WO2002020916A1

WO2002020916A1 - Modular building panel

Info

Publication number: WO2002020916A1
Application number: PCT/AU2001/001120
Authority: WO
Inventors: Selwyn Reed
Original assignee: Selwyn Reed
Priority date: 2000-09-07
Filing date: 2001-09-07
Publication date: 2002-03-14
Also published as: AUPQ995200A0

Abstract

A modular building panel (1) for use in the construction of a building structure, the panel (1) including a layer of cladding material (2) having an inner (3) and outer (4) surface, the outer surface (4) forming at least a part of an exterior surface of the building structure, at least one stud member (5) disposed generally parallel to the inner surface (3) but spaced apart (9) from the inner surface (3).

Description

MODULAR BUILDING PANEL BACKGROUND

The present invention relates to modular building panels and more particularly relates to composite prefabricated panels for construction of structures such as houses, factory buildings and like structures. The invention relates to an alternative modular building panel which includes an outer skin of precast or sheet material, studs spaced apart from an inner surface of said sheet material and a formation included in the panel which allows joining of adjacent panels. The panel further includes means to enable the panel to be lifted without damage to the panel and the carriage therein of a services such as electricity, water or the like. The invention further relates to various methods of construction of a modular panel in which the panel may be constructed off site and lifted into position on site and which is substantially finished requiring a minimum of completion work. PRIOR ART

There are in existence a wide variety of modular panels used in the construction of buildings such as houses, factories or the like. Modular panels have also been employed in internal constructions such as in non load bearing partitioning and in infill panels As an example of the known panels, United States patent 4,276,730 discloses wall structure modules comprising a plurality of narrow ceiling high panels of integral sandwich construction including a thickness of insulation molded between two thicknesses of light weight concrete. The panel includes tongue and groove configurations along opposite sides of the panels conditioning them to be nested together. They include full ceiling height steel studs encased in each exterior panel and with a small bracket at the top exposed for attachment of a top plate which fits over the panels of a complete wall section to unitize it. A transverse channel extends across the bottom of each panel on the inside the lower flange of which is secured to the sub floor. On the assembled wall the channels are aligned to serve as a conduit for plumbing and electrical wiring. United States Patent 3965634 discloses a modular building panel wherein studs and certain other members comprise two half stud members held together by rotating clamps. The half stud members are preferably of identical construction each including a first longer wall and a second shorter wall the first and second walls running generally parallel to each other and connected by a bridging section each wall terminating in a free edge portion. The two half stud members are disposed against each other in such a way that the first longer wall of each half stud member is in abutting relationship such that the respective tabs of the first and second parallel walls extend away from each other and wherein there is a vinyl separator interposed between the first said parallel walls.

United States Patent 4,472919 discloses a prefabricated load bearing wall panel having a layer of concrete attached to a plurality of spaced apart parallel metal wall studs. The slab support is achieved by flexible bolsters secured at spaced apart locations to each stud and fastened to a reinforcing mesh embedded in the concrete slab. This panel demonstrates a synergistic structural effect due to the composite designs.

United States patent 5 524 400 discloses a wall assembly of a building structure which utilizes a plurality of panels having preformed grooves thereon and supports which interface with these grooves. Supports are positioned within the various grooves of each of the panels and are appropriately interconnected. In one embodiment made from styrofoam and the supports are generally U shaped steel studs. A plurality of these panels may be positioned adjacent to each other and the U shaped studs may be interconnected in a manner which provides a desired degree of structural integrity.

United States patent 5,724,783 discloses a building panel apparatus which includes a plurality of elongated panel frame members attached together to form a panel framework and having at least one stud attached between two panel frame members and having panel sides covering at least one side of the framework. This panel is typified by having an aggregate which may be formed using such materials as fibreglass insulation, tyres, waste polystyrene or waste carpet materials. The aggregate is dampened and coated with a coating mixture which includes portland cement and micro silica.

United States Patent 5 746 034 discloses a freestanding portable partition panel and related systems for open office spaces and the like. Each panel includes a skeleton like frame having two vertical uprights positioned adjacent opposite side edges thereof. A foot extends downwardly from the bottom of the frame to abbuttingly support the panel free standing on a floor surface. Two pairs of horizontal stringers are attached- to the outer faces of the uprights in a vertically spaced apart relationship to rigidly interconnect same and define therebetween two horizontal raceway cavities which open to the opposite side faces of the frame and extend continuously between the side edges thereof. Adjacent ends of raceway cavities are aligned and communicate. Cover panels enclose at least those portions of the frame side faces disposed between the stringers and are detachably mounted to provide ready access to the raceway cavities and permit lay in wiring. The upper ends of the vertical uprights have upwardly extending arms which define yoke shaped receptacles for receiving drop in-wiring.-

United States patent 6,076,322 describes another wall stud assembly for use in prefabricated partitions or walls assembled within an interior space of a building. The assembly includes a first stud member and a second elongate stud member each having a joining part and a panel receiving flange disposed along each longitudinal side of the joining part. Each of the joining parts of the stud members include a plurality of punched holes and extruded holes formed therein and relatively oriented to allow interconnecting fasteners to be applied to the stud members from either side of the stud assembly. When assembled, the stud members are arranged so that the joining parts thereof are disposed in substantially confronting relation to one another and with the plurality of punched holes on the first stud member generally aligned^vitb the extruded holes of the second stud member with a pair of prefabricated partitions or wall panels each being received by corresponding panel flanges of the first and second stud members and at least one fastener element extending initially through a punched hole on the first stud member and subsequently into one of the extruded holes on the second stud member.

A further example of known modular panels is described in United States Patent 6,099,768 which teaches a modular building panel and a method constructing the panel. The panel typically comprises a metal frame and a backer board typically formed from a cementious material for receiving an exterior wall coating surface_*. The backer board and framework are separated from and insulated from each other by a layer of foam that is applied in liquid form and that expands and cures into a solid form.

Further examples of modular panels are described in United States Patents 5,901,524; 5,921,047 and 5,950,374 which are incorporated by reference herein. The prior art panels are generally constructed in small lengths and areas due to inherent material weakness and instability prior to installation. Large panels pre fabricated in concrete have been in the past used in lift slab constructions but this form of panel is suitable "mainly in factory and warehouse construction and involves lifting of extremely heavy walls which must be temporarily braced until the building is self supporting. These panels can form whole walls of a building and once installed render the main structure of the building substantially complete.

The known modular smaller scale panels can also be lifted but are generally suitable for small wall sections- In more traditional timber or steel constructions which may be constructed on site or prefabricated off site, typically wall panels are unfinished save for a frame. The size of these frames is restricted due to the limits imposed by loads to which tiie frames are subject during delivery. Lifting loads-are not usually taken into account in the design of most panels although there are panels which include lifting lugs placed at a location in the panel which will minimise the possibility of lifting damage. These are usually solid concrete panels and care must be taken to ensure that the panels are not destroyed during lifting. Where the known timber and steel frames are constructed on site, there axe limitations introduced due to the extensive labour component in erecting the finished frames. Once timber or steel frames are erected, there is still a substantial amount of labour to bring the frames to a stage where the construction is at lock up. There is a need i the building and construction industry to provide panel which is economic to produce and install , preferably prefabricated before installation and which renders the structure substantially completed as soon as it is placed in situ and which is strong enough to be lifted without risk of damage to the panel and which have their thickness by disposition of studs is spaced apart relationship to an inner surface of cladding.

INVENTION

The present invention provides as an alternative to the known modular panels, a modular building panel which may be used either as a load bearing or non load bearing structural panel for walls, ceilings or floors and which includes as part of the load receiving members a space in which services may be placed such as water, telecommunications and electricity. The present invention further provides a prefabricated building panel capable of forming a part of a structure such as but not limited to a wall wherein, when a plurality of panels are installed, the structure which may be a dwelling, factory or the like is substantially completed. The panel is economic to produce and install.

In its broadest form the present invention comprises: a modular building panel for use in the construction of a building structure: the panel comprising a first layer of cladding material having an inner and outer surface, the outer surface forming at least part of an exterior-surface of the J uilding structure; at least one stud member disposed generally parallel to said inner surface but spaced apart from said inner surface; edge members defining edge boundaries of said panel.

Preferably,, there are a plurality of studs spaced apart in the same plane and the edge members form a frame extending about the full periphery of said panel. The panel preferably comprises spacers which retain each said studs in said spaced apart relation to said inner surface. The spacers each have a first end which engages said inner surface of said panel and a second end which engages at least one said studs.

In another broad form the present invention comprises: a modular building panel for use in the construction of a building structure: the panel comprising a first layer of material having an inner and outer surface; means including a first end engaging said inner surface of said layer; at least one stud member engaging a second end of said engaging means such that said at least one stud member is spaced apart from said inner surface of said first layer of material; a second layer of cementitious material adjacent said inner surface of said first layer wherein said second layer embeds at least a part of a first, end of said engaging means. The outer surface of said panel forms at least part of an exterior surface of a building.

The panel further comprises a second layer of cementitious material adjacent said inner surface of said first layer wherein said second layer embeds at least a part of a first end of said engaging. means. The panel further includes a frame member disposed along at least one edge of said first layer of material thereby defining a panel boundary. Preferably, there are a plurality of said engaging means fixed via said second end face to said at least one stud member. According to one embodiment, there are a plurality of spaced apart stud members each fixed to at least one engaging means. Preferably, the frame provides a panel boundary along each edge of said panel.

At least a part of said frame is connected to said inner surface of said first layer.

Preferably, at least a part of said frame is embedded in said cementitious layer to assist in securing the frame to the first layer of material. Preferably the first layer is formed of fibro cement and the engagement means comprise brackets of predetermined length. Preferably, a flange of a stud engages the second end of the brackets.

There is further provided along an edge of said panel a beam which facilitates joining of adjacent panels . Preferably, the studs are channel shaped and the frame members are substantially channel shaped. A flange of said channel shaped members engage said inner surface of said first layer.

According to one embodiment, the brackets are glued to said inner surface of said first layer.

A flange of said frame is connected to said inner face of said first layer, wherein said flange of thed frame is embedded by the cementitious layer. The formation enabling connection of one panel to an adjacent panel comprises a return which abuts and opposes a corresponding return on an adjacent panel. One panel may be attached to an adjacent panel in axial alignment and/or normal to an adjacent panel. The studs receive a cladding forming an interior surface of a building formed by said panel. Preferably, the structure formed by the panels is a dwelling or factory building.

According to another broad form according to a method aspect the present invention comprise: a method of constructing a modular building panel comprising the steps of a) taking a sheet of material for use as an exterior cladding of said panel; b) attaching a plurality of connecting brackets to an inner surface of said substrate; c) attaching members forming a frame at or near at least one edge of said substrate; d) pouring a cementitious layer over said inner surface of said substrate such that at least a part of each said brackets and a part of said frame is embedded in said cementitious layer; e) attaching stud members to one or more said brackets so that the stud members are spaced apart and outstand from said cementitious layer.

In another broad form the present invention comprises; a modular generally rectilinear building panel for use in load bearing and non load bearing applications wherein the panel comprises; a cladding layer having an inner and outer surface wherein the outer surface provides part of an exterior surface of a building constructed from said panel; a plurality of spacing members which attach via a first face to said inner surface; a plurality of stud members attached via one face to a second face of said spacing members thereby causing said studs to be spaced apart from said inner surface; a boundary member attached along at least one edge of said cladding layer; a layer of cementitious material adjacent said inner surface of said cladding layer wherein said cementitous layer at least partially embeds each said brackets and said boundary member wherein an exposed surface of said cementitious layer opposes said plurality of said stud members.

According to one embodiment the panel is further characterized in having at least one services channel which doubles as a top or bottom plate of a frame formed by said at least two studs.

Each said studs engages a member forming a top and bottom plate thereby forming a stud frame; wherein said member forming top and or bottom plates doubles as a services channel and wherein the stud members are spaced equidistant along the length of the panel and outstand from said inner surface of the panel

According to one embodiment, the modular panel is configured with an opening to receive a window or door wherein the supporting arch over the window or door frame is formed by the member forming the services channel.

According to another embodiment, the panel further comprises at side edges joining formations which enable each panel to receive an adjacent panel on one or both edges.

Tn another broad form the present invention comprises: a modular generally rectilinear building panel for use in load bearing and non load bearing applications wherein the panel comprises a plurality of spaced apart stud members each of which include at least one flange and web members wherein the flange members are spaced apart from a rigid sheet material which forms an external skin of a building constructed from said panels; said stud members arranged so that when the panel is installed they are vertical and wherein an end of each said studs engages a beam member forming a top and/or bottom plate thereby forming a frame; and wherein each said beam member has sufficient strength to allow long panel lengths to be constructed and which provides sufficient bracing so as to allow lifting of large panels and to sustain roof loads; wherein, when the panel is placed in situ it forms a substantially finished wall of a structure.

In another broad form according to a method aspect the present invention comprises: a method of construction of a building using modular panels comprising; a modular generally rectilinear panel for use in load bearing and non load bearing applications wherein the panel includes stud members wherein each stud member is spaced apart from a rigid sheet material which forms an external skin of a building constructed from said panels; the panel further characterized in having a beam at the top and/or bottom and which spans the length of the panel and which engages an end of each said studs members; the method comprising the following steps: a) taking a sheet of precast material of a predetermined area: b) taking a beam of length substantially the same as at least one dimension of said sheet; c) fixing said beam to a surface of said panel; d) assembling said studs in spaced apart relationship from said sheet and allowing free ends of said studs to engage a surface of said beam; e) applying a layer of cementious material to key said beam to said sheet material . In another broad form the present invention comprises: a modular building panel for use in load bearing and non load bearing applications wherein the panel comprises an outer skin of material having an inner and outer surface, a plurality of spaced apart stud members forming a frame which engages said beam member, wherein said cementitious material forms a completed face of a structure such as a wall wherein said stud members are disposed in spaced apart relationship to said inner surface of said skin; a surface which receives a sheet of material which completes an opposite face of said panel; wherein the panel further comprises a beam member forming a structural member above window or door openings in the panel and which is capable of supporting a roof load applied to said beam and which is of sufficient strength to allow lifting of the panel ; wherein the panel when installed provides a substantially completed wall, floor or ceiling member.

The beam member has sufficient strength to allow long panel lengths to be constructed and which provides sufficient bracing so as to allow said beam member to form top and/or bottom plates to allow lifting of large panels and to sustain roof loads; wherein, when the panel is placed in situ it forms a substantially finished wall of a structure. Preferably the cement is reinforced. According to one embodiment a suitable reinforcing material is polyester cloth. Preferably, the beam is a steel channel section with openings which enable keying into said cementitious material.

In another broad form according to a method aspect the present invention comprises: a method of construction of a building using modular panels comprising; a modular generally rectilinear panel for use in load bearing and non load bearing applications wherein the panel comprises at least two spaced apart stud members each of which include at least one flange and web members wherein a flange of each member opposes and is spaced apart from a rigid sheet material which forms an external skin of a building constructed from said panels; the panel further characterized in having a beam at the top and/or bottom and which spans the length of the panel and which engages an end of each said studs members; the method comprising the following steps: a) taking a sheet of precast material of a predetermined area: b) taking a beam of length substantially the same as at least one dimension of said sheet; c) assembling said studs in spaced apart relationship over said sheet material; c) fixing free ends of said stud to said beam; d) applying a layer of cementious material to secure said beam to said sheet material d) wherein, when said panel is installed, the channel member/s may receive building services such as electricity, water and telecommunications.

According to one embodiment the precast material is a cementious material reinforced with woven polystyrene. According to an alternative embodiment the reinforced cement panel is formed prior to affixing the beam and stud members.

Tn another broad form according to a method aspect the present invention comprises: a method of construction of a building using modular panels comprising; a generally rectilinear panel for use in load bearing and non load bearing applications wherein the panel comprises a finished skin of cementitious material, stud members the panel further characterized in having a beam at the top and/or bottom of said panel spanning substantially the length of the panel and which engages an end of each said studs members; the method comprising the following steps: a) providing a sheet material of a predetermined are; b) taking a beam of length substantially the same as at least one dimension of said sheet material; c) laying beam in abutting relationship to an inner surface of said sheet material; d) assembling studs in spaced apart relationship to each other and to the inner surface of said sheet material; e) fixing said beam to free ends of said studs to form top or bottom plates of a frame formed from said studs and plates f) applying a cementitious material to a surface of said beam to key said beam to said sheet material. g) wherein, said beam provides means to enable Ufting of said panel when said panel is installed, and wherein said channel member/s may receive building services such as electricity, water and telecommunications.

According to one embodiment said studs are spaced apart from said inner skin of said sheet material.

DETAILED DESCRIPTION

The present invention will now be described in more detail according tø a preferred but non limiting embodiment and with reference to the accompanying illustrations wherein

Figure 1 shows a cross sectional view of an end profile of a panel according to a preferred embodiment of the invention;

Figure 2 shows a perspective view of the profile of the panel of figure 1 ;

Figure 3 shows an alternative perspective view of the panel of figure 1;

Figure 4 shows an elevation view of a completed panel according to one embodiment;

Figure 5 shows an enlarged view of a corner of the panel of figure 4;

Figure 6 shows a plan view of a corner junction of two panels according to one embodiment;

Figure 7 shows two panels joined according to an alternative embodiment;

Figure 8 shows a perspective view of a panel including a window opening. Figure 9 shows a top perspective view of an assembled dwelling house according to one application of the invention.

Referring to figure I there is shown a cross sectional view of an end profile of a modular panel 1 according to a preferred embodiment of the invention. Panel 1 which is suitable for use in load bearing and non load bearing applications comprises a layer of sheet material 2 having an inner surface 3 and outer surface 4. Typically panel 1 includes a plurality of spaced apart stud members 5 each of which typically include flange members 6 and 7 and web member 8. A suitable stud might alternatively be T shaped or channel shaped but other profile shapes may be used. The flange member 7 abuts spacer 9 which maintains studs 5 in spaced apart relationship from sheet material 4 which forms an external skin of a building constructed from the panels. The stud members are arranged so that when panel 1 is installed, the studs are vertical. Figure 1 shows one stud 5 only but it will be appreciated that there will typically be a plurality of studs in spaced apart relationship to each other. Panel 1 further comprises a member 10 which may be channel shaped and includes flanges 11 and 12 and web 13. Web 13 is embedded in cementitious layer 14 which will be poured after member 1 and spacer 9 are affixed to inner surface 3 of sheet material 2. According to one embodiment, layer 14 may be 12mm thick fibrecrete providing additional rigidity to the panel and insulation. The overall thickness of the panel may be adjusted by altering the thicknesses of sheet 2, layer 14 or the height of spacer 9. Spacer 9 may comprise brackets having a first face 15 which engages surface 3 of sheet 2 and a second face 16 which engages flange 7 of stud 5. According to a preferred embodiment, panel 1 further comprises an extension 18 of sheet 2 which receives member 19 which typically will be a channel shaped stud. Stud 19 is adapted to enable one panel to be connected to an adjacent panel via a corner connection ( see figure 5) or aligned end to end connection. Both internal corners such as that shown in figure 5 and external corners may be formed by connecting joining profiles at the edge of each panel. In the case of an internal corner abutting panels will include a joining member which opposes a corresponding joining member of an adjacent panel. For example, stud 19 includes inwardly directed flange 20 which opposes a corresponding flange on an adjacent panel.

Flange 12 of stud 10 further comprises a return 10a which keys stud 10 into engagement with sheet 2.

Figure 2 shows a perspective view of the profile of the panel of figure 1 with corresponding numbering;

Figure 3 shows an alternative perspective view of the panel of figure 1 including a plurality of studs. According to this embodiment, panel 1 includes in addition to stud 5 spaced apart studs 21, 22 and 23. Panel 1 of figure 3 is also adapted with end member 24 which abuts ends of studs 5, and 21- 24.

Figure 4 shows an elevation view of a fully assembled panel 30 according to one embodiment. Panel 30 includes a plurality of spaced apart stud members 31 mounted on bracket spacers 32. In the embodiment shown there are three spacers per stud but it will be appreciated that this arrangement may vary according to particular requirements by reducing the span between spacers and/or their height. Panel 30 further comprises an extension 33 for engagement at 90 degrees with an adjacent panel, top and bottom plates

34 and 35 and extension assembly 36 for receiving an adjacent panel in 180 degree axial alignment. For additional reinforcement, panel 30 includes a beam assembly 37 near the upper reaches of the panel . Beam assembly 37 allows lifting of the panel without risk of damage.

Figure 5 shows an enlarged view of a corner of the panel of figure 4 and particularly the mating engagement between studs 38 and 39 and top plate 34. Studs 38 and 39 sit over the top of bottom chord 40 of beam assembly 37. Extension 33 mates at 90 degrees with a corresponding panel. Formation 41 opposes a corresponding formation on an adjacent panel.

Figure 6 shows a plan view of an internal corner junction of two panels according to one embodiment. In figure 6 there is shown a cross sectional view of an end profile of a modular panel 50 according to a preferred embodiment of the invention. Panel 50 which is suitable for use in load bearing and non load bearing applications comprises a layer of sheet material 51 having an inner surface 52 and outer surface 53. Typically panel 50 includes a plurality of spaced apart stud members 54 each of which typically include flange members 55 and 56 and web member 57. The flange member 55 abuts spacer 58 which maintains stud 54 in spaced apart relationship from sheet material 51 which forms an external skin of a building constructed from the panels. The stud members are arranged so that when panel 50 is installed, the studs are vertical. Figure 6 shows one stud 54 only but it will be appreciated that there will typically be a plurality of studs in spaced apart relationship to each other. Panel 50 further comprises a member 59 which may be channel shaped and includes flanges 60 and 61 and web 62. Web 62 is embedded in cementitious layer 63 which will be poured after member 59 and spacer 58 are affixed to inner surface 52 of sheet material 51. According to a preferred embodiment, panel 50 further comprises an extension 64 of sheet 51 which receives member 65 which typically will be a channel shaped stud. Stud 65 is adapted to enable one panel to be connected to an adjacent panel 70 via a corner connection 71. In the case of an internal corner, abutting panels will include a joining member which opposes a corresponding joining member of adjacent panel 70. For example, stud 65 includes inwardly directed flange 66 which opposes a corresponding flange 72 on adjacent panel 70. Flanges 66 and 72 may be connected by clamps, screws or other fasteners

According to an alternative embodiment, an end of each stud engages a substantially channel shaped member forming a top plate. Typically, a stud frame comprises a plurality of spaced apart studs held together by top and bottom plates. According to the arrangement shown in figure 7 each of the panels have top plate members, which perform the traditional role of a top plate and also provides a cavity in which services ( not shown ) may be placed running substantially normal to the direction of the studs. Preferably, the stud members are spaced equidistant along the length of the panel, or where a window or door is to be provided in the structure, at suitable spacings. According to the embodiment shown in figure 7 the modular panel is configured with an opening 80 to receive a window. A supporting arch over the window is provided by member 81 and 82 which forms the top plates and services channels for panels 83 and 84 respectively. In order to effect joining between the panels there is provided at side edges of the panels joining arrangements which enable joining of the panels end to end. The panels are assembled and a building using the panels is constructed according to the following steps. A plurality of studs having at least a flange and a web are assembled in spaced apart relationship following which a channel member is fixed to the free ends of the studs to form top and /or bottom plates of a frame formed from the studs and plates. A sheet of rigid or semi rigid material 85 such as described in figure 7 is spaced apart from said at least one flange of each stud. The channel member forming the tøp plate receives receive/s building services such as electricity, water and telecommunications. Alternatively, the channel for carrying services may be placed at the bottom of the plurality of studs in which case it will function as a bottom plate.

The present invention provides an alternative pre cast prefabricated wall syste which allows use of a variety of facade cladding materials which themselves may be pre cast or sheet material. The frame may be constructed from studs of known steel sections which will typically be L,C,T Z or U shaped. According to one embodiment the studs may be load bearing or non load bearing and in the latter case the studs may be formed from lightweight materials.

Figure 8 shows a perspective view of a panel according to a preferred embodiment of the invention. The panel may be prepared according to the following regime. A formwork is prepared according to a predetermined area dictated by the size of a wall component of a structure. A sheet material which will form the outer skin of a structure formed by the panel is prepared from a cementitious material and allowed to set. Preferably the sheet material is reinforced by a suitable reinforcing material such as polypropylene fibre. Alternatively the sheet can be fibr cement. Where a window or door opening is to be included in the structure the sheet is provided with formwork which define the door or window opening. Cement is applied about the opening to form reveals for a window or door. A beam is applied along one edge of the panel which will preferably be at the top of the panel. The beam which may be channel shaped, preferably includes openings which behave as keys for positive fixation of the beam to the sheet material. One method of fixation of the beam to the sheet is to apply a layer of reinforced cementitious material to a web of the channel shape whereupon setting of the layer causes the beam to be integral with the sheet material. Studs which will form fixation surfaces for an internal skin tα be applied to the finished panel are arranged according to the panel configuration. The studs abut a face of the beam such that a surface of the studs and a surface of the beam will be substantially flush. The flush surfaces of the beam and stud receive a layer of material which forms an inner skin of a wall formed by the panel wherein the skin abuts the beam and the studs.

According to an alternative embodiment of the invention the panel may be prepared according to the following regime. A formwork is prepared according to a predetermined area dictated by the size of a wall component of a structure. A sheet material which will form the outer skin of a structure formed by the panel is prepared from a cementious material and allowed to set. Preferably the sheet material is reinforced by a suitable reinforcing material such as polypropylene fibre or othe suitable lightweight reinforcement. Where a window or door opening is to be included in the structure the sheet is provided with formwork which defines the door or window opening. Cement is applied about the opening to form reveals for a window or door. Once the sheet material has set, a beam is applied along one edge of the panel which will preferably be at the top edge of the panel. The beam which may be channel shaped, preferably includes openings which behave as keys for positive fixation of the beam to the sheet material. One method of fixation of the beam to the sheet is to apply a layer of reinforced cementious material to a web of the channel shape whereupon setting of the layer causes the beam to be integral with the sheet material. The beam when applied to the sheet material sits proud of the opposing surface of the sheet material providing an upstanding shoulder. When the sheet material is poured, brackets are affixed to the sheet in alignment with predetermined stud positions. According to this embodiment, studs are placed over the beam such that the studs are disposed spaced apart from the surface of the sheet material thereby forming an internal cavity in the finished panel which may accommodate services such as electricity. The finished thickness of the panel according to this embodiment, will comprise the total of the thickness of the sheet material, the thickness of the beam, the depth of the studs and the thickness of the internal skin affixed to the studs. The thickness of the panel can be adjusted according to whether the studs are placed with their ends abutting the beam or are applied over the beam.

The use of spacers to support the studs contributes to the overall strength of the finished panel and it will be understood that closer the spacing of the spacers the stronger the panel internally. The spacers may be selected from (preferably lightweight) materials such as but not limited to polystyrene, steel, aluminium, timber, cellulose fibre or plastics. The panels described herein may be applied in wall, floor or roof construction. In the case of roof construction, the panel may be disposed to form a pitched roof. The internal spaced apart studs may be disposed vertically, . horizontally or diagonally according to design requirements.

Figure 9 shows a top perspective view of an assembled dwelling house according to one embodiment of the invention. The house includes external and internal corners .

It will be recognized by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein without departing from the overall spirit and scope of the invention.

Claims

THE CLAIM DEFINING THE INVENTION ARE AS FOLLOWS:

1 A modular building panel for use in the construction of a building structure: the panel including a layer of cladding material having an inner and outer surface, the outer surface forming at least part of an exterior surface of the building structure; at least one stud member disposed generally parallel to said inner surface but spaced apart from said inner surface; edge members defining edge boundaries of said panel.

2 A modular panel according to claim 1 wherein there are a plurality of studs which engage said edge members.

3 A modular panel according to claim 2 wherein said studs are maintained in said spaced apart relationship; from sai inner surface of said panel by spacers,

4 A modular panel according to claim 3 wherein each said spacer has a first end connected to said inner surface of said cladding and a second end connected to a stud.

5 A modular panel according to claim 4 wherein said edge members provide a peripheral frame forming at least top and bottom plates.

6 A modular panel according to claim 5 wherein the panel further includes a layer of cementitious material which engages at least a part of said frame and at least a part of said spacers.

7 A modular panel according to claim 6 wherein the panel further includes edge formations which facilitate connection of an edge of one panel to a corresponding edge of an adjacent panel.

8 A modular panel, according to_; claim 7 wherein said, edge formations, comprise channel members which engage at least a flange of said stud members.

9 A modular panel according to claim 8 further comprising a connecting member which includes a formation capable of engaging a corresponding formation on a connecting member on an adjacent panel .

10 A modular panel according to claim 9 wherein the formation on said connecting members comprises an inwardly directed flange.

11 A modular panel according to claim 10 wherein at least one said frame members include an extension which engages an extension of an adjacent panel.

12 A modular panel according to claim 11 wherein said cladding layer is fibro cement.

13 A modular building panel for use in a structure: the panel including; a first laye of material having an inner and outer surface: engaging means including a first end engaging said inner surface of said layer; at least one stud member engaging a second end of said engaging means such that said at least one stud member is spaced apart from said inner surface of said first layer of material; frame members along at least one edge of said cladding material which engage said studs.

14 A panel according to claim 13 wherein the frame members are disposed along top and bottom edges of the panel.

15 A panel according to claim 14 wherein said engaging means are spacers and wherein there are a plurality of said spacers fixed via said second end face to said at least one stud member.

16 A panel according to claim 15 wherein there are a plurality of spaced apart stud members each fixed to at least one engaging means.

17 A panel according to claim 16 further comprising a second layer of cementitious material adjacent said inner surface of said first layer wherein said second layer embeds at least a part of a first end of said engaging means.

18 A panel according to, claim 1 wherein, at least a part, of said frame is connected to, said inner surface of said first layer.

19 A panel according to claim 18 wherein at least a part of said frame and each said spacers are embedded in said cementitious layer.

20 A pane) according to elaim 19 further comprising a joining member along an edge of the panel which engages a corresponding joining member of an adjacent panel.

21 A panel according to claim 20 wherein said joining member includes a formation which engages a corresponding formation of an adjacent panel.

22 A panel according to claim 21 wherein said joining formations on adjacent panels are in opposing relationship and are urged into mating engagement by a connecting tube.

23 A panel according to claim 22 wherein said connecting tube includes an elongated slot which receives each said joining formations and urges said formations into a utting engagement..

24. A panel according to claim 23 wherein said spacers comprise brackets of predetermined length.

25 A panel according to claim 24 wherein said studs are channel shaped wherein a flange of a stud engages said second end of said brackets.

26 A panel according to claim 25 wherein said frame comprises a channel shaped members wherein a flange of said channel shaped members engage said inner surface of said cladding layer.

27 A panel according t claim 26; wherei said brackets are glued to, said inner surface of said cladding layer.

28 A panel according to claim 27 wherein a flange of said frame is glued, nailed or screwed to said inner face of said first layer.

29 A panel according to claim 28 wherein said flange of said frame is partially embedded by said cementitious layer.

30 A panel according to claim 29 wherein said joining formation enabling connection of one panel to an adjacent panel comprises a return which abuts and opposes a corresponding return on an adjacent panel.

31 A panel according to claim 30 wherein one panel may be attached to an adjacent panel in axial alignment and/or normal to an adjacent panel.

32 A panel according to claim 31 wherein said first layer is formed of fibro cement.

33 A panel according to claim 32 wherein there is provided along an edge of said panel a strengthening beam.

34 A panel according to claim 33 wherein said studs receive a further cladding forming at least part of an interior surface of a building formed by said panel.

35 A panel according to any of the forgoing claims wherein the structure is a dwelling or factory building.

36 A method of constructing a modular building panel comprising the steps of a) taking a sheet of cladding material and laying said sheet on a surface;

->)• attaching a plurality of connecting spacer members to an inner surface of said cladding; c) attaching members forming a frame at or near at least one edge of said substrate; d) attaching stud members to one or more said brackets and said frame so that the stud members are spaced apart andoutstand from said inner layer.

37 A method according to claim 35 comprising the further step of ; pouring a cementitious layer over said inner surface of said substrate such that at least a part of each said spacer members and a part of said frame members is embedded in said cementitious layer;

38 A method according to claim 37 wherein said frame defines a boundary of said panel.

39 A method according to claim 38 wherein said spacers are brackets glued to an inner surface of said cladding material.

40 A method according to claim 39 comprising the further step of adjoining panels end to end to form the building structure.

41 A method according to claim 40 wherein, the panels include a formation at each end which enables joining of panels end to end.

42 A method according to claim 41 wherein the panel is either load bearing or non load bearing.

43 A method according to claim 42 wherein said building structure is a dwelling or factory.

44 A modular building panel for use in load bearing and non load bearing applications wherein the panel comprises; a first layer of cladding material having an inner and outer surface wherein the outer surface forms at least part of an exterior surface of the building: spacing members engaging said cl dding; a plurality of stud members engaging said spacing members such that said stud members are spaced apart from said inner surface of said cladding; frame members along at least one edge of said cladding material which engage said studs;

a layer of cementitious material adjacent said cladding layer wherein said cementitous layer at least partially embeds each said spacers and said boundary member wherein an exposed surface of said cementitious layer opposes said plurality of said stud members.

45 A modular panel according to claim 44 wherein the stud members are spaced equidistant along one dimension of the panel.

4 A modular panel according to claim 45 wherein the panel further comprises at side edges joining formations which enable each panel to receive an adjacent panel.

47 A modular panel according to claim 46 wherein the panel is configured with an opening to receive a window or door wherein a supporting beam is placed over the window or door.

48 A method of construction of a building using modular panels in load bearing and non load bearing applications, wherein the panels include; a outer cladding member which forms an external skin of a building constructed from said panels; a plurality of spaced apart stud members each of which include at least one flange and web members wherein a flange of each member opposes and is spaced apart from said cladding by means of spacers; the panel further characterized in having a frame about the periphery of said panel; the method comprising the following steps; a) taking a layer of cladding material having inner and outer surfaces; b) connecting studs to said inner surface of said cladding via spacers such that the assembled studs are i spaced apart relationship from the inner surface of said cladding; c) fixing a member to free ends of said studs to form top or bottom plates of a frame formed from said studs and plates d) wherein, when said panel is installed, a space formed between said inner surface and said studs receive/s building services such as electricity, water and telecommunication.

49 A method according to claim 48 comprising the fiirther step of providing a joining formation at side edges of each said panel such that each panel is capable of mating in alignment with or at an angle to an adjacent panel.

50 A method of construction of a building using modular panels, the panels including; outer cladding; a plurality of spaced apart stud members each of which include at least one flange and web members wherein a flange of each member is spaced apart from said outer cladding material which forms an external skin of a building constructed from said panels; the method comprising the following steps: a) taking the sheet of cladding material of a predetermined area: b) assembling said studs in spaced apart relationship over said sheet material supported on spacers such that a space is left between said studs and said sheet; c) applying a layer of cementious material to secure said beam to said sheet material

4) wherein, when said panel is installed, the panel member/s may receive building services such as electricity, water and telecommunications within said space between said studs and said sheet.