WO2016058050A1

WO2016058050A1 - Integrated modular metal frame building system

Info

Publication number: WO2016058050A1
Application number: PCT/AU2015/050633
Authority: WO
Inventors: Michael Smith; Andrew Smith
Original assignee: Michael Smith
Priority date: 2014-10-14
Filing date: 2015-10-14
Publication date: 2016-04-21
Also published as: AU2015333593B2; AU2014101408B4; AU2022201796A1; AU2015333593A1; AU2014101408A4

Abstract

An integrated modular metal frame building system (1) comprising a plurality of structural members (14, 16, 18, 20, 22) taken from a set of structural members (14, 16, 18, 20, 22); at least one key plate (24, 26) taken from a set of key plates (24, 26); and at least one locking peg (28). The plurality of structural members (14, 16, 18, 20, 22) each have at least a pair of apertures provided therein for receiving the at least one key plate (24, 26). The at least one key plate (24, 26) having apertures provided therein for receiving a locking peg (28). The at least one locking peg (28) has at least a pair of retaining arms (136) each having a slight tapered edge. When the key plate (24, 26) is received in the plurality of structural members (14, 16, 18, 20, 22) and the retaining arms (136) are received within the apertures of the key plate (24, 26), the slight tapered edge creates a tensioned connection between the structural members (14, 16, 18, 20, 22).

Description

"INTEGRATED MODULAR METAL FRAME BUILDING SYSTEM" FIELD OF THE INVENTION

[0001] The invention relates to an integrated modular metal frame building system.

The metal frame building system is particularly suited to forming structures which are capable of withstanding extreme weather events, such as hurricanes, and seismic events.

BACKGROUND TO THE INVENTION

[0002] The following discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known or part of the common general knowledge in any jurisdiction as at the priority date of the application.

[0003] Residential structures are typically formed either incorporate brick walls or a framing system. In the former situation, a bricklayer is employed to create the wall on a layered basis. While the end result is a strong structure, it is not resistant to seismic events and is more time consuming and quite costly.

[0004] The latter situation reduces the time needed to construct a building, and therefore its attendant costs, but the relative advantages and disadvantages of the framing system are dependent on the material used, the overall design and the method of construction.

[0005] Wood-based framing systems are the most commonly used framing systems.

This is due to skilled professionals being most familiar with such systems and the ease with which a wooden frame can be modified or adapted as needed to complete the structure. However, wood-based framing systems suffer from significant disadvantages including:

• Wooden frame elements are heavy which can make them awkward to manipulate.

• Wooden frames are not fireproof, nor are they insect resistant;

• Wooden frames are not made with ready accommodation for utilities;

• Wooden frame elements are prone to buckling, warping, splitting, shrinking and otherwise bending out of shape;

• Wooden frames are also affected by high humidity which can cause dry rot; and • installation of the wood-based frames may be delayed in situations of inclement weather so as to avoid the frame taking on moisture which may compromise its structural integrity.

[0006] It should also be noted that wood-based frames often requires modification following installation to account for misalignment - either in installation or resulting from warping, etc. - of the frame.

[0007] As an alternative to wood-based framing systems, metal framing systems have been developed. Prior metal framing systems involve the use of lighter frame elements and generally are less expensive than wood-based framing systems. Metal framing systems are also not likely to warp or otherwise lose their intended shape. However, prior metal-based framing systems also suffer from significant disadvantages including:

• The difficulty with which a metal frame element can be modified and the attendant safety risks from sharp metal edges that can result from such modifications;

• Procedures for erecting such metal frame structures still require a significant amount of site time, which incurs significant costs.

• Due to the difficulty in screw connecting together various metal frame elements, there generally is no time advantage in building or erecting a metal frame structure in a workshop or on site relative to building a wood-based frame structure.

[0008] In response to these problems, a modular metal wall framing system was developed by Zev Rosenberg and made the subject of US Patent 6,983,569. The modular metal wall framing system of this patent relies on a series of tabs and crimp points to connect struts to channel members.

[0009] The problem with this modularised approach is that the tabs are prone to misalignment and the connection created by the tabs and crimps can - depending on the ability of the installer - be flimsy. Additionally, this modular metal wall framing system does not provide any indication as to how to link walls to form corners, linear continuation, the transition from wall to roof structure or connecting internal wall sections.

[0010] This combination of potentially flimsy wall construction and the lack of connectivity between walls can result in a building which - while able to handle common structural stresses - may be prone to collapse in extreme weather conditions such as intense tropical low pressure systems or seismic events. [0011] It is therefore an object of the present invention to provide an integrated modular metal frame building system that solves, or at least ameliorates in part, the aforementioned problems.

SUMMARY OF THE INVENTION

[0012] Throughout this document, unless otherwise indicated to the contrary, the terms "comprising", "consisting of", and the like, are to be construed as non-exhaustive, or in other words, as meaning "including, but not limited to".

[0013] In accordance with a first aspect of the invention there is a an integrated modular metal frame building system comprising: a plurality of structural members taken from a set of structural members;

at least one key plate taken from a set of key plates; and

at least one locking peg

where the plurality of structural members each have at least a pair of apertures provided therein for receiving the at least one key plate and the at least one key plate having apertures provided therein for receiving a locking peg, such that when the key plate is received in the plurality of structural members and the at least one locking peg having at least a pair of retaining arms each having a slight tapered edge, such that when the retaining arms are received within the apertures of the key plate, the slight tapered edge creates a tensioned connection between the structural members.

[0014] The set of structural members preferably includes one or more of the following: a nogging; a connecting stud; a channel stud; a base plate; a top plate. Similarly, the set of key plates preferably includes one or both of the following: a key plate; a corner key plate.

[0015] In its ideal form, the pair of tapered arms each have a tapered edge having a plurality of teeth provided therealong, the plurality of teeth operable to prevent disengagement of the locking peg from the key plate.

[0016] The locking peg may further include a positioning tab for facilitating positioning and receipt of the retaining arms within the apertures of the tabs.

[0017] The first structural member taken from the set of structural members can have at least a pair of tabs protruding therefrom, at least one of the pair of tabs operable to be received within one of the pair of apertures of a second structural member taken from the set of structural members, and, when so received, a tensioned connection is formed between the first and second structural members by the receipt within the apertures of a retaining arm in the apertures of the second structural member. The structural member may also have a pair of structural member apertures for receiving the tabs of the first structural member and where the at least one pair of apertures provided in the structural member for receiving a tab of the key plate is offset relative to the pair of structural member apertures

[0018] Where a structural member taken from the set of structural members is to be used vertically within a structure, the structural member may incorporate utility apertures to facilitate the routing of utility services.

[0019] A third structural member taken from the set of structural members may be used as a base plate, the base plate having at least one securing aperture to facilitate fastening of the third structural member to a slab.

[0020] The key plate can take the form of two slot arms arranged in parallel to form a

"H" shape. Alternatively, the key plate may take the form of a corner key plate, the corner key plate comprising a first pair of tabs and a second pair of tabs, the first pair of tabs being arranged at an angle relative to the second pair of tabs.

[0021] In a further alternative configuration, the corner key plate comprises a first segment and a second segment, each segment having a face edge and a connecting edge and one of the pair of tabs provided for proximate the connecting edge and where each segment is adapted to overlap and be securely connected to the other segment so that the first pair of tabs is angled relative to the second pair of tabs.

[0022] The first pair of tabs may be angled relative to the second pair of tabs at one of the following angles: 30°, 45°, 60°, 90°, 120°, 1 35°, 150°.

[0023] Each structural member in the set of structural members may have at least one securing aperture provided therein, the securing apertures provided at points of potential connection to other structural members and where each securing aperture assists in facilitating fastening of the structural members to each other.

[0024] Each structural member in the set of structural members used at the periphery may incorporate a return flange, the return flanges operable to define a mounting frame for plasterboard.

[0025] The set of structural members may include a door connector, the door connector operable to be retained to a door frame. The return flange can be defined by the retention of the door connector to the door frame. [0026] In accordance with a second aspect of the present invention there is an integrated modular metal frame building system comprising: a partitioning nogging; and at least two partitioning connecting studs; where each partitioning connecting stud has an aperture provided therein to facilitate continuous threading the partitioning nogging.

[0027] The integrated modular metal frame building system may further comprise a partitioning channel stud, each partitioning channel stud also having an aperture provided therein, such that when the partitioning channel studs are arranged intermediate the partitioning connecting studs, the apertures align to facilitate continuous threading of the partitioning nogging.

[0028] The partitioning connecting studs and/or partitioning channel studs can have securing apertures provided proximate each aperture, each securing aperture operable to facilitate fastening of the partitioning nogging to the partitioning connecting stud and/or the partitioning channel stud.

[0029] The integrated modular metal frame may further incorporate a gusset, the gusset operable to transfer load from the partitioning connecting stud and/or partitioning channel stud to the partitioning nogging. Ideally, each gusset connects the partitioning nogging to the partitioning connecting stud and/or partitioning channel stud either side of their respective aperture.

[0030] In accordance with a third aspect of the present invention there is an integrated modular metal frame building system comprising joists, rafters and a cap plate where each rafter is operable to be securely received within a joist and positioned relative to other rafters by way of a cap plate. Ideally, the joists form part of the set of structural members as defined in the first aspect of the present invention.

[0031] The joists may incorporate connecting means for connecting the joist to a structural member from the set of structural members as defined in claim 1 . [0032] In accordance with a fourth aspect of the invention there is a structural member for use in an integrated modular metal frame building system, the structural member has at least a pair of apertures provided therein for receiving at least one key plate taken from a set of key plates, each key plate having apertures provided therein for receiving a retaining arm of a locking peg, such that when the key plate is received in the structural member and the locking peg is received within the apertures of the key plate, a slight tapered edge of the retaining arm creates a tensioned connection between the structural member and another structural member.

[0033] The structural member may have at least a pair of tabs protruding therefrom, at least one of the pair of tabs operable to be received within one of the pair of apertures of a second structural member and, when so received, a tensioned connection is formed between the structural member and the second structural member by the receipt within the apertures of a retaining arm in apertures of the second structural member.

[0034] The structural member may have utility apertures provided therein to facilitate routing of utility services when arranged vertically within a structure.

[0035] In accordance with a fifth aspect of the invention there is a key plate for use in an integrated modular metal frame building system, the key plate having apertures provided therein for receiving a retaining arm of at least one locking peg, such that when the key plate is received within at least one aperture provided in a pair of structural member and a retaining arm of the at least one locking peg is received within the apertures of the key plate, a slight tapered edge of the retaining arm creates a tensioned connection between the pair of structural members.

[0036] In accordance with a sixth aspect of the invention there is a plurality of locking pegs for use in an integrated modular metal frame building system, each locking peg having a pair of retaining arms having a slight tapered edge, the pair of retaining arms also adapted to be received within the apertures of a key plate taken from a set of key plates such that, when the key plate is received within at least a pair of apertures provided in a structural member taken from a set of structural members, the slight tapered edge of the retaining arms create a tensioned connection between the structural member and another structural member.

[0037] The tapered edge may have a plurality of teeth provided there along, the plurality of teeth operable to prevent disengagement of the locking peg from the key plate. The locking peg may also include a positioning tab for facilitating positioning and receipt of the retaining arms within the apertures of the tabs. [0038] In accordance with a seventh aspect of the invention there is a method of creating an integrated modular metal frame for a building comprising the steps of: inserting a key plate taken from a set of key plates into a first structural member taken from a set of structural members, such that at least a first aperture provided in the key plate protrudes therethrough inserting the key plate into a second structural member taken from the set of structural members, such that at least a second aperture provided in the key plate protrudes therethrough and creating a tensioned connection between the first and second structural members by inserting slightly tapered edges of retaining arms of a locking peg into each of the first and second apertures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a first part of a structure built according to the present invention.

Figure 2 is a perspective view of a second part of a structure built according to the present invention.

Figure 3 is a perspective view of a top plate forming part of the modular construction system of the present invention.

Figure 4 is a perspective view of a nogging forming part of the modular construction system of the present invention.

Figure 5 is a top plan view of the nogging shown in Figure 4.

Figure 6 is a perspective view of a connecting stud forming part of the modular construction system of the present invention.

Figure 7 is a side plan view of the connecting stud shown in Figure 6.

Figure 8 is a perspective view of a base plate forming part of the modular connection system of the present invention. Figure 9 is a top plan view of a key plate forming part of the modular construction system of the present invention.

Figure 10 is a top plan view of a corner key plate forming part of the modular construction system of the present invention.

Figure 1 1 is a top plan view of the corner key plates shown in Figure 8 in their installed arrangement.

Figure 12 is a perspective view of a locking peg forming part of the modular construction system of the present invention.

Figure 13 is a top plan view of the locking peg shown in Figure 12.

Figure 14 is a top plan view of the locking peg shown in Figure 12 used to secure the top plate as shown in Figure 8 in its preferred arrangement.

Figure 15 is perspective view of a base plate as used in an alternative modular construction system of the present invention.

Figure 16 is a perspective view of a first metal door frame having a door connector connected thereto.

Figure 17 is a perspective view of a second metal door frame.

Figure 18 is a cross-section, partially exploded, view of the first metal door frame and door connector as shown in Figure 16.

Figure 19 is a plan cross-sectional view of a structure incorporating a first metal door frame as finished using plasterboard.

Figure 20 is a perspective view of a partitioning nogging. Figure 21 is a perspective view of a partitioning channel stud.

Figure 22 is a first perspective view of an internal wall as constructed using an integrated modular metal frame building system according to a third embodiment of the present invention.

Figure 23 is a second perspective view of an internal wall as constructed using an integrated modular metal frame building system according to the third embodiment of the present invention. Figure 24 is a perspective view of a cap plate as used in an integrated modular metal frame building system according to a fifth embodiment of the present invention.

Figure 25 is a perspective view of a joist as used in the integrated modular metal frame building system according to the fifth embodiment of the present invention.

PREFERRED EMBODIMENTS OF THE INVENTION

[0040] In accordance with a first embodiment of the invention there is an integrated modular metal frame building system 10 comprising

• a plurality of structural members; and

• a plurality of connecting members.

[0041] The various types of connecting members are designed to secure structural members, either of the same type or of differing types, together to form a structure 12.

[0042] The plurality of structural members include the following:

• a nogging 14;

• a connecting stud 16;

• a channel stud 1 8;

• a base plate 20; and

• a top plate 22.

[0043] The plurality of connecting members include the following:

• a key plate 24;

• a corner key plate 26; and

• a locking peg 28.

Noqqinq 14

[0044] The nogging 14 is shown in Figures 4 and 5.

[0045] The nogging 14 comprises a base 30. The base 30 has open ends 32 and sides 34. Extending from each open end 32 is a pair of locking tabs 36. Each locking tab 36 extends from the open end 32 at a position proximate a side 34. [0046] Each locking tab 36 has a pair of connector slots 38 provided therein. The connector slots 38 are transversely aligned relative to the open end 32.

[0047] The nogging 14 has a length (L-i). Positioned approximately half way along the length (l_i ) of the nogging 14 are a pair of channel stud slots 40. The channel stud slots 40 are "C"-shaped. The alignment of the channel stud slots 40 are such that back 42 sits along its respective side 34.

[0048] Attached to each side 34 are strengthening flanges 44. The strengthening flanges 44 extend at right angles to the side 34. In this manner each strengthening flange 44, is connected to the base 30 such that a "C"-shaped channel is formed. Furthermore, the strengthening flanges 44 are arranged such that open face 46 of the formed "C"-shaped channels face each other.

[0049] Each strengthening flange 44 has a cut-away portion 48. The cut-away portion

48 is positioned such as to be vertically aligned with its associated channel stud slot 40.

[0050] In this embodiment, a screw hole 50 is also provided in each strengthening flange 44 at a position in vertical alignment with its associated cut-away portion 48 and channel stud slot 40.

Connecting Stud 16

[0051] The connecting stud 16 is shown in Figures 6 and 7.

[0052] The connecting stud 16 takes the form of a flanged "C"-shaped channel 52.

The "C"-shaped channel 52 has a base wall 54 and two opposing side walls 56.

[0053] Pairs of plate slot apertures 58 are located in the base wall 54 equidistantly along the length (L₂) of the connecting stud 16.

[0054] Nogging slot apertures 60 are located in each side wall 56 equidistantly along the length (L₂) of the connecting stud 16. In this embodiment, the nogging slot apertures 60 on each side wall 56 are in exact alignment with each other.

[0055] The connecting stud 16 has a roof end 62. Projecting from each side wall 56 at the roof end 62 is a connector tab 64. A pair of slotted apertures 66 are provided in each connector tab 64 at a position proximate roof end 62 of side walls 56. Each slotted aperture 66 in the pair is parallel to its counterpart. The pair of slotted apertures 66 are positioned so as to be transverse to the roof end 62 of the side wall 56. [0056] Also provided in each connector tab 64 is a hole 68. The role of the hole 68 will be explained in more detail below.

[0057] A plurality of utility apertures 70 are provided in each side wall 56. Each utility aperture 70 is positioned so as to be proximate a nogging slot aperture 60. This position is such that each utility aperture 70 is positioned to the side of the nogging slot aperture 60 towards the roof end 62.

[0058] Extending from each side wall 56, in a direction perpendicular thereto, are flanges 72. The flange 72 attached to a first side wall 56 extends away from the flange 72 attached to the other side wall 56. A securing aperture 74 is provided in end 76 of each flange 72 opposite roof end 62.

Channel Stud 18

[0059] The channel stud 18 also takes the form of an open-ended "C"-shaped channel. The cross-sectional dimensions of the channel stud 18 are identical to that of the channel stud slots 40.

Base plate 20

[0060] The base plate 20 is shown in Figure 8.

[0061] The base plate 20 has a base 78 and two side walls 80. The side walls 80 extend from sides of base 78 in the same perpendicular direction. Flanges 82 also extend from the side walls 80 in a direction parallel to the base 78. The end effect is that the base plate 20 has a cross-section similar to a "C"-shaped channel.

[0062] Located within the base 78 are two securing apertures 84. The securing apertures 84 will be described in more detail below.

[0063] The side walls 80 have a stud end 86 and a free end 88. The stud end 86 has two spaced stud connector apertures 90 provided therein. The space between the stud connector apertures 90 is substantially equivalent to the width of a stud connecting stud 16.

[0064] The free end 88 has an aperture 92 provided therein. The role of this aperture will be explained in more detail below.

[0065] Located mid-length (L₃) of the side wall 80 is a channel stud securing aperture

94. [0066] Located along the length (L₃) of each side wall 80 are a plurality of cut-outs 96.

Each cut-out 96 is aligned with an aperture 90, 92, 94 such that the aperture is proximate the centre of each cut-out 96.

Top Plate 22

[0067] Top Plate 22 is shown in Figure 3.

[0068] Top plate 22 has a base 98 and two side walls 100. The side walls 100 extend from sides of base 98 in a direction perpendicular thereto. Flanges 102 also extend from the side walls 100 in a direction parallel to the base 98. However, the flanges 102 extend away from each other.

[0069] Provided in ends 104 of base 98 are two linear apertures 106. Further "C" shaped apertures 108 are provided in the base 98 at positions in between the ends 104.

[0070] Apertures 106, 108 are provided in facing pairs. Part of each aperture 108 is proximate the edge 1 10 formed by the base and a side wall 100.

Key Plate 24

[0071] Key plate 24 is shown in Figure 9.

[0072] Key plate 24 has two slot arms 1 12 and a spanning body 1 14. The slot arms

1 12 are attached to opposing sides 1 16 of the spanning body 1 14. The slot arms 1 12 and spanning body 1 14 are aligned to the same plane. The end result is that the key plate 24 has an overall shape similar to the letter "H".

[0073] Provided in ends 1 18 of each slot arm 1 12 Is a single slotted aperture 120.

Each slotted aperture 120 is of equal dimensions and is similarly positioned relative to the spanning body 1 14.

Corner Key Plate 26

[0074] Corner key plate 26 is shown in Figures 1 0 and 1 1 .

[0075] The corner key plate 26 has a body 122 and two tabs 124. The body 122 has a connecting edge 1 26 and a face edge 1 28. Two apertures 130 are aligned with the connecting edge 126. [0076] Each tab 1 24 has a pair of slotted apertures 132 provided therein. Each slotted aperture 132 is arranged in parallel within its pair. Each pair of slotted apertures 132 is positioned so as to be transverse to the part of the body 122 to which the tab 1 24 connects.

Locking Peg 28

[0077] The locking peg 28 is shown in Figures 12 and 13.

[0078] The locking peg 28 has a body 134 and retaining arms 136. The body 134 has opposing sides 138 and a bottom side 142. A positioning tab 144 extends away from an open face 146 of the body 134 at an angle. In this embodiment, an aperture 148 is also centrally located within the body 134.

[0079] Each retaining arm 136 has a retainer portion 150 and a stop portion 152. The stop portion 152 has a rounded top 154 and a base 156. The retainer portion 150 extends from the base end 156 such that the stop portion 152 and the base end 156 of each retaining arm 136 are in the same vertical plane X-X. There is a slight taper in each retaining arm 136 as it extends from the base end 156.

[0080] The width (W-i) of the stop portion 152 at the base end 156 is greater than the width (W₂) of the retainer portion 150. In doing so, the part of the base end 1 56 not connected to the stop portion 152 forms an abutment 158.

[0081] Each retaining arm 136 connects to an opposing side 138 of the body 134.

The connection is such that each retaining arm 136 extend perpendicular to the open face 146. This positioning also places the abutment 158 in alignment with the bottom side 142 of the body 134.

[0082] The retaining arms 136 are positioned so as to be parallel to each other.

[0083] The invention will now be described in the context of its intended use.

[0084] After a slab has been formed, a plurality of base plates 20 are placed on the slab at the desired locations. In this instance, two base plates 20 are arranged linearly while a further base plate 20 is positioned at a right angle to one end of the linear arrangement.

[0085] With the base plates 20 suitable arranged, the installer secures them in place using a suitable fastening mechanism (not shown) that is received within securing apertures 84.

[0086] A first stud 200a is then constructed by placing a first connecting stud 16 upside down such that the base wall 54 faces the floor surface. A plurality of key plates 24 are then manipulated such that the slot arms 1 1 2 to one side of the key plate 24 are received within a pair of plate slot apertures 58.

[0087] A second connecting stud 16 is then placed on top of the key plates 24 such that the base wall 54 is face up. The key plates 24 or the connecting stud 1 6 is appropriately manipulated such that the remaining exposed slot arms 1 12 are received within a pair of plate slot apertures 58 in this connecting stud 16.

[0088] It is to be noted that this arrangement sees the base wall 54 of each connecting stud 1 6 abutting the spanning body 1 14 of each key plate 24. This also means that each connecting stud 1 6 partially occludes its corresponding slotted aperture 1 20.

[0089] The first stud 200a is then maneuvered to a position perpendicular to the slab and placed inside the base plate 20. When properly positioned, flanges 72 of each connecting stud 1 6 are received within cut outs 96 of the base plate 20 to which it is to be attached. It also means that stud connector apertures 90 are in alignment with securing apertures 74.

[0090] Stud 200a is then secured in place by the use of a fastening means (not shown), such as a Tek screw, that passes through both the stud connector aperture 90 and securing aperture 74. This now provides the installer with free access to the protruding portions of the slot arms 1 12.

[0091] Each protruding pair of slot arms 1 12 are then locked in place by way of a locking peg 28. To do this, the installer uses the positioning tab to manipulate the retaining arms 1 50 to a position where they are received within slotted apertures 1 20 of the protruding slot arms 1 12.

[0092] When the retaining arms 150 are properly received within the slotted apertures

1 20, the body 134 of the locking peg 28 abuts both the base wall 54 of the connecting stud 16 and the spanning body 1 14 of the key plate 24 being locked in place. The insertion of the retaining arms 1 50 in this manner also ensures that, by reason of the slight taper of the retaining arms, that a tensioned connection is formed between the locking peg 28 and the structural members it retains that resists disassembly of the resulting structure.

[0093] Once secured by locking pegs 28, a nogging 14 is connected to stud 200a such that the pair of locking tabs 36 are received in aligned nogging slot apertures 60 of each connecting stud 1 6. This results in the locking tabs 36 protruding into the interior of its associated connecting stud 1 6. [0094] The protruding locking tabs 36 are then locked in place using a locking peg 28.

Installation of the locking peg 28 is achieved in the same manner as already described.

[0095] When the retaining arms 150 are properly received within the connector slots

38, the body 134 of the locking peg 28 abuts both the side wall 56 of the connecting stud 16 and the open end 32 from which the locking tab 36 projects.

[0096] Additional nogging 14 are then installed as required and connected using this same process.

[0097] A second stud 200b and third stud 200c is then constructed in a manner identical to that described above for the construction of the first stud 200a. The installed nogging 14 are then connected to the second stud 200b using the same connection process as already described.

[0098] If additional rigidity is to be provided to the nogging 14, or further support is needed for fastening of internal wall finishings (not shown) a channel stud 18 may be installed. Installation of a channel stud 18 sees the channel stud 18 inserted through aligned channel stud slots 40 in the installed nogging 14.

[0099] To complete the wall structure, a top plate 22 is then installed such that connector tabs 64 are received within corresponding linear apertures 106 or "C" shaped apertures 1 08, as appropriate. If a channel stud 18 is installed, the channel stud 18 is also received within one of the "C" shaped apertures 108.

[00100] The top plate 22 is then secured in position by way of locking pegs 28. To do this, the installer uses the positioning tab to manipulate the retaining arms 150 to a position where they are received within both sets of slotted apertures 66 of the connector tabs 64 protruding to one side of the stud 200 concerned.

[00101 ] When the retaining arms 150 are properly received within the slotted apertures

66, the body 134 of the locking peg 28 sits on top of base 98.

[00102] To provide the most secure connection possible, ideally, the locking peg 28 used to secure the stud 200 are alternated in their alignment. Thus, if the wall is subject to movement in a direction that may result in the locking peg 28 coming loose, the same force will actually cause the alternate locking peg 28 to move in a direction that further secures it within its connector tabs 64.

[00103] This arrangement is illustrated in Figure 14. [00104] A second wall (not shown) is then constructed using the same process on the base plate 20 positioned at right angles to the constructed wall. This second wall includes stud 200c.

[00105] To provide an integral corner connection between the two walls, corner key plates 26 are used.

[00106] To elaborate, a corner key plate 26 is installed to the free side of stud 200b such that its tabs 124 are received in nogging slot apertures 60 of both connecting studs. The corner key plate 26 is then retained in position by way of a locking peg 28 in a process identical to that used to secure nogging 14.

[00107] This process is then repeated to secure an additional corner key plate 26 to the free side of stud 200c at a vertically aligned position

[00108] Installation of the two corner key plates 26 in this manner creates an area of overlap as shown in Figure 1 1 . This overlap also aligns apertures 130 such that a fastening means (not shown) can be received therethrough and secure the connection of the corner key plates 26. This process is repeated until all desired corner key plates 26 are installed.

[00109] With the structure now complete, the installer can now route utility cabling, such as electrical cabling, gas piping and reticulated vacuum systems to their desired locations by way of the open cavities in the connecting studs 16, through the utility apertures 64 and then into the open cavities of the nogging 14. If necessary, utility cabling can also be routed through the corners at the spaced area created to the side of face edge 128.

[00110] The person skilled in the art should readily understand that the integrated nature of this modular system, combined with its intended anchoring to the floor surface and connection of any roof structure thereto by way of holes 62, means that the structure forms a rigid whole and as such has the capability of withstanding intense tropical low pressure systems or seismic events.

[00111 ] In accordance with a second embodiment of the invention, where like numerals reference like parts, there is a modular metal frame building system 300. The modular metal frame building system 300 is the modular metal frame building system 100 extended to accommodate metal door frames.

[00112] The modular metal frame building system 300 accommodates two types of metal door frames. [00113] The first type of metal door frame is shown in Figure 16. The first metal door frame 302 comprises two arms 304. Each arm 304 comprises a side wall 306 and a return flange 308. The arms 304 are arranged such that each return flange 308 points in a direction towards the other return flange 308.

[00114] The second type of metal door frame 310 is shown in Figure 17. The second metal door frame 310 is of identical construction to the first metal door frame 302 but with the addition of plaster flanges 312. Each plaster flange 312 extends from the open end of the return flange 308. Furthermore, each plaster flange 312 extends in the same direction away from a base 314.

[00115] At least one securing aperture 316 is provided in the plaster flange 312.

[00116] Figures 16 and 18 show an additional connecting member in the form of door connector 318. The door connector 318 comprises a base 320 and side walls 322. The side walls 322 extend from opposing sides of the base 320. Each side wall 322 extends in the same direction away from the base, thus the side walls 322 are arranged in parallel to each other.

[00117] Free end 324 of each side wall 322 has a retaining flange 326. Each retaining flange 326 extends away from the side wall 322 in a direction perpendicular thereto. The retaining flanges 326 extend away from each other.

[00118] As with second metal door frame 310, at least one securing aperture 328 is provided in the retaining flanges 326.

[00119] A plurality of slotted apertures 330 are provided in the base 320. The slotted apertures 330 are arranged in an identical manner to pairs of plate slot apertures 58 as provided in connecting studs 16.

[00120] The invention of the second embodiment will now be described in the context of its intended use.

[00121 ] As described in the first embodiment of the invention, the components of the modular metal frame building system 100 are used to construct the main structural elements (not shown) of the structure. However, where it is desired to implement a metal door frame 302, 310 within the structure, the installation is modified as follows.

[00122] Regardless of the door frame 302, 310 to be installed, at the position of intended installation of the door frame 302, 31 0, stud 200 is replaced with a door connector 318. The door connector 318 is arranged so that the base 320 faces the remainder of the wall to which it is to be attached and aligned so that retaining arms 150 are properly received within slotted apertures 330. The retaining arms 1 50 are then securely retained to the door connector 318 using a locking peg 28 in the manner as already described.

[00123] With the door connector 318 appropriately in place, the builder can install the intended door frame 302, 310.

[00124] If the builder is installing the first door frame 302, the builder can either slide the first door frame 302 wholly over the door connector 318 from the top or flex the first door frame 302 to angle it onto the door connector 318. In either circumstance, once installed, the retaining flanges 326 overlap the return flanges 308. This overlap prevents the first door frame 302 from disassociating itself from the door connector 318 under normal operation.

[00125] If the builder is installing the second door frame 310, the builder can again either slide the second door frame 310 wholly over the door connector 318 or flex the second door frame 310 to angle it onto the door connector 318. In either circumstance, once installed, the retaining flanges 326 overlap the return flanges 308 but additionally each plaster flange 312 overlaps at least part of a side wall 322.

[00126] This extended overlap prevents the first door frame 302 from disassociating itself from the door connector 318 under normal operation.

[00127] It is also to be noted that when the second door frame 310 is installed relative to the door connector 318, securing apertures 31 6, 328 are aligned.

[00128] While the secure connection between the door connector 318 and the door frame 302, 310 is important to maintaining the structural integrity of the door frame and structure, the arrangement between door connector 318 and door frame 302, 31 0 provides an additional benefit. This additional benefit is best shown in Figure 19.

[00129] The modular metal frame building system 300 provides the skeleton for a structure, but ultimately the skeleton must be finished using finishing materials. For internal facing walls, the typical finishing material is plasterboard 332. Installing plasterboard 332 to a structure constructed according to this second embodiment of the invention is much simplified.

[00130] To elaborate, in such a structure, each sheet of plasterboard 332 is provided with something functionally equivalent to a mounting frame. The mounting frame is defined as follows:

• At its top, by the right angle formed by flanges 102 and side walls 100; • At its base, by side walls 80 and the slab; and

• At its sides, in one of three ways. If the side is a natural corner to the internal wall, then the corner (as typically formed between side wall 56 and flange 72) itself acts as part of the mounting frame. If the side is part of a first door frame 302 provided in the internal wall, then the corner as formed by the return flanges 308 and side walls 322. Alternatively, if the side is part of a second door frame 310 provided in the internal wall, then the corner as formed by the return flanges 308 and the plaster flanges 312.

[00131 ] The definition of a mounting frame as described then means that the plasterer can simply abut the sheet(s) of plasterboard 332 against the mounting frame and secure it in place to the mounting frame. If the mounting frame is larger than the sheet of plasterboard 332, the sheet of plasterboard 332 should - by reason of the predetermined spacing of channel studs 18 - be able to be mounted to the channel studs 18. . In this manner, the plasterer is no longer required to use other scrap material to join sheets of plasterboard 332 together. It also removes the need for intervening channel studs 18 to be installed, unless needed for other purposes (such as anchoring points for shelving or the like).

[00132] In accordance with a third embodiment of the invention, where like numerals reference like parts, there is a modular metal frame building system 400. The modular metal frame building system 400 comprises a partitioning nogging 402, a partitioning channel stud 404 and a partitioning connecting stud 406.

[00133] The partitioning nogging 402 takes the form of an open ended "C"-shaped channel.

[00134] The partitioning channel stud 404 also takes the form of an open-ended "C"- shaped channel. The "C"-shaped channel comprises a base 408 and two side walls 410.

[00135] A plurality of first nogging apertures 412 are provided equidistantly in the base

408 along the length (L₄) of the partitioning channel stud 404. First securing apertures 414 are provided in each side wall 410. Each first securing aperture 414 is located such that it is positioned centrally within the side wall 41 0 relative to the area defined by a first nogging aperture 412.

[00136] The partitioning connecting stud 406 is substantially identical in construction to connecting stud 16. The variation in the partitioning connecting stud 406 relates to the replacement of the nogging slot apertures 60 with second nogging apertures 41 6. [00137] Each second nogging aperture 416 is identical in size, shape and position as the first nogging apertures 414 formed within the partitioning channel stud 404. A plurality of second securing apertures 418 are also provided in the partitioning connecting stud 406 of identical size, shape, position and intended use as the first securing apertures 414 formed within the partitioning channel stud 404.

[00138] This embodiment of the invention will now be described in the context of its intended use.

[00139] As described in the first embodiment of the invention, the components of the modular metal frame building system 100 are used to construct all structural elements (not shown) of the structure. Internal partitioning walls 420 are then created using the modular metal frame building system 400 and integrated with the constructed structural elements where appropriate.

[00140] With the structural elements already formed, the builder then positions base plates 20 in locations where internal partitioning is desired. The base plates 20 are then secured in place as already described.

[00141 ] A first partitioning connecting stud 406 is then placed within the base plate 20 such that each of its opposing side walls 56 abuts, and is parallel to, a side wall 80 of the base plate 20. The first partitioning connecting stud 406 is then manipulated until it is perpendicular to the base plate 20 at one end 422 thereof. The first partitioning connecting stud 406 is then secured in this position.

[00142] A second partitioning connecting stud 406 is then positioned and secured within the base plate 20 in an identical manner, but at a second end 424 thereof. Ideally, the first and second partitioning connecting studs 406 are arranged such that the openings of each "C"-shaped channel face away from each other.

[00143] At specified distances along the length of the base plate 20, the builder similarly installs partitioning channel studs 404. It is anticipated that the partitioning connecting studs 406 and the partitioning channel studs 404 will have sufficient rigidity to allow for installation of the partitioning nogging 402 without further assistance. If this is not the case, or there are concerns regarding the rigidity of one or more of the partitioning connecting studs 406 or the partitioning channel studs 404, a top plate 22 can be installed as has already been described in the context of the first embodiment of the invention. [00144] The partitioning channel studs 404 do not need to be secured to the base plate

20 initially. In adopting this approach, it is possible to slide the partitioning channel studs 404 along the base plate 20 to any desired location and then secured. This is particularly advantageous in installing plasterboard 332 as described above, as the partitioning channel studs 404 can be adjusted on site to match the size of the sheet of plasterboard 332 to be installed and thus ensure that sheets of plasterboard are always joined at the site of a partitioning channel stud 404.

[00145] It is to be noted here that it is important following installation that the builder have access to the second nogging apertures 416 of at least one of the partition connecting studs 416.

[00146] The builder then uses the access provided to each second nogging aperture

416 to insert a partition nogging 402. Due to the alignment of first nogging apertures 412 with second nogging apertures 416, it is possible to continuously thread the partition nogging 402 through the partitioning channel studs 404 until the partition nogging 402 is received within the second nogging aperture 416 of the opposing partition connecting stud 406.

[00147] The advantage of this approach is that the partition nogging 402 can either be made to specific length off-site or can be cut to suit following insertion. Either way, speed of construction of the partition is greatly increased.

[00148] To finish off the partition, and assuming it has not already been installed, top plate 22 is then installed as has already been described in the context of the first embodiment of the invention.

[00149] In accordance with a fourth embodiment of the invention, where like numerals reference like parts, there is a variation of the modular metal frame building system 400 of the third embodiment.

[00150] The variation the subject of this fourth embodiment is the inclusion of a gusset

426. The gusset 426 is triangular in shape. A securing aperture 428 is provided in each apex of the gusset 426.

[00151 ] The gusset 424 is used to prevent the potential buckling of partitioning channel studs 404 and partitioning connecting studs 406 about the first nogging aperture 41 2 or second nogging aperture 416, as appropriate.

[00152] A gusset 426 is placed on, and internal to, each side of the first nogging aperture 41 2 or second nogging aperture 416, as appropriate. The gusset 426 is then secured in place using appropriate fasteners (not shown). Each fastener extends through a securing aperture 428 to make contact with either the partitioning channel studs 404 (or partitioning connecting studs 406) or the partitioning nogging. This arrangement is best shown in Figure 23.

[00153] By securing the gusset 426 in this manner, the gusset not only transfers load vertically, but also operates to counteract torsional (side loading) forces.

[00154] In accordance with a fifth embodiment of the invention, where like numerals reference like parts, there is a modular metal frame building system 500. The modular metal frame building system 500 is either of the previously described modular metal frame building systems 100, 300 extended to accommodate roofing structures.

[00155] The modular metal frame building system 500 incorporates joists 502, struts

504, rafters 506 and cap plates 508.

[00156] Each joist 502 takes the form of a Ή" beam. Ideally, the "H" beam comprises two separate "C"-shaped structural elements connected back to back by an appropriate flange 510. Thus, a channel opening 512 is formed that opens up towards the roof space. Figure 25 shows this arrangement in more detail.

[00157] The joists 502 are typically arranged in a grid-like pattern and connected to the top plates 22 of each structural wall in a manner as would be readily apparent to the person skilled in the art.

[00158] Each strut 504 and rafter 506 is dimensioned so as to be received within the channel opening 512. Each strut 504 operates to provide support to at least one rafter 506 (either directly or indirectly).

[00159] Struts 504 and rafters 506 are secured in place by fasteners in a manner as would be known to the person skilled in the art.

[00160] Each rafter 506 has a structure identical in cross-section to that of door connector 318. A plurality of connecting apertures 514 are provided along the length of the rafter 506.

[00161 ] Each cap plate 508 has a plurality of positioning retainers 51 6 and a spanning plate 51 8.

[00162] Each positioning retainer 516 is provided on a first face 520 of the spanning plate 518. Each positioning retainer 516 has a box-shaped cross-section when taken through axis B-B. The size of the positioning retainer 516 is intended to be slightly smaller than the internal profile of rafters 506.

[00163] The spanning plate 518 may take any shape. For example, the cap plate 508 shown in Figure 24 has a spanning plate 51 8 comprising three panels 520 that are arranged so as to rise towards a central point (not shown). Provided centrally on a main panel 520a is a first positioning retainer 516. Additional positioning retainers 516 are provided at the point of connection of main panel 520a with each of remaining panels (only panel 520b is shown in Figure 24).

[00164] As mentioned previously, the joists 502 are connected to the top plates 22 of each structural wall using known techniques and thereby provide a basis for the assembly of the remainder of the roof structure. Struts 504 and rafters 506 may then similarly be connected to the joists 502.

[00165] Where rafters 506 are to meet to provide structural strength or support, a cap plate 508 is installed. The cap plate 508 so installed must have positioning retainers 516 angled towards the intended position of each rafter 506. Each rafter 506 is then manipulated so as to overlay its respective positioning retainer 516.

[00166] Once rafters 506 have been so positioned with respect to each desired positioning retainer 516, the rafter 506 is secured to the positioning retainer by way of a fastener installed through connecting apertures 514. The spanning plate 518 is then similar secured either to a hip rafter 506 or a strut 504. Depending on its position within the roof structure, the cap plate 508 may require a back plate 522 to facilitate this connection.

[00167] A structure formed using the modular metal frame building systems of the present invention is inherently strengthened by the interconnection of the various elements. This strength, in turn, allows the structure to survive the forces of natural catastrophes, such as hurricanes and earthquakes, without any real adverse effect.

[00168] The modular nature of the invention, as described in all its forms, as well as it's means of construction, allows for large portions of the structure to be made to exact tolerances either on-site or off-site as desired. This exactness and ability to almost mass manufacture structures at the factory also results in significant cost savings. Additionally, due to the simplified nature of the invention, it is possible for persons not having a registered trade background to erect any desired structure. [00169] It should be further appreciated by the person skilled in the art that the invention is not limited to the embodiments described above. Additions or modifications described, where not mutually exclusive, can be combined to form yet further embodiments that are considered to be within the scope of the present invention.

• While the invention is considered to provide sufficient strength as described, if the installer wishes to further strengthen the structure Tek screws or other like fasteners can be employed. For instance a Tek screw may be used to fasten a locking peg to a connecting stud 16 by way of the aperture provided in the body of the locking peg.

• In a similar fashion, while the invention has been described in a context where apertures are provided at predetermined locations representing intended positions of connecting or channel studs 16, 1 8. However, such apertures are not required and fasteners can be used that allow for secure connection between components at any desired location.

• While the invention has been described in a configuration that would be readily understood by the person skilled in the art as a double wall construction, the invention can be modified to facilitate single wall construction. In such a configuration, nogging have a smaller width to that as shown and are modified to facilitate connection to a single connecting stud 16. Such a configuration is particularly suited for use as an internal partition wall.

• To prevent further warping or undesired relative movement of the connecting studs forming struts 200a, 200b, a securing plate may be attached.

• Channel stud slots 40 may be omitted.

• Ideally, the plate slot apertures 58 are offset relative to the nogging slot apertures 60 so as to prevent locking pegs 28 from obscuring the open cavity of the connecting stud 16 or from preventing one or more locking pegs 28 from being properly installed as described above.

• Two corner key plates 26 may be combined into an integral whole. However, this requires additional precision on the part of the installer and creates installation difficulties relative to installation of the corner key plates 26 as described above.

• The corner key plate 26 as described above facilitates creation of 90° corners. However, variations on the corner key plate 26 as would be readily understood by the person skilled in the art would allow the corner key plate 26 to facilitate creation of corners of other angles. The locking peg 28 may omit the positioning tab 1 4. Alternatively, the positioning tab 144 may be modified to facilitate ease of secure insertion of the locking peg 28 by way of a hammer or similar tool.

A plurality of teeth (not shown) may be provided along the tapered edge of the retaining arms 136. The plurality of teeth operate in a manner that prevents easy removal of the locking peg 28 while not inhibiting its installation.

The base plates 20 may be secured to a concrete slab, or other like base element, through fastening means such as threaded bolts protruding from the concrete slab (fastening being by means of a nut threaded to the threaded bolt when received through securing apertures 84). Alternatively, nails etc. may be projected through the securing apertures 84 to embed into the concrete slab, or other like base element.

The base plate 20 may take an alternative configuration as shown in Figure 15. In this configuration there is no differentiation made between the stud end 86 and the free end 88. Rather a single cut out 96 is provided at each end to receive connecting strut 16, such that the position where linearly aligned base plates 20 meet is at the centre of the connecting strut 16.

In a variation of the second embodiment, the slotted apertures 330 may be omitted.

Tek screws, or similar fasteners as already described, may be used to connect the door connector 318 to the metal door frames 302, 310 (for example as shown in Figure 18). This can be done through screwing the fastener through one or both securing apertures 316, 328. Plasterboard 332 can then be used to visually hide such fasteners.

The first and second nogging apertures 412, 416 may be of any shape. However, the applicant has found that providing a reasonable size aperture facilitates easier insertion of the partitioning noggings 402.

Tek screws, or similar fasteners as already described, may be used to connect the partition connecting stud 406 and/or partition channel stud 404 by way of securing apertures 414, 418.

Connecting studs 16 and partition connecting studs 406 may be omitted. Omission of these components is particularly suited to small wall sections where there is no need for an intervening stud.

The cap plate 508 may be used to position and secure any number of rafters 506. Furthermore, a variant on the cap plate 508 may be used to facilitate securing and positioning of creeper rafters. [00170] It should be further appreciated by the person skilled in the art that the invention is not limited to the embodiments described above. Additions or modifications described, where not mutually exclusive, can be combined to form yet further embodiments that are considered to be within the scope of the present invention.

Claims

WE CLAIM

1 . An integrated modular metal frame building system comprising: a key plate taken from a set of key plates, the key plate having at least a pair of tabs protruding therefrom;

a structural member taken from a set of structural members, the structural member having at least a pair of apertures provided therein for receiving a tab of the key plate; and

a locking peg having at least a pair of retaining arms arranged in parallel to each other, each retaining arm having a slight tapered edge,

where each tab has an aperture provided therein and when the tabs of the key plate are received within the apertures of the structural member and the retaining arms are received within the apertures of the tabs, the slight tapered edges of the retaining arms create a tensioned connection between the key plate and the structural member

2. An integrated modular metal frame building system according to claim 1 , where the tapered edge has a plurality of teeth provided there along, the plurality of teeth operable to prevent disengagement of the locking peg from the key plate.

3. An integrated modular metal frame building system according to claim 1 or claim 2, where the locking peg further includes a positioning tab for facilitating positioning and receipt of the retaining arms within the apertures of the tabs.

4. An integrated modular metal frame building system according to any preceding claim, where a first structural member taken from the set of structural members has at least a pair of tabs protruding therefrom, at least one of the pair of tabs operable to be received within one of the pair of apertures of a second structural member taken from the set of structural members, and, when so received, a tensioned connection is formed between the first and second structural members by the receipt within the apertures of a retaining arm in the apertures of the second structural member.

5. An integrated modular metal frame building system according to claim 4, where the structural member has a pair of structural member apertures for receiving the tabs of the first structural member and where the at least one pair of apertures provided in the structural member for receiving a tab of the key plate is offset relative to the pair of structural member apertures

6. An integrated modular metal frame building system according to any preceding claim, where a structural member taken from the set of structural members to be used vertically within a structure incorporates utility apertures to facilitate the routing of utility services.

7. An integrated modular metal frame building system according to any preceding claim, where a third structural member taken from the set of structural members used as a base plate has at least one securing aperture to facilitate fastening of the third structural member to a slab.

8. An integrated modular metal frame building system according to any preceding claim, where the key plate has two slot arms arranged in parallel to form a "H" shape.

9. An integrated modular metal frame building system according to any preceding claim, where the key plate is a corner key plate, the corner key plate comprising a first pair of tabs and a second pair of tabs, the first pair of tabs being arranged at an angle relative to the second pair of tabs.

10. An integrated modular metal frame building system according to claim 9, where the corner key plate comprises a first segment and a second segment, each segment having a face edge and a connecting edge and one of the pair of tabs provided for proximate the connecting edge and where each segment is adapted to overlap and be securely connected to the other segment so that the first pair of tabs is angled relative to the second pair of tabs.

1 1 . An integrated modular metal frame building system according to claim 9 or claim 10, where the first pair of tabs is angled relative to the second pair of tabs at one of the following angles: 30°, 45°, 60°, 90°, 120°, 135°, 150°.

12. An integrated modular metal frame building system according to any preceding claim, where each structural member in the set of structural members has at least one securing aperture provided therein, the securing apertures provided at points of potential connection to other structural members and where each securing aperture assists in facilitating fastening of the structural members to each other.

13. An integrated modular metal frame building system according to any preceding claim, where each structural member in the set of structural members used at the periphery incorporates a return flange, the return flanges operable to define a mounting frame for plasterboard.

14. An integrated modular metal fame building system according to any preceding claim, where the set of structural members includes a door connector, the door connector operable to be retained to a door frame.

15. An integrated modular metal frame building system according to claim 14 as dependent on claim 13, where the return flange is defined by the retention of the door connector to the door frame.

16. An integrated modular metal frame building system comprising: a partitioning nogging; and at least two partitioning connecting studs; where each partitioning connecting stud has an aperture provided therein to facilitate continuous threading the partitioning nogging.

17. An integrated modular metal frame building system according to claim 16, further comprising a partitioning channel stud, each partitioning channel stud also having an aperture provided therein, such that when the partitioning channel studs are arranged intermediate the partitioning connecting studs, the apertures align to facilitate continuous threading of the partitioning nogging.

18. An integrated modular metal frame building system according to claim 16 or claim 17, where the partitioning connecting studs and/or partitioning channel studs have securing apertures provided proximate each aperture, each securing aperture operable to facilitate fastening of the partitioning nogging to the partitioning connecting stud and/or the partitioning channel stud.

19. An integrated modular metal frame building system according to any one of claims 16 to 18, further comprising a gusset, the gusset operable to transfer load from the partitioning connecting stud and/or partitioning channel stud to the partitioning nogging.

20. An integrated modular metal frame building system according to claim 19, where a gusset is connects the partitioning nogging to the partitioning connecting stud and/or partitioning channel stud either side of their respective aperture.

21 . An integrated modular metal frame building system according to any one of claims 16 to 20 and claim 4, where the first structural member is a partitioning channel stud and/or partitioning connecting stud.

22. An integrated modular metal frame building system comprising joists, rafters and a cap plate where each rafter is operable to be securely received within a joist and positioned relative to other rafters by way of a cap plate.

23. An integrated modular metal frame building system according to claim 22, where the joists form part of the set of structural members as defined in claim 1 .

24. An integrated modular metal frame building system according to claim 22, where the joists have connecting means for connecting the joist to a structural member from the set of structural members as defined in claim 1 .

25. A structural member for use in an integrated modular metal frame building system, the structural member has at least a pair of apertures provided therein each adapted to receive a tab of a key plate taken from a set of key plates, such that when a tab is received in each aperture of the structural member and a retaining arm of a locking peg is received within an aperture provided in each tab, a slight tapered edge of each retaining arm creates a tensioned connection between the key plate and the structural member.

26. A structural member according to claim 25, the structural member having at least a pair of tabs protruding therefrom, at least one of the pair of tabs operable to be received within one of the pair of apertures of a second structural member and, when so received, a tensioned connection is formed between the structural member and the second structural member by the receipt within the apertures of a retaining arm in apertures of the second structural member.

27. A structural member according to claim 25 or claim 26 having utility apertures provided therein to facilitate routing of utility services when arranged vertically within a structure.

28. A locking peg for use in an integrated modular metal frame building system, the locking peg having a pair of retaining arm having a slightly tapered edge, and where the pair of retaining arms are arranged in parallel to each other, such that when each retaining arm is received within an aperture of a tab of a key plate taken from a set of key plates and each tab is received within an aperture provided in a structural member taken from a set of structural members, the slight tapered edges of the retaining arms create a tensioned connection between the key plate and the structural member.

29. A locking peg according to claim 28, where the tapered edge has a plurality of teeth provided there along, the plurality of teeth operable to prevent disengagement fo the locking peg from the key plate.

30. A locking peg according to claim 28 or claim 29, where the locking peg further includes a positioning tab for facilitating positioning and receipt of the retaining arms within the apertures of the tabs.

31 . A method of creating an integrated modular metal frame for a building comprising the steps of: inserting a key plate taken from a set of key plates into a first structural member taken from a set of structural members, such that at least a pair of first parallel apertures provided in the key plate protrudes therethrough; inserting the key plate into a second structural member taken from a set of structural members, such that at least a pair of second parallel apertures provided in the key plate protrudes therethrough; creating a tensioned connection between the first structural member and the key plate by inserting a slightly tapered edge of a retaining arm of a first locking peg into each of the pair of first parallel apertures; and creating a tensioned connection between the second structural member and the key plate by inserting a slightly tapered edge of a retaining arm of a second locking peg into each of the pair of second parallel apertures.

32. An internal wall having comprising a plurality of structural members arranged to define a mounting frame for plasterboard through a plurality of return flanges.