WO2025136119A1

WO2025136119A1 - Building system and apparatus

Info

Publication number: WO2025136119A1
Application number: PCT/NZ2024/050135
Authority: WO
Inventors: Lee Graham POWELL
Original assignee: Armapal Ip Ltd
Current assignee: Armapal Ip Ltd
Priority date: 2023-12-18
Filing date: 2024-12-18
Publication date: 2025-06-26
Anticipated expiration: 2026-06-18
Also published as: AU2024378984B2; AU2024378984A1

Abstract

A building system which includes a structural connector apparatus. The connector apparatus is made up of a first and a second horizontally orientated flange member spaced apart and joined by a vertically orientated web member; a third horizontally orientated flange member located between the first and second horizontally orientated flange members, wherein the third horizontally orientated flange member comprises an inward end connected to the web member, and an outward end extending beyond at least the extent of the first horizontally orientated flange member; and a first vertically orientated support member having a lower end connected to the third horizontally orientated flange member, and an upper end supported relative to the locations of the first and third horizontally orientated flange members.

Description

BUILDING SYSTEM AND APAPRATUS

FIELD OF THE INVENTION

The invention generally relates to a component used for the construction of a building, and in particular to an extrusion-based apparatus adapted as a building foundation framework.

BACKGROUND

Prefabricated building panels produced by the likes of Metecno ® offer benefits of a large surface area and good insulation properties. However, such panels require supporting framework to facilitate their easy use.

Prefabricated floor components such as those produced by Speedfloor® offer benefits of a fast and strong prefabricated steel joist structure. However, the use of such structures also requires supporting framework to facilitate their use.

There is a desire in the industry to bring provide a system of components which facilitates a connection between different building products, such as prefabricated panels and prefabricated floor systems.

A further issue in the building industry is the use of wood, which require specialist shaping in order to connect with prefabricated panels, floor components and similar materials. A further issue in the building industry is the use of aluminium, which causes galvanic corrosion when interfaced to other metals. Addressing these problems increases the time and cost of building a dwelling and compromise its longevity over time.

In this specification, where reference has been made to external sources of information, including patent specifications and other documents, this is generally for the purpose of providing a context for discussing the features of the present invention. Unless stated otherwise, reference to such sources of information is not to be construed, in any jurisdiction, as an admission that such sources of information are prior art or form part of the common general knowledge in the art.

OBJECT OF THE INVENTION

It is an object of the present invention to provide a that overcomes or at least partially ameliorates some of the abovementioned disadvantages or which at least provides the public with a useful choice.

SUMMARY OF THE INVENTION

In one broad aspect the invention consists in a building system and/or structural connector apparatus for a building comprising: a first and a second horizontally orientated flange member spaced apart and joined by a vertically orientated web member; a third horizontally orientated flange member located between the first and second horizontally orientated flange member, wherein the third horizontally orientated flange member comprises an inward end connected to the web member, and an outward end extending past the extent of at least the first horizontally orientated flange member; a first vertically orientated support member having a lower end connected to the third horizontally orientated flange member, and an upper end supported relative to the locations of the first and third horizontally orientated flange members.

In some embodiments, there are a set of connectors arranged to each partially support a floor component on their horizontal flanges, and thereby form a structural support assembly for a floor. In some embodiments, a connector is also arranged to support post members that are part of a wall assembly for a building. Further, post members are configured to support wall panels, ceiling and roof components. Therefore, the structural connector apparatus forms part of a load bearing foundation of a building.

In some embodiments, the vertically orientated support member has an upper end connected to the first horizontally orientated flange member.

In some embodiments, the outward end of the third horizontally orientated flange member extending past the extent of at least the first horizontally orientated flange member defines a surface adapted to vertically support a floor joist.

In some embodiments, the first vertically orientated support member defines a surface adapted to connect with a floor joist which is supported by the third horizontally orientated flange member.

In some embodiments, the system further comprises a second vertically orientated support member configured laterally adjacent to and connected with the web member, wherein: the inward end of the third horizontally orientated flange member is connected to the second vertically orientated support member, a fourth horizontally orientated flange member is connected to the upper end of the third horizontally orientated flange member at an outer end, and at an inner end, connected to the second vertically orientated support member.

In some embodiments, the second vertically orientated support member, the third horizontally orientated flange member, the fourth horizontally orientated flange member, and first vertically orientated support member comprise a substructure adapted for connection to the vertically orientated web member.

In some embodiments, the first horizontally orientated flange member, the vertically orientated web member or the second vertically orientated support member, and the fourth horizontally orientated flange member define a recess adapted to receive an insulating panel or floorboard.

In some embodiments, the first horizontally orientated flange member, the second horizontally orientated flange member and the vertically orientated web member comprise a PFC beam, I-beam or universal column beam.

In some embodiments, the third horizontally orientated flange member, the vertically orientated web member or the second vertically orientated support member, and the second horizontally orientated flange member define a recess adapted to receive an insulating panel.

In some embodiments, the upper surface of the first horizontally orientated flange member is configured to support one or more of a structural post, an insulating panel, and/or an insulating panel connector.

In another broad aspect there is a building system comprising the structural connector apparatus of any preceding statement, wherein the system further comprises: a panel connector component adapted for support by the structural connector apparatus; an insulating panel comprising a panel connector disposed at at least one end; and wherein the panel connector component comprises a connector complementary to that of the insulating panel such that an interlocking engagement is created when placed together. In some embodiments, the connector component comprises an exterior orientated surface configured to extend down the exterior orientated surface of the structural connector apparatus, and, the lower extent of the exterior orientated surface comprises a water wicking formation adapted to extend downward and away from the structural connector apparatus.

In some embodiments, the connector component comprises an inwardly orientated end adapted to engage within a concrete pad supported by the structural connector apparatus.

In some embodiments, the structural post comprises a flange configured to connect with the upper surface of the first (204, 2191) horizontally orientated flange member by way of one or more fastener devices.

In some embodiments, the apparatus further comprises a fifth horizontal flange member (740) extending from the vertically orientated web member (203, 211) in a direction opposing the first horizontal flange member, the fifth horizontal flange member (740) adapted to support an exterior wall panel.

In some embodiments, the connector component comprises vertically extending walls which extend from a lower surface supported by the structural connector apparatus, wherein the walls and lower surface define an interior region adapted to receive the insulating panel.

In some embodiments, the system further comprises a weather sealing cover, the cover comprising: an upper end configured to extend inward of a cladding layer, and a lower end configured to extend below an intersection between the connector component and structural connector apparatus, the lower end further comprising a water wicking formation adapted to extend downward and away from the structural connector apparatus.

In some embodiments, the system further comprises one or more structural posts adapted for support by the structural connector apparatus, wherein the upper region of the post is adapted to support one or more components of a ceiling or roof.

In some embodiments, the one or more components of a ceiling or roof comprises an upper plate member and an upper plate sealing layer comprising a surface extending from the top of the plate, down an interior orientated vertical surface, horizontally between the post and upper plate to the exterior of the post, and down the exterior orientated surface of the post.

In some embodiments, the system further comprises a foundation assembly adapted to vertically support the structural connector apparatus, the foundation assembly comprising: a ground engaging post, a member having a lower end configured to adjustably engage with the ground engaging post, and an upper end configured to support the structural connector apparatus, whereby adjustment of the member causes variable displacement between the ground engaging post and the structural connector apparatus.

In some embodiments, the foundation assembly further comprises an upper and lower bracket interspersed between the ground engaging post and the structural connector apparatus, and a resiliently deformable member located between the upper and lower bracket such that the weight of the structural connector apparatus is transmitted through the resiliently deformable member.

In some embodiments, the resiliently deformable member is a rubber block.

In some embodiments, the foundation assembly further comprises fastener components extending through the resiliently deformable member and each of the upper and lower bracket so as to couple the upper and lower bracket to the resiliently deformable block. In some embodiments, the insulation panel comprises a polyurethane based form core laminated with outer layers comprising a metal sheet.

In some embodiments, the insulation panel comprises a layup of a metal layer, a synthetic fibre layer, a polyurethane based foam panel layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a polyurethane based foam panel layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a polyurethane based foam panel layer, a synthetic fibre layer, and a metal layer.

In some embodiments, each of the synthetic fibre layers comprise an aramid cloth.

In another broad aspect, there is a building assembly comprising the structural connector apparatus any preceding statement, wherein the assembly comprises: two or more structural connector apparatus arranged on a plane in an opposing orientation such that each of the third horizontally orientated flange members from each apparatus are pointed inward, and a floor joist is arranged to span between the apparatus.

In some embodiments, the floor joist is connected, at each end, to the first vertically orientated support member of a structural connector apparatus.

In some embodiments, the assembly further comprises one or more insulated panels spanning between and supported by the opposing structural connector apparatus.

In some embodiments, the end region of an insulated panel is enclosed by a recess above or below the third horizontally orientated flange member.

The following embodiments may relate to any of the above aspects. Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term “and/or” means “and” or “or”, or both.

As used herein “(s)” following a noun means the plural and/or singular forms of the noun.

The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement or claim, all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:

Figure 1 shows an exemplary foundation frame for a building including steel frame members supported by a foundation.

Figure 2 shows an exemplary diagram of a building floorplan, which may be a based on a concrete or a floor supported by a steel foundation framework.

Figure 3 shows an exemplary framework component which may form a construction strongback as part of a building foundation framework.

Figure 4 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework.

Figure 5 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework.

Figure 6 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework.

Figure 7 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework.

Figure 8 shows an example of an insulated panel.

Figure 9 shows an example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 10 shows an example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 11 shows another example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 12 shows another example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 13 shows another example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 14 shows another example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 15 shows another example of an insulated panel with a panel locking feature adapted to engage with an edge member.

Figure 16 shows the example of the insulated panel and encapsulating or retaining frame components.

Figure 17 shows an example of an insulated panel support component.

Figure 18 shows another example of an insulated panel support component.

Figure 19 shows another example of an insulated panel support component.

Figure 20 shows another example of an insulated panel support component.

Figure 21 shows another example of an insulated panel support component.

Figure 22 shows another example of an insulated panel support component.

Figure 23 shows an example of an exterior cladding component.

Figure 24 shows another example of an exterior cladding component.

Figure 25 shows an example of an exterior cladding and layers of cladding component.

Figure 26 shows an example of an exterior sealing component.

Figure 27 shows another example of an exterior sealing component.

Figure 28 shows another example of an exterior sealing component.

Figure 29 shows another example of an exterior sealing component.

Figure 30 shows another example of an exterior sealing component.

Figure 31 shows an exemplary arrangement of exterior sealing layers applied to a corner post.

Figure 32 shows layers of exterior sealing layers for application to a post.

Figure 33 shows an example of exterior sealing layers applied to a wall post.

Figure 34 shows an exemplary arrangement of upper plate sealing layers. Figure 35 shows an exemplary arrangement of roof cladding, including interior and exterior sealing layers.

Figure 36 shows another exemplary arrangement of roof cladding, including interior and exterior sealing layers.

Figure 37 shows a sealing layer component for ceiling use.

Figure 38 shows an exemplary arrangement for a floor structure comprising the framework component.

Figure 39 shows another exemplary arrangement for a floor structure comprising the framework component.

Figure 40 shows another exemplary arrangement for a floor structure comprising the framework component.

Figure 41 shows another exemplary arrangement for a floor structure comprising the framework component.

Figure 42 shows another exemplary arrangement for a floor structure comprising the framework component.

Figure 43 shows an exemplary floor support structure.

Figure 44 shows an exemplary resilient floor support structure.

Figure 45 shows another exemplary resilient floor support component.

Figure 46 shows an exploded view of an exemplary bulletproof panel constructed from layers of materials.

Figure 47 shows an exemplary beam partly covered by an arrangement of sealing layers. Figure 48 shows a further exemplary arrangement of sealing layers for an upper plate member.

Figure 49 shows a further exemplary arrangement of a sealing layer for an upper plate member.

Figure 50 shows a further arrangement of sealing layers about a post and several panel members.

Figure 51 shows a low part of a vertical post member supported by a strongback component. Figure 52 shows an exemplary component configured to support interior and exterior wall panels.

Figure 53 shows a top view of a vertical post, a panel, and an attachment layer.

Figure 54 shows an upper part of a vertical post member and roof beams.

Figure 55 shows another view of upper part of a vertical post member and roof beams.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Embodiments of the invention discussed herein relate to structural components for the construction of buildings. Such embodiments are intended to address the need for a compact, accurate, load bearing, moment-connected, versatile system of interrelated components for the orientation and assembly of building foundations and walls.

In some embodiments, components of the system facilitate the construction of modules which can be adjoined to create a complex building. In some embodiments, components for the fabrication and assembly of building modules and to interconnect the modules to form buildings composed of those modules. The modules may represent rooms or floors of a building, and hence may be assembled side by side or stacked to create a building. Modules may also facilitate ease of transport from the manufacturer to build site, and the quick and facilitate the dependable rigging and hoisting of the prefabricated modules. Connection of the modules to each other and to other necessary components of the building may also be facilitated. This makes use of the structural properties of the modules and the components which form the modules, which defines and reduces the number of parts, provides features without the need for the fabrication of complex connections in the joining areas. In some embodiments, there is a system of components and work methods which allow a fabricator to construct buildings of a wide range of types economically and safely, from single dwellings to larger two-or-more level dwellings.

In some embodiments, there are structural connectors provide for upper and lower capacity and transmission of compression and tension forces created by the forces acting on the building and by the action of fasteners.

Preferred embodiments of the invention relate to a structural connector apparatus for a building which has a first and a second horizontally orientated flange member spaced apart and joined by a vertically orientated web member, a third horizontally orientated flange member located between the first and second horizontally orientated flange member, wherein the third horizontally orientated flange member comprises an inward end connected to the web member, and an outward end extending past the extent of at least the first horizontally orientated flange member. A first vertically orientated support member having a lower end connected to the third horizontally orientated flange member, and an upper end supported relative to the locations of the first and third horizontally orientated flange members. In this specification, the structural connector apparatus may be referred to a framework and is intended to form at least the first floor of a building, as would be ordinarily suspended on a building foundation. The building may be a residential dwelling having a single level, or a multilevel dwelling, or other building where a steel-based framework would be usefully implemented as part of the building foundation level.

Implementation of the connector apparatus may be based around a preformed steel beam due to the ease of obtaining such components. Beams include I-beams, PFC-beams or other similar beams. Further components are connected to the beams, such as plate, angle- iron or other extrusion-based metals. The connection may be by welding or by fasteners as will be described in further detail below.

In some embodiments, the connector apparatus defines one or more recesses. A recess facilitates the easy connection of other building materials such as floor joists and insulated panels. Floor joists are also available as a prefabricated system of component that can be lifted into place for support by a predetermined framework. Accordingly, embodiments of the invention relate to the provision of such framework. In preferred embodiments, the connector apparatus defines a horizontal support surface upon which a prefabricated floor system is able to be lowered onto and connected with. It is envisaged that the arrangement of a framework in this manner will save substantial assembly time, in addition to providing a structure which is strong enough to withstand weather extremes such as hurricanes. Accordingly, the construction system described in this specification may have particular application in regions which are subject to extreme weather events. Further, the system described in this specification is able to be based around extruded components which lends itself to cost effective shipping methods since extrusions can be comprehensively stacked together for transportation with minimal space wastage. A further advantage of the system described in this specification is the ability to assemble the framework components at the location of the building to be constructed, since only conventional tools may be required to realise the invention.

In some embodiments, there is a system whereby a prefabricated steel beam is used as a first substructure, and attached to the beam is a second substructure. The use of the two substructures may be advantageous where welding of metal to a prefabricated beam may result in warping of the beam. Further, it may be advantageous to construct one substructure in a different location to other parts, thereby further facilitating an ability to construct the framework components at the location of a building site. The following drawings show illustrative examples of the preferred embodiment and associated components. Figure 1 shows an exemplary foundation frame for a building including interconnecting steel frame members 10. The frame members 10 is typically supported by a foundation post or pile as required, which in turn sit on a concrete pad or a concrete foundation 11 prepared in a foot hole. The foundation frame may also comprise bracing members 12 which can be used to further stabilise the frame.

In some embodiments, the frame members are based around steel beam framework, such as I-beams or U-beams, such as universal column and parallel flange channels as will be explained below. Frame members may be connected at intersection locations by means of welding or connecting components according to desired structural principles.

Figure 2 shows an exemplary diagram of a building floorplan, which may be a based on a concrete or a floor supported by a steel foundation framework. The dashed lines indicate exemplary locations where beams may be located.

The building framework items shown and discussed in this specification are intended to be constructed primarily from steel materials. Building framework components may therefore be attached by welding a structure together, or by the use of fasteners and connecting flanges, or a combination of these methods.

Figures 3 to 7 show exemplary embodiments of a foundation beam component according to preferred embodiments. In particular, Figure 2 shows an exemplary diagram of a building floorplan, which may be a based on a concrete or a floor supported by a steel foundation framework, Figure 3 shows an exemplary framework component which may form a construction strongback as part of a building foundation framework, Figure 4 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework, Figure 5 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework. Figure 6 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework, and Figure 7 shows another exemplary framework component which may form a construction strongback as part of a building foundation framework.

In preferred embodiments, each framework component is made of steel, and preferably a hot-rolled carbon steel.

Referring to Figure 3, there is a framework component 20 comprising a structure. The structure comprises parallel flanges 204 spanned on one side by a web member 203. In some embodiments, the parallel flanges 204 and web member 203 are provided by a PFC beam. In some embodiments, there is an inside radius at the intersection of each parallel flange with the spanning web member 203. The parallel flanges are orientated horizontally, whereas the web is orientated vertically. A central horizontal flange 202 extends from the about the middle of the vertical web member and beyond the extent of the parallel flanges situated above and below it. A vertical connecting member 201 extends between the upper horizontal flange and the central horizontal flange at about the extremity of the upper horizontal flange, and from the opposite end to that of the web member 203. The vertical connecting member 201 acts to tie the central connecting member 202 and the upper parallel flange together. In some embodiments, the abutting parts of each member are welded together. In some embodiments, 201 and 202 may be full length or may be interspersed along the length of the beam. The upper surface of the central horizontal flange 202 is adapted to provide a supporting surface for a spanning member within a floor structure, such as floor joist members. The upper surface of the lower parallel flange 206 is adapted to provide a supporting surface for a spanning member within a floor structure, such as an insulating board which may be housed within the recess 205 comprising the flange 206, web member 203 and lower surface of the central horizontal flange 202.

Referring to Figure 4, there is a framework component 21 shown which is a modified embodiment of that the component 20 shown in Figure 3. The framework component 21 has a PFC beam 211 and a support structure attached to the web of the beam 211. The support structure of the framework component 21 comprises a vertical web member 213 adapted to abut against the web of the PFC. Two horizontal flanges 214 and 216 extend from the vertical web member 213. The lower horizontal flange 216 extends beyond at least the outer extent of the upper flange of the PFC, and beyond the outer extent of the upper horizontal flange 214. A vertical connecting member 215 spans between the outer extent of the upper horizontal flange 214 and the lower horizontal flange 216.

The location of the horizontal flanges of the support structure defines a first recess in the region between the upper flange of the PFC, and the upper flange 214 of the support structure, a vertical support surface provided by the upper surface of the lower horizontal flange 216 of the support structure, and a second recess in the region between the lower flange of the PFC, and the underside of the lower horizontal flange 216 of the support structure. Each recess is adapted to receive a building panel which may be primarily for structural or for insulation purposes as will be described later.

The attachment between the support structure and the PFC may be made by welding or by fastener devices 212 as depicted. Preferably the fasteners are bolts and a bolted connection may be preferable to welding to ensure that the PFC beam is not subject to warpage. Accordingly, the framework component 21 may be preferable to the component 20 of Figure 3 where the thickness or other factors of the material in use may be affected by the heat of welding.

The upper surface of the central horizontal flange 216 is adapted to provide a supporting surface for a spanning member within a floor structure, such as floor joist members.

The upper surface of the lower parallel flange 219 is adapted to provide a supporting surface for a spanning member within a floor structure, such as an insulating board which may be housed within a lower recess 218 comprising the flange 219, web member 211 and lower surface of the central horizontal flange 216.

A further upper located recess 217 is provided by the upper flange 214, web member 211 and upper parallel flange 2191. The recess 217 is configured to support a board of floor components such as an insulating board, structural member or other floor related component.

Figure 5 shows an embodiment of a framework component 22 that is complimentary to that shown in Figure 3. In particular, the framework component 22 is based around an I-beam as a foundation to the structure of the component. The I-beam comprises an upper beam member 225, a lower beam member 227, and a vertical web member 226 which extends between the upper and lower members at about the central point thereof.

A pair of complementary and central horizontal flanges 223, 224 extend opposingly from the about the middle of the vertical web member 226 and beyond the extent of the upper and lower members situated above and below it. A pair of complementary and opposing vertical connecting members 221, 222 extend between the upper horizontal member 225 and the central horizontal flanges 223, 224 respectively at about the extremity of the opposing ends of the upper horizontal member. The vertical connecting members 221 , 222 act to tie the central members 223, 224 and the upper parallel member 225 together. In some embodiments, the abutting parts of each member are welded together.

Figure 6 shows a variation of the embodiments of Figures 3-5, whereby there is a framework component 23 which has an I-beam component to form a base component. The I-beam component comprises an upper horizontal member 231 , a lower horizontal member 2312 and a web member 2311 which spans therebetween in a central region thereof.

A pair of inner support structures are attached to the web member 2311 by a plurality of fastener components 238. Each of the support structures comprise vertical members 2313, 2314 which are configured to receive a fastener and connect with the vertical web of the I- beam. Each vertical member has a central horizontal member 236, 237 extending outward from a mid-region thereof. Each vertical member further has an upper horizontal member 231 , 234 extending from an upper region of the vertical members. The horizontal member 236, 237 and horizontal members 231 , 234 are connected by vertical members 232, 235 which extend vertically from the outer extent of each upper horizontal members 231, 234.

Figure 7 shows a framework component 24 which is a variation of the embodiment of Figure 6 and is complementary to the framework component embodiment 21 shown in Figure 4. In this embodiment, the inner support structures are located lower within the interior of the I- beam so as to create an upper void 249 in addition to the lower void 2491, similar to the exemplary embodiment of Figure 4.

Each inner support structure is arranged opposingly about the web member of the I-beam. Each support structure comprises lower horizontal members 244, 248 which extend beyond the upper and lower flanges of the I-beam in laterally opposite directions. The lower horizontal members 244, 248 extend from vertical members which are arranged on opposing sides of the vertical web member and connected to the web member by a plurality of fasteners 245. Each support structure further comprises an upper horizontal member 242, 247 which extends from each vertical member. As for each of the embodiments of Figures 3- 6, the outer extent of each upper horizontal member is connected to the lower horizontal member by a vertical member 243, 2431.

The position of the horizontal members creates a support surface on each the upper side of the lower horizontal members which is adapted to support a floor component. Additionally, the above embodiments are configured with one or two recesses, each adapted to provide a horizontal support surface for further spanning members such as floor components, insulating components or other structural components, including insulation materials.

Manufacturing of the framework components (20-24) as shown in Figures 3-7 is conducted by a process of welding and, in some instances, the application of fasteners. Fasteners may be desirable in instances where welding would warp the metal. In other instances, a stitch welding process may be applied at intervals along the length. Accordingly, some embodiments comprise one or more extrusion-based members which are assembled to construct a framework component.

In some embodiments, one or more members of each framework component is an extrusion. For example, a steel-based extrusion. In some embodiments, a framework component is built around a prefabricated I-beam or PFC-beam. There are several advantages associated with basing the framework component around a prefabricated beam member. For instance, one such application of the framework component is as a building member in low-cost or fast-build type housing. Such housing may be desired to be constructed in remote environments and therefore transportation of the constituent components of framework components is desirable for shipping reasons, where transportation of constituent components in an unassembled state would allow greater numbers of components to be shipped by a measure, such as a truckload or ship-load.

A floor structure can be assembled by the use of the framework components. Figures 38 to 40 illustrate exemplary floor structures comprising the framework components selected from those shown in Figures 3-7. In particular, Figure 38 shows an exemplary floor structure assembly comprising a first framework component 20 (as shown in Figure 3), a second framework component 20 in a mirrored orientation. A third framework component 22 (as shown in Figure 5) is shown positioned between the first and second framework components 20.

Each of the framework components has a mid-located horizontal surface which extends outward and is adapted to vertically support a floor structural component 100 such as floor joist member which spans between other horizontally arranged framework components. Further, each of the framework components has a lower located horizontal surface which, together with other members of the component, forms a recess. The recess is adapted to support a panel 101 which spans between other framework components in horizontal alignment.

Figure 35 shows another exemplary floor structure assembly comprising a first framework component 21 (as shown in Figure 4), a second framework component 21 in a mirrored orientation. In particular, the framework components 21 are adapted to provide a vertical support surface for a floor structure component 100. Further, the lower recess is adapted to support a panel 101 , and the upper recess is adapted to support an upper panel or floor structure component 103. A top layer, such as a board 102 is optionally located on the top floor structure component 103 as shown.

As above, if desired, a third structural component, such as that shown in Figure 7 could be positioned between the first and third framework components so as to enlarge the possible size of the floor area. Further, as many intermediate framework components (as shown in Figures 5-7) could be used to support the span of a desired floor area which is larger than that which span of a floor structure component is intended to support. Hence, Figures 38 and 39 are exemplary of an arrangement of framework components and layouts which are possible.

Figure 40 shows another exemplary assembly of the framework component embodiment 21 of Figure 4 connected with a structural component for supporting a floor such as a joist. In some embodiments, the framework components are adapted to connect with a roll-formed steel joist floor system such as Speedfloor®. In some embodiments, the framework is configured to connect with a joist using fasteners 341 which passes through the joist and the member 215 to connect the two together, while the joist is already being vertically supported by the horizontally extending member 216.

Speedfloor® is one example of a prefabricated flooring structure comprising a lattice of joists, and optionally bearers. In use, the framework components can be assembled to form at least the perimeter of a building foundation such as described in relation to Figures 1 and 2. The mid-located horizontally extending member of each framework component is configured to provide a vertical support surface such that a prefabricated flooring structure can be hoisted over, down and onto the building foundation and can be supported there while being connected to the framework by the fasteners. In some embodiments, there is a cassette floor comprising a plurality of framework components and a floor structure located internally to, and vertically supported by the framework components. A suspended floor is able to be constructed on the topside of the framework components and flooring structure. In some examples, the suspended floor is a concrete composite floor. In some embodiments, the suspended floor is a prefabricated board component.

Figures 43 to 45 show exemplary foundation assemblies operable to support the framework components. Figure 43 shows a foundation assembly 11 comprising a post member 386 which is intended to be ground engaging at a lower end. At the upper end, the foundation assembly 11 comprises a threaded rod 381 which engages at a lower end with a box section 385 at the upper end of the post 386. The threaded rod has a support pad 383 at the upper end which supports the foundation component. The threaded rod advantageously provides for an adjustable distance between the post and the framework component which allows for height adjustment and in particular for the framework component to be aligned level. An upper nut 384 on the threaded rod provides an adjustable upper engagement with the box section, and a lower nut 382 provides an adjustable lower engagement with the box section. In use, the height of threaded rod is adjusted, and the upper and lower nuts tightened to engage with the box section to lock the assembly together.

Figure 44 shows a varied embodiment of a foundation assembly 11 whereby a framework component is supported by a foundation assembly which incorporates a resiliently deformable component. Such a component is typically advantageous for withstanding earthquake forces by allowing some vibration isolation between the ground and a building. In the example of Figure 44, there is a resiliently deformable component 375 sandwiched between an upper support bracket 371 and a lower support bracket 372. An upper fastener 373 mechanically locks the component 375 to the upper support bracket, and a lower fastener 372 mechanically locks the component 375 to the lower support bracket.

Figure 45 shows a variation of the exemplary foundation assembly shown in Figure 44. In particular, the embodiment depicts that the upper support bracket 371 of foundation assembly comprises lateral extension which facilitates the use of fasteners to attach the foundation post with the framework component.

In some embodiments, the resiliently deformable component 375 comprises a rubber-based material such as neoprene which has advantageous properties in many environments.

Figures 8 to 16show a variety of prefabricated panels, including a variety of clip structures. The clip structures represent a variety of connection points which prefabricated panels may include for connection to one or more other panels or supporting devices. The prefabricated panels for use with the technology of this invention comprise polyurethane rigid foam based sandwich panels which have become a fundamental tool for high performance building systems. The panels may be PIR or PUR based panels which are similar but with certain differentiating nuances, such as processing temperatures, higher in the case of PIR panels, or the use of adhesives to improve the adhesion between the sheet and the foam, in the case of PIR panels. Such panels are typically used for external enclosures such as facades and roofs, or compartmentalisation of interior spaces such as the separation of fire sectors, partitions, food processing rooms, clean rooms, cold rooms, or anywhere where a wall is required.

On particular PIR panel is a made of a type of construction material made from polyisocyanurate foam core sandwiched between facing materials like metal, oriented strand board (OSB), or other materials. These panels are used in construction for their excellent insulation properties. Polyisocyanurate foam is a type of rigid foam insulation known for its high thermal resistance. It's effective at reducing heat transfer and maintaining a building's temperature, which helps in energy efficiency by reducing heating and cooling costs. PIR panels are commonly used in both residential and commercial construction for wall insulation, roof insulation, and sometimes as part of flooring systems. They are lightweight, easy to install, and provide good insulation performance, making them popular in modern construction for their energy-saving benefits.

Figure 8 shows an exemplary prefabricated panel which comprises a central polyurethane based layer 31 which provides the majority of the insulating properties of the panel, and on either side, protective layers 30, 32 which act to provide rigidity to the composite, and other mechanical properties such as abrasion and impact resistance. The protective layers are preferably steel, such as Bluescope® steel.

In some embodiments, the panel comprises a clip structure, typically located along at least one edge thereof. Figure 9 shows one example whereby the panel has a clip structure 34. In some embodiments, the clip structure comprises a hook formation whereby there is region which extends and folds back. The clip structure is typically formed by extending the outer layers 30, 32 of the panel beyond the extent of the centre layer 21 and folding the layers into the desired shape which provides the clip. The clip 34 acts in conjunction with a complementary recess in other panels.

Figures 10-15 show particular clip structures and optional complementary receiving formations. Each of the formations provide a particular benefit where a prefabricated panel is able to be clipped into place and held there without the further use of fasteners. This feature has particular application in areas where space is limited, the space is located above the ground, and/or where installation of fasteners may not be possible or at least provided with ease. Securing the receiving formations to a building framework, such as one of the framework components, can be made using fasteners before the panel is added and there is space to work, then the panel added and secured by mechanical engagement to the formations.

Figure 10 shows an exemplary structure where a panel engages with an upper plate member 73 of a building. The structure comprises a layer 38 which extends down an inner vertical surface of the plate, then under the lower horizontal surface. The outward orientated extent of the layer 38 comprises an engaging formation 381. A panel 36 is orientated under the plate 73 and has a clip formation 39 which engages with the engaging formation 381 of the layer 38. This exemplary structure has advantages whereby the layer 38 is able to be attached to an upper plate 73 as would exist in any regular building structure, and a panel be inserted into the cavity beneath the upper plate. Insertion of the panel into the cavity from the inward to the outward direction causes engagement of the clip with the engaging formation of the layer such that the panel clips into place and is retained beneath the plate. Such an assembly process thereby creates a wall from the clip engagement of these components.

Figure 11 shows another example of a prefabricated panel having a clip formation which extends from at least one of the edges of the panel. In particular, a pair of complimentary clip structures 361 A, 361 B are shown as may be located on opposing ends of a panel. For example, a first panel 36A has a receiving clip formation 361A and a second panel 36B has an engaging clip formation 361 B. Engagement of the clip formations creates a locked structure due to the hook nature of the formations.

Figure 12 shows another example where a pair of edge-opposing prefabricated panels 36A, 36B have an engaging formation at an end thereof. Locating components 362A, 362B are located between each panel and locate at the opposing ends of each panel at a first end, and with each other at a second opposing end. The engaging surface of the complementary locating components comprise each a complementary locating formation 363 to stabilise and locate the engagement of opposing locating components and panels. In particular, the engaging formation of each panel comprises a hook structure such that engagement of the panel ends is secured, and release of the panels may only be achieved by deformation of the engaging formations. In this way, a mechanical lock between panels is created, which improves the strength of the assembly.

Figure 13 shows another example of an assembly for securing a prefabricated panel. A panel engaging component 80 is located at the end of a prefabricated panel 36 and adapted to engage with the engaging formation of the panel. In particular, the engaging formation of each panel comprises a hook structure such that engagement of the panel ends is secured, and release of the panels may only be achieved by deformation of the engaging formations. In this way, a mechanical lock between panels is created, which improves the strength of the assembly. Further, an angular component 37 is located on at least one side of the panel and engaging component so as to provide a formation which stabilises and supports the panel engagement with the panel engaging component 80.

In some embodiments, the panel engaging component 80 is adapted for connection to a framework component.

Figure 14 shows another example of an assembly for securing a prefabricated panel. A panel engaging component 81 comprises a U-shaped form and a recess within which a panel 36 and panel engaging component 80 are able to reside. The exemplary assembly of Figure 14 may be advantageous over that of Figure 13 in that each side of the panel is supported.

In some embodiments, the panel engaging component 81 is adapted for connection to a framework component.

Figure 15 shows another example of an assembly for securing a prefabricated panel. A panel engaging component 82 is adapted to provide a vertical support surface which acts to guide and support a panel 36 and panel engaging component 82 on at least one side. On the opposing side, a layer 821 extends downwardly from the bottom surface thereof. The layer 821 may, in some applications, locate about the edge of a flooring component, and in some applications, may act as a weather sealing surface such that water running down an outer facing surface of the panel 36 is guided away from the interior of the engaging parts of the panel and supporting assembly. In some embodiments, the downwardly extending layer acts as a mounting surface for securing the attachment of the layer with one or more other components of a floor structure.

Figure 16 shows a simplified embodiment of an exemplary wall structure whereby there is a prefabricated panel 36 residing on a supporting surface 101 , such as a floorboard or framework component. In some embodiments, the prefabricated panel forms a wall extending from the floor to the ceiling of a building. The wall may comprise one prefabricated panel which spans from the floor to the ceiling, or two or more panels which are joined end- to-end to make up the desired span. Abutting panels may be connected using any of the exemplary connecting formations shown. A plurality of supporting components 37 are shown on each of the upper, lower, inner and outer regions of the panel and acts to support the panel laterally as a vertically disposed wall. In use, a prefabricated panel can be located at a desired position, and the supporting components 37 attached to the panel and surrounding structure, such as the floor or ceiling structures, to thereby secure the position of the panel and structurally support the wall.

Figures 17 to 22 show exemplary profile views of components adapted to support the lower region of a prefabricated panel adapted to provide a wall. Each exemplary component is configured to provide a lower support to a prefabricated panel component. Some embodiments further provide a weather sealing element as may be beneficially located on an exterior facing wall. In particular, Figure 17 shows the profile of a wall support component 40 which may be formed from sheet metal. One method of manufacture includes stamping of sheet metal into a die to form a particular profile. Another method includes roll-forming. In preferred embodiments, profiles are constructed by a roll forming process. Notable features of the component 40 include a first and second downwardly extending recess 402, 403 which are configured to receive protruding clips which extend from a lower surface of a prefabricated panel. The particular profile shown may advantageously be used with Meta I craft® PIR panels.

The wall support component 40 further comprises an upstanding formation 404 intended to be located toward the exterior of a building. Accordingly, the component 40 may be placed around the exterior periphery of a framework component where an exterior wall is located. The upstanding formation 404 is configured to operate in conjunction with one or more other weather sealing layers which may be applied in conjunction with exterior cladding as will be discussed below. Accordingly, the surface 401 of the component 40 may form a weather proofing surface configured to direct water, running down the exterior wall, away from the interior of the building. Further, the component 40 has an outwardly sloped surface 400 configured to direct any water away from the building.

Figure 18 shows a profile of a varied embodiment of a wall support component 41 whereby the component features a downwardly extending surface 412. The surface 412 is intended to be embedded into concrete 411 to secure the component 41. In some embodiments, a floor is applied to the topside of a building floor foundation provided by an assembly of framework components. Wet concrete is poured on the top surface of a floorboard supported by flooring components, such as the exemplary board 102 as shown in Figure 39, and the component 41 inset into the wet concrete where the combination is secured upon curing of the concrete.

Figure 19 shows a profile of a varied embodiment of a wall support component 42 where the component features a substantially U-shaped profile. The upstanding sides of the profile comprises inwardly overturned top edges 421, 423 which define an opening to the component interior 422. The interior is adapted to receive a prefabricated panel and support the panel from lateral movement when received. The overturned edges may serve to engage with any securing formations the panel may have. In some embodiments, the upstanding sides are outwardly deformed by the entry of a panel so as to create an interference engagement.

Figure 20 shows a profile of a varied embodiment of a wall support component 43 where the component features a downwardly sloping outer surface 431. The surface 431 acts to direct any water away from the component.

Figure 21 shows a profile of a varied embodiment of a wall support component 44 where the component features a downwardly sloping outer surface 441. The surface 441 acts to direct any water away from the component.

Figure 22 shows a profile of a varied embodiment of a wall support component 45 where the component features a downwardly sloping outer surface 451. The surface 451 acts to direct any water away from the component.

Figures 23 to 25 show examples of exterior cladding layer components which may be used with an assembly containing components according to the embodiments discussed in this specification. In particular, Figure 23 shows the profile of an exterior cladding layer comprising a prefabricated panel. The panel has an exterior facing skin layer which may be of a material suitable for weatherproofing and abrasion resistance. The panel also an inwardly located insulating layer such as may be found on a regular PIR prefabricated panel. Figure 24 shows a further example of an exterior cladding layer 51 featuring a corrugated profile.

Figure 25 shows a further example of an exterior corrugated cladding layers 52, 53 featuring a corrugated profile in an overlapping arrangement. Each layer features projections 53, 54 which project inward and outward in an alternating fashion on region of alternating corrugations. In some embodiments, the corrugations and projections are complementary such that overlapping regions of the layers are configured to recess aligned projections from each layer.

Figures 26-30 show exemplary profiles of layers configured for the weather sealing of outward regions of the framework components. In particular, Figure 26 shows a sealing layer 60 comprising a flat section 604 adapted to span across the outer region of a framework component and at least part of a floor section residing on the framework. A water diverting edge 601 extends outward and downward from the lower edge of the layer. A horizontally orientated surface 605 extends inwardly from the top region of the outer surface 604, and further comprises a downwardly displaced inward edge 603. The horizontal surface 605 is adapted to extend under, for example, a lower plate of a wall structure, or over a wall panel retaining components. The downwardly displaced inward edge 603 is adapted to span around, cover and engage with a panel retaining component such as those discussed with reference to Figures 19 to 22.

Figure 27 shows a sealing layer embodiment 602 which differs from the embodiment of Figure 27 whereby the edge 604 extends upward from the upper and inward region of the top surface 605. The upward orientated edge 604 is adapted to extend behind any cladding layer to help prevent water ingress from travelling inside the building. Figure 26 shows a sealing layer 61 embodiment which differs in that the upper region extends outward from the vertical region. The upper region comprises an outwardly extending horizontal surface 605 which has a downwardly extending lip on the outer edge thereof. Figure 29 shows a sealing layer embodiment 62 comprising a horizontal surface and a vertical surface which extends from the inside locate edge of the horizontal surface. Figure 30 shows a sealing layer 63 which differs from the embodiments shown in Figures 26 to 28 in that there is a horizontal surface 632 which extends inwardly from the upper region of the outward facing surface, and a vertical surface 631 extends from the inward edge of the horizontal surface 632. The horizontal and vertical surface of the layers 62, 63 define a region where an exterior cladding panel may reside, such as the panel shown in Figure 23.

Figure 41 and 42 each show an exemplary assembly, and cross section of a floor and wall, which includes an exterior sealing layer, an interior panel, and exterior cladding supported by a framework component and floor as depicted in Figures 38 to 40. In particular, Figure 41 shows an interior wall panel, such as a prefabricated panel 36 residing on the top of a floor assembly comprising a framework component 21 and floor structural member 100. The floor assembly further comprises an insulating panel 101 supported on the lower recess of the framework component. The wall panel 36 resides in a support channel 42 as shown in Figure 19. The channel 42 may be attached to the framework component 21 by any desired method, such as by adhesives or fasteners. The exterior facing join between the framework component and interior panel support channel is covered by a sealing layer 602 as shown in Figure 27. The lower edge of the join cover 602 comprises the outwardly extending lower edge to wick water away from the building. A cladding layer 51 is shown on the exterior side of the interior panel 36. In a typical building, the cladding layer will extend to the region of the floor. To seal the floor and wall join, a further flashing component layer 351 may be inserted at the lower region of the cladding, such that a channel is created to direct any water behind the cladding layer 51 away from the building. The flashing layer 351 operates in conjunction with the upper region of the sealing layer 602 which spans across the join between the framework component 21 and the panel support component 42 and tucks up behind the cladding layer. The assembly further comprises an angular member 37 which spans between the floor 100 and the interior panel 36 to prevent lateral movement of the panel once in situ. The angular member 37 may be placed around the entire periphery of the interior panel to essentially trap the panel in place, including being placed up the sidewalls and top edge of the panel.

Figure 42 shows another exemplary assembly comprising a floor assembly based around a framework component. The top surface of the framework component and floor structure is adapted to support a prefabricated interior panel 30 within a supporting base component 41. The prefabricated component 30 comprises locking clips formed by extension of the surface layers of the panel. The base component 411 has a profile complementary to the clips of the panel such that when the panel resides on the base component, the panel is locked into position. This arrangement is advantageous as a panel can be dropped into the place and supported in place, facilitating expedient construction of a building wall. The join between the framework component and the wall panel is like that of Figure 41 , where a sealing layer 602 spans at least these components

Referring to the floor plan of Figures 1 and 2, there are posts 13 denoted at exemplary locations X, which extend upward to support the walls, ceiling and roof components of a building. The post may be a steel tube, or a wooden post as desired to meet the specifications of the building. Figure 31 is a plan view of a post 70 which extends from the indicative locations of the building framework components as indicated. The post is shown at a corner of the building, and two wall members, such as the prefabricated panels 36 are shown abutting the adjacent sides of the post. Further, the assembly shown comprises weather sealing layers, including a weather sealing layer 71 which is adapted to span around the exterior facing adjacent surfaces of the corner post, and a weather sealing layer 72 which is adapted to span around the interior facing surfaces of the corner post. Each of the sealing layers 71 , 72 has ends which extend down the exterior side of the wall panel 36 such that there is an overlapping region of each layer along the wall. The overlapping regions define a weather sealed cavity within which the post resides. Further the overlapping region facilitates the use of a sealant or adhesive fir further sealing properties. On the interior side of the wall panels, the angular member 37 holds the panels in place as described earlier.

Figure 32 shows an alternative arrangement of the sealing layer 72, whereby there is a first layer section 74 and a second layer section 75, and the sections at least partly overlap on the interior side of the post. Effectively breaking sealing layers into sections may be beneficial for installation purposes.

Figure 33 shows a plan view of a post 70 which extends from the indicative locations of the building framework components as indicated. The post is shown at a side of the building, intersecting two wall members, such as the prefabricated panels 36 are shown abutting the opposing sides of the post. The assembly comprises a sealing layer 77 which extends around three sides of the post, with the centre side orientated outward to the exterior of the building. In some embodiments, the sealing layer comprises multiple overlapping layers.

Figure 34 shows an end view of a cross section of an intersection between a vertically orientated post 70 which supports an upper ceiling plate 73 as part of the ceiling structure of a building. A ceiling or roofing board 80 is supported by the upper plate 73. A number of sealing layers are applied to the assembly, including a first layer 83 which extends from the top side of the upper plate 73, down the interior orientated vertical side of the plate, under the lower side of the plate, then down the exterior facing side of the post 70. The first sealing layer 83 acts to seal the upper plate 73 from the interior of the building. To further support weather sealing of the assembly, a weather sealing layer 82 is applied across the exterior facing join between the upper plate and the post. To further support weather sealing, a further sealing layer 81 is applied along the underside of the upper plate 73 which extends to the building exterior, then downward across the exterior facing side of the upper plate 73 and post 70. On the interior side, there is a sealing layer 84 applied to the interior region of the ceiling board 80, and down the interior facing side of the upper plate and post. In some embodiments, adhesive or sealant is applied to any overlapping surface of ceiling layers.

Figure 51 shows an exemplary embodiment of a further view of a vertical post 70 which is supported directly by a strongback component. Vertical posts may be positioned at locations 13 as noted in Figure 1 and can be located on the exterior of the building foundations to support exterior panels 734 and interior panels 735. Vertical posts may also be placed within the building interior and used to support interior wall panels and other interior structural items including door frames and lintels. In this example, the strongback component provides a bottom plate member facilitating support for at least vertical posts and optionally other components including interior or exterior panels.

In some embodiments, the post 70 includes a lower positioned plate member 76 which can be welded, or fastened, to the bottom of the post member. The lower plate member includes flange surfaces 76 which protrude from the lower extent of the post member to allow attachment points whereby one or more fasteners can engage with the flange surface and the strongback to connect these components in a sturdy way. In some embodiments, the exterior wall panel is supported, at least in part, by the vertical post. On the interior side, an interior wall panel is positioned against the interior side of the vertical post, the post providing an attachment point for all panels to be supported by.

The lower region of the interior panel is supported by a floor support member 76 which is supported by a flange of the strongback component. The lower region of the exterior is shown to overlap with the strongback component, and for this purpose, may have part of the panel interior hollowed out such that the panel may sit flush against the vertical post 70 and clear any protruding features of the strongback including fasteners.

In some embodiments, the strongback component has an outwardly extending flange 740 configured to support an exterior panel. The flange allows positioning and support of the panel before it is connected to the framework of the building.

Figure 52 shows a plan view which includes a vertical post 70 positioned between interior and exterior wall panels. A brace component 507 may optionally be included to wrap around the vertical post 70 and provide surfaces which allow a fastener to attach to each of the interior and exterior panels. Each of the contacting surfaces provides a location for a fastener to be positioned to connect the brace component 507 with a panel. In this way, each of the interior and exterior panels can be physically connected within the wall cavity.

Figure 53 shows the vertical post 70 whereby there is engagement with one or more panel members 36. The panel is cut out to fit around the post and any applicable layers 507. The layer Exterior walls will typically have two or more panels, and interior and an exterior panel. An internal wall will typically have a single wall, such as 100 mm thick panel. Posts, therefore, may be located where two panels are intended to intersect to provide support at that panel intersection. In some embodiments, one panels is cut out to intersect with the post. The layer 507 wraps around the post and partially envelops the end of the panel to allow fasteners to secure the panel 36, layer 507 and post 70 together.

In another embodiment, there are two opposing panels, each having a cut out to partially envelop some of the post such that the cutout provides at least some support to each panel. Joining layers 507 are configured accordingly. In another embodiment, each post 70 has attached to it a clip 82 such as shown in Figure 15. In this way, a panel is supported by a vertical post by the clip when attached to it. The clip 82 can be secured to the post by fasteners such as rivets.

Figure 54 shows structure including an upper region of the vertical post supporting a ceiling plate 73. To attach the ceiling panel, the upper region of the vertical post may include flanges similar to those shown at the lower region. A ceiling panel 733 is also shown as part of a ceiling or roof structure in the diagram, where the ceiling panel is supported by the ceiling panel and the vertical post, and any other structural members such as wall and other interior structural walls. A roof support beam 731 is also shown to support roof cladding 85 and is connected to vertical post by a support bracket 732.

On the exterior facing surface, cladding, and flashing is applied. For example, a cladding layer 736 is applied to the exterior panel 734. Further layers are applied in region 737 to ensure weather tightness.

Figure 55 shows a varied example of the structure of Figure 54 whereby the top plate 73 is inwardly aligned above the post 70. In this way, the exterior panel 734 is flush against the outer surface formed by the top plate and post, and the interior panel 735 has a cut out to at the top region thereof to allow fitment around the top plate.

Also shown is a component 744 which provides an attachment layer which, in some embodiments, includes two surfaces extending at different angles. For example, the first surface is configured to align with a surface of the vertical post 70, and the second surface extends tangentially from the first surface and provides a substantially planar surface against which the interior panel can reside. The coplanar surface and panel facilitate the pass- through of a fastener 745 to join these components together. The attachment layer provides for easy attachment of panels to the vertical post without requiring a panel to be directly attached to a post. This may be advantageous since the post is quite thick and it can be difficult to pass a fastener through the post directly. The attachment layer may be positioned in other locations of the structure where an indirect attachment means between is desired. In some embodiments, the component 744 is a section of angle-iron, otherwise known as a metal product with an "L" shape cross-section.

Figures 35 to 37 show roof structure assemblies. In particular, Figure 35 shows a side profile view of roof structure comprising a ridge beam 87 and two prefabricated panels 86 intercepting either side of the ridge beam. A roof cladding layer 85 is located over the exterior peak of the ridge and down each rafter. On the interior side, a cladding layer 89 is positioned to span the interior side of the ridge beam and panels, and a further layer 88 is applied to the interior cladding layer.

Figure 36 shows an alternative structure of a roofing assembly which includes prefabricated panels such as PIR panels. The panels are shown to meet at the apex of a roof and extend downward where rafters would typically be located. The particular assembly comprises an outer cladding layer 94, an inner panel layer 93 such as a prefabricated panel, a roof support beam structure 92 which may be a steel box section, and an inner cladding or sealing layer 91.

Figure 37 shows the profile of a sealing layer 90 as may be applied to a roof structure as a roof top plate.

Figure 46 shows a structure of a composite panel layup adapted for prefabrication and suited for use as a wall panel according to any of the above-described assemblies. The structure comprises a polyurethane foam-based layer in combination with a plurality of synthetic fibre layers and metal layers. The structure shown comprises the following:

• A metal layer 392, • A synthetic fibre layer 390,

• A polyurethane based foam panel layer 391,

• A synthetic fibre layer 390,

• A metal layer 392,

• A synthetic fibre layer 390,

• A metal layer 392,

• A synthetic fibre layer 390,

• A polyurethane based foam panel layer 391,

• A synthetic fibre layer 390,

• A metal layer 392,

• A synthetic fibre layer 390,

• A metal layer 392,

• A synthetic fibre layer 390,

• A polyurethane based foam panel layer 391,

• A synthetic fibre layer 390,

• A metal layer 392.

In some embodiments, each synthetic fibre layer 390 is an aramid cloth such as Kevlar. In some embodiments, each polyurethane-based foam panel layer 391 is ep, 15 to 32 mm thick. In some embodiments, the polyurethane foam comprises a modulus of compression of between 275 and 425psi. The composite structure of the panel in Figure 38 provides advantages of stopping commonplace or small gauge ballistics and thus may be suitable as a wall panel of a building or vehicle where a ‘bullet-proof’ quality is desired.

Figure 47 shows an exemplary beam partly covered by an arrangement of sealing layers. The exemplary beam may be a strongback beam as discussed in other embodiments and particularly those as shown in Figures 3-7. In this example, the sealing layers are located on the top and left side of the beam, hence the exterior or weather facing of the construction is located on the left side. The sealing layers comprise a first layer 471 which extends from an upper horizontal surface of the beam, down most of the exterior face of the beam, then juts outward for a lower portion thereof before tucking under the lower side of a lower horizontal surface of the beam. The outward jutting portion of the layer 471 acts as a rain guide and directs water away from the structure as it travels down the exterior facing surface. A channel layer 475 is located on the outward jutting portion of the layer 471 and has an interior formed to capture an exterior cladding member such as described elsewhere in this specification. The lower surface of the channel layer 475 is complementary to the surface of the outward jutting portion of the layer 471. In some embodiments, the channel layer 475 and sealing layer 471 are joined, such as by fastener or adhesive, and in some embodiments, the channel layer 475 rests on the sealing layer. In some embodiments, there is a small air gap between the layers. An airgap may be preferable in situations where water may find its way behind a cladding layer. An upper sealing layer 472 is located on the upper surface of the top horizontal member of the beam. In preferred configurations, the sealing layer 472 is a layer above the exterior sealing layer 471. The upper sealing layer 472 has a horizontal surface which extends outward and at least party overlaps with the upper surface of the exterior sealing layers. The overlapping region forms a weather sealing region which may be caulked or filled with adhesive to prevent water ingress. The upper sealing layer has an upwardly extending protrusion near a midpoint thereof. The upward protrusion functions to stop water from running along the top surface of the joined layers and may further act to location interior and/or exterior panels. Accordingly, an interior channel layer 473 may be located on an inwardly extending region of the upper sealing layer 472 and locate a PIR panel as discussed elsewhere.

Figure 48 shows a further exemplary arrangement of sealing layers for an upper plate member 73 and in particular around the region where an interior panel layer 36 engages with the upper plate. An upper sealing layer 481 and a lower sealing layer 482 wrap substantially around the upper and lower surface of the plate member 73 and join together in an extended overlapping manner on the interior side of the plate. The upper sealing layer 481 has an upwardly extending protrusion near a midpoint thereof. The upward protrusion may function to stop water from running along the top surface of the layer. In addition, the sealing layers cojoin on the interior facing side of the plate and wrap around at least the upper surface and part of the inward facing surface of the panel member 36. In this way, the entire upper surface of the panel member is encapsulated and by one or more sealing layers. The encapsulation of the upper region of the panel member prevents the ingress of water into the panel ends, and further where the sealing layer.

Figure 49 shows a further exemplary arrangement of a sealing layer for an upper plate member 73 and in particular around the region where an interior panel layer 36 engages with the upper plate. The interior panel layer 36 comprises a cutout recess shaped to receive the lower interior corner of the upper plate. A sealing layer 491 is located between the plate and panel, and extends at least some way outward along the top side of the panel, and at least some way downward on the interior facing side of the panel. The regions of the sealing layer 491 which are not immediately between the panel and plate provide sealing surfaces where further sealing layers may be arranged.

Figure 50 shows a further arrangement of sealing layers about a post 70 and several panel members 36. In the arrangement, the post is positioned with an inner panel members 36A, and outer panel members 36B. Each of the panel members are shaped to form a corner by having angular cuts where the panels meet so as to form a complementary shape in the joining of the panels. The interior panel members 36A further comprise a cutout so as to receive the post member party therein. The post member 70 is encapsulated within the interior panel member 36A. Between each of the post, interior panel members 36A and exterior panel members 36B is a sealing layer, or layers. The sealing layers are arranged to form a continuous weatherproof surface which extends from one side of a panel to another side, and for the purpose of preventing water ingress into the panel, and also to create abutting flat surfaces where sealant or adhesive can be located to seal the layers together. For example, there are first and second sealing layers 503, 504 which extend from an exterior side of each outer panel member 36B, around the edge of the panel, and inward between the opposing sides of the inner and outer panel members. Each of the sealing layers 503, 504, in the region between opposing sides of the inner and outer panel members, comprises a stepped surface. The stepped surface creates an airgap between the inner and outer panel members which may be required to meet building regulations. Further inner sealing layers 505, 506 extend from the edge joined region of the panel members and each wrap around two sides of the post member from the corner of the post proximate the panel edge joins to the opposite corner. One of the inner sealing layers, shown as layer 505 extends around a third side of the post so as to create a region of overlap with the other sealing layer 506. The structure shown may be further supported by an exterior sealing layer 502 which encloses the join between sealing layers 503 and 504. In some embodiments, the exterior sealing layer 502 has is an angle profile spanning down each outward side of the edge join of the exterior panels 36B. Similarly, the structure may be further supported by an interior located sealing layer 501. The interior sealing layer 501 has is an angle profile spanning down each side of the edge join of the interior side of the interior panels 36A.

Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth. Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope of the invention as set out in the claims.

Claims

1. A building system comprising a structural connector apparatus the apparatus comprising: a first (204, 2191) and a second (206, 219) horizontally orientated flange member spaced apart and joined by a vertically orientated web member (203, 211); a third horizontally orientated flange member (202, 216) located between the first and second horizontally orientated flange members, wherein the third horizontally orientated flange member comprises an inward end connected to the web member, and an outward end extending beyond at least the extent of the first horizontally orientated flange member; a first vertically orientated support member (201 , 215) having a lower end connected to the third horizontally orientated flange member, and an upper end supported relative to the locations of the first and third horizontally orientated flange members.

2. The system of claim 1 , wherein the vertically orientated support member (201 , 215) has an upper end connected to the first horizontally orientated flange member.

3. The system of claim 1 or claim 2, wherein the outward end of the third horizontally orientated flange member (202, 216) extending past the extent of at least the first horizontally orientated flange member defines a surface adapted to vertically support a floor joist.

4. The system of any one of claims 1 to 3, wherein the first vertically orientated support member (201, 215) defines a surface adapted to connect with a floor joist which is supported by the third horizontally orientated flange member (202, 216).

5. The system of any one of claims 1 to 4, wherein the apparatus further comprises a second vertically orientated support member (213) configured laterally adjacent to and connected with the web member (211), wherein: the inward end of the third horizontally orientated flange member (216) is connected to the second vertically orientated support member (213), a fourth horizontally orientated flange member (214) is connected to the upper end of the third horizontally orientated flange member (216) at an outer end, and at an inner end, connected to the second vertically orientated support member (213).

6. The system of any one of claims 1 to 5, wherein the second vertically orientated support member (213), the third horizontally orientated flange member (216), the fourth horizontally orientated flange member (214), and first vertically orientated support member (215) comprise a substructure adapted for connection to the vertically orientated web member (211).

7. The system of any one of claims 1 to 6, wherein the first (204, 2191) horizontally orientated flange member, the vertically orientated web member (203, 211) or the second vertically orientated support member (213), and the fourth horizontally orientated flange member (214) define a recess (217) adapted to receive an insulating panel or floorboard.

8. The system of any one of claims 1 to 7, wherein the first horizontally orientated flange member (204, 2191), the second horizontally orientated flange member (206, 219) and the vertically orientated web member (203, 211) comprise a PFC beam, I-beam or universal column beam.

9. The system of any one of claims 1 to 8, wherein the third horizontally orientated flange member (202, 216), the vertically orientated web member (203, 211) or the second vertically orientated support member (213), and the second (206, 219) horizontally orientated flange member define a recess (205, 218) adapted to receive an insulating panel.

10. The system of any one of claims 1 to 9, wherein the upper surface of the first (204, 2191) horizontally orientated flange member is configured to support one or more of a structural post, an insulating panel, and/or an insulating panel connector.

11 . system of any one of claims 1 to 10, further comprising: a panel connector component adapted for support by the structural connector apparatus; an insulating panel comprising a panel connector disposed at at least one end; and wherein the panel connector component comprises a connector complementary to that of the insulating panel such that an interlocking engagement is created when placed together.

12. The system of claim 11 , wherein the panel connector component comprises an exterior orientated surface configured to extend down the exterior orientated surface of the structural connector apparatus, and, the lower extent of the exterior orientated surface comprises a water wicking formation adapted to extend downward and away from the structural connector apparatus.

13. The system of claims 11 or claim 12, wherein the connector component comprises an inwardly orientated end adapted to engage within a concrete pad supported by the structural connector apparatus.

14. The system of any one of claims 11 to 13, wherein the connector component comprises vertically extending walls which extend from a lower surface supported by the structural connector apparatus, wherein the walls and lower surface define an interior region adapted to receive the insulating panel.

15. The system of any one of claims 1 to 14, wherein the system further comprises a weather sealing cover, the cover comprising: an upper end configured to extend inward of a cladding layer, and a lower end configured to extend below an intersection between the connector component and structural connector apparatus, the lower end further comprising a water wicking formation adapted to extend downward and away from the structural connector apparatus.

16. The system of any one of claims 1 to 15, wherein the system further comprises one or more structural posts adapted for support by the structural connector apparatus, wherein the upper region of the post is adapted to support one or more components of a ceiling or roof.

17. The apparatus of claim 16, wherein the structural post comprises a flange configured to connect with the upper surface of the first (204, 2191) horizontally orientated flange member by way of one or more fastener devices.

18. The system of claim 16 or claim 17, wherein the one or more components of a ceiling or roof comprises an upper plate member and an upper plate sealing layer comprising a surface extending from the top of the plate, down an interior orientated vertical surface, horizontally between the post and upper plate to the exterior of the post, and down the exterior orientated surface of the post.

19. The system of any one of claims 1 to 18, wherein the apparatus further comprises a fifth horizontal flange member (740) extending from the vertically orientated web member (203, 211) in a direction opposing the first horizontal flange member, the fifth horizontal flange member (740) adapted to support an exterior wall panel.

20. The system of any one of claims 1 to 19, wherein the system further comprises a foundation assembly adapted to vertically support the structural connector apparatus, the foundation assembly comprising: a ground engaging post, a member having a lower end configured to adjustably engage with the ground engaging post, and an upper end configured to support the structural connector apparatus, whereby adjustment of the member causes variable displacement between the ground engaging post and the structural connector apparatus.

21. The system of claim 20, wherein the foundation assembly further comprises an upper and lower bracket interspersed between the ground engaging post and the structural connector apparatus, and a resiliently deformable member located between the upper and lower bracket such that the weight of the structural connector apparatus is transmitted through the resiliently deformable member.

22. The system of claim 20 or claim 21 , wherein the resiliently deformable member is a rubber block.

23. The system of any one of claims 20 to 22, wherein the foundation assembly further comprises fastener components extending through the resiliently deformable member and each of the upper and lower bracket so as to couple the upper and lower bracket to the resiliently deformable block.

24. The system of claim 11 , wherein the insulation panel comprises a polyurethane based form core laminated with outer layers comprising a metal sheet.

25. The system of claim 24, wherein the insulation panel comprises a layup of a metal layer, a synthetic fibre layer, a polyurethane based foam panel layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a polyurethane based foam panel layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a metal layer, a synthetic fibre layer, a polyurethane based foam panel layer, a synthetic fibre layer, and a metal layer.

26. The system of claim 25, wherein each of the synthetic fibre layers comprise an aramid cloth.

27. A building assembly comprising the structural connector apparatus of any one of claims

1 to 26, wherein the assembly comprises: two or more structural connector apparatus arranged on a plane in an opposing orientation such that each of the third horizontally orientated flange members from each apparatus are pointed inward, and a floor joist is arranged to span between the two or more apparatus.

28. The assembly of claim 27, wherein the floor joist is connected, at each end, to the first vertically orientated support member of a structural connector apparatus.

29. The assembly of claim 27 or claims 28, wherein the assembly further comprises one or more insulated panels spanning between and supported by the opposing structural connector apparatus.

30. The assembly any one of claims 27 to 29, wherein the end region of an insulated panel is enclosed by a recess above or below the third horizontally orientated flange member.