Patent Publication Number: US-2016237683-A1

Title: Building Panels - Systems Components &amp; Methods

Description:
PRIORITY 
     Priority is claimed from Australian patent applications 2013903929, 2013903752, 2013903737 and 2013234383 applied for by AUSSIB GROUPS PTY LTD. All parts and elements of these documents are hereby fully incorporated by reference for all purposes. 
     FIELD OF THE INVENTION 
     In one preferred form there is provided a building panel. Various systems, components and methods are provided. 
     BACKGROUND TO THE INVENTION 
     Building construction generally requires both a consideration of cost and safety. In cyclone affected areas buildings may have to meet legislated cyclone rating requirements. Rating requirements include wind loading requirements and other requirements 
     It is against this background and the problems and difficulties associated therewith that the present invention has been developed. 
     SUMMARY OF THE INVENTION 
     According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising: an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating. 
     Preferably the desirable cyclone rating corresponds with an external pressure loading of greater than 6 kPa. 
     Preferably the desirable cyclone rating corresponds with an external pressure loading of greater than 7 kPa. 
     Preferably the flange portions are provided in the vicinity of the perimeter around the foam core. 
     Preferably the flange portions are provided in the vicinity of the periphery of the frame. 
     Preferably the flange portions extend substantially around the full periphery of each primary face of the frame. 
     Preferably the structural channel members are metal structural channel members. 
     Preferably each structural channel member comprises a u-shaped channel member; with the structural members being welded together in the frame. 
     Preferably each structural channel member comprises an extending channel portion provided by two flanges and a base portion; the base portion connecting the two flanges to form the channel; the base portion extending between the primary faces of the frame; the channel being generally perpendicular to the to the surface normal of the primary faces. 
     Preferably the frame includes at least one internal structural member provided as a vertical strut extending vertically when then frame is standing upright. 
     Preferably the panel includes a series of spaced apart internal structural members; each provided as a vertical strut extending vertically when then frame is standing upright. 
     Preferably the or each internal structural member comprises a structural channel member. 
     Preferably the structural channel members are formed from 1 mm thick steel where the thickness is a base metal thickness. 
     Preferably the structural channel members are formed from steel between 1 to 1.2 mm thick where the thickness is a base metal thickness. 
     Preferably the structural channel members are formed from steel between 1 to 1.5 mm thick where the thickness is a base metal thickness. 
     Preferably the structural channel members are formed from steel between 1 to 2 mm thick where the thickness is a base metal thickness. 
     Preferably the structural channel members providing the perimeter have at least one of the structural channel members facing outwardly to provide a channel for receiving a corresponding panel and allowing fastening of the panels through the flange of the channel into an adjoining flange of the corresponding panel. 
     Preferably the structural channel members providing the perimeter have at least one of the structural channel members facing inwardly to provide a projection for receiving a corresponding panel and allowing fastening of the panels through the flange of the channel of the corresponding panel into a corresponding flange of the projection. 
     Preferably the frame is rectangular; and the side portions of the frame comprise an upper side portion, a lower side portion and two lateral side portions when then frame is standing upright. 
     Preferably the panel is able to support a load on its primary face greater than 4 tonne with a four point bend test. 
     Preferably the panel, when upright, is able to support a vertical load greater than 20 tonne. 
     Preferably the panel weighs at least 70 kg 
     Preferably the panel weighs at least 80 kg. 
     Preferably the panel primary faces of the panel each provide a surface area between 2.5 and 3.5 m̂2. 
     Preferably the thickness of the panel is between 70 mm and 90 mm thick. 
     Preferably the modular building panel includes air-cell material in addition to the foam core. 
     Preferably the air cell material comprises sheet material that is laid between the structural channel members of the panel. 
     Preferably the sheet material overlaps the structural channel members to substantially provide a relatively continuous layer of air-cell material behind at least one primary face of the panel, separated by the structural members. 
     According to one aspect of preferred embodiments herein described there is provided corner piece of a modular building system comprising an elongate body providing a female channel and a male projection; the female channel and male projection extending along a substantial portion of the length of the elongate body. 
     Preferably the female channel and male projection define an L shaped cross-section in the corner piece. 
     Preferably the corner piece includes a u-shaped structural channel member, the opening of the u-shaped channel facing the female channel of the corner piece, the base of the u-shaped channel positioned adjacent a first wall face of the corner piece and one of the arms of the u-shaped channel positioned adjacent a second wall face of the corner piece, the second wall face being substantially at right angles to the first wall face to provide a outwardly facing corner. 
     Preferably the corner piece includes a hole for receiving a foundation securing rod. 
     Preferably the hole is provided centrally provided relative to the extension of the female channel portion and the extension of the male projection. 
     Preferably the corner piece includes a v-shaped portion providing two wall faces. 
     Preferably the female channel and the male projection are formed in a body of rigid foam material. 
     Preferably the body of rigid foam material is provided as an L-shaped extrusion. 
     According to one aspect of preferred embodiments herein described there is provided a modular building system comprising a first joiner having flange portions and a second joiner having flange portions wherein the first joiner is adapted to adapted to be receive flange portions of a number of upper side portions of a number of modular panels and the second joiner is adapted to receive flange portions of a number of lower side portions of the modular panels. 
     Preferably each modular panel comprises: an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating. 
     Preferably the joiners comprise u-shaped channel members. 
     Preferably the joiners are used to fix upper sides and lower sides of the modular panels. 
     According to one aspect of preferred embodiments herein described there is provided a method of constructing a wall comprising fixing a first joiner to lower side portions of a number of modular panels; and fixing a second joiner to upper side portions of the panels; the joiners having flange portions that receive flange portions of the modular panels on their upper and lower sides. 
     Preferably the joiners comprise u-shaped channel members. 
     According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising: an inner foam core and a rectangular frame surrounding the inner foam core; the rectangular frame for standing upright to provide two primary faces joined by an upper side portion, a lower side portion; and two lateral side portions; each of the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces in the vicinity of the perimeter to provide the panel with a desirable cyclone rating. 
     According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising: a frame for surrounding an inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members for providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions. 
     According to one aspect of preferred embodiments herein described there is provided a method of providing a modular building panel comprising: providing a wall facing; providing a frame having the structural channel members providing a perimeter for receiving a foam core; and applying a further wall to provide a mould for the foam core; and filling the mould to provide the foam core; wherein the structural channel members provide flange portions that lie against each wall facing; the flange portions allowing rigid connection of the panel to another panel or structural element using fasteners extending through the wall facings into the flange portions in the vicinity of the perimeter of the panel to provide the panel with a desirable cyclone rating. 
     According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in providing a recess for a window, the panel comprising: a frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the panel having vertical side that provides a stepped configuration where a portion of the side mates with another panel to provide a recess the recess extending between the two panels, the recess able to accommodate a window. 
     Preferably the recess is able to accommodate a window and a further panel than spans the two panels above the window. 
     Preferably the stepped configuration comprise a first step into the panel to accommodate and support the window and then a second further step into the panel to increase the depth of the recess to accommodate and support the further panel. 
     According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising: an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions. 
     Preferably the structural channel members comprise steel of a thickness from 1 mm to 2 mm. 
     As will be discussed embodiments of the present invention are considered to provide number of preferred arrangements including:
         (i) Modular building panels providing ‘extreme’ category cyclone rating compliance;   (ii) Modular building panels providing advantageous insulation and fire ratings;   (iii) Modular building panels having u-channel sections providing flange portions extending substantially along the periphery of the front and rear outward faces of the building panel to provide a band for fastening adjoining panels;   (iv) Module building panels having a foam core and an outer periphery provided by u-channel sections; one or more of the u-channel sections providing a channel facing inwardly into the panel and one or more of the u-channel sections facing outwardly away from the panel; and   (v) Modular building panels that are advantageously able to accommodate windows.       

     It is to be recognised that other aspects, preferred forms and advantages of the present invention will be apparent from the present specification including the detailed description, drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       In order to facilitate a better understanding of the present invention, several preferred embodiments will now be described with reference to the accompanying drawings in which 
         FIG. 1  provides a perspective view of a modular building panel according to a first preferred embodiment of the present invention; 
         FIG. 2  provides a perspective view of the modular building panel shown in  FIG. 1 ; 
         FIGS. 3 and 4  respectively provide a perspective and partial perspective view of the panel shown in  FIG. 1 ; 
         FIG. 5  provides a further perspective view showing a foam core of the panel shown in  FIG. 1 ; 
         FIG. 6  provides a partially exploded view of the panel shown in  FIG. 1 ; 
         FIGS. 7 to 16  provide further views of the panel shown in  FIG. 1 , and portions thereof; 
         FIG. 17  provides a view showing a joiner used in a system involving the panel shown in  FIG. 1 ; 
         FIG. 18  provides a view illustrating how two panels shown in  FIG. 1  are advantageously fixed together; 
         FIGS. 19 and 20  provide further illustrative views of the panel shown in  FIG. 1 ; 
         FIG. 21  illustrates the strength of one embodiment of the present invention; 
         FIG. 22  illustrates a method according to another preferred embodiment of the present invention; 
         FIGS. 23 a  and 23 b    illustrate a corner piece according to a further preferred embodiment of the present invention; 
         FIGS. 23 c  and 23 d    illustrate a corner piece according to a further preferred embodiment of the present invention; 
         FIG. 24  provides a view of a prototype for receiving the panel shown in  FIG. 1 ; 
         FIG. 25  provides an exploded view of a panel system according to another preferred embodiment of the present invention; 
         FIGS. 26 to 28  provide further views of the panel system shown in  FIG. 25 ; 
         FIGS. 29 to 32  show a panel according to a further preferred embodiment of the present invention; 
         FIGS. 33 to 36  provide further illustrations of the panel system shown in  FIG. 25 ; 
         FIGS. 37 to 39  illustrate a panel according to a further preferred embodiment of the present invention; and 
         FIGS. 36 to 44  illustrate yet further preferred embodiments of the present invention that provide a window structure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     It is to be appreciated that each of the embodiments is specifically described and that the present invention is not to be construed as being limited to any specific feature or element of any one of the embodiments. Neither is the present invention to be construed as being limited to any feature of a number of the embodiments or variations described in relation to the embodiments. 
     Referring to  FIG. 1  there is shown a modular building panel  10  according to a first preferred embodiment of the present invention. The modular building panel  10  is able to advantageously fit together with other modular building panels  10  to provide a cyclone rated wall. In this embodiment the modular building panel  10  provides a cyclone rated panel able to withstand an external pressure loading of at least 6 kPa. 
     Referring to  FIG. 2  the modular building panel  10  includes a frame  12 . The frame  12  provides a number of frame partitions  14  for receiving foam material. Three frame partitions  14  are provided. The frame is about 1.2 m in width  18  and about 2.4 m in height  16 . Other embodiments provide different standard sizes such as a 1.2×2.7 m modular panel. 
     Referring to  FIGS. 3 and 4  the frame  12 , can be considered as providing two primary faces  18  joined by a number of side portions  20 . The primary faces  18  comprise general outwardly facing faces of the frame  12 . The primary faces  18  provide a forward outward face  22  and a rearward outward face  24 . The forward outward face  22  provides a surface normal  26 . The rearward outward face  24  provides a surface normal  2 . The building panel provides an upright wall and the surface normals  28 ,  26  are horizontally orientated. The frame is of a rectangular shape having four side portions  20  that define the thickness of the frame  12 . 
     Returning to  FIG. 1  the panel  10  includes two sheet portions  39  that are each fixed to a corresponding primary face  18  of the frame  12 . The sheet portions  30  are provided as rectangular sheets  30  that fit onto the primary faces  18 . The sheets  30  comprise fibre cement sheets as used in the building industry. Of course other forms of sheet  30  could be readily applied including aluminium, calcium silicate, colour bond, timber and so forth. 
     The frame  12  and the sheet portions  30  provide a mould in which foam material is injected into and subsequently cured according to industry standard processes. The foam material provides a PIR-type core having advantageous insulative and fire resistant properties. 
     Referring to  FIGS. 1 and 2 , each frame partition  14  is provided with an inlet hole  32  for admitting the foam material. During manufacture the foam material is injected through each inlet hole  32  into a corresponding partition  14  and cured. 
     Once the foam material has cured three foam cores  34  fill the frame partitions  14  and are visible through the holes  32  as shown in  FIG. 5 . 
       FIG. 6  provides a partially exploded view in which one of the sheets  20  is shown removed from the panel  10 . As shown in  FIG. 6 , the frame  12  surrounds the three foam cores  34  disposed in the partitions  14 . The three foam cores  34  form a foam core  36  having three separate portions. 
     Referring to  FIG. 9 , the foam core  36  is surrounded by the frame  12  that provides a perimeter  38 . The sheets  20  enclose the foam core  36  within the frame  12 . Referring to  FIGS. 7 and 8  the perimeter  38  comprises a band  40  defined by the side portions  20  of the frame  12 . 
     Referring to  FIG. 7 , the frame  12  comprises a number of structural channel members  42 . The structural channel members  42  provide the frame  12  in the form of a grid  36 . The structural channel members  42  provide the side portions  20 . As would be apparent from the desired orientation of the panel  10 , the frame  12  is provided for standing upright. 
     The frame  12  includes six (6) structural channel members  42  that are welded together to provide the frame  12 . Referring to  FIG. 10 , the structural channel members  42  are conceptually identifiable as shown by lines  44 . The structural channel members  42  comprise six lengths of u-shaped metal channel that are welded together at locations  46 . The bases of the u-shaped metal channel (i.e. the connecting web) defines the perimeter  38  and the band  40 . The side portions  20  are provided as three outwardly facing channels  48  and one inwardly facing channel  50 . 
     The structural members  42  provide two horizontal lengths  52  and four vertical lengths  54 . In other embodiments the frame  12  may be formed as one piece providing the structural members  42  without any welds or other joining. Structural members  42  are provided in both variations. 
     Referring to  FIG. 11 , the structural channel members  42  provide an upper side portion  56 , a lower side portion  58  a first lateral side portion  60  and a second lateral side portion  62  to form the frame  12 . The interior of the frame  12  includes two structural channel members  42  that each provide an internal strut  64 . The internal struts  64  span from the lower side portion  58  to the upper side portion  56 . The lateral side portion  60  is provided by a structural member  66  and the lateral portion  62  is provided by a structural member  68 . The internal struts  64  and structural members  68  provide a series  70  of vertically extending struts. 
       FIG. 12  provides a further view of the frame  12 .  FIG. 13  provides a partial view of  FIG. 12 . As shown each, of the structural members  42  in the series  70  apart from the structural member  68  (providing the second lateral side portion  62 ) is provided in the form of a standard U-shaped channel. 
     Referring to  FIG. 14 , each of the standard U-shaped channels comprises a base  72  that connects two flanges  74 . The flanges  74  provide relatively flat surfaces  76  that face outwardly to provide an abutment for the sheets  20 . The channels are about 70 mm across the base  72  and have two flanges  74  on opposite sides, each flange being about 40 mm deep. 
     Referring to  FIG. 15 , the structural member  68  provides a projection  78  sized to fit within a channel provided by an adjacent panel of a similar form to the panel  10 . The size of the channel in which the projection is sized to fit comprises the size of the channel  80  of the structural member  66  (See  FIG. 13 ). 
     As shown in  FIG. 15 , the form of the structural member  68  provides a U-shaped channel having relatively narrow end  82  sized to fit within the channel of the other panel. The structural member  68  comprises base  84  connecting two flange portions  86  having an external width  88 . The flange portions  86  extend outwardly to provide two further spaced apart portions  90  having a greater external width  92 . The structural member  68  provides a U-shaped channel having two flanges of a stepped form. 
     In terms of the panel  10 , the structural member  66  (providing the lateral side portion  60 ) provides an open channel  80  facing in a direction perpendicular to the normal direction of the primary faces  18 . The channel  80  is provided for receiving the equivalent of structural member  68  of another panel  10 . Each of the structural members  42  in the series  70  provides a channel facing in a first direction  94 . The channels are aligned and face in the same direction. 
     In the frame  12  each of the structural channel members  42  are provided by u-shaped channels of relatively thick steel. In the embodiment, the U-shaped channel comprises 1.0 mm steel. When the foam is cured the sheets  20 , foam core  36  and frame  12  provide an advantageous modular building panel  10  for cyclone environments. It is envisaged that the thickness of steel may range between 1 mm to 1.2 mm (base metal thickness). This is of course dependent on the overall design of the panel. The thickness could of course be outside this range. For example the structural channel members  42  of the panel  10  may comprise galvanised steel of a thickness from 1 mm to 2 mm, depending on the required engineering characteristics. 
     With a panel approximately between 1 to 2 m wide and 2 to 3 m tall it has been found advantageous to provide two internal struts and weld each of the structural members together. 
     Returning to  FIG. 12 , each of the structural members  42  have two flange portions  96  arranged to provide flat surfaces  98  aligned with the primary faces  18 . The flat surfaces  96  are aligned in the sense of being generally parallel. The primary faces  18  are general in the sense of defining a general shape. The difference in size between with width  88  and the width  92  in this embodiment, may only be in the order of millimetres. Each of the flange portions  96  is in the vicinity of a corresponding primary faces  18 . As such there is provided a forward flange portion  96  for the forward outward surface  24  and a rear flange portions for the rear outward surface  22  of the frame  12 . 
       FIG. 16  shows an upper side portion  56 , a lower side portion  58 , a first lateral side portion  60  and a second lateral side portion  62 . The upper side portion  56  is provided by a structure channel member  100 . The lower side portion  58  is provided by a structural channel member  102 . The structural member  66 , the structural member  68 , the structural member  102  and the structural member  100  define a band  40  surrounding the foam core  36 . The band  40  is provided by the base of each u-channel section. 
     Referring to  FIG. 17 , the modular building panel  10  provides a channel  104  in each of the upper side portion  56 , the lower side portion  58  and the lateral side portion  60 . This allows the upper side portion  56  to receive a joiner  106  and for the lower side portion to receive a joiner  108 . The joiner  108  is fixed to a foundation and the joiner  106  is fixed to a truss of roof. To fix the joiner  106  a number holes are drilled through the sheet  20  into the metal flanges  96  of the structure channel member  100 . 
     The metal flanges  96  advantageously provide both strength and rigidity to the modular panel  10 . A number of conventional panels formed from fibre cement and foam material are considered not to meet cyclone rating requirements. With the provision of the metal u-channel members  42  a rigid wall can be advantageously provided with fasteners being provided in the vicinity of the periphery  110  of the primary faces  18 . 
     The modular building panel  10  can be secured with advantageous strength and fracture resistant joins about the forward and rear periphery  110  of the panel  10 , through the sheets  20  due to the provision of the structural members  42 . The structural members  42  are provided in the form of metal u-channel of an advantageous thickness. 
       FIG. 18  illustrates how two panels  10  are advantageously fixed together. As shown there is provided a first panel  112  and a second panel  114 . The first panel  112  includes a first structural channel member  116  that provides a projection by having the opening of the channel member  116  facing into the body  118  of the panel  112 . The second panel  114  includes a second structural channel member  120  having the opening of the channel member  120  facing away from the body  122  of the panel  114 . The first channel member  116  includes two flanges providing relatively flat outwardly facing surfaces  124 . The second channel member  114  includes two flanges providing relatively flat inwardly facing surfaces  126 . The panels  112  and  114  are brought together. The flanges of the first and second structure members comprise metal of a substantial thickness allowing for number of holes to be drilled in the flanges and for threaded fasteners  128  to be received therethrough. 
     Referring to  FIG. 19 , the panel  10  according includes a region  130  in the vicinity of the periphery  110  each primary face  18  of the frame  12  allowing for robust connection of the panel  10  to adjoining panels or joiners. A workman can readily fasten a screw type fasteners  132  through the regions  130  of adjoining panels  10  and construct a wall meeting cyclone rating requirements. 
     The regions  110  are located in the vicinity of the periphery  110 . The regions  110  are provided by the flanges  96  of the structural members  42  providing the side portions  20 . The regions  110  are located in the vicinity of the perimeter  38 . The regions  110  define a relatively continuous band  134  on each side of the panel  10 . 
     By using metal u-channel to provide the perimeter of the modular building panels the connection formed using the fasteners provides advantageous strength and fracture resistant properties suitable for providing a Cyclone D rated walls. The holes drilled into the metal flanges provided by the U-Channel are robust and are not prone to fracture of disintegration in cyclone conditions. The use of the vertically extending internal struts provides advantageous strength. 
     It will be appreciated that the embodiment provides a modular building panel  10  for use in forming walls such as the wall  136  of  FIG. 20 . The panel  10  comprises an inner foam core  36  and a frame  12  surrounding the inner foam core  36 . The frame  12  is provided for standing upright to provide two primary faces  18  joined by a number of side portions  20 . 
     The side portions  20  of the frame  12  are provided by structural channel members  42  that provide perimeter  38  around the foam core  36 . The structural channel members  42  provide flange portions  96  to allow rigid connection of the panel  10  to other panels or joiners using fasteners. The fasteners extend through the primary faces  18  through the flange portions  96 . The flange portions  96  are located in the vicinity of the periphery  110  of the primary faces  18 . The flange portions  96  are provided in the vicinity of the perimeter  38 . 
     Each structural channel member  42  comprises a u-shaped channel member having a base that defines the band  40  that surrounds the foam core  36 . The structural members  42  are made from metal. 
     The structural members  42  are welded together in the frame to provide a welded grid for enclosing the foam core to provide the advantageous panel. Each structural channel member  42  comprises an extending channel portion  42  provided by two flanges and a base portion. The base portions extend between the primary faces  18  and connect the two flanges to form a channel. Each of the channels provided by the structural members  96  is generally perpendicular to the surface normal of the primary faces  18 . 
     Two internal structural members  64  provide vertical struts extending vertically when the frame is standing upright. The two internal structural members  64  provide a series  70  of spaced apart internal structural members  42 . The perimeter  38  is provided by four of the structural channel members  42 . The structural member  66  faces outwardly to provide a channel  190  for receiving a corresponding panel having a projection formed from metal u-channel providing a lateral side. When abutted the flanges of the projection are located next to adjoining flanges of the channel. The flanges allow an advantageous connection between the two panels. 
     The weight of the U-channel is about 1.3 kg per meter. In a 1.2 by 2.4 m panel there are about 12 m of u-channel which equates to about 16 kg of structural member  34 . A 90 mm by 2.4 by 1.2 panel weighs about 65 kg without the metal structural members  34 . The total weight is about 80 kg. 
     In embodiments it is considered that a walling system can be advantageously provided meeting the following standards:
         Wind Region A, Terrain Category 1 to AS1170.2011 and AS4055-2012   Wind Region B, Terrain Category 1 to AS1170.2011 and AS4055-2012   Cyclonic Wind Region C, Terrain Category 1 to AS1170.2011 and AS4055-2012   Cyclonic Wind Region D, Terrain Categorγ 2 to AS1170.2011 and AS4055-2012   Full internal pressure Cpi=0.9 Cpe       

     The system is considered to allow for the following walling applications in the above wind regions of Australia:
         Load bearing for timber ‘built up’ roof to AS1684   Load beating for steel or timber truss roofs   Load bearing for metal roof cladding   Internal partitions       

     On the basis of the results of testing data, the applicant believes that such a structural certification is able to be provided with panels in the walling system (installed as per specifications and panel fixing requirements), comprising:
         6 or 10 mm compressed Fibre Sheet (CFC)   70 to 78 mm thick polyisocyanurate P.I.R. sandwich   Concealed 1.0 mm BMT steel stud walling system   Up to 2.7 m high   1.2 m wide       

     For the cyclonic wind regions C &amp; D the external face of the building, once erected is preferably clad with Custom Orb or similar metal sheeting. The cladding is considered to prove a faster external finish to construction as no taping of joints, flushing and application of texture coatings is then required. The over-cladding is considered to provide additional debris protection to the building. 
     With a configuration of 6 mm Calcium Silicate, 78 mm Polyisocyanurate, and 6 mm Calcium Silicate, a number of R value calculations have been performed. The thermal performance of the proposed panel configuration was calculated using the following factors: 
     1) Component; R-Value or Resistivity; Source of Information 
     2) Polyisocyanurate; 38 m·K/W; National Research Council of Canada
 
3) Calcium Silicate; 10 m·K/W; National Institute of Standards and Technology (US); and
 
4) Other factors as listed in the Building code of Australia (BCA) requirements, namely
         Commercial Buildings:
           Internal walls, conditioned space on both sides—no requirements.   Internal walls, conditioned space to unconditioned space (protected)—R1 (Zones 1, 2, 5 &amp; 6), R1.5 (Zone 7), R2.5 (Zone 8).   Internal walls, conditioned space to unconditioned space (unprotected)—R2.3 (Zones 1, 2, &amp; 3), R1.8 (Zones 4 &amp; 5), R2.8 (Zone 7) and R3.8 (Zone 8).   External Walls—R2.8 (Zones 1, 2 &amp; 3 for Light-Med coloured walls, and zones 4 to 7) and R3.8 for Zone 8.   
           Residential Buildings:
           Internal Walls—no requirements.   External Walls—R2.8 (Zones 1 to 7 with some conditions) and R3.8 for Zone 8.   
               

     The panel was assessed for its material R-Value, which includes only the characteristics of the panel materials; and for their Total R-Value, which includes internal and external air films as would be applicable to each proposed application. 
     The calculated performance for the panel arrived at comprised:
         1) Panel; Material R-Value; Total R-Value in Application   2) PIR Panel—(6+78+6); R3.1; R3.3       

     On the basis of the various assumptions it was concluded that the proposed panel satisfied the BCA thermal provisions for use in internal and external wall applications in all types of buildings for climate zones 1 to 7. 
     In order to satisfy the requirements for Climate Zone 8, where a total R-Value of R3.8 is required an alternate panel size was considered to be required. For climate Zone 8a thicker panel (say 6+93+6) or the use of two panels with an air gap and a minimum of 85 mm total thickness of Polyisocyanurate material was suggested. By varying the thicknesses panels with different properties may be provided. 
     The above calculations are based on a number of assumptions and are not to be construed as providing any form guarantee. Various R-values and loading strengths would be able to be calculated by standard mechanical engineering techniques. 
       FIG. 21  illustrates the strength of an embodiment of the present invention. A single panel between 1 and 1.5 m in width supports a lateral load of greater than 4 tonne with the four point bend test shown. The vertical load bearing capacity of the panel is greater than 20 tonne (when upright). The panel when fixed in a paneling system is able to withstand cyclonic winds well in excess of 300 km/hr. 
       FIG. 22  illustrates a method  138  according to another preferred embodiment of the present invention. The method  138  provides a process of manufacturing the modular building panels  10  and fixing the panels to provide a wall  140 . At block  142  the method  138  comprises providing a wall facing in the form of a sheet. At block  144  the method includes providing structural channel members providing a perimeter for surrounding a foam core, the structural members forming a grid. At block  146  the method includes applying a further wall facing to provide a mould for the foam core. At block  148  the method includes filling the mould to provide the foam core. 
     The structural channel members provide flange portions that lie against each wall facing. The flange portions allow rigid connection of the panel to another panel or structural element using fasteners extending through the wall facings through the flange portions in the vicinity of the perimeter of the panel to provide the panel with a desirable cyclone rating. At block  150  the method includes fixing the panels using the flange portions to provide the wall  140 . 
     It is envisaged that embodiments will be provided in widths of between 1 to 3 m, heights of between 1 to 3 m and thicknesses of between 70 to 200 mm. Various other sizes may be provided as well. 
     In this embodiment the structural channel members comprise 1 mm BMT steel u-channel. The foam material advantageously comprises polyisocyanurate foam (PIR). Both PUR and PIR rigid foam panel systems are used for facades and roof elements for buildings. They have excellent thermal properties and mechanical/physical properties. PIR also has significant fire resistant properties. 
     The panel  10  advantageously provides a PIR rigid foam core that provides both cyclone and fire resistant properties. The characteristics of various foams are available from providers such as BASF. Sandwich panel manufacturing and curing techniques follow industry practices. The method at block  148  employs a conventional a multiple shot type process. 
       FIGS. 23 a  and 23 b    illustrates a corner piece  152  according to a further preferred embodiment of the present invention. The corner piece  152  comprises an elongate body  154  providing a female channel portion  156  and a male projection  158 . The female channel portion  156  and male projection  158  are formed from a portion  160  provided in the shape of an L  180 . The elongate body  154  includes a first member  162  and a second member  164  that provide a v-shaped portion  166 . The first member  162  and the second member  164  provide wall faces  168 . In this embodiment the wall faces  168  comprise fibre cement. 
     The portion  160  is provided as a body of rigid foam material  170  that extends along the length of the corner piece  152 . Within the portion  160  there is provided a hole  182  for receiving a foundation rod. 
     The hole includes a conduit  172  in the form of a plastic tube  184  that allows the smooth passage of the foundation rod. The foundation rod serves to hold the corner portion  152  in an upright position. 
     In the embodiment the hole  182  is located centrally relative to the extension  174  of the female channel portion  156  and the extension  176  of the male projection  158 . The extensions are longitudinal as shown in  FIG. 23   b.    
     Referring to  FIGS. 23 c  and 23 d    there is shown a further preferred embodiment of the present invention in the form of a corner piece  152 ′. The corner piece  152 ′ is similar to the corner piece  152  and for this reason similar numerals are used. Advantageously the corner piece  152 ′ further includes a structural support channel member  175 . 
     The channel member  175  comprises u-shaped channel that has the open end of the channel facing the opening of the female channel portion  156 ′. The base  177  of the u-shaped channel  175  is positioned adjacent the wall face  181  and is aligned with the opening of the female channel portion  156 ′. 
     The arm  183  of the u-shaped channel is positioned adjacent the wall face  185  and is substantially aligned with the front of the male projection  581 ′. The u-shaped channel  175  includes a number of holes therein to allow the foam material to flow and readily bond to both the wall face  181  and  185  and the facing surfaces of the u-shaped channel  175  during forming. 
     In this embodiment, the holes are provided in the base  177  and the arms of the u-shaped channel extending therefrom. The u-shaped channel extends the height of the corner piece  152 ′. 
     The corner piece  152 ′ provides a corner of advantageous strength due to the provision of the u-shaped channel  175 . Thus there is provided a corner piece  152 ′ comprising an elongate body  154 ′ providing a female channel  156 ′ and a male projection  158 ′ at right angles to one another. The female channel  156 ′ and male projection  158 ′ extend along the length of the elongate body as does the u-shaped channel  175 . The opening of the u-shaped channel  175  faces the female channel  156 ′ of the corner piece. The base  177  of the u-shaped channel  175 ′ is positioned against the first wall face  181  of the corner piece  151 ′ and the arm  183  of the u-shaped channel  175  is positioned adjacent the second wall face  185  of the corner piece  152 ′. 
     As shown the second wall face  185  is substantially at right angles to the first wall face  181  to provide an outwardly facing corner. The wall faces comprise fibre cement portions connected at right angles. 
     The use of the u-shaped channel  175  provides the corner piece  152 ′ with advantageous strength and, in this embodiment, extends the full length of the corner piece  152 ′. 
       FIG. 24  illustrates a basic prototype, the female channel portion  156  provides a channel for receiving a projection  78  of a structural member of a panel  10 . 
     The male projection  158  is of an external width  178  equivalent to the external with of the projection  78  (eg width  88 ). The male projection  158  is arranged at 90 degrees to the female channel portion  156  to allow for the provision of a corner bend. The v-shaped portion  166  is provided for abutting sheets  26  as shown in  FIG. 23   b.    
     In some embodiments a number of holes  182  are provided in the panel members themselves. The holes  182  provide an aperture through which a bar can be introduced to further hold the modular panels  10  in position. 
     Referring to  FIG. 25  there is provided a panel system  186  according to yet another preferred embodiment of the present invention. The panel system includes two elongate joiners  188  each having two flanges  190 . A number of modular panels  192  are provided having a channel  194  in their upper sides  196  and a channel  198  in their lower sides  200 . The channels  194  and  198  are able to receive the joiners  188  in the manner previously described and be readily fixed with a metal to metal join. The metal to metal join is considered to be advantageous and be able to provide a desirable cyclone rating as previously described. In this embodiment the joiners comprise 1.8 mm BMT u-shaped channels. It is envisaged that the channels may range up to say 2.5 mm in various embodiments. Various other sizes are of course possible. 
       FIG. 26  shows how the joiners  188  could be attached to foundations  202 .  FIG. 27  provides a further view.  FIG. 28  shows how a corner piece  152  could be attached to a truss  206  of a roof  204  in the system  186 . 
       FIGS. 29 to 32  show a plurality of lifting holes  208  provided as part of a panel  210  according to a further preferred embodiment of the present invention. The lifting holes  208  are provided in the flange portions  212  of the structural channel portions in the top portion  214  of the panel  210 . The flange portions  212  are of a strength that is able to accommodate the holes  208  and support the lifting of the panel  210 . The flange portions  212  are about 40 mm tall. The flange portions  212  are sufficiently strong to support lifting of the panels. The lifting holes  208  are sized to receive a number of shackles  214 . Two pairs of lifting holes  208  are provided on the flange portions  212  of the upper side  214  (top) of the panel  210 . In various embodiment the flange portions are at least 30 mm tall. 
       FIGS. 33 to 36  provide further illustrations of the panel system  184 . The panel system  184  provides a modular building system comprising a first joiner having flange portions and a second joiner having flange portions wherein the first joiner is adapted to adapted to be receive flange portions of a number of upper side portions of a number of modular panels and the second joiner is adapted to receive flange portions of a number of lower side portions of the modular panels. 
     The joiners could be provides as rectangular projection in other embodiments rather than a u-channel. In both cases flanges are provided for a metal to metal join. 
     Other embodiments may provide a mechanical inversion where the channels  194  provide projections. In such a case the joiners would receive the upper and lower sides of the modular panels. 
     The method of joining involves fixing a first joiner to lower side portions of a number of modular panels; and fixing a second joiner to upper side portions of the panels; the joiners having flange portions that receive flange portions of the modular panels on their upper and lower sides. 
     The various panels and methods herein described are provided with desirable cyclone characteristics. The provision of the flange portions allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating. The panel is able to withstand a high pressure loading. 
       FIGS. 37 to 39  illustrate a panel  220  according to another preferred embodiment of the present invention.  FIG. 37  provides a partial view showing the provision of an aircell layer  222  in the panel  220 . The air-cell layer  222  comprises three sheets  225  of air-cell material  224 . The sheets  225  are fitted into the three areas  226  defined by the metal vertical struts  228 . The air-cell material  224  comprises insulating material having a number of insulating isolated cells to limit heat transmission. 
     The use of air-cell insulating material is considered to be advantageous for the reason that it is considered to increase the R value and improve the sound characteristics of the panel. The air-cell material is considered to possibly increase the R-value by 1.0 (approximately). With a panel that would otherwise have an R-value of 3.3 this means that the panel would have an R value of 4.3. The air cell layer provides a further layer in combination with the foam core. 
     Apart from the air-cell layer  222 , the panel  220  is of the same form as the panel  10  previously described. Air cell material is well known. It is often provided in rolled form and could be provided by supplied such as King Span Insulation (www.kingspaninsulation.com.au). 
     Again the fire resistant foam core comprises PIR material. The method of manufacture involves positioning the three sheets of air-cell material before the foam is introduced and cured. The outer sheets  215  comprise fibre cement sheets as used in the building industry. 
       FIG. 39  provides a cross-sectional view in the plane A-A of  FIG. 37 . As shown there are provided four vertical u-shaped rigid metal struts  230  defining three intermediate areas  232 . Each sheet of air-cell material is positioned against an outer sheet of the panel  220  and covers the portion  235  of the u-shaped channel spanning the corresponding area  232 . The sheets of air-cell material overlap with the u-shaped metal struts  230  as shown. 
     Consequently there is a panel  220  having insulating air-cell material  224  in addition to the foam core. The air cell material  224  comprises sheet material that is laid between the structural channel members  228  of the panel. In the panel  220 , three sheets  225  of air-cell material are provided that occupy three primary areas  232  of the panel  220 . The sheets  225  overlap the structural channel members  230  to substantially provide a relatively continuous layer of air-cell material behind at least one primary face of the panel as highlighted in  FIG. 39 . The sheets  225  in the panel  20  are separated by the structural members 
       FIGS. 40 to 44  illustrate a window system  250  according to a further preferred embodiment of the present invention. The window system  250  comprises two panels  254  each having a recess  252  in a side thereof. The recesses  252  are each of a stepped configuration  256  to allow the insertion of a window when the panels are adjacent one another. Advantageously, following this a further panel  225  is able to be positioned above the window to span the two panels  254 . 
     In the window system  250  there is provide a first panel  258  and a second panel  260 . A lower side portion  268  of the first panel  262  is arranged to mate with a lower side portion  270  of the second panel  264 . 
     The lower side portion  268  comprises a u-shaped portion providing a female channel  272 . The lower side portion  270  comprises a u-shaped portion providing a male projection  274  sized to fit within the female channel  272 . 
     Each panel  254  is provided for providing a recess  278  for a window. Each panel  254  provides a frame  280  for standing upright to provide two primary faces joined by a number of side portions  284 . As with the panel  10 , the side portions  284  of the frame  280  are provided by u-shaped structural channel members of the type previously described. 
     Each panel  276  has a vertical side  286  that faces the vertical side of the other panel. The vertical sides  286  each provide a stepped configuration. The stepped configuration provides a first step  288  and a second step  290 . 
     The first step  288  is of a first depth for supporting a window. The second step  290  is positioned above the first step  288  and is of a greater depth for supporting the further panel  255  (the connecting panel  292 ). 
     Referring to  FIG. 41 , the lower portions of each vertical side  286  mates with the other panel to provide a mating join  296 . This is similar to the arrangement of  FIG. 18 . The recess between the panels  276  is accordingly able to accommodate a window and a further panel  255  that spans the two panels above the window. 
     In some embodiments there may only be a single step such that a further panel  298  is not required. Along the vertical sides  286  extending up from the ground, each panel  254  includes a female channel above the lower portion  268 ,  270  of each panel. Only one of the lower portions provides a male projection for mating in the female channel of the other panel. The further panel  255  may rest on a member  298  that spans the recess and rests on the second steps  290  that provide a supporting abutment. As would be apparent various side portions could in various embodiments be male or female. 
     In this embodiment the stepped configuration comprise a first step  228  into the panels to accommodate and support the window and then a second further step  230  into the panels to increase the depth of the recess to accommodate and support the further panel. The upwardly facing abutments provided by the first step  228  for the window are female. The upwardly facing abutments provided by the second step  230  are also female. 
     The structural channel members of the embodiments described are made from metal as shown to provide advantageous panels, corner pieces and so forth. In embodiments, modular panels can be provided to fit together to provide advantageous cyclone rated and other buildings. 
     As noted above embodiments of the present invention are considered to provide number of preferred arrangements including:
         (i) Modular building panels providing ‘extreme’ category cyclone rating compliance;   (ii) Modular building panels providing advantageous insulation and fire ratings;   (iii) Modular building panels having u-channel sections providing flange portions extending substantially along the periphery of the front and rear outward faces of the building panel to provide a band for fastening adjoining panels; and   (iv) Module building panels having a foam core and an outer periphery provided by u-channel sections; one or more of the u-channel sections providing a channel facing inwardly into the panel and one or more of the u-channel sections facing outwardly away from the panel.       

     As would be apparent, various alterations and equivalent forms may be provided without departing from the spirit and scope of the present invention. This includes modifications within the scope of the appended claims along with all modifications, alternative constructions and equivalents. 
     There is no intention to limit the present invention to the specific embodiments shown in the drawings. The present invention is to be construed beneficially to the applicant and the invention given its full scope. 
     In the present specification, the presence of particular features does not preclude the existence of further features. The words ‘comprising’, ‘including’ and ‘having’ are to be construed in an inclusive rather than an exclusive sense. 
     It is to be recognised that any discussion in the present specification is intended to explain the context of the present invention. It is not to be taken as an admission that the material discussed formed part of the prior art base or relevant general knowledge in any particular country or region.