A construction system and method of use thereof

Abstract

A method of constructing a floor of a building, the method comprising the steps of: Laying a first one or more first panels in a first horizontal orientation; Laying a plurality of second panels in a second horizontal orientation, the second horizontal orientation being substantially perpendicular to the first horizontal orientation, wherein a first end of each of the plurality of second panels is configured for attachment to an edge of the first of the one or more first panels; and Laying a second one or more first panels in the first horizontal orientation, the second one or more first panels being located parallel to the first one or more first panels, Wherein an opposed second end of each of the plurality of second panels is configured for attachment to an edge of the second one or more first panels; and Wherein at least one of the first one or more first panels and / or the second one or more first panels includes a bore therethough, the bore configured to receive a vertical structural element of the building.

Description

A CONSTRUCTION SYSTEM AND METHOD OF USE THEREOFTECHNICAL FIELD

[0001] The present invention relates to a construction system and method of use. In particular, the present invention relates to preformed construction elements and a method of construction using the same to erect multi-storey buildings.BACKGROUND

[0002] Conventional building techniques often employ precast structural elements for the construction of walls, floors and the like. One of the problems associated with the use of such precast structural elements is the accurate positioning of such elements to produce a true and level wall or floor.

[0003] Another problem with using conventional precast structural elements is the time required to construct walls or floors. This is partially due to the aforementioned problem to accurately position the elements and other alignment drawbacks cause by irregularities in the precast elements. Delays in constructing a wall or floor subsequently delays higher walls and floors being constructed and / or other features of a building being installed. This results in projects falling behind schedule and costly fines being levied against those responsible, particularly in high-rise construction of multi-storey buildings.

[0004] Under conventional building practice, it is typical for the formwork, steel reinforcement and the fabrication of the structural elements to be done by one trade and the infilling between columns with steel studs, insulation, exterior sheathing / curtain walling and interior drywalling to be done by other trades. The use of multiple trades creates problems in terms of coordinating work done by the respective trades and minimising error, i.e., there is more room for error when more than one trade is responsible for interrelated tasks. In some scenarios, the coordination of work between the respective trades can often delay building construction. Again, these delays are particularly pronounced in multi-storey building construction.

[0005] Also, in conventional building practice, walls and ceilings (which become the floors of upper levels) are constructed separately to one another. Once wall panels are in place, scaffolding and formwork must be erected for the construction of a ceiling panel. Once the ceiling panel is constructed (and the cementitious material from which it is formed has set), the formwork and scaffolding must be removed before construction of upper storeys can continue. Not only is this expensive and time consuming the removal of formwork from a ceiling panel is also dangerous and injuries to formwork workers are common.

[0006] In addition, when formwork is in place while a ceiling panel is setting, the area under the ceiling panel is considered to be dangerous (in the event of material falling from the ceiling),meaning that the ability to continue work in this area is restricted, thereby increasing the overall time (and expense) of construction.

[0007] Further, the use of conventional precast structural elements can be problematic in some climates, such as, e.g., cold- or wet-weather climates. For example, extensive tarping or water-proofing is required to keep the vertical elements and / orthe interior of unfinished buildings warm and / or dry.

[0008] Another problem with conventional precast structural elements is that they typically do not comply with seismic building codes. In order to minimise the risk of the catastrophic failure of buildings during a seismic event (such as an earthquake), buildings in many countries must be constructed according to local seismic building codes. However, conventional precast structural elements are typically not constructed in a manner that complies with these codes, making them unsuitable for use in many locations.

[0009] Thus, there would be an advantage if it were possible to provide a construction system and method that not only reduced the time taken to construct a multi-storey building, but significantly reduced costs (in terms of reducing or eliminating scaffolding and / or formwork). In addition, there would be an advantage if it were possible to provide a construction system and method that reduced the risk of injury or death to workers. Further, there would be an advantage if it were possible to provide a construction system and method that provided the abovementioned benefits while also complying with local seismic building codes.SUMMARY OF INVENTION

[0010] Embodiments of the present invention provide a system for constructing multi-storey buildings, construction elements and moulds thereof, and a method of constructing a multi-storey building, which may at least partially overcome at least one of the abovementioned problems or provide the consumer with a useful or commercial choice.

[0011] According to a first aspect of the present invention, there is provided a method of constructing a floor of a building, the method comprising the steps of:Laying a first one or more first panels in a first horizontal orientation;Laying a plurality of second panels in a second horizontal orientation, the second horizontal orientation being substantially perpendicular to the first horizontal orientation, wherein a first end of each of the plurality of second panels is configured for attachment to an edge of the first of the one or more first panels; andLaying a second one or more first panels in the first horizontal orientation, the second one or more first panels being located parallel to the first one or more first panels, Wherein an opposed second end of each of the plurality of second panels is configured for attachment to an edge of the second one or more first panels; andWherein at least one of the first one or more first panels and / or the second one or more first panels includes a bore therethough, the bore configured to receive a vertical structural element of the building.

[0012] The first and second panels may be of any suitable size, shape or configuration. In some embodiments, the first panels and the second panels may be of the same dimensions as one another. More preferably, however, the first panels and the second panels may be of different dimensions to one another.

[0013] Preferably, the first panels and the second panels are substantially planar.

[0014] Preferably, the first panels and the second panels are precast panels. Preferably, the first panels and the second panels are at least partially fabricated from a cementitious material. In some embodiments of the invention the first panels may comprise the preformed construction element of the second, fifth or sixth aspects of the invention. In some embodiments, the second panels may comprise he preformed construction elements of the fifth or sixth aspects of the invention.

[0015] As previously stated, the second panels are laid in a substantially perpendicular orientation to the first panels. Thus, in some embodiments, the width of one second panel may be substantially equal to the length of one first panel. More preferably, the width of a plurality of second panels may be substantially equal to the length of one first panel.

[0016] In a specific embodiment, the width of two second panels may be substantially equal to the length of one first panel. In this embodiment, it is envisaged that the edge of the first of the one or more first panels may be connected to the ends of two second panels, while the opposed ends of the two second panels may be connected to the edge of the second of the one or more first panels.

[0017] The first panels and the second panels may be connected to one another using any suitable technique. For instance, the first panels and the second panels may be connected to one another using one or more mechanical fasteners (nails, rivets, bolts, screws or the like, or a combination thereof). Alternatively, the first panels and the second panels may be provided with complementary engagement portions configured to connect the first panels to the second panels. More preferably, an adhesive, bonding agent, or the like may be used to connect the first panels to the second panels. The bonding agent may be of any suitable form, although in a preferred embodiment the bonding agent may comprise an epoxy or polymer-modified cementitious material.

[0018] The bonding agent may be configured to achieve any suitable compressive strength. In a preferred embodiment of the invention, however, the bonding agent may be configured to achieve a compressive strength of at least 50 MPa.

[0019] In a preferred embodiment of the invention, the bonding agent may be used to connect the ends of the second panels to the first of the first panels and the second of the first panels. In addition, the bonding agent may be used to connect and edge of each of the second panels to an edge of an adjacent second panel. Further, the bonding agent may be used to connect an end of a first panel to an end of an adjacent first panel.

[0020] In still further embodiments, the bonding agent may be used to connect the vertical structural element to at least a portion of the inner surface of the bore.

[0021] The bore may be of any suitable size, shape or configuration. Preferably, however, the bore is substantially linear between an opening in a first face of the first panel and an opening in an opposed second face of the first panel. Preferably, the bore extends in a direction substantially perpendicular to the first face and the second face.

[0022] The bore may be of any suitable cross-sectional shape. For instance, the bore may have a circular, square or rectangular shape, or any other suitable shape. In some embodiments, the shape of the bore may be determined by the shape of the vertical structural shape. For instance, if the vertical structural element has a circular cross-sectional shape, the first panel may be fabricated with a bore having a circular cross-sectional shape. Similarly, if the vertical structural element has a square cross-sectional shape, the first panel may be fabricated with a bore having a square cross-sectional shape.

[0023] In some embodiments of the invention, the first panels may comprise one or more connection members at least partially embedded therewithin. The connection members may be of any suitable form. However, in a preferred embodiment of the invention, the connection members may be configured for connection to the vertical structural element. The connection members may be configured for connection to the vertical structural element using any suitable technique. For instance, the connection members may be connected to the vertical structural element using one or more mechanical fasteners (nails, rivets, bolts, screws or the like, or a combination thereof). Alternatively, the connection members and the vertical structural element may be provided with complementary engagement portions configured to connect the connection members to the vertical structural element. In other embodiments, an adhesive, bonding agent, or the like may be used to connect the connection members to the vertical structural element. More preferably, the connection members may be connected to the vertical structural element using a bonding technique, such as welding, brazing or the like.

[0024] In a preferred embodiment of the invention, the connection members may be fabricated from a metallic material. Any suitable metallic material may be used, although in a preferred embodiment of the invention, the metallic material may comprise steel.

[0025] In some embodiments, the connection members may include an exposed portion. Inthis embodiment, it is envisaged that at least a portion of the connection members may be embedded within the first panels, and at least a portion of the connection members may be exposed. The exposed portion may extend outwardly from the surface of the first panel members, or may be substantially flush with the surface of the first panel members. The exposed portion may be configured for connection to the vertical structural element.

[0026] The exposed portion of the connection members may be located at any suitable location on the first panel members. Preferably, however, the exposed portion may be located within the bore. The exposed portion may be located at any suitable location within the bore, although it will be understood that the exposed portion must be accessible by a user in order to connect the exposed portion to the vertical structural element.

[0027] The connection member may be of any suitable size, shape and configuration. Preferably, however, the connection member is of sufficient size such that, when embedded in the first panel, the connection member bonds to the material from which the first panel is fabricated. In some embodiments, the connection member may include one or more receiving portions therein. The receiving portions may be of any suitable size, shape or configuration, although it is envisaged that the receiving portions may be configured to receive a reinforcing member therein.

[0028] The reinforcing member may be of any suitable form. For instance, the reinforcing member may comprise a mesh, bar, rod or the like. Preferably, the reinforcing member is fabricated from a metallic material, such as, but not limited to, steel.

[0029] The reinforcing member may comprise reinforcing elements, post-tensioning elements, and the like, or a combination thereof.

[0030] In some embodiments of the invention, the receiving portions may include one or more apertures, recesses, slots, channels, cut-out portions or the like. In these embodiments, it is envisaged that the reinforcing members may be received in the receiving portions and then the first panel may be fabricated, such as by pouring a cementitious material onto and around the reinforcing members and the connection members to form the first panels.

[0031] While it will be understood that any suitable shape of connection member may be used, in some embodiments of the invention, the connection members may be in the form of plates. In these embodiments, it is envisaged that an edge or side of the connection member may form the exposed portion.

[0032] The vertical structural element may be of any suitable type. For instance, the vertical structural element may comprise a beam, column, post, wall or the like, or any suitable combination thereof.

[0033] It is envisaged that any suitable number of panels may be used in the construction of the floor of the building. However, it is envisaged that the floor will comprise an alternating pattern of first panels located in a first orientation adjacent second panels located in a second orientation that is substantially perpendicular to the first orientation.

[0034] It is envisaged that at least a portion of the first panels will comprise a bore therein. Depending on the position of vertical structural elements within the building, the first panels may comprise one bore, two or more bores, or no bores.

[0035] In some embodiments, once the first panels and second panels are laid, a cementitious material may be poured onto an upper surface of the first panels and the second panels. The cementitious material may be allowed to at least partially set and bind with the first panels, the second panels and the vertical structural elements.

[0036] Additional floors (or storeys) of the building may then be fabricated in the same manner as described above.

[0037] In some embodiments, one or more cover members may be located over the first panel members and / or the second panel members. Any suitable cover members may be provided. For instance, the cover members may comprise flooring members, such as tiles, carpet, polymeric flooring material, floorboards the like. Alternatively, the cover members may comprise metallic members, such as structural steel members. In this embodiment, it is envisaged that the cover members may be configured for connection to the vertical structural elements. The cover members may be configured for connection to the vertical structural elements using any suitable technique, although in a preferred embodiment the cover members may be welded to the vertical structural elements.

[0038] In these embodiments, the cover members may cover all of the first panels and the second panels. Alternatively, the cover members may only cover a portion of the first panels and the second panels.

[0039] In a preferred embodiment of the invention, the first panels and the second panels may be laid on a base structure. Any suitable base structure may be provided. For instance, the base structure may comprise a wooden or concrete base structure on which the first panels and the second panels may be laid.

[0040] In some embodiments of the invention, the first panels and the second panels may be laid on a polymeric base structure. The polymeric base structure may be of any suitable form. In one embodiment, the polymeric base structure may comprise corflute.

[0041] In some embodiments, one or more additional layers, such as layers of waterproofing materials or the like, may be located below and / or above the first panels and thesecond panels.

[0042] It is envisaged that the connection of the connection members (and therefore the first panels) to the vertical structural element may result in increased mechanical strength of the connection. Thus, the present invention may increase the overall strength of the building constructed in the manner described. It is envisaged that this increase in strength may result in the building constructed according to the method of the present invention being resistant to extreme weather (such as cyclones, monsoons or the like) as well as natural phenomena, such as earthquakes.

[0043] In some embodiments the first panels and / or the second panels may include a surface member connected to the body of the panels and forming an outer surface thereof.

[0044] In preferred embodiments, the surface member may extend across an entire surface of the panel to facilitate the forming of a ceiling surface when the panels are coupled and / or joined relative to one another.

[0045] In some embodiments, surface members may be provided on more than one surface. For example, surface members may be provided on a surface and an adjacent edge of an element to define a corner in room of the building, for example.

[0046] The at least one surface member may include any suitable material configured to form an interior wall or ceiling surface. For example, the surface member may include internal cladding, corflute or plasterboard. In some embodiments, the plasterboard may be fire-resistant, such as, e.g., Type X or Type C gypsum panels.

[0047] The at least one surface member may be associated with the body of the panel in any suitable way. For example, the at least one surface member may be directly or indirectly bonded or fastened to the body, preferably indirectly. The surface member may be associated with the body during manufacture, or may be associated with the body in situ during the construction of the building.

[0048] Thus, in some embodiments, the panel may be fabricated without a surface member attached thereto. As the surface member may be fabricated from a material that may degrade under certain conditions (such as when wet) it may be preferable to only attach the surface member to the panel in situ (or at least subsequent to manufacture) in order to reduce or eliminate the possibility of the surface member becoming degraded (such as by becoming wet) during transportation to site, or on site prior to installation.

[0049] In embodiments of the invention in which a surface member may be connected to the panel subsequent to manufacture, it is envisaged that one or more pieces of material may be connected to the panel during fabrication to protect the panel. Any suitable pieces of materialmay be used, such as, but not limited to plasterboard, cardboard, polymer materials (such as but not limited to corflute), wood, metal and the like, or any suitable combination thereof. In a preferred embodiment of the invention, a plurality of pieces of material may be configured to removable connection to the panel, for example in the form of strips. The plurality of pieces of material may be removably connected to the panel using any suitable technique, such as by using one or more mechanical fasteners (screws, bolts, nails, rivets or the like) and / or by using an adhesive. The pieces of material may be connected to the body of the panel and / or to at least one of a plurality of spacing members connected to the body of the panel and extending outwardly therefrom.

[0050] In some embodiment, an outer surface of the first panels and / or the second panels may include one or more protrusions and / or one or more reinforcing members thereon. In these embodiments, at least one of the one or more protrusions and / or one or more reinforcing members may be connected to any suitable member. For instance, at least one of the one or more protrusions and / or one or more reinforcing members may be connected to a connection member and / or one or more structural reinforcement members.

[0051] The one or more structural reinforcement members may be of any suitable form. It is envisaged, however, that the use of the one or more structural reinforcement members may ensure that the present invention generally complies with local seismic building codes.

[0052] Thus, it is envisaged that the one or more structural reinforcement members may be of relatively robust construction, and may increase the strength and / or ductility of the construction. The one or more structural reinforcement members may be fabricated from any suitable material, although in a preferred embodiment of the invention, the one or more structural reinforcement members may be fabricated at least in part from a metallic material. The metallic material may be any suitable type, such as, but not limited to, aluminium, steel, titanium or the like, or a combination thereof. In a specific embodiment of the invention, the one or more structural reinforcement members may be at least partially fabricated from high strength low alloyed steel (HSLA).

[0053] The one or more structural reinforcement members may be of any suitable size and shape. For instance, the one or more structural reinforcement members may be provided in the form of a bracket or section configured for connection to the reinforcing members and / or protrusions. In some embodiments, the one or more structural reinforcement members may be C-, U-, or V-shaped in order to facilitate connection of the one or more structural reinforcement members to the reinforcing members and / or protrusions.

[0054] In an alternative embodiment of the invention, the one or more structural reinforcement members may be substantially linear. Specifically, the one or more structuralreinforcement members may be in the form of plates.

[0055] In embodiments of the invention in which the one or more structural reinforcement members comprise plates, the plates may be of any suitable thickness. For instance, the plates may be between 10mm and 1000mm. More preferably, the plates may be between 20mm and 900mm thick. More preferably, the plates may be between 30mm and 800mm thick. More preferably, the plates may be between 40mm and 700mm thick. More preferably, the plates may be between 50mm and 600mm thick. More preferably, the plates may be between 60mm and 500mm thick. More preferably, the plates may be between 70mm and 400mm thick. More preferably, the plates may be between 90mm and 250mm thick. Most preferably, the plates may be between about 125mm and about 200mm thick.

[0056] The one or more structural reinforcement members may be connected to the reinforcing members and / or the protrusions using any suitable technique. For instance, the one or more structural reinforcement members may be connected to the reinforcing members and / or the protrusions via one or more fasteners (such as mechanical fasteners, including one or more nails, bolts, screws, rivets, bolts or the like), via adhesives, or via a heat treatment process (such as welding or brazing).

[0057] The one or more structural reinforcement members may be of any suitable size. For instance, the one or more structural reinforcement members may be of substantially the same length as the reinforcement members and / or the protrusions. In this embodiment, the structural reinforcement members may extend substantially the entire length of the preformed construction element. Alternatively, the one or more structural reinforcement members may be of shorter length than the reinforcement members and / or the protrusions. In these embodiments, it is envisaged that the structural reinforcement members may be at least partially embedded within the layer of cementitious material poured onto the preformed construction element.

[0058] In some embodiments, a plurality of structural reinforcement members may be associated with each of the preformed construction elements. In these embodiments, the plurality of structural reinforcement members may abut one another, may overlap with one another and / or may be joined to one another (such as by welding, one or more mechanical fasteners or the like).

[0059] In other embodiments, the structural reinforcement members may extend beyond at least one edge of the preformed construction element. In these embodiments, the structural reinforcement members may be configured for connection to one or more building elements. The structural reinforcement members may be configured for connection to any suitable building element, such as, but not limited to, one or more beams, rafters, studs, joists, battens, purlins, stanchions, sills, posts, plates, struts or the like, or any suitable combination thereof.

[0060] The one or more structural reinforcement members may be connected to the building elements using any suitable technique. For instance, the one or more structural reinforcement members may be connected to the building elements via one or more fasteners (such as mechanical fasteners, including one or more nails, bolts, screws, rivets, bolts or the like), via adhesives, or via a heat treatment process (such as welding or brazing).

[0061] In some embodiments of the invention, the one or more structural reinforcement members may be provided with one or more apertures therein through which one or more mechanical fasteners are configured to pass to facilitate connection to the building elements and / or to the reinforcing members and / or the protrusions.

[0062] In some embodiments, a plurality of structural reinforcement members may be stacked on top of one another. In other embodiments, one or more structural reinforcement members may be located on each opposed side or face of a reinforcing member and / or a protrusion.

[0063] The one or more structural reinforcement members may be configured for connection to any building element. For instance, the one or more structural reinforcement members may be configured for connection to a vertical building element, a horizontal building element, or a building element oriented at an angle to both the vertical and horizontal.

[0064] In some embodiments, at least one structural reinforcement member may be connected to each of the reinforcing members and / or the protrusions. In other embodiments, one structural reinforcement member may be connected to each of the reinforcing members and / or the protrusions. In yet further embodiments, a structural reinforcement member may be connected to only a portion of the reinforcing members and / or the protrusions

[0065] In some embodiments, the first panels and / or second panels are configured to be laid substantially horizontally, such that the one or more protrusions and / or the one or more reinforcing members may be configured to bond with a layer of cementitious material laid onto an upper surface of the first panels and / or the second panels.

[0066] In some embodiments of the invention, one or more edge members may be used to define at least a portion of the floor of the building. The edge members may be of any suitable form, although in some embodiments, the edge members comprise beams. The beams may be fabricated from any suitable material, although in a preferred embodiment of the invention the beams may be fabricated from a cementitious material.

[0067] In a preferred embodiment of the invention, the edge members define at least a portion of the periphery of the floor. In some embodiments, the edge members define substantially the entire periphery of the floor.

[0068] According to a second aspect of the present invention, there is provided a preformed construction element, said element including: a cementitious body having: a first face and an opposed second face; one or more side walls interconnecting the first face and the second face; and a bore extending between the first face and the second face, the bore configured to receive a vertical structural element of the building therethrough, wherein the preformed construction element further comprises one or more connection members at least partially embedded within the cementitious body, each of the one or more connection members including one or more receiving portions configured to receive a reinforcing member therein, and wherein the one or more connection members include an exposed portion located within the bore, the exposed portion configured for connection to the vertical structural element.

[0069] Preferably, the preformed constructions elements may be connectable with other like horizontal preformed construction elements to define a floor and / or ceiling of the building (or a storey thereof). The preformed construction element may be configured for connection to adjacent constructions elements in an edge to edge arrangement. The edge to edge arrangement may comprise a side edge to side edge arrangement, an end edge to side edge arrangement, and end edge to end edge arrangement, or a combination thereof.

[0070] As indicated, each preformed construction element includes a cementitious body. The cementitious body is preferably fabricated by pouring cement or concrete in a mould together with other components (such as reinforcing steel, post-tensioning elements, he one or more connection members, etc.) of the element. In some embodiments, the mould may include a casting bed and formwork. In other embodiments, the mould may be formed from just formwork.

[0071] The bore may be of any suitable size, shape or configuration. Preferably, however, the bore is substantially linear between an opening in a first face of the first panel and an opening in an opposed second face of the construction element. Preferably, the bore extends in a direction substantially perpendicular to the first face and the second face.

[0072] The bore may be of any suitable cross-sectional shape. For instance, the bore may have a circular, square or rectangular shape, or any other suitable shape. In some embodiments, the shape of the bore may be determined by the shape of the vertical structuralelement. For instance, if the vertical structural element has a circular cross-sectional shape, the construction element may be fabricated with a bore having a circular cross-sectional shape. Similarly, if the vertical structural element has a square cross-sectional shape, the construction element may be fabricated with a bore having a square cross-sectional shape.

[0073] As previously stated, the construction element comprise one or more connection members at least partially embedded within the cementitious body. The connection members may be of any suitable form. However, in a preferred embodiment of the invention, the connection members may be configured for connection to the vertical structural element. The connection members may be configured for connection to the vertical structural element using any suitable technique. For instance, the connection members may be connected to the vertical structural element using one or more mechanical fasteners (nails, rivets, bolts, screws or the like, or a combination thereof). Alternatively, the connection members and the vertical structural element may be provided with complementary engagement portions configured to connect the connection members to the vertical structural element. In other embodiments, an adhesive, bonding agent, or the like may be used to connect the connection members to the vertical structural element. More preferably, the connection members may be connected to the vertical structural element using a bonding technique, such as welding, brazing or the like.

[0074] In a preferred embodiment of the invention, the connection members may be fabricated from a metallic material. Any suitable metallic material may be used, although in a preferred embodiment of the invention, the metallic material may comprise steel.

[0075] As stated, the connection members include an exposed portion located within the bore. In this embodiment, it is envisaged that at least a portion of the connection members may be embedded within the construction element, and at least a portion of the connection members may be exposed. The exposed portion may extend outwardly from the surface of the construction element, or may be substantially flush with the surface of the construction element.

[0076] The exposed portion of the connection members may be located at any suitable location on the construction element. Preferably, however, the exposed portion may be located within the bore. The exposed portion may be located at any suitable location within the bore, although it will be understood that the exposed portion must be accessible by a user in order to connect the exposed portion to the vertical structural element.

[0077] The connection member may be of any suitable size, shape and configuration. Preferably, however, the connection member is of sufficient size such that, when embedded in the construction element, the connection member bonds to the material from which the construction element is fabricated. In some embodiments, the connection member may include one or more receiving portions therein. The receiving portions may be of any suitable size,shape or configuration, although it is envisaged that the receiving portions may be configured to receive a reinforcing member therein.

[0078] The reinforcing member may be of any suitable form. For instance, the reinforcing member may comprise a mesh, bar, rod or the like. Preferably, the reinforcing member is fabricated from a metallic material, such as, but not limited to, steel.

[0079] The reinforcing member may comprise reinforcing elements, post-tensioning elements, and the like, or a combination thereof.

[0080] In some embodiments of the invention, the receiving portions may include one or more apertures, recesses, slots, channels, cut-out portions or the like. In these embodiments, it is envisaged that the reinforcing members may be received in the receiving portions and then the construction element may be fabricated (such as by pouring a cementitious material onto and around the reinforcing members and the connection members to form the construction element.

[0081] While it will be understood that any suitable shape of connection member may be used, in some embodiments of the invention, the connection members may be in the form of plates. In these embodiments, it is envisaged that an edge or side of the connection member may form the exposed portion.

[0082] The vertical structural element may be of any suitable type. For instance, the vertical structural element may comprise a beam, column, post, wall or the like, or any suitable combination thereof.

[0083] In some embodiments the construction element may include a surface member connected to the body of the panels and forming an outer surface thereof.

[0084] In preferred embodiments, the surface member may extend across an entire surface of the construction element to facilitate the forming of a ceiling surface when the construction elements are coupled and / or joined relative to one another.

[0085] In some embodiments, surface members may be provided on more than one surface of the construction element. For example, surface members may be provided on a surface and an adjacent edge of a construction element to define a corner in room of the building, for example.

[0086] The at least one surface member may include any suitable material configured to form an interior wall or ceiling surface. For example, the surface member may include internal cladding, corflute or plasterboard. In some embodiments, the plasterboard may be fire-resistant, such as, e.g., Type X or Type C gypsum panels.

[0087] The at least one surface member may be associated with the body of theconstruction element in any suitable way. For example, the at least one surface member may be directly or indirectly bonded or fastened to the body, preferably indirectly. The surface member may be associated with the body during manufacture, or may be associated with the body in situ during the construction of the building.

[0088] Thus, in some embodiments, the construction element may be fabricated without a surface member attached thereto. As the surface member may be fabricated from a material that may degrade under certain conditions (such as when wet) it may be preferable to only attach the surface member to the construction element in situ (or at least subsequent to manufacture) in order to reduce or eliminate the possibility of the surface member becoming degraded (such as by becoming wet) during transportation to site, or on site prior to installation.

[0089] In embodiments of the invention in which a surface member may be connected to the construction element subsequent to manufacture, it is envisaged that one or more pieces of material may be connected to the construction element during fabrication to protect the panel. Any suitable pieces of material may be used, such as, but not limited to plasterboard, cardboard, polymer materials (such as but not limited to corflute), wood, metal and the like, or any suitable combination thereof. In a preferred embodiment of the invention, a plurality of pieces of material may be configured to removable connection to the construction element, for example in the form of strips. The plurality of pieces of material may be removably connected to the construction element using any suitable technique, such as by using one or more mechanical fasteners (screws, bolts, nails, rivets or the like) and / or by using an adhesive. The pieces of material may be connected to the body of the construction element and / or to at least one of a plurality of spacing members connected to the body of the construction element and extending outwardly therefrom.

[0090] In some embodiment, an outer surface of the construction element may include one or more protrusions and / or one or more reinforcing members thereon. In these embodiments, at least one of the one or more protrusions and / or one or more reinforcing members may be connected to one or more structural reinforcement members.

[0091] In some embodiments, the construction element may be configured to be laid substantially horizontally, such that the one or more protrusions and / or the one or more reinforcing members may be configured to bond with a layer of cementitious material laid onto an upper surface of the construction element.

[0092] According to a third aspect of the present invention, there is provided a method of constructing a floor of a building, the method comprising the steps of:Laying a first one or more first panels in a first horizontal orientation;Laying a plurality of second panels in the first horizontal orientation; andLaying a second one or more first panels in the first horizontal orientation, such that the first panels and the second panels extend substantially parallel to one another, the first and second panels being configured for connection to one another along adjacent side edges thereof; andWherein at least one of the first one or more first panels and / or the second one or more first panels includes a bore therethough, the bore configured to receive a vertical structural element of the building.

[0093] According to a fourth aspect of the present invention, there is provided a method of constructing a multi-storey building including the following steps:(i) laying and coupling an assembly of horizontal preformed construction elements atop one or more vertical construction elements to define a ceiling of a lower storey of the building, the horizontal preformed construction elements including one or more reinforcing members on an upper surface thereof and at least one panel member associated with a lower surface thereof in use;(ii) providing one or more structural reinforcement members, the one or more structural reinforcement members configured for connection to at least one of the one or more reinforcing members;(iii) pouring a cementitious material onto the upper surface of the assembly of horizontal preformed construction elements, and allowing the cementitious material to at least partially set and bind with the plurality of reinforcing members and the structural reinforcement members; and(iii) repeating steps (i) to (iii) until a desired number of storeys of the multi-storey building are constructed, wherein, when the preformed construction elements are coupled and / or joined together relative to one another, the at least one panel member of each said element is arranged relative to other panel members to form an internal ceiling surface of at least one room of the multi-storey building.

[0094] According to a fifth aspect of the present invention, there is provided a method of constructing a multi-storey building including the following steps:(i) laying and coupling an assembly of horizontal preformed construction elements atop one or more vertical construction elements to define a ceiling of a storey of the building, each of the construction elements including a cementitious body having one or more protrusions extending therefrom and at least one panel member defining at least one surface of the element, said element configured to be joined with adjacent like elements in a side edge to side edge arrangement;(ii) providing one or more structural reinforcement members, the one or more structural reinforcement members configured for connection to at least one of one or more protrusions;(iii) forming an upper construction base over the assembly of horizontal preformed construction elements, the construction base being formed from a cementitious material configured to bind to the cementitious body, the one or more protrusions of the construction element and the one or more structural reinforcement members; and(iii) repeating steps (i) to (iii) until a desired number of storeys of the multi-storey building are constructed, wherein, when the construction elements are coupled and / or joined together relative to one another, the at least one panel member of each said element is arranged relative to other panel members to form an internal ceiling surface of at least one room of the multi-storey building.

[0095] According to a sixth aspect of the invention, there is provided a preformed construction element, said element including: a cementitious body; one or more spacing members partially embedded in the cementitious body; and a panel member connected to the cementitious body and forming an outer surface ofthe construction element; wherein an outer surface of the cementitious body includes one or more protrusions and / or one or more reinforcing members thereon, wherein at least one of the one or more protrusions and / or one or more reinforcing members is connected to one or more structural reinforcement members, and wherein, in use, the construction element is configured to be located substantially horizontally, such that the one or more protrusions and / or the one or more reinforcing members are configured to bond with a layer of cementitious material laid onto the outer surface of the cementitious body.

[0096] According to a seventh aspect of the invention, there is provided a preformed construction element, said element including: a cementitious body; and one or more spacing members partially embedded in the cementitious body; wherein an outer surface of the cementitious body includes one or more protrusions and / or one or more reinforcing members thereon, wherein at leastone of the one or more protrusions and / or one or more reinforcing members is connected to one or more structural reinforcement members, and wherein, in use, the construction element is configured to be located substantially horizontally, such that the one or more protrusions and / or the one or more reinforcing members are configured to bond with a layer of cementitious material laid onto the outer surface of the cementitious body.

[0097] Preferably, the preformed construction element (or the horizontal preformed construction elements) further includes at least one coupling member adapted to couple with a like coupling member provided on an adjacent preformed construction element (or horizontal construction element) to couple the preformed construction elements (or horizontal construction elements) together.

[0098] It will be understood that the term “construction element” as used herein is intended to refer to the horizontal preformed construction elements of the second, fourth or fifth aspects of the invention unless otherwise stated.

[0099] Advantageously, the system and construction elements of the present invention enable a multi-storey building to be quickly and readily constructed with minimal error and by a single trade. This in part minimises delays caused by interrelated tasks carried out by multiple trades. Further embodiments of the construction elements including the coupling member in part minimise delays by enabling the construction elements to be readily aligned and coupled to one another. Lastly, the construction elements of the present invention provide the means for multi-storey buildings to be constructed in a methodical, precise and rapid manner and thereby minimise the need for extensive tarping.

[0100] The preformed construction elements may be of any suitable size and shape for defining a floor, or part thereof.

[0101] As used herein, the term “preformed” means that the construction elements have been fabricated prior to assembly. For example, the construction elements may be fabricated prior to being transported to a job or construction site. Alternatively, the construction elements may be fabricated on the job site but prior to assembly (i.e., not cast in place), preferably using a rapid set cement or concrete.

[0102] Generally, each element may be in the form of a panel having a substantially polygonal shape, preferably rectangular.

[0103] Typically, each preformed construction element may include a pair of opposed surfaces extending substantially parallel to one another, a pair of opposed side edges and a pair of opposed end edges.

[0104] In preferred embodiments, the construction elements may comprise horizontal preformed construction elements configured to define a ceiling and / or floor of the multi-storey building.

[0105] Preferably, each horizontal preformed construction element includes a pair of opposed surfaces, a pair of opposed end edges and a pair of opposed side edges. The opposed surfaces may include a downward facing surface and an opposed upward facing surface. Again, at least one of the opposed surfaces may be at least partially formed by the at least one panel member, preferably the downward facing surface.

[0106] Preferably, the horizontal preformed constructions elements may be connectable with other like horizontal preformed construction elements to define a floor and / or ceiling of the building (or a storey thereof), preferably in an edge to edge arrangement, more preferably a side edge to side edge arrangement.

[0107] In preferred embodiments, the at least one panel member of each element may extend across an entire surface of the element to facilitate the forming of a ceiling surface when the elements are coupled and / or joined relative to one another.

[0108] In some embodiments, panel members may be provided on more than one surface. For example, panel members may be provided on a surface and an adjacent edge of an element to define a corner in room of the building, for example.

[0109] As indicated, each element includes a cementitious body. The cementitious body is preferably fabricated by pouring cement or concrete in a mould together with other components of the element. In some embodiments, the mould may include a casting bed and formwork. In other embodiments, the mould may be formed from just formwork.[001 10] In some embodiments, the preformed construction element may include one or more hollow sections at least partially embedded within the cementitious body. It will be understood that the term “hollow section” refers to elongate tubing, and in particular elongate metal tubing. Most preferably, the hollow section may be elongate steel tubing. The hollow section may have any cross-sectional area. For instance, the hollow section may be circular, square, rectangular or the like in cross-sectional shape. The hollow section may be of any suitable length.[001 11] In some embodiments of the invention a single hollow section may be embedded within the cementitious body. In other embodiments, a plurality of hollow sections may be embedded within the cementitious body. In a preferred embodiment of the invention, the plurality of hollow sections is substantially identical in cross-sectional shape. In some embodiments of the invention, the plurality of hollow sections may also be substantially identical in length, width and height.[001 12] Preferably, the plurality of hollow sections is positioned substantially co-axially with one another (i.e. in an end to end arrangement), so that the hollow sections extend along at least a portion of the length of the cementitious body. More preferably, the hollow sections extend substantially the entire length of the cementitious body.[001 13] In some embodiments of the invention, the hollow sections may be provided with one or more apertures in a wall thereof. The one or more apertures may be provided such that, when forming the preformed construction element, cementitious material may flow through the one or more apertures into the interior of the hollow sections.[001 14] In some embodiments of the invention, an aperture may be provided on opposed sides of a hollow section. In this way, one or more reinforcing members (such as steel bars) may be passed through the opposed apertures and cemented into place by the cementitious material.[001 15] Generally, the cementitious body may include one or more reinforcing members at least partially embedded in the body, and preferably completely embedded in the body. In some embodiments, the reinforcing member may be a U-shaped rod or bar. In other embodiments, the reinforcing member may be a reinforcing mesh.[001 16] The at least one panel member may include any suitable panel configured to form an interior wall or ceiling surface. For example, the panel member may include internal cladding, corflute or plasterboard. In some embodiments, the plasterboard may be fire-resistant, such as, e.g., Type X or Type C gypsum panels.[001 17] The at least one panel member may be associated with the cementitious body in any suitable way. For example, the at least one panel member may be directly or indirectly bonded or fastened to the body, preferably indirectly. The panel member may be associated with the cementitious body during manufacture, or may be associated with the cementitious body in situ during the construction of the building.[001 18] Thus, in some embodiments, the construction element may be fabricated without a panel member attached thereto. As the panel member may be fabricated from a material that may degrade under certain conditions (such as when wet) it may be preferable to only attach the panel member to the construction element in situ (or at least subsequent to manufacture) in orderto reduce or eliminate the possibility of the panel member becoming degraded (such as by becoming wet) during transportation to site, or on site prior to installation.[001 19] In embodiments of the invention in which a panel member may be connected to the construction element subsequent to manufacture, it is envisaged that one or more pieces of material may be connected to the construction element during fabrication to protect the construction element. Any suitable pieces of material may be used, such as, but not limited toplasterboard, cardboard, polymer materials (such as but not limited to corflute), wood, metal and the like, or any suitable combination thereof. In a preferred embodiment of the invention, a plurality of pieces of material may be configured to removable connection to the construction element, for example in the form of strips. The plurality of pieces of material may be removably connected to the construction element using any suitable technique, such as by using one or more mechanical fasteners (screws, bolts, nails, rivets or the like) and / or by using an adhesive. The pieces of material may be connected to the cementitious body or to at least one of a plurality of spacing members connected to the cementitious body and extending outwardly therefrom.

[0120] The pieces of material may remain connected to the construction element for any suitable period of time. For instance, the pieces of material may remain connected to the construction element until the construction element arrives at the construction site. Alternatively, the pieces of material may only be removed from the construction element when a user wishes to connect the panel member to the construction element. In a preferred embodiment, the panel member may only be connected to the construction element relatively close to the installation of the construction element.

[0121] In preferred embodiments, a plurality of spacing members may extend between the cementitious body and the at least one panel member, preferably at spaced intervals. Advantageously, the spacing members may define a space between the panel member and the cementitious body for the passage of services, such as, but not limited to, cabling, piping (including, fire sprinkler piping) and insulation materials.

[0122] The spacing members may be of any suitable size, shape and form to provide a space between the panel member and the cementitious body. Generally, the spacing members may each be in the form of an elongate member that transversely extends across and between the cementitious body and the panel member.

[0123] The spacing members may or may not be load-bearing, typically the former.

[0124] The spacing member may be formed from wood, plastic or metal material or materials.

[0125] In some embodiments, the spacing member may have a rectangular shape and may be of tubular or solid construction. In other embodiments, the spacing member may have a U or C-shaped profile shape.

[0126] In some embodiments, the spacing members may additionally function as studs, joists, battens or purlins.

[0127] In preferred embodiments, the spacing member may include a batten, a purlin or a hat-type batten.

[0128] Generally, the at least one panel may be fastened to the one or more spacing members, which may be fastened or bonded to the cementitious body.

[0129] The panel member, the spacing members and the cementitious body may be fastened together in any suitable way. For example, in some embodiments, the at least one panel may be fastened to the one or more spacing members, which may be fastened to the cementitious body by one or more fasteners. The one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and / or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).

[0130] In some embodiments, the panel member may be fastened to the spacing members by one or more threaded fasteners and the cementitious body may be poured in a mould at least partly about the adjoined panel member and spacing members such that the cementitious body sets and bonds with the adjoined panel member and spacing members.

[0131] In some embodiments, the construction element may further include sheeting extending between the spacing members and the cementitious body to prevent wetting of the at least one panel memberwhen the body is cast. In such embodiments, the sheeting may include plastic, cardboard or paper sheeting. The sheeting may or may not be impermeable to wet cement, preferably the former. In some such embodiments, the sheeting may include waterproof or water-resistant sheeting, such as, e.g., waxed cardboard or paper sheeting.

[0132] Typically, the sheeting may be fastened to a side of the spacing members opposite the at least one panel member, preferably with one or more fasteners. Again, the one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and / or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).

[0133] In some particular embodiments, the sheeting may include cardboard that may be fastened to the spacing members with one or more threaded fasteners. The sheeting may be fastened such that a head of each fastener protrudes out from a surface of the sheeting to facilitate bonding between the cementitious body and the adjoined panel member and spacing members when wet cement cures in the mould about the protruding heads. In preferred such embodiments, a sealant or sealing member may be applied about each protruding fastener head prior to the cement being poured into the mould containing the adjoined panel member and spacing members.

[0134] In preferred embodiments, each construction element may further include insulation and / or sound proofing material provided between the at least one panel member and the cementitious body, preferably in spaces defined by the plurality of spacing members. The insulation and / or sound proofing material may preferably be fire resistant or fireproof. In someembodiments of the invention, one or more layers of waterproofing material may be provided between the at least one panel member and the cementitious body, preferably in spaces defined by the plurality of spacing members.

[0135] In some embodiments, the construction elements may be enveloped or partly enveloped in a waterproof coating during transit and prior to being assembled. For example, the construction elements may preferably include a removable waterproof coating configured to keep the at least one panel member dry until it has been located in position. The waterproof coating may typically include a plastic coating.

[0136] Adjacent construction elements may be connected to one another in any suitable way such that the elements are aligned relative to one another, preferably in a spaced apart arrangement or relationship.

[0137] For example, in some embodiments, each construction element may include a connecting mechanism or part of a connecting mechanism for connecting the element with adjacent elements.

[0138] The connecting mechanism may include a first part associated with an edge of the element and a second part connectable to the first part and associated with an adjacent edge of an adjacent element.

[0139] The parts of the connecting mechanism may respectively include mateable male and female portions that couple together, including threaded connections, bayonet-type connections or interference (snap-fit) connections, for example.

[0140] A first part of the connecting mechanism associated with an edge of the element may include a male formation configured to be at least partially inserted into or coupled with a female formation of a second part of the connecting mechanism associated with an adjacent edge of an adjacent construction element. Conversely, the first part of the connecting mechanism may include the female formation configured to at least partially receive or be coupled with the male formation of the second part of the connecting mechanism.

[0141] In other embodiments, the connecting mechanism may include a coupling member protruding from an edge of the construction element, preferably an edge of the cementitious body. In preferred such embodiments, each element may include a pair of coupling members extending from opposed edges of the cementitious body. Each coupling member may be adapted to couple with a coupling member provided on an adjacent edge of an adjacent construction element. It is envisaged that, once coupled together, the adjacent construction elements may form a substantially smooth surface.

[0142] Each coupling member may include at least one opening configured to align with anadjacent coupling member and receive a fastener therethrough. Advantageously, alignment of the coupling members may align the construction element relative to one another, preferably in a spaced apart relationship.

[0143] In some embodiments, at least one coupling member may include an elongate alignment or abutment flange extending transversely across the coupling member. The elongate alignment or abutment flange facilitates positive location of a portion of the coupling member of an adjacent element and in doing so aligns the respective openings of the coupling members to receive a fastener therethrough.

[0144] Generally, the elongate alignment or abutment flange may be attached to or secured relative to the at least one coupling member, preferably welded thereto.

[0145] In some embodiments, the coupling members may include metal plates extending from an edge and the opposed edge of the construction element. The metal plates may be at least partially embedded in the body.

[0146] In some such embodiments, the construction elements may include reinforcing members welded to the metal plates. The reinforcing members may be completely embedded in the body and may be U-shaped as previously described. It is envisaged that the use of hollow sections embedded in the cementitious body may allow for the reinforcing members to be of relatively small diameter in comparison to reinforcing members used when hollow sections are not embedded within the cementitious material.

[0147] In some embodiments of the invention, U-shaped reinforcing members may protrude from opposed ends of the construction element. The U-shaped reinforcing members may be connected to, or otherwise associated with, the U-shaped reinforcing members of an adjacent construction element to assist in connecting adjacent construction elements to one another.

[0148] In some embodiments, at least one of the coupling members protruding from an edge of the element may be a rod and the coupling member protruding from an opposed edge of the element may be a socket extending into the cementitious body. The rod may be at least partially embedded in the body. The socket may include a hollow tube at least partially embedded in the body.

[0149] In some such embodiments, the construction element may further include a bearing plate around the rod at the edge of the body and / or around the socket at the opposed edge of the body.

[0150] In use, the rod of the coupling member on a first construction element may be aligned relative to and be at least partially received in the socket of the coupling member on a second construction element to connect and align the first and second construction elements relative toone another.

[0151] In some particular embodiments, each element may further include a conduit extending between the opposed edges of the cementitious body.

[0152] In some embodiments, the coupling members are I-beams. For example, in some such embodiments, the at least one coupling member protruding from an edge of the element and the at least one coupling member protruding from an opposed edge of the element may be an I-beam embedded in the cementitious body and protruding outwardly from the first edge and the opposed second edge. In other such embodiments, each coupling member may include an I-beam at least partially embedded in the cementitious body and protruding from an adjacent edge.

[0153] In such embodiments, the construction element may further include a bearing plate provided on an end of each said I-beam or on each end of the I-beam.

[0154] As indicated, the construction elements may each include at least one substantially U-shaped bar protruding from an edge of the cementitious body, preferably from at least one pair of opposed edges.

[0155] Suitably, when the construction element is coupled to adjacent construction elements, the at least one substantially U-shaped bar protruding from an edge of the cementitious body may substantially align with a like at least one substantially U-shaped bar protruding from an adjacent edge of the adjacent element.

[0156] The bars may be substantially aligned with a central axis of an edge and / or an opposed edge of the element. Alternatively, the bars may be substantially perpendicular to the central axis of an edge and / or and opposed edge of the element.

[0157] In some embodiments, each construction element may include at least one adjustable bolt for adjusting a position of the construction element relative to other construction elements.

[0158] It is envisaged that construction elements may be connected to one another using adjustable steel column tops. This may be done in instances in which, for instance, it is desirable to increase the speed of construction (such as when limited crane time is available).

[0159] Preferably, in the construction of a horizontal course between storeys of a multistorey building (i.e. the course that forms the ceiling of a lower storey and the floor of an upper storey), it is envisaged that an outer surface of the construction member (and particularly the outer surface that, when located in a horizontal orientation, is configured to face upwards) may include one or more reinforcing members. The reinforcing members may be of any suitable form, although preferably the reinforcing members comprise steel reinforcing members.

[0160] The outer surface of the construction element may further comprise one or more protrusions thereon. The protrusions may be of any suitable size, shape or configuration, although in a specific embodiment, the one or more protrusions may be in the form a truncated pyramid. Preferably, each protrusion is fabricated from the cementitious material and may include one or more reinforcing members located therein or thereon.

[0161] As previously stated, a cementitious material may be poured onto the outer surface of the construction element once the construction element is in place to form a ceiling course. It is envisaged that the cementitious material may form at least a portion of the floor of an upper storey. Thus, the cementitious material may form a construction base for an upper storey of a multi-storey building.

[0162] In a preferred embodiment, one or more structural members may be located on the outer surface of the construction element once the construction element is in place to form a ceiling course. The one or more structural members may be of any suitable form, although in a preferred embodiment of the invention, the one or more structural members comprise beams, and in particular steel beams. The structural members may be of any suitable construction and may comprise Universal Beam (UB) members, Universal Column (UC) members, parallel flanged channel (PFC) members of the like, or any suitable combination thereof.

[0163] The one or more structural members may simply be placed on the outer surface (and particularly the upper surface when in use) of the construction element. Alternatively, the one or more structural members may be suspended above the outer surface of the construction element.

[0164] Preferably, the one or more structural members may be configured for attachment to one or more vertical elements of the structure, such as a column, wall, shear wall, lift shaft wall or the like, or any suitable combination thereof. The one or more structural members may be attached to the one or more vertical elements using any suitable technique. For instance, the one or more structural members may be attached to the one or more vertical elements via mechanical fasteners (screws, bolts or the like). In other embodiments, the one or more structural members may be attached to the one or more vertical elements by welding, or a similar joining technique. While it is envisaged that the structural members may be attached to a vertical member at one end thereof, it is preferred that both opposed ends of the structural members may be attached to vertical members.

[0165] The one or more structural members may be located within the cementitious material poured onto the outer surface of the construction element. Alternatively, the one or more structural elements may be located between the construction element and the cementitious material. In this embodiment, the cementitious material may be poured onto an intermediatelayer located on top of the one or more structural elements.

[0166] In some embodiments of the invention, the one or more structural elements may further be configured for attachment to the construction element, or to one or more intermediate members located between the construction element and the one or more structural elements. The one or more intermediate members may be of any suitable form, although in a preferred embodiment, the one or more intermediate members may comprise beams or bars (such as steel beams or bars) connected to the construction element. The one or more structural elements may be connected to the construction element and / or the intermediate members using any suitable technique, such as by using one or more mechanical fasteners, or by welding or a similar process. It is envisaged that, by attaching the one or more structural elements to the construction element and / or the intermediate members, deflection of the construction element in use may be reduced or eliminated.

[0167] The structural members may be attached to the construction element and / or the intermediate members at any suitable point. Preferably, however, the structural members may be attached to the construction element and / or the intermediate members at one or more points between opposed ends of the structural members. Preferably, the structural members may be attached to the construction element and / or the intermediate members at a plurality of points between opposed ends of the structural members.

[0168] By providing the one or more structural elements, the construction element, and therefore the ceiling course formed by one or more construction elements, may be strengthened. It is envisaged that this strengthening of the construction element (and the ceiling course formed therefrom) may allow the system of the present invention to be used for the construction of multistorey buildings to a height not achievable using conventional suspended ceiling constructions.

[0169] It is envisaged that, as the cementitious material sets on the outer surface of the construction element, the cementitious material may bind or otherwise engage with the outer surface (including the protrusions and reinforcing members). Thus, the cementitious material may become fixedly connected to the outer surface of the construction element.

[0170] The cementitious material may be poured onto the outer surface of the construction element in situ (i.e. when the construction element is positioned in place as the ceiling of a lower storey of a building), on-site but before the construction element is lifted into position, or off-site.

[0171] In an eigth aspect, the invention resides broadly in a system of constructing a multistorey building according to the fourth aspect wherein the preformed construction elements comprise the preformed construction element of the second, fourth or sixth aspects of the invention.

[0172] According to a ninth aspect of the present invention, there is provided a mould forforming the preformed construction element of the second, fourth or sixth aspects.

[0173] The moulds may include one or more characteristics or features of the system and construction element as hereinbefore described.

[0174] Generally, each mould will be sized and shaped for the fabrication of preformed construction elements according to engineered specifications specific to the building being constructed.

[0175] The mould may be permanent or temporary.

[0176] In some embodiments, the mould may include a casting bed and formwork. In other embodiments, the mould may be formed from just formwork.

[0177] Typically, the mould may include an open or partially open bottom to enable access for a worker to fasten the at least one panel member to the plurality of spacing members prior to concrete or cement being poured atop the adjoined panel member and spacing members.

[0178] In preferred embodiments, the mould may be suspended above a support surface, again to provide access for a worker to the open or partially open bottom of the mould.

[0179] According to a tenth aspect of the present invention, there is provided a preformed construction element formed by the mould of the ninth aspect.

[0180] Again, the construction element may include one or more characteristics or features of the system, construction element and mould as hereinbefore described.

[0181] Generally, the preformed construction element may include horizontal preformed construction elements.

[0182] A method of forming construction elements using the mould will now be described.

[0183] The at least one panel member may first be aligned and placed in the mould. In some embodiments, a protecting layer may be applied between a bottom of the mould and the panel member to prevent any damage to the panel member.

[0184] The plurality of spacing members may then be arranged atop the panel member at spaced intervals.

[0185] The panel member and spacing members may be fastened together with one or more fasteners, preferably a combination of mechanical and chemical fasteners. The mechanical fasteners may preferably be inserted via the open or partially open bottom of the mould such that the head of each mechanical fastener is flush with, or counter-sunk in, the surface of the panel member.

[0186] In some embodiments, insulation and / or sound proofing material and / orwaterproofing material may be applied between the spacing members according to engineered specifications.

[0187] Sheeting may then be fastened atop the spacing member preferably with one or more mechanical fasteners to separate and protect the underlying spacing members and panel member from cement or concrete subsequently poured into the mould to form the cementitious body.

[0188] The sheeting advantageously prevents the cement or concrete from mixing and wetting the underlying spacing members, insulation and / or sound proofing material and / or waterproofing material and / or panel member.

[0189] The sheeting may be fastened with one or more mechanical fasteners to the underlying spacing members. Preferably, the heads of the mechanical fasteners may be allowed to protrude to enhance bonding between the adjoined panel member and spacing members and the cementitious body.

[0190] In preferred embodiments, a sealing member or sealant may be applied about each fastener and / or along each edge of the sheeting to prevent the cement or concrete from passing around or through the sheeting.

[0191] Prior to pouring the cement or concrete into the mould, the hollow sections, along with one or more reinforcing members or mesh, coupling members, U-shaped bars, I-beams, bearing plates and / or adjustable bolts may be arranged and positioned within the mould atop the sheeting with supports and / or couplings.

[0192] The cement or concrete may then be poured and allowed to cure in the mould to form the cementitious body (including, where present, the one or more protrusions) and complete the fabrication of the construction element. Preferably, the concrete or cement is a rapid set concrete or cement.

[0193] In some embodiments, one or more reinforcing members may be located on top of the cement or concrete so that the cement or concrete binds to the reinforcing members, but the reinforcing members are at least partially exposed on the outer surface of the construction element.

[0194] Once cured, the construction element may be freed from the mould and lifted to a desired location, preferably by one or more cranes.

[0195] Alternatively, the mould containing the construction element may be temporarily lifted to the desired location where the construction element may be freed, and the mould may be returned to its original position. Again, the mould may be lifted and lowered by one or more cranes.

[0196] In some embodiments, each mould may be used to consecutively form a plurality of preformed construction elements. For example, the plurality of preformed construction elements may be formed in a stack build. The mould containing the plurality of preformed construction elements may then be temporarily lifted to a desired location where the plurality of construction elements may be individually freed and positioned. The mould may then be returned to its original position to resume the stack build.

[0197] In some embodiments of the invention, and particularly in the construction of a horizontal course between storeys of a multi-storey building (i.e. the course that forms the ceiling of a lower storey and the floor of an upper storey), it is envisaged that an outer surface of the construction member and / or cementitious body (and particularly the outer surface that, when located in a horizontal orientation, is configured to face upwards) may include one or more reinforcing members. The reinforcing members may be of any suitable form, although preferably the reinforcing members comprise steel reinforcing members.

[0198] As previously stated, the outer surface of the cementitious body may further comprise one or more protrusions thereon. The protrusions may be of any suitable size, shape or configuration, although in a specific embodiment, the one or more protrusions may be in the form a truncated pyramid. Preferably, each protrusion is fabricated from the cementitious material and may include one or more reinforcing members located therein.

[0199] It is envisaged that a cementitious material may be poured onto the outer surface of the construction element. It is envisaged that the cementitious material may form the floor of an upper storey (or flooring materials may be laid on top of the cementitious material). Thus, the cementitious material may form a construction base for an upper storey of a multi-storey building.

[0200] It is envisaged that, as the cementitious material sets on the outer surface of the cementitious body, the cementitious material may bind or otherwise engage with the outer surface (including the protrusions and reinforcing members). Thus, the cementitious material may become fixedly connected to the outer surface of the cementitious body, and therefore the construction element.

[0201] The cementitious material may be poured onto the outer surface of the construction element in situ (i.e. when the construction element is positioned in place as the ceiling of a lower storey of a building), on-site but before the construction element is lifted into position, or off-site

[0202] The method may include one or more characteristics or features of the system and construction elements and moulds as hereinbefore described.

[0203] As indicated, the method includes an initial step of preparing a construction site. Typically, the preparing may include pouring a floor slab. The preparing may further include positioning upright reinforcement members in the slab for the erecting of an assembly of thevertical construction elements.

[0204] The reinforcement members may include upright rebar at least partially embedded into the floor slab.

[0205] Generally, the upright reinforcement members may be positioned to align with the vertical construction elements according to a desired plan or arrangement.

[0206] The preparing may further include establishing one or more casting beds or moulds for the fabrication of the preformed construction elements. A person skilled in the art will appreciate that the number of working moulds will depend on the size of the building being constructed. For example, a construction site may include one, two, three, four, five, six, seven, eight, nine or 10 or more working moulds.

[0207] Generally, the horizontal preformed construction elements are fabricated according to engineered specifications that may be specific to the building being constructed.

[0208] In some embodiments, the moulds may be suspended moulds so that a worker may have access to an underside of the mould. For example, it is envisaged that a worker will need access to an underside of the mould to fasten the at least one panel member to the plurality of spacing members prior to the cementitious body being poured atop the adjoined panel member and spacing members.

[0209] In some embodiments, the moulds may be transportable or portable. For example, the moulds together with the cast construction elements may be temporarily lifted to a desired storey of a building being constructed, typically via tower crane. Alternatively, the moulds may be mounted to a vehicle, such as a truck (for example, a flat bed truck) and then transported to a building site. In this way, the construction elements may be case on site.

[0210] As previously stated, the method includes locating the preformed construction elements on top of vertical construction elements. Preferably, the vertical construction elements define one or more walls and / or columns of a storey of the building. The vertical construction elements may be erected using any suitable technique, although in some embodiments the vertical construction elements may be erected by aligning and coupling a lower edge of each element to a protruding upright reinforcement member, preferably via one or more coupling members protruding from a lower edge each construction element.

[0211] The vertical construction elements may further be coupled to another along adjacent side edges, again preferably via one or more coupling elements protruding from one or both side edges.

[0212] In embodiments of the invention in which the vertical construction elements comprise walls and / or columns of the building, the vertical construction elements may be configured toremain in place in the structure. In other embodiments of the invention, the vertical construction elements may comprise temporary support elements configured to be removed at a later point during construction, or at the completion of construction.

[0213] In some embodiments of the invention, the vertical construction elements may comprise preformed construction elements. In this embodiment, the vertical construction elements may comprise a cementitious body, one or more spacing members partially embedded in the cementitious body and a panel member connected to the one or more spacing members. In some embodiments, the vertical constructions element may further comprise waterproof or water-resistant sheeting extending between the spacing members and the cementitious body to prevent wetting of the panel member when the body is cast.

[0214] In other embodiments of the invention, the vertical construction element may further comprise one or more hollow sections at least partially embedded within the cementitious body. It will be understood that the term “hollow section” refers to elongate tubing, and in particular elongate metal tubing. Most preferably, the hollow section may be elongate steel tubing. The hollow section may have any cross-sectional area. For instance, the hollow section may be circular, square, rectangular or the like in cross-sectional shape. The hollow section may be of any suitable length.

[0215] In some embodiments of the invention a single hollow section may be embedded within the cementitious body. More preferably, a plurality of hollow sections may be embedded within the cementitious body. In a preferred embodiment of the invention, the plurality of hollow sections is substantially identical in cross-sectional shape. In some embodiments of the invention, the plurality of hollow sections may also be substantially identical in length, width and height.

[0216] Preferably, the plurality of hollow sections is positioned substantially co-axially with one another (i.e. in an end to end arrangement), so that the hollow sections extend along at least a portion of the length of the cementitious body. More preferably, the hollow sections extend substantially the entire length of the cementitious body.

[0217] In some embodiments of the invention, the hollow sections may be provided with one or more apertures in a wall thereof. The one or more apertures may be provided such that, when forming the preformed construction element, cementitious material may flow through the one or more apertures into the interior of the hollow sections.

[0218] In some embodiments of the invention, an aperture may be provided on opposed sides of a hollow section. In this way, one or more reinforcing members (such as steel bars) may be passed through the opposed apertures and cemented into place by the cementitious material.

[0219] In embodiments of the invention in which the vertical construction elements comprise preformed construction elements, it is envisaged that the body may include one or more reinforcing members at least partially embedded in the body, and preferably completely embedded in the body. In some embodiments, the reinforcing member may be a U-shaped rod or bar. In other embodiments, the reinforcing member may be a reinforcing mesh. The at least one panel member may include any suitable panel configured to form an interior wall surface. For example, the panel member may include internal cladding or plasterboard, typically the latter. In some embodiments, the plasterboard may be fire-resistant, such as, e.g., Type X or Type C gypsum panels.

[0220] The at least one panel member may be associated with the cementitious body in any suitable way. For example, the at least one panel member may be directly or indirectly bonded or fastened to the body, preferably indirectly. The panel member may be associated with the cementitious body during manufacture, or may be associated with the cementitious body in situ during the construction of the building.

[0221] In preferred embodiments, a plurality of spacing members may extend between the body and the at least one panel member of the vertical preformed construction elements, preferably at spaced intervals. Advantageously, the spacing members may define a space between the panel member and the body for the passage of cabling, piping (such as, but not limited to, fire sprinkler piping) and insulation materials.

[0222] The spacing members may be of any suitable size, shape and form to provide a space between the panel member and the body. Generally, the spacing members may each be in the form of an elongate member that transversely extends across and between the body and the panel member.

[0223] The spacing members may or may not be load-bearing, typically the former.

[0224] The spacing member may be formed from wood, plastic or metal material or materials.

[0225] In some embodiments, the spacing member may have a rectangular shape and may be of tubular or solid construction. In other embodiments, the spacing member may have a U or C-shaped profile shape.

[0226] In some embodiments, the spacing members may additionally function as studs, joists, battens or purlins.

[0227] In preferred embodiments, the spacing member may include a batten, a purlin or a hat-type batten.

[0228] Generally, the at least one panel may be fastened to the one or more spacingmembers, which may be fastened or bonded to the cementitious body.

[0229] The panel member, the spacing members and the cementitious body may be fastened together in any suitable way. For example, in some embodiment7s, the at least one panel may be fastened to the one or more spacing members, which may be fastened to the cementitious body by one or more fasteners. The one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and / or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).

[0230] In some embodiments, the panel member may be fastened to the spacing members by one or more threaded fasteners and the cementitious body may be poured in a mould at least partly about the adjoined panel member and spacing members such that the cementitious body sets and bonds with the adjoined panel member and spacing members.

[0231] In some embodiments, the element may further include sheeting extending between the spacing members and the cementitious body to prevent wetting of the at least one panel member when the body is cast. In such embodiments, the sheeting may include plastic, cardboard or paper sheeting. The sheeting may or may not be impermeable to wet cement, preferably the former. In some such embodiments, the sheeting may include waterproof or water-resistant sheeting, such as, e.g., waxed cardboard or paper sheeting.

[0232] Typically, the sheeting may be fastened to a side of the spacing members opposite the at least one panel member, preferably with one or more fasteners. Again, the one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and / or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).

[0233] In some particular embodiments, the sheeting may include cardboard that may be fastened to the spacing members with one or more threaded fasteners. The sheeting may be fastened such that a head of each fastener protrudes out from a surface of the sheeting to facilitate bonding between the cementitious body and the adjoined panel member and spacing members when wet cement cures in the mould about the protruding heads. In preferred such embodiments, a sealant or sealing member may be applied about each protruding fastener head prior to the cement being poured into the mould containing the adjoined panel member and spacing members.

[0234] In some embodiments, the vertical preformed construction elements may further include exterior sheathing pre-attached, typically along an outer surface. The exterior sheathing may include one or more cladding panels, preferably fastened to an outer surface of the element with one or more fasteners.

[0235] In preferred embodiments, each vertical element further includes insulation and / orsound proofing material provided between the at least one panel member and the cementitious body, preferably in spaces defined by the plurality of spacing members. The insulation and / or sound proofing material may preferably be fire resistant or fireproof.

[0236] Typically, the vertical construction elements may be covered in a waterproof coating to keep the at least one panel member on each element dry until the elements have been covered by the one or more horizontal preformed construction elements. Once covered, the waterproof coating may be removed and reused or recycled.

[0237] In some embodiments, the erected vertical construction elements may be crossbraced or temporarily braced in position. Workers may check that the vertical construction elements are plumb and aligned before fastening them to the floor slab.

[0238] As previously stated, the method includes laying and coupling an assembly of horizontal preformed construction elements atop vertical construction elements to define a ceiling of a lower storey of the building.

[0239] The horizontal preformed construction elements may be laid by aligning and coupling the elements to one or more upper end edges of the erected vertical construction elements. This may particularly be the case where the vertical construction elements form walls and / or columns of the building.

[0240] The horizontal preformed construction elements may be directly or indirectly fastened or coupled to the vertical construction elements. In some embodiments, the construction elements may be coupled via one or more coupling members protruding from edges of the vertical elements and adapted to couple with corresponding coupling members protruding from the upper end edges of the vertical construction elements.

[0241] Adjacently laid horizontal preformed construction elements may be coupled together in an edge to edge arrangement with one or more lap bars. In some embodiments, a sealant or sealing member be applied along adjoining edges, such as, e.g., a silicone sealant.

[0242] In some embodiments, one or more of the horizontal preformed construction elements may include one or more coupling members or upright reinforcing members protruding upwards from edges or the upward facing surface of the horizontal preformed construction elements for the erection of an upper storey of vertical construction elements.

[0243] The one or more coupling members or upright reinforcing members may be at least partially embedded in the cementitious body of the horizontal preformed construction elements.

[0244] Again, the one or more coupling members or upright reinforcement members may be positioned to align with the vertical construction elements of the subsequent storey according to a desired plan or arrangement.

[0245] Once the horizontal preformed construction elements are laid and coupled, the waterproof coating (if present) may be removed from the underlying the vertical construction elements as the at least one panel member (f present) of each element may now be sheltered by the laid horizontal preformed construction elements.

[0246] The steps of the method may be repeated until the desired number of storeys of the multi-storey building have been constructed. As indicated, the storeys of the building and, in particular, the construction elements are assembled in a stack build method that enables the multi-storey building to be constructed in a methodical, precise and rapid manner.

[0247] Advantageously, upon completion of construction of each storey of the building, the panel members of the assembled elements are aligned and arranged relative to one another to form internal ceiling surfaces of the storey of the building, preferably of all rooms on the storey constructed. The aligned panel members may then be sealed, sanded and painted according to a desired finish.

[0248] In some embodiments of the invention, a water guiding portion may be provided on one or more of the preformed construction elements. The water guiding portion may be of any suitable form, and may comprise a drain, pipe, conduit, channel or the like, or any suitable combination thereof. It is envisaged that the water guiding portion may be provided in order to provide a pathway for water to flow away from the preformed construction element and / or the building under construction. In particular, the water guiding portion may be provided for situations in which water may collect (for instance overnight during construction) so that the water is able to flow away from the level of the building under construction prior to concrete being poured.

[0249] Preferably, the construction element may be fabricated remote to the multi-storey building and transported thereto using any suitable technique. Preferably, the construction element is fabricated on a surface, such as a table surface. Preferably, the surface is positioned a sufficient height above the ground so as to prevent the construction element from contacting the ground during construction. Preferably, the surface is at least 900mm above the ground.

[0250] It will be understood that the term “remote to the multi-storey building” does not mean that the horizontal preformed construction elements must be formed remote to the building site. Instead, this term is intended to mean that the horizontal preformed construction elements are not formed in situ within the multi-storey building (i.e., with the use of formwork). Instead, the horizontal preformed construction elements may be fabricated on the construction site (but not in situ within the multi-storey building) or may be fabricated off site and transported thereto.

[0251] The one or more structural reinforcement members may be of any suitable form. It is envisaged, however, that the use of the one or more structural reinforcement members mayensure that the present invention generally complies with local seismic building codes.

[0252] Thus, it is envisaged that the one or more structural reinforcement members may be of relatively robust construction, and may increase the strength and / or ductility of the construction. The one or more structural reinforcement members may be fabricated from any suitable material, although in a preferred embodiment of the invention, the one or more structural reinforcement members may be fabricated at least in part from a metallic material. The metallic material may be any suitable type, such as, but not limited to, aluminium, steel, titanium or the like, or a combination thereof. In a specific embodiment of the invention, the one or more structural reinforcement members may be at least partially fabricated from high strength low alloyed steel (HSLA).

[0253] The one or more structural reinforcement members may be of any suitable size and shape. For instance, the one or more structural reinforcement members may be provided in the form of a bracket or section configured for connection to the reinforcing members and / or protrusions. In some embodiments, the one or more structural reinforcement members may be C-, U-, or V-shaped in order to facilitate connection of the one or more structural reinforcement members to the reinforcing members and / or protrusions.

[0254] In an alternative embodiment of the invention, the one or more structural reinforcement members may be substantially linear. Specifically, the one or more structural reinforcement members may be in the form of plates.

[0255] In embodiments of the invention in which the one or more structural reinforcement members comprise plates, the plates may be of any suitable thickness. For instance, the plates may be between 10mm and 1000mm. More preferably, the plates may be between 20mm and 900mm thick. More preferably, the plates may be between 30mm and 800mm thick. More preferably, the plates may be between 40mm and 700mm thick. More preferably, the plates may be between 50mm and 600mm thick. More preferably, the plates may be between 60mm and 500mm thick. More preferably, the plates may be between 70mm and 400mm thick. More preferably, the plates may be between 90mm and 250mm thick. Most preferably, the plates may be between about 125mm and about 200mm thick.

[0256] The one or more structural reinforcement members may be connected to the reinforcing members and / or the protrusions using any suitable technique. For instance, the one or more structural reinforcement members may be connected to the reinforcing members and / or the protrusions via one or more fasteners (such as mechanical fasteners, including one or more nails, bolts, screws, rivets, bolts or the like), via adhesives, or via a heat treatment process (such as welding or brazing).

[0257] The one or more structural reinforcement members may be of any suitable size. Forinstance, the one or more structural reinforcement members may be of substantially the same length as the reinforcement members and / or the protrusions. In this embodiment, the structural reinforcement members may extend substantially the entire length of the preformed construction element. Alternatively, the one or more structural reinforcement members may be of shorter length than the reinforcement members and / or the protrusions. In these embodiments, it is envisaged that the structural reinforcement members may be at least partially embedded within the layer of cementitious material poured onto the preformed construction element.

[0258] In some embodiments, a plurality of structural reinforcement members may be associated with each of the preformed construction elements. In these embodiments, the plurality of structural reinforcement members may abut one another, may overlap with one another and / or may be joined to one another (such as by welding, one or more mechanical fasteners or the like).

[0259] In other embodiments, the structural reinforcement members may extend beyond at least one edge of the preformed construction element. In these embodiments, the structural reinforcement members may be configured for connection to one or more building elements. The structural reinforcement members may be configured for connection to any suitable building element, such as, but not limited to, one or more beams, rafters, studs, joists, battens, purlins, stanchions, sills, posts, plates, struts or the like, or any suitable combination thereof.

[0260] The one or more structural reinforcement members may be connected to the building elements using any suitable technique. For instance, the one or more structural reinforcement members may be connected to the building elements via one or more fasteners (such as mechanical fasteners, including one or more nails, bolts, screws, rivets, bolts or the like), via adhesives, or via a heat treatment process (such as welding or brazing).

[0261] In some embodiments of the invention, the one or more structural reinforcement members may be provided with one or more apertures therein through which one or more mechanical fasteners are configured to pass to facilitate connection to the building elements and / or to the reinforcing members and / or the protrusions.

[0262] In some embodiments, a plurality of structural reinforcement members may be stacked on top of one another. In other embodiments, one or more structural reinforcement members may be located on each opposed side or face of a reinforcing member and / or a protrusion.

[0263] The one or more structural reinforcement members may be configured for connection to any building element. For instance, the one or more structural reinforcement members may be configured for connection to a vertical building element, a horizontal building element, or a building element oriented at an angle to both the vertical and horizontal.

[0264] In some embodiments, at least one structural reinforcement member may be connected to each of the reinforcing members and / or the protrusions. In other embodiments, one structural reinforcement member may be connected to each of the reinforcing members and / or the protrusions. In yet further embodiments, a structural reinforcement member may be connected to only a portion of the reinforcing members and / or the protrusions.

[0265] It is envisaged that the manner in which the one or more structural reinforcement members are connected to the reinforcing members and / or the protrusions, as well as to the building elements may provide the building with improved strength and / or ductility. In doing so, it is envisaged that the preformed construction elements may provide the building with improved strength (and therefore improved resistance to damage) in seismic events, or in extreme weather events (such as cyclones or the like).

[0266] The present invention provides numerous advantages over conventional construction systems. Firstly, the present invention reduces or eliminates the requirement to use formwork during the construction of a multi-storey building, resulting in a significant reduction in construction time. For instance, it is envisaged that the present invention may provide a three day floor to floor construction cycle.

[0267] It is envisaged that the present invention may provide significant cost reductions over conventional construction systems. It is envisaged that the present invention may reduce the labour requirement by up to 85% in comparison to conventional construction systems, representing a significant cost saving. In addition, the reduction or elimination of formwork represents a significant cost saving in materials and associated equipment (such as cranes, winches, hydraulic lifts etc.).

[0268] Further, the reduction or elimination of the use of formwork means that labour required forthe most dangerous part of the construction process (i.e. the installation and removal of formwork) may also be reduced or eliminated, thereby reducing the risk of injuries to workers.

[0269] Advantageously, it is envisaged that the present invention may allow for the construction of a 950 m2floor of both precast suspended floor and plasterboard ceiling in approximately 8 hours.

[0270] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0271] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.BRIEF DESCRIPTION OF DRAWINGS

[0272] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0273] Figures 1A and 1 b respectively show sectional views through vertical preformed construction elements according to embodiments of the present invention;

[0274] Figure 2 is a sectional view through a horizontal preformed construction element according to an embodiment of the present invention;

[0275] Figure 3 is a sectional view of a horizontal preformed construction element coupled together with a like horizontal preformed construction element in a side edge to side edge arrangement;

[0276] Figure 4 is a flowchart showing steps in a method of constructing a multi-storey building according to an embodiment of the present invention.

[0277] Figure 5 is a side sectional view of a vertical preformed construction element according to embodiments of the present invention.

[0278] Figure 6 is a cross-sectional view of a vertical preformed construction element according to embodiments of the present invention.

[0279] Figure 7 is a sectional view of a construction element according to an embodiment of the present invention coupled together with a like construction element in a side edge to side edge arrangement.

[0280] Figure 8 illustrates a method of constructing a floor of a building according to an embodiment of the present invention.

[0281] Figure 9 illustrates a method of constructing a floor of a building according to an embodiment of the present invention.DETAILED DESCRIPTION

[0282] Figures 1A and 1 B show various embodiments of a vertical preformed construction element (200).

[0283] As shown, each element (200) is in the form of a panel having a substantially rectangular shape.

[0284] Each element (200) includes a pair opposed surfaces, a lower end edge (not visible), an opposed upper end edge (202) and a pair of opposed side edges (204). The opposed surfaces include an inward facing surface (206) and an opposed outward facing surface (208).

[0285] In Figure 1A the plasterboard panel (220) extends entirely across the inward facing surface (206) to facilitate the formation of wall surfaces (912; not shown) when the elements (200) are coupled and / or joined relative to one another in a side edge (204) to side edge (204) arrangement.

[0286] In Figure 1 B both of the opposed surfaces include a plasterboard panel (220) extending entirely across each surface. The provision of plasterboard panels (220) across each of the surfaces facilitates the forming of internal dividing walls in a building, for example.

[0287] Referring again to Figures 1A and 1 B, each element (200) includes a cementitious body (210), which is cast in a mould together with other components of the element (200).

[0288] The body (210) includes reinforcing members at least partially embedded in the body (210; i.e., rebar)

[0289] As indicated above, the plasterboard panel(s) (220) are indirectly fastened to the cementitious body (220) via the plurality of spacing member (230) extending therebetween. The spacing members (230) are wooden battens.

[0290] Generally, the plasterboard panel(s) (220) are fastened to the spacing members (230) with mechanical fasteners and adhesive and the cementitious body is poured in a mould at least partly about the adjoined plasterboard panel(s) (220) and spacing members (230).

[0291] The element (200) further includes waterproof sheeting (240) extending between the spacing members (230) and the body (210) to prevent wetting of the plasterboard panel(s) (220) and spacing members (230) when the body (210) is cast. Typically, the sheeting (240) is fastened to the spacing members (230) with mechanical fasteners. The head (242) of each fastener protrudes out from the sheeting (240) to facilitate bonding between the body (210) and the adjoined plasterboard panel(s) (220) and spacing members (230).

[0292] Once fabricated, the construction elements (200) are enveloped or partly enveloped in a waterproof coating during transit and prior to being assembled to protect the plasterboard panels (220) from being dampened or wet.

[0293] Figure 2 shows an embodiment of a horizontal preformed construction element (300).

[0294] The element (300) is in the form of a panel having a substantially rectangular shape.

[0295] Each element (300) includes a pair opposed surfaces, a pair of end edges (302) and a pair of opposed side edges (304). The opposed surfaces include a downward facing surface (306) and an opposed upward facing surface (308).

[0296] The plasterboard panel (320) extends entirely across the downward facing surfaceto facilitate formation of a ceiling surface (not shown) when the element (300) is coupled and / or joined relative to other elements in a side edge (304) to side edge (304) arrangement as shown in Figure 3.

[0297] Each element (300) includes a cementitious body (310), which is cast in a mould together with other components of the element (300).

[0298] The body (310) includes reinforcing members, i.e., rebar, at least partially embedded in the body (310).

[0299] The plasterboard panel (320) is indirectly fastened to the cementitious body (320) via the plurality of spacing member (330) extending therebetween. The spacing members (330) are wooden battens.

[0300] The plasterboard panel (320) is fastened to the spacing members (330) with mechanical fasteners and adhesive and the cementitious body is poured in a mould at least partly about the adjoined plasterboard panel (320) and spacing members (330).

[0301] Again, the element (300) includes waterproof sheeting (340) extending between the spacing members (330) and the body (310) to prevent wetting of the plasterboard panel (320) and spacing members (330) when the body (310) is cast. The sheeting (340) is fastened to the spacing members (330) with mechanical fasteners. The head (342) of each fastener protrudes out from the sheeting (340) to facilitate bonding between the body (310) and the adjoined plasterboard panel (320) and spacing members (330).

[0302] Referring to Figure 3, the horizontal preformed construction elements (300) are coupled together in a side edge (304) to side edge (304) arrangement with one or more lap bars (350). A sealant or sealing member is applied along adjoining side edges (304). The lap bars (350) are received and fastened with one or more mechanical fasteners (not shown) in recessed grooves (309) provided on opposite sides of the upward facing surface (308) of each element (300).

[0303] Figure 4 illustrates a method (700) of constructing a multi-storey building (900).

[0304] At step 710, a construction base is prepared, including pouring a floor slab or foundation. The preparing further includes upright reinforcement members in the slab for erection of the assembly of vertical construction elements (200). The preparation of the construction base and the assembly of vertical construction elements are conventional and do not form part of the present invention.

[0305] The reinforcement members include upright rebar at least partially embedded into the floor slab or foundation.

[0306] The preparing further includes establishing one or more casting beds or moulds forthe fabrication of the preformed construction elements (300). A person skilled in the art will appreciate that the number of working moulds will depend on the size of the building (900) being constructed.

[0307] Generally, the horizontal preformed construction elements (300) are fabricated according to engineered specifications that may be specific to the building (900) being constructed.

[0308] The moulds are suspended moulds so that a worker may have access to an underside of the mould. For example, a worker will need access to an underside of the mould to fasten the plasterboard panel (320) to the spacing members (330) prior to the cementitious body (310) being poured atop the adjoined plasterboard panel (320) and spacing members (330).

[0309] Further, the moulds are transportable or portable. For example, the moulds together with the cast construction elements (300) are temporarily lifted to a desired storey of the building (900) being constructed via tower crane.

[0310] At step 720, vertical construction elements are erected to define walls and / or columns within the building (900).

[0311] At step 730, the horizontal preformed construction elements (300) are laid and coupled atop the erected vertical construction elements to define at least a portion of a floor (920) of the building (900) and a construction base for a subsequent storey.

[0312] The horizontal preformed construction elements (300) are coupled together in a side edge (304) to side edge (304) arrangement with one or more lap bars (350). A sealant or sealing member is applied along adjoining edges.

[0313] At step 740, steps 720 and 730 are consecutively repeated until the desired number of storeys of the multi-storey building (900) have been constructed.

[0314] Upon completion of construction of each storey of the building (900), the plasterboard panels (320) of the assembled elements (300) form internal ceiling surfaces (922) of the storey of the building (900). The plasterboard panels (320) are ready to be sealed, sanded and painted according to a desired finish.

[0315] Figure 5 is a side sectional view of a vertical preformed construction element 1000 according to embodiments of the present invention. The construction element includes a plurality of rectangular hollow sections 1001 positioned end on end within the element 1000. The hollow sections 1001 are embedded within a cementitious body 1002. Spacing members 1003 in the form of battens are partially embedded within the cementitious material 1002 to form a portion of the outer surface of the element 1000.

[0316] Apertures 1004 are provided in the hollow sections 1001 to both allow the flow of wet cementitious material therethrough during the forming of the element 1000 and to allow reinforcing members (not shown in this Figure) to pass through the apertures 1004.

[0317] A coupling member 1005 extends along the length of the element 1000 and protrudes from opposed ends thereof. The coupling member 1005 may be connected to the coupling member 1005’ of an adjacent element 1000’ to form levels or floors within the structure being constructed. Typically, coupling members 1005, 1005’ are connected using mechanical fasteners, such as, but not limited to, bolts, and in particularly high tensile bolts.

[0318] U-bars 1006 also extend outwardly from opposed ends of the element 1000, and the U-bars 1006 projecting from adjacent elements 1000, 1000’ may also be joined together in order to connect the adjacent elements 1000, 1000’ to one another.

[0319] Once adjacent elements 1000, 1000’ are connected to one another concrete 1007 is poured into the gap between the cementitious bodies 1002 of adjacent elements 1000, 1000’. In this way, a floor may be formed between adjacent levels or storeys within the structure.

[0320] Figure 6 is a cross-sectional view of a vertical preformed construction element 1000 according to embodiments of the present invention. In this Figure, the rectangular hollow section 1001 may be seen embedded within the cementitious body 1002, with the coupling member 1005 positioned within the rectangular hollow section 1001 and surrounded by the cementitious body 1002.

[0321] Reinforcing members 1008 may be seen passed through apertures (obscured) in the hollow section 1001.

[0322] Spacing members 1003 are partially embedded within the cementitious body 1002 and form part of the outer surface of the element 1000. The spacing members 1003 are configured to allow the connection of a panel member (not shown in this Figure) thereto.

[0323] Figure 7 is a sectional view of a construction element 2000 according to an embodiment of the present invention coupled together with a like construction element 2001 in a side edge to side edge arrangement. In this Figure, the construction element 2000 is used to form the ceiling 2002 of a lower storey of a multi-storey building.

[0324] The construction element 2000 includes a cementitious body 2003 which may also be a mixture of cementitious material and insulation material. A panel member 2004 is connected a lower surface of the cementitious body 2003 in use.

[0325] An upper surface of the cementitious body 2003 (and therefore the upper surface of the construction element 2000) includes a pair of protrusions 2005 in the form of truncated pyramids thereon. The protrusions 2004 including reinforcing members 2006, and additionalreinforcing members 2007 are located on the outer surface of the cementitious body 2003.

[0326] Cementitious material in the form of concrete 2008 is poured onto the exposed upper surface of the cementitious body 2003 and, as the concrete 2008 sets, it binds with the protrusions 2005 and reinforcing members 2006, 2007.

[0327] The concrete 2008 forms a construction base for an upper storey of the building. The concrete 2008 may form the floor of the upper storey, or flooring material may be laid on top of the upper surface of the concrete 2008.

[0328] Figure 8 illustrates a method of constructing a floor of a building according to an embodiment of the present invention. In this Figure, a cross-sectional view, a preformed construction element 2100 is shown when connected to a vertical structural element 2101. The vertical structural element 2101 comprises two sections 2101 a, 2101 b joined together in an end to end configuration by a weld 2102 to form a vertical column.

[0329] The construction element 2100 is in the form of a panel including a bore extending therethrough between a first face 2103 and an opposed second face 2104. The panel 2100 is positioned such that the column 2101 passes through the bore.

[0330] A pair of connection members 2105 are embedded within the cementitious body of the panel 2100. The connection members 2105 include a plurality of receiving portions 2106 in the form of apertures and slots therein. The receiving portions 2106 are configured to receive reinforcing members (such as steel reinforcement, post-tensioning members and the like) therein. When the cementitious material comprising the body of the panel 2100 is poured, the cementitious material, reinforcing members and connection members 2105 are bonded together to increase the overall mechanical strength of the panel 2100.

[0331] The connection members 2105 are provided in the form of plates having an exposed edge 2107 located within the bore. The exposed edges 2107 of each connection member is connected to the column 2101 via a weld 2108.

[0332] The surface of the bore (other than the exposed portions 2107 of the connection members 2105) is connected to the column 2101 using a bonding agent. In particular, the bonding agent may be configured to achieve a compressive strength of at least 50 MPa.

[0333] Figure 8 illustrates a method of constructing a floor of a building according to an embodiment of the present invention. Figure 9 comprises a plan view of the floor of a building comprising a first plurality of first panels 2120 located in a first orientation and a second plurality of first panels 2121 located in the first orientation. The first plurality of first panels 2120 and the second plurality of first panels 2121 are spaced apart from one another by a plurality of second panels 2122 that are positioned in a second orientation, the second orientation beingsubstantially perpendicular to the first orientation.

[0334] Each of the first panels 2120, 2121 includes a bore 2123 therethrough. In use, a vertical structural element, such as a column (not shown in this Figure) passes through the bore 2123 and is connected thereto.

[0335] The column is connected to the bore 2123 by welding connection members (not shown in this Figure) located within the bore 2123 to the column. In addition, a bonding agent (not shown) is used to connect the internal surfaces of the bore 2123 to the column.

[0336] The first plurality of first panels 2120 are connected to one another using a bonding agent in an end on end configuration, as is the second plurality of first panels 2121 .

[0337] The plurality of second panels 2122 are connected to the first plurality of first panels 2120 and the second plurality of first panels 2121 at opposed ends thereof using a bonding agent. The second panels 2122 are each connected to adjacent second panels 2122 in a side to side configuration using a bonding agent.

[0338] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0339] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0340] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

CLAIMS1 . A method of constructing a floor of a building, the method comprising the steps of:Laying a first one or more first panels in a first horizontal orientation;Laying a plurality of second panels in a second horizontal orientation, the second horizontal orientation being substantially perpendicular to the first horizontal orientation, wherein a first end of each of the plurality of second panels is configured for attachment to an edge of the first of the one or more first panels; andLaying a second one or more first panels in the first horizontal orientation, the second one or more first panels being located parallel to the first one or more first panels,Wherein an opposed second end of each of the plurality of second panels is configured for attachment to an edge of the second one or more first panels; andWherein at least one of the first one or more first panels and / or the second one or more first panels includes a bore therethough, the bore configured to receive a vertical structural element of the building.

2. The method according to claim 1 wherein the first panels and the second panels are precast panels.

3. The method according to claim 1 or claim 2 wherein the first panels and the second panels are connected to one another using a bonding agent.

4. The method according to any one of the preceding claims wherein the first panels include one or more connection members at least partially embedded therewithin.

5. The method according to claim 4 wherein the one or more connection members are configured for connection to the vertical structural element.

6. The method according to claim 4 or claim 5 wherein the one or more connection members are configured for connection to the vertical structural element by welding.

7. The method according to any one of claims 4 to 6 wherein the one or more connection members include an exposed portion configured for connection to the vertical structural element.

8. The method according to claim 7 wherein the exposed portion is located within the bore.

9. The method according to any one of claims 4 to 8 wherein the connection member includes one or more receiving portions therein, the receiving portions configured to receive a reinforcing member therein.

10. The method according to claim 9 wherein the reinforcing member comprises reinforcingelements or post-tensioning elements.11 . The method according to any one of the preceding claims wherein the first panels and / or the second panels include a surface member forming an outer surface of the panels.

12. The method according to claim 11 wherein the surface member comprises corflute.

13. A preformed construction element, said element including: a cementitious body having: a first face and an opposed second face; one or more side walls interconnecting the first face and the second face; and a bore extending between the first face and the second face, the bore configured to receive a vertical structural element of the building therethrough, wherein the preformed construction element further comprises one or more connection members at least partially embedded within the cementitious body, each of the one or more connection members including one or more receiving portions configured to receive a reinforcing member therein, and wherein the one or more connection members include an exposed portion located within the bore, the exposed portion configured for connection to the vertical structural element.

14. The performed construction element according to claim 13 wherein the bore is substantially linear between an opening in a first face of the first panel and an opening in an opposed second face of the construction element.

15. The preformed construction element according to claim 13 or claim 14 wherein the one or more connection members are configured for connection to the vertical structural element by welding.

16. A method of constructing a floor of a building, the method comprising the steps of:Laying a first one or more first panels in a first horizontal orientation;Laying a plurality of second panels in the first horizontal orientation; andLaying a second one or more first panels in the first horizontal orientation, such that the first panels and the second panels extend substantially parallel to one another, the first and second panels being configured for connection to one another along adjacent side edges thereof; andWherein at least one of the first one or more first panels and / or the second one ormore first panels includes a bore therethough, the bore configured to receive a vertical structural element of the building17. A method of constructing a multi-storey building including the following steps:(i) laying and coupling an assembly of horizontal preformed construction elements atop one or more vertical construction elements to define a ceiling of a lower storey of the building, the horizontal preformed construction elements including one or more reinforcing members on an upper surface thereof in and at least one panel member associated with a lower surface thereof in use;(ii) providing one or more structural reinforcement members, the one or more structural reinforcement members configured for connection to at least one of the one or more reinforcing members;(iii) pouring a cementitious material onto the upper surface of the assembly of horizontal preformed construction elements, and allowing the cementitious material to at least partially set and bind with the plurality of reinforcing members and the one or more structural reinforcement members; and(iv) repeating steps (i) to (iii) until a desired number of storeys of the multi-storey building are constructed, wherein, when the preformed construction elements are coupled and / or joined together relative to one another, the at least one panel member of each said element is arranged relative to other panel members to form an internal ceiling surface of at least one room of the multi-storey building.

18. A method of constructing a multi-storey building including the following steps:(i) laying and coupling an assembly of horizontal preformed construction elements atop one or more vertical construction elements to define a ceiling of a storey of the building, each of the construction elements including a cementitious body having one or more protrusions extending therefrom and at least one panel member defining at least one surface of the element, said element configured to be joined with adjacent like elements in a side edge to side edge arrangement;(ii) providing one or more structural reinforcement members, the one or more structural reinforcement members configured for connection to at least one of one or more protrusions;(iii) forming an upper construction base over the assembly of horizontal preformed construction elements, the construction base being formed from a cementitious material configured to bind to the cementitious body and the one or moreprotrusions of the construction element; and(iv) repeating steps (i) to (iii) until a desired number of storeys of the multi-storey building are constructed, wherein, when the construction elements are coupled and / or joined together relative to one another, the at least one panel member of each said element is arranged relative to other panel members to form an internal ceiling surface of at least one room of the multistorey building.

19. A method according to claim 17 or claim 18 wherein the horizontal preformed construction elements include a pair of opposed surfaces extending substantially parallel to one another, a pair of opposed side edges and a pair of opposed end edges.

20. A method according to claim 19 wherein the at least one of the opposed surfaces is at least partially formed by the at least one panel member.

21. A method according to claim 19 or claim 20 wherein the horizontal preformed construction elements are connectable with other horizontal preformed construction elements in an edge to edge arrangement to define a floor and / or ceiling of the building, or a storey thereof.

22. A method according to claim 17 wherein he horizontal preformed construction elements include a cementitious body, the cementitious body including one or more reinforcing members at least partially embedded therein.

23. A method according to any one of claims 17 to 22 wherein the at least one panel member is configured to form a ceiling surface.

24. A method according to claim 18 or claim 22 wherein a plurality of spacing members extend between the cementitious body and the at least one panel member.

25. A method according to claim 24 wherein the plurality of spacing members define a space between the panel member and the cementitious boy for the passage of services.

26. A method according to claim 24 or claim 25 wherein the at least one panel member is fastened to the plurality of spacing members, which are fastened or bonded to the cementitious body.

27. A method according to any one of claims 24 to 26 wherein the horizontal preformed construction element further comprises waterproof or water-resistant sheeting extending between the spacing members and the cementitious body to prevent wetting of the at least one panel member.

28. A method according to any one of claims 17 to 27 wherein each horizontal preformedconstruction element includes a connecting mechanism, or a part of a connecting mechanism, for connecting the horizontal preformed construction elements with adjacent horizontal preformed construction elements.

29. A method according to claim 27 wherein the connecting mechanism includes a coupling member protruding from an edge of the horizontal preformed construction elements, the coupling member being adapted to couple with a coupling member provided on an adjacent edge of an adjacent horizontal preformed construction element such that, once coupled together, the adjacent horizontal preformed construction elements form a substantially smooth surface.

30. A method according to any one of claims 17 to 29 whether the horizontal preformed construction elements include at least one adjustable bolt for adjusting a position of the horizontal preformed construction element relative to other horizontal preformed construction elements.31 . A method according to claim 18 wherein the one or more protrusions are in the form of a truncated pyramid, and include one or more reinforcing members located therein or thereon.

32. A method according to any one of claims 17 to 31 wherein the cementitious material forms at least a portion of a floor of an upper storey, such that the cementitious material forms a construction base for an upper storey of a multi-storey building.

33. A method according to any one claims 17 to 32 wherein one or more structural members are located within the cementitious material.

34. A method according to any one of claims 17 to 31 wherein the cementitious material is poured onto an intermediate layer located on top of one or more structural members, such that the one or more structural members are located between the horizontal preformed construction element and the cementitious material.

35. A method according to any one of claims 17 to 34 wherein the horizontal preformed construction elements are laid atop the vertical construction elements by aligning and coupling the horizontal preformed construction elements to one or more upper edges of the vertical construction elements.

36. A method according to any one of claims 17 to 35 wherein one or more of the horizontal preformed construction elements include one or more coupling members or upright reinforcing members protruding upwards from edges or an upward facing surface of the horizontal preformed construction elements for the erection of an upper storey of vertical construction elements.

37. A method according to any one of claims 17 to 36 wherein the horizontal preformed construction elements are fabricated remote to the multi-storey building.

38. A preformed construction element, said element including: a cementitious body; one or more spacing members partially embedded in the cementitious body; and a panel member connected to the cementitious body and forming an outer surface of the construction element; wherein an outer surface of the cementitious body includes one or more protrusions and / or one or more reinforcing members thereon, wherein at least one of the one or more protrusions and / or one or more reinforcing members is connected to one or more structural reinforcement members, and wherein, in use, the construction element is configured to be located substantially horizontally, such that the one or more protrusions and / or the one or more reinforcing members are configured to bond with a layer of cementitious material laid onto the outer surface of the cementitious body.

39. A preformed construction element according to claim 38, wherein the preformed construction element comprises the horizontal preformed construction element of any one of claims 17 to 37.

40. A preformed construction element, said element including: a cementitious body; and one or more spacing members partially embedded in the cementitious body; wherein an outer surface of the cementitious body includes one or more protrusions and / or one or more reinforcing members thereon, wherein at least one of the one or more protrusions and / or one or more reinforcing members is connected to one or more structural reinforcement members, and wherein, in use, the construction element is configured to be located substantially horizontally, such that the one or more protrusions and / or the one or more reinforcing members are configured to bond with a layer of cementitious material laid onto the outer surface of the cementitious body.

41. A preformed construction element according to claim 40, wherein the preformed construction element comprises the horizontal preformed construction element of any one of claims 17 to 37.

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