface and a second surface comprising a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members; and, providing services, insulation or sound-proofing within the open channels of the structural element.

38. The method of claim 38 wherein the length of the elongate members is greater than an anticipated final dimension of the structural element and the method further comprises the step of reducing the size of the elongate members.

39. The method of claim 38 wherein the length of the elongate members is less than the anticipated final dimension of the structural element and the method further comprises the step of providing a plurality of rows of structural elements aligned in an end-to-end arrangement, the structural elements within each row being aligned in a side-by-side arrangement.

40. The method of any one of claims 37 to 39 wherein the plurality of elongate members are arranged in side-by-side alignment to form the structural element and adjacent elongate members are connected together using a plurality of second connectors received within apertures provided in the first and second arms of the elongate members.

41. The method of claim 40 wherein the second connectors further comprise a locating pin for guiding side by side alignment of adjacent elongate members, the elongate members further comprise corresponding locating pin slots for receiving the locating pin of a second connector and the method further comprises the step of aligning the elongate members using the locating pins as a guide.

42. The method of any one of claims 37 to 41 further comprising the step of installing a plurality of first brackets for bridging the open channels and to provide a surface for attaching fixings to the second surface of the structural element.

43. The method of claim 42 wherein the first brackets are installed during the step of sequentially connecting adjacent aligned elongate members together.

44. The method of any one of claims 37 to 43 further comprising the step of providing a first series of aligned elongate members connected together using a plurality of connectors and a second series of members, the second series of members being positioned adjacent to a first series of members in an offset overlapping arrangement.

45. The method of any one of claim 44 wherein the outer surfaces of the planar web portions of the first series of members form an exterior surface of the building and the outer surfaces of the planar web portions of the second series of wall members form the interior wall surface of the building.

46. The method of any one of claims 37 to 45 wherein the connectors include locating pins for guiding the alignment of adjacent members, the locating pins having a hollow bore to accommodate the passage of a tensioning means therethrough and the method includes the step of post-tensioning the structural element using the tensioning means.

47. The method of claim 46 wherein the tensioning means is a rope, wire, rod or cable.

48. The method of claim 46 or 47 further comprising the step of anchoring the building to the ground using a ground anchoring system co-operatively associated with the tensioning means.

49. The method of any one of claims 37 to 48 further comprising the step of manufacturing the elongate members by- moulding geopolymer.

50. A tensioning system for post-tensioning one or more structural elements of a building, the structural element comprising a plurality of aligned stiff elongate members connected together using a plurality of connectors, the connectors comprising a plate arranged to be receivable within corresponding apertures provided in the elongate members, the connectors further comprising a locating pin extending outwardly from the plane of a plate for guiding alignment of adjacent elongate members, the locating pin having a hollow bore, the tensioning system comprising a tensioning means threadingly receivable through the hollow bore of the locating means such that application of a pulling force to the tensioning means causes post-tensioning of the structural element.

51. The tensioning system of claim 50 wherein the locating pins extend at right angles to the plane of the plate.

52. The tensioning system of claim 50 wherein the locating pins are arranged to guide side-by-side alignment of adjacent elongate members.

53. The tensioning system of claim 50 wherein the locating pins are arranged to guide perpendicular alignment of adjacent members.

54. The tensioning system of claim 50 wherein each connector comprises a first locating pin for guiding side by side alignment of adjacent members and a second locating pin for guiding perpendicular alignment of adjacent members.

55. The tensioning system of claim 50 wherein each elongate member comprises a planar web portion extending between a first arm and a second arm, the first and second arms extending at right angles outwardly from the planar web portion.

56. The tensioning system of claim 55 wherein the structural element comprises a planar first surface and a second surface comprising a plurality of open channels extending parallel to the longitudinal axis of the aligned elongate members, the open channels being provided for receiving services, insulation or sound-proofing.

57. The tensioning system of any one of claims 50 to 56 wherein adjacent elongate member comprise at least two connectors positioned proximate the distal ends of the elongate member.

58. The tensioning system of any one of claims 50 to 57 wherein each connector further comprises a plate with a locking slot for receiving a wedge to lock the connector in position when the wedge is driven into the locking slot.

59. The tensioning system of claim 58 wherein the wedge comprises a hole for receiving a locking pin to positively lock the position of the wedge relative to the plate.

60. The tensioning system of any one of claims 50 to 59 wherein the tensioning means is a rope, wire, rod or cable.

61. The tensioning system of any one of claims 50 to 60 further comprising a ground anchoring system co-operatively associated with the tensioning means to secure the position of the building relative to the ground.

62. A modular system for the construction of one or more structural elements of a building substantially as herein described with referent to and as illustrated in the accompanying drawings.

63. A structural element substantially as herein described with reference to and as shown in the accompanying drawings.

64. An elongate stiff member substantially as herein described with reference to and as illustrated in the accompanying drawings.

65. A modular building substantially as herein described with reference to and as shown in the accompanying drawings.

66. A method of constructing a building substantially as herein described with reference to and as illustrated in the accompanying drawings.

67. A tensioning means substantially as herein described with reference to and as shown in the accompanying drawings.

68. A ground anchoring system substantially as herein described with reference to and as shown in the accompanying drawings.