Apparatus and methods for manufacturing a building structure

Abstract

The invention relates to apparatus and methods for manufacturing a building structure. An apparatus 10, 200 is disclosed for manufacturing the building structure, including methods for assembly of the

Description

Technical Field The invention relates to apparatus and methods for manufacturing a timber building structure. 5 Background It is known to manufacture timber building structures for buildings such as houses, offices, schools, care homes and hotels. Such building structures may be made from prefabricated timber panels which are manufactured in a factory. The timber panels, such as wall, floor and 10 ceiling panels, are transported to a building site for assembly into a building structure on preprepared concrete foundations. The timber panels typically comprise a frame of wood which is provided with a front and rear skin of Oriented Strand Board (OSB). The OSB is typically Grade 3 OSB having a thickness of up to 2cm, which is an engineered wood product formed of layered strands of wood in specific orientations. The fixtures, fittings and finishings of the 15 building are installed to complete the building after the timber building structure has been assembled at the building site. Such a way of constructing a building has many advantages when compared to more traditional building structures primarily constructed of bricks or blocks. These advantages 20 typically include speed of construction, improved overall efficiency of construction, reduced cost, improved insulation and reduced environmental impact of construction of the building structure. The known timber building structures are generally constructed in a similar manner to traditional brick or block buildings whereby the building is designed, 28 01 25 and the component parts of the building are transported to a building site and assembled to form the building. Whereas such timber building structures allow buildings to be assembled more quickly when compared to traditional brick or block buildings, there are still numerous disadvantages and problems with their manner of construction. 5 Building sites are notoriously difficult places in which to operate, and to project manage the construction of buildings in an efficient manner. The requirement to transport the timber panels to the building site for construction of the building does not promote the efficient running of the building site, or the efficient construction of the building. 10 A further demand being placed on new buildings is the increasing amount of legislation relating to improved energy efficiency, the use of sustainable building materials, and generally reducing the carbon footprint for constructing the building, and the use of the building throughout its lifetime. Such legislation is becoming increasingly important for new-15 build domestic housing. Whereas the known way of manufacturing timber building structures may provide an improvement in some of these areas, the manner in which they are constructed introduces a limitation on the possibility to control the costs of manufacture, which includes the financial and environments costs. Furthermore, since the known way of manufacturing timber building structures requires assembly of building panels onto concrete 20 foundations on a building site, the tolerance of dimensions and the overall quality control of the building structure may be compromised, which may cause gaps between panels and thereby heat or air to escape. This may have a consequential effect on limiting the energy efficiency for the overall building process, and for the finished building during use. 28 01 25 A further demand being placed on new buildings is the increasing requirement for affordable and high quality living accommodation. Such a requirement may be a particular need in relatively poorer regions or countries. For example, third world countries may have “shanty towns”, which may be small informal settlements or may house millions of people. There is 5 a great demand for suitable living accommodation in such areas, which has the potential to greatly improve the life quality and life chances of residents. It is broadly an object of the present invention to address one or more of the above mentioned disadvantages of previously known timber building structures. 10 Summary What is required is a way of readily permitting additional stages of timber building structures to be manufactured in a more controlled manner or environment, which may reduce or minimise at least some of the above-mentioned problems. 15 In particular, according to a first aspect of the invention, there is provided a timber building structure manufacturing apparatus for manufacturing a timber building structure comprising a support, a cylindrical frame rotatably mounted to the support about a horizontal axis, the cylindrical frame having a substantially open end and an inner space for receiving Structurally Insulated Panels, SIPs, for assembly into a building structure within the inner 20 space, a drive device for rotatable movement of the cylindrical frame relative to the support, and a conveyor arranged to deliver SIPs in a horizontal manner through the open end of the cylindrical frame and into the inner space, wherein the drive device is configured to rotate the cylindrical frame in portions of substantially 90° such that, during use, the cylindrical frame is adapted to receive first SIP in a first rotational position of the cylindrical frame and 25 a second SIP in a second rotational position of the cylindrical frame such that the first and 28 01 25 second SIPs are arranged perpendicular to each other and can be fastened together to form a corner joint of the timber building structure. Such an apparatus permits timber building modules to be manufactured in a more controlled 5 manner. The rotatable frame permits building panels (SIPs) to be readily handled and manipulated prior to joining them to each other. The apparatus may be located at a factory location such as a yard or warehouse. Accordingly, the timber building structure may be finished with fixtures and fittings, and decorated away from a building site and then transported to the building site, which means that the timber building structure may be 10 manufactured with improved efficiency and with a reduced environmental impact. The apparatus may further permit the timber building structure to be manufactured with an improved tolerance for dimensions of the timber building structure, which may further assist with control of quality of the timber building structure. This has a consequential effect on improving the energy efficiency of the finished timber building structure due to a reduction 15 of gaps in joints of the building structure, or adjacent building structures when many building structures are assembled adjacent to one another at a building site. Such an improvement in the tolerances of dimensions of the building structure may reduce draughts and thereby heat loss from the finished building. Using such an apparatus further permits the timber building structure to be manufactured to an appropriate financial and environmental cost. The finished 20 building structure may therefore be manufactured with a reduced environmental impact. The frame may be suitable for receiving at least one building panel (SIP) for assembly into a building structure. Preferably the frame comprises at least one track provided on an outer extent thereof, and the 25 support has at least one roller, the track for rolling engagement with the roller to provide said rotatable mounting of the cylindrical frame to the support. Preferably the cylindrical frame 28 01 25 comprises at least two tracks on an outer extent thereof, and the support has at least two rollers for rolling engagement with a respective track to provide said rotatable mounting of the cylindrical frame to the support. Such a track and roller arrangement has the advantage of permitting the cylindrical frame to rotate about an outer extent which leaves at least one 5 end of the cylindrical frame open to receive a building panel (SIP). Preferably the tracks are provided at respective ends of the cylindrical frame. Preferably the support has at least four rollers, wherein a respective two of the rollers are for rolling engagement with a respective track so that each track sits on its associated rollers. Such an 10 arrangement provides a way of permitting the cylindrical frame to sit on the rollers under the action of gravity. Preferably each track is a channel. Such a channel may assist with location of the roller within its associated track. 15 Preferably the support is cuboid in shape and the cylindrical frame is substantially within said cuboid shape. Such an arrangement permits a convenient way to package the cylindrical frame and support of the apparatus. 20 Preferably the at least four rollers are located at respective lower comers of the support. 28 01 25 Preferably the support has at least eight rollers, a respective four of the rollers for rolling engagement with a respective track, wherein at least four rollers are located at respective upper corners of the support. 5 The cylindrical frame is rotatable in portions of substantially 90° with the drive device, the cylindrical frame adapted to receive consecutive building panels (SIPs) after a said portion of rotation for assembly into a timber building structure. Such an arrangement permits ready handling of building panels (SIPs) so that they can be manipulated with the apparatus and formed into the shape of a building structure. 10 Preferably the support includes a first flip device arranged at an end of said rotatable cylindrical frame, the first flip device for pivotable movement of a building panel (SIP) by substantially 90° for assembly into a timber building structure. Preferably the support includes a second flip device arranged at an opposite end of said rotatable cylindrical frame, 15 the second flip device for pivotable movement of a building panel (SIP) by substantially 90° for assembly into a timber building structure. Such flip devices permit the closing of a building structure. Preferably at least one of the first and second the flip devices comprises at least one actuator 20 arm which is pivotably connected to the support. The apparatus may further include incremental adjustment means for movement of adjacent building panels (SIPs) relative to each other. Such a means permits accurate placement of adjacent panels (SIPs) prior to joining them. 28 01 25 Preferably the support further includes at least one fastener device for fastening adjacent building panels (SIPs) to one another. Preferably the at least one fastener device is further operable to clamp adjacent building panels (SIPs) to one another prior to fastening them. Such clamping may improve the accuracy with which adjacent panels (SIPs) are joined together. Preferably the at least one fastener device is movably mounted to the support so that it is movable along a joint between adjacent building panels (SIPs) when they are received in the frame, the at least one fastener device for fastening adjacent building panels (SIPs) along at least a portion of the length of the joint. Preferably the at least one fastener device is movable mounted on a beam of the support. Preferably the beam is movably mounted to the support. Preferably the fastener device is provided with a drive device for providing said movable mounting to the support. Such movable arrangements of the beam and or fastener improve the versatility of the apparatus to join building panels (SIPs) and assemble them into a timber building structure. Preferably the at least one fastener device includes a drill tool. Preferably the at least one fastener device includes a hammer tool. Preferably the drill tool and the hammer tool are 28 01 25 located on a tool carriage of the fastener device. Such tools may permit the use of impact driven fasteners to be used for joining adjacent building panels (SIPs). Preferably the tool carriage is movably mounted on the fastener device in a direction 5 perpendicular to the direction of travel of the fastener device. This has the advantage of providing an improved versatility to the fastener device when joining adjacent building panels (SIPs). The apparatus may be provided as a portable trailer. Such an arrangement permits the 10 apparatus to be transported to a building site for manufacture of the building structures on site. This may reduce some of the problems at a building site when assembling building panels (SIPs) into timber building structures. The apparatus may further include a plurality of conveyor line means for providing building 15 panels (SIPs) to the apparatus. Such conveyor line means may provide different sized panels to the apparatus, and help to improve the efficiency of operation of the apparatus when manufacturing building structures. Preferably the plurality of conveyor line means are connected to one another at an end 20 thereof. Connecting the conveyor line means in this way may be useful when locating building panels (SIPs) of different sizes into the apparatus. According to a second aspect of the invention there is provided a method of assembling a timber building structure using a timber building structure manufacturing apparatus, the 25 apparatus comprising a support, a cylindrical frame rotatably mounted 28 01 25 to the support about a horizontal axis, the cylindrical frame having a substantially open end and an inner space for receiving Structurally Insulated Panels, SIPs, for assembly into a building structure within the inner space,, a drive device for rotatable movement of the cylindrical frame relative to the support, and a conveyor arranged to deliver SIPs in a 5 horizontal manner through the open end of the cylindrical frame and into the inner space, the method including: receiving, from the conveyor, a first SIP in the inner space of the cylindrical frame in a horizontal manner through the open end of the cylindrical frame; rotating the cylindrical frame through substantially 90°; 10 receiving a second SIP in the inner space of the cylindrical frame in a horizontal manner through the open end of the cylindrical frame such that the second SIP is arranged perpendicularly to the first SIP; and joining the first and second SIPs together to form a comer joint of the timber building structure. 15 Such a method permits timber building modules to be manufactured in a more controlled manner. Loading building panels (SIPs) into the apparatus after rotation of the frame permits building panels (SIPs) to be readily handled and manipulated prior to joining them to each other. The timber building structure may be manufactured with improved efficiency and with 20 a reduced environmental impact. The apparatus may further permit the timber building structure to be manufactured with an improved tolerance for dimensions of the timber building structure, which may further assist with control of quality of the timber building structure. This has a consequential effect on improving the energy efficiency of the finished building structure due to a reduction of gaps in joints of the building structure, or adjacent 28 01 25 building structures when many building structures are assembled adjacent to one another at a building site. Such an improvement in the tolerances of dimensions of the building structure may reduce draughts and thereby heat loss from the finished building. Using such a method further permits the timber building structure to be manufactured to an appropriate financial 5 and environmental cost. The finished building structure may therefore be manufactured with a reduced environmental impact. The method further includes rotating the frame in successive portions of substantially 90°, and receiving consecutive building panels (SIPs) in the frame after a said portion of rotation. 10 Such a method can be used to manufacture a timber building structure comprising four sides to be manufactured within the frame. The successive portions of substantially 90° may be two portions of substantially 90° or in other words 180°. Preferably the method further includes providing the apparatus with at least one flip device 15 arranged at an end of the rotatable frame, the method including pivoting a building panel (SIP) by substantially 90° using the at least one flip device to at least partially close the building structure. Preferably the method includes using incremental adjustment means for moving of adjacent 20 building panels (SIPs) relative to each other prior to joining them together. Such a means permits accurate placement of adjacent panels (SIPs) prior to joining them. Preferably the method includes using at least one fastener device for joining adjacent building panels (SIPs) to one another with fasteners. Preferably the method includes clamping 25 adjacent building panels (SIPs) to one another prior to joining them. Such a method may improve the accuracy with which adjacent panels (SIPs) are joined together. 28 01 25 Also disclosed is a timber building structure produced using an apparatus of the first aspect of the invention, or produced using a method of the second aspects of the invention. 5 The timber building structure may further include at least one gasket between at least one pair of adjacent building panels (SIPs). Also disclosed is a building comprising a timber building structure produced according to an aspect of the invention. 0 Brief Description of the Drawings Other features of the invention will be apparent from the following description of preferred embodiments shown by way of example only with reference to the accompanying drawings, in which; 28 01 25 Figure 1 shows a perspective view of an apparatus for manufacturing a building structure according to an embodiment of the invention; Figure 2 shows a side view of the apparatus of Figure 1; Figure 3 shows a perspective view of an arm and actuator arrangement of Figure 1 5 in an open condition; Figure 4 shows a perspective view of the arm and actuator arrangement of Figure 3 in a closed condition; Figure 5 shows a perspective view of a comer joint of a building module according to an embodiment of the invention; 10 Figure 6 shows a side view of the corner joint of Figure 5; Figure 7 shows a perspective view of a fastening device shown in Figure 1; Figure 8 shown a perspective view of the fastening device of Figure 7 in situ on a beam together with a corner joint; Figure 9 shows a diagram of a method according to an embodiment of the present 15 invention; Figure 10 shows a perspective view of an apparatus for manufacturing a building structure according to another embodiment of the invention; Figure 11 shows another view of the apparatus of Figure 10; and Figures 12a-g show seven perspective views of the assembly of the building module 20 using the apparatus. Detailed Description Figure 1 shows a perspective view of an apparatus for manufacturing a building structure according to an embodiment of the invention, generally designated 10. The apparatus 10 28 01 25 has a body 12 that is cuboid in shape and which is defined by a perimeter frame. The body 12 has four vertical steel beams 14 which are connected together at a top region by four horizontal steel beams 16. The four vertical steel beams 14 are also connected at a bottom region by four horizontal beams 18. Together, the steel beams 14, 16 and 18 comprise the 5 body 12 and define an inner space 19 of the body 12. The body 12 has dimensions of about 8m in height, 7m in width, and 9m in length. The body 12 has a sub-frame 20 located in the inner space 19 and which is rotatably mounted to the body 12. It is envisaged that the sub-frame 20 is fully rotatable about 360° relative to 10 the body 12, however it will be appreciated that the sub-frame 20 may be pivotable mounted to the body 12 such as up to 360°, or more than 360°. The sub-frame 20 is substantially cylindrical in shape and is defined by a perimeter frame of steel which comprises two circular end beams 22 which are connected together by eight horizontal beams 24. Together, the two circular end beams 22 and the eight horizontal beams 24 comprise the sub-frame 20 and 15 define an inner space 21 of the sub-frame 20. The steel beams 14, 16, 18, 22, 24 are I-beams having a suitable section to provide structural rigidity and dimensional stability to the body 12 and the sub-frame 20. Connection of the steel beams 14, 16, 18, 22, 24 to one another is provided by bolting and / or welding as appropriate. 20 Each of the circular end beams 22 comprises a track 26 on an outer circumferential part thereof. Each track 26 sits on two rollers 28 of the body 12, and each roller 28 is substantially at a lower comer of the body 12. In Figure 1 only one roller 28 can be seen due to the particular perspective view shown. It can also be seen that each track 26 28 01 25 comprises an inner part of the I-beam of each circular end beam 22. Together the sub-frame 20 is supported in the body 12 by the four rollers 28 to provide said rotatable mounting of the sub-frame 20 to the body 12. It will be appreciated that one or more of the rollers 28 may be provided with a drive mechanism 30 so that the sub-frame 20 can be rotated within the 5 body 12 as required. Alternatively the sub-frame 20 or the body 12 may be provided with a separate drive mechanism to rotate the sub-frame 20 in the body 12. It will also be appreciated that the rollers 28 may be gear wheels having teeth, and the tracks 26 may be shaped to correspond with the teeth. Such an arrangement may provide an advantageous way of rotating the sub-frame 20 and providing grip between the gear wheels and the tracks. Alternatively, 10 the rollers 28 may be termed wheels. Alternatively bearings may be used instead of, or as well as, the rollers 28. Each end of the cylindrical sub-frame 20 is substantially open so that it can receive panels via the open ends. A building structure, such as a timber building module 32, can then be 15 assembled within the inner space 21 of the sub-frame 20. Figure 1 shows the timber building module 32 partially constructed so that it has a floor panel, a ceiling panel and two long sidewall panels already in place. The timber building module 32 has dimensions of about 2.5m in height, 4.5m in width, and 8m in length. The floor panel, the ceiling panel and the two long side-wall panels are fed into the inner space 21 of the sub-frame 20 from three conveyor 20 belts in a horizontal manner and in a direction indicated by arrow 34. After one panel is fed into the inner space 21, the sub-frame 20 is rotated through 90° before inserting another panel into the inner space. The apparatus 10 has incremental adjustment means to move one panel relative to another panel so that they are positioned next to one another to an accuracy of ±lmm, or up to ±10mm. Such an incremental 28 01 25 adjustment means may be provided by actuator devices or hammer devices to move one panel relative to another panel. Once the floor panel, the ceiling panel and the two long side-wall panels have been fed into 5 the inner space 21, they are clamped and fastened together with fastener devices 36 which are movable on horizontal beams 38 of the body 12. The sub-frame 20 has bearing means along the length of the horizontal beams 24 so that the panels can be inserted into the inner space 21. The panels which form the timber building module 32 comprise a frame of wood which is filled with insulating material and clad with a front and rear skin of Oriented Strand 10 Board (OSB). Structural members may also be contained within the panels to form Structurally Insulated Panels (SIPs). Such panels are known to the skilled person and will not be described further. It will be appreciated that the panels would be constructed with door openings and / or window openings. Such openings have been omitted for the purposes of clarity. The panels which form the timber building module 32 are wooden panels, but it will 15 be appreciated that the apparatus 10 is capable of handling any type of panel, having any type of construction and generally made from any type of building material. The horizontal beams 38 are arranged on the body 12 such that there are two horizontal beams 38 at each end of the cylindrical sub-frame 20, and two horizontal beams 38 on either side of 20 the cylindrical sub-frame 20. In total there are eight horizontal beams 38, and eight fastener devices 36. Each horizontal beam 38 is connected to the body 12 so that they are movable in the vertical direction. Such vertical movability is provided by a rack and pinion arrangement 42 at each end of the horizontal beams 38. Each rack and 28 01 25 pinion arrangement 42 is provide with a drive arrangement to permit incremental adjustment and accurate positioning of the fastener devices 36 relative to the timber building module 32. It will be appreciated that this arrangement of fastener devices 36 and horizontal beams 38 permit the fastening of panels to each other along all joints as required. The arrangement of 5 horizontal beams 38 permits fastening of panel joints in the x and y directions of the timber building module 32. Rotation of the sub-frame 20 about 90° permits the fastening of panel joints in the z direction of the timber building module 32. In this manner all panel joints in all three dimensions can be fastened. Further details of the fastening arrangements are shown in Figures 7-11. Figure 1 also shows an end panel 44 that is about to be flipped though 90° 10 by actuator arms 46 which are mounted in respective arm frames 48 of the body 12. The actuator arms 46 and arm frames 48 are located at an end of the body 12 and further details are provided in Figure 3. When the end panels 44 are flipped through 90° they are clamped and fastened in position by the fastener devices 36 to provide the timber building module 32 with six sides. 15 Figure 2 shows a side view of the apparatus of Figure 1. In Figure 2 like features to the arrangements of Figure 1 are shown with like reference numerals. In Figure 2 it can be seen that at another end of the body 12 there is also an arrangement of two actuator arms 46 and two arm frames 48 for flipping an end panel 44 through 90° for attachment to the timber 20 building module 32. Further details of this arrangement are described in Figure 3. Figure 3 shows a perspective view of an arm and actuator arrangement of Figure 1 in an open condition. In Figure 3 like features to the arrangements of Figure 1 and 2 are shown with like reference numerals. In Figure 3 each actuator arm 46 is shown to pivot about a 28 01 25 pivotable connection 50 of an end frame 52 which is a part of the body 12. Also shown is the arrangement of the track 26 of the circular end beam 22 which sits on the roller 28. The I-beam which comprises the circular end beam 22 has side-cheeks 54 which at least partially envelop the roller 28 to form a guide or channel. This arrangement ensures that the roller 28 remains in contact with the track 26. In Figure 3 the roller 28 is shown to be a pneumatic tyre or a solid rubber tyre having a tread or gripping surface to inhibit slipping of the surface of the roller 28 relative to the track 26. It will be appreciated that the roller 28 may be of another suitable material to limit slippage such as steel. Figure 4 shows a perspective view of the arm and actuator arrangement of Figure 3 in a closed condition. In Figure 4 like features to the arrangements of Figures 1 - 3 are shown with like reference numerals. In Figure 4 an end of each actuator arm 46 is shown to be connected to a flipping plate 56 which is connected to the body 12 by the pivotable connection 50. The other end of each actuator arm 46 is shown to be connected to its associated arm frame 48. Each actuator arm 46 is shown in an extended condition so that the end panel 44 is flipped through 90°. The end panel 44 can then be fastened to the side wall panels, the ceiling panel, and the floor panel to form the timber building module 32. Figure 5 shows a perspective view of a corner joint of a building module according to an embodiment of the invention, generally designated 60. The corner joint 60 comprises a side wall panel 62, and a floor panel 64. The skin 66, 68 of OSB of each panel 62, 64 is also shown. The panels 62, 64 are joined together using known HELIFIX™ fasteners 70, which are known to the skilled person, and comprise an elongate pin having two helical flutes terminating at a cutting end. The fasteners 70 are inserted by firstly drilling a pilot 28 01 25 hole from a surface of the floor panel 64, through the depth of the floor panel 64, and into a plane of the side wall panel 62. The fasteners 70 are then driven into the pilot hole using a reciprocating power driven tool which engages the fastener 70 without a driven torque. The helical flutes of the fastener 70 cause the fastener to rotate while confined within the pilot 5 hole, which joins the panels 62, 64 together. Pairs of fasteners 70 are inserted along the length of the joint between the panels 62, 64. One pair of fasteners typically has a spacing of 0.2 -0.3m from the adjacent pair of fasteners 70. Figure 6 shows a side view of the corner joint of Figure 5. In Figure 6 like features to the 10 arrangements of Figure 5 are shown with like reference numerals. In Figure 6, the OSB skin 66 of the side wall panel 62 is shown to have an extension part 72 which covers an end of the floor panel 64. A gasket 74 is also shown between the extension part 72 and the end of the floor panel 64. Another gasket 76 is shown between an end of the side wall panel 62 and an upper surface of the floor panel 64. The gaskets 74, 76 extend along the whole length of the 15 panels 62, 64 and assist in reducing the air flow between inner and outer parts of the timber building module 32. The gaskets 74, 76 are of a rubber like material which conforms to the panels 62, 64 which are intended to provide an hermetic seal between an exterior and interior of the timber building module 32. The gaskets 74, 76 may assist with closing gaps between the panels 62, 64. 20 Figure 7 shows a perspective view of a fastening device 36 shown in Figure 1. In Figure 7 like features to the arrangements of Figure 1 - 6 are shown with like reference numerals. In Figure 7, the fastening device 36 comprises a body 80 which has a first set of rollers 82 and a second set of rollers 84. The rollers 82, 84 sit on the horizontal beam 38 and 28 01 25 permit movement of the fastening device 36 on it. The rollers 82, 84 are provided with drive means (not shown) located in the body 80. The body 80 also has a fastener magazine 86 that is movable on the body 80 by a drive means 88 in a direction parallel to the direction of travel of the body 80 on the horizontal beam 38. Whereas the drive means 88 is shown to be outside 5 the body 80 it will be appreciated that it may be inside the body 80. The fastener magazine 86 hold fasteners 70 which are selectable by a selection device 90. The body 80 also has a tool carriage 92 that is movable on the body 80 in a direction perpendicular to the direction of travel of the body 80 on the horizontal beam 38. The tool carriage 92 has a drive means (not shown) to move it which is located within the body 80. The tool carriage 92 has a first 10 set of tools 94 for drilling pilot holes, and a second set of tools 96 for engaging and securing fasteners 70. The selection device 90 picks up fasteners 70 from the fastener magazine 86 and locates them into the second set of tools 96. It will be appreciated that the first set of tools 94 are drill devices which operate with a rotational action and without a hammer action to drill pilot holes in timber building panels. The second set of tools 96 are impact hammer 15 device which operate without a rotational action and with a hammer action to drive fasteners 70 as per the arrangements of Figures 5 and 6. Figure 8 shows a perspective view of the fastening device 36 of Figure 7 in situ on a beam 38 together with a comer joint 60. In Figure 8 like features to the arrangements of Figure 1 - 20 7 are shown with like reference numerals. In Figure 8, the rollers 82 are rollable on inner surfaces 98 of the horizontal beam 38 with the I-beam being located in its normal orientation so that a bar of the I is vertical. The rollers 84 are shown to be rollable on an upper surface 100 of the horizontal beam 38. The body 80 is substantially the shape of a 28 01 25 chair and the comer joint 60 is arranged within a free space defined by a back of the chair and a seat of the chair. In operation the apparatus 10 is provided with clamping means which may be a part of each fastening device 36. The clamping means are operable to clamp up to six wall, floor and ceiling panels before they are fastening together with the fastener device 5 36 as shown with reference to Figures 17a-d. In an alternative embodiment the apparatus 10 may be transported to a building site so that timber building modules 32 can be manufactured at the building site and placed in situ on concrete foundations and assembled to form a building. In one embodiment the apparatus 10 10 is provided as a movable trailer that may be transported to a building site. The panels comprising the timber building module 32 may be manufactured away from the building site and transported to the apparatus 10 at the building site for assembly into timber building modules 32. Alternatively the panels may be manufactured at the building site. These arrangements avoid the requirement to have a factory location, and the requirement to store 15 the assembled timber building modules 32 at a factory location. Instead, the timber building modules 32 can be manufactured and placed in situ directly at the building site. Furthermore, the assembled building may be fitted out with house fixtures, fittings and furnishings at the building site using a local workforce. This arrangement may have the advantage of avoiding the requirement for a dedicated workforce at a factory location. 20 Figure 9 shows a diagram of a method according to an embodiment of the present invention, generally designated 180. The method 180 is a method of assembling a timber building module 32 using an apparatus 10 comprising a body 12, a sub-frame 20 rotatably 28 01 25 mounted to the body 12, and a drive device 30 for rotatable movement of the sub-frame 20 relative to the body 12. The method includes receiving a first building panel in the frame as shown at 182. The method includes rotating the sub-frame 20 by a required angle, for example substantially 90°, as shown at 184. The method includes receiving a second building 5 panel in the sub-frame 20 as shown at 186. The method includes joining the first and second building panels together to form a building structure 32 as shown at 188. The method includes providing the sub-frame 20 as a cylinder and receiving 182 at least one panel in the sub-frame 20 via an end of the cylinder. The method further includes rotating 10 184 the sub-frame 20 in portions of substantially 90°, and receiving consecutive building panels in the sub-frame 20 after a said portion of rotation. The method further includes at least one actuator arm 46 arranged at an end of the sub-frame 20 for pivotable moving a building panel by substantially 90° to at least partially close the building structure 32. The method further includes using incremental adjustment means for moving adjacent building 15 panels relative to each other prior to joining them together. The method further includes using at least one fastener device 36 for joining adjacent building panels to one another with fasteners. The method further includes clamping adjacent building panels to one another prior to joining 188. 20 The manner of construction of the complete building described above permits timber building modules 32 to be manufactured at a factory location, such as a warehouse or a yard, and then transported by lorry to a building site. Alternatively they may be manufactured at the building site by transporting the apparatus 10 to the building site. 28 01 25 The building modules 32 can then be lifted into place on concrete foundations, using a crane. Figure 10 shows a perspective view of an apparatus for manufacturing a building structure according to another embodiment of the invention, generally designated 200. In Figure 10 like features to the arrangements of Figures 1 to 4 are shown with like reference numerals. In Figure 10 it can be seen that there are eight rollers 28 of the body 12 for the two tracks 26 such that each track 26 has four rollers 28. Four rollers 28 are substantially at a lower comer of the body 12. Four rollers 28 are substantially at an upper comer of the body 12. In Figure 10 only seven rollers 28 can be seen due to the particular perspective view shown. The subframe 20 is supported in the body 12 by the eight rollers 28 to provide said rotatable mounting of the sub-frame 20 to the body 12. In the embodiment of Figure 10 the rollers 28 are not drive rollers, and instead a separate drive device is provided to rotate the sub-frame 20. The separate drive device comprises a drive mechanism 30 with a cord 202 (for example a belt or chain etc), which acts on a wheel 204 of one of the tracks 26. The wheel 204 being secured to one of the tracks 26. Alternatively one or more of the rollers 28 may be gear wheels having teeth, and the corresponding wheel 204 may be shaped to engage with the teeth. The wheel 204 is a driven wheel, and may be termed a cog, a pulley, or gear etc. Alternatively bearings may be used instead of, or as well as, the rollers 28. It will be appreciated that the apparatus 200 shown in Figure 10 is illustrated in a “stripped back” form without a conveyor apparatus (see Figure 11) that allows SIP panels to be inserted into the apparatus 200 and joined together to form housing modules using fastener devices 36 (also not shown in Figure 10). 28 01 25 Figure 11 shows another view of the apparatus of Figure 10. In Figure 11 like features to the arrangements of Figure 10 are shown with like reference numerals. In Figure 11 the apparatus 200 is shown with a cage-like structure 206 comprising a conveyor apparatus to transport SIPs into the apparatus 200 and to hold the SIPs in place when they are joined together. In other words, each SIP comprising the four walls, the ceiling, and the floor are sequentially conveyed into position. The conveyor apparatus comprises, for example, rollers or other bearings to allow the SIPs to be moved into place on top of one of the sides of the cage-like structure 206 when horizontal. The cylindrical sub-frame 20 is systematically rotated through 90° or 180° to enable positioning and fixing of the two side-walls, the ceiling and the floor. It will be appreciated that an end gable wall (not shown) is the first SIP to be loaded into the cylindrical sub-frame 20 via a portion 207 of the conveyor apparatus as shown by arrow 208. This first SIP passes through the cylindrical sub-frame 20 and is ‘parked’ on another portion 210 (i.e. the portion 210 is horizontal when the first SIP is ‘parked’ on it) of the conveyor apparatus until the two side-walls, the ceiling and the floor are secured together. The portions 207, 210 of the conveyer apparatus are not part of the apparatus 200, and are instead a part of a production line for transporting the SIPs in a factory in which the apparatus 200 is located. The portions 207, 210 are moved into position as shown by arrow 212, for example by hydraulic actuators and arms (see Figure 3), so that they are substantially vertical. In this manner the two end gable walls are positioned horizontally prior to securing them to the rest of the housing module structure. In other words, the four long sides of the building module (i.e. the two side-walls, the ceiling and 28 01 25 the floor) are fixed to one another and are structurally stable before the two end gable walls are secured. After assembly of the six SIPs the building structure is ready for transport and ‘fit out’ with housing fixtures, fittings and / or furnishings. 5 Figures 12a-g show seven perspective views of the assembly of the building module using the apparatus 200. In Figures 12a-g like features to the arrangements of previous embodiments are shown with like reference numerals. In Figure 12 the cage-like structure 206 shown in Figure 11 has been omitted for clarity, and all views in Figure 12a-g are from the same end of the apparatus 200. The first stage of assembly of the building module is to 10 position a far end gable SIP onto the portion 210 of the conveyor apparatus, as previously described with reference to Figure 11. As shown in Figure 12a ceiling panel SIP 214 is then moved into the sub-frame 20. The ceiling panel SIP 214 is positioned by digital location sensors (not shown) and is secured by temporary or sacrificial fixings (e.g. strops or fasteners etc). The sub-frame 20 is then rotated anticlockwise by 90° as shown by arrow 216 in Figure 15 12b, where it is locked in place so that it is secure, for example with failsafe electromagnetic solenoid bolts (not shown). A first side-wall SIP 218 is then moved into the sub-frame 20 as shown in Figure 12c. The side-wall SIP 218 is positioned by digital location sensors (not shown) and is secured by temporary or sacrificial fixings (e.g. strops or fasteners etc). The sub-frame 20 is then rotated clockwise by 180° (i.e. two portions of 90°) as shown by arrow 20 221 in Figure 12d and locked in place. A second side-wall SIP 220 is then moved into the sub-frame 20 as shown in Figure 12e. The second side-wall SIP 220 is positioned by digital location sensors and is secured by temporary or sacrificial fixings. The sub-frame 20 is then rotated clockwise by 90° as shown by arrow 222 in Figure 12f and locked in place. A floor SIP 224 is then moved into the sub-frame 28 01 25 20 as shown in Figure 12g. The floor SIP 224 is positioned by digital location sensors and is secured by temporary or sacrificial fixings. The four SIP panels 214, 218, 220, 224 are now secure and are ready to receive the gable end walls (one of which is shown at 4 in Figure 1). 5 From Figures 12a-g it can been seen that the four SIP panels 214, 218, 220, 224 are inserted into the sub-frame 20 when they are horizontal, which allows them to be supported by the conveyor apparatus as they are moved into place within the sub-frame 20 and secured together. It is to be noted that less energy may be used for some of the rotation steps due to the mass of one or more SIPs already secured together. For example, the rotation step shown 10 by arrow 221 may require relatively less energy. Manufacture and assembly of the building in such a manner means that the timber building modules 32 can be manufactured in a more controlled way using the apparatus 10, 200. This is a more efficient way of constructing the building and provides a timber building module 15 of an improved quality when compared to the prior art which requires assembling panels directly onto concrete foundations to form a building at the building site. Manufacturing the timber building modules 32 using the apparatus 10, 200 provides the advantage of reducing the time to manufacture the building. With the embodiment having the apparatus 10, 200 located at the factory building, the build process is even more controlled, which provides a 20 further improvement in the quality of manufacture of the building. 28 01 25 Using such a method of manufacture reduces the environmental impact of constructing the building, and may improve the overall energy efficiency for such a building. This may further improve the overall efficiency and reduced environmental impact for the building over its lifetime. 5 The embodiments described above can be used to provide high-volume manufacturing of timber building modules 32, such as the manufacture of up to 1000 timber building modules 32 per month. At least one of the technical features of the apparatus 10, 200 the sub frame 20, drive mechanism 30, the fastener devices 36, the drive arrangement of the rack and pinion 10 arrangement 42 of horizontal beams 38, the actuator arms 46, the drive means 88 of the fastener devices 36, the selection device 90, the tool carriage 92, may be controlled by an automated control system. The automated control system is a computer apparatus which provides control signals to the technical features of the embodiments of the invention. The computer apparatus has a computer program for controlling the efficient running of the 15 technical features of the embodiments of the invention. Such a computer program may also include adaptive learning sub-routines and / or neural network software to maintain an efficient operation for the technical features of the embodiments of the invention. The computer apparatus may also include Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) apparatus to further assist with the construction of the timber building 20 modules 32. It will be understood that in one embodiment the apparatus 10, 200 is part of a production line at a factory location (i.e. a factory building). The production line may assemble and handle the SIPs 44, 214, 218, 220, 224 and deliver them to the apparatus 10, 200 for manufacture into the timber building modules 32. The production line may also transport the finished timber building modules 32 in and around the factory where the apparatus 10, 200 is located. It will be understood that the apparatus 10, 200 is secured to the ground (i.e. a foundation) of a factory floor so that the forces generated by operation thereof (e.g. rotation 5 of the sub-frame 20) do not cause the apparatus 20, 200 to move substantially. 28 01 25 14 1024

Claims

1. A timber building structure manufacturing apparatus for manufacturing a timber building structure, the apparatus comprising:5 a support,a cylindrical frame rotatably mounted to the support about a horizontal axis, the cylindrical frame having a substantially open end and an inner space for receiving Structurally Insulated Panels, SIPs, for assembly into a building structure within the inner space,10 a drive device for rotatable movement of the cylindrical frame relative to the support,anda conveyor arranged to deliver SIPs in a horizontal manner through the open end of the cylindrical frame and into the inner space,wherein the drive device is configured to rotate the cylindrical frame in portions of15 substantially 90° such that, during use, the cylindrical frame is adapted to receive a first SIP in a first rotational position of the cylindrical frame and a second SIP in a second rotational position of the cylindrical frame such that the first and second SIPs are arranged perpendicular to each other and can be fastened together to form a corner joint of the timber building structure.14 10242. An apparatus according to claim 1, wherein the cylindrical frame comprises at least one track provided on an outer extent thereof, and the support has at least one roller, the track for rolling engagement with the roller to provide said rotatable mounting of the cylindrical frame to the support.

53. An apparatus according to claim 2, wherein the cylindrical frame comprises at least two tracks on an outer extent thereof, and the support has at least two rollers for rolling engagement with a respective track to provide said rotatable mounting of the cylindrical frame to the support.

104. An apparatus according to claim 3, wherein the tracks are provided at respective ends of the cylindrical frame.

5. An apparatus according to claim 3 or 4, wherein the support has at least four rollers, 15 a respective two of the rollers for rolling engagement with a respective track so that each track sits on its associated rollers.

6. An apparatus according to any preceding claim, wherein the support is cuboid in shape and the cylindrical frame is substantially within said cuboid shape.14 10247. An apparatus according to claim 6 when appended to claim 5, wherein the at least four rollers are located at respective lower corners of the support.

8. An apparatus according to claim 7, wherein the support has at least eight rollers, a 5 respective four of the rollers for rolling engagement with a respective track, wherein at least four rollers are located at respective upper comers of the support.

9. An apparatus according to any preceding claim, wherein the support includes a first flip device arranged at an end of said cylindrical frame, the first flip device for pivotable 10 movement of a SIP by substantially 90° for assembly into the building structure.

10. An apparatus according to claim 9, wherein the support includes a second flip device arranged at an opposite end of said cylindrical frame to the first flip device, the second flip device for pivotable movement of a SIP by substantially 90° for assembly into the building 15 structure.

11. An apparatus according to claim 9 or 10, wherein at least one of the first and second the flip devices comprises at least one actuator arm which is pivotably connected to the support.14 102412. An apparatus according to any preceding claim, and further including incremental adjustment means for movement of adjacent SIPs relative to each other.

13. An apparatus according to any preceding claim, wherein the support further includes5 at least one fastener device for fastening adjacent SIPs to one another.

14. An apparatus according to any preceding claim, provided as a portable trailer.

15. A method of assembling a timber building structure using a timber building structure10 manufacturing apparatus, the apparatus comprising:a support,a cylindrical frame rotatably mounted to the support about a horizontal axis, the cylindrical frame having a substantially open end and an inner space for receiving Structurally Insulated Panels, SIPs, for assembly into a building structure within the inner15 space,a drive device for rotatable movement of the cylindrical frame relative to the support, anda conveyor arranged to deliver SIPs in a horizontal manner through the open end of the cylindrical frame and into the inner space20wherein the method comprises:14 1024receiving, from the conveyor, a first SIP in the inner space of the cylindrical frame in a horizontal manner through the open end of the cylindrical frame;rotating the cylindrical frame through substantially 90°;receiving a second SIP in the inner space of the cylindrical frame in a horizontal5 manner through the open end of the cylindrical frame such that the second SIP is arranged perpendicularly to the first SIP; andjoining the first and second SIPs together to form a comer joint of the timber building structure.10 16. A method according to claim 15, and further including providing the frame as acylinder, the method including receiving at least one panel in the frame via an end of the cylinder.

17. A method according to claim 15, and further comprising:15 rotating the cylindrical frame through a further 90°,receiving, from the conveyor, a third SIP in the inner space of the cylindrical frame in a horizontal manner through the open end of the cylindrical frame such that the third SIP is arranged perpendicularly to the second SIP, andjoining the second and third SIPs together to form a second comer joint of the timber 20 building structure.14 102418. A method according to claim 16 or 17, wherein the apparatus further includes at least one flip device arranged at an end of the cylindrical frame, the method including pivoting a SIP by substantially 90° using the at least one flip device to at least partially close the building 5 structure.

19. A method according to any of claim 16 to 18, and further including using incremental adjustment means for moving of adjacent SIPs relative to each other prior to joining them together.1020. A method according to any of claim 16 to 19, and further including using at least one fastener device for joining adjacent SIPs to one another with fasteners.

21. A method according to any of claim 16 to 20, and further including clamping adjacent 15 SIPs to one another prior to joining them.

Images