BACKGROUND OF THE INVENTION

THIS invention relates to■ system and method for constructing■ bulking. Mora spedflcsJy, the invention relates to a system and method for constructing a cost- effective, modular, pf*4ebricated, boiled-together buMng capable of being quickly erected and, if required, easily disassembled, moved and re-erected such that the building may be used as a permanent or temporary stmcture.

BoHed-togetner but ding systems and methods are generaHy weO known in the art For example, U8 patent no. 3,845,502 discloses a system for modular construction that employs an Inner steel frame and outer dadding panels that are belted together to construct a home.

Although this prior art system provides a far quicker way of constructing houses as compared to the masonry systems used in many countries, H has three shortcoming*. Firstly, some of the bolts are accessible from outside the house posing a safety and security risk. Secondly, the dadding panels do not appear to support any load, requiring that the internal support frame be bun from steel members of sufficient dimension to support the required toads, making the internal support frame umecessarty expensive to menufacture. Thirdly, the bufding constructed from this prior art system is aestheticaJy more applicable to industrial use rather than for the construction of homes. it is an object of tie present invention to provide a system and method fx constructing a building that addresses the shortcomings of the known prior art systems and methods. SUMMARY OF THE INVENTION

According to the invention there is provided a system for constructing a building comprising at least: a plurality of primary columns for fastening to an anchorage such that the primary columns are operatively erectable substantially vertically and in a spaced relationship relative to one another; a plurality of loadbearing sidewall panels for fastening to at least the primary columns thereby to operatively construct a pair of spaced apart opposing sidewalls, the sidewall panels defining a plurality of truss slots along operative top ends sized and shaped for supporting roof trusses therein; a plurality of loadbearing end wall panels for fastening to at least the primary columns to operatively construct a pair of end walls being spaced from one another by the sidewalls, thereby to define a building space delimited by external surfaces of the sidewalls and end walls jointly; a plurality of roof trusses for fastening to the sidewalls and/or to the end walls, the roof trusses being operatively receivable within the truss slots in the sidewall panels with the weight of the roof trusses being supportable by the sidewalls and/or the end walls; one or more roofing panels for fastening to the roof trusses thereby to operatively close a top end of the building space; and a plurality of bolts and/or nuts for fastening the primary columns, sidewall panels, end wall panels, roof trusses and roofing panels to one another in a manner where all bolts and/or nuts are operatively accessible for tightening and/or loosening from within the building space only.

Generally, the system includes a plurality of secondary sidewall columns for fastening to an anchorage such that the secondary sidewall columns are operatively erectable substantially vertically, in a spaced relationship relative to one another and intermediate the primary columns along which the sidewalls of the building are erectable. The sidewall panels are typically fastenaWe between adjacent columns with one or more of the secondary sidewall columns defining a truss slot for operatively receiving roof trusses therein.

The system may also include a plurality of tertiary end wall columns for fastening to an anchorage such that the tertiary end wall columns are operatively erectable substantially vertically, in a spaced relationship relative to one another and intermediate the primary columns along which the end walls of the building are erectable. The end wall panels are preferably fastenable between adjacent columns.

In one embodiment, the tertiary end wall columns have a height greater than the height of the primary columns and the secondary sidewall columns, such that the sections of the tertiary end wall columns operatively higher than the height of the primary columns and the secondary sidewall columns are gable sections of the tertiary end wall columns, thereby to form gable or gambrel roof structures.

In an alternative embodiment, the tertiary end wall columns have a height substantially similar to the height of the primary columns and the secondary sidewall columns thereby to form a flat roof structure.

In yet another embodiment, the height of the primary columns and secondary sidewall columns along one of the opposing side walls is greater than the height of those along the other of the opposing side walls, with the height of the tertiary end wall columns varying therebetween thereby to form a shed roof structure.

It will be appreciated that although only a few roof type structures are mentioned above, the system for constructing a building according to the present invention may be used to construct any number of different roof structures. Typically, the sidewall panels are substantially quadrangular in shape having a height substantially the same as the height of the primary and secondary sidewall columns. Preferably, the sidewall panels are rectangular.

Generally, the end wall panels are divided into at least a first wall section and a second gable section about a virtual line thereon being substantially parallel to and spaced from an operatively bottom edge of the end wall by a dimension substantially equal to the wall height of the sidewall panels, such that the gable sections of adjacent end wall panels and tertiary end wall columns jointly form a gable to which the end-most roof trusses are fastenable by bolting.

It will be appreciated that for roof structures other than gable and gambrel roof structures, the term gable section will be understood to mean any section of end wall panels above the height of the shortest primary column or secondary sidewall column.

The sidewall panels, end wall panels and/or roof trusses may each be made from a first skin, a second skin and a loadbearing core sandwiched between the first and second skins. Preferably, one or more of the sidewall panels and/or the end wall panels define one or more window or doorway cutouts into which respective window and door frames are mountable.

It will be appreciated that the anchorage(s) to which the columns are fastenable may be one common foundation or a plurality of plinths local to each column. Where the anchorage is one common foundation, the common foundation doubles up as the flooring of the building.

Whether the anchorage is one common foundation or a plurality of plinths local to each column, each of the columns comprise a base plate capable of being fastened to the anchorage(s) by holding down bolts cast or bonded into the anchorage(s).

Where the anchorage is a plurality of plinths local to each column, the system preferably includes a plurality of floor beams for fastening between the columns and/or anchorages to construct a floor supporting structure, the floor supporting structure being operatively spaced above the ground on which the building is erectaWe. Generally, the system further includes a plurality of floor panels for fastening to the floor supporting structure thereby to form a flooring inside the building space, wherein the floor beams and floor panels are fastened using a plurality of bolts and/or nuts in a manner where all bolts and/or nuts are operatively accessible for tightening and/or loosening from within the building space only.

Typically, the system yet further includes a plurality of security covering brackets for fastening over the bolts and/or nuts used to secure the columns and/or beams to the anchorages and/or to each other, the security covering brackets being fastenable there over by bolts and/or nuts prior to the floor panels being fastened to the floor beams and being operatively accessible for tightening and/or loosening from within the building space and from an operatively upper side of the flooring only.

Preferably, the system includes a plurality of inner wall panels for fastening to the sidewalls, end walls, trusses, floor panels, other inner wall panels and/or inner columns within the building space thereby to construct a plurality of inner walls for dividing the building space into a plurality of rooms.

The system may also include a plurality of ceiling panels for fastening to the sidewalls, end walls, inner walls and trusses, wherein the inner wall panels and the ceiling panels are fastenable by bolts and/or nuts being operatively accessible for tightening and/or loosening from within the building space.

Generally, the system includes a plurality of L-shaped brackets for fastening at least between: the floor panels and floor beams; the trusses to the sidewalls; the inner walls and/or between the inner walls and the sidewalls or end walls; and the ceiling panels and the inner walls and trusses.

Typically, the floor panels, inner wall panels and/or ceiling panels are each made from a first skin, a second skin and a loadbearing core sandwiched between the first and second skins.

It is envisaged that the sidewall panels, end wall panels, roof trusses, floor panels, inner wall panels, roof panels and/or ceiling panels may be made by bonding the first and second skins to the loadbearing core. Alternatively, the loadbearing core and the first skin may be cast or moulded as a single integral component, with the second skin bonded to the loadbearing core. It will be appreciated that the skins may be bonded to the core in many different ways, including adhesive bonding, thermal bonding and/or pressure bonding.

Furthermore, one or more of the sidewall panels, end wall panels, floor panels, inner wall panels, roof panels and/or ceiling panels have one or more tapped holes and/or floating nuts in the structure for receiving a bolt therein.

One or more of the sidewall panels, end wall panels and/or inner wall panels may have one or more bolt receiving channels defined therein for enabling the shank of a bolt dropped therein to extend out of an adjacent side of the respective sidewall panel, end wall panel and/or inner wall panel.

Preferably, electrical, gas and/or plumbing services are built, preferably cast, moulded or glued, into the sidewall panels, end wall panels, inner wall panels, floor panels and/or ceiling panels.

It will be appreciated that reference to electrical, gas and/or plumbing services will be understood to include electrical services such as conduit, wiring, switches, plug points and light fitting; gas services such as piping and valves; and plumbing services such as hot and cold water piping, sewerage piping and fittings.

Although the loadbearing core may take any form, it is preferable that it is a honeycomb structure. More preferably, the sidewall panels, end wall panels, roof trusses, roof panels, floor panels, inner wall panels and ceiling panels are preferably partially made from recycled and/or virgin non-degradable materials. It will be appreciated that any composition of materials can be used.

Generally, the system includes one or more tie rod braces for fastening at or near a ridge end of the roof trusses thereby to brace the roof trusses, the tie rods being fastened to the roof trusses by bolts and/or nuts via brackets. Typically, the system also includes one or more bracing struts for fastening across one or more corners of the floor supporting structure, the bracing struts being fastened to the floor supporting structure by bolts and/or nuts.

Preferably, the system further includes doors, windows, roof paneling strips for fastening between adjacent roof panels, a roof ridge strip for fastening over the roof panels to form a roof ridge, skirting to finish the comers between the flooring and the wails and cornicing to finish the corners between the ceiling and the walls, wherein the skirting and cornicing clips or is bonded into the bolt holes in the flooring, the ceiling and the walls thereby to conceal such holes.

More preferably, the columns, beams, brackets, panels and trusses of the system are pre-fabricated and transportable to site for erection, the building constructible by the system being modular and capable of being disassembled, moved and re-built in an alternative location. It will be appreciated that the anchorage plinths are pre-fabricated or cast in-srtu.

According to a second aspect of this invention, there is provided a method for constructing a building using the above described system including the steps of:

(A) fastening a plurality of primary columns to an anchorage such that the primary columns are operatively erectable substantially vertically and in a spaced relationship relative to one another;

(B) fastening a plurality of (oadbearing sidewall panels to at least the primary columns thereby to operatively construct a pair of spaced apart opposing sidewalls, the sidewall panels defining a plurality of truss slots along operative top ends sized and shaped for supporting roof trusses therein;

(C) fastening a plurality of ioadbearing end wail panels to at least the primary columns to operatively construct a pair of end walls being spaced from one another by the sidewalls, thereby to define a building space delimited by external surfaces of the sidewalls and end walls jointly; (D) fastening a plurality of roof trusses to the sidewalls and/or to the end walls, the roof trusses being operatively receivable within the truss slots in the sidewall panels with the weight of the roof trusses being supportable by the sidewalls and/or the end walls; and

(E) fastening one or more roofing panels to the roof trusses thereby to operatively close a top end of the building space; wherein the fastening of all components in this method is by means of a plurality of brackets, bolts and/or nuts in a manner where all bolts and/or nuts are operatively accessible for tightening and/or loosening from within the building space only.

Generally, the method includes the step of bolting a plurality of secondary sidewall columns to an anchorage such that the secondary sidewall columns are operatively erectable substantially vertically, in a spaced relationship relative to one another and intermediate the primary columns along which the sidewalls of the building are erectable. The sidewall panels are typically fastenable between adjacent columns with one or more of the secondary sidewall columns defining a truss slot for operatively receiving and supporting a respective roof truss therein.

Typically, the method includes the step of bolting a plurality of tertiary end wall columns to an anchorage such that the tertiary end wall columns are operatively erectable substantially vertically, in a spaced relationship relative to one another and Intermediate the primary columns along which the end walls of the building are erectable. Generally, the end wall panels are fastenable between adjacent columns.

In one embodiment, the end walls and the tertiary end wall columns have a height greater than the height of the primary columns and the secondary sidewall columns, such that the sections of the end walls and tertiary end wall columns operatively higher than the height of the primary columns and the secondary sidewall columns are gable sections of the end walls and tertiary end wall columns, thereby to form gable or gambrel roof structures. In an alternative embodiment, the tertiary end wall columns have a height substantially similar to the height of the primary columns and the secondary sidewall columns thereby to form a flat roof structure.

In yet another embodiment, the height of the primary columns and secondary sidewall columns along one of the opposing side walls is greater than the height of those along the other of the opposing side walls, with the height of the tertiary end wall columns varying therebetween thereby to form a shed roof structure.

It will be appreciated that although only a few roof type structures are mentioned above, the method for constructing a building according to the present invention may be used to construct any number of different roof structures.

The method may also include the steps of: (i) bolting the end-most roof trusses to the gable sections of the end walls; and (ii) bolting tie rods braces at or near a ridge end of the roof trusses thereby to brace the roof trusses.

Preferably, the method further includes the step of erecting an anchorage to which the columns are fastenable, the anchorage is one common foundation built into the ground, a plurality of plinths precast and dropped into holes in the ground or a plurality of plinths cast in-situ into such holes, with holding down bolts to which base plates of the columns are fastenable being cast or bonded into such anchorage(s). It will be appreciated that the step of erecting an anchorage precedes the step of fastening the columns to the anchorages.

Furthermore, the method includes the step of bolting a plurality of floor beams between the columns and/or anchorages to construct a floor supporting structure, the floor supporting structure being operatively spaced above the ground on which the building is erectable.

The method may further include the step of bolting a plurality of floor panels to the floor supporting structure thereby to form a flooring inside the building space, wherein the steps of bolting down the floor beams and floor panels may precede the step of erecting the sidewalls and end walls.

Generally, the method includes the step of bolting a plurality of security covering brackets over the bolts and/or nuts used to secure the columns and/or beams to the anchorages and/or to each other, wherein the step of bolting the security covering brackets precedes the completion of the step of bolting the floor panels to the floor supporting structure.

Typically, the method includes the step of bolting inner wall panels to the sidewalls, end walls, trusses, floor panels, other inner wall panels and/or inner columns within the building space thereby to construct a plurality of inner walls for dividing the building space into a plurality of rooms, followed by the step of bolting ceiling panels to the sidewalls, end walls, inner walls and trusses.

Preferably, the method includes the further step of bolting one or more bracing struts across one or more comers of the floor supporting structure, wherein the step of bolting the bracing struts precedes the step of bolting the floor panels to the floor supporting structure, and further wherein some of the bracing struts may be removed from the buiiding once the construction of the building is completed.

The method may also include the step of installing doors, windows, roof paneling strips between adjacent roof panels, a roof ridge strip over the roof panels to form a roof ridge, skirting to finish the comers between the flooring and the walls and cornicing to finish the comers between the ceiling and the walls, wherein the skirting and cornicing clips or is bonded into the bolt holes in the flooring, the ceiling and the wails thereby to conceal such holes.

In one embodiment, a film strip may be bonded over the holes and joining lines on the walls. Where the building is of a permanent nature, the holes and joining lines on the walls might alternatively be plastered or sealed to provide an uninterrupted finish, which can then be painted together with the rest of the wall. It will be appreciated that this may equally apply to the outside walls. Furthermore, the method may include the step of pre-fabricating the columns, the beams, the panels, the trusses, the strips, the skirting, the cornicing and bolting brackets and transporting such components to site for erection, thereby employing the method to construct a building that is modular (i.e. can be extended during easy alterations) and capable of being disassembled, moved and re-built in an alternative location, wherein the step of pre-fabrication precedes and/or overlaps the erecting of the anchorages.

Generally, the panels and trusses are pre-fabricated from a loadbearing core sandwiched between first and second skins, with one or more of the: sidewall panels and end wall panels defining one or more window or doorway cutouts into which respective window and door frames are mountable; sidewall panels, end wall panels, floor panels, inner wall panels and/or ceiling panels having one or more tapped holes and/or floating nuts for receiving a bolt therein; sidewall panels, end wall panels and/or inner wall panels may have one or more bolt receiving channels defined therein for enabling the shank of a bolt dropped therein to extend out of an adjacent side of the respective sidewall panel, end wall panel and/or inner wall panel; and the sidewall panels, end wall panels, inner wall panels, floor panels and/or ceiling panels have built there into, preferably cast, moulded to glued, electrical, gas and/or plumbing services.

Typically, the loadbearing core is a pre-fabricated honeycomb structure, and further wherein the sidewall panels, end wall panels, roof trusses, roof panels, floor panels, inner wall panels and ceiling panels are preferably partially made from recycled and/or virgin non-degradable materials.

In a particularly preferred method, where a plurality of plinths is used for the construction of the building, the method extends to the use of a first and second |g structures for marking out the position of holes to be dug out and the casting of the plinths in such holes.

The first jig structure includes: a plurality of marking templates; and a support body on which the marking templates are supported, wherein in use and with the first jig positioned such that the marking templates are in contact or close proximity with the ground, the outline of the marking templates is transferrable to the ground thereby to mark out the position and size of the required holes.

The first jig structure may further include a plurality of support legs for supporting the support body at the required height to ensure contact or close proximity between the marking templates and the ground. The legs may be telescopicalty adjustable to account for uneven ground conditions. Furthermore, the marking templates may be adjustably supported on the support body such that they may be raised and/or lowered as required to come in contact or close proximity with the ground.

Generally, the first jig structure also includes one or more locating formations for marking the location of the first jig relative to the ground and subsequently for locating the second jig structure relative to such location markings. Preferably, the location markings are locating pins capable of being forced into the ground or cast in-situ thereto

The second jig structure includes: a plurality of formwork boxes; and a support body on which the formwork boxes are supported, wherein in use and following the marking out and digging of the required holes, the second jig structure is capable of being lowered relative to the ground thereby to position the formwork boxes in the respective holes, ready for a settable material, such as concrete, to be poured there into.

Generally, the second jig structure comprises locating formations engageable with the locating formations transferred to the ground from the first jig structure thereby to accurately locate the position of the plinths to be cast.

Typically, the formwork boxes are releasably attachable to the support body such that one and the same support body is usable with multiple sets of formwork boxes.

Preferably, the formwork boxes include: a plurality of sidewall shuttering panels being removably fastenable to each other; an operatively upper shuttering panel being removably fastenable to the sidewall shuttering panels jointly to form a box into which a settable material is introducible, the operatively upper shuttering panel defining one or more apertures through which the settable material is introducible into the box; a plurality of holding down bolts bolted to the operatively upper shuttering panel such that (i) first portions of the holding down bolts are located within the box thereby to capture such first portions in the plinths to be cast; and (ii) second portions of the holding down bolts are located above the operatively upper shuttering panel thereby to provide, following the setting of the plinths and removal of the formwork therefrom, fastening points for the columns.

Reinforcing is generally pre-assembled and fixed to the holding down bolts within the box.

According to a third aspect of this invention, there is provided a building constructed from the above described method and system including: a plurality of primary columns fastened to an anchorage such that the primary columns are substantially vertical and in a spaced relationship relative to one another; a pair of opposing loadbearing sidewalls made up of one or more sidewall panels fastened to the primary columns, the sidewall panels defining a plurality of truss slots along operative top ends sized and shaped for supporting roof trusses therein; a pair of opposing loadbearing end walls spaced apart by the sidewalls and made up of one or more end wall panels fastened to the primary columns thereby to define a building space delimited by external surfaces of the sidewalls and end walls jointly; a plurality of roof trusses fastened to the sidewalls and/or to the end walls, the roof trusses being operatively receivable within the truss slots in the sidewall panels with the weight of the roof trusses being supportable by the sidewalls and/or the end walls; and a plurality of roofing panels fastened to the roof trusses thereby to operatively dose a top end of the building space; wherein the primary columns, sidewall panels, end wall panels, roof trusses and roofing panels are fastened to one another by a plurality of bolts and/or nuts in a manner in which they are operatively accessible for tightening and/or loosening from within the building space only.

Generally, the building includes a plurality of secondary sidewall columns fastened to an anchorage such that the secondary sidewall columns are substantially vertical, in a spaced relationship relative to one another and intermediate the primary columns along which the sidewalls of the building are erected. Typically, the sidewall panels are fastened between adjacent columns with one or more of the secondary sidewall columns defining a truss slot being operatively alignable with the truss slot in the sidewall panel such that one or more of the roof trusses are receivable therein. Typically, the building includes a plurality of tertiary end wall columns fasten to an anchorage such that the tertiary end wall columns are substantially vertical, in a spaced relationship relative to one another and intermediate the primary columns along which the end walls of the building are erected. Generally, the end wall panels are fastened between adjacent columns.

In one embodiment, the tertiary end wall columns have a height greater than the height of the primary columns and the secondary sidewall columns, such that the sections of the tertiary end wall columns operatively higher than the height of the primary columns and the secondary sidewall columns are gable sections of the tertiary end wall columns, thereby to form gable or gambrel roof structures.

In an alternative embodiment, the tertiary end wall columns have a height substantially similar to the height of the primary columns and the secondary sidewall columns thereby to form a flat roof structure.

In yet another embodiment, the height of the primary columns and secondary sidewall columns along on of the opposing side walls is greater than the height of those along the other of the opposing side walls, with the height of the tertiary end wall columns varying therebetween thereby to form a shed roof structure.

It will be appreciated that although only a few roof type structures are mentioned above, the building constructed from the system and method for constructing according to the present invention may be used to construct any number of different roof structures.

The sidewall panels may be substantially quadrangular in shape having a height substantially the same as the height of the primary and secondary sidewall columns.

Preferably, the end wall panels are divided into at least a first wall section and a second gable section about a virtual line thereon being substantially parallel to and spaced from an operatively bottom edge of the end wall by a dimension substantially equal to the wall height of the sidewall panels, such that the gable sections of adjacent end wall panels and tertiary end wall columns jointly form a gable to which the end- most roof trusses are fastened.

The anchorage(s) to which the columns are fastened may be one common foundation or a plurality of plinths local to each column, each of the columns having a base plate fastened to the anchorage(s) by holding down bolts cast or bonded into the anchorages). Alternatively, the structure may sit on a steel structure, i.e. for a temporary site office.

Where the anchorage is a plurality of plinths local to each column, the building may further include a plurality of floor beams fastened between the columns and/or anchorages to form a floor supporting structure, the floor supporting structure being operativefy spaced above the ground on which the building is erected.

Generally, the building includes a plurality of floor panels fastened to the floor supporting structure thereby to form a flooring inside the building space, wherein the floor beams and floor panels are fastened using a plurality of bolts and/or nuts in a manner where all bolts and/or nuts are operatively accessible for tightening and/or loosening from within the building space only.

Typically, the building includes a plurality of security covering brackets fastened over the bolts and/or nuts used to secure the columns and/or beams to the anchorages and/or to each other, the security covering brackets being fastened there over by bolts and/or nuts prior to the floor panels being fastened to the floor beams and being operatively accessible for tightening and/or loosening from within the building space and from an operatively upper side of the flooring only.

Preferably, the building includes a plurality of inner wall panels fastened to the sidewails, end walls, trusses, floor panels, other inner wall panels and/or inner columns within the building space thereby to construct a plurality of inner walls for dividing the building space into a plurality of rooms.

The building may further include a plurality of ceiling panels fastened to the sidewails, end walls, inner walls and trusses, wherein the inner wall panels and the ceiling panels are fastened by bolts and/or nuts being operatively accessible for tightening and/or loosening from within the building space.

The building may also include a plurality of L-shaped brackets for fastening at least between: the floor beams to the plinths, the floor panels and floor beams; the trusses to the sidewalls; the inner walls and/or between the inner walls and the sidewalls or end walls; the ceiling panels and the inner walls and trusses; and the roof panels to the trusses.

The sidewall panels, end wall panels, trusses, floor panels, roof panels, inner wall panels and/or ceiling panels may each be made from a first skin, a second skin and a loadbearing core sandwiched between the first and second skins.

Generally, one or more of the: sidewall panels and/or the end wall panels define one or more window or doorway cutouts into which respective window and door frames are mountable; sidewall panels, end wall panels, floor panels, roof panels, roof trusses, inner wall panels and/or ceiling panels have one or more tapped holes in the structure and/or floating nuts for receiving a bolt therein; sidewall panels, end wall panels and/or inner wall panels may have one or more bolt receiving channels defined therein for enabling the shank of a bolt dropped therein to extend out of an adjacent side of the respective sidewall panel, end wall panel and/or inner wall panel; and sidewall panels, end wall panels, inner wall panels, floor panels and/or ceiling panels have built in electrical, gas and/or plumbing services.

Preferably, the loadbearing core is a honeycomb structure, wherein the sidewall panels, roof panels, end wall panels, roof trusses, floor panels, inner wall panels and ceiling panels are preferably partially made from recycled and/or virgin non-degradable materials. It will be appreciated that any composition of materials can be used. Preferably, the building includes one or more tie rod braces fastened at or near a ridge end of the roof trusses thereby to brace the roof trusses, the tie rods being fasten to the roof trusses by bolts and/or nuts.

The building may also include one or more bracing struts fastened across one or more comers of the floor supporting structure, the bracing struts being fastened to the floor supporting structure by bolts and/or nuts.

More preferably, the building includes doors, windows, roof paneling strips fastened between adjacent roof panels, a roof ridge strip fastened over the roof panels to form a roof ridge, skirting finishing the comers between the flooring and the walls and cornicing finishing the comers between the ceiling and the walls, wherein the skirting and cornicing clips or is bonded into the bolt holes in the flooring, the ceiling and the walls thereby to conceal such holes.

Most preferably, the columns, beams, brackets, panels and trusses are pre-fabricated and transported to site for erection, the building being modular and capable of being disassembled, moved and re-built in an alternative location.

Accordingly, the buildings can be utilised as permanent or temporary structures. Furthermore, the buildings can be extended, re-arranged or reduced in size.

The anchorage plinths may be pre-fabricated or cast in-situ.

BRIEF DESCRIPTION OF THE DRAWINGS

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

Figure 1 is a perspective view of a first jig structure employed in the system and method for constructing a building in accordance with the present invention; Figure 2 is a perspective view of a second jig structure employed in the system and method for constructing a building in accordance with the present invention;

Figure 3 is an exploded perspective view of a formwork box used on the second jig structure of Igure 2;

Figure 4 is a perspective view of the formwork box of figure 3 in an assembled condftion;

Figure 5 is a perspective view of a foundation anchorage cast using the formwork box of figure 4;

Figure 6 is a perspective view of a plurality of foundation anchorages cast using the second jig structure of figure 2;

Figure 7 is a perspective view of a plurality of columns bolted to the foundation anchorages of figure 6;

Figure 8 is a perspective view of a plurality of floor beams bolted across the columns of figure 7 to form a floor supporting structure;

Figure 9 is a perspective view of the floor supporting structure of figure 8 supported above the level of the ground;

Figure 10 is a perspective view of the floor supporting structure of figure 8 covered over with floor panels bolted down to the floor supporting structure;

Figure 11 is a perspective view of sidewall panels and end walls panels bolted to the floor supporting structure and to the columns thereby to form sidewalls and end walls of the building respectively;

Figure 12 is a perspective view of a plurality of roof trusses supported across the sidewalls of the building and spaced apart relative to one another between the end walis of the building; Figure 13 is the perspective view of figure 12 with certain of the roof trusses hidden from view thereby to show inner wafe inside the building;

Figure 14 is the perspective view of figure 12 with certain of the roof trusses hidden from view thereby to show cellng panels inside the building; and

Figure 15 is a perspective view of roof panels being bolted to the trusses thereby to close off the roof area of the building.

DETAILED DESCRIPTION OF THE DRAWINGS

The system and method for constructing a building, according to a preferred embodiment of the invention, is best described by setting out the steps employed in such method and the components of the system employed in each step.

With reference to figure 1 , a first jig structure 10 is used for marking out a plurality of holes that need to be dug and into which foundation anchorages are capable of being cast. The first jig structure 10 comprises a plurality of marking templates 12, a support body 14 on which such marking templates 12 are supported, support legs 16 on which the support body is supportable on the ground and location formations 18 for locating the first jig structure 10 to the ground.

It will be appreciated that a crane (not shown) may be used to move the first jig structure 10 into the required position on the ground. Once in position, with the marking templates 12 in contact or close proximity with the ground, the outlines thereof are transferrable to the ground thereby to mark off the holes to be dug.

Preferably, the location formations 18 are locating pins that may be hammered or cast into the ground. With the holes to be dug marked off and with the locating pins 18 anchored to the ground, the first jig structure 10 is lifted and moved away, and the holes are dug out in accordance with the markings left on the ground. With reference now to figure 2, and with the holes having been dug out, a second jig structure 20 is craned into position. The second jig structure 20 comprises a plurality of formwork boxes 22, a support body 24 on which such formwork boxes 22 are supported and locating formations 26 for locating the second jig structure 20 relative to the ground and particularly, the holes dug out.

As the second jig structure 20 is lowered into position, the locating formations 26 are aligned and lowered into engagement with the locating formations 18 left behind by the first jig structure 10. This enables the formwork boxes 22 to be accurately positioned within the holes and relative to one another.

It will be appreciated that although the first and second jig structure 10, 20 are preferably craned into position, they may be carried into position manually by a plurality of labourers.

The formwork boxes 22, as illustrated in figures 3 and 4, comprise of sidewall shuttering panels 28, an operatively upper shuttering panel 30, a reinforcement cage 32 and a plurality of holding down bolts 34.

The sidewall shuttering panels 28 are releasably bolted to one another and to the operatively upper shuttering panel 30 such that the formwork boxes 22 substantially enclose the reinforcement cage 32 and first portions 34B of the holding down bolts 34.

The operatively upper shuttering panel 30 is releasably bolted to support legs 36 extending from the support body 24 of the second jig structure 20, and further defines apertures 38 through which a settabfe material, such as concrete, is introducible into the formwork boxes 22.

It will be appreciated that with the formwork boxes 22 being releasable from the second jig structure 20, the second jig structure 20 may be used in conjunction with multiple sets of formwork boxes 22 thereby to cast multiple sets of foundation anchorages on a production type basis. With the formwork boxes 22 positioned in the holes, the settable material is poured there into. Once set, and with reference to figures 5 and 6, the formwork boxes 22 are disassembled leaving behind foundation anchorages 40 made up of a subterranean base 42 and a plinth 44, with second portions 34B of the holding down bolts 34 cast into the plinths 44 and exposed above ground.

It will be appreciated that although the anchorages 40 illustrated in figure 6 are configured relative to one another to form a building having a substantially rectangular footprint, buildings of any shape or size may be constructed from the system and method of the present invention.

(t will be appreciated further that although jig structures 10, 20 are preferably used to increase the speed and accuracy of the construction of the buildings, the marking out of the holes and casting of the foundation anchorages 40 may be performed manually.

Furthermore, it will also be appreciated that instead of casting a plurality of individual foundation anchorages 40 as illustrated in figure 6. a single foundation may be constructed, which will in turn double as the flooring of the building.

It will even further be appreciated that instead of casting the holding bolts 34 into the plinths 44, they may be bonded there into after having cast the plinths. The second jig structure 20 will during construction be used for accurate positioning of the bolts 34.

Reverting back to the preferred embodiment illustrated in the accompanying figures, and specifically now to figure 7. a plurality of columns are now bolted to the holding down bolts 34 extending from the plinths 44 using a plurality of nuts.

The columns are typically made up of a plurality of three types of columns namely, primary columns 46, secondary sidewall columns 48 and tertiary end wall columns 50. With reference also to figure 8, each of the columns 46, 48, 50 have a plurality of tapped bolt holes 51 and a base plate 52 that is bolted to the respective plinth 44 such that the columns 46, 48, 50 are erected and fastened in a substantially vertical orientation. The primary columns 46 are typically located at each of the corners of the building, with the secondary sidewall columns 48 spaced apart relative to one another and intermediate the primary columns 46 along a sidewall dimension "A" of the building to be constructed, and the tertiary end wall columns 50 spaced apart relative to one another and intermediate the primary columns 46 along an end wall dimension "B" thereof.

Each of the secondary sidewall columns 48, and preferably also the primary columns 46, define a truss slot 54 at free ends thereof, the use of which will be described later in this description, the height "H" thereof being substantially the same as the height of the primary columns 46.

Each of the tertiary end wall columns 50 have a height Ή + h" greater than the height Ή" of the primary and secondary columns 46, 48, with the sections "h" of the tertiary end wall columns 50 operatively higher than the height Ή" forming gable sections of Ihe tertiary end wall columns 50. Preferably, the free ends of the primary and tertiary columns 46, 50 have an angle substantially the same as the angle of the gable the building will have once constructed.

With reference now to figure 8 and figure 9, a plurality of floor beams 54, defining a plurality of tapped bolt receiving holes 51 , are bolted to the columns 46, 48, 50, to the base plates 52 of the columns and/or to intermediate inner base plates 56 to construct a floor supporting structure 58, which structure 58 is supported above the level of the ground "G".

A plurality of bracing struts 59 are bolted across at least some of the comers of the floor supporting structure 58 between floor beams 54 thereof thereby to brace the structure while being constructed. Although these bracing struts 59 may remain on the structure permanently, they may be removed at any time thereafter, even from beneath the building once erected.

To conceal and prevent access to the nuts and bolts that would otherwise be accessible from beneath the building (i.e. at least the nuts and bolts for securing the base plates 52 and floor beams 54), a plurality of security covering brackets 60 are bolted into position over such nuts and bolts.

With reference now also to figure 10, it will be appreciated that once floor panels 62 have been bolted down onto the floor supporting structure 58 by a plurality of bolts fastened through aligned bolt holes 51, 64 in the floor supporting structure 58 (or L- shaped brackets fixed thereto) and the floor panels 62 respectively, the nuts and bolts securing the base plates 52, floor beams 54 and the security cover brackets 60 are rendered inaccessible from beneath the building.

At this point, and with reference to figure 11 , sidewall panels 66 and end wail panels 68 are bolted to the columns 46, 48, 50 by a plurality of bolts fastened through aligned bolt holes 51, 70 in the columns 46, 48, 50 and wall panels 66, 68 respectively. Furthermore, the sidewall panels are also securable to the floor beams 54 by bolts passing through aligned bolt holes 55, 51 in the sidewall panels 66 and the floor beams 54 respectively.

As is the case with the primary and secondary columns 46, 48, the sidewall panels 66 similarly define a plurality of truss slots 54 in which roof trusses 72 are receivable and supportable as illustrated in figures 12 to 15, such that the sidewall panels 66 form a pair of opposing loadbearing sidewa!ls 74 of the building being constructed.

The end wall panels 68 similarly form a pair of opposing loadbearing end walls 76, with each end wall panel 68 divided into at least a first wall section 68A and a second gable section 68B about a virtual line 76 thereon being substantially parallel to and spaced from an operatively bottom edge of the end wall 68 by a dimension substantially equal to the wall height Ή" of the sidewall panels 66.

It will be appreciated that the gable sections 68B, h of adjacent end wall panels 68 and tertiary end wall columns 50 respectively jointly form a gable to which the end-most roof trusses 72A is fastenable by bolting.

At this juncture, it is important to note that the external surfaces of the sidewalls 74 and the end walls 76 jointly define a tubular building space unlimited in a vertical direction and delimited by such external surfaces in a horizontal direction, and within which all of the nuts and bolts used to construct the building are located within, thereby making the system and method very secure. Furthermore, it will be appreciated that specially coded locking nuts and/or bolts may be used in strategic locations within the building to better secure it.

With reference to figure 12, tie rod braces 78 bolted to the roof trusses 72 near an operatively ridge end 80 thereof, and L-shaped brackets 82 bolted between the roof trusses 72 and the sidewalls 74 act to stabilize and secure the roof trusses to themselves and the rest of the structure.

As illustrated in figure 13, inner wall panels 84 are securable within the building volume to each other via internal columns 85, the sidewalls 74, the end walls 76 and/or to the roof trusses 72 thereby to divide the building volume into separate rooms. It will be appreciated that L-shaped brackets bolted between the inner walls 84and the aforementioned components 74, 76, 72 may be used to secure the inner walls 84. Furthermore, some of the inner walls 84 also define trusses slots 54 for accommodating roof trusses 72 passing there through.

With reference now to figure 14, ceiling panels 86 are securable in place by bolted L- shaped brackets 82 such that the ceiling panels 86 separate the roof area of the building from the living area there beneath.

Finally, the roof panels 88 are bolted to the roof trusses 72 via brackets thereby to close off the roof area of the building from the elements. Roof panelling strips 90 and a roof ridge strip 92 are used to finish the roof off between adjacent roof panels 88 and along the ridge of the roof respectively.

The living area of the building is also finished off by plugging the bolt holes therein. In one particularly preferred embodiment, skirting and cornicing strips that clip or are bonded into the bolt holes finish off comers between walls, walls and floor and walls and ceiling respectively.

Some or all of the panels 62, 66, 68, 84, 86, 88 and the roof trusses 72 are each made from a loadbearing core, preferably in a honeycomb configuration, sandwiched between first and second skins. The panels and trusses 62, 66, 68, 84, 86, 88, 72 are preferably made from non-degradable materials and more preferably recycled plastic, rubber and tyres (or other rubber products, i.e. conveyor belting), or any combination and/or composite thereof.

With reference again to figure 11 , at least the sidewall panels 74 define one or more window or doorway cutouts 94, 96 into which respective window and door frames are mountable, thereby to enable windows and doors to be fitted thereto.

Preferably, electrical, gas and/or plumbing services are built, cast, moulded or glued into at least some of the panels 62, 66, 68, 84, 86. Also, the panels 62, 66, 68, 84, 86 may each include one or more tapped holes in the structure and/or floating nuts for receiving bohs there into for the purposes of fastening such panels 62, 66, 68, 84, 86 to the other components making up the system. It will be appreciated that the trusses 72 and roof panels 88 also have tapped holes and/or floating nuts for receiving bolts there into for the purposes of fastening such trusses and panels to the other components making up the system.

A key feature of the invention is that all components, except for the anchorages 40 in certain scenarios, can be mass-produced in a pre-fabricated fashion. Once fabricated, the components of the system may be transportable to site for erection. It is envisaged that the high tolerances achievable in this fashion will enable unskilled persons armed with basic tools and very simple instructions to erect the buildings very rapidly.

With the panels being made of a non-degradable material and the columns being coated with such a material or other rust resistant coating, the building is to a large extent maintenance free and weather and vermin resistant.

Furthermore, the building constructed from such system and method, being of a modular, do-it-yourself, kit-like nature, lends itself to being easily added onto or even completely disassembled, moved and re-erected.

It is envisaged that a complete building for domestic use will be very affordable, of high quality and capable of being shipped or transported in 20 or 40 foot containers. Although the invention has been described above with reference to preferred embodiments, it will be appreciated that many modifications or variations of the invention are possible without departing from the spirit or scope of the invention.

One example is that although the specification has been described with reference to a building having a gable or gambrel roof structure, it will be appreciated that any number of roof structures may be constructed from this system and method, indudingflat roof, shed roof, mansard roof, hip roof, etc.

Another example is that other components not specifically mentioned in this description may be mounted or bolted to the roof structure - i.e. gutters, downpipes, solar panels, etc.

Furthermore, it will be appreciated that there are many steps employed in the method that may be ordered other than in the sequential way described herein. Also, the system and method may be used for constructing buildings having multiple floors, with the columns being longer in length and the flooring structure being replicated for each storey.

It will be appreciated further that affordable buildings, from low-income to high-income level, may be constructed from this system and method. The buildings may be constructed in any number of colours, typically with the selected colour being impregnated into the panels during manufacture. In this manner, no painting and very tittle maintenance will be required.