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Title:
BUILDING COMPONENTS, A BUILDING STRUCTURE FORMED THEREFROM AND A METHOD OF CONSTRUCTION THEREOF
Document Type and Number:
WIPO Patent Application WO/2022/087674
Kind Code:
A1
Abstract:
A panel for forming part of a frame of a building structure, comprising: (a) an opposed pair of longitudinally extending beams; (b) spaced apart transverse joists interconnecting the beams; and (c) a layer of lightweight insulation material underlying the joists.

Inventors:
ZHENG PIN (AU)
PRATT SIMON (AU)
Application Number:
PCT/AU2021/051263
Publication Date:
May 05, 2022
Filing Date:
October 29, 2021
Export Citation:
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Assignee:
QUANTUM BUILDINGS PTY LTD (AU)
International Classes:
E04B1/343; E04B1/348; E04B1/61; E04B2/58; E04B5/10; E04B7/02; E04C2/284; E04C2/38; E04F15/024; E04H15/00
Domestic Patent References:
WO2012129601A12012-10-04
Foreign References:
CN107338902A2017-11-10
US2137767A1938-11-22
EP1333129A12003-08-06
US20080263968A12008-10-30
Attorney, Agent or Firm:
COOPER IP PTY LTD (AU)
Download PDF:
Claims:
CLAIMS:

1. A panel for forming part of a frame of a building structure, comprising:

(a) an opposed pair of longitudinally extending beams;

(b) spaced apart transverse joists interconnecting the beams; and

(c) a layer of lightweight insulation material underlying the joists.

2. The panel of claim 1, wherein the beams comprise structural channels configured to receive ends of the joists and the insulation layer.

3. The panel of claim 1 or 2, wherein in use, the beams of adjacent panels are secured together such that a cross-section thereof is substantially in the form of an I- beam.

4. The panel of any one of the preceding claims, wherein the joists and/or beams comprise service access openings.

5. The panel of any one of the preceding claims, being configured to form the floor and/or roof panels of the building frame.

6. The panel of any one of the preceding claims, wherein the insulation layer comprises an expanded polystyrene (EPS) layer.

7. A wall panel for forming a wall structure of a building, comprising:

(a) an external wall layer;

(b) an internal wall layer; and

(c) a spaced apart and opposed pair of substantially parallel and vertically extending beams sandwiched between the wall layers, the beams being configured to connect to the beams of adjacent wall panels so as to form the wall structure of the building.

8. The wall panel of claim 7, wherein the wall layers comprise layers of lightweight insulation material and the beams comprise structural beams.

9. The wall panel of claim 7 or 8, wherein, when viewed from above:

(a) one of the beams is inwardly offset from first lateral edges of the wall layers such that a vertical slot is defined between the layers and the beam; and

(b) the other of the beams is outwardly offset from second lateral edges of the wall layers such that the beam protrudes outwardly from between the wall layers, wherein in use, the protruding beam of a first wall panel is inserted into the slot of a second wall panel to connect the two panels.

10. The wall panel of any one of claims 7 to 9, further comprising one or more noggings between wall panel beams, wherein the end of each nogging comprises flanges for receiving and securing to a beam.

11. The wall panel of claim 10 as appended to claim 9, wherein the lateral flanges of at least one nogging protrude into the slot so as to be configured to be secured to the protruding beam of an adjacent wall panel.

12. The wall panel of any one of claims 7 to 11, wherein:

(a) one of the opposed beams comprises one or more outwardly extending flaps; and

(b) the other of the opposed beams comprises one or more respective openings configured to releasably receive a respective flap of an adjacent wall panel.

13. The wall panel of any one of claims 7 to 12, wherein the insulation layers comprises EPS layers.

14. A building structure, a floor and roof of which comprise panels according to any one of claims 1 to 6, and walls of which comprise panels according to any one of claims 7 to 13.

15. The building structure of claim 14 being supported by adjustable posts, which posts comprise:

(a) a support head jack for supporting the floor;

(b) a base jack disposed on a top of a footing at ground base level (GBS) beneath the floor; and

(c) an adjustable threaded shaft between the base and support head jacks configured to operate as a turnbuckle.

16. The building structure of claim 15, wherein the support head jack and the base jack are aligned with a vertical axis to form an always adjustable structural support to the floor.

17. The building structure of claim 15 or 16, wherein a height of the support head jack above the GBS is adjustable. - 19 -

18. The building structure of any one of claims 15 to 17, wherein the shaft is screwthreadingly engaged with the support head jack and base jack to effect permanent (turnbuckle) height adjustment thereof.

19. The building structure of any one of claims 15 to 18, further comprising one or more self-contained kitchen and/or wet area Hubs supported by the adjustable posts.

20. The building structure of claim 19, wherein the or each Hub creates at least one structural node to provide structural support to the floor, wall and/or roof of the building structure.

21. A method of constructing a building structure according to claim 19 or 20, wherein the kitchen and/or wet area Hubs are separated from dry areas of the building structure and focused into service hubs prefabricated off-site, comprising the steps of:

(a) commencing installation of a structural support system by installing the adjustable posts configured for supporting the kitchen and/or wet area Hubs;

(b) installing the or each Hub so as to be supported by the installed adjustable posts;

(c) completing installation of the structural support system by installing the remaining adjustable posts required for the building structure;

(d) constructing a floor structure using panels according to any one of claims 1 to 6;

(e) constructing a wall structure using wall panels according to any one of claims 7 to 13; and

(d) constructing a roof structure using panels according to any one of claims 1 to 6.

Description:
Building components, a building structure formed therefrom and a method of construction thereof

Field of the invention

The present invention relates to building components, a building structure formed from those components, and a method of constructing the building structure.

Background

Existing construction methods and building components used to erect buildings such as residential homes suffer a range of shortcomings. In at least Australia, housing construction is burdened by regulations, inefficient construction methodologies, legislation, costs of lengthy financing requirements, a relatively high number of litigation cases and so on which have the effect of stifling building and construction innovations which may otherwise: reduce construction periods, and costs, and OHS hazards; improve the quality, dimensional and/or precision level of the workmanship and construction improve on-site labour management and productivity; improve construction efficiencies; facilitate less complex installation requirements; and enhance the flexibility, creativity and simplicity with which houses can be designed and constructed.

The modular construction of houses attempts to address these issues, whereby various sections of the house to be built are prefabricated off-site. The prefabricated sections are then transported on-site and craned into position, connected, assembled, and finished off to form a complete house.

However, the design of modular houses can be rather restrictive, owning to limitations such as road conditions, regulations and capacity, truck size, site access, and crane capacity. Moreover, additional costs associated with crane usage, additional built-in structures necessary for transport and lifting operations and transport damage reduce the cost-effectiveness of modular house construction in many cases. There is a need to address the above, and/or at least provide a useful alternative.

According to a first aspect of the present invention, there is provided a panel for forming part of a frame of a building structure, comprising:

(a) an opposed pair of longitudinally extending beams;

(b) spaced apart transverse joists interconnecting the beams; and

(c) a layer of lightweight insulation material underlying the joists.

In embodiments of the invention, the beams comprise structural channels configured to receive ends of the joists and insulation layer.

In embodiments of the invention, in use, the beams of adjacent panels are secured together such that a cross-section thereof is substantially in the form of an I- beam.

In embodiments of the invention, the joists and/or beams comprise service access openings.

In embodiments of the invention, the panel is configured to form the floor and/or roof panels of the building frame.

In embodiments of the invention, the insulation layer comprises an expanded polystyrene (EPS) layer.

According to a second aspect of the present invention, there is provided a wall panel for forming a wall structure of a building, comprising:

(a) an external wall layer;

(b) an internal wall layer; and

(c) a spaced apart and opposed pair of substantially parallel and vertically extending beams sandwiched between the wall layers, the beams being configured to connect to the beams of adjacent wall panels so as to form the wall structure of the building.

In embodiments of the invention, the wall layers comprise layers of lightweight insulation material and the beams comprise structural beams.

In embodiments of the invention, when viewed from above: (a) one of the beams is inwardly offset from first lateral edges of the wall layers such that a vertical slot is defined between the layers and the beam; and

(b) the other of the beams is outwardly offset from second lateral edges of the wall layers such that the beam protrudes outwardly from between the wall layers, wherein in use, the protruding beam of a first wall panel is inserted into the slot of a second wall panel to connect the two panels.

In embodiments of the invention, the wall panel further comprises one or more noggings between wall panel beams, wherein the end of each nogging comprises flanges for receiving and securing to a beam.

In embodiments of the invention, the lateral flanges of at least one nogging protrude into the slot so as to be configured to be secured to the protruding beam of an adjacent wall panel.

In embodiments of the invention:

(a) one of the opposed beams comprises one or more outwardly extending flaps; and

(b) the other of the opposed beams comprises one or more respective openings configured to releasably receive a respective flap of an adjacent wall panel.

In embodiments of the invention, the insulation layers comprise EPS layers.

According to a third aspect of the present invention, there is provided a building structure, a floor and roof of which comprise panels according to a first aspect of the present invention, and walls of which comprise panels according to a second aspect of the present invention.

In embodiments of the invention, the building structure is supported by adjustable posts, which posts comprise:

(a) a support head jack for supporting the floor;

(b) a base jack disposed on a top of a footing at ground base level (GBS) beneath the floor; and

(c) an adjustable threaded shaft between the base and support head jacks configured to operate as a turnbuckle.

In embodiments of the invention, the support head jack and the base jack are aligned with a vertical axis to form an always adjustable structural support to the floor. In embodiments of the invention, a height of the support head jack above the GBS is adjustable.

In embodiments of the invention, the shaft is screwthreadingly engaged with the support head jack and base jack to effect permanent (turnbuckle) height adjustment thereof.

In embodiments of the invention, the building structure further comprises one or more self-contained kitchen and/or wet area Hubs supported by the adjustable posts.

In embodiments of the invention, the or each Hub creates at least one structural node to provide structural support to the floor, wall and/or roof of the building structure. For example, in one embodiment, the or each Hub creates at least one structural node to provide structural support to the roof of the building structure and provides lateral support against wind and earthquake loading.

According to a fourth aspect of the present invention, there is provided a method of constructing a building structure according to a third aspect of the present invention, wherein the kitchen and/or wet area Hubs are separated from dry areas of the building structure and focused into service hubs prefabricated off-site, comprising the steps of:

(a) commencing installation of a structural support system by installing the adjustable posts configured for supporting the kitchen and/or wet area Hubs;

(b) installing the or each Hub so as to be supported by the installed adjustable posts;

(c) completing installation of the structural support system by installing the remaining adjustable posts required for the building structure;

(d) constructing a floor structure using panels according to a first aspect of the present invention;

(e) constructing a wall structure using wall panels according to a second aspect of the present invention; and

(d) constructing a roof structure using panels according to a first aspect of the present invention.

Brief description of the drawings In order that the invention may be more easily understood, an embodiment will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a top perspective view of a frame and self-contained hubs of an incomplete building structure formed from building components embodying the present invention;

Figure 2 is a partially transparent front perspective view of an incomplete building structure formed from building components embodying the present invention;

Figure 3 is a partially transparent front view of an incomplete building structure formed from building components embodying the present invention;

Figure 4 is a perspective view of an external corner adjustable post (leg) building component according to embodiments of the present invention;

Figure 5 is a perspective view of an internal adjustable post at a junction of 4 floor panels;

Figure 6 is a partially transparent top perspective view of a floor structure of an incomplete building structure formed from building components embodying the present invention;

Figure 7 is a front perspective view of a floor panel building component according to embodiments of the present invention;

Figure 8 is a close-up side view of a lower edge of an incomplete building structure showing engagement between the footing, floor panel and wall panel building components embodying the present invention;

Figure 9 is a close-up front view showing engagement between a footing and adjacent floor panel building components according to embodiments of the present invention;

Figure 10(a) is a side perspective view of an incomplete building structure with a range of wall panel building components according to embodiments of the present invention;

Figure 10(b) is a cross-sectional front view of a range of differently dimensioned wall panel building components according to embodiments of the present invention; Figure 11(a) is a top perspective cross-sectional view of two wall panel building components according to embodiments of the present invention;

Figure 11(b) is a top cross-sectional view of a wall panel building component according to embodiments of the present invention;

Figure 12 is a partially transparent perspective view of two wall panel building components according to embodiments of the present invention;

Figure 13(a) is a close-up cross-sectional front view of two adjacent wall panel building components according to embodiments of the present invention, prior to being installed together;

Figure 13(b) is a close-up cross-sectional front view of the wall panel building components of Figure 13(a) installed together;

Figure 14(a) is an exploded front perspective view of a wall panel building component according to embodiments of the present invention;

Figure 14(b) is an exploded front perspective view of a wall panel building component according to embodiments of the present invention;

Figure 15 is a close-up front perspective view of a wall panel frame according to embodiments of the present invention;

Figure 16(a) is a side perspective view of a roof panel building component according to embodiments of the present invention;

Figure 16(b) is a cross-sectional end view of a roof panel building component according to embodiments of the present invention;

Figure 17 is a close-up side view showing engagement between a roof panel building component and a wall panel building component according to embodiments of the present invention; and

Figure 18 is a partially transparent internal perspective view showing engagement between roof panel and wall panel building components according to embodiments of the present invention.

Detailed description Figures 1 to 3 show partially complete residential building structures 2 formed from building components according to embodiments of the present invention. The building components include the following:

• adjustable posts (legs) 4 for supporting the aboveground building structure 2;

• self-contained kitchens and/or wet areas hubs 6;

• floor panels 8 which form a floor structure of the building structure 2;

• wall panels 10 which form a wall structure of the building structure 2; and

• roof panels 12 which form a roof structure of the building structure 2.

These relatively light-weight building components may be mass-produced off-site, then transported and installed on-site with less effort and time without the need for cranes and other specialized machinery and equipment. The self-contained wet area and kitchen hubs 6 can be lifted and installed using cranes, though forklifts may optionally be used. The building components are described below with reference to the Figures.

Building support components

Figures 4 and 5 show views of an adjustable post (leg) building component 4 configured to form a support system that underlies and connects the aboveground building structure 2 to footings. The support 4 comprises a head jack 16 , a base jack 14, with a connecting threaded shaft 20 or 'turnbuckle'. The base jack 14 of the support 4 is fixed to the top of the in-ground footings at the GBL, and the head jack 16 is fixed to the frame of the floor panel system 8.

The support 4 comprises a support head jack 16 and a base jack 14 for securing to and supporting the floor structure of the building by being fixed to and bearing upon the top of the inground footing at GBL. The support head jack 16 shown in Figures 4 and 5 comprises a "T" bracket 17 for receiving edges of the flooring structure, as will be described with reference to Figure 8. Supports 4 configured to underlie and support flat surfaces of the flooring structure are configured with a flat support head 16 (e.g., not a "T" bracket 17), as will be described with reference to Figure 9. In the depicted embodiment, the support head jack 16 is supported by a central shaft 20 and base jack 14 connected by a screwed shaft 18 as an adjustable turnbuckle. In preferred embodiments of the support 4, a height of the support head 16 above the base jack 14 is adjustable to allow the height of the support head 16 to be finetuned to securely abut against and receive the floor structure which it is to support and ensure floor levelling precision. To this end, and with reference to Figure 5, the pipe 18 is threaded such that an upper end thereof is configured to receive a lower end of a threaded shaft 20, and the support head jack 16 comprises a downwardly extending and threaded pipe 22 configured to receive an upper end of threaded shaft 20. In this way, the central shaft 18 and the support head jack 16 are screwthreadingly engaged to effect rough-in or fine adjustment of the height of the support head jack 16 above the footing and base jack 14.

Self-contained wet area and kitchen building components (Hubs)

Figures 1, 2, 3 and 10 show embodiments of self-contained kitchens and/or wet area building components 6 according to embodiments of the invention (henceforth also referred to as Hubs 6). The Hubs 6 are prefabricated and contain the wet areas of the house (e.g. kitchen, bathrooms, powder rooms, laundry etc). The Hubs may be constructed in a factory environment, including their walls, insulation, linings, wet area amenities, cabinetry and finish off. Services and features such as plumbing, waterproofing, wall tiling, vanities, joinery and kitchen and bathroom facilities may all be installed in the Hub 6 off-site. The prefabricated Hub 6 can then be transported on-site and craned or forkl ifted into position to be supported by the adjustable posts (legs) 4 (see Figure 10). Standardized Hubs can be designed and built to fit within the dimensions of internal high-cube containers. This facilitates ease of transport, cranage, and protection from damage during transport.

Existing bathroom pods produced by local manufacturers do not form part of a complete building methodology. In contrast, the present Hubs 6, either as standardized or non-standardized, are built in a factory environment so as to be transported and installed as part of a complete building methodology which comprises the other building components disclosed herein. In terms of the installation procedure, the adjustable posts (legs) 4 for supporting the Hubs 6 should be installed on the footings first. Next, the Hubs 6 can be placed on those adjustable posts (legs) 4. Then, the remaining adjustable posts (legs) 4 of the overall house can be installed.

Unlike existing modular wet areas that are simply installed within a building structure, it is envisaged that the present Hubs 6 actually form part of the building structure and create structural nodes to provide both vertical and lateral support. For example, with reference to Figure 1, it can be seen that the Hubs 6 are not installed behind the outer wall panels 10, but instead form the very structural nodes of the overall building structure 2 itself. In this way, the Hubs 6 also define key and fixed structural elements of the building structure 2 via which other elements can be secured. In this way, the need for structural elements such as lateral bracing (e.g., via plywood panels) and the associated labour can be significantly reduced or eliminated. The Hubs 6 can also serve has a central hub via which service connections can be localised. In essence, the functionality and structural role of the present Hubs 6 may deviate from known modular wet areas in that the Hubs 6 are not simply modular wet areas installed in a building structure 2, instead, the Hubs 2 define key structural nodes of the building structure 2.

Notwithstanding the above, it is envisaged that a building structure 2 may comprise one or more such Hubs 6 (e.g., a house with multiple bathrooms), and one or more Hubs 6 may form key parts of the building structure 2.

Floor panel building components

After the adjustable posts (legs) system and Hubs 6 have been installed, the floor structure of the building can be formed from floor panel building components 8 embodying the present invention. Figures 2, 3, 6, 8 and 9 show floor panel building components 8 installed in place and supported by the adjustable posts (legs) system 4.

With reference to Figures 7 to 9, the floor panel 8 comprises a pair of spaced apart and opposed structural beams or bearers 36 having a Light Gauge Steel (LGS) C- shaped cross-section. The beams 36 are oriented such that the C-shaped channels 38 thereof face one another. A series of longitudinally spaced transverse floor joists 40 are disposed between the C-shaped channels 38 and interconnect the beams 36. A layer of expanded polystyrene (EPS) or other lightweight insulation cladding material 42 underlies the joists 40 and is similarly disposed between and interconnects the beams 36. Since the joists 40 and EPS 42 are contained within the height of the C-shaped channels 38, the overall floor thickness of the present floor panels 8 can be significantly less than conventional bearer and joist floor systems.

As shown in Figures 8 and 9, the ends of the joists 40 are adjacent to if not flush against an upper flange surface 44 of the C-shaped channel 36. Similarly, the EPS layer 42 is adjacent to if not flush against a lower surface 46 of the C-shaped channel 38. Advantageously, the EPS layer 42 acts as thermal insulation and also provides a vapour barrier.

With reference to Figure 9, when installed, the beams 36 of adjacent floor panels 8 are secured to one another to form, in cross-section, an I-section beam. The footing 4 in Figure 9 comprises a flat support head 16(a) or "T" support head 16(b) configured to secure against and support the lower flange 46 of the I-section beam (i.e. the two lower flanges 46 of the C-shaped channels 38 of the adjacent floor panels 8).

Figure 8 shows a close up of a lower perimeter of the building structure 2 to illustrate how the adjustable post 4, floor panel 8, square hollow section RHS steel or timber edge beam 48 and wall panel 10 (to be discussed) are secured together. As shown, the C-section beams 38 which define the perimeter of the building structure 2 are screw fixed to a RHS Steel or timber edge beam 48. The RHS Steel or timber edge beam 48 is in turn fixed to the upright face 36 of the T-bracket 17 of the footing 4. The steel SHS or timber edge beam 48 is also screw fixed to a bottom of the wall panel 10 to achieve a complete structural 'tie down'. In this way, the perimeter of the floor is strengthened, improving both load and deflection resistance, and no straps or conventional tie-downs are necessary. Figure 8 also shows a floorboard 50 covering the floor panel 8, with a protective steel Z-Flashing plate screw 52 fixed to the floorboard 50 and to the outer edge of the steel SHS or timber edge beam 48.

After the floor panels 8 are installed, services (mainly electrical and mechanical cabling) are to be installed within the depth of the cavity created by the panel frame before covering the floor panels 8 with floorboards 50. Advantageously, the floor joists 40 are provided with through-holes 54 for convenient service access and installation. It is envisaged that the bearers 38 may also be provided with such through-holes for service access. Advantageously, a clearance between the floor structure and natural ground therebeneath also provides service access.

The present standardised floor panels 8 can be mass-manufactured off-site and transported and installed on-site. The floor panels 8 are dimensioned and configured to be of lightweight construction and can be manually handled and installed by two people without needing lifting equipment.

It is envisaged that the floor panels 8 are to be made according to a limited range of dimensions; if the building structure 2 requires differently-sized floor panels, the mass- produced floor panels 8 can be supplemented by a small number of infill floor panels 56 either custom-made in a factory or 'stick-built' on-site from the relevant supplied materials, as shown in Figure 6.

Wall panel building components

After floorboards 50 and the flashing bottom plates 52 are installed around the floor perimeter, wall panel building components 10 may then be installed to define a wall structure of the building 2. Figures 10 to 15 show wall panel building components 10 according to embodiments of the present invention.

Referring to Figures 11, 12 and 14, each wall panel 10 comprises an opposed pair of structural beams 60 sandwiched between two layers of EPS 62. A first EPS layer 62(a) defines the external side of the building structure 2 and is ready for rendering or cladding. The second EPS layer 62(b) may be lined with a reflective foil facing the beam and defines an internal side of the building structure 2 and is ready to be finished with conventional plasterboard or other internal wall linings. The external EPS 62(a) layer is preferably thicker than the internal EPS layer 62(b), and the configuration of layers 62 an LGS frame 78 provides qualities of thermal and acoustic insulation and helps stabilise the wall panel 10 during handling and installation. The EPS layers 62 are glued with a structural, chemical glue and/or screw fixed to the structural beams 60.

With reference to Figures 11(a) and 11(b), the wall panels 10 are configured to fasten together via a tongue and groove mechanism and a flap and slot mechanism. Looking down at the cross-sectional wall panel 10 in Figure 11(b), the left-hand side beam 60 juts out leftwardly from between the two EPS layers 62. This protruding beam defines the "tongue" of the tongue and groove mechanism. Meanwhile, the right-hand side beam 60 is "tucked in" leftwardly between the two EPS layers 62. As such, a space or groove 64 is defined between the two EPS layers 62 and the outer surface of the beam 60. This space 64 defines the "groove" of the tongue and groove mechanism. In other words, although the width of the EPS layers 62 is similar if not identical to the external width between the beams 60, viewed from above, the beams 60 are offset from the EPS layers 62. As such, in fitting adjacent wall panels 10 together, the protruding tongue beam 60 of a first wall panel 10 is inserted into the vertical space or groove 64 of a second wall panel 10, as indicated by Figure 11(a).

With reference to Figures 10(a) and 10(b), together with Figures 14(a) and 14(b), the wall panels 10 are made according to a limited range of dimensions and design; if the building structure 2 requires a small number of differently-sized wall panels 10, the mass- produced wall panels 10 can be supplemented by a small number of manufactured infill wall panels or 'stick-built' on-site. The infill panels provide electrical and mechanical cable management.

Referring to Figures 10(b) and 14(b), the narrower left-most three wall panels 10a comprise opposed beams 60 interconnected by transverse noggings 66a and diagonal noggings 66b; the fourth wall panel 10b from the left may be similarly constructed. The wider and right-most two wall panels 10c in Figures 10(b) and 14(a) comprise a third and central beam 68 between the opposed end beams 60, the central beam 68 being interconnected to the end beams 60 via noggings 66.

Figure 12 shows two of the wider wall panels 10 side by side. In addition to the aforementioned tongue and groove mechanism, the beams 60 have complementary flap and slot engagement features to help facilitate installation of the wall panels 10. With reference also to Figures 11(a), 13(a) and 13(b), one outer beam 60 in the groove of a wall panel 10 comprises vertically spaced apart flaps 70, and the other outer beam 60 of the wall panel 10 comprises corresponding vertically spaced apart slots or openings 72 for receiving respective flaps 72. The flaps 70 of one wall panel 10 clip in through a "lift and drop" manner with the respective openings 72 of an adjacent wall panel 10 during installation and help lock the panels 10 in position before additional structural securing means can be implemented. The bottom of the connection slots will be used to give access to allow the bottom frame of the wall panel to be screw fixed into the floor edge beam below. To get access this will be done before the following wall panel is installed.

Figures 14 and 15 illustrate additional means for securing adjacent wall panels 10 together. Figure 14(a) shows an exploded view of a wall panel 10c. The internal frame 78 thereof comprises a central beam 68 interconnected to a pair of opposed outer beams 60 via upper and lower joists 80 and central noggings 66a.

Figure 14(b) shows an exploded view of a wall panel 10a. The internal frame 78 thereof comprises a pair of outer beams 60, upper and lower joists 80, horizontal noggings 66a, and diagonal noggings 66b.

Wall panel 10a acts to support higher concentration loads in lieu of an external wall structural post and resists horizontal loads such as wind or earthquake loads in lieu of a conventional lateral braces.

LGS truss frame 78 without EPS layers can also be engaged as an internal loadbearing wall or post.

Figure 15 shows a close-up of noggings 66a which facilitate the securing of one wall panel 10 to another. In the depicted embodiment, the noggings 66a are formed from LGS channels similar to those which form the beam 60. At each end of the nogging 66a, a top and bottom face 84 thereof is cut away such that the top and bottom faces 84 abut against the respective beams 60, 68. The sides of each end of the nogging 66a define flanges 86 which can be fixed to the respective vertical beams 60, 68 using a punch/stamping jointing method or conventional threaded fasteners. In Figure 15, the left-hand side nogging is disposed towards the side of the wall panel 10 where the groove 64 is (see Figure 11(b)). As such, the side flanges 86 of this nogging 66a protrude into the groove 64 and are configured for being fixed to the vertical tongue beam 60 of an adjacent wall panel 10. For example, the flanges 86 may be screw fixed to structurally join the wall panels 10 together.

Referring back to Figure 8, the wall panels 10 are also screwed fixed to the bottom flashing plates 52. Top flashing plates (not shown) are also screw fixed along an upper end of the wall panels 10. The flashing plate acts as water barriers and an important part of the tie-down mechanism, while also helping to ensure the wall panels 10 are installed in a straight and accurate alignment. The bottom flashing plates 52 also help spread the load from the wall panels 10 above and functions as a positioning element to facilitate installation of the wall panels 10. Additionally, a top timber wall plate 76 (see Figures 17 and 18) is fastened between roof panel 12 and wall panel 10 by a hold-down bracket 112 along the top of the installed wall panels 10.

Roof panel building components

After the wall panels 10, top flashing plate and top timber wall plate 76 are installed, roof panel building components 12 may then be installed to define a roof structure of the building 2. Figures 16 to 18 show roof panel building components 12 according to embodiments of the present invention.

It is envisaged that the roof panels 12 are to be made according to a limited range of dimensions; if the building structure 2 requires differently-sized roof panels, infill panels can be custom-made in a factory environment or constructed in-situ on site from the relevant supplied materials on-site.

Figures 16(a) and 16(b) show a roof panel building component 12 according to embodiments of the invention. The composition and configuration of the roof panel 12 is similar to that of the floor panel 8. The roof panel building component 12 is also made from a pair of opposed structural beams (i.e. rafters) 100 having LGS C-shaped cross- sectional channels 102 between which transverse joists 104 and an EPS layer 106 are disposed. In the embodiment depicted in Figure 16(b), the EPS layer 106 is thicker than the joist 104 and is preferably vertically spaced from the joist 104. The spacing 108 allows for condensation and access for services such as electrical cable management.

The installation of roof panels 12 next to one another to form the roof structure is also not dissimilar to the installation of adjacent floor panels 8. In this regard, the adjacent C-channel beams 100 of two roof panels 12 are screw fixed together to form an I-section beam. With reference to Figure 17, to install a roof panel 12, the lower flange 110 of each C-shaped channel 102 is fixed to the upper timber top wall plate 76 installed along the top of the wall panels 10. To this end, the C-shaped channel 102 can be screw fixed to the upright portion 112a of a hold-down bracket 112 indicated in Figures 17 and 18, thereby interconnecting the roof panels 12 to the wall panels 10. The present roof panels 12 are relatively light such that they can be handled and lifted into position by two or more people without needing additional lifting assistance. Due to the simple linear construction of the roof panels 12, with no conventional truss required, a roof space can be formed and utilised as an attic, a loft room, a storage space etc. Chamfered, high, or cathedral ceilings with skylights are accommodated by the present roof panels 12. The joists 104 and/or opposed rafters 100 of the roof panels 12 are also provided with service access openings 114 for easy installation and access of cabling and the like.

Owing to the aforementioned building components 4, 6, 8, 10, 12, a significant proportion of a building structure 2 can be mass prefabricated off-site in factory environments and conditions due to the repetitive modular nature of the panel system. This allows much of the components of the building structure 2 to be strictly quality controlled and error proofed. This in turn can reduce manufacturing and construction costs through repetition and reduced material wastage. The prefabricated components can then be transported and installed relatively quickly on-site with little need for specialist equipment and machinery on site. The remaining construction work can therefore mostly be carried out in indoor conditions after building structure 2 is constructed and the roof cladding is installed. The reduced construction time also translates to reduced costs, OHS hazards during construction, and risk of on-site vandalism and theft.

Many modifications of the above embodiments will be apparent to those skilled in the art without departing from the scope of the present invention. For example, other means for adjusting a height of the support head jackl6, wall panels on other footing or floor system, roof panels on other walling system, any adaptable dimension of kitchen or wet area are considered within the scope of the present specification.

In embodiments of the invention, the framing (e.g. beams, joists, noggings etc.) of the floor, wall and roof panels is formed from light gauge steel (LGS). For insulation and condensation protection purposes, the floor, wall and roof panels are formed from EPS with a layer of sarking. Of course, framing formed from other materials is also within the scope of the present specification. Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.