BACKGROUND OF THE INVENTION

Hitherto it has been very difficult in relation to insulated building panels for providing access in said panels for service such as electrical wiring or hot and cold water pipes, gas pipes or channels through which solar heated air may be passed or cold air as the case may be. Use can be made of structural panels formed of ribbed structures of thermoplastic resin such as described in US Patent 3664906 or FR 2828132 but such structural panels are complicated in construction or expensive to manufacture. Alternatively it was necessary to provide insulation panels having an upper face which contained grooves or channels to facilitate in the evaporation of moisture through the insulation channels to the outside atmosphere as described in US Patent 4492064. Alternatively it was necessary to provide insulated panels containing a plurality of spaced projections forming a network of interconnected air channels which are complicated in construction and costly to produce as described in US Patent 5473847. Alternatively use could be made of channels formed from galvanized steel in insulated panels as described in US Patent 5638651 or channels located on an upper surface of an insulation layer or core such as described in US Patents 4712349, 4677800, 4628650, 4586304, 4492064 and 5260525. However the location of these channels often makes it difficult to access services internally. Reference also may be made to US Patent 7797908 which described an insulated panel formed from metal components as separate pieces and where there were provided a series of fingers extending therefrom. The two metal components could be attached together near tips of the fingers so that an alternative sequence of fingers and spaces through which spaces wires or pipes may be passed. However, again the panel was complicated in construction and expensive to manufacture. JP 8312121 provides a wall assembly having an inner wall frame which is fixed to a heat insulative outer wall panel and there is also provided an inner wall backing board formed from plaster. Electrical wiring or gas or water pipes are located in a space between the backing board, inner wall frame and heat insulative outer wall panel thereby avoiding the formation of holes in the heat insulative outer panel. Again however such wall assembly is complicated in construction.

US Patent 5771645 relates to cuts being made to insulation cores of panels in the form of elongate channels or slots which are made by a hot wire for the purpose of locating electrical wiring and pulling out foam strips through a hole in an outer facing of the panel. However this method is not only complicated but expensive in manufacture.

US Patent 3707165 refers to a wall unit having integrally formed surface panels and a foam core which surrounds hot and cold water pipes and drain and vent piping along with electrical wiring. The foam is pumped into a hollow interior of the wall unit after initial attachment of the hot and cold water pipes and drain and ^' vent piping and electrical wiring to the wall unit. US Patent 3783563 refers to prefabricated building construction using panel and connector modules which are elongate beams having longitudinally extending open channels adapted to receive complementary ribs on the edges of flat panel modules. The connector modules are provided with interior passageways constituting conduits for electrical wiring, heating water and waste facilities. These interior passageways were formed integrally into the connector modules and thus the connector modules were expensive to manufacture.

US Patent 4777774 refers to extruded panel components joined together to form a building structure which are internally ribbed and may be partially or fully insulated. Internal conduits in the panel components provide passageways for electrical wiring, plumbing and other required services or utilities. If fully insulated the foam material is injected into each panel component. The practice of pumping or injecting foam material into a hollow interior of a panel as described in US Patents 4777774 and 3707165 was expensive and required initial attachment of wiring looms or pipes to an internal frame which could be time consuming and difficult in certain cases.

OBJECT OF THE INVENTION

It is therefore an object of the invention to provide a building system which reduces the problems of the prior art and which is simple and effective in practice.

SUMMARY OF THE INVENTION

The invention therefore in one aspect provides a building system which includes one or more insulated wall panels having a core of insulation material wherein one or more internal passages are formed in said core and services are located in a respective passage including electrical wiring and plumbing facilities inclusive of plumbing pipe(s) whereby a cable support member such as a cable tray is located adjacent one or more said insulated panels for supporting electrical wiring which is then passed through said one or more internal passages and said plumbing pipe(s) are passed through said one or more internal passages for accessing internally of said insulated panels.

In this building system the cable tray may be supported by one or more support brackets which are attached directly to a roof panel which also may be an insulated panel. The support bracket(s) may also be directly attached to the wall panel(s).

The cable tray may also be used for supporting plumbing pipes inclusive of hot and cold water pipes which may be passed from the cable tray into the internal passages. In this building system there also may be provided an attachment spike which suitably has a plate or shank with outwardly extending barbs for insertion into an insulation core of a roof panel. The spike may have an attachment plate to which a fascia bracket or gutter bracket may-be attached. Also in this building system there may be provided an access assembly for accessing plumbing pipes and this may include a plate located within a mounting frame optionally having a cover attached thereto wherein the access assembly may be located in a mounting aperture in the wall panel. The plate may be formed from plywood or other suitable material for attachment of taps and faucets and the like.

In another aspect of the invention there may be provided a ridge or hip or valley assembly having a main support beam having a pair of outwardly projecting flanges for carrying a plurality of roofing panels on each side of the main support beam and provided with a tensioning wire or cable within a hollow interior of the main support beam to stabilize the beam when supported by a plurality of support posts or other support members.

The invention also includes within its scope a method of manufacture of a panel or wall assembly for use with a building which includes the steps of:

(a) forming a panel assembly including a plurality of panels at a manufacturing site remote from an installation site wherein said panels are provided with one or more internal passages or service ducts as well as a multiplicity of support columns or tubes which may be provided at a junction between adjacent panels or intermediate said junctions;

(b) attaching said plurality of panels to a bottom plate and top plate respectively at said manufacturing site;

(c) transporting said plurality of panels to an installation site wherein a hold down mechanism is employed to attach each of said panels to a support surface wherein each support column or tube is attached directly to said support surface; and

(d) installing electrical wiring or plumbing facilities within said service ducts at either the manufacturing site or the installation site.

The invention also includes within its scope an attachment spike having an insertion component which carries a plurality of barbs for penetrating insulation material or material having a similar consistency and an attachment component to which a gutter bracket or fascia bracket may be attached. The attachment component may be oriented at a plurality of different angles to vertical to allow for different angles of raked roof panels.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

Reference may be made to a preferred embodiment of the invention as shown in the attached drawings wherein:

FIG 1 is a perspective view of a building in the form of a house partially constructed in accordance with the building system of invention;

FIG 2 is a perspective view showing how the wall panels forming part of the building shown in FIG 1 are attached to each other and also to a concrete slab;

FIG 3 is a plan view of the wail panel;

FIG 4 is a cross sectional view of the wall panel shown in FIG 3 along the line A-A; FIG 5 is a perspective view of the wall panel shown in FIG 3 and FIG 4 together with an adjacent support post or upright;

FIG 6 is a detailed view of a top end "P" of the support post shown in FIG 5;

FIG 7 is an exploded perspective view similar to FIG 2 taken from another angle; FIG 8 is a side view of the wall panel shown in FIG 7;

FIG 9 is a detailed perspective view of a fastener used to connect the top wall to each wall panel shown in FIG 7 shown by location "F" in FIG 7;

FIG 10 is a side view of a threaded rod and bottom rail member or bottom plate used to connect each wall panel shown in FIG 7 to the concrete slab;

FIG 10A is a sectional view of an alternative building system for use in the invention;

FIG 10B is a detail of area "A" of FIG 10A;

FIG 10C is a detail of area "B" shown in FIG10A;

FIG 10D is a perspective view of the building system shown in FIG 10A;

FIG 10E is a detail of area "C" shown in FIG 10D;

FIG 10F is a detail of area "D". shown in FIG 10D;

FIG 10G is a detail of area Έ" shown in FIG 10D; FIG 10H is a plan view of an alternative roll formed top plate for use in the invention; FIG 101 is an end view of the top plate shown in FIG 10H

FIG 11 is a view showing the interconnection of a wall panel to the concrete slab and also to a raked or angled roof panel;

FIG 12 is a detailed view of area "K" shown in FIG 11 ;

FIG 13 shows a perspective view of a roof panel and adjacent attachment spike used for attaching the roof panel to a fascia bracket;

FIGS 14- 5 are alternative views of the attachment spike shown in FIG 14;

FIG 16 shows a perspective view of the attachment of the roof panels to an adjacent wall assembly;

FIG 17 is a detailed view of the area marked "W" shown in FIG 17;

FIG 18 is a side view of the assembly of roof panels and wall panels shown in FIG 16;

FIG 19 is a perspective view of the assembly shown in FIG 16 from the underside;

FIG 20 is a perspective view of the fascia bracket;

FIG 21 is a detailed view of area "T" shown in FIG 20;

FIG 22 is a perspective view of the support bracket used for supporting the cable tray shown in FIG 20;

FIG 23 shows a method of internally accessing electrical or water facilities which extend through an adjacent wall panel;

FIG 24 is an exploded perspective view of the accessing assembly used in, the method of FIG 23;

FIG 25 is a view of a ridge support system for supporting roof panels;

FIG 26 is a detailed view of location "S" shown in FIG 25;

FIG 27 is a perspective view from the underside of the assembly shown in FIG 26; FIG 28 is a perspective view of a threaded support rod for use in the ridge support system shown in FIG 26;

FIG 29 is a plan view of the ridge beam ^' assembly shown in FIG 26;

FIG 30 is a side view of the ridge beam assembly shown in FIG 29;

FIG 31 is a sectional view of the roof support beam shown in FIGS 29-30 along the line X-X showing a cable or wire tensioning arrangement;

FIG 32 is a detail of location "A" shown in FIG 31 ;

FIG 33 is a detail of location "B" shown in FIG 31 ; FIG 34 is a detail of location "C" shown in FIG 31 ;

FIG 35 is a front view of the ridge beam assembly shown in FIG 29, 30 and 31 ;

FIGS 36-37 show an alternative embodiment in relation to a bottom support rail assembly for the wall of insulated panels to that shown in FIG 10; and

5 FIG 38 is a plan view of a schematic roof of a house or other building showing simple hip lines, a simple ridge line and a simple valley.

In the drawings there is shown in FIG 1 a building in the form of a house 10 which includes a concrete slab 11 , wall 12 having adjacent wall panels 13, roof support rods It) or posts 14 and roof 15 having a ridge beam 16 and roof panels 17 supported by ridge beam 16 and wall panels 13.

In FIG 2 there is shown wall 12 having a plurality of adjoining panels 13 having a support column or rod 9 which engages with adjacent side edges 15 of each panel 13 15 as shown in FIG 5 wherein support rod 9 is received in each longitudinal groove 16 bounded by planar areas 17. There is also provided a top support beam or top plate 18 and a bottom support channel or bottom plate 19 for accommodating bottom edges 20 of each panel 13 as shown in FIG 7. Top support beam 18 is attached to groove 32 of each panel 13 by fasteners 2 .

0

In FIGS 3-4 there is shown insulated panel 13 having metal skins 22 and 23 and a core 24 of insulation material. Extending through the core 24 are longitudinal slots or passages 25 which are service ducts. 5 FIG 5 as mentioned above, shows upright support rods 9 and accommodating grooves 16.

FIG 6 shows a top end 27 of support rod 9 having a cap 28 and internally threaded stud 29 which is engaged by shank 38 of each fastener 21 shown in FIG 9.

30 In FIGS 7-8 there is shown top plate or top support beam 18 which includes a pair of RHS rails welded to each other wherein rail 30 is received in groove 32 of each panel 13 and rail 31 is received in recess 33 formed by flange 34 of metal skin 23 and projection 35. Groove 32 is located between projection 35 and flange 36 of metal skin 22.

Top plate 18 also includes apertures 37 which are engaged by fasteners 21 wherein 5 shank 38 shown in FIG 9 extends through washers 39 shown in FIG 8 and washers 40 of fasteners 21 abut top plate 18.

In FIG 10 there is shown detail of bottom plate 19 or channel 9 which has screw threaded studs 41 extending upwardly from slab 11 to engage with a threaded bottom I0 end 42 of each support rod 9 shown in FIG 5. Bottom plate 19 also has flanges 43 and 44 as well as weather strip 45. Bottom edge 20 of each panel 13 engages with channel 19 as shown in FIG 7.

In another embodiment of the invention as shown in FIGS 10A, 10B, 10C, 10D, 10E J 5 and 10F there is provided a panel assembly 13A farmed by adjoining panels 37 A which have attached thereto a top plate 8 and bottom plate or channel 19. In regard to top plate 18 and as shown in detail in FIG 10A there is provided a rod or booker rod 9A which is threaded at a top end to engage with a cap plate 28A and nut 8B so as to correct top plate 18A to panel assembly 13A. It will be noted that rod 9A 0 extends through an internal bore 9C of a tube 9B which extends through panel assembly 13A at spaced intervals and usually but not essentially at a junction between adjoining panels 37A as shown in FIG 10B. Tube 9B is different from tube 9 shown in FIG 6 in that it does not have a cap 28 or threaded bottom end 42 and is just a length of plain tube of constant diameter. The booker rod 9A has a hexagonal 25 coupling 18B which may be attached to a threaded stud 9D which is embedded in concrete slab 1 as shown in FIG 0C.

In FIGS 10D, 10E, 10F and 10G it will be noted that panel assembly 13A are provided with fasteners 19B in outer skin 23 adjacent top plate 8 as well as fasteners 19C in 30 bottom channel 19. The purpose of fasteners 19B is to securely attach top plate 18 or 18A to panel system 13A and this is shown for example in phantom in FIG 8. The purpose of fasteners 9B is to securely attach bottom plate or channel 19 or 9A to panel system 13 and this is shown for example in FIG 7 in phantom wherein each fastener 19B 5 extends through adjacent flanges 34 and 36 and each fastener 9C extends through adjacent flanges 43 and 44.

In FIG 10G is shown a roll formed version of a top plate 18A which includes apertures 29A in web 29B as well as flanges 30A and 30B which correspond to flanges 31 and 10 30 of top plate 18 shown in FIG 8. The apertures 29A are aligned with passages 25 in each panel 13 or 37 A. There is also provided recess 30C. It will be appreciated as shown in FIG 6 top plate 18A will engage with a correspondingly shaped top end of panel 37A. FIG 10F shows that flange 30 of top plate 18A may also have openings 29A at spaced locations to correspond with passages 25.

I 5

FIGS 1 1-12 show the inclusion of an alternative top plate or top beam 18B which is useful for supporting angled or raked roof panels 17. In this arrangement top plate 18B has a pair of RHS rails 47 and 48 welded to each other wherein vertical rail 47 is located in recess 49 of panel 13 and rail 48 is attached to each support rod 9 by 0 fasteners 50 extended through opposed washers 51 and 52. Each roof panel 17 includes flat areas 62.

It will be appreciated that cross sectional profiles of top plates 18, 18A and 18B may be varied as required to suit a flat roof or skillion roof as is the case with top plate 8 5 or raked or angled roofs as is the case with top plate 18A.

FIGS 13- 5 show the inclusion of an attachment spike 55 which has a flange 56 with barbs 57 and a plate 58 normal thereto or which may be oriented at an angle to horizontal such as 10° - 35° as shown by lines 56A in phantom. Attachment spike 55 0 may be inserted into a foam layer 59 of a roof panel 17 as shown in FIG 13 by the arrow for supporting a fascia bracket 61 which is shown in FIG 16. Roof panel 17 includes planar areas 62 and ribs 63. In FIG 16 there is shown the structural detail of a roof overhang 64 which includes the wall panels 13 and top plate 18 already shown in FIGS 7-8. There is also shown cable tray 66 which has a plurality of attachment apertures 67 for inclusion of ties (not shown) for securing wiring looms or harnesses 68 shown in FIG 17. There is also provided a series of mounting brackets 69 attached to an adjacent metal skin 23 of wall panels 13 by fasteners 70 and 70A as best shown in FIG 22. Each mounting bracket 69 has an aperture 71 through which each cable tray 66 may be passed. Fasteners 70A also attach each mounting bracket 69 to roof panels 17. In FIGS 18-19 there is shown the inclusion of hot and/or cold water pipes 72 in each internal passage 25 of insulated wall panels 3 wherein an upper end 73 of each pipe is supported by an adjacent cable tray 66. In fact a series of pipes 72 may be supported in cable tray 66 by a proximal flange 74 of cable tray 66. There is also shown an additional support 75 for pipes 72. There is also shown in FIGS 18-19 how each fascia bracket 61 shown in detail in FIG 20 is attached to a proximal support plate 58 of each attachment spike 55 wherein fasteners (not shown) may extend through apertures 75 as shown in planar component 76. Planar component 77 has a mounting slot 78 and mounting parts 79 and 80 supporting a fascia (not shown) as best shown in FIG 20.

FIG 18 also includes gutter 81 and horizontally oriented insulated panel 82 supported by beam 48. Panels 17 are also attached to beam 48 by fasteners 83.

In FIGS 23-24 there is shown an access facility for pipes 72 which are included in slots 25 of each wall panel 13 as described above. Thus a suitable access assembly 84 is shown in FIG 24 and includes a mounting frame 85, plywood plate 86 and cover plate 87. Each of tabs 88 of cover plate 87 may be inserted into corresponding slots 89 and there is also provided inner spikes or tabs 90 which may be inserted into plywood plate 86 or bent around the edges of plywood plate 86 to retain plywood plate 86 within mounting frame 85. Each plywood plate 86 may then be used for supporting a tap or faucet (not shown) for accessing water flowing in pipes 72. Each i I of cover plate 87, plywood plate 86 and mounting frame 85 may be mounted in a recess 91 of each panel 13 as shown in FIG 7 to gain ^' access to pipes 72.

In FIGS 25-28 there is shown a roof support system or more particularly a ridge support system 92 wherein support posts 14 are each provided with a pair of threaded studs 93 which are attached to an adjacent end of a support post 14 by nuts 94 whereby threaded studs 93 have a lower end 102 which extends into a hollow interior 95 of each support post 14 as shown in FIG 27. Each threaded stud 93 has a U shaped bracket 96 at its top end as shown in FIG 28 for supporting a ridge beam assembly 97. The bracket 96 has opposed apertures 98 for insertion of fasteners 99 into ridge beam assembly 97, Ridge beam assembly 97 is also provided with planar flanges 100 welded to an RHS component 101 as also best shown in FIG 27.

In FIGS 29-35 there is shown a detailed view of ridge beam assembly 97 and there is provided an elongate hollow beam or RHS component 101 which has a wire or cable 103 located in hollow interior 104 of channel component 101. Cable 103 is supported at one end 105 by one of a pair of bolts 106 and there is also an intermediate or middle pair of bolts 107 as well as a pair of plates 108 located at the other end 109 of channel component 101. Each plate 108 has a threaded aperture 109A and a nut 110 so that the cable 103 may be tensioned as required by an appropriate tool such as a screwdriver (not shown). Each bolt 07 and 108 and each plate 109 is provided in duplicate for ease in installation of ridge beam assembly 97 to roof panels 17 and support rods 14. In FIGS 36-37 there is provided an alternative bottom plate or bottom support 110 for each insulated panel 13 included in wall assembly 12. This is shown in more detail in FIG 37 where there is provided a bottom plate or beam 110 attached to a side surface 111 of concrete slab 112 by fasteners 113. Bottom plate 10 is also provided with an outer retaining flange 114 for supporting insulated panels 13 as. well as an inner flange 1 5 and top lip 116 which is attached to the top surface 1 17 of slab 11 by fasteners 1 18. There is also provided drain apertures 19 in web 120 of bottom plate 1 0, Each drain aperture may be formed by punching out a section of metal so to form a cut out in the shape of drain apertures 119 with the tab 121 punched out from cut out 119 then bearing against side surface 111 to provide additional support for bottom plate 110. In FIG 38 a view is provided showing a simple hip, a simple ridge and a simple valley constructed in accordance with the invention. The term "simple" is used herein to describe a ridge, hip or valley which has a much simplified structure in comparison to the prior art. In relation to the ridge, the construction thereof is as shown in FIGS 25- 35. In regard to the hip, the construction thereof is also as shown in FIGS 25-35. Concerning the valley, the construction thereof is different with flanges 100 changed to have an upward slant to horizontal instead of a downward slant as shown in phantom lines 97A and 97B shown in FIG 25.

It will also be appreciated that as shown in FIGS 31 -35 that in some cases use may be made of a pair of tensioning cables or wires which each are attached to an adjacent bolt 106, extend around an adjacent bolt 107, and are attached to attachment plate 108. The use of one or more tensioning cables 103 greatly increases the stability of the beam 97 and its support when supported by support rods 14,

In the practice of the invention it is necessary to the manufacture of wall 12 shown in FIGS 1-10 or wall or panel assembly 13A shown in FIGS 10A-10G that the following steps are followed: (i) the panels 13 or 37A are laid down flat and a choice is made concerning support columns or tubes 9 or 9B which may have a round cross section, RHS or other suitable cross section shape. The location of such support columns is made in accordance with engineering requirements which may vary from location to location. This also applies to location of hollow passages or service passages 25 which is also chosen according to engineering requirements. It also is appropriate to utilise instead of support columns 9 or 9B and service passages 25 that adjacent panels 13 or 37A may be connected to each other by a rib-socket interaction accompanied by use of sealant. Sealant may also be used in regard to installation of support columns 9 or 9B

the panels 13 or 37A are then located in bottom plate or channel 19 and a holding down system such as by use of columns 9 shown in FIGS 1-10 or use of tubes 9B shown in FIGS 10A-10G is then employed wherein panels 13 or 37A are retained within bottom plate by fasteners 19C and are also retained in top plate 18 or 18A by fasteners 19B. At this stage the location of the use of support columns 9 or tubes 9B is then chosen according to engineering requirements as well as the choice of service passages 25. In this regard loadings are one element that has relevance to choice of locations of support columns 9 or tubes 9B. Service passages 25 are usually chosen within or internally of panels 13 or 37A and the use of support columns 9 or tubes 9B are usually located at the junction of adjoining panels 13 or 37A. In one example one may have 3 service ducts at 300mm centres in relation to a panel of 1200mm width

after service ducts 25 have been located wiring 68 and pipes 72 may then be located in service ducts 25 as shown in FIG 18

the formation of apertures 72 in panels 13 or 37A may then be carried out followed by insertion of frame 85 and plywood plate 86 and cover plate 87 the wall 12 or 37A may then be lifted into a vertical orientation and each wall transported to an installation site

after being retained in a vertical orientation at the installation site the hold down systems inclusive of support columns or rods 9 or booker rods 9B are then connected to bottom plate 19 and top or bottom plate 8 or 18A after step (vi) roof panels 17 are then installed as shown in FIGS 11-12 and cable trays 66 are installed by attachment of support brackets 69 to walls 2 or 13A as shown in FIGS 13-22. At this stage wires 68 and pipes 72 are supported in cable trays 66

installation of panel 82 which is supported by beam 48 shown in FIG 18 wherein roof panels 17 are attached to beam 48

installation of ridge support system 92 and ridge beam assembly 97. The advantage of construction of hips, ridges and valleys as described above means that construction time is substantially reduced thereby saving costs and is much more efficient. Another advantage of the ridge, hip or valley assembly of the invention is that there is no need for conventional roof bearers such as trusses or joists.

Also in relation to the insulated panels for use in the invention it will be appreciated that use may be made of suitable skins which may be formed of metal or any other suitable rigid facing. The insulation core may be formed from foam material such as polystyrene or polyurethape.