SCHOCK, Robert John Leslie (1 Avalon Rise, Carine, Western Australia 6020, AU)
SCHOCK, Michael James (14 Euston Street, Wembley Downs, Western Australia 6019, AU)
SCHOCK, Robert John Leslie (1 Avalon Rise, Carine, Western Australia 6020, AU)
| CLAIMS : 1. A method of constructing a building, said method comprising : prefabricating at least one building module prior to transportation to site, each building module comprising at least two connected sections that extend in different directions, each section including at least two panels and settable filler material disposed between the panels; transporting the at least one building module to a construction site; and constructing the building at the construction site using the at least one building module. 2. A method as claimed in claim 1, wherein the prefabricated building module is a prefabricated accommodation module. 3. A method as claimed in claim 2, wherein the prefabricated accommodation module comprises a preinstalled internal fit out. 4. A method as claimed in any one of claims 1 to 3, wherein the step of prefabricating a building module comprises providing a plurality of fabrication stations, and providing tracks arranged to enable building modules at different stages of fabrication to move between the fabrication stations. 5. A method as claimed in any one of the preceding claims, wherein the step of prefabricating a building module comprises constructing a base slab and/or a roof slab . 6. A method as claimed in any one of the preceding claims, wherein the step of prefabricating a building module comprises providing a plurality of panels, providing one or more joining devices for joining and holding the panels at a desired relative location and spacing, joining the panels together so as to define walls of the building module with each wall having two spaced panels defining a space therebetween, and pouring concrete material into the spaces between the panels. 7. A method as claimed in any one of the preceding claims, wherein the step of prefabricating a building module comprises disposing plaster on internal walls of the building modules. 8. A method as claimed in any one of the preceding claims, wherein the step of transporting the at least one building module to a construction site comprises loading a building module onto suitable transport at a dispatch station . 9. A method as claimed in any one of the preceding claims, wherein at least one panel comprises a thermally insulating panel. 10. A method as claimed in claim 9, wherein at least one insulating panel comprises expanded polystyrene material. 11. A method as claimed in any one of the preceding claims, wherein at least one panel comprises a non- thermally insulating panel. 12. A method as claimed in any one of the preceding claims, wherein the filler material comprises concrete. 13. A method as claimed in any one of the preceding claims, wherein the prefabricated building module is a prefabricated C, H or I section module. 14. A prefabricated building module comprising: at least two connected sections, each section including at least two panels and settable filler material disposed between the insulating panels, and the sections being connected together so as to extend in different directions; the prefabricated building module being transportable to a construction site for inclusion in a building. 15. A system as claimed in claim 14, comprising at least one joining device for joining and holding the panels at a desired relative location and spacing prior to receiving settable material between the panels. 16. A system as claimed in claim 14 or claim 15, wherein the building module comprises a preinstalled internal fit out . 17. A system as claimed in any one of claims 14 to 16, wherein the at least one panel comprises a thermally insulating panel. 18. A system as claimed in claim 17, wherein at least one insulating panel comprises expanded polystyrene material. 19. A system as claimed in any one of claims 14 to 18, wherein the at least one panel comprises a non-thermally insulating panel. 20. A system as claimed in any one of claims 14 to 19, wherein the filler material comprises concrete. 21. A system as claimed in any one of claims 14 to 20, wherein the prefabricated building module comprises a prefabricated C, H or I section module. 22. A system as claimed in any one of claims 14 to 21, wherein the prefabricated building module is a prefabricated accommodation module. 23. A building construction system comprising: a plurality of prefabricated building modules as claimed in any one of claims 14 to 22; the prefabricated building modules being used at a construction site to construct a building. 24. A system as claimed in claim 23, comprising a plurality of fabrication stations, and tracks arranged to enable building modules at different stages of fabrication to move between the fabrication stations . 25. A system as claimed in claim 24, comprising at least one fabrication station for constructing a base slab and/or a roof slab of a building module. 26. A system as claimed in claim 24 or claim 25 when dependent on claim 15, comprising at least one fabrication station for joining and holding the panels at a desired relative location and spacing using the at least one joining device and disposing settable material between the panels . 27. A system as claimed in any one of claims 24 to 26, comprising at least one fabrication station for applying render and/or cladding to internal and/or external walls of the building module. 28. A system as claimed in any one of claims 24 to 27 when dependent on claim 16, comprising at least one fabrication station for providing the building module with an internal fit out. 29. A method of constructing a building, a prefabricated building module, or a building construction system substantially as hereinbefore described with reference to the accompanying drawings. |
Field of the Invention The present invention relates to a construction system, to a method of construction, and to a building module for use in the construction method.
Background of the Invention
It is known to provide a construction method wherein a plurality of panel members are joined together so as to define a space, and settable filler material, such as concrete, is poured between the panels. An advantage of this type of construction method is that strong building walls can be constructed on site with the shape of the wall being readily customizable by selecting appropriately shaped panels . Summary of the Invention
In accordance with a first aspect of the present
invention, there is provided a method of constructing a building, said method comprising:
prefabricating at least one building module prior to transportation to site, each building module comprising at least two connected sections defining an angle
therebetween, each section including at least two panels and settable filler material disposed between the panels; transporting the at least one building module to a construction site; and
constructing the building at the construction site using the at least one building module. In one embodiment, the prefabricated building module is a prefabricated accommodation module. In one arrangement, the prefabricated accommodation module comprises a preinstalled internal fit out.
In one embodiment, the step of prefabricating a building module comprises providing a plurality of fabrication stations, and providing tracks arranged to enable building modules at different stages of fabrication to move between the fabrication stations . In one embodiment, the step of prefabricating a building module comprises constructing a base slab and/or a roof slab .
In one embodiment, the step of prefabricating a building module comprises providing a plurality of panels,
providing one or more joining devices for joining and holding the panels at a desired relative location and spacing, joining the panels together so as to define walls of the building module with each wall having two spaced panels defining a space therebetween, and pouring concrete material into the spaces between the panels.
In one embodiment, the step of prefabricating a building module comprises disposing plaster on internal walls of the building modules.
In one embodiment, the step of transporting the at least one building module to a construction site comprises loading an building module onto suitable transport such as a dispatch truck at a dispatch station.
In one embodiment, at least one panel comprises thermally insulating material . In one embodiment, all panels comprise thermally
insulating material. In an alternate embodiment, at least one panel comprises non-thermally insulating material. In one embodiment, each insulating panel comprises expanded polystyrene material. In one arrangement, the filler material comprises
concrete .
In one embodiment, the prefabricated building module is a prefabricated C, H or I section module.
In accordance with a second aspect of the present
invention, there is provided a prefabricated building module comprising:
at least two connected sections, each section including at least two panels and settable filler material disposed between the insulating panels, and the sections being connected together so as to extend in different directions ;
the prefabricated building module being transportable to a construction site for inclusion in a building.
In accordance with a third aspect of the present
invention, there is provided a building construction system comprising:
a plurality of prefabricated building modules, each building module comprising at least two connected
sections, each section including at least two panels and settable filler material disposed between the insulating panels, and the sections being connected together so as to extend in different directions;
the prefabricated building modules being used at a construction site to construct a building.
Brief description of the drawings
The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Figure 1 is a diagrammatic perspective view of a plurality of prefabricated modules according to an embodiment of the present invention;
Figure 2 is a diagrammatic perspective view of a prefabricated module according to a further embodiment of the present invention;
Figure 3 is a diagrammatic perspective view of a plurality of prefabricated modules stacked together;
Figure 4 is a diagrammatic perspective view of a plurality of prefabricated modules stacked together so as to form a building;
Figure 5 is a diagrammatic perspective view of a prefabricated accommodation module; and,
Figure 6 is a diagrammatic perspective view of a fabrication facility for fabricating accommodation modules of the type shown in Figure 5.
Description of an Embodiment of the Invention
Referring to the drawings, in Figure 1 a plurality of prefabricated building modules 10 are shown, in this example each module 10 being of generally I-section shape. In this specification it will be understood that the term "prefabricated" in relation to an item will be understood to mean that the item concerned is fabricated prior to on site construction of a building; in other words, the item concerned is not fabricated in situ.
Each prefabricated building module 10 comprises several panels 12, in this example of insulating type formed of expanded polystyrene (EPS) material with a density of the order of 28 kg/m 3 , although it will be understood that any suitable material may be used. Between the panels 12 is disposed filler material such as concrete so as to provide the building module 10 with the necessary rigidity and the strength required, in this example for a wall of a building .
While the present embodiment uses insulating panels 12, it will be understood that other types of panels are
envisaged, such as non-thermally insulating panels, for example formed of magnesium oxide board or aluminium composite board. It will also be understood that the building module 10 may comprise a combination of
insulating panels and non-insulating panels. The non- insulating panels may be about 12mm thick, although it will be understood that any suitable thickness is
envisaged . The building module 10 may also be reinforced, for example by providing reinforcing members, such as steel rods or a steel grid, between opposite panels 12.
It will be understood that the prefabricated building modules 10 may be constructed in any suitable way. For example, the panels 12 may be joined together using connectors which span across the space defined between the panels 12 and connect to associated receiving devices formed in or attached to the panels 12. After the insulating panels 12 have been connected together in this way, filler material such as concrete 14 may be poured into the space between the panels 12 and allowed to set.
As shown in Figure 1, the prefabricated building modules 10 may be transported to site and stacked on top of each other during a building construction process, for example so as to define walls of the building.
An alternative prefabricated building module 20 is shown in Figure 2. As with the building module 10 shown in
Figure 1, the building module 20 includes panels 22, in this example of insulating type, between which is disposed filler material such as concrete during a prefabrication process. The module 20 also includes a base panel 26, in this example formed of concrete material which extends horizontally between two generally vertically disposed concrete sections. The base panel 26 may optionally be formed in a similar way to the walls of Figure 1 defined by the insulating panels 12 and intermediate concrete so as to incorporate a degree of insulation. As shown in Figure 3, prefabricated modules 30 of the type shown in Figure 2 may be transported to site and stacked on top of each other during a building construction process so as to define floors and/or ceilings, and walls of a building.
Referring to Figure 4, a building formed of a plurality of prefabricated modules 40 is shown, each module 40
comprising walls formed by panels between which filler material such as concrete 14 is disposed during a
prefabrication process.
Referring to Figure 5, a prefabricated accommodation module 50 complete with internal fitout is shown, walls of the prefabricated accommodation module 50 comprising panels 52, in this example of insulating type, with filler material disposed therebetween.
A fabrication facility 60 for fabricating building modules, in this example accommodation modules 50, is shown in Figure 6.
The fabrication facility 60 includes parallel tracks 62 arranged to enable accommodation modules 50 at different stages of fabrication to move between fabrication stations 64a, 64b, 64c, 64d, 64e and 64f.
At first and second fabrication stations 64a, 64b, a base slab 68 is constructed, in this example by pouring concrete material into a base form 66.
At a third fabrication station 64c, panels 12, in this example of insulating type, are joined together so as to define walls of the accommodation module 50, with each wall having two spaced panels defining a space
therebetween and one or more joining devices extending between the spaced panels for joining and holding the panels at a desired relative location and spacing.
Concrete material is then poured into the spaces between the panels 52 from a concrete repository 72 using a directable chute 74. Reinforcing members may also be incorporated into the concrete material at the third fabrication station 64c and a base slab and/or a roof slab may be formed. Lifting lugs may also be incorporated into the walls and/or a roof slab during fabrication of the walls and/or roof slab, the lugs (not shown) facilitating lifting of the module 50, for example by a crane.
At a fourth fabrication station 64d, plaster 76, render and/or cladding is disposed on internal and/or external walls of the accommodation modules 50, and services such as electrical and/or plumbing services incorporated into the modules 50. Furring strips may also be included so as to facilitate ease of attachment of the cladding.
At a fifth fabrication station 64e an initial internal fitout is carried out wherein items such as furniture 18 are disposed in the accommodation module 50. Final fitout is carried out at a sixth fabrication stage 64f wherein items such as a bed 82 are disposed in the accommodation module 50. In order to facilitate ease of installation of services, ducts may be provided in internal and/or external panels 12. The fabricated accommodation modules 50 are then loaded onto suitable transport such as a dispatch truck 90 at a dispatch station for transportation to the desired destination such as a mine site.
It will be appreciated that the present system and method envisages prefabrication of basic three dimensional building modules for subsequent transportation to site, which modules are strong and optionally insulated for energy efficiency. Since the modules are three dimensional in the sense that each module includes multiple connected panels, the modules may be readily stacked without the need for any bracing.
It will also be understood that building modules may be provided such that two or more modules together define an accommodation module, with the building modules being arranged such that by disposing multiple such modules side by side and/or stacked on top of each other, multiple accommodation modules may be defined with only single walls between them. In this way, excessive internal walls and associated material wastage is avoided.
Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.
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