CA1315065C - Methods of building construction - Google Patents

Abstract

ABSTRACT

A method of modular building contruction has structural wall panels (18) of metal skin (19)/
insulating foam (20)/fibrous cement sheet (or structural plywood)(21) laminate construction secured to a floor assembly (10) by brackets (24) which are bolted to the longitudinal bearers (11) and to roof truss flames (35) by brackets (41) to enable loads to be distributed through the wall panels (13), floor assembly (10) and roof truss frames (35).
The longitudinal bearers (11) are formed of C-section beams (12) secured back-to-back and the joists (13) are secured by tabs extending from the webs of the bearers.

Description

131~06~

TITLE: "METHODS OF BUILDING CONSTRUCTION"
BACKGROUND OF THE INVENTION
(1) Field of the Invention THIS INVENTION relates to improved methods of building construction.

(2) Prior Art Many methods of modular building construction have been proposed. While many of these have certain advantages (eg. they are less expensive and allow the use of semi-skilled labour) over conventional building techniques, they generally have inherent problems which limit their flexibility in floor plan and ease of erection.
SUMMA~Y OF THE PRESENT INVENTION
According to one aspect of the invention, there is provided a building structure including a floor assembly supported on a plurality of stumps or piles; a plurality of wall panels secured to the floor assembly; a plurality of roof truss frames supported on, and secured to, the wall panels: first bracket means securing the wall panels to the floor assembly; and second bracket means securing the roof truss frames to the wall panel, each of said first and second bracket means being received between adjacent wall panels; wherein said wall panels are arranged such that any loads between the floor assembly and the roof truss frames are transferred through the wall panels, and each wall panel has a peripheral metal frame to which is bonded or fixed a pair of cladding sheets and the cavity therein is filled with insulating foam.
According to a further aspect of the invention, there is provided a building structure including a floor assembly supported on a plurality of stumps or piles; a plurality of wall panels secured to the floor assembly; a plurality of roof truss frames supported on, and secured ~L
, ~ .

' - ' ~ . ,~ .

' ' ' '. '.
: ' . , ~ ' 2 131506~
to, the wall panels; first bracket means securing the wall panels to the floor assembly; and second bracket means securing the roof truss frame to the wall panel, each of said first and second bracket means being received between adjacent wall panels; wherein said wall panels are arranged such that any loads between the floor assembly and the roof truss frames are transferred th~rough the wall panels; and said floor assembly comprises a floor assembly frame and said wall panels comprise peripheral frames having stiles, each of said first bracket means to secure the wall panels to the floor assembly is of substantially L-shape in side view and has a foot section arranged to be bolted to the floor assembly frame and a leg section to be received between, and bolted to, the stiles in the peripheral frames of the adjacent wall panels.
According to yet a further aspect of the invention, there is provided a building structure including a floor assembly supported on a plurality of piles or stumps; a plurality of wall panels secured to the floor assembly: a plurality of roof truss frames supported on, and secured to, the wall panels; first bracket means securing the wall panels to the floor assembly; and second bracket means securing the roof truss frame to the wall panel means, each bracket means being received between adjacent wall panels; wherein the floor assembly includes a peripheral frame having longitudinal bearers comprising a plurality of assembled I-beams, each I-beam being assembled from a pair of substantially identical C-section beams, whexein each C-section beam has a web member interconnecting a pair of substantially identical C-section beams, wherein each C-section beam has a web member interconnecting a pair of substantially parallel side flange members directed to one side of the web member, the C-section beams being ;.. .. ...

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arranged with their web members back-to-back and interconnected by aligned tab members and slots in the web members; at least one lateral beam or joist is connected thereto, each lateral beam or joist having a web between a pair of parallel side flanges, the lateral beam or joist being received between a pair of the side flange members of the longitudinal bearers; first fastener means engaged in respective aligned holes in the lower of the side flanges in the lateral beam or joist and the lower of the side flange members of the longitudinal bearer to secure the peripheral frame to the stumps or piles; and second fastener means engaged in respective aligned holes in the upper of the side flanges of the lateral beam or joist, the upper of the side flange members of the longitudinal bearer and the first bracket means to secure the wall panels to the floor assembly; so arranged that any loads between the floor assembly and the roof truss frame are transferred through the wall panels.
BRIEF DESCRIPTION OF THE DRAWINGS
Specific embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG 1 shows a schematic layout of the method of building construction;
FIG 2 is a perspective view of an I-beam, used in the floor structure before assembly;
FIG 3 is a perspective view of a 3-way beam : 30 ~ 35 , : ` , ` ' ' ' .
:
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4 1~1~065 connection in the floor assembly;
FIGS. 4 to 7 are plan views of a beam corner, beam joint, 3-way beam connection and a 4-way beam connection respectively in the floor assembly; and FIG. 8 is a sectional side view of a portion of the floor assembly.
FIG. 9 is a front view of a "Warren" truss frame which may be used in the roof assembly;
FIG. 10 is a front view of a "Fink" truss-frame which may be used in the roof assembly;
FIG. 11 is a front view of the apex of the truss frame;
FIG. 12 is an isometric view showing how the top chords are notched at the apex;
FIG. 13 is a front view of the junction of two struts with the bottom chord;
FIGS. 14(a) and (b) show how the alternative struts are notched;
FIG. 15 is a side view of the junction of a top and bottom chord;
FIG. 16 is an isometric view showing how the top chords are notched at the junction with the bottom chord;
FIG. 17 is a perspective view of a ceiling 2S batten connecting a pair of the roof trusses;
FIG. 18 is an underside isometric view of one of the ceiling battenj FIG. 19 is an isometric view of a plurality of diminishing roof trusses fixed to standard roof trusses at the junction of two sections of a building;
FIG. 20 is an end view corresponding to FIG.
11;
FIG. 21 is a front view of a "Fink" type diminishing truss frame;
FIG. 22 is a front view of a "Warren" type `~

' 131~6~

dlminishing tr~ss frame;
FIG. 23 is a sect1onal end ~iew of a ~ottom chord of a dimlni~hing tru68 taken on l~ne 23-23 on F'G.
11;
S F~G. 24 19 a sectional end vlew o~ a valley gutter for use ~ith the dimlni~hing roof tx~sse~;
FIG. 25 is a per3pective view ~howing the layout grld ~or the lnternal walls;
FiGS. 26 to 29 ~how alter~ktive positlon~ for the wall ~racket to recei~e the wall panels o~ and off the ~r~d lines;
FIG. 30 is a pl~n vle~ of t~e wall pane~ to roof truss loo~tion p~ate~ and F}GS. 31 an~ 32 ~re plan view~ of alternate interaectlon~ of two w~ll panel~.
D~TAIL~D DESCRSPTIO~ OF _ TH~ EF~RED
EM~OD~MENTS
Refsrring to FIG. 1 a floor ~ssem~ly 10 ha~
longltud~nal bea~er~ 11, of ~ubstantially I-sectlon forme~ of C---ctlon beam~ 12 bac~-to-~ack, lnter~onnected by tran~vers- jol~ts 13 of oub~tantl~ly Z-section. Th~ C-~ection beam-, and th- bearer~ ant ~oi~t~, are ~ecured togot~e~ by t~b-~n-slot ~a6te~ng mean~ to be doscrlbod ln mor- detall with re'erencc to 2~ FIGS. 2 to 8. The floor assem~ly 10 16 su?ported on a plurality o stumpE having a~u~ta~le ~t~p ca~ 14 ~rranged to receivc four ~tuds 15 whlch 9ecure the bearer~ 11 of the th- floor a~se~bly 10 to the ~tump~
1~ .
~ floor panel 16 18 l~id over the floo~
~embly 10, She exterio~ wa~ 7 are ~ormed of composlte ~anel~ 18 ~e.g. of ~h-et mctal 191poly~tyrene fo-~ 201 flbrouc cement ~heet 21 l~m1natod construct~on) wh~ch hae a ~orlpheral fr~me with me~al ~t~le~ 22 (and top an~

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bottom rails) o~ Aubstantlally C-6ection. ~he panels 18 are arranged wlth thelr ad~acent metal stiles 22 face-to-face, separated by ~n insulati~/weather proofing s~rip 23.
The sheet metal out~r skln and ~ibrou6 cement 6heet inner skln are bonded to the peripheral metal frame before the polystyrene insul~tinq foam i9 foamed ln the cavlty of the wall psnel. The resultant panels form a structur~l member whlch can di~trlbute a load applie~ to ~.,.. ~., - - .

~15065 e.g. one corner of the panel throughout the p~nel.
Internal wall panels are of generally the . same construction, with the sheet metal skin being replaced by plasterboard or other suitable sheet material.
The bases of the wall panels 18 are secured to the floor assembly 10 by L-shaped brackets 24. Each brac~et has a foot 25 with two holes which receive studs 26 which pass through the floor panel 16 and are received in holes 27 in the upper flanges 28 of the bearers 11. ~As shown, a further two studs 29, secures the floor panel 16 to the bearers at the junction of the bearer members over a stump 14.) Each bracket 24 has a vertical leg 30 which is received between the adjacent stiles 22 of two wall panels 18 and the leg is secured thereto by a single bolt 31 which passes through aligned holes 32 in the stiles 22 and the hole 33 in the leg 30.
The roof assembly 34 (to be described in more detail with reference to FIGS. 9 to 24) is supported on a plurality of roof truss frames 35, whére the top and bottom chords 36, 37 are formed of "top-hat" roll~formed ; metal sections which, at the junction 38 thereof, are nested together and fixed by "Tek-screws" 39. (The interior wall panels (not shown) can be bolted to the bottom chord 37 via holes 40 therein.~
To secure the roof truss frames 35 to the exterior wall panels 18, a bracket 41 has a plate 42 received between the adjacent stiles 22 of two panels 18 and is secured thereto by a bolt 43 passing through aligned holes 44, 45 in the plate 42 and stiles 22. A
threaded stud 46 extends upwardly from the plate 42 and passes through aligned holes 47 in the top and bottom chords 36, 37 and receives a nut 48.
The brackets 24, 41 enable the wall panels 18 to be secured together and ties the wall panels 18 to the floor assembly 10 and the roof assembly 34 and also 131~06~
a enables loads on the building structure ~o be distributed between the floor, walls and roof.- In addition the brackets enable the components to be quickly and accurately connected together.
The general floor assembly lO, and the method by which the longitudinal bearers are produced from the C-section beams will now be described with reference to FIGS. 2 to 8.
Referring to FIGS. 2 and 3, the assembled I-beam 110 comprises a pair of roll-formed C-section metal beams 111, 112 arranged with their respective webs 113 back-to-back and their upper and lower side flanges 114, 115 directed outwardly.
A plurality of tabs 116 are punched or otherwise formed out of the webs 113 of the C-section beams, only one tab per beam being shown. Each tab 116 has a leg 116A extending substantially perpendicular to the web 113 and a toe 116B substantially parallel to, but spaced from, the web 113. A respective slot 117 for each tab 116 remains in the web 113. As shown, the tabs 116 of the beams 111, 112 are oppositely directed to each other so that the tabs 116 of beam 111 enter the corresponding aligned slots 117 of beam 112 and vice versa.
When the beams 111, 112 are brought together, with the tabs 116 through the aligned slots 117, the tabs 116 of each beam are deformed, e.g. with a hammer, to cause the legs 116A and toes 116B to engage the web of the other beam to so secure the C-section beams 111, 112 together with a single assembled I-section beam 110, suitable for structural purposes.
Holes 118, 119 of different diameters, are provided in the side flanges 114, 115 respectively adjacent their ends, and in pairs at modular lengths along the flanges, to enable two or more of the I-~1506~
9 . .
section beams 110 to be secured together.
As shown in FIG. 3, the holes 118, 119 are spaced so that when two or more I-beams 110 are connected together, the ends of their webs 113 are slightly spaced, with their side flanges 114, 115 overlapped.
FIGS. 4 to 7 show how the assembled I-beams 110 may be connected together at a joint e.g. over a supporting stump or pier, where bolts passing through 1~ the holes 118, 119 connect the beams 110 to structural fixing brackets or stump head ~lates (provided with aligned holes) not shown.
FIG. 8 illustrates how the I-beams 10 are used as part of a floor assembly for a building, the beams also enabling a wall structure to be attached to the supporting stumps or piers.
The floor assembly 120 is supported on a plurality of building stumps 121. Each stump 121 has a rectangular cap 122 with four holes to receive holts 123. The floor assembly 120 has a peripheral frame and cross-members formed of the assembled I-beams 110 interconnected by joists 124. Each joist 124 is of modified Z-section roll-formed steel, with top and bottom flanges 2S connected by a web 126.
2S A slot 127 is formed centrally in the web 126 adjacent each end and is engaged by one of the tabs 116 of the adjacent I-beam 110 to secure joist 124 to the I-beam ilO (the side flanges 125 of the joist being closely interfitted with the side flanges 114, 115 of the I-beam 110).
As shown, the hole 127 is spaced from the end of the joist 124 a distance substantially equal to the height of the leg 116A of the tab 116 and the toe 116B
is received in the hole 127 and then deformed (e.g. with a hammer) to form a hook to secure the joist 124 and I-:

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beam 110 together.
Bolts 123 through aligned holes (not shown) inthe lower side flanges 125 of the joist 124, the I-beam 110 (i.e. holes 119) and the cap 122 of the stump 121 enable the floor assembly 120 to be secured to the stump 121. A floor panel 128 is laid over the floor assembly 120 and is clamped to the I-beams 110 by bolts 129 passing through the holes 118 in the I-beams, the floor panel 128 and angled fixing ~rackets 130 for wall panels 131. The floor panel 128 is fixed to the joists 124 by suitable screws, studs or adhesives.
A cover sheeting 132 is provided around the floor structure 120, to enclose the I-beam 110 of the peripheral frame, and weather-proofing is provided between the wall panels 131 and the cover sheeting 132 by suitable flashing 133.
If, at any time, the building is to be extended, the cover sheeting 132 and ~lashing 133 may be removed and joists 124 may be connected to the I-beams 110 i.e. to extend to the right in FIG. 8. (The new joist 124 would be connected to the I-beam 110 by the free tabs 116 and the bolts 123, 129.) The general roof assembly 34 will now be described in more detail with reference to FIGS . 9 to 24.
Referring to FIG. 9, the truss frame 210 is a "Warren" type truss frame which has a pair of top chords 211, 212 and a bottom chord 213 of "top-hat" cross-section roll-formed metal (see FIG. 14(b)) and diagonal struts 214 of "C" section rolled-formed metal (see FIG.
14(a)). FIG. 10 shows a "Fink" type truss frame 220 where the top chords 221, 222 and bottom chord 223 are of the "top-hat" section, the inner struts 224 are of the "top-hat" section and the outer strut 225 are of the "C" section.

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Re~erring to FIG. 14(a), the "C" section components 230 have downwardly divergent side walls 231, 232 interconnected by a base web 233. The "top-hat"
section components 240 (see FIG. 14(b)) have side walls 241, 242 and a base web 243 configured as for the "C"
section components 230, with the addition of laterally extending side flanges 244, 24S which are co-planar. As the side walls 231, 232 and 241, 242 are divergent, the components 230 and 240 can be nested together to enable adjacent side walls to be fixed together by studs or bolts, rivets or self-piercing fasteners (e.g. of the type known as "Tek-screws").
Referring to FIGS. 11 and 12, the top chords 211, 212 and 221, 222 are notched as shown in FIG. 12, where the side flanges 244, 245 are terminated a preselected distance "d" from the inner ends of the chords and an inclined cut forms a relieved portion 246 in the upper portion of the inner ends of the chords.
When the two top chords 211, 212 and 221, 222 are brought together, one is nested within the other and their adjacent side walls are fixed with "Tek-screws"
25', thereby avoiding the need for connector plates or brackets.
The upper ends of the struts 214, 224, 225 are received within the top chords 211, 212 and 221, 222 and their adjacent side walls are fixed using "Tek-screws".
At the lower ends of the struts 214 and 224, 225, the ends are relieved, as shown in FIGS. 14(a) and 141b) at 247 and 248 respectively. As shown in FIG. 13, the ends of the struts 211, and 224, 225 are placed over, and nestably receive, the bottom chords 213, 223.
The adjacent side walls are then secured together with "Tek-screws" 251 at the junction 252, 253. Referring to FIGS. 15 and 16, the junctions 254 between the top chords 211, 212 and 221, 222 and the bottom chords 213, ', ,, ~, , .
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223 are similar to the junctions 252, 253 in that the bottom chords are nested within, and fixed to, the top chords, the latter being notched on each side at 255 as shown in FIG. 16.
The overlapping junctions between the top and bottom chords, the top chords at the apex 250 and the chords and struts at junctions 252, 253, 254 results in truss frames with very high strength-to-weight ratios.
It is possible to partially assemble the truss frames, fold the frames down f or transport and to complete assembly on site. Only a pair of fasteners are provided to connect the outer ends of the top chords to the bottom chords, the top chords not being connected at the apex, and only one pair of fasteners connects one end of each strut to either the top or bottom chord.
This enables the semi-assembled truss frame to be folded down, with the chords and struts nested together, f or transport. On site, the truss frame is opened out to the desired configuration and the assembly is completed.
With this arrangement, transport costs are reduced while allowing more accurate final assembly on site than if the erectors were supplied only with the individual components.
Referring now to FIGS. 17 and 18, when erected, adjacent roof truss frames 210, 220 are interconnected by parallel, spaced ceiling battens 260 of substantially channel section (see FIG. 18). A tab 261 is punched out of the central web 262 of the batten adjacent each end and is arranged to frictionally engage the adjacent side flanges 244, 245 of the adjacent bottom chord 213, 223.
The ceiling battens 26~ are aligned with the side flanges 244, 245 and then rotated to cause the side flanges to be frictionally engaged between the tabs 261 and the central web 262.

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When all the ceiling battens have been installed, the ceiling panels Inot shown) are fixed to the ceiling battens 260 using fasteners ~e g. "Tek-screws"). By the provision of the tabs 261 at each end of the ceiling battens, and the frictional engagement between the ceiling battens and the bottom chords 213, 223 of the roof truss frames 210, 220, the necessity for separate fasteners is avoided.
Referring now to FIGS. 19 to 22, these show ~0 "diminishing" roof trusses which are employed at the junction of two wings of a building, where the gables on each are brought to a single point.
The trusses 220 of the main wing are of the "Fink" type shown in FIG. 10. The diminishing trusses 1~ 270 of the side wing are also of the "Fink" type ~see FIG. 21) but may be of the `'Warren" type (see trusses 272 of FIG. 22) if preferred. As shown in both FIGS. 19 and 20, the diminishing trusses 270 are of reducing width and height as they are provided up the trusses 220 of the main wing. Generally the main trusses 27i of the side wing will be the same as the trusses 220 of the main wing.
The construction of the diminishing trusses 270 will be generally as for the main trusses 210, 220 (see FIGS. 9 to 16~, with two major differences.
Firstly, as shown in FIGS. 19, 21 and 22, the bottom chords 273, 274 extend pass the junctions with the top chords 275, 276. This enables the trusses to span, and be fixed to, the main trusses 220 of the main wing to either side of the side wing - see FIG. 1~. Secondly, the bottom chcrds 273, 274 have the "modified top-hat"
profile shown in FIG. 23 where the side flanges 277, 278 are co-planar but inclined relative to the vertical plane through the section. The angle of inclination of the flanges corresponds to the inclination of the top ~, ~,.. .... . .
-.

-, :
~:

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( see ~GS. 9 to 16), with two ma~or differences.
Firstly, as shown in FIGS. 19, 21 and 22, the bottom chord~ 273, 274 extend pass the junction~ wlth the top c~ord ~75, 276. This enable~ the trus~es to span, and 5 be fixed to, the main trusses 220 o~ the main wing to either ~ide o~ the ~ide wing - ~ee ~IG. 19. S~condly, the bottom chord~ 273, 27~ have the "modified top-~at"
proflle shown in FIG. 23 where the side flanges 277, 278 are co-planar but inclined relatlve to the vertical 10 plane through the section. The angle of inclinaelon of the f lar.~es correspond~ to the inclinatiorl of the top chord~ 222 of the main trus~e3 220 and the ~lange~ 277, 27B ~re flxed to the ba5e webs 243 of the to~ chord~ by "T~k-screws" or other sultable fa~tener3. Thi5 ena~les 15 the "dlm~n1shing" tru~ses 270, 272 to ~e easlly flxe~ to the main trusses 210, 220.
~ eferring now to FIG. 24, thls ~hows an end view of a valley gutter 2ao to be use~ with the d1mlnishing trusse6 270, 272. A~ the gutter 2~0 runs diagon*lly to ~oth the main trus~e~ 210, 220 and t~e dimlnlshing tru~es 270, 272, lt ha~ u~war~ly lncllned side flanges 291, 282 to be flxod to roof purlln~
supported by the top chords 212, 222 and 275, 276 thereof lby e.g. "Te~-sc~ews") as ~t ~g laid down the valley prior to the roof 3heetln~ being lnstalled. The ~-~haped floor 283 enable6 the gutter 280 ~o nest on the extension at the ends o~ the ~ottom chords 273, 274 of the ~lminishlng t~ugse3.
once th~ roo~ trusses have been positloned ana fixet, the intern~l wall pan~ls may ~e poslt~onsd.
Referr~ng to F~G. 25, the ba~i3 of the location of the lnternal wall ~y~tem la a grid 300 ~e.g.
at ~45 mm centres) w~th a 4 holo x (e.g. 38 mm) sguare patte~n 301 layout at each lnter~-ctlon 302 throuqh 3~ wh~ch the panel ~racket~ 303 (see r~Gs~ 26 to 29) may ~e . ~ ' fixet. (The panel ~rackets 303 al an alternatlve embodiment to the wall ~anel brackets 25 shown ln FIG.
1.) Each wall bracket 303 ha~ four holes 304, 30~
in its hor~20ntal foot 306 and a slo~ted hole 307 ln lts vertlcal leg 303. The holo~ 304 are ~paced a dlstance d from he centre line of the vertical ~eg 308 wh1ch ls one half of the distance D ~etween the holes 301 at the lnter~ectlon 302 (and whlch 18 al80 the distanoe of holes 30S from the vertlcal leg 30a o~ the ~ra~ket and the thlcknee~ o~ the wall panel~).
For wall p~nel~ which have their centre linc located on a grld llne and whose end~ 8 ) start a~dJor f~nlsh a~ the intersection 302 (e.~. 93~ m~ panel3 on a 945 mm grid), the bracket 303 sho~ld be fixed with lts vertical le~ 3~a dlrectly ov~r the in~rsectlon 302 of the grld llne~ ~ 8ee FIG. 26). In thl3 posl~ion, the hole~ 304 wlll be aligned with the hole~ 27 ln the floor (~e~
However, the 8ygtom allow~ the wall pa~els to be offset relativ- to the ~rld 300. For example, with ~he wall panels havlng thelr centre lines locate~ on the grld 300 but their end~ step~e~ off the grld (e.g. a 900 mm p~nel), thc bracXet 303 1~ rotated throu~h 180 (see FIG. 27) ~o that the centre line o~ the ver~1cal leg 1 the dl6tance ~ from the lntersectlo~ 302. Similarly, the brack2t 303 may be posl~lonet to fix the wall panel with ~t~ cen~re ll~e of the grid 300 but lts end on the grld (FIG. 28) or wit~ both the pane~ cen~re line and panel end o~f the grld (FIG. 29). It will be noted th~t ~n the arrangements o FIGS. 28 ~nd 29, only one of the hole~ 304 i~ u~ed to flx the wall bracket 303 to the ~loor. lWhere the wall panel does not s~an a gr~d e.g.
whore the panel lncorporates a doorway, the bracket 303 iJ fixod to the floor uslng two ~o~-~orewsl~ through 16 131~06~
hole~ 3 o 5 ), Where tho walls use p~nels of tw~ di~ferent lengths e.g. 938 mm $or the extexior panels and some lnterior panels and e.~. 900 mm for some lnterios panels, the distance D ~ equal to the dlfference in t~e panel length~ ~e.g. D = 938 -900 = 38 mm).
The top~ of ~he panel- are anchored to the roo~ trus~e~ 34 ~ee FIG. 1) uslnq brackets 41. A9 the wall panel~ can be of f -~et relat1 ve to the roof tru8~es 34, a flxing plate 310 19 fixed to t~e under~lde of the bottom chord 37 (8hown in pl~n vlew ln dashed lines).
Where the wall panel~ are on ~he grid lines 300 and thelr end~ are at the lntersection 302 ~a~ ln FIG. 26), the threa~ed ~tud 46 on the bracXet pas~es t~r~ugh tho central hole 311 in the plate and central hole 40 ln the ~ottom chord 37 to f~x the panel and plate to the chord.
~owever, lf the panelQ are on the grid lines 300 but t~ L ~fL~ 6 ib F~G. 27), ~ bslt paoses thr~ugh central hole 311 to fix the pla~e 310 to 2~ the bott~m chord and the threaded ~tud 46 on the bra~ket p~s~e~ through one of tho allgned hole~ 312 in the plate 310, two of the hole~ b~lng al~gned with the ~l~e hsles 40 in the bottom chord. Sf the panel~ are off th- srid, then the plat- 310 i8 ~oltod to the chord 37 and the th~ated ~tud 46 wlll be secured in one of tho cor~er hol-~ 313 ln the plate 313 in the ~late 310 (which will nece~ ate drl~ling a correspondlng hole in the bottom chor~ 37).
Referring now to FIGS. 31 and 32, these s~own ln plan v~ew, the internal wall panel~ 320 can be flxed with thelr ends allgned (FIG. 31) or overlapping (FIG~
32), when the bolt~ 321 engage ~he respective studs 322 o the p~nel- to en~ure ef~ective tran~fer of ~ny loads therebetween. A ~pacex washer 323 1B provlded between the nd o~ one pane~ and the ~kin of the second panel at !

, ' ' .~. `
~ , ' , ' , , .
, -' ' ' . ' ' ' ' , ' , ' ':
-;

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tha corner. . .
Because the internal wall panels can be ~tep~ed off the grid line~, it allowa simpler fix~ng of the panels e.g. where windows and doors occur and the S offse~, being half the thickncs~ of the pa~el, and allow~ the faces of panel~ to ~e posltioned on the ~rtd line~ ~e.g. see Fl~. 31).
~ t will ~e readlly appar~nt to the ~Xilled addr~ssee that the present invention provldes a ~imple, ~tron and easy-to-aroct method of modular building ~on$t~uction.
Varlous Changes and modlf~cat~on~ may ~e made to ~he embodlments de~cribe~ wlthout departing from the ~cope o~ the pre89nt lnventlon defi~ad in the a~pended claims.

Claims (16)

1. A building structure including:
a floor assembly supported on a plurality of stumps or piles;
a plurality of wall panels secured to the floor assembly;
a plurality of roof truss frames supported on, and secured to, the wall panels;
first bracket means securing the wall panels to the floor assembly; and second bracket means securing the roof truss frames to the wall panel, each of said first and second bracket means being received between adjacent wall panels;
wherein said wall panels are arranged such that any loads between the floor assembly and the roof truss frames are transferred through the wall panels, and each wall panel has a peripheral metal frame to which is bonded or fixed a pair of cladding sheets and the cavity therein is filled with insulating foam.

2. A building structure including:
a floor assembly supported on a plurality of stumps or piles;
a plurality of wall panels secured to the floor assembly;
a plurality of roof truss frames supported on, and secured to, the wall panels;
first bracket means securing the wall panels to the floor assembly; and second bracket means securing the roof truss frame to the wall panel, each of said first and second bracket means being received between adjacent wall panels;
wherein:
said wall panels are arranged such that any loads between the floor assembly and the roof truss frames are transferred through the wall panels; and said floor assembly comprises a floor assembly frame and said wall panels comprise peripheral frames having stiles, each of said first bracket means to secure the wall panels to the floor assembly is of substantially L-shape in side view and has a foot section arranged to be bolted to the floor assembly frame and a leg section to be received between, and bolted to, the stiles in the peripheral frames of the adjacent wall panels.

3. A structure according to Claim 1 wherein:
said floor assembly comprises a floor assembly frame and said wall panels comprise peripheral frames having stiles, each of said first (floor) bracket means to secure the wall panels to the floor assembly is of substantially L-shape in side view and has a foot section arranged to be bolted to the floor assembly frame and a leg section to be received between, and bolted to, the stiles in the peripheral frames of the adjacent wall panels.

4. A structure according to Claim 3 wherein:
the second bracket means to secure the wall panels to the roof truss frames have a leg arranged to be received between, and bolted to, the stiles of the peripheral frames of the adjacent wall panels and a vertical threadshaft which passes through the roof truss frame and is secured thereto by fastener means.

5. A building structure including:
a floor assembly supported on a plurality of piles or stumps;
a plurality of wall panels secured to the floor assembly;
a plurality of roof truss frames supported on, and secured to, the wall panels;

first bracket means securing the wall panels to the floor assembly; and second bracket means securing the roof truss frame to the wall panel means, each bracket means being received between adjacent wall panels;
wherein:
the floor assembly includes a peripheral frame having longitudinal bearers comprising a plurality of assembled I-beams, each I-beam being assembled from a pair of substantially identical C-section beams, wherein each C-section beam has a web member interconnecting a pair of substantially identical C-section beams, wherein each C-section beam has a web member interconnecting a pair of substantially parallel side flange members directed to one side of the web member, the c-section beams being arranged with their web members back-to-back and interconnected by aligned tab members and slots in the web members;
at least one lateral beam or joist is connected thereto, each lateral beam or joist having a web between a pair of parallel side flanges, the lateral beam or joist being received between a pair of the side flange members of the longitudinal bearers;
first fastener means engaged in respective aligned holes in the lower of the side flanges in the lateral beam or joist and the lower of the side flange members of the longitudinal bearer to secure the peripheral frame to the stumps or piles; and second fastener means engaged in respective aligned holes in the upper of the side flanges of the lateral beam or joist, the upper of the side flange members of the longitudinal bearer and the first bracket means to secure the wall panels to the floor assembly;
so arranged that any loads between the floor assembly and the roof truss frame are transferred through the wall panels.

6. A structure according to Claim 5 wherein:
each wall panel has a peripheral metal frame to which is bonded or fixed a pair of cladding sheets and the cavity therein is filled with insulating foam, the wall panels being so arranged to distribute a load applied at one position in the panel throughout the panel.

7. A structure according to Claim 5 wherein:
each of said first bracket means to secure the wall panels to the floor assembly is of substantially L-shape in side view and has a foot section arranged to be bolted to the floor assembly frame and a leg section to be received between and bolted to, the stiles in the peripheral frames of the adjacent wall panels.

8. A structure according to Claim 5 wherein:
the second bracket means to secure the wall panels to the roof truss frames have a leg arranged to be received between, and bolted to, the stiles of the peripheral frames of the adjacent wall panels and a vertical threaded shaft which passes through the roof truss frame and is secured thereto by fastener means.

9. A structure according to Claim 5 wherein:
each C-section beam has a plurality of tab members formed out the web member directed outwardly therefrom in the opposite direction to the side flange members, and a slot or hole formed in the web member adjacent each tab member, each tab member of each C-section beam entering the corresponding slot or hole of the other C-section beam, the tab members being deformed to engage the web members of the other C-section beam to secure the C-section beams together.

10. A structure according to Claim 9 wherein:
each tab member has a leg extending substantially perpendicularly to the web member and a toe member substantially parallel to, but spaced from, the web member;
each lateral beam or joist has a slot in its web adjacent the end received in the longitudinal bearer; and one end of the tab member of the longitudinal bearer is engaged in the slot to assist in the connection of the lateral beam or joist to the longitudinal bearer.

11. A structure according to Claim 10 wherein:
the slot in the web is spaced from the end of the lateral beam or joist a distance substantially equal to the height of the leg of the tab member, and the toe of the tab member is engaged in the slot and deformed to create a hook to secure the lateral beam to the longitudinal bearer.

12. A structure according to Claim 5 wherein each roof truss frame is of the type having a pair of inclined top chords and base chord braced by inclined struts wherein:
the chords and struts are formed of top hat and/or C-section sheet metal components and at each junction between two chords or a chord and a strut, one of the components is received within, and fixed to, the other of the components; and the metal components are roll-formed from sheet metal strip and have downwardly-divergent side walls to enable the components to be nested together at the junction.

13. A structure according to Claim 5 wherein each roof truss frame is of the type having a pair of inclined top chords and base chord braced by inclined struts wherein:
the top chord and struts are formed of top hat or C-section sheet metal components, the base chords are formed of modified top-hat section sheet metal components wherein the side flanges of the chord are coplanar and inclined to the longitudinal axis of the base chord; and wherein at each junction between two chords or a chord and a strut, one of the components is received within, and fixed to, the other of the components.

14. A structure according to Claim 13 wherein:
the bottom chord extends beyond its junction, with the top chords to span two or more roof trusses arranged laterally to the first truss.

15. A structure according to Claim 5 wherein each roof truss frame has a bottom chord of substantially top-hat section with horizontal side flanges, arranged in spaced parallel arrangement;
at least one ceiling batten interconnects a pair of the roof truss frames, the ceiling batten having a tab adjacent each end thereof to releasably secure the end of the batten to the horizontal side flange of the bottom chord with which it is engaged.

16. A structure according to Claim 15 wherein:
the ceiling batten is of substantially U-section and the tab is formed out of, and lies in parallel, spaced relationship relative to, the central web of the ceiling batten.