WO2019006504A1

WO2019006504A1 - A load bearing module and method for constructing an insulated structure

Info

Publication number: WO2019006504A1
Application number: PCT/AU2018/050691
Authority: WO
Inventors: Daniel JUKIC
Original assignee: Pro9 Global Limited
Priority date: 2017-07-05
Filing date: 2018-07-04
Publication date: 2019-01-10
Also published as: AU2018271239A1

Abstract

A load bearing module (100') for use in constructing an insulated structure (10) comprises: a first sheet member (100'A) having first and second sides (100'J, 100'K); a second sheet member (100'B) spaced from the first sheet member (100AA) and having first and second sides (100'J, 100'K); and an insulating portion (100'C) extending at least between the first and second sheet members (100'A,100'B). The load bearing module (100', 100A) includes a plurality of laterally extending load bearing structural members (100'E, 100'F; 100AE) wherein at least one of the load bearing structural members (100'E, 100'F) is connectable by connecting components to a structural member (100BF) of an adjacent building component such as an adjacent further load bearing module (100B).

Description

A LOAD BEARING MODULE AND METHOD FOR CONSTRUCTING AN

INSULATED STRUCTURE

The present invention relates to a load bearing module and method for constructing an insulated structure, which may be a multi-storey structure, including connection of load bearing modules to form an insulated wall section of the structure.

A range of approaches for constructing structures, especially building structures, is known in the art. One such approach involves the connection of panels with various fastening systems following abutment of neighbouring panels. A range of panel designs exist though a failing of a range of patent prior art is the likely unacceptable cost to building companies, especially where the panels have significant weight or require any complexity of components such as connectors or complexity of methods of construction. Construction is a conservative industry and unless sometimes strict cost targets can be met by a construction system, it is unlikely to be adopted.

Other problems of construction are more easily tackled. Some objectives for construction systems may involve avoidance of scaffolding and lifting equipment as well as the need for safety in construction. Construction hazards are well known to the industry and indeed the public.

One panel design involves a so-called dual core panel where a panel comprises first and second outer sheet members disposed apart with an inner sheet member disposed between the pair of outer sheet members. Each of the sheet members has rigidity and structural strength aimed at construction of a durable structure. Between the sheet members are disposed cores of insulating material, such as polyurethane foam, these cores being bonded to the sheet member and typically having some fire retardancy.

A building system using such panels is described in US Patent Publication No. 2009/0205277 and Australian Patent No. 2012201775. Abutting panels are engaged, at top and bottom of a proposed wall section, with respective track members and secured into position using suitable fasteners. The bottom track member may be connected to the slab of a proposed building. Abutting panels may be coupled using side track members, in the form of channels.

Dual core panels have advantages but difficulties have been encountered in cost effective implementation due mostly to cost and weight issues and complexity of interconnection.

Generally, building panels have, despite perceived potential, been found by the Applicant to have deficiencies that require an improved approach to economic building construction.

The present invention has been developed against this background and with an object of developing a cost effective load bearing module and system for constructing structures using such load bearing modules.

With this object in view, the present invention provides a load bearing module for use in constructing an insulated structure, the load bearing module comprising:

a first sheet member having first and second sides;

a second sheet member spaced from the first sheet member and having first and second sides which may correspond with the first and second sides of the first sheet member; and

an insulating portion extending at least between said first and second sheet members wherein said load bearing module includes a plurality of laterally extending load bearing structural members wherein at least one of said load bearing structural members is connectable by connecting components to a structural member of an adjacent building component such as, but not limited to, a further load bearing module, window frame or doorframe. The load bearing module may have sufficient dimensions to form a wall section of substantial length, allowing reduction in the number of load bearing modules that require connection, for example through mechanical fasteners, to form a wall section. Such structural members may also be referred to as studs.

The load bearing module may include at least one load bearing structural member corresponding with the first side of the load bearing module and at least one further load bearing structural member corresponding with the second side of the load bearing module. The first and second sides of the load bearing module may correspond with the first and second sides of the first and second sheet members. However, one or more load bearing structural members may be disposed at any desired orientation at any desired intermediate position between the first and second sides of the load bearing module. The structural members may also, or alternatively, be oriented at a desired angle, say between 0 degrees and perpendicular to a lateral axis of a load bearing module. This provides flexibility in orientation of wall sections so that these may be constructed as required by an architect or building designer. This may enable smoother connection at wall section corners for example.

The load bearing structural members, which represent most of the weight of a desirable load bearing module, may be disposed between the first and second sheet members, or embedded, desirably during an offsite fabrication operation, in insulating portion extension portions extending beyond the laterally extending sides of said first and second sheet members. A structural member may be a beam of any desired section, preferably a C-section, though desirably with closed section at at least one end for enabling connection to other building structural components such as foundation or floor slabs. The plurality of structural members, which may include additional laterally or transversely extending load bearing structural members to those described above, provide the module with required structural rigidity for building construction without adding excessive weight to a load bearing module. Structural members may be provided with an end portion, at one or both ends, conveniently including one or more apertures or other connection means allowing connection to further structural members, such as roof truss members at the top of a wall section. Such connection means, such as aperture(s), may also be used as lifting point(s). Structural members may have end portion(s) of narrower dimension, for example being swaged, to extend through upper track members at the top of a wall section, again facilitating construction tasks such as connection to roof truss elements or members. Such end portion(s) may also be accommodated within a lower track member at the bottom of a wall section.

Transverse structural members, which may be used to assist load bearing module connection, may be particularly useful at locations such as for windows or doors. In such cases, header or footer modules for a window or door may be connected to a structure including load bearing modules as described above with the aid of transverse structural members, preferably a plurality of horizontally disposed transverse structural members. Where a plurality of structural members or studs are used, a pair of structural members extending along the sides (or positioned as described above) can be sufficient dependent on the dimensions of the load bearing modules. Such structural members should be formed of a material durable under construction conditions. Metal, such as steel, is preferred for this structural purpose and connections should be made at the structural members, for example as described below, to avoid damage to the desirably lightweight material, whether timber, MgO, MgSO4 or like material, used for the first and second sheet members which are advantageously not relied on as load bearing members, their light weight and availability rather being desired. Structural members may be connected to, and may lie in abutting relationship with, at least one of the first and second sheet members.

The load bearing structural members may have a laterally extending centre axis offset from a laterally extending centre axis of the load bearing module and extending at least between the first and second sheet members of the load bearing module. The centre axis of one structural member may conveniently be disposed parallel to the centre axis of another structural member.

The load bearing module includes an insulating portion - typically a core - which may accommodate one insulating layer though desirably accommodates a plurality, typically a pair, of spaced apart insulating layers of material such as polyurethane or polyisocyanurate foam of selected density to achieve a lightweight construction, that is substantially below 100 kg/m³ and preferably below 50 kg/m³. Core weight is to be reduced as far as possible while desirably providing the required insulation for a typically permanent structure. The load bearing modules should consequently avoid direct connection of the insulating portions of adjacent building modules rather relying on connection through load bearing structural members to provide the required load bearing capacity and structural rigidity and durability. The insulating layers should not be separated by a rigid load bearing sheet but most advantageously an air gap which improves both acoustic and thermal insulation properties without introducing weight to the load bearing module.

The, desirably lightweight, sheet members may be connected to the load bearing structural members in a range of ways. However, a particularly desirable way, aimed at minimising need for mechanical fasteners which can reduce load bearing module durability, involves reinforcing members located within, for example embedded within, sheet member material during manufacture. The reinforcing members, for example in the form of wire loops which accommodate and engage the structural members. Such a construction reduces the risk of sheet members coming apart from the load bearing modules or separating, for example by delaminating, from a layer of the insulating portion.

Weight is desirably reduced as much as possible consistent with the need to construct an insulated wall section fit for purpose through structural rigidity and load bearing capacity typically for a permanent structure. In such cases, especially when applied to larger load bearing modules, the plurality of structural members of the load bearing module each desirably has a centre axis coincident with the centre axis of the load bearing module.

The load bearing module includes a number of features enabling connection of adjacent load bearing modules together through the structural members to form an insulated wall section whether a linear wall section or a corner wall section. Preferably, load bearing modules are provided with connecting components to enable connection to, for example, adjacent load bearing modules at least through connection of a structural member of one load bearing module with the structural member of an adjacent load bearing module or building component as exemplified above. Connections should not be made at the sheet material which, desirably being a lightweight material, typically has a tendency to fail at points of connection with mechanical fasteners. The present load bearing modules may also include connection components as described below.

First, a structural member of one load bearing may be connected to a structural member of an adjacent load bearing module using suitable complementary connection components such as threaded fasteners and bolts. Some such connection components may advantageously be integrally formed with the structural members of a load bearing module during fabrication to further facilitate on site construction.

Second, and in a preferred embodiment of the first, the connecting components desirably include complementary connecting components which connect adjacent load bearing modules through corresponding structural members while leaving a space between them. The distance between the edges should be a small distance, for example on the order of millimetres, sufficient to allow for expansion/contraction of adjacent connected load bearing modules due to temperature variation and minimise risk of sheet members cracking due to interference between load bearing modules and other forces acting on the wall. The space is available for filling with a resilient sealant which should also have fire retardancy. The Applicant has found that it is undesirable to connect load bearing modules which have abutted edge portions as this induces stresses that can lead to cracking of the sheet members. Cracking is an undesirable consequence of construction providing poor aesthetic quality and implying structural defects exist. In addition, such stresses may be encountered to greater extent in earthquake prone regions. The load bearing members here described will assist in addressing such issues.

Conveniently, a structural member of a load bearing module as described above may be provided along its length with a plurality of studs intended to mate with corresponding apertures arranged in spaced apart relationship along the length of a structural member of an adjacent load bearing module as described above. Load bearing modules may be equipped only with studs or only with apertures. Frusto-conically shaped studs are conveniently adapted to engage with apertures which have a wide portion to enable accommodation of the studs but which transition to a narrow portion in which the studs become fixed into position by interference fit on completion of connection of structural members of adjacent load bearing modules leaving the space referred to above. The studs are dimensioned to leave the above mentioned space sufficient to allow for expansion/contraction. The invention provides a set of load bearing module comprising a pair of load bearing modules, each load bearing module including a structural member comprising:

(a) a first structural member forming part of one load bearing module of the pair and provided with a plurality of studs, optionally of frusto-conical shape, disposed along a length of the first structural member; and

(b) a second structural member forming part of the second load bearing module of the pair and provided with a plurality of apertures for accommodating said plurality of the studs wherein co-operation between each frusto-conical stud and a corresponding aperture causes connection of said structural members and said load bearing modules desirably by interference fit. The set of load bearing modules are useful in the construction of insulated structures including in the connection of wall sections and other modular building elements such as in roof elements connected together to form roof trusses. The structural members, as alluded to above, may have end portion(s) connectable with roof truss elements or members with such end portions conveniently protruding through an upper track member for a load bearing module. The end portions may accordingly be made of narrower dimension than a body portion of the structural members, for example by swaging, to facilitate this and/or accommodation within lower and/or upper tracj members. The structural members may also be configured with end portions at both ends to allow end to end rotation so that insertion into either a lower track member or upper track member is possible. Structural members may also be oriented to align connecting components as required for connection of load bearing modules and other adjacent building components, particularly at corners.

A set of load bearing modules could conveniently be provided which, though remaining as described above, have differing relative disposition of the insulating portion and the first and second sheet members facilitating the alignment step of assembly analogously with the 'tongue and groove' principle. So a first load bearing module may have its insulating portion disposed relative to one or both sides of the first and second sheet members to provide a recess into which extension portion(s) of the lightweight insulation portion of an adjacent load bearing module may be accommodated, to align the modules and ease construction. An extension portion is a portion of an insulating layer which extends beyond the first and/or second sheet members on at least one side of, or along, a load bearing module. A load bearing module could also have an extension portion of its insulation portion at one side and a recess at its other side enabling connection, through connection of structural members as above described, to adjacent load bearing modules of complementary design. The 'tongue and groove' option should not replace this requirement. The load bearing module may further have a first sheet member of greater length than its second sheet member, this overlapping portion being available for overlapping a slab or useful for forming a corner. Such features assist initial location of the modules in a desired position for connection with such initial location conveniently being further secured by connecting the load bearing modules to a track member fixed to a selected surface such as a building foundation or floor slab.

The load bearing structural members also conveniently enable connection of a load bearing module to a selected surface such as a building slab or foundation, through a waterproofing layer if necessary, using suitable connection means. The structural member can be connected to the selected surface by engagement with and/or fastening to a track member conveniently of the same shape section as the structural member, for example being in the form of a C section or U Shaped section (i.e a C shaped section facing upward or downward). A track member may have an unequal U shape with one side wall of a track member extending higher than the other side wall of the track member to provide improved support and assist in alignment when installing load bearing modules and wall sections into track members. Track members could be provided at the top and bottom of a load bearing module with upper track member(s) or structural member end portions protruding beyond the upper track members, as above described, being connectable, for example, to roof truss members or elements where required. Again, threaded fasteners and bolts may conveniently be used for fastening. A closed section of the structural member provides a suitable point for such fastening. The load bearing modules, as above described, may conveniently be used in a method for constructing an insulated structure comprising:

providing a plurality of load bearing modules as above described; and connecting the plurality of load bearing modules together by connecting at least one of said structural members of one load bearing module to a structural member of an adjacent load bearing module to a structural member of an adjacent building component such as, but not limited to, a further load bearing module, window frame or doorframe. Each load bearing module may have sufficient dimensions to form a wall section of substantial length, allowing reduction in the number of load bearing modules that require connection, for example through mechanical fasteners, to form a wall section. Such structural members may also be referred to as studs.

Each load bearing module may include at least one load bearing structural member corresponding with the first side of the load bearing module and at least one further load bearing structural member corresponding with the second side of the load bearing module. However, one or more load bearing structural members may be disposed at any intermediate position between the first and second sides of the sheet members which correspond with the sides of the load bearing module. The structural members may also, or alternatively, be disposed at a convenient angle, say between 0 degrees and perpendicular to a lateral centre axis of a load bearing module. This provides flexibility in orientation of wall sections so that these may be constructed as required by an architect or building designer. Length of sides of adjacent load bearing modules may be the same or different. The method of connecting the adjacent load bearing modules remains the same in principle.

The plurality of load bearing modules may be aligned through a step of accommodating an extension portion of the desirably lightweight insulation portion extending beyond the sheet members at at least one side of a load bearing module within a recess formed between first and second sheet members of an adjacent load bearing module. Such recess may be at one side of the load bearing module or at a desired location along its length. The recess may be oriented at a desired angle between 0 and 90 degrees to a lateral centre axis of the adjacent load bearing module. Connection is then made between corresponding structural members of the load bearing modules.

The method of connecting the plurality of load bearing modules further advantageously includes connection of structural members by complementary connecting components which leave a space between edges of the adjacent sheet members for reasons provided above. The complementary components may include a plurality of studs for one load bearing module and a plurality of corresponding apertures, each being respectively arranged along the length of a structural member of an adjacent load bearing module. As described above frusto-conically shaped studs are conveniently adapted to engage with apertures which have a wide portion to enable accommodation of the studs to a selected depth suitable for forming the space referred to above but which transition to a narrow portion in which the studs become fixed into position on completion of connection of adjacent load bearing modules for example by lifting or pressing into position. Apertures may be oriented to enable connection by lifting, pressing or both. In the latter case, a convenient aperture shape is dog bone shape which can reduce fabrication cost as the same aperture design allows for either lifting or pressing into position.

The method desirably involves connecting of a load bearing module to a selected surface such as a building slab or foundation, through a waterproofing layer if necessary, using suitable connection means, for example a track member in the form of a channel. The structural member can be connected to the selected surface by engagement with and/or fastening to a track member as described above. Track members could be provided at the top and bottom of a load bearing module, with end portions, conveniently of narrowed dimension relative to the body of structural members, of load bearing module lateral structural members accommodated in track members and/or protruding from upper track members for connection to roof truss elements for example. Again, threaded fasteners and bolts may conveniently be used for fastening. A closed section of the structural member provides a suitable point for such fastening.

At other locations, such as at wall corners, adjacent load bearing module may be abutted at a required angle and connected through connection of their structural members by suitable complementary connecting components such as threaded fasteners and bolts. Load bearing modules may also be connected at corners by complementary connecting components, such as those described above, which connect adjacent load bearing modules through corresponding structural members while leaving a space, desirably of fixed distance, between the two load bearing modules.

The method may include assembling load bearing modules with a tolerance or end float allowing for inaccuracies, particularly those arising from construction of the building slab or foundation. One or more packers may be deployed to provide an end float relatively small in comparison with the dimensions of a load bearing module.

A range of buildings, including multi-storey buildings, may be constructed with insulation using the load bearing modules and method as above described. One embodiment of a method for constructing multi-storey buildings with an insulated wall section comprises:

connecting a first plurality of load bearing modules as above described by connecting at least one structural member of one load bearing module with the structural member of an adjacent load bearing module to form a first insulated wall section of a lower storey of a building;

constructing formwork to lie flush with an upper surface of the lower storey; pouring concrete onto the formwork to form, upon setting, a suspended floor slab wherein a peripheral edge of the slab is supported above said first wall section; and

coupling a second plurality of further insulating modules as above described to the suspended slab to construct a second insulated wall section of a second storey.

For multi-storey construction, the assemblies and methods described in the Applicant's co-pending International Application No. PCT/AU2018/050652 filed 27 June 2018 under Attorney Docket P42405PCAU, the contents of which are hereby incorporated herein by reference may be used.

The method may involve use of a system as described in the Applicant's co-pending International Patent Application Publication No. WO2018/081874, the contents of which are hereby incorporated herein by reference. In this case, the system is employed to assist in the connection of load bearing modules as above described.

The load bearing module and methods of constructing insulated structures using such panels is expected to be cost effective while enabling good thermal and acoustic insulation properties and avoiding use of scaffolding and heavy lifting equipment during construction. Wall sections can also be constructed in a convenient and safe manner.

The load bearing module and method for constructing an insulated structure using the load bearing module will be further understood from the following description of preferred embodiments thereof in which:

Fig. 1 is an orthogonal schematic view of a wall section of a building constructed using the load bearing modules and method of construction of an insulated structure in accordance with one embodiment of the present invention.

Fig. 2 is a detailed orthogonal schematic view of the wall section of Fig. 1 .

Figs. 3A(a) to (h) show top section views of a range of load bearing modules corresponding to the first embodiment of the present invention and the load bearing modules of Fig. 3A(b) and 3A(d) being included in the wall section shown in Figs. 1 and 2.

Figs 3B(a) to (h) show top section views of a range of load bearing modules corresponding to the first embodiment of the present invention and the load bearing modules of Fig. 3B(b) and 3B(d) being included in the wall section shown in Figs. 9 to 17.

Figs. 3C(a) and (b) show top section views of load bearing modules corresponding to a further embodiment of the present invention.

Fig. 3C(c) shows a top section view of a wall constructed using load bearing modules corresponding to a still further embodiment of the present invention.

Fig. 4 is a top section view of the wall section shown in Figs. 1 and 2.

Fig. 5 is detail 2 from Fig. 4.

Fig. 6 is detail 3 from Fig. 4 showing a corner of the wall section. Fig. 7 is a side section view of complementary connecting components including stud and aperture for connecting two adjacent load bearing modules as shown in Fig. 3 and used to construct the wall section of Figs. 1 and 2.

Fig. 8A is a side schematic view of a structural member of one load bearing module as shown in Fig. 3 and used to construct the wall section of Figs. 1 and 2 showing further detail of the aperture of the complementary connecting components shown in Fig. 7.

Fig. 8B is an orthogonal view showing two load bearing modules of Figs. 7 and 8A to be joined with stud and aperture located for fitting after pressing into position.

Fig. 8C is an orthogonal view showing the two load bearing modules of Figs. 7 to 8B when stud is interference fitted into aperture.

Fig. 8D shows a plan view of another wall section constructed in the manner shown in Figs. 7 to 8C.

Fig. 8E is a plan schematic view of connection of two load bearing modules using a stud, packer and aperture according to second embodiment of connection.

Fig. 8F is a side schematic view showing the connection of two load bearing modules as also shown in Fig. 8E.

Fig. 8GA is a detail front view of the connection taken along line GA of Fig.

8E.

Fig. 8GB is a detail rear view of the connection taken along line GB of Fig.

8GA.

Fig. 8H is a side schematic section view showing connection of a load bearing module to a building slab with a stud and aperture with, in a third embodiment of connection, reverse orientation to that schematically shown in Figs. 7 to 8GB.

Fig. 8I is a plan schematic view of connection of two load bearing modules using a stud, packer and aperture according to a fourth embodiment of connection.

Fig. 8J is a side schematic view showing the connection of two load bearing modules as also shown in Fig. 8E. Fig. 8K is a detail front view of the connection taken along line K of Fig. 8I.

Fig. 8L is a detail rear view of the connection taken along line L of Fig. 8K.

Fig. 8M is a side schematic section view showing connection of a load bearing module to a building slab with a stud and aperture with the fourth embodiment of connection as schematically shown in Figs. 8I to 8L.

Fig. 9 is an orthogonal schematic view of a wall section of a building constructed using the load bearing modules and method of construction of an insulated structure in accordance with a further embodiment of the present invention.

Fig. 10 is a detailed orthogonal schematic view of the wall section of Fig. 9.

Fig. 1 1 is a top section view of the wall section shown in Figs. 9 and 10. Fig. 12 is detail 2 from Fig. 10.

Fig. 13 is detail 3 from Fig. 10 showing a corner of the wall section.

Fig. 14 is a top section view of a wall section constructed in accordance with a further embodiment of the method of constructing a structure in accordance with the invention and using load bearing modules of the type shown in Figs. 3A and 3B.

Fig. 15 is detail 2 from Fig. 14 showing a first corner of the wall section.

Fig. 16 is detail 3 from Fig. 14.

Fig. 17 is detail 3 from Fig. 14 showing a further corner of the wall section.

Fig. 18 is a side schematic section view showing connection of a load bearing module of the type shown in Fig. 3A to a building slab.

Fig. 19 is a side schematic section view showing connection of a load bearing module of a type similar to that shown in Fig. 3A to a building slab.

Fig. 20 is a side schematic section view showing connection of load bearing modules of the type shown in Fig. 3B to a building slab during a method of construction of a multi-storey building in accordance with a further embodiment of the present invention.

Fig. 21 is a side schematic section view showing connection of load bearing modules of the type shown in Fig. 3B to a building slab during a method of construction of a multi-storey building in accordance with a further embodiment of the present invention. Fig. 22 is a side schematic section view showing connection of load bearing modules of the type shown in Fig. 3B though with a modification to that shown in Fig. 21 to a building slab during a method of construction of a multistorey building in accordance with a further embodiment of the present invention.

Figs. 23A to 23C schematically indicate how load bearing module structural members may be connected at a range of corners.

Fig. 23D is a plan view of a further embodiment of structural member suitable for connection at a corner.

Fig. 23E is a side view of the structural member of Fig. 23D.

Fig. 23F is a detail D showing a connecting aperture enabling connection of the structural member of Figs. 23D and 23E to a further structural member.

Fig. 23G is a detail G of an end portion of narrowed dimension of the structural member of Figs. 23D to Fig. 23F.

Fig. 23H shows a detail of an end portion of the structural member with means for connection to a roof truss member or element, also acting as a lifting point.

Fig. 23I is a side section along section line E-E of Fig. 23E.

Fig. 23J is a first isometric view showing accommodation of the structural member of Figs. 23D to Fig. 23I, connected to a further structural member, within upper track members for an internal wall corner.

Fig. 23K is a second isometric view showing accommodation of the structural member of Figs. 23D to Fig. 23I, connected to a further structural member, within upper track members for an wall corner.

Fig. 23L is a view showing an external corner with structural element(s), as shown in Figs. 23D to 23K, having end portions accommodated in lower track members.

Fig. 24 is a plan view of a section of a wall showing a range of connections between load bearing module structural members including at corners and above a window.

Fig. 25A is a plan view of a wall section indicating connection of load bearing modules above a window.

Fig. 25B is a front view of the wall section of Fig. 25A. Fig. 26A is a plan view of a wall section comprised of building panels according to a third embodiment of the present invention.

Fig. 26B is a plan detail view at A of Fig. 26A.

Fig. 27 shows a schematic diagram of a transporter suitable for transporting first and second load bearing modules as shown elsewhere in the Figures.

Referring first to Figs. 1 and 2, there is shown a wall section 10 for a building formed by connecting a plurality of insulation carrying load bearing modules 100A, 100B, 100C, 100D, 100E and 100F ("100A-F") together. Each of the load bearing modules 100A-F is connected to its adjacent load bearing module by complementary connecting components as will be described below with reference to Figs. 7 and 8. In particular, load bearing module 100A is connected to load bearing modules 100B and 100C. Load bearing module 100C is connected to load bearing module 100D which is connected to load bearing module 100E. Load bearing module 100E is, in turn, connected to load bearing module 100F. Each of the load bearing modules is connected using the same method.

Wall section 10 is constructed using a set made up of a plurality of insulation carrying load bearing modules of the type as shown in Fig. 3A. A set of such load bearing modules 100', 100A and 100B and so on can be delivered to a construction site for construction of a wall section such as wall section 10.

Load bearing modules 100' are formed with a first sheet member 100Ά and a second sheet member 100'B, spaced from first sheet member 100Ά, each sheet member 100Ά, 100'B having corresponding first side 100'J and corresponding second side 100'K. The first and second sheet members 100Ά and 100'B are formed of a lightweight material such as MgO and are so not intended to bear significant structural loads. Other materials that could be used, without limitation, are fibre cement board, plasterboard, wood and wood substitutes, treated metal, polymers and polymer composites. Sheet members 100Ά and 100'B need not be made of the same material. Reference to Figs. 1 and 2 shows that side 100xA is an outer side of the wall section 10 and side 100xB is an inner side of the wall section 10 where x is a shorthand for load bearing modules 100A-F. The first sheet member 100xA may, for example, therefore be required to be made of a weatherproof corrosion resistant material. Inner sheet member 100xB, not having the same demands placed on it, may not be required to be made of the same material. The selection will depend on cost considerations.

An insulating portion 100'C extends at least between said first and second sheet members 100Ά and 100'B and may have an extension portion 100'D extending beyond first and second sheet members 100Ά and 100'B. The insulating portion 100'C is formed from a suitable insulating material, preferably a rigid thermosetting polymer such as polyurethane (PU) foam or polyisocyanurate (PIR) foam. Expanded polystyrene foam could also be used. A convenient density for PU foam is 45 kg/m³. Such foams are to be formulated with good fire retardant properties in accordance with applicable standards for buildings. The insulating portion 100'C may be adhered or bonded together by any suitable technique. Thickness of a load bearing module including first and second sheet members 100Ά, 100'B and insulating portion 100'C may be as desired though for the illustrated construction would be 70 to 100mm, say 85mm.

At first side 100'J of each load bearing module 100' is laterally extending and load bearing structural member 100'F which is embedded in the insulating layer 100'C during fabrication of the load bearing module 100' (and the others described herein). At second side 100'K of each load bearing module 100' is laterally extending load bearing structural member 100Έ which is likewise embedded in insulating layer 100'C as a result of the fabrication process conveniently involving moulding. Load bearing structural members 100Έ and 100'F provide each load bearing module 100' with required structural rigidity without adding excessive weight. To that end, structural members 100Έ and 100'F are formed with a suitable structural section, here C-section, of a load bearing material durable under construction conditions. Metal, such as structural steel, has been employed here.

Structural members 100Έ and 100'F may be connected to, and may lie in abutting relationship with, at least one of the first and second sheet members 100Ά and 100'B as shown in Figs. 3A(a),(b),(c), (d), (e), (f) and (h). Structural members 100Έ and 100'F each have a laterally extending centre axis offset from the laterally extending centre axis of a load bearing module 100' and extending at least between the first and second sheet members 100Ά and 100'B of the load bearing modules 100' though further for load bearing modules 100' with extension portions 100'D. The load bearing structural members 100Έ and 100'F are disposed symmetrically with the centre axis of structural member 100Έ being disposed parallel to the centre axis of structural member 100'F.

As shown, the pair of laterally extending load bearing structural members 100Έ and 100'F extend the whole length of the respective first and second sides 100'J and 100'K of load bearing modules 100'. However, load bearing structural members 100Έ and 100'F need not extend the whole length of the first and second sides 100'J and 100'K and a greater number of structural members could perhaps be provided. Furthermore, the sides 100'J and 100'K could have different lengths. For example, as shown in Fig. 2, a window 170 extends between load bearing modules 100C and 100E. The sides 100DJ and 100DK of load bearing module 100D have the same length but the sides 100CJ and 100CK have different length. Load bearing module 100G located below window 170 has first sheet member 100GA of longer length than second sheet member 100GB, the overlap portion 100GL assisting with connection of load bearing module 100G to slab 160.

Each of load bearing modules 100A-100F of Fig. 2 has the same construction as described above and as shown by the second letter of each of the reference numerals for load bearing modules. Fig. 3A(b) shows load bearing module 100A and Fig. 3A(d) shows load bearing module 100B which have load bearing structural members 100AE, 100AF, 100BE and 100BF respectively.

Structural members 100Έ and 100'F (100AE,100AF,100BE,100BF) are either disposed between the first and second sheet members 100Ά and 100'B for the load bearing modules 100', 100A, 100B or embedded in insulating portion extension portions 100'D (100AD, 100BD) extending beyond the sides of said first and second sheet members 100'J and 100'K. Examples of structural members being embedded in extension portions 100'D, 100BD at one end of a load bearing modulel OO' or 100B are shown in Fig. 3A(c),(d), (e) and (f). Two such extension portions 100'D are shown in the load bearing module 100' of Fig. 3A(g). Alternatively, insulation carrying load bearing modules 100' may have insulating portions 100'C disposed relative to one or both sides 100'J, 100'K of the first and second sheet members 100Ά, 100'B to provide recess(es) 100'G. Examples of load bearing modules 100' of such construction are shown in Fig. 3A(a),(b),(c) and (d). A load bearing module 100' with a recess 100'G formed at each end is shown in Fig. 3A(h). Finally, a load bearing module 100' may be provided which has an insulating portion 100'C terminating flush with one side 100'J as shown in Fig. 3A(b) or another side 100'K as shown in Fig. 3A(e). The insulating portion 100'C could also terminate flush with both ends 100'J and 100'K (not shown). These features assist connection of adjacent load bearing modules 100' and 100A-F to form insulated wall section 10 as described below.

The provision of insulation portion extension portions 100'D and corresponding recesses 100'G allow adjacent load bearing modules to be connected together, with a neat fit, analogously with the 'tongue and groove' principle. Put simply, the extension portion 100'D of one load bearing module 100' may be located within a corresponding recess 100'G of its adjacent load bearing module 100' to form a portion of wall section 10. Such connection requires to be made secure by connecting components as described below but this design feature greatly facilitates construction.

Structural members 100Έ, 100AE and 100'F, 100AF are provided with connecting components for connecting a load bearing module, say 100A, to a first adjacent load bearing module 100B and its second adjacent load bearing module 100C. Connection at the load bearing structural members 100 is done purposefully to avoid damage to the desirably lightweight material used for the first and second sheet members 100AA and 100AB which are not relied on as load bearing members. A range of connecting components could be used for this purpose with a basic requirement being that the connecting components are complementary. That is, the connecting components for example on load bearing structural member 100AE co-operate with complementary connecting components located for example on structural member 100BF. A plurality of such complementary connecting components such as described below are spaced apart along the lengths of structural members 100AE and 100BF.

Highly preferred complementary connecting components, as shown in Figs. 7 to 8M, connect adjacent load bearing modules 100A to 100B through corresponding load bearing structural members 100AE and 100BF while leaving a space 80 between them. The distance between the load bearing structural members 100AE and 100BF is a small distance, here about 2 mm, sufficient to allow for some expansion/contraction of adjacent connected load bearing members 100A and 100B due to temperature variation and minimise risk of sheet members cracking due to interference between load bearing modules and other forces acting on the wall section 10. The space 80 is available for filling with a resilient sealant. The Applicant has found that it is undesirable to connect load bearing modules which have abutted edge portions as this induces stresses that can often lead to cracking of the sheet members. Cracking is an undesirable consequence of construction providing poor aesthetic quality and implying structural defects exist. In addition, such stresses may be encountered to greater extent in earthquake prone regions. The load bearing modules 100', 100A and 100B as here described will assist in addressing such issues.

More specifically, and with reference to load bearing modules 100A and 100B for purposes of illustration, load bearing structural member 100AE of load bearing module 100A is provided spaced apart along its length with a plurality of frusto-conically shaped studs 70. Studs 70 are connected to structural member 100AE by bolts 85 which are spring loaded by spring 87. Such connection is desirably done at the factory and not on site, this saving time and cost.

Studs 70 mate with corresponding apertures 90 arranged in spaced apart relationship along the length of a structural member 100BF of adjacent load bearing module 100B while leaving the space 80 between structural members 100AE and 100BF as referred to above. Apertures 90 have a wide portion 91 to ease accommodation of the studs 70 as load bearing modules 100A and 100B are located as described above (and as shown in Fig. 8B) but which transition to a narrow portion 92 in which the studs 70 become fixed into position by interference fitting on completion of connection of the adjacent load bearing modules 100A and 100B through structural members 100AE and 100BF as described below (and as shown in Fig. 8C). Similar connection principles apply to connection of other load bearing modules 100' when connected to form an insulated wall section. A plan view of load bearing modules 101 and 102 connected in the above described manner is shown in Fig. 8D. The load bearing modules 101 and 102 can be connected by pressing them into position such that the studs and apertures 70, 90 engage to fix the load bearing modules 101 and 102 into position. The connection is intended to be permanent, for the life of the building.

Figs. 8E to 8GB show the same form of connection as described with reference to Figs. 8A to 8D but with the addition of a plate packer 88 with thickness 2mm to provide the same spacing between the load bearing structural members 100AE and 100BF to allow for expansion and contraction in the manner above described.

Fig. 8H shows connection of a load bearing module 1900, with MgO sheet members 1900A and 1900B, to a concrete slab 160 through a channel shaped track member 1965 connected to concrete slab 160 using bolts 1950. Structural member 1900BF is connected to track member 1965 using a number of fasteners such as self drilling metal screws 1970, one screw 1970 and integral nut 1971 of which is shown. A stud/aperture connection arrangement is again used - including with a 2mm thickness packer 88 - but, in this embodiment, apertures 90 are reversed in orientation to have a narrow portion 92A at the top and a wide portion 91 A at the bottom. Alternatively, a dogbone shaped aperture 90 - as described below - could be used, this being convenient as it allows connection from either direction, i.e pushing, pressing or lifting. In this case, load bearing module1900 can be connected with adjacent load bearing modules through lifting into position. Connection is also made between load bearing module 1900 and track member 1965 as above described.

Figs. 8I to 8M show a still further embodiment of stud/aperture connection - similar to those embodiments described above but in this case allowing either lifting, pushing or pressing of adjacent load bearing modules into connection with load bearing module 3100 (having first and second lightweight MgO sheet members 3100A and 3100B) using a dog bone shaped aperture 3090 having wide portions 3091 A and 3091 B and narrow portion 3092 into which stud 70 can be interference fitted, again with the assistance of a 2mm thickness packer 88 to allow flexibility for construction tolerances.

As with load bearing module 1900, load bearing module 3000 is connected to a concrete slab 160 through a channel shaped track member 3220 connected to concrete slab 160 using bolts 3050. Load bearing structural member 3100BF is connected to track member 3220 using a number of fasteners such as self drilling metal screws 3070, one screw 3070 and integral nut 3071 of which is shown. Load bearing structural members 100Έ, 100AE, 100'F, 100BF and so on also enable connection of the plurality of load bearing modules 100', 100A, 100B to a selected surface, such as building slab 160 or foundation, through a waterproofing layer if necessary, using suitable fasteners, desirably using a track member 1 12 into which the load bearing structural members 100Έ, 100AE, 100'F, 100BF and so on are located and then fastened into position by bolts 1 12. First and second MgO sheet members 100AA, 100AB, 100BA are counter-bored at their bases to allow the bolts 1 10 to be secured through the structural members 100AE and 100BF. More description of connection of load bearing modules to slabs and channel members is provided below with reference to Figs. 18 to 22.

It will be noted that load bearing module 100G, as partly described above, has a different orientation to the other load bearing modules 100A-F of Figs. 1 and 2. Structural members 100GE and GF are oriented horizontally rather than vertically to support window 170.

Referring now to Fig. 3B, there are shown load bearing modules 200' with similar features to those described above and so the same reference letters are used to indicate the same features including structural members E and F, recesses G. However, there are some differences. Load bearing modules 200' include an insulating portion made up of a pair of spaced apart insulating layers 200'C, 200'C of the same sorts of insulating material as described above, for example PU, PIR or EPS of selected density. Such load bearing modules 200' and so on can be constructed to have good thermal and acoustic insulation properties with a target high efficiency rating for buildings constructed with them. Insulating layers 200'C and 200'C are separated by an air gap 200Ή which improves insulation properties without introducing weight to the load bearing modules 200'. The thickness of load bearing modules 200' is above about 150mm, say 215mm. Weight is desirably reduced as much as possible consistent with the need to construct a load bearing insulated wall section fit for purpose. The weight disadvantages typical of concrete based materials are thus avoided. With greater thickness and load bearing requirements than load bearing modules 100', the load bearing structural members 200Έ and 200'F - though again C- section beams - have greater channel width with the structural members 200Έ, 200'F having a centre axis coincident with the centre axis of the load bearing module 200' which extends along the air gap 200Ή.

Referring to Figs. 3C(a) and (b), there are shown load bearing modules 200' with similar features to the load bearing modules described above. However, one or more load bearing structural member(s), here 200'K, for interconnection to other load bearing modules can be disposed at a desired intermediate position between the first and second sides of the sheet members 200Ά and 200'B which correspond to the first and second sides 200'L and 200'M of the load bearing module 200'X as shown in Fig 3C(a). In Fig. 3C(a), load bearing modules 200'X and 200Ύ are connected through structural members 200'K and 200Ύ respectively. Fig. 3C(b) shows how structural members 200Έ and 200'F can be oriented perpendicularly to air gap 200Ή of load bearing module 200'Z. Connection between the structural members 200'F and 200'K is made in the same manner as described above.

Referring to Fig. 3C(c), there is shown a wall section 10 made up of three load bearing modules 200', 200'X and 200Ύ. Structural member 200ΈΧ of load bearing module 200'X is oriented along an axis corresponding with lateral axis M of load bearing module 200Ύ at an angle of 45 degrees to lateral axis L of load bearing module 200'X. Structural member 200'FY of load bearing module 200Ύ is oriented along an axis corresponding with lateral axis N of load bearing module 200'Z. Lateral axis N extends perpendicular to lateral axis M of load bearing module 200Ύ. Connection between the structural members 200Έ, 200'FY; 200'D and 200ΈΧ and so the load bearing modules 200'X, 200Ύ and 200'Z is made in the same manner as described above. The method is particularly advantageous for smoother cornering.

The orientation of the structural members 200Έ, 200'F, 200'K, 200ΈΧ and 200'FY of the respective load bearing modules 200'X, 200Ύ and 200'Z is determined for fabrication in a mould. Once the structural members 200Έ and 200'F and 200'K are oriented correctly, polyurethane or polyisocyanurate foam is injected into a mould embedding the structural members in a structurally sound manner.

The structural members may also, or alternatively, be disposed at a convenient angle, say between 0 degrees and perpendicular to a lateral centre axis of a load bearing module. This provides flexibility in orientation of wall sections so that these may be constructed as required by an architect or building designer.

It will be understood that wall sections and structures may be constructed from a combination of load bearing modules 100' and 200'

Referring generally to Figs 4 to 6, further description of the connection of the plurality of load bearing modules 100A-M to form insulated wall section 10 is provided. Load bearing modules 100D, 100G and 100H are not shown in Figs. 4 to 6 as they underlie windows 170 and 171 . Load bearing module 100H will also have the same orientation as load bearing module 100G with structural members extending horizontally.

Fig. 5 shows a detail of the connection of load bearing modules 100A and 100B to form a linear wall section 10A. Load bearing module 100B is connected to track member 1 12 (of steel and itself connected to slab 160 by threaded fastener 1 12A) extending the length of insulated wall section 10A as above described by bolts 1 10. Load bearing module 100A is then located such that its recess 100AG accommodates extension portion 100BD of load bearing module 100B. First and second MgO sheet members 100AA, 100AB overlap extension portion 100BD a distance M. First and second sheet members 100BA and 100BB can also be seen in Fig. 5. Connection of load bearing modules 100A and 100B is then made using the complementary connecting means 70 and 90 as described above with reference to Figs. 7 and 8. In the final step, load bearing module 100A is connected to track member 1 12 by bolts 1 10 and the insulated wall section 10A is then completed with required structural integrity.

Fig. 6 shows the different construction method at a right angle corner C1 of wall section 10. Here, load bearing module 100F with first and second lightweight MgO sheet members 100FA and 100FB and its insulating portion 100FC terminating flush with one side 100FJ has its structural member 100FF connected to track member 1 12 by bolts 1 10.

Load bearing module 100E is then located into position with one side 100EB located flush against portion 100FB of load bearing module 100F. First sheet member 100EA has longer length than second sheet member 100EB, with which insulation portion 100EC terminates flush. The extended portion 100EH of first sheet member 100EA is located flush with side 100FJ of load bearing module 100F. Load bearing module 100E then has its load bearing structural member 100EF connected to track member 1 12 by bolts 1 10. Connection of load bearing modules 100E and 100F to complete the corner C1 is then completed by first connecting extended portion 100EH to load bearing structural member 100FF by bolts 1 1 OA (one being shown), it being noted that an aperture may be pre-formed in structural member 100FF to ease this process; and then connecting structural members 100EF and 100FF together using bolts 1 10B (one being shown). Corner C2 can be formed in the same way.

Referring now to Figs. 9 and 10, there is shown an insulated wall section 20 constructed with a plurality of load bearing modules 200A-D and 100' which have the same design as described above and which are connected to slab 160 through track members as described above. Methods of connection are very similar to those described for load bearing modules 100 and interconnection of load bearing modules 200A and 200B through location of insulation extension portion 200AD in recess 200BG; and alignment of load bearing modules 200A and 200C through location of insulation extension portion 200CD in recess 200AG is shown through Fig. 10. Load bearing module 100' is positioned against extension portion 200BL of load bearing module 200 and connected using the same methods as described above. Referring to Figs. 1 1 to 13, constructional details of an insulated wall section 20' constructed from a plurality of load bearing modules 200A-F and having windows 210, 21 1 and 217 fastened to load bearing modules 200B, 200C and 200E by fastening means 271 are provided. Fig. 12 shows a detail of the connection of load bearing modules 200A and 100B to form a linear insulated wall section 20A. Load bearing module 200B is connected to track member 212 (of steel and itself connected to slab 160 by threaded fasteners 212A) extending the length of insulated wall section 20A as above described by bolts 210 (which have greater length than bolts 1 10 because of the larger module thickness). Load bearing module 200A is then located such that its extension portion 200AD is accommodated within the corresponding recess 200BG of load bearing module 200B. First and second MgO sheet members 200BA, 200BB overlap extension portion 200AD a distance M. First and second sheet members 200BA and 200BB can also be seen in Fig. 12. Connection of load bearing modules 200A and 200B is then made using the complementary connecting means 70 and 90 as described above with reference to Figs. 7 and 8. In the final step, load bearing module 200A is connected to track member 212 by bolts 210 and the linear insulated wall section 20A is then completed with required structural integrity. Bolts 210 may be of any suitable corrosion resistant material, for example zinc coated mild steel. Bolts 210 are sized with reference to the dimensions of the load bearing structural members.

Referring to Fig. 13, there is shown the detail of construction of a right angle corner C4. A similar method is followed to that described above with reference to Fig. 6. Here, load bearing module 200F - effectively a column - with first and second lightweight MgO sheet members 200FA and 200FB and its insulating portion 200FC terminating flush with one side 200FJ has its structural members 200FE and 200FF connected to track member 212 (itself connected to slab 160 by bolts 212A) by bolts 210.

Load bearing module 200E is then located into position with one side 200EB located flush against portion 200FB of load bearing module 200F. First MgO sheet member 200EA has longer length than second MgO sheet member 200EB, with which insulation portion 200EC terminates flush. The extended portion 200EH of first sheet member 200EA is located flush with side 200FJ of load bearing module 200F. Load bearing module 200E then has its structural member 200EF connected to track member 212 by bolts 210. Connection of load bearing modules 200E and 200F to complete the corner C1 is then completed by first connecting extended portion 200EH to load bearing structural member 200FF by bolts (not shown).

Referring now to Figs. 14 to 17 there is shown an insulated wall section 30 constructed from a plurality of load bearing modules 200F, 200G and 200H and load bearing modules 300A and 400A. Load bearing module 300A is of the same type as load bearing modules 100', 100A-F described above. Load bearing module 400A is similar to these load bearing modules as well but has a larger thickness, between 100 and 150mm, say 125mm and its steel load bearing structural members, one of which 400AF is shown, have a C-section of width intermediate that of load bearing modules 100', 100A-F and load bearing modules 200. Centre axis of structural member 100AF remains offset from the centre axis of load bearing module 400A.

As shown in Fig. 15, load bearing module 300A has its load bearing structural member 300AF connected to track member 212 by bolts 310. Load bearing module 200F can then be located into position with its extension portion 200FH lying flush with one side 300AJ. Structural member 200FE of load bearing module 200F can then be fixed to track member 212 (itself connected to slab 160 by bolts 212A) by bolts 210. Bolts 212A have greater dimension than bolts 210. Load bearing module 400A is fixed into position in much the same manner as load bearing module 300A but noting that longer length bolts 410 are required in comparison to bolts 310 given the larger dimension of structural member 400AF in comparison to structural member 300AF.

Load bearing modules 200F to 200H are connected following alignment as described above. Fig. 16 shows alignment through the extension portion 200GD of load bearing module 200G being located into position within recess 200FG formed between the first and second sheet members 200FA and 200FB of load bearing module 200F. Structural members 200FF and 200GE are then connected using the studs 70 and apertures 92 as described above. Load bearing modules 200G and 200H are aligned and connected in the same manner noting that extension portion 200HD would be located into position within recess 200GG formed between the first and second MgO sheet members 200GA and 200GB of load bearing module 200G. The rest of the connection process would proceed as described above.

Referring now to Figs. 18 to 20, more detail is shown of the connection of load bearing modules of varying thickness to foundation slabs. Fig 18 shows the connection of load bearing module 500 (of the same construction as described for load bearing modules 100', 100A-F) to a selected surface in the form of concrete foundation slab 600. First, a track member in the form of a steel channel 620 is connected to slab 600 to extend along one of its sides 610 by bolts 550, one of which is shown, being sufficient for the thickness of load bearing module 500. The load bearing module 500 can then be positioned such that its load bearing structural member 500F is accommodated within channel 620 while portion 500D of its first MgO sheet member 500A is enabled to lie almost flush with slab side 610 but for the waterproofing or flashing layer 630. The load bearing module 500 is then connected by bolts 510 inserted through apertures formed in the second sheet member 500B. The apertures have the same form as described above. Bolts 510 extend through the second MgO sheet member, a portion of the insulation and through the walls of steel channel 620.

Fig. 19 shows connection of load bearing module 1500, similar to load bearing module 400A as described above. The same reference numerals are used but for the prefix "1 ". Here, recognising the greater thickness of load bearing module 1500, two spaced apart bolts 1550 are required to connect the steel channel 1620 to the concrete slab 1600 to provide the required structural strength. Bolts 1510 have greater length than bolts 510 for the same reason.

Fig. 20 shows connection of building panel 2500, the same as load bearing modules 200', 200A-H, as described above. The same reference numerals are used but for the prefix "2". Here, recognising the greater thickness of load bearing module 2500, two spaced apart bolts 2550 are required to connect the steel channel 1620 to the concrete slab 1600 to provide the required structural strength. Bolts 2510 have greater length than bolts 510 and 1510 and bolts 2550 are spaced apart a greater distance than bolts 1550 for the same reason.

Before leaving the construction of insulated wall sections as described above, and noting that inner walls can be constructed in the same manner, it will be appreciated that the wall sections can be connected to other building components such as roof truss members or elements, not shown, and other items such as roofing to complete the structure. To assist such further construction, track members may also be provided at the top of the load bearing modules.

Referring now to Figs. 21 and 22, the load bearing modules and methods of construction can also be applied to construction of multi-storey buildings. For the first storey, a plurality of load bearing modules may be connected to form a first insulated wall section in the above described manner. Then, using appropriate steel formwork 3670, 4670 a suspended concrete slab 3600, 4600 can be poured and set as a base for the second storey. Referring to Fig. 21 , the bottom storey G is constructed using load bearing modules 700 which are of the same construction as load bearing modules 200', 200A-H. Load bearing modules 700 have disposed apart first and second MgO sheet members 700A and 700B with an insulating portion 700C formed from a pair of insulating layers of PU, PIR or EPS foam spaced apart by an air gap 700H.

An upper track member 3640, 4640 is connected to the top of load bearing module 700 so as to accommodate structural member 700F and fixed into position using bolts 3610. Formwork 3670, 4670 is formed flush with upper track members 3640, 4640 and concrete is poured to form, on setting, the suspended slab base for the next storey 1 .

A portion 700D forming part of the first MgO sheet member 700A of building panel 700 overlaps suspended slab 3670. A plurality of load bearing modules 800 to form a second insulated wall section of the further storey 1 , and of the same design as load bearing modules 200', 200A-H, can then be aligned, connected to the concrete suspended slab 3600 using a track member in the form of a steel channel 3620 extending along the side of slab 3600 and interconnected. Channel 3620 is fixed to the suspended slab 3600 by spaced apart bolts 3650. Structural member 800F of load bearing module 800 is engaged with the channel 3620 and connected to the channel 3620 using bolts 3610 inserted through complementary circular apertures formed in MgO second sheet member 800B. First sheet member 800A has a portion 800D that overlaps and lies flush with a periphery of slab 3600 analogously with portion 700D of Load bearing module 700. Plastic flashing 3630 is then provided for the necessary waterproofing.

Referring now to Fig. 22, the construction and method follows much the same lines noting that load bearing modules 700 are replaced with load bearing modules 1000. Load bearing modules 800 are replaced with load bearing modules 1 100. Suspended slab 4600, though formed in the same way using steel formwork 4670, replaces concrete suspended slab 3600. Bolts 3610 are replaced with bolts 1 1 10 and bolts 3650 with bolts 4650. The one difference is that no gap is left between the respective sheet portions of first storey building panels and ground storey building panels as shown for building panels 700 and 800. Rather the first sheet portion 1000D of building panel 1000 is rebated so that portion 1000E of the first sheet member 1 100A of building panel 1 100 overlaps rebated portion 1000D to provide a level surface. Waterproofing compounds to complete a seal may be applied as required.

Referring to Figs. 23A to 23C schematically indicate how load bearing structural members may be connected at a range of corners, both internal and external. Stud/aperture connections, as above described, are also provided at corners C1 , C2 and C3 with connections being made at respective structural member pairs 4750E and 4850E; 4850E and 4860E; and 4780E and 4880E. The connections would be made in the manner described with reference to Figs. 8I to 8M with apertures having a dog bone shape. The shape of the apertures may change, for example from more ellipsoidal to circular as a function of the dimensions of the structural members and correspondent building panels.

Inaccuracies in construction of building slab or foundation can create construction difficulties, particularly at points such as corners C1 to C3. The method therefore includes assembling load bearing modules with a tolerance or end float F allowing for inaccuracies, particularly those arising from construction of the building slab or foundation. To that end, allowances can be made both in sheet member dimensions so that load bearing module 4750 is left with an overhang of material 4750A which can be trimmed away at the end of the construction.

In addition, one or more packers in the form of plates may be deployed, if required, to provide an end float relatively small in comparison with the dimensions of a building panel, for example of +/- 6mm allowing an end float of 12mm. The arrows in Figs. 23A to 23C indicate the end float and construction flexibility available to address any such inaccuracies which may arise for example during slab or foundation construction. The packers also permit the fixed distance spacing of the respective structural member pairs 4750E and 4850E; 4850E and 4860E; and 4780E and 4880E.

Referring to Figs. 23D to 23L, there is schematically shown detail of load bearing module structural members 100" and 120" of C shaped section, structural members 100" and 120" facilitating connection at a corner formed by members 100' and 120". Sheet elements of the load bearing modules are not shown for ease of illustration. Connecting components are again studs, as described above, and dogbone shaped apertures 3090 enabling connection of the structural members 100", 120". As shown in Fig. 23F, the apertures 3091 have wide portions in the form of circular portions 3090A and 3090B separated by a narrow portion 3091 . Such configuration allows lifting or pressing into position of the studs with the narrow portion 3091 and fitting by interference fit, alignment of studs with circular portions 3090A and 3090B in a first step easing the construction process.

Structural members 100" and 120" have a C section with side walls of unequal dimension as illustrated, for structural member 100", in Fig. 23I where side wall 100"Bb has greater width than side wall 100"Bc. Side walls 100"Ba and 100"Bb are joined by web 100"Ba, lending further structural support at the corner.

Each structural member 100" and 120" also has a pair of end portions 100"A, 120A" as shown in Figs. 23E to 23L, each of narrower dimension than the body (and substantially the length of) the structural members 100", 120". End portions 100"A and 120"A may be formed by swaging and this allows a number of options. Structural members 100" and 120" may a) be rotated end to end, as required to ease construction, b) be fitted into either lower track member 620A, 620B (Fig. 23L) or c) fitted into upper track members 101 ", 102" (Figs. 23H, 23J and 23K, Fig. 23J showing an internal corner, Fig. 23K being either an internal or external corner). An end portion 100"A, 120"A may also include an aperture to enable connection to other building components such as roof truss elements and/or to act as a lifting point. One option schematically shown in Fig. 23H involves end portion 100"A being formed to protrude above capping member 101 " and connect, through a fastener connected through aperture 101 "Ab, to a roof truss element. Structural members 100", 120" could have extensions allowing connection to roof truss elements through a stud, aperture arrangement as described above.

Referring further to Fig. 23L, respective end portions 100"A, 120"A of structural members 100", 120" have the same section as lower track members 620A and 620"B (and, incidentally, upper track members 101 " and 102"). Structural members 100", 120" are fitted together through an aperture, stud connection as described above so as to fit within the abutting lower track members 620A, 620B to which they are fixed by fasteners (not shown) in the manner above described. This enables convenient construction of corner C100". Lower track members have a inner side wall 620AB of greater height, and therefore unequal to, the height of outer side wall 620AA. This allows further support.

The building section 5570 of Fig. 24 includes internal wall section 5770A and external wall sections 5770B and 5770C constructed with load bearing modules 5120 having lateral load bearing structural members 5120E and 5120F having regard to the above described principles as regards corners CI, CJ and CE. Some further features will now be described.

First, fireproof joints may be required within a building section, particularly at corners CI, CJ and CE. To this end, suitable voids to accommodate fireproofing material were cast into the insulation portion during manufacture and fireproofing material fitted into the voids during construction. Alternatively, slots can be cut into the insulation portion to enable accommodation of fireproofing material. Conveniently, fireproofing material is provided as sheets 5200 at these corners and secured using an adhesive though the sheets 5200 could also be fitted during manufacture of the load bearing modules. The fireproofing material is a fire and flame retardant material suitable for construction of structures under applicable standards.

Second, wall section 5770B includes a window (not shown). Construction at windows, and also appropriately at doors, is described below with reference to Figs. 24, 25A and 25B. Fig. 24 shows some features of the connection of a header panel 5155 to adjacent load bearing modules 5100 and 51 10, the connection employing two horizontally disposed transverse load bearing structural members in the form of steel pipe sections ("cross rods") 5150 located into position between MgO sheets 5100A, 51 1 OA and 5100B and 51 10B and specifically within the wide dimension portions 3093 of the dog bone shaped apertures 3090 formed within load bearing structural members 5120EA and 5120EB. More than two cross rods 5150 may be provided. These structural members 5120EA and 5120EB are located with their open ends in alignment to form a hollow channel and connected to neighbouring structural member 5120E by the stud/aperture connections described above, if necessary using packers 88 to allow for construction inaccuracies.

Connections between the structural members 5120EA, 5120EB and 5120E and upper and lower track members are made using bolts 5121 in the manner described above. Similarly, connections between structural members 5120E and 5120F and upper and lower track members are made using bolts 5121 in the same manner as described above.

Pipe sections 5150 are here a heavy wall thickness steel pipe, in this case having a 32mm diameter. This dimension is not intended as limiting. The insulating portion 5155C is then filled with insulating material by any suitable method such as injection of an insulating foam, for example a PU foam.

As shown in Figs. 25A and 25B, the window is located and connected below header module 5155 and between load bearing modules 5120', these being connected through the header module 5155 using the pipe sections or cross rods 5150 and their connection with structural members 5120EA and 5120EB. MgO sheet material from the panels 5120' has been trimmed back from the dashed lines 5120J indicated on both sides of the window space W. Structural members 5120EA and 5120EB are connected to upper channel track member 5130 in the previously described manner using bolts 5121 .

Third, and returning to Fig. 24, the role of bolts 85 forming part of stud/aperture connections has been described above. Fig. 24 shows how the length of bolts 85 is selected to enable building panels of different dimensions to be connected together.

Referring to Fig. 27, there is shown a suitable transporter 800 for the load bearing modules such as those described above. The load bearing modules may be of sufficient dimension to form an entire or substantial portion of a wall section. Transporter 800 is of the self propelled modular transporter or trailer (SPMT) type with prime mover not shown but of conventional design for prime movers. Load bearing modules may be located in block 808 above the platform 807 of the transporter 800. A diesel fuelled power pack 804 drives the transporter 800 and, in particular, the wheels and wheel sets 802, a number of which are provided. Control unit 804A (which may be networked with other control systems if used during construction) enables the power pack 804 to control operation of the wheel sets 802 to locate the transporter 800 in a desired location, the transporter 800 being able to move in up to a 360 degree circle if required. Transporter 800 also has self-levelling capability, a useful characteristic where ground surface 890 is uneven. A crane 810 is available for loading and unloading of equipment stored on the transporter 800.

Exemplary specifications for transporter 800 include:

• Ability to carry 350m² of full size 3 metre high, 8 metre width and 125mm thickness load bearing modules as well as other module sizes. Load limit may be 10 to 15 tonnes.

Structures constructed using the load bearing modules and methods of construction described above can be constructed cost effectively without need for scaffolding or heavy lifting equipment. The load bearing module insulation also enables good thermal and acoustic properties to be achieved with the potential for high energy rating buildings. Insulated structures constructed using the load bearing modules and methods of construction described above can be constructed cost effectively without need for scaffolding or heavy lifting equipment. The insulation portion provided within the load bearing modules also enables good thermal and acoustic properties to be achieved with the potential for high energy rating buildings.

Modifications and variations to the load bearing modules and methods for constructing an insulated structure as described herein will be apparent to the skilled reader of this disclosure. Such modifications and variations are deemed within the scope of the present invention.

In one such modification, illustrated in Figs. 26A and 26B, connection between load bearing modules forming an insulated wall section 3005 is still made, in manner as above described, at structural members 3000E and 3000F. In this case, the load bearing modules include reinforcing members, in the form of wire strapping reinforcing members 3001 and 3002. The use of the reinforcing members 3001 and 3002 enables the MgO lightweight sheet members 3000A and 3000B to be connected to load bearing modules without the use of mechanical fixings and so allows for more durable load bearing module construction. A number of spaced apart reinforcing members, in the same form as wire loop reinforcing members 3001 and 3002 are desirably provided to make the required connections. The reinforcing members can be made, for example, from woven fibre mesh, plastic or similar pliable material that is compatible both with the sheet material and the insulating material, i.e PU and MgO in this instance. It is conveniently embedded within at least the sheet material during manufacture. The reinforcing members 3001 and 3002 are provided to minimise risk of sheet members 3000A and 3000B, for example and as here made from MgO board, falling from the modules, separating from the structural members or delaminating from the insulating portion 3000C.

The wire loop reinforcing members 3001 and 3002 are configured within the sheet members 3000A and 3000B and the insulating portion 3000C so as not to interfere with the structural members 3000E and 3000F. In addition, wire loop reinforcing members 3001 and 3002 are also spaced apart to avoid interference between them. During manufacture, one of the sheet members 3000A or 3000B can be laid flat with embedded loops, say wire reinforcing loop 3001 , facing upwards on a flat surface such as a table. Then the inside or top sheet member, say 3000B, can be laid on top with embedded wire reinforcing loops 3002 facing downwards to interlock with wire reinforcing loops 3001 and spaced apart sufficient distance for the structural members 3000E and 3000F of required dimension to be are conveniently inserted into position extending through the wire reinforcing loops 3001 and 3002 which accommodate and engage with the load bearing structural members 3000E and 3000F to make the required connection. This process is repeated along a load bearing module section which may have sufficient dimensions to form even a substantial wall section. PU foam is then injected to form an integral load bearing module.

Claims

CLAIMS:

1 . A load bearing module for use in constructing an insulated structure, the load bearing module comprising:

a first sheet member having first and second sides;

a second sheet member spaced from the first sheet member and having first and second sides; and

an insulating portion extending at least between said first and second sheet members wherein said load bearing module includes a plurality of laterally extending load bearing structural members wherein at least one of said load bearing structural members is connectable by connecting components to a structural member of an adjacent building component, optionally being selected from the group consisting of a further load bearing module, window frame or doorframe.

2. The load bearing module of claim 1 comprising at least one load bearing structural member corresponding with the first side of the load bearing module and at least one further load bearing structural member corresponding with the second side of the load bearing module.

3. The load bearing module of claim 1 or 2 wherein one or more load bearing structural members are disposed at a selected orientation at a selected intermediate position between the first and second sides of the load bearing module.

4. The load bearing module of any one of the preceding claims wherein said load bearing structural members are oriented at a selected angle, optionally between 0 degrees and perpendicular to a lateral axis of a load bearing module.

5. The load bearing module of any one of the preceding claims comprising connecting components to enable connection to an adjacent load bearing module at least through connection of a structural member of a first load bearing module with the structural member of the adjacent load bearing module; or connection to a structural member of a building component.

6. The load bearing module of any one of the preceding claims comprising reinforcing members in the form of wire loops embedded within said insulating portion to accommodate and engage the structural members.

7. The load bearing module of any one of the preceding claims wherein the connecting components are configured to connect adjacent load bearing modules through corresponding structural members while leaving a space between them, said space optionally being a small distance, preferably on the order of millimetres.

8. The load bearing module of claim 7 wherein a structural member of a load bearing module is provided along its length with a plurality of studs, optionally frusto-conically shaped, intended to mate with corresponding apertures arranged in spaced apart relationship along the length of a structural member of an adjacent load bearing module.

9. The load bearing module of claim 8 wherein said apertures have a wide portion to enable accommodation of the studs, said wide portion transitioning to a narrow portion in which the studs become fixed into position by interference fit on completion of connection of structural members of adjacent load bearing modules, said studs optionally being dimensioned to leave a space between adjacent load bearing modules.

10. A set of load bearing modules, each load bearing module being as claimed in any one of the preceding claims ,wherein load bearing modules comprising the set have differing relative disposition of the insulating portion and the first and second sheet members facilitating an alignment step of assembly, a first load bearing module having its insulating portion disposed relative to one or both sides of the first and second sheet members to provide a recess into which extension portion(s) of the lightweight insulation portion of an adjacent load bearing module may be accommodated, to align the modules and ease construction.

1 1 . A set of load bearing modules as claimed in claim 10, each load bearing module being connected to a selected surface such as a building slab or foundation, optionally through a waterproofing layer, by engagement with and/or fastening to a track member connected to the selected surface.

12. A set of load bearing modules as claimed in claim 1 1 comprising structural members provided with at least one end portion, optionally including one or more connection means for connection to further structural members, said end portion(s) being of narrower dimension than a body of the structural member to be accommodated in, or extend through, a track member.

13. A set of load bearing modules comprising a pair of load bearing modules, each load bearing module including a structural member comprising:

(b) a second structural member forming part of the second load bearing module of the pair and provided with a plurality of apertures, optionally of dog bone shape, for accommodating said plurality of studs wherein co-operation between each stud and a corresponding aperture causes connection of said structural members and said load bearing modules, optionally by interference fit.

14. A method for constructing an insulated structure comprising:

providing a plurality of load bearing modules as claimed in any one of claims 1 to 9 or a set of load bearing modules as claimed in any one of claims 10 to 13; and connecting the plurality of load bearing modules together by connecting at least one of said structural members of one load bearing module to a structural member of an adjacent load bearing module a structural member of an adjacent building component optionally being selected from the group consisting of a further load bearing module, window frame or doorframe.

15. The method of claim 14 wherein said plurality of load bearing modules is aligned through a step of accommodating an extension portion of an insulation portion extending beyond the sheet members at at least one side of a load bearing module within a recess formed between first and second sheet members of an adjacent load bearing module.

16. The method of claim 15 wherein said recess is at one side of the load bearing module or at a desired location along its length said recess being oriented at a desired angle between 0 and 90 degrees to a lateral centre axis of the adjacent load bearing module.

17. The method of any one of claims 14 to 16 further including connection of structural members by complementary connecting components, optionally leaving a space between edges of the adjacent sheet members.

18. The method of claim 17 wherein said connection is made by complementary components including a plurality of studs, optionally frusto- conically shaped, for one load bearing module and a plurality of corresponding apertures, each being respectively arranged along the length of a structural member of an adjacent load bearing module.

19. The method of claim 18 comprising engaging frusto-conically shaped studs of a structural member of one load bearing module with apertures of a structural member of an adjacent load bearing module, said apertures, optionally of dog bone shape, having a wide portion to enable accommodation of the studs to a selected depth suitable for forming a space between the sheet members but which transition to a narrow portion in which the studs become fixed into position on completion of connection of adjacent load bearing modules for example by lifting or pressing into position.

20. The method of any one of claims 14 to 19 comprising connecting a load bearing module to a selected surface such as a building slab or foundation, optionally through a waterproofing layer, to a connection means such as a track member in the form of a channel, optionally having side walls of unequal dimension.

21 . The method of any one of claims 14 to 20 including assembling load bearing modules with a tolerance or end float allowing for inaccuracies including inaccuracies arising from construction of the building slab or foundation and optionally deploying one or more packers to provide an end float relatively small in comparison with the dimensions of a load bearing module.

22. A method for constructing multi-storey buildings with an insulated wall section comprising:

connecting a first plurality of load bearing modules, each load bearing module being as claimed in any one of claims 1 to 9 or a set of load bearing modules as claimed in any one of claims 10 to 13 by connecting at least one structural member of one load bearing module with the structural member of an adjacent load bearing module to form a first insulated wall section of a lower storey of a building;

coupling a second plurality of further load bearing modules, each load bearing module being as claimed in any one of claims 1 to 9 to the suspended slab to construct a second insulated wall section of a second storey.