Modular building systems

Abstract

A building module for forming a building structure, the module being made of a concrete mixture material using a substantially automated process in which the concrete mixture is dispensed in a plastic state, the module comprising a first layer of the concrete mixture for forming a first face of the module, a second layer of the concrete mixture for forming a second face of the module, and a core layer formed intermediate the first layer of concrete mixture and the second layer of concrete mixture, the core layer being substantially continuous and substantially embedded within the first and second layers, wherein the module, when cured, includes one or more side walls of the building structure integrally with the roof of the structure extending between the side walls to form the module.

Description

[0001] Modular Building Systems

[0002] Field of the invention

[0003] The present description relates to 3-D printing or 3-D extrusion of concrete mixtures to form structural concrete building modules for use in modular building systems.

[0004] In one form the present description relates to 3-D printing of individual concrete structural modules in one orientation which modules when in a different orientation are assembled together to form concrete building structures.

[0005] In one form the present description relates to forming individual concrete structural modules using 3-D printing of a concrete mixture at one location and assembling the modules into a concrete building structure at a different location.

[0006] In one form the present description relates to methods of forming individual concrete modules in a first orientation using 3-D printing of suitable concrete mixtures as one step in a modular building system.

[0007] In one form the present description relates to methods of assembling individual concrete modules when in a second orientation to form a building structure as one step in a modular building system in which the individual modules are formed remotely from where the modules are assembled.

[0008] Although the present description refers in particular to one or more specific embodiments it is to be noted that the scope of protection afforded by the description is not restricted to the described embodiments but rather the scope of protection is more extensive so as to include other forms, modifications or variations of the described embodiments and the use of the various embodiments in applications other than specifically described herein.

[0009] Background

[0010] Although kit homes or similar kit-style homes made from interlocking components in one form or another exist, such previously available homes have not been entirely satisfactory for one or other reasons, including having inadequate insulation and sound proofing properties rendering the houses uncomfortable to occupy on occasions. Additionally, existing kit houses have high maintenance expenses due to the inherent nature of the individual components from which the homes are made and erected, such homes being usually made from lightweight materials to reduce costs and ease of transportation which lightweight materials are not usually durable or long lasting, particularly when exposed to adverse environments in harsh locations, such as for example, remote geographical areas. Attempts to increase the durability of such relocatable or kit homes have resulted in using more heavy-duty components which increases the weight and complexity of such homes, particularly as the kit of components require transportation to the eventual site of the home. So as to address the disadvantages of using more heavy weight components, attempts have been made to make and construct the components of a home in situ such as at the site of the home which is to say such homes are made and erected at the same location.

[0011] Making and erecting homes at the home site often encounters problems due to unforeseen circumstances such as increased construction complexity, difficult site limitations, material cost overruns and similar, all of which introduce problems and delays into the construction process. Other problems which can arise during existing on site manufacturing and erection processes include defective houses being constructed with defects such as rapid moisture loss from the materials used in the construction when such materials are formed or moulded on site which can lead to extensive cracking, lack of vertical support, inadequate drying, inconsistent material quality and similar. Furthermore, making the components on site, particularly when moulded or using formwork such as timber or moulds, requires transportation of the manufacturing equipment used to make or mould the building components in addition to transporting the building materials, including raw materials, used to make or mould the components. Furthermore, manufacturing equipment can be heavy and complex and requiring many individual parts to be joined together in the correct sequence and in cooperating relationship with adjacent parts for the overall process to work satisfactorily. Additionally, set up and adjustment of the manufacturing equipment once delivered on site requires significant time, effort and expense as well as expert know-how from well trained personnel before making of the home can commence. Thus, it is desirable to have a building system that requires the manufacturing equipment be set up only once for repeated use at that site to make multiple homes at different sites. Accordingly, there is a need to provide a building system for more economical manufacturing and constructing homes by using methods of building homes, particularly modular concrete homes which alleviate at least some of the disadvantages of existing on-site manufacture and erection of homes._The embodiments in the present description seek to address the above, and / or at least provide a useful alternative.

[0012] According to one aspect of the present invention there is provided a building module for forming a building structure

[0013] the module being made of a concrete mixture material using a substantially automated process in which the concrete mixture is dispensed in a plastic state

[0014] the module comprising a first layer of the concrete mixture for forming a first face of the module, a second layer of the concrete mixture for forming a second face of the module, and a core layer formed intermediate the first layer of concrete mixture and the second layer of concrete mixture, the core layer being substantially continuous and substantially embedded within the first and second layers

[0015] wherein the module when cured includes one or more side walls of the building structure integrally with the roof of the structure extending between the side walls to form the module.

[0016] According to one aspect of the present invention there is provided a building module for forming a building structure

[0017] the module made of a concrete material using a substantially automated process to dispense the concrete material in a plastic state

[0018] the module comprising a first layer of the concrete material for forming a first face of the module, a second layer of the concrete material for forming a second face of the module, and a core layer formed intermediate the first layer of concrete material and the second layer of concrete material, the core layer being substantially continuous and substantially embedded within the first and second layers

[0019] wherein the module which is formed at a first location is transportable to a second location for assembly to form the building structure at the second location.

[0020] According to one aspect of the present invention there is provided a building structure comprising two or more individual building modules

[0021] the individual modules being made of a concrete material using a substantially automated process to dispense the concrete material in a plastic state

[0022] the module comprising a first layer of the concrete material for forming a first face of the module, a second layer of the concrete material for forming a second face of the module, and a core layer formed intermediate the first layer of concrete material and the second layer of concrete material, the core layer being substantially continuous and substantially embedded within the first and second layers

[0023] such that the modules when assembled together form the building structure having one or more side walls and an integral roof extending between the side walls in which the building structure is assembled from the individual modules in which the first or second face of one module of an adjacent pair of modules is in abutting relationship with first or second face of the other module of the pair of modules to form the roof of the building structure.

[0024] According to one aspect of the present invention there is provided a building structure comprising two or more individual building modules in which each module is made of a concrete material using a substantially automated process to dispense the concrete material in a plastic state

[0025] the module comprising a first layer of the concrete material for forming a first face of the module, a second layer of the concrete material for forming a second face of the module, and a core layer formed intermediate the first layer of concrete material and the second layer of concrete material, the core layer being substantially continuous and substantially embedded within the first and second layers

[0026] the module being formed at a first location for transportation to a second location different from the first location

[0027] wherein the building structure is assembled from the individual modules at the second location in which the first or second face of one module of an adjacent pair of modules is in abutting relationship with first or second face of the other module of the pair of modules.

[0028] According to one aspect of the present invention there is provided a method of forming a building module comprising the steps of

[0029] dispensing an amount of concrete mixture along a predetermined pathway to form a first layer of a concrete material

[0030] locating a core layer upon the first layer in alignment therewith

[0031] dispensing a further amount of concrete mixture along a predetermined pathway to form a second layer of concrete material in alignment with the first layer

[0032] the core layer being an intermediate layer embedded within the first and second layers

[0033] wherein after curing of the concrete mixture the first layer, second layer and core layer form the module having an integral roof section extending between an opposed side sections.

[0034] According to one aspect of the present invention there is provided a method of forming a building structure by assembling individual building modules

[0035] the method comprising the steps of

[0036] forming a first building module from a concrete material in a substantially horizontal orientation using 3-D printing or extrusion of the concrete material in which the module includes a first layer, a second layer and an intermediate core layer and has an integral roof section extending between opposed side wall sections

[0037] lifting the module from the horizontal orientation to a substantially vertical orientation

[0038] connecting the building module to a similar second building module when the modules are in the vertical orientation in side-by-side abutting relationship to from the building structure.

[0039] Brief description of embodiments

[0040] Building modules in accordance with the present description are made using additive manufacturing techniques in which objects are formed or built by repeatedly adding layer upon layer of material extruded from a moveable nozzle, the movement of which is controlled in accordance with instructions from a digital file to the required shape and size. Typically, the additive manufacturing technique is a 3-D printing technique or 3-D extrusion technique or similar in which a suitable material in a plastic condition is dispensed from the moveable nozzle to form a layer of the plastic material which is left to cure and harden sufficiently to allow the next layer to be deposited thereon. In the context of the present description the object being formed is a concrete house or dwelling made by depositing multiple layers of wet concrete repeatedly one upon the other along a predetermined pathway in alignment with each other to form the shape and size of house and then allowing the concrete to harden sufficiently to enable the module to be moved.

[0041] The material from which the modules are made can be any suitable or convenient material, or materials or mixture or mixtures or combination of materials. Typical forms of the material include concrete, cement, concrete-like materials, concrete substitute materials, cementitious materials generally or mixtures such as pastes and similar. More typically, the concrete material is a concrete mixture which is suitable for 3-D printing of concrete, particularly large concrete products such as components of a building. In forms the concrete mixture contains other materials in addition to sand, cement, aggregate and water such as for example fibrous materials, including fibre reinforcement, typically in the form of natural or synthetic fibres, polymeric fibres, metallic fibres, steel fibres, glass fibres, polyester fibres and the like. One form of concrete material is a reinforced geopolymer concrete of the type that typically uses waste and sustainable materials.

[0042] Additionally, the concrete mixture can contain processing aids or additives. In forms, the additives include accelerants, retarders, as well as other processing agents, such as lubricants, for modifying the properties of the finished concrete products, mainly the concrete modules. Common examples of additives used in 3D printed concrete include superplasticizers, shrinkage-reducing agents, metakaolin, hydrophobic polymers, and calcium-based admixtures. A significant advantage of 3D printing technology is its capacity to incorporate materials typically considered industrial by-products, such as fly ash, slag, and silica fume. The desired properties of 3D printed concrete— such as enhanced flowability, workability, and buildability— can be achieved through the judicious inclusion of such additives, while also promoting environmental sustainability.

[0043] The building module can have any suitable or convenient form, type, size, style, shape, profile or contour. One form of the module is a structural module having integral components formed with the structure of the module. In one form, the structural module has side walls with an integral roof section or roof extending between the side walls. Typically, there are two side walls, more typically two opposed side walls being side walls on opposite sides of the building. By forming the walls and roof together, the overall integrity and strength of the building is improved, as well as contributing to the cost effective construction of the house by reducing the number of components needed to build the house. In another form, the module is a structural module having integral components formed with the structure of the module wherein the structure of the module comprises side walls with integral roof section and with integral floor section. In one form, the structural module may have side walls integral floor section or floor section extending between the two side walls.

[0044] The side walls have internal surfaces and external surfaces in which the internal surface forms the interior of the building structure, typically the interior walls of rooms formed within the building structure and the external surfaces form the exterior of the building structure such as the external walls of the building structure. Similarly, the roof section of the module extending between the two opposed side walls has an external surface forming the roof or the outer surface or exposed surface of the roof and an internal surface forming the ceiling of the roof. Similarly, the floor section of the module extending between the two opposed side walls has an external surface forming the outer surface at the floor base or exposed surface of the building which will stand on the ground and an internal surface forming the floor of the building. Generally, the first layer forms the external surface of the walls and roof, and the second layer forms the internal surface of the walls and ceiling. It is to be noted that the module is formed in the factory in the horizontal orientation and lifted or otherwise hoisted into the vertical orientation for assembly to form the building structure.

[0045] In forms, the first layer is the layer of concrete located between the core and the exterior surface of the side walls and roof section and can be regarded as the exterior layer forming the external wall or side section of the module.

[0046] In forms, the second layer is the layer of concrete located between the core and the interior surface of the sides or side walls and roof section and can be regarded as the interior layer forming the internal walls or side wall sections of the module. It is to be noted that the concrete material of the first and second layers has the same composition. However, in some forms, the compositions of the two layers may be different.

[0047] In forms, the sides or side walls of the module are provided with discontinuities such as for example openings, apertures, holes, ports or similar corresponding to doorways, windows, ventilation screens or similar. In forms, the walls are manufactured to receive fittings and fixtures during the construction of the house or similar, such as for example services and facilities including power, plumbing, wiring, waste pipes, drainage and the like.

[0048] In forms, the building module has side faces or side edges. Typically, there are two side faces or edges which are referred to as a first or lower side face forming one end of the module referred to as the lower end and a second or upper side face forming the other end of the module referred to as the upper end when the module is in the horizontal orientation. The lower side face or lower face or lower end is formed first during manufacture of the building module in the horizontal orientation as the first filament or tier of plastic concrete is deposited and is the face in contact with the solid substrate upon which the module is formed in the factory, usually the factory floor. The upper side face or upper face or upper end is the last uppermost filament or tier of plastic concrete deposited on the building module when in the horizontal orientation. Both upper and lower faces completely surround and obscure the core layer or web in the finished module.

[0049] After the module is lifted into the vertical orientation the upper and lower faces or ends are the faces or edges of the module which are in abutting opposed contact with each other when two modules are connected to each other in a side-by-side abutting relationship to form the building structure. In one form, the surfaces of the lower and upper faces are generally smooth to allow close contact between them.

[0050] It is to be noted that each of the adjacent filaments within the stacked array of individual layers or tiers are printed in the reverse order or boustrophedonically to promote interlocking between adjacent concrete layers or tiers to improve bonding between the separate layers. Thus, the direction of printing of individual filaments of concrete alternates as the layers are printed.

[0051] The building structure can be of any suitable or convenient form and have any reasonable size, shape, style, profile or contour in accordance with the modules selected to form the building structure. In forms, the building structure is a house, unit, cottage, portable home, relocatable house, temporary accommodation, or other domestic dwelling, particularly a low cost affordable house that is able to be produced in a relatively short time frame as compared to homes built using more traditional or conventional methods, such as, for example, to provide more or less temporary shelter in times of crises including natural disasters, social upheaval, sporting events, cultural events, mining sites or the like. The homes produced in accordance with the present description have particular application in producing low-cost affordable housing in regional or impoverished areas for occupancy by socially or economically disadvantaged peoples or temporary or permanent accommodation in remote locations, such as mining camps, construction sites or encampments, farms and other agricultural establishments. Typically, the material of the first layer is identical to the material of the second layer so that both the first layer and the second layer can be produced in sequence by the same equipment using the same nozzle to dispense the same cementitious material with the core web or other reinforcement strategically placed in alignment with the layers at the appropriate time in the sequence of making the module.

[0052] In one form, the intermediate layer or core of the module is a web, typically in the form of a truss, brace, joist, beam, strut, prop, mesh, perforated strip or perforated plate or similar supporting structure provided with arcuate sections, bends, curves, apertures, slots, slits, voids or the like. Although the web can have any suitable or convenient form, typically, the web or truss has alternately arranged oppositely curved sections. More typically, the curved sections are concave and convex curved sections, even more typically, smoothly curved alternately arranged concave and convex curved sections over the entire length thereof or over most of the length thereof. Forms of the web are generally sinusoidal, zig zag shaped, sinuous, boustrophedonic, meandering, or similar. Forms of the web or truss are arranged generally horizontally when the module is being manufactured in the generally horizontal orientation. The web or truss or similar is securely anchored to both the first layer and the second layer by being embedded within or completely surrounded by the concrete material of the first and second layers. Thus, the concave and convex parts of the web invade into both the internal and external layers of the module to form a selflocking arrangement or pattern to enhance the strength and rigidity of the module, and hence the structural integrity of individual modules and the building structure made therefrom.

[0053] In forms, the intermediate layer has gaps, voids, spaces, or similar, typically defined in between the alternately curved sections, particularly the internally curved concave sections of the truss or web and the straight sections. In forms, the voids hold an insulation material, such as sound proofing material and / or thermal insulation layer or similar, typically in the form of a foam or aerated material provided with cells, including open and closed cells. Preferably, the foam insulation material can be a Polyurethane foam layer or similar, which is located within and fills the space extending between the inner and outer layers around and through the sections of the web. In another form, voids may not hold any insulation material, as the printed structure itself already demonstrates excellent thermal performance.

[0054] In forms, the module is provided with reinforcements or reinforcing elements located between each layer of the module. One form of reinforcement is a generally planar section such as for example a sheet, panel, layer, or the like, preferably a perforated sheet or panel having multiple holes, apertures, openings or the like located in alignment with the first and second layers of concrete. Typically, the reinforcement sheet or panel is arranged to extend substantially parallel to the concrete layers. Forms of the reinforcement include elongate reinforcing steel members, typically in the form of a mesh or interconnected network of individual rods, bars or other elongate sections or similar, which are located to provide additional support for the module and connectors within the module to improve the structural integrity of the module. By having a consistent profile, the reinforcements along with the printed concrete layers of the module form a closed-shaped house structure.

[0055] One form of reinforcement is a horizontally arranged reinforcement which is oriented substantially perpendicular to the direction of printing of the individual layers in the module. Forms of the reinforcements include rods, bars, shafts, poles, posts, stays, struts, spurs, or the like. In forms of the module there are multiple reinforcements securely interconnected to each other and arranged horizontally, such as by welding. In one form, the web or truss comprises a pair of spaced apart lengthwise extending rods or bars in parallel relationship defining a space therebetween, typically made from rebar or similar, and a sinusoidal bar or rod meandering zig-zaggedly from one rod to the other in the space defined between the pair of parallel rebar rods. In one form, the sinusoidal rod is welded to the straight bars at the change in direction of the curved sections of the sinusoidal rod, particularly, the internal corners of the concave and convex corners. The reinforcements may improve the strength and integrity of the modules and may increase the overall load bearing capacity of the modules and more importantly, the building structure made from assembling interconnectedly individual modules together.

[0056] In forms, the modules are provided with fittings, typically embedded within the layers of the module to serve as lifting anchors of the module during transportation and assembly processes of the modules. In one form, the lifting anchors are made from steel, such as high strength steel, typically in the form of a double wavy rod or bar, and are provided with threaded sections or ports at both ends thereof for forming connection points for connecting to other fittings for other functions such as forming connection points for attachment of fittings used to lift or secure the module, particularly during hoisting and transporting the module and during assembly of the modules into the building structure.

[0057] The structure of the module having a first layer in the form of an outer layer, a second layer in the form of an inner layer and a continuous web connecting both the first and second layers to one another forms a self-supporting module having the necessary structural rigidity and strength for forming a building component of the building structure. Such a three-layer concrete module may provide adequate insulation, soundproofing, fire resistance and impermeability to moisture penetration for use as a suitable domestic dwelling.

[0058] Forms of the module include fittings and fixtures which are formed simultaneously as the module is produced as part of the 3-D printing or extrusion process or are added to the module after forming but before curing or after curing. One form of fitting is a lifting element or an attachment to assist in lifting the module from the horizontal manufacturing orientation on the floor of the factory to a vertical orientation when assembling the module to form the building structure. One example of the lifting element is a lifting anchor for ease of lifting the individual module for easy rotation, transportation, and assembly. One form of the lifting anchor is a double wavy tail rod or shaft, typically made from rebar or similar.

[0059] One form of the fittings of a module is an interlocking mechanism or fastening. Forms of the interlocking mechanism include connectors for connecting two adjacent modules to one another. Typically, the connector is an interlocking connector for interlockingly connecting two modules together or linking two abutting modules to one another in side-by-side relationship when assembling the modules to form the building.

[0060] A supplementary connection system between adjacent or intersecting modules incorporates specialized cables engineered to provide enhanced flexibility, facilitating the structure's ability to adapt to soil movements. These cables perform a function analogous to post-tensioning, while significantly reducing the complexity typically associated with traditional post-tensioned steel systems.

[0061] Forms of the module include modules which are self-insulated, standardised, factory produced and designed for assembly-based construction of building such as domestic dwellings.

[0062] Forms of the module and of the building constructed using the modules include integrated modular fit outs which can in some circumstances reduce, sometimes significantly, the on-site costs, work, waste, and construction time.

[0063] Brief description of the drawinas

[0064] In order that the scope of protection may be more easily understood, an embodiment will now be described, by way of example only to illustrate aspects of the description, with reference to the accompanying drawings, in which:

[0065] Figure 1 is a schematic vertical cross section view of one form of a building module in a vertical orientation as installed upon one form of solid substrate.

[0066] Figure 2 is a schematic top perspective view of the form of the module of Figure 1 shown in isolation in a horizontal orientation as manufactured in a factory.

[0067] Figure 3 is a schematic top perspective view of one form of building structure comprising two individual modules assembled together in side-by-side abutting relationship in a vertical orientation located on a solid substrate.

[0068] Figure 4 is an enlarged schematic side elevation view of one form of a truss for forming the core layer of the building module.

[0069] Figure 5 is a schematic perspective view of a building module showing a lifting anchor in the form of a double wavy rod. Figure 6 is a schematic vertical cross section view of a form of a building module in a vertical orientation.

[0070] Detailed description

[0071] One form of module will now be described. As a preliminary, it is to be noted that the module is formed in a manufacturing position which is a substantially horizontal orientation such as, for example, with the lower end or face on the floor of a factory, and when completed, is lifted through about 90 degrees to a substantially vertical orientation by a suitable hoist into the assembled position. The module can be transported from the factory to the construction site in either the horizontal orientation as manufactured or in the vertical orientation as assembled.

[0072] Module, generally denoted as 10, is produced in a generally horizontal orientation, as shown in Figure 2, on the floor of a factory or other manufacturing facility using a 3-D printing technique in which a gantry is provided with a mobile nozzle or similar (not shown) from which a suitable concrete mixture is discharged or dispensed such as by printing or extrusion. The nozzle is capable of movement with three degrees of freedom along three mutually orthogonal axes, being the X, Y, and Z axes, corresponding to three different directions of movement, notably (1) back and forth horizontally, (2) side to side horizontally and (3) up and down vertically, to extrude a generally cylindrical plug of the concrete mixture, typically in the form of a filament, nurdle, rope, pipe, rod, tube, sausage or roll of concrete mixture along the precise trajectory as required to form the module. The filament of concrete is extruded from the nozzle to build up tiers or layers of concrete material one by one in stacked relationship, one upon the other to the required height of the module in the factory as the nozzle travels along a predetermined path, usually back and forth in alternating directions or boustrophedonically in accordance with the shape of the module, which process is referred to as additive printing. It is to be noted that the height of the stacked layers one upon the other corresponds to the width of the module when vertical as installed in the building structure in the form of a house. Further, it is to be noted that in some forms, the nozzle is supported by a gantry, whereas in other forms the nozzle is supported by one or more or robotic arms. In some forms, there are more than a single nozzle such as multiple nozzles, including two, three, four or more which can operate simultaneously and independently or in coupled combination to print different parts of the module.

[0073] Module 10 includes a first layer 12 of cementitious material which is deposited as several tiers or layers in side-by-side relationship on the floor of the manufacturing facility in the form of filaments or ropes to the required thickness of the first layer 12. It is to be noted that the first plugs, filaments or nurdles form one end face of module 10.

[0074] A layer of strengthening material in the form of a substantially continuous web or truss 14 having a pair of substantially parallel spaced apart straight outboard sections 15, 17 of rebar defining a gap therebetween in which is located a sinusoidal inboard section comprising straight sections 16 separated by alternately arranged oppositely curved sections in a concavely curved 18 and convexly curved 20 pattern is located upon first layer 12 to form the core of module 10. Although in one form, truss 14 is in the form of a pair of substantially parallel spaced apart lengthwise extending rods 15, 17 defining a space therebetween in which is located a substantially sinuous or sinusoidal length of steel or similar material having alternating arcuate or curved sections arranged in an alternating oppositely curved pattern as shown more particularly in Figures 1 and 4, truss or web 14 can have any suitable or convenient shape or form.

[0075] Module 10 further includes a second layer 22 of cementitious material dispensed from the nozzle of the 3-D printing equipment onto web 14 so that web 14 forms the core of module 10 as a layer intermediate first layer 12 and second layer 22 by being entirely embedded within module 10. It is to be noted that web or truss 14 is completely surrounded by concrete so that no part of the truss is exposed.

[0076] It is to be noted that truss 14 extends continuously substantially from one end of module 10 to the other end of module 10, or if the module includes side walls, roof and floor, as shown in Figure 6, truss 14 extends continuously throughout the module 10. Further it is to be noted that module 10 is substantially U-shaped having a first side or side wall 30 at one end thereof corresponding to the one leg of the "U" and a second side or side wall 32 at the opposite end thereof corresponding to the other leg of the "U" with a roof section 34 extending between the side walls 30, 32 corresponding to the web of the "U". In another form, module 10 can be substantially D-shaped as shown in Figure 6, having a first side or side wall 30 at one end thereof corresponding to the top of the "D" and a second side or side wall 32 at the opposite end thereof corresponding to the other leg of the "D" with a roof section 34 corresponding to the curved side of the "D" and a floor section 31 extending between the side walls 30, 32, corresponding to the straight side of the "D".

[0077] First layer 12, in addition to forming an external surface of side walls 30, 32 in the form of the exterior wall surface 36 of module 10 also forms the external roof surface 38 of the roof section 34 of module 10. Second layer 22, in addition to forming an internal surface of side walls 30, 32 in the form of the interior wall 40 of module 10 also forms the internal roof surface of roof section 34 in the form of ceiling 42 of module 10.

[0078] Insulation, typically a polyurethane material 44 is provided to fill the gaps 46 or interstices in truss 14 as shown more particularly in Figure 1.

[0079] With particular reference to Figure 5, there is shown one type of anchor in the form of a lifting rod, more particularly, a double wavy lifting rod 60 which extends transversely through the roof of the module to extend at either side thereof for cooperative engagement with a suitable hoist or crane for lifting module 10 as required. It is to be noted that the engineered double-wavy tail anchor 60 has three spaced apart oppositely curved sections 62, 64, 66 or s-bends and a lifting port 68 at either end. Such an arrangement, when embedded within the layers of module 10 as shown in Figure 5, presents a satisfactory solution for lifting applications, functioning as an integrated concrete beam within corner regions of module 10 without the need for supplementary structural elements. The distinct geometry of the double curved rod having oppositely inclined curved sections 62, 64, 66 distributed throughout the concrete units, enhances load-bearing capacity and effectively mitigates bending and shear stresses. Further, one end wall of module 10 of Figure 5 is provided with a cutout in the form of a window space 80 for receiving a window therein during fit out of the house incorporating module 10.

[0080] Module 10 is manufactured in a substantially horizontal orientation as shown in Figure 2. After curing, module 10 is hard enough to be transported to another site. Using the lifting points 68 provided by the double wavy rods 60, module 10 is hoisted by a suitable lifting device such as a crane to adopt a substantially vertical orientation whereupon the module is transported to a construction site for accurate placement on a suitable foundation, such as a concrete slab 50 (Figures 1 and 3) or similar, for secure anchoring thereto by suitable fasteners as shown in Figure 1. Once the first module is installed on slab 50 a second module is placed in close proximity to the first module and interlockingly connected thereto to form part of the house 52 as shown in Figure 3.

[0081] To address the environmental factors that impact concrete mixing, delivery, and printing— particularly, the fluctuations in ambient temperature and the pronounced variations in water temperature experienced during summer and winter— a dynamic temperature control system is instituted. This system is designed to meticulously regulate and maintain optimal printing speed and efficiency throughout the year. By ensuring that water temperature remains within a specified range, the system effectively mitigates the seasonal fluctuations in production capacity that can occur due to extreme weather conditions.

[0082] Moreover, it enhances overall productivity by allowing for consistent mixing and curing processes, thereby minimizing downtime associated with adverse temperature effects. The dynamic control of water temperature also plays a crucial role in regulating the cement hydration process, which is vital for achieving the desired strength and durability of the concrete. Furthermore, maintaining optimal hydration conditions significantly reduces the risk of thermal cracking, a common issue arising from rapid temperature changes that can compromise structural integrity. In summary, the implementation of a dynamic temperature control system not only stabilizes production rates but also contributes to the long-term performance and reliability of concrete structures.

[0083] Many modifications of the above embodiments will be apparent to those skilled in the art without departing from the scope of the present invention.

[0084] Advantages One or more of the embodiments of the present description have one or more of the following advantages.

[0085] Forms of the modules and / or buildings assembled from the modules may be of lower cost, quicker to produce, generate less waste than many traditional or conventional home building methods.

[0086] Modules and homes assembled from such modules produced by 3-D printing may be stable, durable and may require minimal labour for construction while providing good insulation and functionality.

[0087] Modules and homes assembled from such modules may be self-insulating, standardised, factory produced 3D printed modules having assembly based construction and integrated modular interior fit outs.

[0088] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0089] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

CLAIMS:

1. A building module for forming a building structure, the module being made of a concrete mixture material using a substantially automated process in which the concrete mixture is dispensed in a plastic state,the module comprising a first layer of the concrete mixture for forming a first face of the module, a second layer of the concrete mixture for forming a second face of the module, and a core layer formed intermediate the first layer of concrete mixture and the second layer of concrete mixture, the core layer being substantially continuous and substantially embedded within the first and second layers,wherein the module, when cured, includes one or more side walls of the building structure integrally with the roof of the structure extending between the side walls to form the module.

2. A building module for forming a building structure, the module made of a concrete material using a substantially automated process to dispense the concrete material in a plastic state,the module comprising a first layer of the concrete material for forming a first face of the module, a second layer of the concrete material for forming a second face of the module, and a core layer formed intermediate the first layer of concrete material and the second layer of concrete material, the core layer being substantially continuous and substantially embedded within the first and second layers,wherein the module which is formed at a first location is transportable to a second location for assembly to form the building structure at the second location.

3. A building structure comprising two or more individual building modulesthe individual modules being made of a concrete material using a substantially automated process to dispense the concrete material in a plastic state,the module comprising a first layer of the concrete material for forming a first face of the module, a second layer of the concrete material for forming a second face of the module, and a core layer formed intermediate the first layer of concrete material and the second layer of concrete material, the core layer being substantially continuous and substantially embedded within the first and second layerssuch that the modules when assembled together form the building structure having one or more side walls and an integral roof extending between the side walls in which the building structure is assembled from the individual modules in which the first or the second face of one module of an adjacent pair of modules is in abutting relationship with first or second face of the other module of the pair of modules to form the roof of the building structure.

4. A building structure comprising two or more individual building modules in which each module is made of a concrete material using a substantially automated process to dispense the concrete material in a plastic state,the module comprising a first layer of the concrete material for forming a first face of the module, a second layer of the concrete material for forming a second face of the module, and a core layer formed intermediate the first layer of concrete material and the second layer of concrete material, the core layer being substantially continuous and substantially embedded within the first and second layers,the module being formed at a first location for transportation to a second location different from the first location,wherein the building structure is assembled from the individual modules at the second location in which the first or second face of one module of an adjacent pair of modules is in abutting relationship with first or second face of the other module of the pair of modules.

5. A method of forming a building module comprising the steps of:dispensing an amount of concrete mixture along a predetermined pathway to form a first layer of a concrete material,locating a core layer upon the first layer in alignment therewith,dispensing a further amount of concrete mixture along a predetermined pathway to form a second layer of concrete material in alignment with the first layer,the core layer being an intermediate layer embedded within the first and second layers ,wherein after curing, the first layer, second layer and core layer form the module having an integral roof section extending between opposed side sections.

6. A method of forming a building structure by assembling individual building modules the method comprising the steps of:forming a first building module from a concrete material in a substantially horizontal orientation using 3-D printing or extrusion of the concrete material in which the module includes a first layer, a second layer and an intermediate core layer and has an integral roof section extending between opposed side wall sections,lifting the module from the horizontal orientation to a substantially vertical orientation,connecting the building module to a similar second building module when the modules are in the vertical orientation in side-by-side abutting relationship to form the building structure.

7. A building module or method according to any preceding claim in which the substantially automated process is an additive manufacturing technique in the form of a 3-D printing technique or 3-D extrusion technique or similar in which a suitable material in a plastic condition is dispensed from the moveable nozzle to form a layer of the plasticmaterial which is left to cure and harden sufficiently to allow the next layer to be deposited thereon.

8. A building module or method according to any preceding claim, wherein the material from which the modules are made is concrete, cement, a concrete-like material, a concrete substitute material, a cementitious materials or mixtures such as pastes and similar.

9. A building module or method according to any preceding claim, wheren the concrete mixture contains other materials in addition to sand, cement, aggregate and water, such as, for example, fibrous materials, including fibre reinforcement, typically in the form of natural or synthetic fibres, polymeric fibres, metallic fibres, steel fibres, glass fibres, polyester fibres and the like particularly a reinforced geopolymer concrete of the type that typically uses waste and sustainable materials optionally containing processing additives.

10. A building module or method according to any preceding claim, wherein the module has side walls with an integral roof section, wherein the side walls are two opposed side walls being side walls on opposite sides of the building.

11. A building module or method according to any preceding claim, wherein the side walls have internal surfaces and external surfaces, wherein the internal surface forms the interior of the building structure, typically the interior walls of rooms formed within the building structure and the external surfaces form the exterior of the building structure such as the external walls of the building structure.

12. A building module or method according to any preceding claim, wherein the roof section of the module extending between the two opposed side walls has an external surface forming the roof or the outer surface or exposed surface of the roof and an internal surface forming the ceiling of the roof.

13. A building module or method according to any preceding claim, wherein the module is formed in the factory in the horizontal orientation and lifted or otherwise hoisted into the vertical orientation for assembly to form the building structure.

14. A building module or method according to any preceding claim, wherein the first layer is the layer of concrete located between the core and the exterior surface of the side walls and roof section, and can be regarded as the exterior layer forming the external wall or side section of the module, and wherein the second layer is the layer of concrete located between the core and the interior surface of the sides or side walls and roof section andcan be regarded as the interior layer forming the internal walls or side wall sections of the module.

15. A building module or method according to any preceding claim, wherein the sides or side walls of the module are provided with discontinuities, such as, for example, openings, apertures, holes, ports or similar corresponding to doorways, windows, ventilation screens or similar.

16. A building module or method according to any preceding claim, further comprising side faces or side edges in which one of the side faces or edges is a first or lower side face and another of the side faces or side edges is a second or upper side face when the module is in the horizontal orientation wherein the lower side face or lower face or edge is formed first during manufacture of the building module in the horizontal orientation as the first layer of plastic concrete dispensed and is the face in contact with the solid substrate upon which the module is formed in the factory on the factory floor and the upper side face or upper face or edge is the last uppermost layer of plastic concrete deposited on the building module when in the horizontal orientation.

17. A building module or method according to any preceding claim, wherein both the upper and the lower faces completely surround and obscure the core layer or web in the finished module.

18. A building module or method according to any preceding claim, wherein after the module is lifted into the vertical orientation, the upper and lower faces or edges are the faces or edges of the module which are in abutting opposed contact with each other when two modules are interconnected to each other in side-by-side abutting relationship to form the building structure.

19. A building module or method according to any preceding claim, wherein the surfaces of the lower and upper faces or edges are generally smooth to allow close contact therebetween.

20. A building module or method according to any preceding claim, wherein the intermediate layer or core of the module is a web in the form of a truss, brace, joist, beam, strut, prop, mesh, perforated strip, perforated plate or similar supporting structure provided with arcuate sections, bends, curves, apertures, slots, slits, voids or the like.

21. A building module or method according to any preceding claim, wherein the web or truss has alternately arranged oppositely curved sections being smoothly curved alternately arranged concave and convex curved sections separated by straight sections over the entire length of the web or over most of the length thereof.

22. A building module or method according to any preceding claim, wherein the web or truss is securely anchored to both the first layer and the second layer by being embedded within or completely surrounded by the concrete material of the first and second layers.

23. A building module or method according to any preceding claim, wherein the intermediate layer does not include an insulation material.

24. A building module or method according to Claims 1 to 24, wherein the intermediate layer includes an insulation material, such as sound proofing material and / or thermal insulation layer, typically in the form of a Polyurethane foam layer or similar which is located within and fills the space extending between the inner and outer layers.

25. A building module or method according to any preceding claim, wherein the module further comprises reinforcements or reinforcing elements located between each layer of the module wherein the reinforcement is in the form of reinforcing steel members, typically in the form of mesh or other perforated items or similar which are located at spaced apart intervals to provide additional support for the module and connectors within the module to improve the structural integrity of the module.

26. A building module or method according to any preceding claim, wherein the reinforcement is oriented substantially perpendicular to the direction of printing of the individual layers in the module wherein the reinforcements include mesh, perforated plates, rods, bars, shafts, poles, posts, stays, struts, spurs, or the like.

27. A building module or method according to any preceding claim, wherein the reinforcements are in the forms of rods, spears, barbs, rebar, or similar.

28. A building module or method according to any preceding claim, wherein the module further includes a lifting anchor for hoisting the module during transportation and assembly processes of the modules, wherein the lifting anchor is a double wavy rod having curved sections, including oppositely curved sections, preferably three alternately curved sections.

29. A building module or method according to any preceding claim further comprising an interlocking mechanism or fastening for lockingly interconnecting two adjacent modules to one another in side-by-side abutting joined relationship.

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