Abstract:
A building system is disclosed having building constituent assemblies including wall panels ( 10 ), a flooring assembly ( 60 ), a ceiling assembly ( 94 ) and a roofing assembly ( 96 ). Each of the building constituent assemblies includes a supporting structure ( 12, 62 ) and a covering member ( 14, 64 ). The supporting structure ( 12, 62 ) includes a supporting member ( 20, 66 ) which has a corrugated first side portion ( 30, 74 ) and second side portion ( 34, 76 ). The side portions of adjacent supporting structures ( 12, 62 ) overlay each other and interlock the adjacent constituent assemblies together.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a building system.  
       BACKGROUND TO THE INVENTION  
       [0002]     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.  
         [0003]     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 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.  
         [0004]     Building constituents such as walls, floors, ceilings and roofs are generally constructed by erecting a supporting structure, and then mounting the constituent to 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.  
         [0005]     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 great deal of specialised construction work to be undertaken at the site. Supplying the constituents in a partially assembled form can reduce this problem, however the partially assembled constituents are often bulky and difficult to transport.  
         [0006]     The present invention attempts to overcome at least in part some of the aforementioned disadvantages of previous building methods.  
       SUMMARY OF THE INVENTION  
       [0007]     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 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 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.  
         [0008]     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 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 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.  
         [0009]     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 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 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.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:  
         [0011]      FIG. 1  is an exploded plan view of a wall panel in accordance with the present invention;  
         [0012]      FIG. 2  is a plan view of the wall panel of  FIG. 1  shown in an assembled configuration;  
         [0013]      FIG. 3  is a plan view of two wall panels such as that in  FIG. 2 , shown in a connected configuration;  
         [0014]      FIG. 4  is a partially cut away perspective view of a supporting structure of the wall panel of  FIG. 2 ;  
         [0015]      FIG. 5  is a partially cut away perspective view of the wall panel of  FIG. 2 ;  
         [0016]      FIG. 6  is a perspective view of a supporting member of a flooring assembly in accordance with the present invention;  
         [0017]      FIG. 6   a  is a cross sectional view of the supporting member of  FIG. 6 ;  
         [0018]      FIG. 7  is an exploded view of a supporting structure of a flooring assembly in accordance with the present invention;  
         [0019]      FIG. 8  is a perspective view of the supporting structure of  FIG. 7  in an assembled configuration;  
         [0020]      FIG. 9  is an upper perspective view of the supporting structure of  FIG. 7 ;  
         [0021]      FIG. 10  is an exploded side view of a flooring assembly in accordance with the present invention;  
         [0022]      FIG. 11  is a side view of the flooring assembly of  FIG. 10  in an assembled configuration;  
         [0023]      FIG. 12  is an exploded side view of a ceiling assembly in accordance with the present invention;  
         [0024]      FIG. 13  is a side view of the ceiling assembly of  FIG. 12  in an assembled configuration;  
         [0025]      FIG. 14  is an exploded side view of a roofing assembly in accordance with the present invention;  
         [0026]      FIG. 15  is a side view of the roofing assembly of  FIG. 14  in an assembled configuration;  
         [0027]      FIG. 16  is an end view of the roofing assembly of  FIG. 15 ; and  
         [0028]      FIG. 17  is a partially cut away view of a building constructed of constituent assemblies in accordance with the present invention. 
     
    
     DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0029]     Referring FIGS.  1  to  5 , there is shown a building constituent assembly comprising a 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 .  
         [0030]     The supporting structure  12  includes two supporting members  20  in the form of 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 .  
         [0031]     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 ; and 1.5 peaks forming a transverse portion  32  extending inwardly of the rear end  18  of the covering member  14 .  
         [0032]     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 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 .  
         [0033]     The wall panel  10  further includes a plurality of bracing members  38 . The bracing 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 .  
         [0034]     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  FIG. 4 . In the connected configuration, the transverse portions  32  of the two corrugated sheets  22  overlie one 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  FIG. 5 .  
         [0035]     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 the second side portions  34 .  
         [0036]     Successive wall panels  10 ,  10   a  are connected as shown in  FIG. 3 .  
         [0037]     The first side portions  30  of the supporting members  20  of wall panel  10  are received within the receiving areas  36  of wall panel  10   a , that is between the second side portions  34  and the covering members  14 . It will be appreciated that the corrugations 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 .  
         [0038]     When in the position shown in  FIG. 3 , the first side portions  34  of wall panel  10  engage the second side portions  36  of wall panel  10   a , and thus prevent movement of the two wall panels  10 ,  10   a  relative to each other in a direction perpendicular to the 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 .  
         [0039]     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 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  10   a  though bolts  50  or similar connection means.  
         [0040]     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  FIGS. 4 and 5 . Referring to FIGS.  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 .  
         [0041]     The supporting structure  62  includes a plurality of supporting members  66  as shown in  FIGS. 6 and 6   a . 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 .  
         [0042]     Each supporting member  66  has a first side portion  74  and a second side portion  76 . 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.  
         [0043]     The supporting members  66  are constructed from a corrugated material having waveforms oriented in the transverse direction. In the embodiment shown in the 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 .  
         [0044]     The supporting structure  62  comprises supporting members  66 , secondary support members  78  and base members  80 . These elements can be seen in  FIG. 7 .  
         [0045]     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  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 .  
         [0046]     Each secondary support member  78  has a horizontal portion  86   a ,  86   b  at both outer ends thereof. The horizontal portion  86   b  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  86   a  at one end of a first secondary support member  78  located above the horizontal portion  86   b  at the other end of a second secondary support member  78   a.    
         [0047]     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.  
         [0048]     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 .  
         [0049]     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 members  66  to the secondary support members  78 , thus forming the supporting structure  62 .  
         [0050]     In use, the supporting members  66  are effectively tiled in both the elongate and transverse directions. In the transverse direction, adjacent supporting members  66  engage each other by overlay of the first side portion  74  of a first supporting member  66   a  and the second side portion  76  of the second supporting member  66   b . In the elongate direction, adjacent supporting members  66   a ,  66   c  are arranged such that a portion of the length of a third supporting member  66   c  is contiguous with, and overlaps, the first supporting member  66   a . The arrangement is such that the overlapping portion extends between, and is supported by, two parallel secondary support members  78 .  
         [0051]     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 a particular construction.  
         [0052]     Preferably, the supporting members  66  are tiled in an offset pattern as shown in  FIG. 3 .  
         [0053]     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 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.  
         [0054]     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  64   a . The completed flooring assembly is shown in  FIGS. 10 and 11 .  
         [0055]     Each flooring sheet  64   a  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  64   a  engages the supporting members  66  and acts to lock them in position relative to one another.  
         [0056]      FIGS. 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  64   b , such as cement sheeting.  
         [0057]     In a preferred embodiment of the ceiling assembly  94 , each ceiling sheet  64   b  corresponds to an associated supporting member  66 , and is sized so as to abut an adjacent ceiling sheet  64   b  when the supporting members  66  are tiled as described herein above with respect to the flooring assembly  60 .  
         [0058]     FIGS.  14  to  16  show a roofing assembly  96 . The roofing assembly  96  is substantially similar to the ceiling assembly  94 , with the covering members  64  comprising of an eves lining sheet  64   c . In the roofing assembly  96  the base member  80  is preferably a “Z” purlin  80   b , to which is attached corrugated roofing sheets  98 .  
         [0059]     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.  
         [0060]      FIG. 17  shows a building  100  having a flooring assembly  60 , wall panels  10 , a ceiling assembly  94  and a roofing assembly  96  all in accordance with the present invention.  
         [0061]     Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.