AU2005254580B2 - Building system - Google Patents

Description

WO 2005/124049 PCT/AU2005/000837 TITLE BUILDING SYSTEM 5 FIELD OF THE INVENTION The present invention relates to a building system. BACKGROUND TO THE INVENTION 10 There are several known approaches to the construction of buildings such as houses. These approaches include the use of bricks and mortar, the use of pre-cast concrete panels and the construction of a frame for upon which cladding is affixed. These approaches all require considerable work to be done at the site of the building. An alternative approach is construct a building at a location, and then transport the 15 building to the site on which it is to be located. The logistics of this alternative approach are quite complex, and such an approach clearly limits the size and shape of the building able to utilise such a method. Building constituents such as walls, floors, ceilings and roofs are generally constructed by erecting a supporting structure, and then mounting the constituent to 20 the supporting structure. Such an approach requires the entire supporting structure of the constituent to be fixed in position before the constituent can be mounted. Building constituents such as walls, floors, ceilings and roofs, along with their associated supporting structure, can be supplied to a building site as raw building materials or in a partially assembled form. Supplying the raw materials requires a 25 great deal of specialised construction work to be undertaken at the site. Supplying the WO 2005/124049 PCT/AU2005/000837 constituents in a partially assembled form can reduce this problem, however the partially assembled constituents are often bulky and difficult to transport. The present invention attempts to overcome at least in part some of the 5 aforementioned disadvantages of previous building methods. SUMMARY OF THE INVENTION In accordance with one aspect of the present invention there is provided a building constituent assembly comprising at least one covering member and at least one 10 supporting structure, the supporting structure including a plurality of supporting members each having first and second side portions located adjacent a covering member, characterised in that the first side portion of a first supporting member is complementary in shape to the second side portion of a second supporting member such that the first and second supporting members can engage each other by the 15 overlay of the first side portion of the first supporting member and the second side portion of the second supporting member, such engagement restraining relative movement of the first and second supporting members in at least one direction. Preferably, the first and second side portions are corrugated. 20 In accordance with a second aspect of the present invention, there is provided a wall panel comprising a supporting structure and at least one covering member, the supporting structure having at least one supporting member adjacent a covering member, characterised in that the supporting member has as first side portion extending beyond the covering member and a second side portion adjacent the 2 WO 2005/124049 PCT/AU2005/000837 covering member, a receiving area being defined between the second side portion and the covering member, wherein the first side portion of the supporting member of a first wall panel is receivable within the receiving area of a second wall panel, the first side portion being complementary in shape to the second side portion such that the 5 first side portion of the first wall panel engages the second dies portion of the second wall panel, the engagement restraining relative movement of the first and second wall panels in at least one direction and the covering member restraining relative movement of the first and second wall panels in a second direction. 10 In accordance with a third aspect of the present invention there is provided a building constituent assembly comprising a supporting structure and at least one covering member, characterised in that the supporting structure includes at least one supporting member having as a trough portion which is substantially V-shaped in a transverse direction, the supporting member having first and second side portions on opposed 15 sides of the trough portion, the first side portion of a first supporting member being complementary in shape to the second side portion of a second supporting member such that the first and second supporting members can engage each other by the overlay of the first side portion of the first supporting member and the second side portion of the second supporting member, such engagement restraining relative 20 movement of the first and second supporting members in at least one direction. The building constituent assembly of the third aspect may be a flooring assembly, a ceiling assembly and/or a roofing assembly. 3 WO 2005/124049 PCT/AU2005/000837 BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is an exploded plan view of a wall panel in accordance with the present 5 invention; Figure 2 is a plan view of the wall panel of Figure 1 shown in an assembled configuration; Figure 3 is a plan view of two wall panels such as that in Figure 2, shown in a connected configuration; 10 Figure 4 is a partially cut away perspective view of a supporting structure of the wall panel of Figure 2; Figure 5 is a partially cut away perspective view of the wall panel of Figure 2; Figure 6 is a perspective view of a supporting member of a flooring assembly in accordance with the present invention; 15 Figure 6a is a cross sectional view of the supporting member of Figure 6; Figure 7 is an exploded view of a supporting structure of a flooring assembly in accordance with the present invention; Figure 8 is a perspective view of the supporting structure of Figure 7 in an assembled configuration; 20 Figure 9 is an upper perspective view of the supporting structure of Figure 7; Figure 10 is an exploded side view of a flooring assembly in accordance with the present invention; Figure 11 is a side view of the flooring assembly of Figure 10 in an assembled configuration; 4 WO 2005/124049 PCT/AU2005/000837 Figure 12 is an exploded side view of a ceiling assembly in accordance with the present invention; Figure 13 is a side view of the ceiling assembly of Figure 12 in an assembled configuration; 5 Figure 14 is an exploded side view of a roofing assembly in accordance with the present invention; Figure 15 is a side view of the roofing assembly of Figure 14 in an assembled configuration; Figure 16 is an end view of the roofing assembly of Figure 15; and 10 Figure 17 is a partially cut away view of a building constructed of constituent assemblies in accordance with the present invention. DESCRIPTION OF PREFERRED EMBODIMENTS Referring Figures 1 to 5, there is shown a building constituent assembly comprising a 15 plurality of wall panels 10. Each wall panel 10 comprises a supporting structure 12 and two covering members 14. The covering members 14 are constructed from a suitable building cladding material such as cement sheeting. Each covering member 14 has a front end 16 and a rear end 18. The supporting structure 12 includes two supporting members 20 in the form of 20 corrugated sheets 22 affixed to each covering member 14. Each corrugated sheet 22 extends from a front end 24 beyond the front end 16 of the covering member 14, to a bend 26 adjacent the rear end 18. Each corrugated sheet 22 is bent at approximately 90* at the bend 26, and extends from the bend 22 to a rear end 28. The rear end 28 is displaced internally of the wall panel 10. 5 WO 2005/124049 PCT/AU2005/000837 In the embodiment of the drawings, each corrugated sheet 22 has 11.5 wave peaks or corrugations. These are arranged with two wave peaks extending beyond the front end 16 of the corresponding covering member 14, and comprising a first side portion 30 of the supporting member 20; 8 wave peaks lying adjacent the covering member 14; 5 and 1.5 peaks forming a transverse portion 32 extending inwardly of the rear end 18 of the covering member 14. Each corrugated sheet 22 is fixed to a corresponding covering member 14 by suitable means such as adhesive along the first six peaks closest to the front edge 16 of the covering member 14. The two peaks adjacent the covering member 14, which are 10 closest to the rear edge 18 comprise a second side portion 34 of the supporting member 20. These peaks 34 are not fixed to the covering member 14. A receiving area 36 is thus defined between the second side portion 34 and the covering member 14. The wall panel 10 further includes a plurality of bracing members 38. The bracing 15 members 38 support the supporting members 20 in opposed parallel relationship. Each bracing member 38 has a front end 40 and a rear end 42. The rear end 42 is at least partially complementary in shape to the portion of the corrugated sheet 22 between the bend 26 and the rear end 28. 20 The supporting structure 12 of a wall panel 10 is formed by bringing the two supporting members 20 into the correct opposed relationship, with a plurality of bracing members located therebetween as shown in Figure 4. In the connected configuration, the transverse portions 32 of the two corrugated sheets 22 overlie one 6 WO 2005/124049 PCT/AU2005/000837 another, and the rear end 42 of the bracing members 38. The covering members 14 are affixed externally of the supporting structure 12, as shown in Figure 5. When thus assembled, the wall panel 10 has a male end 44 from which the first side portions 30 of the supporting members 20 protrude, and a female end 46 defined by 5 the second side portions 34. Successive wall panels 10, 1 0a are connected as shown in Figure 3. The first side portions 30 of the supporting members 20 of wall panel 10 are received within the receiving areas 36 of wall panel 10a, that is between the second side portions 34 and the covering members 14. It will be appreciated that the corrugations 10 of the first and second side portions 34, 36 are complementary in shape, thus allowing each first side portion 34 to overlay a corresponding second side portion 36. When in the position shown in Figure 3, the first side portions 34 of wall panel 10 engage the second side portions 36 of wall panel 10a, and thus prevent movement of the two wall panels 10, 10a relative to each other in a direction perpendicular to the 15 corrugations. The covering members 14 prevent the disengagement of the first side portions 34 from the second side portions 36 in a direction perpendicular to the covering members 14. In a preferred embodiment of the wall panel 10, an aperture 48 passes through the front and rear ends 40, 42 of each bracing member 38, and through corresponding 20 locations in the transverse portions 32 of each supporting member 12. Brace members 38 of one wall panel 10 can thus be connected to brace members 38 of an adjacent wall panel 1Oa though bolts 50 or similar connection means. In a further preferred embodiment of the invention, the covering members 14 are contained within upper and lower extruded channels 52, 54 as seen in Figures 4 and 5. 7 WO 2005/124049 PCT/AU2005/000837 Referring to Figures 6 to 11, there is shown a building constituent assembly comprising a flooring assembly 60. The flooring assembly 60 comprises a supporting structure 62 and a plurality of substantially planar covering members 64. The supporting structure 62 includes a plurality of supporting members 66 as shown 5 in Figures 6 and 6a. Each supporting member 66 is elongated, and extends between a first end 68 and a second end 70. Each supporting member 66 is substantially V shaped in cross section, that is in a transverse direction, with a trough portion 72 extending between the first end 68 and the second end 70. Each supporting member 66 has a first side portion 74 and a second side portion 76. 10. The first and second side portions 74, 76 are on opposed sides of the trough portion 72, and extend outwardly from the upper ends of the V-shape in a transverse direction. The supporting members 66 are constructed from a corrugated material having waveforms oriented in the transverse direction. In the embodiment shown in the 15 drawings, the first side portion 74 comprises one waveform, the second side portion 76 comprise one half of a wave form, and each of the side walls of the trough portion 72 comprise four and a half wave forms. A portion of the first side portion 74 is thus complementary in shape to the second side portion 76. The supporting structure 62 comprises supporting members 66, secondary support 20 members 78 and base members 80. These elements can be seen in Figure 7. The secondary support members 78 are preferably formed from a flat metal bar 82 which is bent along its length. The bar is bent to form a plurality of V-shaped sections 84, joined at their upper ends by short horizontal portions 86. The V-shaped sections 84 have a profile similar to that of the trough portion 72 of the supporting members 8 WO 2005/124049 PCT/AU2005/000837 66. The length of the horizontal portions 86 is similar to the width of the second side portion 76 of the supporting members 66. In use, a plurality of supporting members 66 can be placed along the secondary support member 78, with one supporting member 66 located within each V-shaped section 84. 5 Each secondary support member 78 has a horizontal portion 86a, 86b at both outer ends thereof. The horizontal portion 86b at a second end of a secondary support member 78 is slightly lower than other horizontal portions 86, all of which are substantially co-planar. This allows a plurality of secondary support members 78 to be connected end to end, with a horizontal portion 86a at one end of a first secondary 10 support member 78 located above the horizontal portion 86b at the other end of a second secondary support member 78a. It will be appreciated that the number of V-shaped sections 84 along each secondary support member 78, and therefore the length of each secondary support member 78, can be varied for particular applications. 15 The base members 80 are preferably formed from angle iron lengths having a first end 88 and a second end 90. Each base member 80 has a depression formed at its second end 90, to allow the endwise connection of a plurality of base members 80 whilst maintaining a substantially planar upper surface. Preferably, the base members 80 are similar in length to the secondary support members 78. 20 A plurality of apertures 92 are located at appropriate points within the supporting members 66, along the secondary support members 78 and in the base members 80. These apertures allow the insertion of suitable fixing devices such as bolts or rivets to hold the secondary support members 78 to the base members 80, and the supporting 9 WO 2005/124049 PCT/AU2005/000837 members 66 to the secondary support members 78, thus forming the supporting structure 62. In use, the supporting members 66 are effectively tiled in both the elongate and transverse directions. In the transverse direction, adjacent supporting members 66 5 engage each other by overlay of the first side portion 74 of a first supporting member 66a and the second side portion 76 of the second supporting member 66b. In the elongate direction, adjacent supporting members 66a, 66c are arranged such that a portion of the length of a third supporting member 66c is contiguous with, and overlaps, the first supporting member 66a. The arrangement is such that the 10 overlapping portion extends between, and is supported by, two parallel secondary support members 78. Secondary support members 78 and corresponding base members 80 are located beneath the supporting members 66 in a plurality of substantially parallel lines. The placement and number of the parallel lines can be determined by the requirements of 15 a particular construction. Preferably, the supporting members 66 are tiled in an offset pattern as shown in Figure 3. It will be appreciated that the support structure 62 of the flooring assembly 60 can be constructed in a sequential fashion from an initial location. When the support 20 structure 62 is to be located on supporting poles (not shown), it only becomes necessary to erect a supporting pole at a location when the support structure 62 reaches that location. In this way, a building can be constructed over irregular terrain without the need for extensive site preparation. 10 WO 2005/124049 PCT/AU2005/000837 The flooring assembly 60 of the present invention is completed by the use of the substantially planar covering members 64. The covering members 64 are comprised of flooring sheets 64a. The completed flooring assembly is shown in figures 10 and 11. 5 Each flooring sheet 64a is fixed to the supporting members 66 by suitable means such as a fastener passing through the side portions 74, 76 of adjacent supporting members 66 and an associated secondary support member 78. In this way the flooring sheet 64a engages the supporting members 66 and acts to lock them in position relative to one another. 10 Figures 12 and 13 show a ceiling assembly 94. The ceiling assembly 94 is substantially similar to the flooring assembly 60, however is inverted with respect to the flooring assembly 60. The ceiling assembly 94 has a support structure 62 similar to that of the flooring assembly 60, and a plurality of covering members 64 comprised of ceiling sheets 64b, such as cement sheeting. 15 In a preferred embodiment of the ceiling assembly 94, each ceiling sheet 64b corresponds to an associated supporting member 66, and is sized so as to abut an adjacent ceiling sheet 64b when the supporting members 66 are tiled as described herein above with respect to the flooring assembly 60. Figures 14 to 16 show a roofing assembly 96. The roofing assembly 96 is 20 substantially similar to the ceiling assembly 94, with the covering members 64 comprising of an eves lining sheet 64c. In the roofing assembly 96 the base member 80 is preferably a "Z" purlin 80b, to which is attached corrugated roofing sheets 98. 11 WO 2005/124049 PCT/AU2005/000837 The roofing assembly 96 is erected in a manner similar to that of the ceiling assembly 94, but is erected at a suitable pitch. Preferably, supporting struts 99 extend from the ceiling assembly 94 to support the roofing assembly 96 during construction. Figure 17 shows a building 100 having a flooring assembly 60, wall panels 10, a 5 ceiling assembly 94 and a roofing assembly 96 all in accordance with the present invention. Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention. 12

Claims (25)

1. A building constituent assembly comprising at least one covering member and at least one supporting structure, the supporting structure including a plurality of supporting members each having first and second side 5 portions located adjacent a covering member, characterised in that the first side portion of each supporting member is complementary in shape to the second side portion of each supporting member such that a first supporting member and a second supporting member can engage each other by the overlay of the first side portion of the first supporting member and the second 10 side portion of the second supporting member, such engagement restraining relative movement of the first and second supporting members in at least one direction.

2. A building constituent assembly as claimed in claim 1, characterised in that the first and second side portions are corrugated. 15

3. A building constituent assembly as claimed in claim 1 or claim 2, characterised in that the covering member restrains relative movement of the first and second supporting members in a second direction.

4. A wall panel comprising a supporting structure and at least one covering member, the supporting structure having at least one supporting 20 member adjacent a covering member, characterised in that the supporting member has a first side portion extending beyond the covering member and a second side portion adjacent the covering member, a receiving area being defined between the second side portion and the covering member, wherein the first side portion of the supporting member of a first wall panel is 25 receivable within the receiving area of a second wall panel, the first side portion being complementary in shape to the second side portion such that the first side portion of the first wall panel engages the second side portion of the second wall panel, the engagement restraining relative movement of the first and second wall panels in at least one direction and the covering member 30 restraining relative movement of the first and second wall panels in a second direction. 14

5. A wall panel as claimed in claim 4, characterised in that the first and second side portions are corrugated.

6. A wall panel as claimed in claim 4 or claim 5, characterised in that the supporting structure includes two opposed supporting members. 5

7. A wall panel as claimed in claim 6, characterised in that the supporting members each have a transverse portion extending internally of the wall portion from the second side portion, the transverse portions engaging each other.

8. A wall panel as claimed in claim 6, characterised in that the transverse 10 portions are corrugated.

9. A wall panel as claimed in claim 7 or claim 8, characterised in that the wall panel supporting structure includes at least one bracing member located internally of the wall panel, the bracing member being in contact with each of the supporting members. 15

10. A wall panel as claimed in claim 9, characterised in that each bracing member includes apertures aligned with apertures of the transverse portions of the supporting members to allow connection of corresponding bracing members of adjacent wall panels.

11. A wall panel as claimed in any one of claims 4 to 10, characterised in 20 that the covering member is fixed to the supporting member.

12. A building constituent assembly comprising a supporting structure and at least one covering member, characterised in that the supporting structure includes at least one supporting member having as a trough portion which is substantially V-shaped in a transverse direction, the supporting member 25 having first and second side portions on opposed sides of the trough portion, the first side portion of a first supporting member being complementary in shape to the second side portion of a second supporting member such that the first and second supporting members can engage each other by the overlay of the first side portion of the first supporting member and the second 15 side portion of the second supporting member, such engagement restraining relative movement of the first and second supporting members in at least one direction.

13. A building constituent assembly as claimed in claim 12, characterised in 5 that the first and second side portions are corrugated.

14. A building constituent assembly as claimed in claim 12 or claim 13, characterised in that supporting structure includes at least one secondary support member, the or each second support member including at least one V-shaped section with a similar profile to the trough portion, such that a 10 supporting member can be located in the V-shaped section.

15. A building constituent assembly as claimed in claim 14, characterised in that the secondary support member includes substantially horizontal portions arranged to receive the first and second side portions of the supporting member. 15

16. A building constituent assembly as claimed in claim 15, characterised in that the secondary support member has a horizontal portion at respective first and second ends thereof, and the horizontal portion at the second end is slightly lower than that at the first end to permit end-to-end connection of secondary support members. 20

17. A building constituent assembly as claimed in any one of claims 14 to 16, characterised in that the supporting structure includes at least one base member arranged to receive the secondary support members.

18. A building constituent assembly as claimed in any one of claims 12 to 17, characterised in that the building constituent assembly is a floor assembly, 25 and the covering member is a flooring sheet.

19. A building constituent assembly as claimed in any one of claims 12 to 17, characterised in that the building constituent assembly is a ceiling assembly, and the covering member is a ceiling sheet. 16

20. A building constituent assembly as claimed in any one of claims 12 to 17, characterised in that the building constituent assembly is a roofing assembly, and the cover member is an eves lining sheet.

21. A building constituent assembly as claimed in claim 20, characterised in 5 that the roofing assembly has roofing sheets opposed to the covering member.

22. A supporting structure for a building constituent assembly, the supporting structure including two supporting members, each supporting member having a side portion extending in a longitudinal direction and a 10 transverse portion, wherein the transverse portions of the two supporting members are complementary in shape and overlie each other at least in part thus restricting relative movement of the supporting members in at least one direction, and the respective side members are spaced from each other in substantially opposed parallel relationship. 15

23. A supporting structure as claimed in claim 22, wherein the transverse portions are corrugated.

24. A supporting structure as claimed in claim 22 or 23, wherein the side members are maintained in an opposed parallel relationship by bracing members. 20

25. A supporting structure as claimed in any one of claims 22 or 23, wherein the supporting structure is arranged to receive panels affixed to at least one side member. TRIPOD COMPONENTS PTY LTD By its Patent Attorneys 25 ARMOUR IP P2020AUOO