A building system and method of building

Abstract

A building system and method of building, including a floor system. The floor system including a structural insulated panel (SIP) and a reinforcing panel. The reinforcing panel being positionable adjacent a side of the SIP. The floor system further including a perimeter frame member positionable about the perimeter of the building, and a support flange attachable to the perimeter frame member. The support flange being configured to support the floor panel.

Description

A BUILDING SYSTEM AND METHOD OF BUILDINGFIELD OF INVENTION

[0001] The present invention relates to a building system and method of building. The present invention has particular but not exclusive application for lightweight building structures.BACKGROUND OF THE INVENTION

[0002] Modern construction techniques for buildings require complex arrangements of structural elements, complicated processes and highly skilled labour. For example, conventional techniques for constructing lightweight floor structures require primary support bearers, joists at set intervals, floor panel sheeting, and insulation.

[0003] Structural insulated panels (SIPs) are widely used in building construction as a modern alternative to traditional timber framed construction. Composite panels typically consist of two layers of sheet material bonded to a core of expanded polystyrene or similar material.

[0004] However, there are inherent structural issues present in SIPs. The cores of SIPs typically have poor compressive strength which is unsuited for supporting heavy loads. To enable a SIP to be load-bearing a structural member is inserted into the core to take on the load transfer independent from the core. The insertion of such additional load-bearing structural members is costly. Further, the structural members can create a barrier which prevents services such as plumbing and electrical services to pass to other building levels.OBJECT OF THE INVENTION

[0005] It is an object of the present invention to alleviate at least in part one or more of the aforementioned problems or at least provide a viable alternative.SUMMARY OF THE INVENTION

[0006] The present invention was developed in consideration of conventional construction technology and the benefits and detriments of SIPs.

[0007] The inventor developed a method and system using an advanced composite panel. The composite panel integrates the functions of joists, floor sheetingand insulation into a single cohesive unit. The inventor aimed to enhance the performance and application of SIPs by simplifying the corresponding construction and improving the structural capacity of the SIPs, thereby introducing new applications for building construction and enhancing the ability of SIPs to integrate with third-party service providers.

[0008] The developed method and system provided reduced material usage and simplified building processes.

[0009] In one aspect the present invention broadly resides in a floor system for a building, including a floor panel including a structural insulated panel (SIP) and a reinforcing panel, wherein the reinforcing panel is positionable adjacent a side of the SIP; a perimeter frame member positionable about the perimeter of the building; and a support flange attachable to the perimeter frame member and configured to support the floor panel.

[0010] Preferably, the perimeter frame member has a base portion, a side portion and a top portion. In one embodiment, the perimeter frame member preferably has a substantially C-shaped profile. Preferably, the base portion is a lower flange of the substantially C-shaped profile. Preferably, the top portion is an upper flange of the substantially C-shaped profile.

[0011] Preferably, the side portion has a length substantially equal to a width of the floor panel.

[0012] Preferably, when in position the side portion is substantially vertical.

[0013] Preferably, when in position an opening of the perimeter frame member faces externally from the building to form an outer opening.

[0014] Preferably, the floor system has a wall frame base flashing attachable to the perimeter frame member, the wall frame base flashing being configured to cover the outer opening. Preferably, the wall frame base flashing is turned down and affixed to the base of the perimeter frame member.

[0015] The perimeter frame member has an internal cavity that is preferably configured to house building services.

[0016] Preferably, when in position the support flange is substantially horizontal.

[0017] Preferably, when in position a lower portion of the support flange is substantially aligned with the base portion of the perimeter frame member.

[0018] Preferably, the support flange has an attachment portion. Preferably, the attachment portion is attachable to the side portion. Preferably, when in position the attachment portion is substantially vertical.

[0019] In one embodiment, the support flange preferably has a substantially L- shaped profile.

[0020] In one embodiment, the support flange is preferably integrally formed with the perimeter frame member.

[0021] Preferably, the reinforcing panel is positioned at an underside of the SIP. Preferably, the reinforcing panel is made of metal. Preferably, the reinforcing panel has a plurality of ribs. More preferably, the reinforcing panel has a corrugated profile. Preferably, the reinforcing panel has a plurality of parallel ridges and grooves. Preferably, the support flange has a length of at least the distance between adjacent ridges of the corrugated profile.

[0022] Preferably, the reinforcing panel is made from a metal material. More preferably, the reinforcing panel is made from steel.

[0023] Preferably, the perimeter frame member is supported by one or more posts or walls of the building. More preferably, the perimeter frame member is supported by one or more posts or walls of the building at intervals corresponding to the spanning capabilities of the perimeter frame member.

[0024] Preferably, the floor panel does not contribute to the load-bearing capacity of any load bearing structure above the floor panel.

[0025] Preferably, the perimeter frame member is fastened to one or more posts or walls of the building.

[0026] In one embodiment, the floor system preferably has at least two floor panels which are joinable together to form a floor. Preferably, each floor panel is joinable by a side cap member positionable at a joinable end of the corresponding floor panel. Preferably, each side cap member has a substantially C-shaped profile. In one embodiment, each adjacent floor panel preferably has a corresponding side cap member, and the side cap members are attachable together. In one embodiment, the attached side cap members preferably form an I-beam. In one embodiment, each side cap member is preferably integral with another side cap member. Preferably, the attached side cap members are supported by one or more posts or walls of the building. Preferably, the attached side cap members are arranged to carry a load-bearing internal structure of the building. In one embodiment, an I-beam is preferably used to form a pair of side cap members to join at least two adjacent floor panels.

[0027] In one embodiment, the floor panel is preferably supported by a first perimeter frame member on one side of the building and a second perimeter frame member on an opposing side of the building.

[0028] Preferably, the SIP has a core of expanded polystyrene.

[0029] In one embodiment, the floor system perimeter frame member is supported by one or more adjustable posts.

[0030] Preferably, each adjustable post includes a base plate and an upright support. Preferably, the base plate has a top face and a bottom face. Preferably, the upright support is oriented perpendicular to the top face of the base plate.

[0031] Preferably, the upright support is slidably movable along the top face of the base plate.

[0032] Preferably, the upright support is telescopic. Preferably, the upright support has an upper female portion and a lower male portion, wherein the lower male portion is at least partially received within the upper female portion. Preferably, when in position the upper female portion is slidably moveable relative to the lower male portion along a substantially vertical axis. Preferably, the upper female portion is securable in position relative to the lower male portion. Preferably, the upper female portion has a least one female portion hole and the lower male portion has at least one male portion hole. Preferably, the upper female portion is positionable relative to the lower male portion to align at least one female portion hole with at least one male portion hole, and wherein a locking pin is insertable into the aligned female portion hole and one male portion hole to lock the upper female portion in position relative to the lower male portion. In an alternate embodiment, the upright support preferably has an upper male portion and a lower female portion, wherein the upper male portion is at least partially received within the lower female portion.

[0033] Preferably, the upright support has a support foot on a lower end thereof, wherein the support foot is configured to rest on the top face of the base plate. Preferably, the support foot is on a lower end of the lower male portion. Preferably, the support foot is substantially crucifix-shaped.

[0034] In one embodiment, the base plate is attached to a pre-poured concrete pier. In another embodiment, the base plate is attached to walls of a pier hole.

[0035] Preferably, the one or more adjustable posts are secured in position with concrete. Preferably, the one or more adjustable posts are secured in position with concrete to secure the upright support in position relative to the base plate.

[0036] Preferably, the base plate has one or more anchorage members configured to provide stability to the base plate when the adjustable post is secured in position with concrete. Preferably, the one or more anchorage members are attached to the bottom face of the base plate. Preferably, each anchorage member is in the form of a looped bar.

[0037] Preferably, the base plate has one or more stake tubes, each stake tube being configured to receive a corresponding stake, wherein each stake is configured to be driven into the ground to secure the one or more adjustable posts. Preferably, the one or more stake tubes are angled to, when in position, orient each stake between 5 to 60 degrees from a vertical axis.

[0038] In an embodiment wherein the base plate has a plurality of stake tubes, the plurality of stake tubes are arranged in an array around the base plate substantially equidistant from each other.

[0039] In an embodiment wherein the base plate has a plurality of stake tubes, the plurality of stake tubes are reinforced with a reinforcing member. Preferably, the reinforcing member is a rod or bar. Preferably, each stake tubes are reinforced to at least one other stake tube.

[0040] Preferably, each of the one or more adjustable posts has a top plate. Preferably, the top plate is on an upper end of the upper female portion. Preferably, the position of the top plate relative to the upper female portion is adjustable. Preferably, the upper female portion has a threaded rod, and the top plate is adjustably securable to the threaded rod. Preferably, the top plate is configured to support the perimeter frame member.

[0041] In another aspect the present invention broadly resides in a building system including a floor system in accordance with the above aspect; a wall system; and a roof system.

[0042] In one embodiment the wall system is preferably a conventional building wall.

[0043] In one embodiment, the wall system preferably includes at least one wall with a wall frame, wherein the wall frame is comprised of a single elongate frame member.

[0044] Preferably, the frame member has a profile with a web section and two flange portions, wherein the web section is positioned between the two flange portions. Preferably, each flange portion is perpendicular to the web section. Preferably, the frame member has a C-shaped profile.

[0045] Preferably, the flange portions have gaps along the length of the frame member. Preferably, each flange portion has a gap at the same position along the length of the frame member. In one embodiment, the gaps are preferably formed by cutting the flange portions.

[0046] Preferably, the frame member is able to be bent during preparation for installation to form the wall frame. Preferably, the frame member is able to be bent during preparation for installation at the web section where there are gaps in the flange portions. Preferably, the frame member is bendable to 90 degrees at each bend.

[0047] Preferably, the frame member has a length equal to the perimeter of the wall frame.

[0048] Preferably, the frame member is made of metal.

[0049] In one embodiment, the wall frame is preferably formed by bending the frame member at four places to position a first end of the frame member adjacent a second end of the frame member, thereby forming an enclosed shape. In one embodiment, the enclosed shape is preferably a rectangle. Preferably, the first end and the second end are secured to each other. Preferably, the first end and the second end are secured to each other by one or more of riveting, welding or fastening with a splice plate.

[0050] Preferably, the frame member is welded to form the wall frame.

[0051] In one embodiment, the at least one wall has at least one stud member positionable between portions of the wall frame. Preferably, the at least one stud member is elongate with a C-shaped profile. Preferably, the at least one stud member is secured to the wall frame.

[0052] In one embodiment, the wall system preferably includes at least one wall with a wall frame, wherein the wall frame is comprised of a plurality of elongate frame members.

[0053] Preferably, each of the plurality of frame members has a profile with a web section and two flange portions, wherein the web section is positioned between the two flange portions. Preferably, each flange portion is perpendicular to the web section. Preferably, each frame member has a C-shaped profile.

[0054] Preferably, each flange portion has a lip.

[0055] Preferably, a first of the plurality of frame members has gaps in the web section at one end, wherein the gaps define a tab portion. Preferably, the tab portion is bendable to be perpendicular to the rest of the web section. In one embodiment, the gaps are preferably formed by cutting the web section.

[0056] Preferably, the tab portion is engageable with a web section of a second of the plurality of frame members. Preferably, the tab portion is securable to the web section of a second of the plurality of frame members. Preferably, the tab portion is securable with rivets, screws or other suitable metal-to-metal fasteners.

[0057] Preferably, the wall frame is constructed to align the flange portions of adjacent frame members to form a continuous flange around an edge of the wall frame.

[0058] Preferably, the wall frame defines an internal wall volume. Preferably, the internal wall volume is configured to receive an expanded polystyrene core. Preferably, the core is fastened to the wall frame. Preferably, the core has an inner face and an outer face.

[0059] Preferably, the wall system includes a wall sheet attachable to the wall frame.

[0060] Preferably, the wall system includes a wall sheet securable to the core. Preferably, the wall sheet is adhered to the core.

[0061] Preferably, the wall sheet and the core are pressed-together during curing of the adhesive to form a solid composite panel.

[0062] Preferably, the wall system includes a utility duct. Preferably, a portion of the utility duct is formed by a cavity in the core. Preferably, the one or more of the plurality of frame members have at least one hole which forms part of the utility duct. Preferably, the at least one hole aligns with the cavity. The utility duct is preferably used for electrical lines, water supply lines, sewerage lines, communication lines, and / or associated equipment.

[0063] Preferably, the one of the plurality of frame members forms a base portion of the wall frame and another one of the plurality of frame members forms a top portion of the wall frame.

[0064] Preferably, the wall system includes one or more wall panel attachable to the wall frame.

[0065] Preferably, the wall system includes one or more wall panel securable to the core. Preferably, the one or more wall panel is adhered to the core.

[0066] Preferably, the wall system includes a continuous base track. Preferably, the continuous base track is fastened to a floor member, and / or a footing.

[0067] Preferably, the continuous base track is an elongate member with a C- shaped profile. Preferably, the base portion is at least partially receivable within the C-shaped profile of the continuous base track.

[0068] Preferably, the continuous base track is a drainage channel. Preferably, the continuous base track has a plurality of drainage slots along the length of the continuous base track.

[0069] Preferably, the base portion is attachable to the continuous base track, a floor member, and / or a footing.

[0070] Preferably, the wall system includes a continuous top track.

[0071] Preferably, the continuous top track is an elongate member with a C- shaped profile. Preferably, the top portion is at least partially receivable within the C- shaped profile of the continuous top track.

[0072] Preferably, the continuous top track has a plurality of slots along the length of the continuous top track.

[0073] Preferably, the wall system includes one or more post members. Preferably, when in position the one or more post members are oriented substantially vertically. Preferably, the one or more post members are attachable to the continuous base track, the continuous top track, a floor member, and / or a footing. Preferably, the wall frame is secured to at least one of the one or more post members.

[0074] Preferably, each of the one or more post members are an elongate member with a web section and two flange portions. Preferably, each of the one or more post members has a substantially C-shaped profile. Preferably, each of the one or more post members has a continuous longitudinal recess along the web section.

[0075] In an embodiment with at least two adjacent post members, the continuous longitudinal recesses of each post member preferably enable face-to-faceengagement of the posts. In an embodiment with at least two adjacent post members, when the posts are adjoined the continuous longitudinal recesses, the continuous longitudinal recesses preferably form a cavity. Preferably, the cavity accommodates tie-down brackets and associated screw fixings.

[0076] Preferably, each of the one or more post members has a recess which enable close engagement with an open face of an adjacent wall frame without extending beyond the vertical edge of the frame. Preferably, each of the one or more post members is receivable within an adjacent wall frame.

[0077] Preferably, the wall system includes one or more tie-down brackets. Preferably, the one or more tie-down brackets are securable to the continuous base track or the continuous top track.

[0078] Preferably, the one or more tie-down brackets is securable to the one or more post members. Preferably, the one or more tie-down brackets are securable within the recess of the post member.

[0079] Preferably, the wall system includes at least one seal configured to provide a waterproof seal between adjacent wall panels.

[0080] Preferably, the wall system includes at least one seal cover configured to cover the seal and adjoining edges of adjacent wall panels. Preferably, the at least one seal cover is an elongate member with a web section and two flange portions. Preferably, the at least one seal cover has a substantially C-shaped profile. Preferably, the flange portions are shaped to conform with the surface of the corresponding wall panel.

[0081] In one embodiment, the wall system preferably includes at least one wall with a wall frame, wherein the wall frame is comprised of a primary frame and a secondary frame.

[0082] Preferably, the primary frame is comprised of a plurality of elongate primary frame members. Preferably, each primary frame member has a longitudinal recess. Preferably, the longitudinal recesses are arranged to form a perimeter recess around the primary frame.

[0083] Preferably, the secondary frame is comprised of a plurality of elongate secondary frame members.

[0084] Preferably, a portion of each secondary frame member is receivable within a recess of a corresponding primary frame member. Preferably, the recess has a width dimension of greater or equal to a width dimension of the correspondingsecondary frame member. Preferably, the recess has a depth dimension of approximately half of a depth dimension of the corresponding secondary frame member.

[0085] In one embodiment, a first primary frame is preferably installable adjacent to a second primary frame, wherein each primary frame engages with a common secondary frame.

[0086] Preferably, the secondary frame is fastened to a floor member, and / or a footing.

[0087] Preferably, the secondary frame is configured to be received within the perimeter recess.

[0088] Preferably, the primary frame is assembled using mitre joints.

[0089] Preferably, the primary frame is made from wood.

[0090] Preferably, the secondary frame is made from a metal material.

[0091] Preferably, the wall system includes a tie-down rod. Preferably, the secondary frame has at least one cavity adapted to accommodate the tie-down rod.

[0092] Preferably, the wall system includes a wall sheet attachable to the primary frame.

[0093] Preferably, the primary frame defines an internal wall volume. Preferably, the internal wall volume is configured to receive a core of insulative material. Preferably, the core is made from expanded polystyrene. Preferably, the core is fastened to the primary frame.

[0094] In an embodiment wherein the wall system includes a utility duct formed by a cavity in the core, preferably the one or more of the plurality of primary frame members have at least one hole which forms part of the utility duct. Preferably, the at least one hole aligns with the cavity.

[0095] In one embodiment, the building system includes a ceiling system. Preferably, the ceiling system has the same features of the floor system as described in the above aspect, wherein a structural insulated panel (SIP) and a reinforcing panel form a ceiling panel. Preferably, a perimeter frame member of the ceiling system is positionable on a wall of the wall system. Preferably, the reinforcing panel is positionable adjacent a side of the SIP.

[0096] Preferably, the ceiling system further includes a ceiling batten array positioned beneath the panel. Preferably, the ceiling batten array includes a pluralityof elongate ceiling battens which are oriented perpendicular to ridges of the reinforcing panel.

[0097] Preferably, the ceiling system further includes a ceiling cover sheet.

[0098] Preferably, the ceiling cover sheet and the reinforcing panel define a ceiling void. Preferably, the ceiling void is used for electrical lines, water supply lines, sewerage lines, communication lines, and / or associated equipment.

[0099] Preferably, the ceiling cover sheet, the ceiling batten array and the ceiling panel are supported by the support flange.

[0100] Preferably, a perimeter frame member of the ceiling system is secured to the wall system. In one embodiment, a perimeter frame member of the ceiling system is preferably secured to a tie-down rod of the wall system.

[0101] In one embodiment the roof system is preferably a conventional building roof.

[0102] In one embodiment, the roof system preferably includes, a SIP; a perimeter bracket positionable about the perimeter of the building; and a ridge bracket positionable at a ridge of the building.

[0103] Preferably, the SIP is attachable to the perimeter bracket. In one embodiment, the SIP is preferably slidably attachable to the perimeter bracket.

[0104] Preferably, the perimeter bracket has a wall portion, a top flange connected to the wall portion, and a base flange connected to the wall portion.

[0105] Preferably, when in position the wall portion is substantially vertical.

[0106] Preferably, the SIP has an attachment member configured to attach the SIP to the perimeter bracket.

[0107] Preferably, the attachment member is attached to an underside of the SIP.

[0108] Preferably, the attachment member is elongate.

[0109] Preferably, the attachment member has a profile with a first portion and a second portion. Preferably, the first portion is attached to the SIP.

[0110] Preferably, the attachment member is configured to engage with the top flange of the perimeter bracket. Preferably, the second portion and the SIP define a cavity, wherein the cavity is adapted to receive a portion of the top flange of the perimeter bracket. Preferably, the cavity has a width approximately a width of the top flange of the perimeter bracket. Preferably, the cavity has a length which defines thedistance that the SIP can slidably move when the top flange of the perimeter bracket is received within the cavity.

[0111] Preferably, the top flange of the perimeter bracket is angled to a desired roof pitch angle.

[0112] Preferably, the ridge bracket is configured to receive an end of the SIP. In one embodiment, the ridge bracket is configured to slidably receive the SIP.

[0113] Preferably, the ridge bracket has a wall portion, a top flange connected to the wall portion and a base flange connected to the wall portion. Preferably, the top flange and the base flange are angled to the desired roof pitch angle.

[0114] Preferably, the top flange of the perimeter bracket aligns with the base flange of the ridge bracket.

[0115] Preferably, the ridge of the building comprises a support in the form of a boxed ridge beam supported by SIP gable walls for a single-sided roof or post sections for a two-sided roof. Preferably, the ridge further comprises a ridge cap. Preferably, the ridge cap covers the top flange of the ridge bracket.

[0116] Preferably, the perimeter bracket is secured to a perimeter frame member of the ceiling system. Preferably, the base flange of the perimeter bracket is secured to a perimeter frame member of the ceiling system.

[0117] Preferably, the roof system includes a roof sheet. Preferably the roof sheet is attached to the SIP. Preferably, the roof sheet is corrugated.

[0118] In another aspect the present invention broadly resides in a method of constructing a building, the building including a floor system in accordance with the above aspect, the method including, positioning a perimeter frame member about the perimeter of the building and securing the perimeter frame member to one or more posts or walls of the building; attaching a support flange to the perimeter frame member; and supporting the floor panel on the support member, wherein the floor panel includes a structural insulated panel (SIP) and a reinforcing panel.

[0119] In one embodiment wherein the floor system has at least two floor panels which are joinable together to form a floor, the method preferably includes attaching a corresponding cap member to each floor panel at a joinable edge of the floor panels; andattaching the cap members together.

[0120] Preferably, the method includes securing the floor panel to the support member.

[0121] Preferably, the method includes attaching a wall frame base flashing to perimeter frame member to cover an outer opening of the perimeter frame member.

[0122] In one embodiment, the building further includes an adjustable post system as described above and the method includes, positioning a base plate at a desired location about the perimeter of the building; securing the base plate in position relative to a ground surface; positioning an upright support on the base plate; slidably moving the upright support relative to the base plate to a desired position; and securing the upright support in position relative to the base plate.

[0123] In one embodiment, the method preferably includes securing the base plate to the ground using a plurality of stakes, each stake being received within one of the plurality of stake tubes.

[0124] In another embodiment, the method preferably includes securing the base plate to the ground with concrete.

[0125] In one embodiment wherein the upright support is telescopic, the method preferably includes adjusting the height of the upright support. Preferably, the method includes securing the upright support at a desired height.

[0126] Preferably, the adjustable post has an adjustable top plate, and the method includes positioning the perimeter frame member on the top plate; adjusting the height of the top plate; and securing the perimeter frame member to the adjustable post.

[0127] In one embodiment, the building further includes a wall system wherein the wall frame is comprised of a single elongate frame member as described above and the method includes, bending a web section of the frame member to form a wall frame to position a first end of the frame member adjacent a second end of the frame member, thereby forming an enclosed shape.

[0128] In one embodiment, the enclosed shape is preferably a rectangle. Preferably, the method includes securing the first end and the second end. Preferably, the first end and the second end are secured to each other by one or more of riveting, welding or fastening with a splice plate.

[0129] In one embodiment, the method preferably includes cutting gaps along the length of a frame member.

[0130] Preferably, the method includes securing at least one stud member between portions of the wall frame.

[0131] Preferably, the method includes attaching a wall sheet to the wall frame.

[0132] In one embodiment, the building further includes a wall system wherein the wall frame is comprised of a plurality of elongate frame members as described above and the method includes, engaging a tab portion of at least one of a plurality of frame members with a web section of another of the plurality of frame members; and securing the tab portion to the web section of another of the plurality of frame members to form a wall frame.

[0133] Preferably, the method includes bending the tab portion to a desired orientation.

[0134] Preferably, the method includes constructing the wall frame so that flange portions of adjacent frame members align to form a continuous flange around an edge of the wall frame.

[0135] Preferably, the method includes forming the tab portion with gaps in the web section. In one embodiment, the method preferably includes cutting the gaps in the web section.

[0136] Preferably, the method includes constructing the wall frame to define an internal wall volume.

[0137] Preferably, the method includes inserting a core into the internal wall volume. Preferably, the method includes attaching a wall sheet to the wall frame. Preferably, the method includes securing a wall sheet to the core. Preferably, the wall sheet is secured to the core with adhesive. Preferably, the method includes attaching a wall panel to the wall frame.

[0138] Preferably, the method includes securing a wall panel to the core. Preferably, the wall panel is secured to the core with adhesive.

[0139] Preferably, the method includes forming a utility duct. Preferably, the utility duct is at least partially formed by a cavity in the core. Preferably, the utility duct is at least partially formed by one or more holes of the plurality of frame members.

[0140] Preferably, the method includes attaching a continuous base track to the perimeter frame member of the floor system, and attaching the wall frame to the continuous base track.

[0141] Preferably, the method includes attaching a continuous top track to the wall frame, and attaching the continuous top track to a perimeter frame member of the ceiling system.

[0142] In one embodiment wherein the wall system includes a plurality of wall frames, the method includes installing one or more post members between adjacent wall frames.

[0143] Preferably, the method includes attaching one or more tie-down brackets to the wall frames to reinforce the building.

[0144] Preferably, the method includes fitting a seal to cover adjoining edges of adjacent wall panels.

[0145] Preferably, the method includes pressing the wall sheet and the core together during curing of the adhesive to form a solid composite panel.

[0146] In one embodiment, the building further includes a wall system wherein the wall frame is comprised of a primary frame and a secondary frame as described above and the method includes, assembling a plurality of elongate primary frame members to form the primary frame, the primary frame having a perimeter recess; and assembling a plurality of elongate secondary frame members to form the secondary frame around the primary frame, the secondary frame being received within the perimeter recess.

[0147] Preferably, the primary frame defines an internal wall volume, and the method includes inserting a core into the internal wall volume. Preferably, the method includes attaching a wall sheet to the wall frame. Preferably, the method includes securing a wall sheet to the core. Preferably, the wall sheet is secured to the core with adhesive. Preferably, the method includes attaching a wall panel to the wall frame. Preferably, the method includes securing a wall panel to the core. Preferably, the wall panel is secured to the core with adhesive.

[0148] Preferably, the method includes attaching the secondary frame to the perimeter frame member of the floor system.

[0149] Preferably, the method includes installing a tie-down rod within a corresponding cavity of one of the secondary frame members to reinforce the building.

[0150] Preferably, the method includes pressing the wall sheet and the core together during curing of the adhesive to form a solid composite panel.

[0151] Preferably, the method includes forming a utility duct. Preferably, the utility duct is at least partially formed by a cavity in the core. Preferably, the utility duct is at least partially formed by one or more holes of the plurality of primary frame members.

[0152] In one embodiment, the building further includes a ceiling system as described above and the method includes, positioning a perimeter frame member about the perimeter of the building and securing the perimeter frame member to one or more walls of the building; attaching a support flange to the perimeter frame member; and supporting a ceiling panel on the support member, wherein the ceiling panel includes a structural insulated panel (SIP) and a reinforcing panel.

[0153] In one embodiment wherein the ceiling system has at least two ceiling panels which are joinable together to form a ceiling, the method preferably includes, attaching a cap member to each SIP at a joinable edge of the ceiling panels; and attaching the cap members together.

[0154] Preferably, the method includes securing the ceiling panel to the support member.

[0155] Preferably, the method includes attaching a ceiling batten array beneath the reinforcing panel.

[0156] Preferably, the method includes attaching a ceiling cover sheet beneath the ceiling batten array.

[0157] Preferably, the method includes securing the perimeter frame member to a tie-down rod of the wall system.

[0158] In one embodiment, the building further includes a roof system as described above and the method includes, positioning a perimeter bracket about the perimeter of the building; positioning a ridge bracket at a ridge of the building; andmoving a SIP to be received by the ridge bracket; and moving the SIP to engage the attachment member with the ceiling perimeter bracket.

[0159] Preferably, the SIP is attached to the perimeter bracket by an attachment member.

[0160] Preferably, the method includes installing a ridge cap on to the ridge.

[0161] Preferably, the method includes securing the perimeter bracket to a perimeter frame member of the ceiling system. Preferably, the base flange of the perimeter bracket is secured to a perimeter frame member of the ceiling system.

[0162] Preferably, the method includes attaching roof sheet to the SIP.

[0163] In another aspect the present invention broadly resides in a kit for the building system in accordance with the above aspect.

[0164] In a further aspect the present invention broadly resides in an adjustable post system for a building, the adjustable post system including one or more adjustable posts, wherein the at least one adjustable post includes a base plate with a top face and an upright support, wherein the upright support is slidably movable along the top face of the base plate. Preferably, the upright support is telescopic. Preferably, the one or more adjustable posts is secured in position with concrete to secure the upright support in position relative to the base plate. Preferably, the base plate has one or more anchorage members configured to provide stability to the base plate when the adjustable post is secured in position with concrete.

[0165] In a further aspect the present invention broadly resides in a wall system for a building, the wall system including at least one wall with a wall frame, wherein the wall frame is comprised of a single elongate frame member, wherein the frame member has a profile with a web section and two flange portions, wherein the web section is positioned between the two flange portions, wherein the flange portions have gaps along the length of the frame member, and wherein the frame member is able to be bent during preparation for installation to form the wall frame. In one embodiment, the wall frame is formed by bending the frame member at four places to position a first end of the frame member is adjacent a second end of the frame member, thereby forming an enclosed shape. In one embodiment, the enclosed shape is preferably a rectangle.

[0166] In a further aspect the present invention broadly resides in a wall system for a building, the wall system including at least one wall with a wall frame, whereinthe wall frame is comprised of a plurality of elongate frame members, wherein each of the plurality of frame members has a profile with a web section and two flange portions, wherein the web section is positioned between the two flange portions, wherein a first of the plurality of frame members has gaps in the web section at one end, wherein the gaps define a tab portion, wherein the tab portion is bendable to be perpendicular to the rest of the web section, and wherein the tab portion is engageable with a web section of a second of the plurality of frame members. Preferably, the wall frame is constructed to align the flange portions of adjacent frame members to form a continuous flange around an edge of the wall frame.

[0167] In a further aspect the present invention broadly resides in a wall system for a building, the wall system including at least one wall with a wall frame, wherein the wall frame is comprised of a primary frame and a secondary frame, wherein the primary frame has a perimeter recess around the exterior of the primary frame, and the secondary frame is receivable within the perimeter recess.

[0168] In a further aspect the present invention broadly resides in a ceiling system for a building, the ceiling system including a ceiling panel, a perimeter frame member positionable about the perimeter of the building, and a support flange attachable to the perimeter frame member and configured to support the ceiling panel. The ceiling panel including a structural insulated panel (SIP) and a reinforcing panel. Preferably, the ceiling system further includes a ceiling batten array positioned beneath a ceiling panel and a corresponding reinforcing panel. Preferably, the ceiling batten array includes a plurality of elongate ceiling battens which are oriented perpendicular to ridges of the reinforcing panel. Preferably, the ceiling system further includes a ceiling cover sheet. Preferably, the ceiling cover sheet, the ceiling batten array and the ceiling panel are supported by the support flange.

[0169] In a further aspect the present invention broadly resides in a roof system for a building, the roof system including a structural insulated panel, a perimeter bracket positionable about the perimeter of the building; and a ridge bracket positionable at a ridge of the building. Preferably, the SIP is attachable to the perimeter bracket and the ridge bracket is configured to receive an end of the SIP.

[0170] The features described with respect to one aspect also apply where applicable to all other aspects of the invention. Furthermore, different combinations of described features are herein described and claimed even when not expressly stated.BRIEF DESCRIPTION OF THE DRAWINGS

[0171] In order that the present invention can be more readily understood reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein:Figure 1 is a cross-sectional perspective view of a floor system of a building in accordance with an embodiment of the present invention.Figure 2 is a cross-sectional exploded perspective view of the floor system of Figure 1 from a first angle.Figure 3 is a cross-sectional exploded perspective view of the floor system of Figure 1 from a second angle.Figure 4 is a cross-sectional elevation view of the floor system of Figure 1 .Figure 5 is a perspective view of an adjustable post of the building.Figure 6 is an exploded perspective view of an adjustable post of Figure 5.Figure 7 is a top perspective view of an adjustable post of Figure 5.Figure 8 is a series of perspective views of a first wall system of the building.Figure 9 is an exploded perspective view of a perimeter frame of a second wall system of the building.Figure 10 is an exploded perspective view of the perimeter frame of the second wall system of Figure 9.Figure 11 is a cross-sectional perspective view of the second wall system of Figure 9.Figure 12 is a perspective view of a tie-down bracket of the second wall system of Figure 9.Figure 13 is an underside cross-sectional perspective view of the second wall system of Figure 9.Figure 14 is a cross-sectional perspective view of the second wall system of Figure 9.Figure 15 is a cross-sectional perspective view of the second wall system of Figure 9 with wall panels.Figure 16 is a cross-sectional perspective view of the second wall system of Figure 9 with a corrugated wall sheet.Figure 17 is a cross-sectional perspective view of a third wall system of the building.Figure 18 is a cross-sectional perspective view of a ceiling system of the building.Figure 19 is a cross-sectional perspective view of a roof system of the building.Figure 20 is a cross-sectional elevation view of the roof system of the Figure 19 with a SIP in a first position.Figure 21 is a cross-sectional elevation view of the roof system of the Figure 19 with the SIP in a second position.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0172] Referring to Figures 1 to 4 there is shown a preferred embodiment of a floor system 10 for a building.

[0173] The floor system 10 has two floor panels which are joinable together to form a floor. Each floor panel includes a structural insulated panel (SIP) 20A.20B and a corresponding corrugated steel reinforcing panel 22A.22B positioned underneath the SIP 20A.20B. The corrugated profile increases the tension capabilities of the corresponding floor panel, thereby enhancing the spanning capacity of the floor.

[0174] The floor system 10 further includes a plurality of perimeter frame members 30A.30C positionable about the perimeter of the building, and a plurality of support flanges 40A.40C attachable to a corresponding one of the perimeter frame members 30A.30C and configured to support the floor panels.

[0175] Figures 1 and 2 show the floor system 10 from a perspective wherein a perimeter frame member 30A is perpendicular with the corrugations of the reinforcing panels 22A. The perimeter frame member 30A is supported by an adjustable post 100.

[0176] Figure 3 shows the floor system 10 from a perspective wherein a perimeter frame member 30C is parallel with the corrugations of the reinforcing panel 22A. The perimeter frame member 30C is supported by a wall 460.

[0177] Figure 4 shows the floor system 10. The floor system 10 is supported by adjustable posts 100. The floor panel is supported by a first perimeter frame member 30A on one side of the building and a second perimeter frame member 30B on an opposing side of the building.

[0178] The SIPs 20A.20B have cores of expanded polystyrene.

[0179] The perimeter frame member 30A has a substantially C-shaped profile with a base 32, a side portion 36 and a top portion 34. The side portion 36 faces internally to the building. The perimeter frame member 30A has an outer opening. When in position the outer opening faces externally from the building.

[0180] The perimeter frame member 30A has an internal cavity. The internal cavity is configured to house building services. The outer opening is configured to enable access to the internal cavity for the purposes of installation during and / or postconstruction and / or maintenance. The outer opening enables the fixing of bolts to connect external wall frames or cyclone tie-down rods.

[0181] The perimeter frame members 30A.30C each have a width substantially equal to a width of the floor panel.

[0182] The support flange 40A has a substantially L-shaped profile. When in position a lower portion of the support flange 40A is substantially horizontal and aligned with the base 32. When in position the support flange 40A has a substantially vertical attachment portion attachable to the side portion 36.

[0183] The reinforcing panels 22A.22B are positioned at undersides of the corresponding SIP 20A.20B.

[0184] The floor system 10 includes a side cap member 50A.50B for each floor panel. The side cap members 50A.50B enhance the span capacity of the floor. The side cap members 50A.50B are positionable at a joinable edge of a corresponding floor panel. Each side cap member 50A.50B has a substantially C-shaped profile. The side cap members 50A.50B are attachable together.

[0185] Referring to Figures 5 to 7 there is shown a preferred embodiment of the adjustable post 100. The adjustable post 100 addresses the common problem of precisely positioning structural support posts such as during the concrete pouring process.

[0186] The adjustable post 100 includes a base plate 110 and a telescopic upright support.

[0187] The base plate 110 is rectangular with a top face and a bottom face.

[0188] The upright support is oriented perpendicular to the top face of the base plate 110. The upright support is slidably movable along the top face of the base plate110.

[0189] The upright support has an upper female portion 130 and a lower male portion 120, wherein the lower male portion 120 is at least partially received within theupper female portion 130. When in position the upper female portion 130 is slidably moveable relative to the lower male portion 120 along a substantially vertical axis.

[0190] The upper female portion 130 has a plurality of holes 136 and the lower male portion 120 has a plurality of holes 124. The holes 124,136 are arranged to align at different positions of the upper female portion 130 and the lower male portion 120. The holes 124,136 are configured to receive a locking pin to secure the upper female portion 130 in position relative to the lower male portion 120.

[0191] The lower male portion 120 has a substantially crucifix-shaped support foot 122 on a lower end thereof. The support foot 122 is configured to rest on the top face of the base plate 110.

[0192] The base plate 110 has four anchorage members 116 in the form of looped bars attached to the bottom face of the base plate 110. The anchorage members 116 are configured to provide stability to the base plate 110 when the adjustable post 100 is secured in position with concrete.

[0193] The base plate 110 has a plurality of stake tubes 112 arranged in an array around the top face at the corners of the baes plate 100. Each stake tube 112 is configured to receive a corresponding stake. Each stake is configured to be driven into the ground to secure the adjustable post 100. The plurality of stake tubes 112 are reinforced with reinforcing members 114.

[0194] The adjustable post 100 has a top plate 134 on an upper end of the upper female portion 130. The upper female portion 130 has a threaded rod 132 and the top plate 134 is adjustably securable to the threaded rod 132.

[0195] In use, the base plate 110 is positioned at a desired location about the perimeter of the building and secured in position relative to a ground surface. The upright support is then moved to a desired position relative to the base plate 110 and secured in position. The height of the upright support is adjustable by moving the upper female portion 130 and / or the top plate 134 to install the corresponding perimeter frame member 30A,30C at a desired height.

[0196] Referring to Figure 8 there is shown a series of perspective views of a first wall system of the building. The first wall system is suitable for structures where the corners of the wall do not require full protection. The first wall system includes a wall frame comprised of a single elongate frame member 200 and a stud member 300.

[0197] The frame member 200 has a C-shaped profile with a web section 210 and two flange portions 220A,220B. The web section 210 is positioned between the twoflange portions 220A.220B. Each flange portion 220A.220B is perpendicular to the web section 210.

[0198] The frame member 200 has a length equal to the perimeter of the wall frame.

[0199] The frame member 200 is made of metal.

[0200] The flange portions 220A,220B have paired gaps 222 along the length of the frame member 200. The frame member 200 is bendable at the web section where there are gaps 222 in the flange portions 220A,220B.

[0201] The wall frame is formed by bending the frame member 200 at four places to position a first end of the frame member 200 is adjacent a second end of the frame member 200, thereby forming a rectangular enclosed shape. The first end and the second end are secured to each other by one or more of riveting, welding or fastening with a splice plate. An expanded polystyrene core is able to be installed within the wall frame.

[0202] The stud member 300 is elongate with a C-shaped profile similar to the frame member 200. A web section of the stud member 300 is bent on either end to be parallel to the corresponding portions of the wall frame. The stud member 300 is positionable between portions of the wall frame. The stud member 300 is fastened to the wall frame.

[0203] Referring to Figures 9 and 10 there is shown a wall frame 400 of a second wall system of the building. The second wall system is suitable for structures where continuous support at the corners of the external sheets is required.

[0204] The wall frame 400 is comprised of a plurality of elongate frame members 401 ,402,403,404. Each of the plurality of frame members 401 ,402,403,404 has a substantially C-shaped profile with a web section 410 and two flange portions 430. The web section 410 is positioned between the two corresponding flange portions 430. Each flange portion 430 is perpendicular to the corresponding web section 410. Each flange portion 430 has a lip.

[0205] A first and third of the plurality of frame members 401 ,403 have gaps in the web section 410 at one end, wherein the gaps define tab portions 420. The tab portions 420 are bendable to be perpendicular to the rest of the web section 410.

[0206] The tab portions 420 are engageable with a web section 410 of a second and fourth of the plurality of frame members 402,404. The tab portions 420 aresecurable to the web section of frame members 402,404 with rivets, screws or other suitable metal-to-metal fasteners.

[0207] The wall frame 400 is constructed to align the flange portions 430 of adjacent frame members 401 ,402,403,404 to form a continuous flange around an edge of the wall frame 400.

[0208] Referring to Figures 11 to 16 there is shown the second wall system of the building.

[0209] The wall frame 400 defines an internal wall volume. The internal wall volume is configured to receive a core 440 of expanded polystyrene. The core 440 is fastened to the wall frame 400. The core 440 has an inner face and an outer face.

[0210] The wall system includes a wall sheet 450 attachable to the wall frame 400 and to the core 440 with adhesive.

[0211] The wall sheet 450 and the core 440 are pressed-together during curing of the adhesive to form a solid composite panel 460.

[0212] A utility duct 470 runs through the core 440.

[0213] The second wall system has a structure for mounting the wall frame 400. The structure includes a continuous top track 501 , a plurality of post members 502, and a continuous base track 503. When in position the top track 501 is substantially horizontal. When in position the post members 502 are substantially vertical. When in position the base track 503is substantially horizontal. The continuous top track 501 , the post members 502, and the continuous base track 503 are elongate members with a C-shaped profile having an open side. The frame members 401 ,402,403,404 are receivable within the open sides of the continuous top track 501 , the post members 502, and the continuous base track 503.

[0214] Each post member 502 is attachable to the continuous top track 501 and the continuous base track 503.

[0215] The wall frame 400 is secured to the structure.

[0216] The continuous base track 503 is installed on top of the floor system 10 and secured to the perimeter frame member 30A. The continuous base track 503 has a plurality of drainage slots along the length of the continuous base track 503 and which enables the continuous base track 503 to act as a drainage channel.

[0217] The post member 502 has a web section with a continuous longitudinal recess.

[0218] The post member 502 is shown situated above the adjustable post 100.

[0219] The post member 502 is attached to the continuous top track 501 and the continuous base track 503 with tie-down brackets 510. Each tie-down bracket 510 has a mating flange 512 and a threaded rod 514 extending from the mating flange 512. The mating flanges 512 are received within the continuous longitudinal recess of the post member 502. The mating flanges 512 have holes 516 for fasteners to attach the tie-down brackets 510 to the post member 502. The threaded rods 514 are arranged to protrude through corresponding holes in the continuous top track 501 and the continuous base track 503 and are secured with nuts 520.

[0220] The continuous longitudinal recess of adjacent post members 502 form a cavity which accommodates the tie-down brackets 510 and associated screw fixings.

[0221] Figure 15 shows an exploded view of a wall assembly with panels attached to one side of the core 440. A flexible seal 480 is configured to cover adjoining edges of adjacent wall panels and form a waterproof seal.

[0222] The wall system includes a seal cover 490 configured to cover the flexible seal 480 and the adjoining edges of adjacent wall panels. The seal cover 490 is an elongate metal member with a web section and two flange portions. The flange portions are shaped to conform with the surface of the corresponding wall panels.

[0223] Figure 16 shows an exploded view of an alternate with a corrugated wall sheet attached to one side of the core 440. A flexible seal 480A is configured to cover adjoining edges of adjacent wall sheets and form a waterproof seal. The wall system includes a seal cover 490A configured to cover the flexible seal 480A and the adjoining edges of adjacent wall sheets. The seal cover 490A is an elongate metal member with a web section and two flange portions. The flange portions are shaped to conform with the surface of the corresponding wall sheets.

[0224] Referring to Figure 17 there is shown a wall frame 600 of a third wall system of the building. The wall frame 600 is comprised of a wooden primary frame and a metal secondary frame.

[0225] The primary frame is comprised of a plurality of elongate primary frame members 601 ,602,603. Each primary frame member 601 ,602,603 has a longitudinal recess. The longitudinal recesses are arranged to form a perimeter recess around the primary frame. The primary frame members 601 ,602,603 are connected with mitre joints.

[0226] The secondary frame is comprised of a plurality of elongate secondary frame members 611 ,612,613.

[0227] The secondary frame members 611 ,612,613 are hollow. The secondary frame member 612 accommodates a tie-down rod 640 which passes through each secondary frame member 611 ,612,613. The tie-down rod 640 is secured on both ends by washers 642 and nuts 644.

[0228] A portion of each secondary frame member 611 ,612,613 is receivable within a recess of the corresponding primary frame members 601 ,602,603 to configure the secondary frame to be received within the perimeter recess. The recess has a width of greater or equal to a width of the corresponding secondary frame member 611 ,612,613. The recess has a depth dimension of approximately half of a depth dimension the corresponding secondary frame member 611 ,612,613.

[0229] A first primary frame is installable adjacent to a second primary frame, wherein each primary frame engages with a common secondary frame.

[0230] The secondary frame is securable to the floor system 10.

[0231] The primary frame defines an internal wall volume. The internal wall volume is configured to receive an expanded polystyrene core 620.

[0232] The wall system includes wall sheets 630 attachable to the primary frame. The wall sheets 630 are adhered to the core. The wall sheets 630 and the core 620 are pressed together during curing of the adhesive to form a solid composite panel.

[0233] A utility duct is partially formed by a cavity 622 in the core 620. One of the primary frame members has a hole 604 which aligns with the cavity 622 and forms part of the utility duct.

[0234] Referring to Figure 18 there is shown a ceiling system 700 of the building. The ceiling system 700 includes a ceiling panel. The ceiling panel includes a SIP 720 and a corrugated steel reinforcing panel 722 positioned underneath the SIP 720. The corrugated profile increases the tension capabilities of the ceiling panel, thereby enhancing the spanning capacity of the ceiling.

[0235] The ceiling system 700 further includes a plurality of perimeter frame members 730 positionable about the perimeter of the building, and a plurality of support flanges 740 attachable to a corresponding one of the perimeter frame members 730.

[0236] Figure 18 shows the ceiling system 700 from a perspective wherein a perimeter frame member 730 is parallel with the corrugations of the reinforcing panel 722.

[0237] A ceiling batten array 724 is positioned beneath the ceiling panel. The ceiling batten array 724 includes a plurality of elongate ceiling battens which are oriented perpendicular to ridges of the reinforcing panel 722. The ceiling battens are thin elongate members which are not required to support significant structural loads.

[0238] A ceiling cover sheet 726 is positioned beneath the ceiling batten array 724.

[0239] The ceiling cover sheet 726 and the reinforcing panel 722 defines a ceiling void. The ceiling void can be used for electrical lines, water supply lines, sewerage lines, communication lines, and / or associated equipment.

[0240] The ceiling cover sheet 726, the ceiling batten array 724, and the ceiling panel are supported by the support flange 740.

[0241] The perimeter frame member 730 of the ceiling system is secured to the solid composite panel 460 via the tie-down bracket 510.

[0242] Referring to Figures 19 to 21 there is shown a roof system 800 of the building. The roof system 800 includes a SIP 820, a perimeter bracket 830 positionable about the perimeter of the building, and a ridge bracket 850 positionable at a ridge 900 of the building.

[0243] The SIP 820 is slidably attachable to the perimeter bracket 830.

[0244] The perimeter bracket 830 has a wall portion 832, a top flange 834 connected to the wall portion 832 and a base flange 834 connected to the wall portion 832.

[0245] When in position the wall portion 832 is substantially vertical.

[0246] The SIP 820 has an elongate attachment member 840 configured to attach the SIP 820 to the perimeter bracket 830.

[0247] The attachment member 840 is attached to an underside of the SIP 820.

[0248] The attachment member 840 has a profile with a first portion 842 and a second portion 844. The first portion is attached to the SIP 820.

[0249] The attachment member 840 is configured to engage with the top flange 834. The second portion 844 and the SIP 820 define a cavity, wherein the cavity is adapted to receive a portion of the top flange 834. The cavity has a width of approximately a width of the top flange 834 of the perimeter bracket. The cavity has a length which defines the distance that the SIP 820 can slidably move when the top flange 834 is received within the cavity.

[0250] The top flange 834 is angled to a desired roof pitch angle.

[0251] The ridge bracket 850 is configured to slidably receive an end of the SIP 820.

[0252] The ridge bracket 850 has a wall portion 852, a top flange 854 connected to the wall portion and a base flange 856 connected to the wall portion. The top flange854 and the base flange 856 are angled to the desired roof pitch angle.

[0253] The top flange 834 aligns with the base flange 856.

[0254] The ridge 900 comprises a support of a boxed ridge beam supported bySIP gable walls for a single-sided roof or post sections for a two-sided roof. The ridge 900 further comprises a ridge cap 910. The ridge cap 910 covers the top flange 854.

[0255] The base flange 836 is secured to a perimeter frame member 730 of the ceiling system 700.

[0256] The roof system 800 includes a corrugated roof sheet 860 attached to the SIP 820.

[0257] In use, the perimeter bracket 830 is installed on the perimeter frame member 730 of the ceiling system 700 and the ridge bracket 850 is installed at the ridge 900. The SIP 820 is slid towards the ridge 900 to be received by the ridge bracket 850. The SIP 820 is then slid in the opposite direction to engage the attachment member 840 with the top flange 834. The SIP 820 is then secured in place.ADVANTAGES

[0258] An advantage of the preferred embodiment of the building system includes that the building system effectively uses structural insulated panels (SIPs) to replace traditional floor, wall, ceiling and roof construction systems. The building system overcomes the known detriments of using additional load-bearing structural members with SIPs. By enabling the effective use of SIPs while maintaining load-bearing functionality, the building system of the present invention simplifies construction processes and reduces material usage. Compared with conventional construction technology the preferred embodiment of the building system enhances structural integrity, improves thermal performance, is efficient, and is cost effective.

[0259] Another advantage of the preferred embodiment of the building system is that the adjustable posts reduce the necessity for high levels of accuracy at the time of securement to the ground. The adjustable posts allow for post-installation adjustments, ensuring the support posts are correctly aligned and secured even if their initial placement was imprecise. This approach enhances construction efficiency,reduces labour costs, and minimises potential errors associated with traditional methods of support post installation. The adjustable posts allow for horizontal and vertical adjustments. The adjustable posts reduce the need for exact placement of the posts during initial setup. The adjustable posts enhance the overall stability and integrity of the elevated floor structure.

[0260] A further advantage of the preferred embodiment of the building system includes that the array of stake tubes of the adjustable posts enable an alternative mechanism to anchor the structure to the ground. The stake tube array allows the base plate to be anchored without requiring concrete.

[0261] Another advantage of the preferred embodiment of the building system is that the first wall system is suitable for structures where the corners of the wall do not require full protection. The first wall system provides a streamlined method for forming a wall frame suitable for receiving an expanded polystyrene core. Traditional lightweight wall frames with mitre joints are difficult to manufacture out of light gauge metal members. The first wall system provides an alternative to traditional light-weight metal wall frames.

[0262] A further advantage of the preferred embodiment of the building system includes that the second wall system is suitable for structures where continuous support at the corners of the external sheets is required. The flanges provide for enhanced load bearing capacity.

[0263] Another advantage of the preferred embodiment of the building system is that the second wall system enables the integration of a tie-down system without requiring long tie-down rods. Long tie-down rods can be difficult to install and can present issues when trying to waterproof the building.

[0264] A further advantage of the preferred embodiment of the building system includes that the third wall system enables integration of SIPs and traditional wooden wall frames. In comparison to conventional wall systems, the third wall system provides improved structural integrity against surface loads and racking forces. By using timber wall components, the wall panels of the third wall system can be constructed without the need for specialised testing.

[0265] Another advantage of the preferred embodiment of the building system is that the use of SIPs for the ceiling system and roof system eliminates the traditional multicomponent ceiling and roof assembly, which typically includes trusses, ceiling battens, roof battens, insulation, and roof sheeting. The SIPs enable a streamlinedconstruction process and reduce the need for skilled labour. The SIPs eliminate the traditional requirement for separate top and bottom chords and webbing by using the SIPs to form the ceiling and roof structures directly. The utilisation of SIPs reduces material usage, enhances energy efficiency, and improves thermal performance. Additionally, the construction method ensures structural integrity, safety during construction, and creates an open, unencumbered loft space beneath the roof, allowing for a clean, pitched design.

[0266] A further advantage of the preferred embodiment of the building system is that the ceiling system eliminates the need for workers to operate at the top of a wall frame.

[0267] Another advantage of the preferred embodiment of the building system includes that the roof system removes the need for the roof to be trafficked during installation. The roof system can be installed by standing on the completed ceiling system.VARIATIONS

[0268] It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.

[0269] Throughout the description and claims of this specification the word “comprise” and variations of that word such as “comprises” and “comprising”, are not intended to exclude other additives, components, integers or steps.

Claims

CLAIMS1. A floor system for a building, including a floor panel including a structural insulated panel (SIP) and a reinforcing panel, wherein the reinforcing panel is positionable adjacent a side of the SIP; a perimeter frame member positionable about the perimeter of the building; and a support flange attachable to the perimeter frame member and configured to support the floor panel.

2. A floor system according to claim 1 , wherein the perimeter frame member has a substantially C-shaped profile with a base portion, a side portion and a top portion, and wherein the side portion has a length substantially equal to a width of the floor panel.

3. A floor system according to claims 1 or 2, wherein, the reinforcing panel has a plurality of parallel ridges and grooves, and the support flange has a length of at least the distance between adjacent ridges.

4. A floor system according to any one of claims 1 to 3, wherein the floor system includes at least two floor panels which are joinable together to form a floor, each floor panel is joinable by a side cap member with a substantially C-shaped profile, said side cap member is either integral with another side cap member or attachable with another side cap member, wherein each side cap member is positionable at a joinable end of the corresponding floor panel, and wherein the side cap members are integral or attachable together.

5. A floor system according to any one of the preceding claims, wherein the floor system perimeter frame member is supported by one or more adjustable posts, each adjustable post including a base plate and an upright support, and wherein the upright support is slidably movable along a top face of the base plate.

6. A floor system according to claim 5, wherein the upright support has an upper female portion, a lower male portion and a support foot on a lower end of the lower male portion, wherein the lower male portion is at least partially received within theupper female portion, wherein when in position the upper female portion is slidably moveable relative to the lower male portion along a substantially vertical axis, and wherein the upper female portion is securable in position relative to the lower male portion.

7. A floor system according to any one of claims 5 or 6, wherein the base plate has one or more anchorage members configured to provide stability to the base plate when the adjustable post is secured in position with concrete.

8. A floor system according to any one of claims 5 to 7, wherein the base plate has one or more stake tubes, each stake tube being configured to receive a corresponding stake, wherein each stake is configured to be driven into the ground to secure the corresponding adjustable post.

9. A floor system according to any one of claims 5 to 8, wherein each of the one or more adjustable posts has a top plate configured to support the perimeter frame member, and wherein the position of the top plate relative to the upper female portion is adjustable.

10. A building system including, a floor system according to any one of the preceding claims; a wall system including at least one wall with a wall frame; a ceiling system including ceiling panel including a SIP and a reinforcing panel positionable adjacent a side of the SIP; a ceiling perimeter frame member positionable about the perimeter of the building; and a ceiling panel support flange attachable to the ceiling perimeter frame member and configured to support the ceiling panel; and a roof system.

11. A building system according to claim 10, wherein the wall frame is comprised of a single elongate frame member, the frame member having a profile with a web section and two flange portions, the flange portions having gaps along the length ofthe frame member, and wherein the frame member is able to be bent during preparation for installation at the web section adjacent the gaps in the flange portions to form the wall frame.

12. A building system according to claim 10, wherein the wall frame is comprised of a plurality of elongate frame members, each of the plurality of frame members has a profile with a web section and two flange portions, wherein a first of the plurality of frame members has gaps in the web section at one end, wherein the gaps define a tab portion, wherein the tab portion is engageable with a web section of a second of the plurality of frame members, and wherein the wall frame is constructed to align the flange portions of adjacent frame members to form a continuous flange around an edge of the wall frame.

13. A building system according to claim 10, wherein the wall frame is comprised of a primary frame and a secondary frame, the primary frame being comprised of a plurality of elongate primary frame members, each primary frame member having a longitudinal recess, the secondary frame being comprised of a plurality of elongate secondary frame members, and wherein a portion of each secondary frame member is receivable within the recess of a corresponding primary frame member.

14. A building system according to any one of claims 10 to 13, wherein the ceiling further includes a ceiling batten array positioned beneath the ceiling panel, and a ceiling cover sheet, and wherein the ceiling cover sheet and the reinforcing panel define a ceiling void.

15. A building system according to any one of claims 10 to 14, wherein the roof system includes a perimeter bracket positionable about the perimeter of the building; a SIP with an attachment member configured to attach the SIP to the perimeter bracket; and a ridge bracket positionable at a ridge of the building and configured to slidably receive the SIP.

16. A method of constructing a building, the building including a floor system as claimed in any one of claims 1 to 15, the method including positioning a perimeter frame member about the perimeter of the building and securing the perimeter frame member to one or more posts or walls of the building; attaching a support flange to the perimeter frame member; and supporting the floor panel on the support member.

17. A method of constructing a building according to claim 16 wherein the building further includes an adjustable post according to any one of claims 5 to 15, wherein the method includes positioning a base plate at a desired location about the perimeter of the building; securing the base plate in position relative to a ground surface; positioning an upright support on the base plate; slidably moving the upright support relative to the base plate to a desired position; and securing the upright support in position relative to the base plate.

18. A method of constructing a building according to claims 16 or 17 wherein the building further includes a wall system according to claim 12, wherein the method includes engaging a tab portion of at least one of a plurality of frame members with a web section of another of the plurality of frame members; and securing the tab portion to the corresponding web section to form a wall frame.

19. A method of constructing a building according to any one of claims 16 to 18 wherein the building further includes a roof system according to claim 15, wherein the method includes positioning a ceiling perimeter bracket about the perimeter of the building; positioning a ridge bracket at a ridge of the building; and moving a SIP to be received by the ridge bracket; and moving the SIP to engage the attachment member with the ceiling perimeter bracket.

20. A kit for the building system as claimed in any one of claims 10 to 15.

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