Pile cap

Abstract

A pile cap is disclosed which is configured to interface between a pile or flooring support and a flooring or building component. The pile cap comprises a connection portion configured to connect the pile cap to a pile or flooring support, a support portion configured to support one or more flooring or building components and one or more articulated joints configured to enable an angle of inclination of the support portion to be varied.

Description

[0001] PILE CAP

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a pile cap, apparatus, a building system and a method of construction.

[0004] BACKGROUND

[0005] Foundation structures or flooring support structures are important components in the construction of buildings. Such foundation structures or flooring support structures may serve as the base upon which a residential, commercial or public property may be constructed especially if the ground is loosely compacted. Foundation structures or flooring support structures are known which are designed to penetrate the ground to an extended depth in order to contact solid rock or other formations which can provide an effective load bearing support. Foundation structures or flooring support structures are designed to bear the weight of an above-ground building including gravity loads and to transfer that weight effectively to the underlying soil, ground or rock.

[0006] Various foundation structures or flooring support structures are known. For example, foundation structures or flooring support structures such as piles, stumps or posts may be utilised. In particular, foundation structures or flooring support structures are known which comprise screw piles having a helical design which are rotated or screwed into loosely compacted soil in order to provide a firm foundation for a superstructure such as a building.

[0007] It will be understood that a building’s foundation is normally arranged so as to provide a stable level surface which is capable of supporting a superstructure such as a building and wherein the weight of the building is ideally distributed as evenly as possible in order to prevent differential settlement of the building which could, in the extreme, cause the building to fail.

[0008] In addition, by anchoring the building to the ground using foundation structures, the foundation structures also serve to resist natural forces such as wind, water and seismic activity that might otherwise displace or destabilise the building. The effectiveness and reliability of a foundation depends upon its integration with the soil and the suitability of its design for the specific environmental conditions.

[0009] Various foundation structures and flooring support structures are known and the choice as to which foundation structure or flooring support structure is utilised for a building may depend upon the specific soil conditions and the load-bearing requirements of the building. For example, in environments with loose or less cohesive soils thatcannot adequately support structural loads at shallow depths, then deep foundations may be necessary which can transfer loads to deeper, more stable soil layers or bedrock. One common deep foundation system involves the use of piles which are driven or drilled into the ground at predetermined locations to provide stability for a supporting building. Piles offer resistance against vertical forces, such as the weight of the building. In addition, piles are able to resist lateral forces such as wind and seismic activity thereby ensuring structural integrity of the building.

[0010] Conventional foundation structures are typically permanent installations and may be constructed in situ at the building site. For example, conventional piles may comprise poured concrete or other rigid materials which are allowed to set before the building is erected being supported upon the piles or other foundation structures. Once installed, foundation structures or flooring support structures such as piles, for obvious reasons, cannot be easily adjusted or relocated. For example, if a foundation structure or flooring support structure is installed and is misaligned slightly either laterally and / or vertically during installation, then the resulting misalignment of the foundation structure or flooring support structure is problematic especially in terms of securing a flooring or building component to the foundation structure or flooring support structure. The installation process for foundation structures or flooring support structures such as piles is therefore typically a labour-intensive and time-intensive process as deep piles often need to be anchored into the ground with a high degree of accuracy.

[0011] A pile cap is a structural component which is used in conjunction with a pile (or other foundation structure or flooring support structure) which provides an interface between the foundation structure or flooring support structure and the structure it is intended to support (such as a flooring system or other part of a building). One particular type of pile is a screw pile which is a deep foundation structural component having a helical screw for efficient insertion into the ground and to provide stability in loose soil conditions. Screw piles are commonly used to enhance stability in various soil conditions especially in sand, shingle and clay. A pile cap may be configured to facilitate the transfer of loads from the superstructure to the screw pile thereby ensuring effective load distribution and structural integrity.

[0012] A pile cap is typically constructed from durable materials, such as steel or reinforced concrete and may be configured to meet specific design requirements.

[0013] Depending on the application, the pile cap can be attached to the pile shaft or other foundation structure by bolting or welding, enabling a secure and reliable connection to be made. Pile caps may be utilised in a range of applications including foundations for residential and commercial buildings, bridge supports, boardwalks, telecommunication towers and temporary structures.One problem with conventional foundation structures is that the foundation structures need to be installed with a high degree of accuracy and that once installed there is no possibility of being able to adjust the position or inclination of a foundation structure or flooring support structure such as a pile. As a result, the installation of foundation structures, flooring support structures and associated pile caps is currently both labour-intensive and time-intensive.

[0014] Another problem is that increasingly components for a building are prefabricated offsite and are assembled on site. As a result, due to operator differences and variations in soil conditions, there can be a discrepancy between where foundation structures or flooring support structures are actually installed compared with their intended precise location on a building plan. In particular, foundation structures or flooring support structures may be installed such that there is a discrepancy in either the horizontal and / or vertical positioning of the foundation structure or flooring support structure from the intended position. With regards position, it will be understood that the installed location of a foundation structure or flooring support structure may be offset from an intended position in either a horizontal x-axis and / or an orthogonal horizontal y-axis and / or a vertical z-axis. Furthermore, it will be appreciated that any such misalignment in either the x-axis, y-axis or z-axis will cause problems which then need to be compensated for onsite. In particular, a person skilled in the art will appreciate that it is important that flooring or building components are installed level and that if a flooring or building component were to be installed which was uneven then this will cause additional problems in terms of misalignment of structures built on the flooring or building components i.e. walls and roofs supported by such walls.

[0015] Accordingly, the misalignment of foundation structures or flooring support structures such as piles during the initial stages of constructing a building can cause significant problems to correct which are both labour and time intensive.

[0016] It is therefore desired to provide an improved method of constructing a building and in particular to improve the process of installing foundation structures and flooring or building support structures.

[0017] SUMMARY

[0018] According to an aspect there is provided a pile cap configured to interface between a pile or flooring support and a flooring or building component, wherein the pile cap comprises:

[0019] a connection portion configured to connect the pile cap to a pile or flooring support;

[0020] a support portion configured to support one or more flooring or building components; andone or more articulated joints configured to enable an angle of inclination of the support portion to be varied.

[0021] Throughout this specification, the term “support portion” is used consistently to denote the plate or bracket that interfaces with the flooring or building component. The terms “bearer plate”, “supporting plate” and “top plate” are used as synonyms of “support portion” unless context demands otherwise. The term “articulated joint” encompasses ball joints, pin joints, universal joints and swivel connections, and includes both “ball-up” and “ball-down” orientations.

[0022] It will be appreciated that when building even a modest single storey building then up to approximately one hundred piles or other foundation structures may need to be installed into the ground and that every pile or foundation structure needs to be installed accurately both in terms of angle to the vertical and its horizontal position. It will be appreciated that any deviation from either a vertical installation or a desired horizontal location is difficult and expensive to rectify.

[0023] The pile cap according to various embodiments is particularly advantageous in that it allows piles or other foundation structures to be installed into the ground with less precision than is currently required. This is because if a pile or foundation structure is installed at a slight angle to the vertical and / or if the pile or foundation structure is installed at a horizontal position which is a slight deviation from the intended horizontal position then the error in the angle to the vertical and / or the error in the horizontal position of the pile or foundation structure can compensated for by virtue of manipulating the articulated joint. In particular, the articulated joint can be rotated in order to vary the angle of inclination of a support portion. The vertical height of the support portion may also be adjusted.

[0024] It will be appreciated, therefore, that the present invention represents a significant advance in the art as a pile cap according to various embodiments enables a building to be constructed in a significantly reduced period of time and with substantially reduced labour costs.

[0025] The connection portion may comprise a first threaded (male) portion which may be configured to engage, in use, with a corresponding second threaded (female) portion formed on or within a pile or flooring support. Alternatively, the connection portion may comprise a first threaded (female) portion which may be configured to engage, in use, with a corresponding second threaded (male) portion formed on or within a pile or flooring support.The pile cap may be screwable, in use, towards and / or away from a pile or flooring support so as to adjust the relative height of the support portion relative to the pile or flooring support.

[0026] The support portion may comprise a first bearer plate. The first bearer plate may have a relatively large surface area so as to provide a large surface area for contacting or interfacing with a flooring or building component such as a panel, cassette, slab or beam. According to various embodiments the first bearer plate may have an upper surface area of at least x m2, wherein x is selected from (i) < 0.05; (ii) 0.05-0.06; (iii) 0.06-0.07; (iv) 0.07-0.08; (v) 0.08-0.09; (vi) 0.09-1.00; (vii) 1.00-1.10; (viii) 1.10-1.20; (ix) 1.20-1.30; (x) 1.30-1.40; (xi) 1.40-1.50; and (xii) > 1.50.

[0027] The support portion may further comprise one or more support fins which may be configured to strengthen the support portion.

[0028] The pile cap may have a longitudinal axis and the one or more of the support fins may extend radially outwards relative to the longitudinal axis.

[0029] The one or more articulated joints may comprise one or more ball joints.

[0030] According to an embodiment the one or more ball joints may comprise a ball connector and a ball joint thread, wherein in use either the ball joint thread connects to a complementary thread provided in or on the support portion or in or on a pile or flooring support.

[0031] The one or more articulated joints may according to other embodiments comprise one or more pin joints, one or more universal joints or one or more swivel connections.

[0032] The pile cap may further comprise a locking mechanism configured to lock the one or more articulated joints in position so as to substantially prevent or restrict movement or rotation of the one or more articulated joints. For example, once a pile cap has been installed and the support portion of the pile cap has been adjusted or set to a desired angle of inclination (e.g. 0° to the horizontal) then the locking mechanism may be set, activated or energised in order to lock the one or more articulated joints in position and to prevent the articulated joint from moving. In particular, the articulated joint may be prevented from rotating by the locking mechanism. Accordingly, both the angle of inclination and / or the relative height and / or the relative horizontal position of the support portion may be varied or adjusted and then set or locked in place or position.

[0033] According to various embodiments the locking mechanism may also be subsequently unlockable so as to allow subsequent movement or rotation of the one or more articulated joints after the one or more articulated joints have been previouslylocked in position. For example, it is contemplated that a support portion may be initially set or locked in position but then once a neighbouring pile cap and corresponding support portion has been installed then it may be desired to adjust the angle of inclination and / or horizontal position and / or vertical position of one or both support portions in order to ensure that neighbouring floor or building components, once installed, are accurately aligned or otherwise positioned relative to each other.

[0034] According to embodiments the locking mechanism may comprise one or more fasteners. For example, the one or more fasteners may comprise one or more bolts, one or more screws, one or more clamps, one or more magnets, one or more pins, one or more locks, one or more fixings, or one or more cam locks. According to an embodiment the articulated joint may be provided in a housing comprising a first portion and a second portion, wherein the first and second portions may be secured to each other by one, two, three, four, five, six or more than six bolts or other fasteners. As a result, the articulated joint is effectively clamped into a fixed or locked position and movement including rotation of the articulated joint is effectively prevented or at least substantially restricted or constrained. It will also be understood that the locking mechanism may be reversed and in particular that the bolts may be undone (e.g. with an Allen key) in order to allow further adjustment of the articulated joint and the support portion of the pile cap.

[0035] According to an aspect there is provided apparatus comprising:

[0036] one or more piles or flooring supports configured to form a foundation for a building structure; and

[0037] one or more pile caps as described above, wherein the one or more pile caps are secured, in use, to the one or more piles or flooring supports.

[0038] The one or more of the piles or flooring supports may comprise one or more screw piles which are configured to be secured, in use, into the ground in order to form a foundation fora building structure.

[0039] According to an embodiment the one or more piles or building supports may comprise one or more posts, one or more stumps, or one or more foundation structures. In particular, it should be understood that a pile cap according to various embodiments may be used in conjunction with a foundation structure other than a pile such as a post or anchor.

[0040] According to an aspect there is provided apparatus comprising:

[0041] one or more pile caps as described above; and

[0042] one or more flooring or building components configured to be secured, in use, to the one or more pile caps.The one or more flooring or building components may comprise one or more composite flooring cassettes or one or more flooring components fabricated from fibre reinforced polymer (“FRP”).

[0043] The one or more of the flooring or building components may comprise a plurality of reinforcing members arranged in a grid, array or other format.

[0044] According to other embodiments the one or more flooring or building components may comprise one or more bearers or joists, one or more precast concrete flooring panels, one or more timber beams or panels, or one or more metal flooring cassettes. In particular, it should be understood that a pile cap according to various embodiments may be installed to support a building component such as a concrete slab or panel.

[0045] Furthermore, a flooring system may then be installed upon or suspended from the building component(s) e.g. concrete slabs or panels. Accordingly, it is not essential that the support portion supports a floor panel but it may instead support a different building component such as a concrete slab.

[0046] According to an aspect there is provided a building system comprising:

[0047] one or more piles or flooring supports;

[0048] one or more pile caps as described above, wherein the one or more pile caps are configured to be secured to the one or more piles or flooring supports; and

[0049] one or more flooring or building components configured to be secured to the one or more pile caps.

[0050] According to an aspect there is provided a method of construction comprising: installing one or more piles or flooring supports; and

[0051] securing one or more pile caps as described above on to the one or more piles or flooring supports.

[0052] The method may further comprise varying the angle of inclination of a support portion of one or more of the pile caps in order to incline an upper portion of a support portion either substantially horizontally or otherwise at a desired angle to the horizontal.

[0053] The method may further comprise locking the angle of inclination of the support portion in order to substantially prevent movement or rotation of the support portion.

[0054] The method may further comprise unlocking the angle of inclination of the support portion in order to allow further adjustment of the support portion.

[0055] The method may further comprise reversibly locking or fixing the horizontal and / or vertical position of a support portion of one or more pile caps.It has been observed during prototyping that multi-bolt housings for ball joints demand careful even tightening to maintain plate level. To address this, a development providing a single large annular thread in co-operating housings has been developed so that a single tightening motion uniformly clamps the joint. Handles may be integrated for manual tightening where tool access is limited.

[0056] In embodiments, the locking mechanism comprises upper and lower housings having complementary annular threads which, when rotated relative to each other, compress a socket around the articulated joint to lock the joint with a single tightening motion. Handles may be integrated with one or both housings to permit manual tightening in constrained conditions, and a tool-engageable interface, such as paired recesses adapted to receive a two-projection tool, may be provided to apply torque for tightening or release. In alternative embodiments the housings are clamped around the joint with three or more bolts arranged symmetrically to provide even clamping and maintain support portion levelness.

[0057] The support portion may be formed as a plate having arcuate and / or orthogonal slots adapted to receive a pin or threaded stud from the articulated joint, permitting combined rotation and translation of the support portion to effect horizontal positional correction prior to locking. The support portion may alternatively be configured for traditional bearer and joist systems as an L bracket adapted for side fixing, or as a Y bracket adapted to receive a hinge pin, to ensure compatibility with conventional flooring frameworks.

[0058] Modular blocks or spacers of different heights may be interposed on or integrated with the support portion under one or more adjacent cassettes or building components to produce intentional step-downs or elevation differences. One or more components of the pile cap may be formed from steel, fibre-reinforced polymer, thermoplastics, fibre-reinforced thermoplastics, concrete or ceramics, including hybrid constructions such as a steel housing with an FRP support portion and polymer wear liners within the socket.

[0059] In further embodiments, the articulated element may comprise a semi-dome having a convex curved bearing surface corresponding to a spherical cap, co-operating with a complementary concave socket. The semi-dome may be oriented dome-up or dome-down and may be manufactured from fibre-reinforced polymer or thermoplastics by compression moulding, resin transfer moulding, vacuum infusion or injection moulding, optionally with bonded wear liners or bushings. The spherical cap may subtend a half-angle in the range 20-45 degrees, concentrating bearing contact in near-horizontal curvature regions to reduce material usage while retaining adequate angular adjustment.According to various embodiments there is provided a pile cap wherein the one or more articulated joints comprise a ball-and-socket joint. It will be understood that providing the articulated joint as a ball-and-socket delivers multi-axis angular adjustment with a compact, robust geometry, enabling rapid inclination correction to achieve level support portions even when piles are out of plumb.

[0060] According to various embodiments there is provided a pile cap wherein the ball-and-socket joint comprises a spherical or semi-spherical ball received within a cup-like socket portion. It will be understood that receiving a spherical or semi-spherical ball in a cup-like socket ensures continuous bearing contact and smooth articulation, improving load transfer and reducing stress concentrations under service loading.

[0061] According to various embodiments there is provided a pile cap wherein the ball-and-socket joint further comprises a shaft or shank portion, the shaft or shank portion being either integrally formed with the spherical or semi-spherical ball or attached thereto. It will be understood that integrating or attaching a shaft or shank to the ball simplifies mechanical coupling to the support or connection portions, enhancing structural integrity and facilitating straightforward assembly and adjustment.

[0062] According to various embodiments there is provided a pile cap wherein, in use, the cup-like socket portion is attached to the support portion with the shaft or shank portion extending downwards from the spherical or semi-spherical ball. It will be understood that orienting the shaft downward from the ball when the socket is attached to the support portion positions the articulation proximate the supported element, enabling fine control of the support orientation and improving levelling accuracy.

[0063] According to various embodiments there is provided a pile cap wherein, in use, the cup-like socket portion is attached to the connection portion with the shaft or shank portion extending upwards from the spherical or semi-spherical ball. It will be understood that attaching the socket to the connection portion with the shaft extending upwards configures the joint to correct inclination at the pile interface, enhancing tolerance absorption for installation deviations at the foundation.

[0064] According to various embodiments there is provided a pile cap wherein the cup-like socket portion comprises a first portion and a second portion, the spherical or semi-spherical ball being received within the first portion and the second portion being secured to the first portion using one or more fasteners. It will be understood that forming the socket from first and second portions secured by fasteners enables service access and controlled clamping of the ball, improving maintenance, adjustability and retention under dynamic loads.

[0065] According to various embodiments there is provided a pile cap further comprises a locking mechanism, the locking mechanism comprising an upper housing and a lowerhousing having complementary annular threads, rotation of the upper housing relative to the lower housing tightening or securing the ball-and-socket joint. It will be understood that complementary annular threads in upper and lower housings provide single-motion, uniform clamping of the joint, reducing installation time, improving levelness and mitigating clamp asymmetry compared with multi-bolt sequences.

[0066] According to various embodiments there is provided a pile cap wherein the upper housing and / or the lower housing comprise integrated handles configured for manual tightening. It will be understood that integrating handles allows manual torque application in constrained spaces without specialist tools, enabling reliable locking and rapid adjustments during levelling phases.

[0067] According to various embodiments there is provided a pile cap wherein the upper housing and / or the lower housing comprise a tool-engageable interface adapted to receive a two-projection tool to apply torque to tighten or release the housings. It will be understood that a dedicated two-projection tool interface ensures positive engagement and repeatable torque application, improving operator ergonomics and enabling controlled clamp force where access is limited.

[0068] According to various embodiments there is provided a pile cap wherein the support portion comprises one or more arcuate slots adapted to receive a pin or threaded stud from the articulated joint, rotation of the support portion about the stud within the arcuate slot permitting horizontal positional adjustment prior to locking. It will be understood that arcuate slots provide rotational freedom about the joint output to correct angular and lateral offsets, reducing sensitivity to pile placement tolerances and improving fit-up between adjacent modules.

[0069] According to various embodiments there is provided a pile cap wherein the support portion comprises one or more orthogonal slots permitting translation along x- and / or y-axes prior to locking. It will be understood that orthogonal slot translation enables fine linear adjustment along principal axes, achieving precise horizontal alignment without foundation rework and minimising cumulative tolerance build-up across a grid.

[0070] According to various embodiments there is provided a pile cap further comprising a locking mechanism comprising bolts arranged symmetrically around the articulated joint. It will be understood that symmetric multi-bolt clamping scales clamp capacity to larger joints and permits cross-pattern tightening to maintain plate levelness, providing a familiar fastening method for diverse site conditions.

[0071] According to various embodiments there is provided a pile cap wherein the support portion is configured as an L-shaped bracket adapted for side fixing to a bearer or joist. It will be understood that the L-shaped bracket format enables direct side fixingto timber or steel bearers and joists, ensuring compatibility with traditional flooring systems and simplifying perimeter and edge details.

[0072] According to various embodiments there is provided a pile cap wherein the support portion is configured as a Y-shaped bracket adapted to receive a hinge pin. It will be understood that the Y-shaped bracket provides controlled pivot via a received hinge pin, facilitating limited articulation where desirable whilst reliably transmitting vertical loads into the joint and connection portion.

[0073] According to various embodiments there is provided a pile cap wherein one or more components are formed from steel, fibre-reinforced polymer, thermoplastic, fibre-reinforced thermoplastics, concrete, ceramic or combinations thereof. It will be understood that multi-material construction allows optimisation of strength, corrosion resistance, weight and cost; steel offers high clamp capacity, FRP and thermoplastics reduce weight and corrosion, and hybrid designs extend service life in aggressive environments.

[0074] According to various embodiments there is provided apparatus comprising interchangeable height blocks configured to be mounted on or integrated with the support portion to produce a step-down or elevation difference between adjacent flooring or building components. It will be understood that interchangeable height blocks deliver on-site configurability of floor levels, enabling intentional step-downs for patios or thresholds, improving drainage falls and eliminating bespoke fabrication for level transitions.

[0075] According to various embodiments there is provided a method comprising tightening a locking mechanism by rotating complementary annular threads of upper and lower housings in a single motion, optionally using integrated handles ora two-projection tool. It will be understood that single-motion tightening with annular threads shortens installation and adjustment cycles and provides uniform clamp forces, with optional handles or a simple tool ensuring reliable operation in constrained spaces.

[0076] According to various embodiments there is provided a method comprising performing horizontal correction by rotating and / or sliding the support portion within one or more arcuate and / or orthogonal slots prior to locking. It will be understood that performing horizontal correction at the cap absorbs pile positioning tolerances and improves alignment of adjacent components, enhancing modular assembly speed and joint quality.

[0077] According to various embodiments there is provided a method comprising installing one or more height blocks on the support portion to produce a step-down between adjacent flooring or building components. It will be understood that installing height blocks at the support portion enables rapid creation of designed elevationdifferences without structural rework, improving adaptability of the flooring system to site-specific requirements.

[0078] According to various embodiments there is provided a pile cap wherein the articulated joint comprises a semi-dome articulated element having a convex curved bearing surface corresponding to a spherical cap and a complementary concave socket, the semi-dome being oriented dome-up or dome-down. It will be understood that the semi-dome articulated element concentrates bearing in near-horizontal curvature regions to reduce material usage and weight while retaining adequate angular adjustment for inclination correction.

[0079] According to various embodiments there is provided a pile cap wherein the spherical cap subtends a half-angle in the range 20-45 degrees. It will be understood that specifying a half-angle in the stated range balances adjustment capability with efficient contact geometry, enhancing load transmission and manufacturability of the semi-dome element.

[0080] According to various embodiments there is provided a pile cap wherein the semi-dome articulated element is manufactured from fibre-reinforced polymer or thermoplastics and optionally comprises a wear liner or bushing within the complementary socket. It will be understood that manufacturing the semi-dome in FRP or thermoplastics yields lightweight, corrosion-resistant components suited to moulding processes, while optional liners or bushings reduce friction and wear to extend service life.

[0081] BRIEF DESCRIPTION OF THE DRAWINGS

[0082] Various embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:

[0083] Fig. 1 shows a floor plan of a building featuring modular flooring panels supported on piles and associated adjustable pile caps, wherein the piles are arranged in a grid format according to an embodiment;

[0084] Fig. 2 shows a flooring system comprising modular composite flooring cassettes supported by piles anchored into the ground and wherein a pile cap provides an interface between the pile and the composite flooring cassette according to an embodiment;

[0085] Fig. 3A shows an upper view of a mould arranged to form a composite flooring cassette having a lid according to an embodiment and Fig. 3B shows a lower view of a composite flooring cassette according to an embodiment illustrating its structural design which may comprise a grid pattern;Fig. 4 shows an upper view of a composite flooring cassette having a square profile configured for modular construction according to an embodiment;

[0086] Fig. 5 shows a testing arrangement for a composite flooring cassette wherein the composite flooring cassette is subjected to a uniform distributed load according to an embodiment;

[0087] Fig. 6 shows a testing set up together with the results of the test wherein a composite flooring cassette was subjected to increasing applied loads in order to measure the deflection of the composite flooring cassette according to an embodiment;

[0088] Fig. 7 shows a testing arrangement simulating a line load applied to a composite flooring cassette to replicate wall loading conditions according to an embodiment;

[0089] Fig. 8A shows a testing arrangement for evaluating a composite flooring cassette's performance wherein weights were applied to the composite flooring cassette via steel channels which were secured to the composite flooring cassette and Fig. 8B shows steel weights being applied to the composite flooring cassette via a steel channel in a testing environment;

[0090] Fig. 9 shows the results of a load test wherein weights were applied to a composite flooring cassette according to various embodiments via a steel batten and comparative data showing the results without a steel batten;

[0091] Fig. 10A shows a timber beam bolted on to a composite flooring cassette according to an embodiment and Fig. 10B shows a side view of the timber beam under loading conditions and wherein the deflection of the composite flooring cassette is measured;

[0092] Fig. 11A shows two composite flooring cassettes joined utilising an adhesive according to an embodiment, Fig. 11 B shows how a rivet may be used to secure a steel channel component to a composite flooring cassette according to an embodiment, Fig.

[0093] 11C shows the use of a bolt and associated washer secured to a composite flooring cassette according to an embodiment, Fig. 11 D shows how screws and associated washers may be secured to a composite flooring cassette according to an embodiment and Fig. 11 E also shows how a screw may be secured directly to a composite flooring cassette according to an embodiment;

[0094] Fig. 12 shows a pull test being conducted to assess tensile strength and failure behaviour of various fixing methods for composite flooring cassettes according to various embodiments;Fig. 13 shows a side connection method for joining two composite flooring cassettes together according to an embodiment wherein an adhesive may be used to join two adjacent composite flooring cassettes together;

[0095] Fig. 14 shows a table summarising the thermal resistance R-values of various conventional building materials, composite flooring cassettes according to various embodiments and composite flooring cassettes according to various embodiments having compartments which were filled with different insulation materials according to various embodiments;

[0096] Fig. 15A shows a map of the population density of Australia and Fig. 15B shows how different regions of Australia may be subjected to different climatic conditions and in particular highlights regions which might be subjected at times to extreme weather events (and hence where local building regulations may have enhanced building requirements);

[0097] Fig. 16 shows a load test being conducted on a rectangular hollow section ("RHS") edge beam under a line load testing regime according to an embodiment;

[0098] Fig. 17 shows a load test being conducted on a parallel flange channel ("PFC") edge beam under a line load testing regime according to an embodiment;

[0099] Fig. 18 illustrates a vacuum infusion process for fabricating fibre-reinforced polymer ("FRP") solid edge beams according to an embodiment;

[0100] Fig. 19A shows a first relatively thick FRP solid edge beam fabricated according to an embodiment and Fig. 19B shows a second relatively thinner FRP solid edge beam fabricated according to various embodiments;

[0101] Fig. 20A shows how a line load test may be conducted on a FRP solid edge beam according to an embodiment and Fig. 20B shows steel weights being applied to a FRP solid edge beam in order to evaluate the structural performance of the FRP solid edge beam under loading according to an embodiment;

[0102] Fig. 21 shows a point load test being conducted on an FRP solid edge beam in order to evaluate its response under concentrated forces according to an embodiment;

[0103] Fig. 22 shows a steel loading test being performed on an FRP solid beam with a concentrated load being located at the midpoint of the FRP solid beam according to an embodiment;Fig. 23 shows a FRP perimeter edge beam constructed with multiple foam layers which was compared against the performance of steel parallel flange channel (“PFC”) beam according to an embodiment;

[0104] Fig. 24 shows a test setup for assessing the structural performance of a FRP edge beam under load conditions according to an embodiment;

[0105] Fig. 25 shows a table comparing the weight / m, cost / m and deflection of various perimeter edge beam configurations according to various embodiments when subjected to a centre point load of 2283 kg;

[0106] Fig. 26A illustrates how the horizontal position of a screw pile cap may be adjusted according to various embodiments and Fig. 26B illustrates how a plurality of screw pile caps may be integrated into a modular flooring system according to various embodiments;

[0107] Fig. 27 shows a screw pile cap according to an embodiment wherein the screw pile cap comprises a ball joint having a threaded screw and wherein the ball joint allows the vertical height of a supporting plate to be adjusted so as to adjust the relative height of the supporting plate, and wherein the ball joint is secured between an upper housing and a lower housing by four bolts which when tightened lock the ball joint into position so as to prevent rotation of the ball joint;

[0108] Fig. 28A illustrates how the horizontal position of a screw pile cap according to various embodiments may be adjusted and Fig. 28B shows a top view and side views of a screw pile cap according to various embodiments together with a supporting plate which is secured to the thread of a ball joint;

[0109] Fig. 29 shows a cross-sectional schematic of a screw pile cap according to various embodiments, wherein the screw pile cap comprises a ball joint and wherein the screw pile cap is secured to a pile and supports a bearer plate which supports a flooring cassette (or more generally a building component such as a concrete slab) according to an embodiment;

[0110] Fig. 30 shows a screw pile cap according to various embodiments showing a bearer plate supporting a composite flooring cassette according to an embodiment, wherein the composite flooring cassette includes fixing blocks through which screws or bolts may be utilised in order to secure an upper portion of the composite flooring cassette to a bracing or bearer plate of the screw pile cap;

[0111] Fig. 31 shows a ball down configuration for a screw pile cap according to an embodiment, wherein a supporting plate which includes reinforcing support fins is shownand wherein the ball joint is housed between two housings which may be secured together by one or more bolts in order to prevent rotation of the ball joint;

[0112] Fig. 32 shows a ball down configuration for a screw pile cap according to an embodiment wherein a supporting plate without reinforcing support fins is shown and wherein the ball joint is housed between two housings which may be secured together by one or more bolts in order to prevent rotation of the ball joint;

[0113] Fig. 33A shows a plurality of composite flooring cassettes according to various embodiments wherein each composite flooring cassette comprises an array of 3x3 compartments, Fig. 33B shows a plurality of composite fixing blocks which may be inserted into a compartment of a composite flooring cassette, Fig. 33C shows a rearview of two different formats of composite flooring cassettes according to various embodiments and Fig. 33D shows a side view of composite fixing blocks according to various embodiments;

[0114] Fig. 34A shows a standard format composite flooring cassette according to an embodiment comprising a uniform grid configuration and Fig. 34B shows a different format composite flooring cassette which is customisable and wherein the flooring cassette may comprise reinforcements according to an embodiment;

[0115] Fig. 35A shows a perimeter edge beam according to an embodiment wherein the perimeter edge beam is supported on an adjustable screw pile cap according to various embodiments and Fig. 35B shows a cross-sectional view of a perimeter edge beam according to an embodiment;

[0116] Fig. 36A shows for summary purposes a ball-down configuration for a screw pile cap according to various embodiments, wherein the ball joint is housed between two housings which may be secured together by one or more bolts in order to prevent rotation of the ball joint and Fig. 36B shows a ball-up configuration for a screw pile cap according to various embodiments and wherein the ball joint is housed between two housings which may be secured together by bolts in order to prevent rotation of the ball joint;

[0117] Fig. 37A shows a centre connection detail for a modular construction using screw piles and flooring panels according to an embodiment, Fig. 37B shows a patio step down detail for a modular construction using screw piles and flooring panels according to an embodiment and Fig. 37C shows an edge connection detail fora modular construction using screw piles and flooring panels according to an embodiment;

[0118] Fig. 38 shows various different adjustable support arrangements for composite flooring cassettes according to various embodiments;Fig. 39 shows test data and a graph of deflection behaviour in steel plates under a line load according to various embodiments;

[0119] Fig. 40 shows a comparative analysis of various different composite flooring cassette configurations in terms of weight, load limits and deflection characteristics according to various embodiments;

[0120] Fig. 41 shows an alternative configuration for a screw pile cap featuring a singlethread mechanism in top and bottom housings of a ball thread joint according to various embodiments;

[0121] Fig. 42 shows a screw pile cap according to an embodiment having integrated handles allowing for manual adjustment of the housing according to an embodiment;

[0122] Fig. 43 shows a screw pile cap with integrated handles for manual adjustment of the housing according to an embodiment;

[0123] Fig. 44 shows top down view of a screw pile cap with integrated handles for manual adjustment of the housing according to an embodiment and shows an upper bearing plate upon which a flooring cassette or other building component may be attached or otherwise secured;

[0124] Fig. 45 shows an alternative embodiment wherein a pile cap may be provided having an upper housing and a lower housing fora ball joint, wherein both housings may be secured to an upper plate of a pile or flooring support using a dedicated tool having two projections; and

[0125] Fig. 46 shows a tool having two projections for tightening the upper housing shown in Fig. 45 so as to secure a screw pile cap according to various embodiments to an upper plate of a pile or flooring support.

[0126] DESCRIPTION

[0127] According to various embodiments a pile cap is provided which is configured to form an interface between a pile (or flooring support) and a flooring or building component which may form part of a modular flooring or building system. The pile cap may form an interface with a flooring component directly, or alternatively the pile cap may form an interface with a building component such as a concrete slab, panel or a cassette upon which a floor may be subsequently installed or suspended. Accordingly, the pile cap may interface either directly or indirectly with a flooring system. The pile or flooring support may comprise a screw pile and the flooring component may comprise acomposite or metal flooring cassette. The pile cap includes a connection portion which is configured to engage with a pile or flooring support and to secure the pile cap to the pile or flooring support. The pile cap also includes a support portion such as a bearer plate which is intended to support a flooring or building structure such as a flooring cassette or concrete slab according to various embodiments. The bearer plate may have a relatively large surface area so as to provide a large surface area for contacting or interfacing with a flooring or building component such as a panel, cassette, slab or beam. According to various embodiments the bearer plate may have an upper surface area of at least x m2, wherein x is selected from (i) < 0.05; (ii) 0.05-0.06; (iii) 0.06-0.07; (iv) 0.07-0.08; (v) 0.08-0.09; (vi) 0.09-1.00; (vii) 1.00-1.10; (viii) 1.10-1.20; (ix) 1.20-1.30; (x) 1.30-1.40; (xi) 1.40-1.50; and (xii) > 1.50.

[0128] The pile cap may comprise one or more articulated joints which enable the angle of the support portion to be varied in order to accommodate different inclinations or alignments during construction. Furthermore, as will be described in more detail below, the pile cap according to various embodiments enables both the height of the bearer plate and / or the horizontal position of the bearer plate to be adjusted which is particularly beneficial in instances where a pile or flooring support may not have been installed to a sufficient degree of accuracy. Furthermore, even if the pile or flooring support has been installed accurately, the adjustable nature of the pile cap according to various embodiments enables the position, height and angle of inclination of a bearer plate or other structure for supporting a flooring or building component to be easily adjusted for other reasons.

[0129] According to various embodiments the connection portion of the pile cap may be configured with a (male) threaded section which is configured to engage with a corresponding (female) threaded section provided on or within the pile or flooring support. This threaded arrangement allows the pile cap to be rotated or screwed towards or away from the pile or flooring support thereby enabling precise adjustment of the height of the support portion relative to the pile or flooring support. This feature is particularly advantageous in terms of ensuring level alignment of the flooring or building component even if the piles or flooring supports are installed in uneven terrain or of there are variations in pile or flooring support installation depth various reasons.

[0130] The support portion of the pile cap may take the form of a flat or contoured plate which is intended to provide a stable platform for an overhead flooring structure or more generally a building component. For example, the overhead flooring structure may comprise one or more metal or composite flooring cassettes. Alternatively, more generally, the support portion may be configured to support a building component such as a concrete structure upon which a floor or wall may be formed. In order to enhance the structural strength and load-bearing capacity of the support portion, one or more support fins may be incorporated. The support fins may be configured so as to extendradially outward from a longitudinal axis of the pile cap and may be located in order to distribute loads more evenly so as to resist bending or deformation under significant weight. However, the provision of support fins is not essential and this feature is therefore optional. According to various embodiments some pile caps especially those which might experience relatively light loading during use may include a bearer plate which is not reinforced with support fins whereas other pile caps especially those which might experience relatively heavy loading during use may include a bearer plate which is reinforced with support fins.

[0131] According to various embodiments one or more articulated joints may be integrated into the pile cap and may be configured to offer flexibility in terms of positioning of the support portion which may comprise a bearer plate. The one or more joints may comprise one or more ball joints which allow multi-directional rotation.

[0132] Alternatively, the one or more joints may comprise pin joints which enable pivoting motion. Further embodiments are contemplated wherein the one or more joints may comprise one or more universal joints which facilitate angular adjustments in multiple planes. According to yet further embodiments the one or more joints may comprise one or more or swivel connections which may be configured to provide rotational freedom. Such flexibility ensures that the support portion can be precisely inclined to either a substantially horizontal position or at a specific angle as desired.

[0133] According to various embodiments an apparatus is provided comprising the combination of one or more foundation components such as piles together with one or more pile caps. The pile caps may be arranged to be securely attached, in use, to the foundation components or piles. According to various embodiments the foundation components or piles may comprise one or more screw piles. Screw piles are particularly effective as they are configured to be screwed into the ground thereby offering a robust and stable foundation for building structures. Pile caps as disclosed according to various embodiments, when integrated with screw piles or other forms of piles, provide an adjustable interface for subsequent structural elements such as flooring or building components. It will be apparent that the pile caps or screw pile caps according to various embodiments are particularly beneficial and enable a building constructor potentially to save considerable time and labour costs when constructing a building. It will be apparent, therefore, that the present invention represents a significant advance in the art.

[0134] According to an embodiment apparatus may be provided comprising one or more pile caps in combination with one or more flooring or building components such as composite flooring cassettes or concrete slabs. The flooring or building components may be configured to be secured to the pile caps and may comprise composite flooring systems for enhanced durability. The flooring components or composite flooring cassettes may incorporate grids of reinforcing members which may be arranged in asystematic array or regular format. This configuration allows for the construction of flooring structures that are both strong and adaptable.

[0135] A building system is also disclosed comprising foundation components such as piles or screw piles, pile caps (or screw pile caps) and one or more flooring or building components such as one or more composite flooring cassettes, one or more metal flooring cassettes or one or more concrete slabs or panels. The foundation components may be arranged or installed so as to provide a stable base, while the pile caps or screw pile caps may be arranged to connect securely to the foundation components and to offer a customisable platform for flooring or building components which may be installed or otherwise attached above the pile caps. This modular system allows for efficient assembly, adaptability to site-specific requirements and a streamlined construction process.

[0136] Additionally, a method of construction is also disclosed and will be described in more detail below. The method may comprise the step of installing piles, screw piles or flooring supports at designated locations for example in a grid or array format. Then in a subsequent step pile caps or screw pile caps may be attached to the tops of the piles, screw piles or flooring supports. The pile caps according to various embodiments include a support portion such as a bearer plate for supporting a flooring or building component such as a composite flooring cassette, metal flooring cassette or a concrete slab or panel. The method may further comprise the step of adjusting the support portion of one or more of the pile caps so that the support portion and any flooring or building component attached thereto is arranged to be substantially level or horizontal. However, it is also contemplated that the support portion and any associated flooring component may in certain situations be desired to be inclined at an angle to the horizontal in order, for example, to provide a slight slope which may encourage e.g. water to run off from e.g. a patio area towards a drain. In will be appreciated that the flexible nature of the pile cap or screw pile cap according to various embodiments which may include one or more articulated joints enables the support portion and any attached flooring or building component to be inclined at a desired angle a to the horizontal, wherein a may comprise 0-5°, 5-10°, 10-15°, 15-20°, 20-25°, 25-30°, 30-35°, 35-40°, 40-45° or> 45°. The adjustable nature of the articulated joint enables the upper surface of the support portion to be optimally aligned to support a flooring or building structure. The method provides a practical and efficient approach to construction, accommodating variations in site conditions and structural requirements while maintaining precision and structural integrity.

[0137] Various embodiments will now be described in further detail with reference to the drawings.Fig. 1 shows a floor plan of a building according to various embodiments wherein seventy-two full-sized flooring panels 130 (each measuring 2m x2m) and eight half-sized flooring panels 130 (each measuring 2m x 1m) are installed upon piles 110 arranged in a regular array. The flooring panels 130 according to various embodiments may be configured to form a modular flooring system which is configured to provide structural support for various parts of a building which is subsequently constructed upon the flooring system. In the particular case of the embodiment shown in Fig. 1 , the total floor area spans 304 m2. However, it will be understood that the modular nature of the flooring system enables the footprint of the building to be varied as desired.

[0138] As is apparent, the majority of the flooring panels 130 in the example shown in Fig. 1 are configured to support primary living areas such as bedrooms, a lounge or living area, a dining room etc. or other communal spaces. The flooring panels 130 are configured to provide a stable and uniform base for a variety of flooring finishes including timber, tile or carpet. The modularity and standardised dimensions of the flooring panels 130 allows for efficient manufacturing and installation whilst facilitating customisation to meet bespoke requirements.

[0139] According to various embodiments some of the flooring panels 130 may be configured to support wet areas such as bathrooms, kitchens or laundries. According to various embodiments flooring panels 130 which are intended to support wet areas may be reinforced to handle additional structural loads and may include features such as integrated plumbing channels, drainage systems and waterproofing membranes. For example, a flooring panel 130 located beneath a bathroom may include pre-fitted conduits for water supply and waste removal thereby streamlining installation and minimising the need for post-construction modifications.

[0140] According to various embodiments one or more of the flooring panels 130 may be configured to support outdoor areas such as a porch, balcony or terrace. It will be understood that outdoor flooring panels 130 may be configured both for structural stability whilst also addressing environmental factors. For example, balcony flooring panels 130 may include integrated attachment points for railings or balustrades and may include a sloped surface to aid water run-off. Additionally, outdoor flooring panels 130 according to various embodiments may incorporate weather-resistant finishes which are provided in order to enhance longevity and performance in outdoor conditions.

[0141] Transitional spaces, such as porches which may connect indoor and outdoor spaces or areas may incorporate flooring panels 130 which integrate both environments thereby ensuring a cohesive aesthetic and functional layout.

[0142] An important aspect of the building method illustrated in Fig. 1 and the associated modular flooring system is the provision of a plurality of pile caps, such as screw pile caps (not shown), which may be secured to the piles or flooring supports 110. The pilecaps may include a bearer plate which is configured to support or provide support to the flooring panels 130 (or more generally a building component such as a concrete panel or slab) and ensure structural stability.

[0143] The flooring and building system according to various embodiments may comprises an array of piles or flooring supports 110 which may be anchored into the ground. Each pile or flooring support 110 (which may comprise one or more screw piles) may comprise, for example, a steel tube or pile having a 90 mm outside diameter and wherein a pile or flooring support top plate may be located on the top surface of the pile or flooring support 110. The pile or flooring support top plate may comprise a square steel plate which according to various embodiments may comprise a 100 mm x 100 mm steel plate having a thickness of 16 mm. The steel plate may be configured for secure attachment to a pile cap via a central M36 female thread. It will be understood that a threaded connection between the pile or flooring support, pile or flooring support top plate and the pile cap ensures efficient load transfer and stability whilst at the same time simplifying assembly and integration with the flooring panels 130 or building components.

[0144] According to various embodiments the flooring panels or other flooring supports may comprise one or more flooring cassettes 130 may be constructed from composite materials such as fibreglass which benefits from a high strength-to-weight ratio.

[0145] Accordingly, a building system according to various embodiments is disclosed comprising a plurality of composite flooring cassettes 130. It will be understood that fabricating the composite flooring cassettes 130 from fibreglass is particularly advantageous in terms of fibreglass being resistant to corrosion, environmental degradation and fire. As a result, the installation of composite flooring panels 130 according to various embodiments enables a building to be constructed having a high fire resistance rating. Furthermore, buildings can be constructed utilising the building method according to various embodiments and the building components such as pile caps and composite flooring cassettes 130 according to various embodiments in locations or otherwise challenging environments e.g. in regions wherein strong winds may be experienced such as a cyclones, hurricanes or typhoons. The building system according to various embodiments is therefore particularly beneficial when seeking to construct a building in a region which may experience severe storms and / or in regions which may from time to time experience seismic activity. Over the past decade, countries that have experienced significant seismic events resulting in the destruction of buildings include Turkey and Syria (February 2023), Afghanistan (June 2022), Haiti (August 2021), Indonesia (September 2018), Italy (August 2016), Nepal (April 2015), Albania (November 2019), Taiwan (April 2024) and Morocco (September 2023).

[0146] According to various embodiments the composite flooring panels 130 (or building components supported by the pile caps) may be pre-fabricated and may be lightweight, durable and can be fabricated according to various embodiments in a range of differentshapes and sizes. In particular, composite flooring cassettes 130 may be utilised which according to various embodiments can be mass produced in a range of different standardised formats enabling architects and builders to design and build a building using modular construction techniques. It will be understood that one of the benefits of the modular flooring system and generally modular approach according to various embodiments is that it enables construction companies to operate a significantly reduced inventory.

[0147] One of the benefits of using according to various embodiments composite (e.g. fibreglass) flooring cassettes or panels 130 is that they can be fabricated quickly and with reduced labour costs enabling construction times to be significantly shortened. For example, according to various embodiments a building can be constructed on an urgent basis using prefabricated components and with a smaller team of builders.

[0148] With reference to Fig. 1, two wet areas are shown which may require additional structural considerations such as increased density of piles and / or specialised connections to handle environmental loads. Other regions are also highlighted which may also require reinforcement but for different reasons. For example, it is contemplated that if a particular region of the floor plan is likely to receive increased loading (such as a loading bay for lorries) then the density of piles may be varied i.e. increased. Also, certain regions of a building may require bespoke joint configurations to accommodate specific load transfer requirements.

[0149] The floor plan as shown in Fig. 1 further shows various configurations for piles (and associated pile caps) including one-way, two-way, three-way and four-way dogbone connections in order to accommodate different load directions and transfer requirements.

[0150] Fig. 2 shows a flooring system according to various embodiments wherein multiple screw piles 110 are securely anchored into the ground 100 thereby providing a stable foundation fora flooring system that incorporates a plurality of composite flooring cassettes 130 or other flooring panels. It will be understood that whilst various embodiments relate to the use of a pile cap 120 or screw pile cap 120 which is adjustable and which according to an embodiment may be deployed in conjunction with one or more composite flooring cassettes 130 that it is not essential that the pile cap 120 is utilised in conjunction with a composite flooring cassette 130. Accordingly, embodiments are contemplated wherein the pile cap 120 according to various embodiments may be utilised together with a conventional flooring system such as concrete slabs or panels.

[0151] The piles or screw piles 110 according to various embodiment may be configured to resist both vertical and lateral loads, serving as primary structural supports and wherein the piles or screw piles 110 are configured to efficiently transfer loads from theflooring system (or building components) to the underlying ground and sub-surface supporting structures such as bedrock.

[0152] The piles or screw piles 110 may be arranged in a predetermined grid or other pattern. Other embodiments are contemplated wherein the piles or screw piles 110 may be installed in a configuration which is tailored to specific structural and design requirements. Each pile or screw pile 110 may be driven into the ground to a depth sufficient to ensure stability taking into account factors such as soil conditions, anticipated loads and environmental variables. According to a preferred embodiment, installation of the piles or screw piles 110 may involve rotating a screw pile 110 into the ground 100. It will be understood that the helical design of a screw pile 110 enhances their load-bearing capacity by distributing forces over a larger area thereby providing secure anchorage.

[0153] A plurality of modular composite (or metallic or other) flooring cassettes 130 may be provided above the piles or screw piles 110 and may be secured to the piles or screw piles 110 using one or more fasteners or fixings such as screws or bolts. Each flooring cassette 130 may be pre-fabricated and may incorporate features such as integrated reinforcement, attachment points for additional structural components and accommodations for housing utilities such as electrical wiring or plumbing. The modular nature of the flooring cassettes 130 according to various embodiments facilitates rapid installation as a flooring cassette 130 can be quickly aligned and secured to a pile 110 via a pile cap 120 using standardised connectors (e.g. bolts) or brackets.

[0154] It will be understood that an aspect of various embodiments is that a pile cap 120 may be provided which provides an effective interface between a pile 110 or flooring support and a flooring cassette 130 or other flooring or building component. According to various embodiments a pile cap 120 may be configured to allow for an adjustable connection thereby enabling precise alignment of a flooring cassette 130 to ensure a level flooring system (or more generally a building component) even on uneven terrain or varying soil conditions. The ability to adjust the connection height and inclination contributes to the overall adaptability and stability of the system.

[0155] The one or more flooring cassettes 130 may be arranged contiguously to form a uniform and stable base for a building. According to various embodiments, each flooring cassette 130 (or building component) may be constructed so as to support a portion of the building's weight and to resist dynamic loads such as those caused by occupants or equipment. According to various embodiments, the one or more composite flooring cassettes 130 may include specialised materials or treatments to enhance properties such as thermal or acoustic insulation, fire resistance or overall durability.Fig. 3A shows an upper view of a moult for forming a composite flooring cassette 130 having a lid according to various embodiments and Fig. 3B shows a lower view of the same composite flooring cassette 130 and shows how the rear of the composite flooring cassette may according to various embodiments incorporate a plurality of compartments which may be defined by reinforcing members. According to various embodiments a modular, lightweight and structurally robust modular flooring cassette 130 may be provided. The composite flooring cassette 130 may comprise an upper lid portion and a lower portion which may be configured to accommodate various floor components (such as insulation) and utilities. For example, the upper lid portion as shown in Fig. 3A and / or the lower portion as shown in Fig. 3B may incorporate various recesses or cavities which may be configured for installing electrical wiring, plumbing or insulation materials.

[0156] For example, with reference to Fig. 3B the rear portion of a composite flooring cassette 130 according to various embodiments may include a plurality of compartments 130A and according to various embodiments thermal insulation and / or acoustic insulation and / or fireproof insulation may be incorporated into one or more of the compartments 130A.

[0157] It will also be understood that one or more integrated channels or pathways (not shown) may also be included to facilitate the routing of utilities across the flooring system thereby enhancing functionality and minimising the need for additional modifications during installation.

[0158] The lower portion of the composite flooring cassette 130 as shown in Fig. 3B may be configured so as to provide an optimum strength-to-weight ratio thereby ensuring that the composite flooring cassette 130 is both durable and lightweight. According to various embodiments, the rear of the composite flooring cassette 130 may comprise a grid, polygonal or other regular structure or an array of structural support elements which are configured to maximise the strength of the composite flooring cassette 130 while also ensuring minimisation of material usage and an even distribution of loads across the composite flooring cassette 130. As a result, the composite flooring cassette 130 according to various embodiments may have an enhanced load-bearing capacity without adding unnecessary weight.

[0159] According to other embodiments, the lower portion of the composite flooring cassette 130 may comprise a honeycomb or other polygonal structure which is preferably configured to provide resistance to compressive forces while further reducing material requirements. Additionally, a honeycomb geometry may be configured to enhance thermal and acoustic insulation properties thereby making it suitable for specialised applications requiring improved environmental performance.The composite flooring cassette 130 may be fabricated using a moulding process which may employ materials such as fibre-reinforced composites, lightweight metals or advanced polymers. The manufacturing method according to various embodiments may allow precise replication of complex geometries thereby ensuring uniformity across multiple units. Moulding also facilitates cost-effective and rapid production particularly for large-scale applications.

[0160] The flooring cassettes 130 may be arranged so as to be highly customisable to meet specific requirements and budgets. For example, additional reinforcements may be integrated into high-load areas of the flooring cassettes 130 for added strength.

[0161] Insulating materials may also be incorporated into the flooring cassettes 130 and in particular into one or more of the compartments 130A (or in a lid portion if provided) in order to improve thermal, acoustic or fire resistance performance. As a result, the flooring cassettes 130 according to various embodiments are particularly adaptable for various building applications including residential, commercial and industrial buildings.

[0162] Fig. 4 shows an upper view of a composite cassette 130 according to various embodiments. The particular composite cassette 130 shown in Fig. 4 has dimensions of 2 m by 2 m. However, it will be understood that the composite flooring cassette 130 according to various embodiments may have different dimensions. The composite flooring cassette 130 may have a square profile which is advantageous in terms of modularity and standardised construction. However, various other embodiments are also contemplated wherein the composite flooring cassette 130 may comprise alternative geometries allowing for flexibility in design and application to suit different structural or architectural requirements.

[0163] According to embodiments the composite flooring cassette 130 may comprise a rectangular structure. Rectangular cassettes may be particularly suited for use in spaces with elongated layouts such as corridors, galleries or specialised industrial settings where the floor dimensions are not symmetrical. Such flooring cassettes 130 may retain the modular properties of a square design while offering extended coverage along one axis thereby enhancing adaptability to a wide range of building configurations.

[0164] Further embodiments are contemplated wherein the composite flooring cassette 130 may comprise a circular or oval shape. For example, a circular flooring cassette 130 may be particularly useful for applications requiring fluid or non-angular design aesthetics such as flooring in auditoriums, arenas or other structures featuring curved layouts. Similarly, an oval flooring cassette 130 may be similarly advantageous in elongated or curved settings or where a combination of strength and aesthetic appeal is desired. The curved profiles of these configurations may also reduce material stresses at the edges contributing to enhanced durability.According to other embodiments, the composite flooring cassette 130 may comprise a polygonal configuration such as a hexagonal structure wherein a plurality of hexagonal flooring cassettes 130 are provided which may optionally having interlocking capabilities thereby allowing for seamless integration between adjacent units without gaps. Embodiments are contemplated wherein a plurality of square, rectangular or hexagonal composite flooring cassettes 130 may be provided which are particularly suitable for creating a tessellated floor designs and / or which may be utilised in spaces where load distribution and structural stability are of particular concern.

[0165] The versatility in shape and dimensions of composite flooring cassettes 130 which may be provided according to various embodiments ensures that they can be tailored to meet the needs of various construction scenarios. According to various embodiments various aspects of a composite flooring cassette 130 may be customised including the thickness, material composition or integrated features. As a result, composite flooring cassettes 130 according to various embodiments can be produced which may be optimised for specific load bearing, thermal or acoustic performance criteria.

[0166] Fig. 5 shows a testing arrangement according to various embodiments wherein a 2m x2m composite flooring cassette 130 was supported upon four posts positioned at its corners and was then subjected to an evenly distributed loaded. This setup was intended to simulate a composite flooring cassette 130 according to various embodiments resting on pile or screw pile caps according to various embodiments thereby replicating the support conditions typically encountered in practical applications. The test aimed to evaluate the structural performance and load-bearing capacity of the composite flooring cassette 130 under controlled conditions. The composite flooring cassette 130 was tested by loading the composite flooring cassette 130 with a load such as that shown in Fig. 5 i.e. a stack of standard-sized construction bricks six layers high. It will be understood that the load as shown in Fig. 5 was approximately 500 kg. This weight simulates a uniform distributed load that a composite flooring cassette 130 according to various embodiments might be expected to encounter in real-world scenarios.

[0167] The testing arrangement as shown in Fig. 5 allowed for precise measurements to be taken of the extent to which the composite flooring cassette 130 deformed in response to an applied load. Deformation was measured at multiple points across the surface of the composite flooring cassette 130 including at the centre and near the edges in order to determine how the load distributed and how effectively the composite flooring cassette 130 maintained its structural integrity. Various measurements were taken including vertical displacement which indicated the amount of deflection caused by the load. According to various embodiments the vertical displacement was recorded using one or more laser measuring devices, dial gauges or other instruments.Further tests were conducted to assess the performance of the composite flooring cassette 130 under dynamic conditions such as when the composite flooring cassette 130 is subjected to cyclic loading or impacts in order to replicate scenarios wherein the flooring system experiences movement or vibrations. These tests established the resilience of the composite flooring cassette 130 and its ability to return to its original form after being subjected to repeated or temporary loads.

[0168] The testing arrangement shown in Fig. 5 allowed an evaluation to be made as to the impact of various design features of the composite flooring cassette 130 on its performance. For example, the presence of a grid or honeycomb structure on the rear surface of the composite flooring cassette 130 influences how a load is distributed and how effectively the composite flooring cassette 130 is able to resist deformation.

[0169] According to further embodiments the geometry and / or thickness of the reinforcing structures may be further optimised in order to improve (or vary) the strength-to-weight ratio.

[0170] The testing process was useful for validating the suitability of the composite flooring cassette 130 according to various embodiments for use in diverse construction environments. In particular, by simulating realistic loading conditions and measuring performance, the testing arrangement established that the composite flooring cassette 130 according to various embodiments met various safety, durability and structural requirements thereby providing confidence in its application across a range of building scenarios.

[0171] Fig. 6 shows a prototype testing arrangement for a composite flooring cassette 130 according to various embodiments wherein the testing arrangement was configured to evaluate the load-bearing capacity of a composite flooring cassette 130 and to measure the deflection of the composite flooring cassette 130 under varying applied loads. The composite flooring cassette 130 may according to various embodiments comprise a square composite flooring cassette 130 having dimensions of 2m x2m and wherein fortesting purpose the composite flooring cassette 130 was supported at its four corners in order to simulate conditions wherein a composite flooring cassette 130 according to various embodiments is supported at its corners by four screw pile caps or equivalent support structures. The testing arrangement involved loading the composite flooring cassette 130 with bricks in order to create a uniform distributed load representative of a real-world usage scenario.

[0172] The testing results detail the load applied to the composite flooring cassette 130 in terms of kg / m2and the corresponding total load per composite flooring cassette 130 (kg / cassette). Deflection measurements were recorded in mm and indicate the extent ofdeformation at the centre and edges of the composite flooring cassette 130 under specific loading condition.

[0173] According to the results, under an Australian standard load of 153 kg / m2, equivalent to 612 kg / flooring cassette 130, the deflection at the centre of the composite flooring cassette 130 was measured as being 2.56 mm. Under a USA standard load of 195 kg / m2, equivalent to 780 kg / flooring cassette 130, the deflection increased to 3.20 mm at the centre. Higher load testing namely applying 512 kg / m2or 2050 kg / flooring cassette 130 resulted in a deflection of 8.03 mm at the centre, while maximum load testing which involved applying 673 kg / m2or 2691 kg / flooring cassette 130 led to a deflection of 10.10 mm at the centre.

[0174] The deflection may be measured across multiple points on the composite flooring cassette 130 including the centre and edges thereby providing a comprehensive understanding of how the load is distributed and how the composite flooring cassette 130 deforms under stress. The results indicate that deflection is greater at the centre compared to the edges, as the centre experiences the highest concentration of stress under loading.

[0175] This testing arrangement demonstrated the structural performance of the composite flooring cassette 130 according to various embodiments under both standard and extreme loading conditions.

[0176] Fig. 7 shows a testing arrangement according to various embodiments wherein a composite flooring cassette 130 was subjected to a line load in order to replicate the conditions which might expect to be experienced under the weight of a two-storey brick external wall. The test setup involved supporting a composite flooring cassette 130 on a foundation whereupon weights were added incrementally in order to simulate increasing load. The line load was applied along the edge of the composite flooring cassette 130 in order to mimic the force exerted by a wall structure.

[0177] The total applied load was increased incrementally and the corresponding deflection was measured at the edge of the composite flooring cassette 130. The load values, recorded in kg, ranged from 80 kg to 2257 kg. The deflection, measured in mm, increased progressively with the load, starting at 0.03 mm under an 380 kg load and reached a maximum of 14.17 mm under a maximum load of 2257 kg.

[0178] This testing arrangement provided data related to the structural behaviour of the composite flooring cassette 130 under edge-loading conditions. The deflection values reflect the stiffness and load-bearing capacity of the composite flooring cassette 130 particularly when subjected to concentrated linear loads such as those produced by heavy wall structures.The test demonstrates that the composite flooring cassette 130 according to various embodiments maintains structural integrity under significant loads with deformation remaining within acceptable limits for construction applications. The results also provide insights into how the material composition and geometry of the composite flooring cassette 130 according to various embodiments influence its performance. Further embodiments are contemplated wherein further reinforcement elements may be incorporate along the edge of the composite flooring cassette 130 in order to further enhance the resistance of the composite flooring cassette 130 to line loads while maintaining a favourable strength-to-weight ratio.

[0179] Fig. 8A shows a testing arrangement for a composite flooring cassette 130 according to various embodiments wherein the composite flooring cassette 130 is subjected to loads due to steel weights being applied to the composite flooring cassette 130 via a steel rolled channel which was secured to the composite flooring cassette 130 using rivets. The arrangement demonstrates the structural response of a composite flooring cassette 130 according to various embodiments under concentrated loads distributed along the steel channel. The test replicates conditions wherein a composite flooring cassette 130 supports linear or point loads such as might be encountered in structural or industrial applications.

[0180] Fig. 8A shows the composite flooring cassette 130 positioned horizontally with two steel rolled channels placed on its surface. The channels are connected to the composite flooring cassette 130 via rivets or other fixing devices thereby providing a rigid interface for load application. The channels are shown in the process of being secured to the composite flooring cassette 130 and in the process of being aligned.

[0181] Fig. 8B shows steel weights which were used to apply incremental weights to the composite flooring cassette 130 via a steel channel. The steel weights simulate real-world loading scenarios allowing for controlled measurement of deformation and stress distribution. The composite flooring cassette 130 was supported on brick stacks at its edges replicating typical installation conditions where the composite flooring cassette 130 may be arranged to be supported by one or more pile caps.

[0182] The test setup allows for the evaluation of load-bearing capacity, deflection and structural integrity of a composite flooring cassette 130 according to various embodiments when subjected to concentrated linear loads. The test arrangement is particularly suited for assessing the effectiveness of the riveted connection and the ability of the composite flooring cassette 130 according to various embodiments to distribute force through its composite material and internal structure. Such testing provides important data to optimise the design of the composite flooring cassette 130 according to various embodiments.Fig. 9 shows the results of testing a composite flooring cassette 130 according to various embodiments. The composite flooring cassette 130 was subjected to a line load test in order to evaluate its structural performance under incremental loading conditions. The test incorporated a steel batten to enhance load distribution and wherein deflection measurements were taken to compare performance both with and without the steel batten.

[0183] The testing procedure involved systematically increasing the load by layering bricks to achieve a total weight of up to 2257 kg. The load was applied evenly across two sides of the composite flooring cassette 130 wherein a digital hoist meter was used to ensure precise and balanced loading. Each incremental load step was followed by taking a deflection measurement which was recorded at the edge of the composite flooring cassette 130 with a steel batten and which was referred to as "Edge #2."

[0184] The results demonstrate the positive reinforcing effect of utilising a steel batten on the structural performance of a composite flooring cassette 130. For example, at a total load of 1240 kg, the deflection recorded utilising a steel batten was 12.15 mm whereas without the steel batten the deflection was recorded as being 20.03 mm. At a maximum loading of 2257 kg, the deflection with the batten was 30.29 mm.

[0185] It will be apparent from the results that utilising a steel batten resulted in a reduced deflection and that the reduction in deflection highlights the role of the steel batten in distributing the load more evenly, reducing localised deformation and enhancing the overall rigidity of the composite flooring cassette 130.

[0186] The data which is presented shows that the inclusion of a steel reinforcing batten significantly improved the performance of the composite flooring cassette 130 under heavy line loads. This improvement is particularly relevant in applications involving concentrated linear loads such as those exerted by structural walls or similar installations. The ability of the composite flooring cassette 130 to maintain structural integrity while limiting deflection under high loads validates its suitability for demanding construction scenarios.

[0187] This testing arrangement and the corresponding results enable composite flooring cassettes 130 for specific applications to be designed and tested. The use of one or more reinforcing steel battens demonstrates a practical method for improving load distribution and minimising deflection thereby ensuring that the composite flooring cassette 130 meets performance requirements in both residential and commercial construction environments.Figs. 10A and 10B shows a testing arrangement which was used fortesting a composite flooring cassette 130 according to various embodiments. The composite flooring cassette 130 was subjected to a loading test utilising steel weights. According to this arrangement a timber beam 200 measuring 50 mm x 100 mm was bolted on to the composite flooring cassette 130 utilising three bolts. The purpose of this configuration was to evaluate the load-bearing performance and deflection characteristics of the composite flooring cassette 130 according to various embodiments when reinforced with a timber beam 200 under loading conditions.

[0188] Fig. 10A shows the timber beam 200 securely attached to the surface of a composite flooring cassette 130 according to various embodiments. The timber beam 200 is shown positioned longitudinally and was bolted into place to ensure stability and an even distribution of the applied load. This configuration simulates conditions wherein additional structural reinforcement may be provided by a timber beam.

[0189] Fig. 10B shows the application of incremental loads which were applied along the length of the timber beam 200. The total applied load ranged up to 2257 kg and the deflection was measured at various load increments. For example, at a load of 1760 kg, the measured deflection was 12.26 mm and at a maximum load of 2257 kg the deflection was measured as being 17.88 mm.

[0190] This test arrangement provides insights into the effectiveness of using a timber beam 200 as a reinforcement method for composite flooring cassettes 130 according to various embodiments. The results demonstrate that the inclusion of a timber reinforcing beam 200 helps to distribute loads more effectively and reduces deflection thereby enhancing the overall structural performance of the system.

[0191] Figs. 11 A-E illustrate various different fixing methods which may be utilised to secure or assemble different components of a composite flooring cassette 130 according to various embodiments. According to various embodiments composite flooring cassettes 130 may be joined to each other utilising either an adhesive, one or more rivets, one or more screws or one or more bolts such as M12 bolts. Similarly, one or more components may be secured to a composite flooring cassette 130 according to various embodiments utilising either an adhesive, one or more rivets, one or more screws or one or more bolts such as M12 bolts.

[0192] Fig. 11 A shows how according to an embodiment one or more adhesives may be applied to the joints of the two composite flooring cassettes 130 in order to join them together. Adhesives may be used to create a seamless bond between components, providing uniform load distribution and minimising stress concentrations. This method may be particularly advantageous for applications requiring watertight or airtight seals.Fig. 11 B shows a packet of rivets and their application in securing metal components to a composite flooring cassette 130 according to various embodiments. Rivets, such as the large flange aluminium rivets as shown, may be used for lightweight and durable connections. The riveted joint shown on a steel rolled channel demonstrates their effectiveness in providing secure permanent attachments.

[0193] Fig. 11C shows how one or more M12 (or other size) bolts together with an optional metal washer may be secured to a composite flooring cassette 130 according to various embodiments. It will be understood that bolts may be utilised on account of being particularly suitable for making a high-strength connection. One or more bolts may be used to fasten heavier components or to reinforce structural joints, particularly in areas subjected to high stress or load.

[0194] Fig. 11 D shows how according to other embodiments one or more screws may be secured directly into the surface of a composite flooring cassette 130 according to various embodiments. The screws may, if desired, be countersunk so as to ensure a flush finish with the surface of the composite flooring cassette 130 thereby maintaining a smooth upper surface and preventing any protrusions.

[0195] Fig. 11E shows how one or more screws may be inserted into the composite flooring cassette 130 according to various embodiments. It will be understood that one or more screws may be used for removable or adjustable connections thereby providing flexibility in assembly and maintenance.

[0196] Fig. 12 shows a pull test which was conducted on various fixing methods together with a composite flooring cassette 130 according to various embodiments in order to enable the tensile strength and failure behaviour of different fasteners. The testing involved the application of controlled tensile loads using precision equipment to determine the force required to induce failure. The images illustrate the test setup showing the composite material securely fixed in place and the equipment used to apply and measure tensile forces.

[0197] The pull tests illustrated that there were a range of tensile strengths for the different fixing methods tested. For example, small fine-thread screws demonstrated tensile strengths of between 0.4 kN and 0.7 kN and as such are suitable for light-duty applications. Wide flange rivets exhibited a tensile strength of approximately 1.4 kN per rivet and hence offer a balance in terms of strength and ease of installation for mediumload requirements. Large coarse-thread screws achieved tensile strengths ranging from 2.2 kN to 6.8 kN depending on the screw design and the thickness of the composite material thereby making them effective for higher-load applications and thicker composite sections.M12 bolts, used in conjunction with washers and nuts, displayed tensile strengths ranging from 12.1 kN to 38.7 kN. In these tests, the washers, bolts or nuts typically failed before the composite material itself highlighting the robustness of the composite under tensile loads. Anchor bolts measuring 10 mm x 75 mm were installed in predrilled holes in solid fibreglass and achieved a tensile strength of 60.0 kN. These anchor bolts demonstrate excellent performance making them suitable for heavy-duty applications requiring maximum tensile strength.

[0198] The test apparatus shown includes a rig configured to apply precise tensile forces to the fasteners while recording the forces at which failure occurs. The results provide data on the performance of each fixing method, including the load capacity, the point of failure and any deformation of the composite material. This data can be used to guide the selection of fixing methods based on the specific load requirements of a project.

[0199] Fig. 13 shows a side connection method for composite flooring cassettes 130 according to various embodiments. In particular, adhesives may be utilised to secure adjacent composite flooring cassettes 130. Fig. 13 shows a close-up of a side connection formed using adhesives which provides a strong and seamless bond between adjoining composite surfaces. Adhesives are effective for creating a long-lasting and rigid connection that distributes loads evenly across the joint. This method is particularly advantageous for quick installation and is compatible with off-the-shelf adhesive products. However, adhesive connections can be challenging to undo once cured and may incur higher costs due to the need for specialised materials.

[0200] An alternative approach involves the use of a key joint system according to various embodiments. Various key joints are contemplated and have been developed which are configured to provide a quick and strong connection similar to adhesives but with the added benefit of being easier to disassemble if needed. It will be understood that a key joint system offers a cost-effective solution that retains high performance and durability whilst also enabling flexibility in terms of assembly and maintenance. A key joint system according to various embodiments may be particularly suited for applications requiring repeated disassembly or modular construction.

[0201] Both methods provide reliable options for securing composite flooring cassettes 130 together with the choice depending on the specific requirements of the project. Adhesives are suitable for permanent installations while key joints may be more appropriate for projects requiring adjustability.

[0202] Fig. 14 shows a table summarises the thermal resistance (R-values) of composite flooring cassettes and related building materials highlighting their performance in various configurations and applications. R-values measure the ability of a material to resist heat flow with higher values indicating better insulating properties. This information is helpfulwhen assessing the thermal efficiency of composite flooring cassettes in building construction.

[0203] The R-values for common building sections are presented as a baseline. Ceilings typically have an R-value of 1.0 while wood frame walls typically have an R-value of 3.0. Floors above unheated spaces typically have a R-value of 2.0 and an air film layer typically has a R-value of 0.68. These values indicate the need for additional insulation to meet energy efficiency requirements in most building scenarios.

[0204] The R-values of composite flooring cassettes according to various embodiments are shown to vary depending on their configuration and the temperature differential applied during testing. For example, a corner flooring cassette which when installed and which experienced a 8°C temperature difference had a R-value of 0.72 indicating that it provided only moderate thermal resistance. Another composite flooring cassette, tested with a 1°C temperature difference, exhibited a lower R-value of 0.05. By contrast, a composite flooring cassette tested with a 6°C temperature difference achieved a significantly higher R-value of 6.00 illustrating superior thermal performance under those conditions.

[0205] According to various embodiments various insulation materials may be used within one or more composite flooring cassettes and may be installed in one or more compartments formed within the rear of a composite flooring cassette 130 according to various embodiments. It will be understood that the insulation materials will influence the overall thermal resistance of the composite flooring cassette 130. For example, loose-fill cellulose was found to provide a R-value per inch ranging between 2.8 to 3.7. When applied at thicknesses of between 13.7 mm and 18.1 mm the total R-value ranged from 8.4 to 11.1. Loose-fill rock wool was found to achieve a R-value of 3.1 per inch resulting in a total R-value of 9.3 at a thickness of 16.4 mm. Moulded expanded polystyrene ("EPS") was found to have a R-value per inch of 3.6, yielding a total R-value of 10.8 at a thickness of 14.1 mm. Sprayed polyurethane foam offered the highest thermal resistance with a R-value per inch of between 5.6 and 6.2. At a thicknesses of between 8.2-9.1 mm sprayed polyurethane provided a total R-value of between 16.8 and 18.6 making it a highly effective insulating material for composite flooring cassettes according to various embodiments.

[0206] The table also shows R-values of common floor covering materials. For example, carpet with a typical thickness of 12.9 mm has a R-value of 1.4 and hence offers good insulation. Engineered wood with a flooring pad 10 mm thickness has a R-value of 0.825. 10 mm thick ceramic tiles with thinset mortar have a R-value of 0.3 while linoleum with a 3.2 mm thickness has a R-value of 0.2.Figs. 15A and 15B shows various factors influencing the use of composite flooring systems according to various embodiments in Australia and illustrate how population density and environmental factors may impact construction costs and design considerations.

[0207] The population density map as shown in Fig. 15A demonstrates that the majority of Australia's population is concentrated in urban and coastal areas, particularly in cities such as Sydney, Melbourne, Brisbane and Perth. These regions exhibit high population densities which correlate with increased construction activity and demand for efficient building systems such as composite flooring systems according to various embodiments. Conversely, much of the interior and remote areas of Australia exhibit low population densities wherein construction demands are lower but may still require robust building solutions due to harsh environmental conditions.

[0208] Fig. 15B divides Australia into regions based on wind and climatic loads which are important considerations for determining the structural requirements of composite flooring systems. Region A, classified as "Normal," covers much of the southern and eastern parts of the country, including cities such as Perth, Adelaide, Melbourne, Hobart, Canberra and Sydney. In these areas, construction primarily involves standard load cases with lower costs associated with typical design and material requirements.

[0209] Regions C and D, located in the northern coastal areas such as Darwin, Cairns and Broome are subject to tropical and severe tropical cyclones. These regions require buildings to withstand higher wind and environmental loads which significantly influence the design and cost of flooring systems. According to various embodiments composite flooring systems may be installed in these areas which may incorporate additional reinforcement structures and utilise stronger materials. According to various embodiments composite flooring systems may be provided which provide sufficient structural integrity as to enable a building to be substantially unaffected by severe or extreme weather conditions.

[0210] Intermediate regions, such as Region B, represent transitional zones where the environmental load requirements may vary based on specific locations and local weather patterns. Brisbane, for example, lies within Region B and may experience higher wind loads than areas classified as Region A but not as severe as those in Region C or D.

[0211] Fig. 16 shows a test being performed on a composite edge beam 300 for use in a composite flooring system according to various embodiments. According to various embodiments a flooring system may be provided comprising one or more steel and / or composite edge beams 300. The edge beams 300 may be provided in order to provide structural stability and load distribution along the edges of a flooring system according to various embodiments.According to various embodiments steel edge beams were tested including rectangular hollow section ("RHS") beams and parallel flange channel ("PFC") beams. According to an embodiment RHS beams having dimensions of 100 mm x 75 mm with a wall thickness of 4 mm may be utilised and which offer a balance of strength and lightweight properties. According to embodiments PFC beams having dimensions of 180 mm x 75 mm with a flange thickness of 7 mm may be utilised providing enhanced structural rigidity for applications requiring higher load-bearing capacity or resistance to bending and torsion.

[0212] Composite beams were also evaluated in various configurations. The tested composite profiles include solid beams with dimensions of 120 mm x 80 mm which were configured for high strength and durability. A thinner solid profile, measuring 120 mm x 20 mm was also tested which offers a lightweight alternative for applications where reduced material usage and weight are priorities. Additionally, multi-layer foam core laminated composite beams according to various embodiments were tested and which advantageously combine strength, lightweight properties and thermal or acoustic insulation.

[0213] The test evaluated the beam’s ability to withstand a line load equivalent to 2283 kg which is composed of a primary load of 2257 kg plus an additional 26 kg. The beam was supported at its ends using brick stacks simulating typical support conditions and was subjected to a controlled load distributed along its length.

[0214] The test setup measured the deflection of the RHS beam under an applied load. The recorded deflection was 5.47 mm demonstrating the beam's capacity to resist significant loads while maintaining structural integrity.

[0215] Fig. 17 shows a load test conducted on a parallel flange channel ("PFC") perimeter edge beam 310 with dimensions of 180 mm x 75 mm. The test evaluated the beam’s structural performance under a line load equivalent to 2283 kg which included a primary load of 2257 kg plus an additional 26 kg.

[0216] The measured deflection of the PFC beam under the applied load was 1.85 mm indicating excellent rigidity and load-bearing capacity. The low deflection value demonstrates the beam's ability to resist significant forces with minimal deformation, making it particularly suitable for applications where structural stability and minimal deflection are important considerations.

[0217] Fig. 18 shows the preparation process for fabricating fibre-reinforced polymer ("FRP") solid perimeter edge beams 330 using a vacuum infusion method according to various embodiments. As shown in Fig. 18, fibre reinforcement materials were layeredwithin a mould which was configured to create a desired perimeter edge beam profile. According to various embodiments the mould may comprise a rigid smooth surface that ensures precision in the final dimensions and geometry of the FRP beams 320 which are produced.

[0218] The fibre reinforcement layers may be positioned in the mould in order to achieve optimal strength and load-bearing capacity for the finished beams. These layers may include woven or unidirectional fibres which may be oriented to enhance mechanical properties such as tensile strength, stiffness and resistance to bending. The vacuum infusion process may involve drawing resin through the fibre layers under vacuum pressure thereby ensuring complete saturation and bonding of the fibres while minimising voids or imperfections.

[0219] According to various embodiments the process may be arranged to produce high-quality composite beams with a consistent finish and superior structural performance. The vacuum infusion method as utilised according to various embodiments allows for efficient use of resin and reduces material waste making it a cost-effective and environmentally friendly fabrication technique.

[0220] The completed FRP solid beams 320 may be configured to serve as perimeter edge beams in composite flooring systems according to various embodiments offering lightweight yet robust support for structural loads. The fabrication process demonstrated in Fig. 18 ensures that the perimeter edge beams 320 achieve the necessary strength-to-weight ratio and durability for use in demanding construction environments.

[0221] Figs. 19A and 19B shows two fibre-reinforced polymer ("FRP") solid beams 320 with differing thicknesses and demonstrates the variations in geometry and structural composition which may be achieved during the fabrication process according to various embodiments. Fig. 19A shows a FRP solid beam 320 with a thickness of 90 mm while Fig. 19B shows a FRP solid beam 320 with a thickness of 20 mm. Both beams 320 were configured for use as perimeter edge beams in composite flooring systems according to various embodiments and provide lightweight and robust structural support.

[0222] The beams 320 were fabricated using a vacuum infusion method. According to this method uniform resin distribution was ensured and strong bonding between the layers of reinforcement material were achieved. The upper images in Figs. 19A and 19B show the longitudinal profile of the beams 320 and highlight that a smooth consistent surface was achieved through precision moulding. The lower images of Figs. 19A and 19B show cross-sectional views of the beams 320 and show their internal structure and the consolidation of fibres within the resin matrix.According to various embodiments a 90 mm thick beam 320 may be configured for applications requiring high load-bearing capacity and resistance to bending or torsional forces. It will be understood that the increased thickness enhances stiffness and structural integrity making it suitable for demanding construction environments or installations subject to heavy loads. By contrast, a 20 mm thick beam 320 is lighter and is particularly suitable for applications where reduced weight is a priority such as in modular or transportable structures. Its thinner profile offers sufficient strength for less demanding load conditions while minimising material usage and associated costs.

[0223] Both beams 320 demonstrate the adaptability of FRP materials in producing components tailored to specific structural requirements. The fabrication process ensures consistency and durability making these beams 320 particularly versatile solutions for various construction scenarios where performance and efficiency are important considerations.

[0224] Fig. 20A and 20B show a load test conducted on a solid fibre-reinforced polymer ("FRP") beam 320 with dimensions of 90 mm x 120 mm according to an embodiment. The test evaluated the structural performance of the beam 320 under a line load of 2283 kg which included a primary load of 2257 kg and an additional 26 kg. Fig. 20A shows the setup prior to applying the load with the FRP beam 320 positioned on supports and instrumentation in place to measure deflection. Fig. 20B shows the loaded beam 320 where weights were stacked upon the beam 320 in order to achieve the total applied load. Under the applied load, the beam 320 exhibited a measured deflection of 9.44 mm.

[0225] Fig. 21 shows a point load test conducted on a solid fibre-reinforced polymer ("FRP") beam 320 with dimensions of 90 mm x 120 mm according to an embodiment. The beam 320 was subjected to a concentrated load of 2283 kg applied at its midpoint simulating conditions wherein significant forces are focused upon a single location along the beam’s length. The beam 320 was supported at its ends using fixed supports replicating typical installation conditions.

[0226] The load was achieved by stacking steel weights directly at the centre of the beam 320. This configuration allowed for precise measurement of deflection under the applied load. The recorded deflection at the midpoint of the beam 320 was 14.96 mm.

[0227] Fig. 22 shows a loading test conducted on a solid fibre-reinforced polymer ("FRP") beam 320 with dimensions of 90 mm x 120 mm according to an embodiment. The beam 320 was subjected to a concentrated point load of 2283 kg applied at its midpoint. The load was achieved by stacking steel plates directly on the centre of the beam 320 creating significant force at a single point to evaluate the structural response under such conditions.The FRP beam 320 was supported at its ends using fixed supports replicating realistic installation conditions. Under the applied load the deflection at the midpoint of the beam 320 was measured to be 14.96 mm. The test highlights the performance characteristics of the solid FRP beam 320 and demonstrated its capacity to withstand significant forces while maintaining structural integrity.

[0228] Fig. 23 shows a fibre-reinforced polymer ("FRP") perimeter edge beam 320 constructed using six layers of 30 mm foam with two layers of reinforcement material. This setup was configured to simulate the structural performance of a parallel flange channel ("PFC") beam with dimensions of 180 mm allowing for a direct comparison between a FRP composite beam 320 and a steel reinforcing beam.

[0229] The foam core provides a lightweight base while the outer layers of reinforcement enhance the beam’s structural rigidity and load-bearing capacity. The use of multiple foam layers allows for customisable thickness and stiffness enabling the beam 320 to replicate the mechanical properties of a steel PFC beam in certain applications. The smooth outer finish and the uniformity of the structure highlight the precision of the fabrication process.

[0230] Fig. 24 shows a centralised load test wherein multiple stacked weights were applied to a FRP beam 320 to simulate typical stress conditions that such structures may encounter in practical applications. The load was evenly distributed ensuring that the testing conditions closely reflect operational circumstances. A measurement device was positioned beneath the beam to monitor and record deflection and other important performance metrics during the test.

[0231] Fig. 25 shows a table illustrating the results of evaluating the structural performance of different formats of perimeter edge beams under simulated load conditions. A composite beam comprising six layers of 30 mm foam combined with two layers of board was tested along with a 180 mm PFC beam for comparative purposes. The beams were supported on either side by stacks of bricks creating a stable testing arrangement.

[0232] The table shows the comparative performance of various perimeter edge beam configurations under a central point load of 2283 kg. The data compares beam types based on their weight / m, cost / m and resulting deflection. The 180 mm PFC beam weighed 20.7 kg / m with a cost range of $31 to $98 / m. Under the given load it demonstrated a deflection of 6.20 mm indicating a robust structural performance. The solid FRP beam, slightly lighter at 18.7 kg / m, cost $58 / m but showed a higher deflection of 14.96 mm.A composite beam configuration comprising four FRP layers weighed 11.6 kg / m, cost $73 / m and exhibited a deflection of 7.04 mm providing a balance between weight and performance. Meanwhile, a six layer FRP beam was tested which weighed 15.7 kg / m, had the highest cost at $109 / m but offered the least deflection at 3.35 mm indicating superior load-bearing capability with minimal deformation.

[0233] Figs. 26A and 26B illustrate how screw pile caps may be integrated into a modular construction system according to various embodiments. Fig. 26A shows the vertical alignment requirements and includes tolerances for positioning a screw pile 110 wherein, for example, the maximum desired deviations are 0.86° out of plumb, 25 mm out of horizontal alignment and 5 mm out of vertical alignment. According to various embodiments a worst-case alignment error of 10 mm may be tolerated. Laser levels with sound alarms may be utilised for accurate placement of screw piles 110 and associated screw pile caps 120.

[0234] As shown in Fig. 26A, a screw pile cap 120 according to various embodiments may comprise a series of plates. The plates may include a plate having a circular aperture within which an inner circular plate 111 may be inserted. The screw pile cap 120 according to various embodiments may be configured to be able to both slide and rotate relative to a pile 110. The ability to slide horizontally and / or rotate is particularly advantageous as it enables compensation to be made for minor misalignments and minor installation errors in respect of a pile 110. According to various embodiments an adjustment may be made by sliding the plate 111 having an aperture relative to a projecting thread which may form part of an articulating joint as described in more detail below. According to various embodiments the screw pile cap 120 may comprise one or more ball joints arrangements as described below. Embodiments are also contemplated wherein one or more screws and / or one or more wedges may be utilised in addition to achieve desired horizontal and vertical levelling.

[0235] Fig. 26A illustrates a method of adjusting the position and angle of inclination of a screw pile cap 120 according to various embodiments. The vertical alignment requirements including tolerances for the position of screw piles 110 are that the tolerances allow for a maximum desired deviation of 30 mm from plum, 25 mm from horizontal alignment and 5 mm from vertical alignment. Ideally, screw piles 110 should be installed with a maximum deviation error of 10 mm. According to various embodiments laser levels may be utilised when installing the piles 110 wherein the laser levels may be equipped with sound alarms to help ensure precise placement.

[0236] Fig. 26A also shows a top-down view of a screw pile cap 120 according to various embodiments. The screw pile cap 120 may comprise a circular plate 111 having an aperture through which the thread of a ball joint connector may extend. The screwpile cap 120 may have a circular design which may be configured to slide and rotate to correct for minor misalignments.

[0237] Fig. 26B shows the integration of multiple direction dogbone connectors with edge beams according to an embodiment. Sections A-A and B-B indicate cross-sectional views of an edge beam connection highlighting the detail between dogbone joints. A steel plate with a thickness of 6 mm may be incorporated in order to enhance structural stability.

[0238] Fig. 27 shows a screw pile cap 120 according to various embodiments comprising a ball joint 140 having a screw thread 141. The screw thread 141 enables a support plate 120 to be screwed on to the screw thread 141 thereby enabling the relative height of the support plate 120 to be vertically adjusted. The support plate 120 may be circular and may be arranged to sit within or above a circular aperture of a bearer plate 120A.

[0239] The ball joint 140 according to various embodiments may positioned at the interface between the screw pile cap 120 and a support structure for a flooring or building assembly and may allow for multi-directional rotation. This capability enables the screw pile cap 120 to accommodate minor angular misalignments enabling that the supported structure to be supported at a desired height and also to be supported horizontally. The ball joint 140 may be housed within an upper housing 250 and a lower housing 251. When the housings 250,251 are loosely attached to each other then the ball joint 140 may be rotated. However, the ball joint 140 may be locked in position by tightening the bolts 145 using e.g. an Allen key. The ball joint 140 may be configured to be secured to an upper plate of a pile 110 while allowing the ball joint 140 sufficient freedom of movement for alignment adjustments but also enabling the ball joint 140 to be locked into position as desired.

[0240] In the particular configuration shown a threaded screw mechanism 141 may be provided to enable fine vertical adjustments of the support plate 120 or bearer plate 120A to be made. The screw 141 may be arranged to pass through a threaded support plate 120 wherein the relative height of the threaded support plate 120 may be adjusted. The screw thread 141 may comprise a fine screw thread enabling slight adjustments in vertical height of the support plate 120 to be made.

[0241] Fig. 28A shows a screw pile cap according to various embodiments which is configured to provide horizontal adjustments through the integration of a bearer plate 120A and a slider or support plate 120 according to various embodiments wherein alignment discrepancies can be compensated for by rotating the support plate 120.Fig. 28A shows a top-down view of a support plate 120 and a bearer plate 120A , wherein the support plate 120 may be configured to comprise a curved slot that allows for controlled horizontal adjustments. The slider plate or support plate 120 may be mounted within or on top of a bearer plate 120A and a pin or threaded connection from a joint may extend into the slot. This configuration enables a slider plate or support plate 120 to move horizontally within a predefined range of the slot facilitating fine-tuning of the alignment.

[0242] Fig. 28B includes a plan view of the screw pile cap assembly according to various embodiments and illustrates the alignment mechanism from above. The overlapping geometry of the bearer plate 120A and the slider plate or support plate 120 ensures stability while allowing sufficient freedom for lateral adjustments. An exploded view of the assembly is also shown detailing the interaction between the plates forming part of the screw pile cap according to various embodiments.

[0243] Fig. 29 shows a cross-sectional view of a screw pile cap according to an embodiment. The screw pile cap may comprise a ball joint comprising an upper housing 151 housing a ball connector 140, wherein the ball connector 140 is secured in position by a lower housing 152 which is secured to the upper housing 151 via four M12 bolts. The ball joint may be configured to support a composite flooring cassette 130 or more generally a metallic flooring cassette or other building component.

[0244] According to various embodiments a composite flooring cassette 130 (or other flooring or building component) may be positioned and supported by the screw pile cap and in particular supported by a bearer plate 120A. The distance between the top of the composite flooring cassette 130 and the bearer plate 120A may be arranged to be approximately 100-200 mm depending on the structural requirements. For example, embodiments are contemplated wherein the distance may be arranged to be approximately 100 mm, 120 mm, 150 mm, 180 mm or 200 mm. According to embodiments the bearer plate 120A may comprise a 350 mm diameter steel disc plate which may have a minimum thickness of 6 mm thereby ensuring load distribution and durability.

[0245] The ball joint according to various embodiments may comprise a 50 mm outer diameter ball connector 140. In the particular configuration shown, the ball connector 140 may be located between the bearer plate 120A and a square steel plate 150 which may be provided on top of a screw pile 110. The square steel plate 150 may have dimensions of 100 mm x 100 mm and may be 16 mm thick according to an embodiment. The screw pile 110 may comprise a steel pipe having a 90 mm outer diameter and which may be configured to provide a stable connection to the ground. Accordingly, the screw pile 110 effectively acts as a foundation structure for a building which may be built upona plurality of screw pile caps which are located on the tops of piles 110. The pile 110 may form part of an array of piles.

[0246] The distance between the top square steel plate 150 to the ground level may be set at a minimum height of 80 mm in order to provide a sufficient gap for effective underfloor ventilation and also to protect against invasion by termites. Further embodiments are also contemplated wherein a crawlspace under the building may be provided. In such embodiments, the minimum crawlspace height may be arranged to be 450 mm in order to facilitate access, ventilation and to accommodate plumbing pipes with a 1:100 fall.

[0247] According to various embodiments the ball connector 140 may be configured to allow for rotational adjustment so that a composite flooring cassette 130 (or other flooring or building component) secured to a bearer plate 120A connected to the ball connector 140 can be manipulated and in particularthe horizontal position and / or angle of inclination of the bearer plate 120A can be adjusted even when the pile 110 is installed in uneven terrain. The ball connector 140 may comprise a ball neck 141 which may have a threaded connection together with threaded bolt head 142. The threaded connection may be secured into a M36 female thread which may be provided at the centre of the square steel plate 150. The gap between the top of the ball connector 140 and the bearer plate 120A may be at least 6 mm according to various embodiments.

[0248] The ball connector 140 may be housed in a housing 151 ,152 which may be secured utilising upwardly directed M12 bolts 145 in order to secure the housing together. According to various embodiments optional welded support fins 160 may be provided for additional stability to the bearer plate 120A. The assembly may be secured using a lock nut having a height calculated as 0.5 times the diameter of the bolt ensuring proper fastening and load resistance.

[0249] Fig. 30 shows a cross sectional view of a screw pile system according to various embodiments. The screw pile system includes a ball joint having a ball head 140 which is configured to being rotatable within an upper housing 151. The upper housing 151 is attached to a bearer plate 120A which is configured to support a composite flooring cassette 110. The arrangement includes one or more fixing blocks 170, one or more bracing plates 180 and optional welded support fins 160 for enhanced stability and alignment.

[0250] A composite flooring cassette 130 is shown in an installed position on top of the assembly and is supported by block plates and slider plates 190. The distance between the top of the composite flooring cassette 130 and the top of the bearer plate 120A may be arranged to be 100-200 mm. For example, embodiments are contemplated wherein the distance may be arranged to be 100 mm, 120 mm, 150 mm, 180 mm or 200 mm.Fixing blocks 170 may be provided and may be utilised to secure the position of the composite flooring cassette 130 ensuring stability and alignment during and after installation.

[0251] A 50 mm outer diameter ball connector 140 may be located beneath the bearer plate 120A enabling rotational adjustments to correct angular misalignments. The ball connector 140 may support a 350 mm diameter steel bearer plate 120A having a minimum thickness of 6 mm which is configured to distribute the load from the flooring assembly or building component effectively. The ball neck 141 and threaded bolt head 142 may be secured into an M36 female thread provided on a 100 mm x 100 mm x 16 mm square steel plate mounted to the top of the pile 110. A minimum 6 mm gap may be maintained between the top of the ball 140 and a lower surface of the bearer plate 120A.

[0252] The system may be mounted on a screw pile 110 which may comprise a 90 mm outer diameter steel pipe which may be configured so as to provide a robust foundation. The height from the top of the screw pile 110 to ground level may be set at a minimum of 80 mm in orderto provide unfloor ventilation and prevention the ingress of termites. According to further embodiments the height may be increased in orderto provide a crawlspace having a height of 450 mm to allow for access, ventilation and the installation of plumbing with a 1 :100 fall.

[0253] The bearer plate 120A may include optional welded support fins 160 which may be provided in orderto enhance lateral stability. One or more M12 bolts may be secured in an upwards orientation enabling access during assembly. A lock nut 142 may be used to secure the bolt, with its height calculated at 0.5 times the diameter of the bolt for proper fastening and stability.

[0254] Fig. 31 shows a ball joint connector system according to various embodiments which comprises a ball connector 140 having a 50 mm outer diameter. The ball connector 140 may be integrated into a lower housing 161 that facilitates rotational adjustment while maintaining structural stability. An upper housing 162 may be secured to the lower housing 161 and a plurality of bolts 145 may be used to tighten the upper housing 162 to the lower housing 161. The ball connector 140 and housing may be secured to a steel disc bearer plate 120 having a 350 mm outer diameter with a minimum thickness of 6 mm in orderto ensure robust load distribution. The ball connector 140 may comprise a (male) thread 146 which is secured within a (female) thread forming a connection portion of a bearer plate 120A. The lower housing 161 which houses the ball joint 140 may be secured by an M36 threaded connection which is secured to a 100 mm x 100 mm x 16 mm square steel plate 150 which incorporates a central M36 female thread for precise alignment. A lock nut may be utilised to maintain the position of the bolt, with its height specified as 0.5 times the bolt's diameter, ensuring stability under load.Optional welded support fins 160 may extend laterally from the assembly enhancing resistance to lateral forces and providing additional stability to the structure.

[0255] The upper and lower housings 161 ,162 surrounding the ball joint 140 may be secured and tightened to each other using one or more M12 bolts. According to various embodiments the housings 161,162 may include four threaded bores into which M12 bolts may be inserted and wherein the upper 162 and lower housings 161 may be screwed or otherwise secured together. According to various embodiments an Allen key may be utilised to tighten the M12 bolts which advantageously simplifies the installation and adjustment process.

[0256] The entire system may be mounted on a pile 110 or other flooring support which may comprise a 90 mm outer diameter steel pipe thereby providing a stable foundation for the structure. The ball connector design ensures that minor misalignments can be accommodated, making this configuration particularly suitable for modular systems where precision and adaptability are important considerations.

[0257] Fig. 32 shows a ball joint assembly according to various embodiments wherein the ball joint is provided in a downwards orientation. The ball joint according to various embodiments provides for a stable and precise alignment in modular construction applications. The ball joint assembly may comprise a ball connector 140 having a 50 mm outer diameter wherein the ball connector 140 is configured to be rotatable within a lower housing 161 having an inner concave profile. As a result, the ball connector 140 is able to rotate secured within the lower housing 161 and enables the angle of inclination of a bearer plate 120Ato be rotationally adjusted in order to correct angular misalignments which may have occurred when the pile 110 was installed. An upper housing 162 may be secured to the lower housing 161 via one or more bolts 145. The bolts may be tightened to secure the housing 161 ,162 togetherto prevent rotation of the ball connector 140.

[0258] The ball connector 140 according to various embodiments may be secured to a 350 mm outer diameter steel disc bearer plate 120A having a minimum thickness of 6 mm ensuring effective load distribution. The ball connector 140 and lower housing 161 may be secured by an M36 threaded connection which interfaces with a 100 mm x 100 mm x 16 mm square steel plate 150 provided on top of the pile 110. The bearer plate 120A may also incorporate a fixing portion having a M36 internal female thread at its centre to facilitate a stable and precise connection with the thread 146 of the ball connector 140.

[0259] M12 bolts may be positioned on either side of the assembly to secure the structure. These bolts ensure a firm connection between the ball housing and the steel- M -plate 150. The system may be mounted on a 90 mm outer diameter steel pile 110 which serves as the primary foundation element providing robust support for the modular structure.

[0260] According to various embodiments a mould may be provided to fabricate composite flooring cassettes 130 having a top hat profile which is easier to manufacture with glass fibre lay-up techniques and provides additional internal volume enabling targeted reinforcement in important areas. These areas include perimeter line loads, internal line loads and point loads which are beneficial for structural stability and performance.

[0261] Further embodiments are contemplated wherein one or more composite beams may be inserted into a composite flooring cassette in order to manage line loads. The one or more composite beams may be configured to distribute loads more evenly and enhance the overall structural integrity of the composite flooring cassette.

[0262] According to further embodiments a composite flooring cassette may include a key joint to enable two composite flooring cassettes to be secured to each other. Other embodiments are contemplated wherein flooring cassettes may comprise one or more projections and / or one or more recesses enabling two composite flooring cassettes to be stacked on top of each other in a vertical connection. For example, a lower composite flooring cassette may comprise one or more upwardly orientated projections on its upper surface which are arranged, in use, to be inserted into one or more recesses provided in the lower surface of an upper composite flooring cassette. Alternatively, a lower composite flooring cassette may comprise one or more recesses provided on its upper surface which are arranged, in use, to receive one or more downwardly orientated projections provided on the lower surface of an upper composite flooring cassette.

[0263] Figs. 33A shows composite flooring cassettes 130 configured for modular construction according to various embodiments. According to various embodiments a grid-like structure of composite flooring cassettes 130 may be formed within a mould. According to an embodiment the mould may be arranged to form a plurality of moulded square cavities in the lower portion of the composite flooring cassette 130. The array of cavities provided in the composite flooring cassette 130 results in the formation of a composite flooring cassette 130 which is lightweight but yet also strong. The cavities which are formed may be configured so as to provide an optimised the strength-to-weight ratio ensuring structural integrity while minimising material use.

[0264] Fig. 33B shows close-up images of smaller moulded components which may be utilised as insert or connection blocks 170. For example, an insert or connection block 170 may be installed in one of the cavities of the composite flooring cassette 130 and a hole, aperture or threaded aperture may be provided in the insert or connection block170 enabling a bolt, rod or otherwise securing device to be inserted through the hole or aperture. For example, a bolt may be installed through a plate provided in an upper portion of a composite flooring cassette 130, wherein the bolt passes through the insert or connection block 170 and is secured to a plate which forms part of a pile cap according to various embodiments. Accordingly, embodiments are contemplated wherein one or more inserts or connection blocks 170 may be used to secure or reinforce joints within a composite flooring cassette assembly.

[0265] Fig. 33C shows a single 11 x 11 composite flooring cassette 130 together with a composite flooring cassette formed of nine cassette elements, each cassette element comprising a 3 x 3 array. The nine cassette elements may be located together in a tray.

[0266] Fig. 33D shows in more detail some moulded inserts of connection blocks 170 according to various embodiments.

[0267] Figs. 34A and 34B show two different configurations of composite flooring cassettes 130 according to various embodiments. Fig. 34A shows a first type composite flooring cassette 130 having a uniform grid. Fig. 34B shows a second type of composite flooring cassette 130 wherein the grid may be customised and may include one or more reinforcement elements.

[0268] The grid arrangement shown in Fig. 34A features evenly distributed square cavities or compartments and according to various embodiments such a layout may be optimised for applications where uniform load distribution is sufficient ensuring consistent structural performance across the entire composite flooring cassette 130. The uniform grid simplifies manufacturing and is well-suited for general-purpose use in modular construction.

[0269] The customisable grid with targeted reinforcement as shown in Fig. 34B introduces additional structural elements in specific areas. This configuration highlights reinforced zones which may be configured to accommodate higher loads or specific structural demands such as perimeter line loads or cross-sectional reinforcements for internal support. Other areas may be configured to maintain the standard grid design, providing a balance between weight reduction and structural integrity in less important regions.

[0270] According to various embodiments one or more perimeter edge beams may be incorporated into a modular construction system. According to such embodiments, the frequency of screw piles at the perimeter edge may be increased by spacing them at 1 m intervals instead of e.g. 2 m intervals. This adjustment may eliminate the need for perimeter edge beams by distributing loads more effectively.Additional screw piles may be located directly under locations with heavy point loads such as columns supporting upper storeys. This targeted reinforcement negates the requirement for internal beams, simplifying the structural framework while maintaining stability.

[0271] For projects requiring perimeter edge beams, steel sections such as a 180 mm PFC beam may be utilised. Alternatively, composite beams may be employed for the same purpose but which offer a lightweight yet strong solution. Composite beams can be integrated into the edges of a composite flooring cassette 130 allowing for single-piece installation. This design approach simplifies assembly and ensures a seamless connection between structural components.

[0272] Other embodiments are contemplated wherein a combination of composite and steel beams may be incorporated into floor panels or flooring components. This approach enhances the overall rigidity of the structure and streamlines the construction process by combining multiple functions into a single component.

[0273] Fig. 35A shows the application and design details of a perimeter edge beam for modular construction according to various embodiments. Fig. 35A shows an implementation wherein a steel perimeter edge beam is supported by a screw pile foundation 110. The beam may be securely mounted atop the screw pile 110 thereby ensuring a stable and robust connection.

[0274] Fig. 35B shows a cross-sectional view of the steel perimeter edge beam according to an embodiment. The beam may have a width of 50 mm for the web and a height of 150 mm for the flange and may be optimised to balance strength and material efficiency. Fig. 35B also shows the integration points allowing for seamless connections with other structural components such as cassettes or additional beams.

[0275] Figs. 36A and 36B summarise two different configurations for a screw pile cap 120, contrasting ball-down and ball-up flat arrangements.

[0276] Fig. 36A shows a ball-down configuration wherein the ball connector 140 comprises a 50 mm outer diameter ball connector housed within a housing and which supports a steel disc bearer plate 120A having a 350 mm diameter and a minimum thickness of 6 mm. The ball connector 140 is threaded onto an M36 central thread 146 for secure placement. Optional welded support fins 160 may extend outward to support the bearer plate 120A and provide enhanced lateral stability. M12 bolts 145 ora combination of top and bottom housing screws may be used to secure the assembly with adjustments facilitated by an Allen key.Fig. 36B shows a ball-up configuration wherein the ball connector 140 directly supports a bearer plate 120A and a composite flooring cassette 130. This system provides flexibility in allowing adjustment of the height between the top of the screw pile 110 and the composite flooring cassette 130 wherein the height may be set between 100-200 mm. The composite flooring cassette 130 may include one or more fixing blocks 170 and a block plate and slider plate 190 may be included to allow for horizontal adjustment. The configuration accounts for crawlspace requirements wherein a recommended minimum height of 450 mm may be provided to also accommodate ventilation and slung plumbing pipes with a 1 :100 fall. Optional welded fins may be included to increase stability under load.

[0277] Figs. 37A-C shows detailed connection designs for modular construction using screw piles and flooring panels 130 according to various embodiments.

[0278] Fig. 37A shows a centre connection detail showing two flooring panels 130 joined over a screw pile foundation. The connection may utilise a 36 mm threaded rod to secure the structure to a Katana screw pile. The flooring panels 130 may be reinforced by a 200 mm x 200 mm x 6 mm steel plate made from grade 500 material ensuring stability and load distribution. TEK screws may be used to secure the flooring panels 130 to the plate, maintaining alignment and preventing movement.

[0279] Fig. 37B shows a connection detail showing a configuration for securing flooring panels 130 along the perimeter of the structure. Similar to the centre connection, a Katana screw pile may be used as the foundation with a 6 mm thick steel plate (grade 500) supporting the connection. The panel may be joined to a steel edge beam ensuring structural rigidity at the perimeter. A 36 mm threaded rod and TEK screws may be utilised to securely anchor the assembly.

[0280] Fig. 37C shows a patio step-down detail and shows a configuration that incorporates a stepped transition between flooring panels 130 in order to accommodate different elevations. The design includes a combination of steel trusses and plastic spacers to manage the step-down ensuring a seamless integration of levels. A threaded rod and grade 500 steel plate provide the same level of structural support as in the other configurations while the TEK screws maintain secure connections.

[0281] Fig. 38 shows a variety of different support arrangements which may be utilised to support a composite flooring cassette according to various embodiments. The support arrangements may be adjustable in height and may have different mounting options. The pedestals as shown may be configured so as to form part of an adjustable floor system and may enable enabling precise levelling and support for raised platforms or modular flooring applications.Fig. 39 shows test data and a graph of deflection behaviour in steel plates under a 2-m line load applied along one edge. The table summarises the applied load, recorded deflections and corresponding measurements for edge and centre points of the steel plate.

[0282] According to various embodiments the load distribution testing may commence with the addition of small incremental weights gradually increasing to a total load of 2257 kg. The load may be measured using a digital hoist meter on both sides. Data for deflection are provided for two positions: Edge #2 and Centre #5. The recorded deflection values indicate that the edge experiences significantly higher deformation compared to the centre, as shown by the tabulated differences.

[0283] The graph shows the relationship between applied load and deflection for both positions. The upper line shows the deflection along Edge #2 while the lower line shows the deflection at Centre #5. The trend shows a steady increase in deflection with load, reaching a peak before stabilising or reducing slightly, suggesting a material or structural limit. A circle highlights an important point where Edge #2 experiences a pronounced peak in deflection.

[0284] Fig. 40 shows a comparative analysis of different composite flooring cassette 130 configurations which are referred to as CBT 00, CBT 02, CBT 01 and CBT 03 and wherein their weights, load limits and deflection characteristics under various load conditions are detailed. It is noted that the weight of the different flooring cassettes varies. It is also noted that composite flooring cassette CBT 00 is the stiffest and heaviest at 88.4 kg whereas flooring cassette CBT 02 is the weakest and lightest at 54.2 kg. The top cover weight and adhesive weight also differ contributing to the total combined weight which ranges from 69.7 kg for CBT 02 to 134.0 kg for CBT 00.

[0285] Load limits are also presented for both Australian and US standards. In the Australian context, the weight limit is 153 kg / m2or 612 kg per cassette with deflections ranging from 2.62 mm to 5 mm. For US standards, the weight limit increases to 195 kg / m2or 780 kg per cassette with deflections ranging from 3.15 mm to 6.45 mm.

[0286] The table also highlights the loaded weight at 8 mm deflection with CBT 00 accommodating the highest load of 2053 kg while CBT 02 supports the lowest at 1001 kg. At the point of buckling failure loads ranged from 1723 kg for CBT 02 to 1794 kg for CBT 00 with deflections ranging from 12.22 mm to 15.61 mm.

[0287] Steel edge deflection data indicates that maximum deflections vary significantly across configurations with values such as 13 mm for CBT 00 and 33.66 mm for CBT 02 demonstrating the impact of material composition and design on structural performance.Fig. 41 shows an alternative configuration fora screw pile cap according to various embodiments wherein instead of a four-bolt mechanism a single-thread 800 design may be incorporated into top 802 and bottom housings 801 of a ball thread arrangement. A ball connector 140 may be inserted into the lower housing 801 and then the upper housing may be screwed on to the thread 800. A bearer plate 120A may then be screwed to the upper housing 802. It will be apparent that this configuration simplifies the assembly process and reduces the number of components required. Furthermore, the arrangement also improves the structural reliability by minimising potential points of failure. Such a design is particularly advantageous in construction scenarios where efficiency and ease of installation are paramount. By eliminating the need for multiple bolts, this embodiment reduces assembly time and provides a more streamlined installation process. The single-thread design also enhances durability by distributing stress more evenly across the connection, which may lead to a longer operational lifespan in demanding conditions.

[0288] Fig. 42 shows an embodiment which integrates handles 1100 into the screw pile cap comprising a bearer plate 120A. The handles 1100 may be configured to allow manual adjustment and tightening of a ball connector, thereby eliminating the need for additional tools in scenarios where portability or rapid installation is prioritised. The inclusion of handles also enhances user convenience, particularly in remote or confined site conditions where tool access may be limited. This embodiment is well-suited for applications requiring flexibility and adaptability during assembly. The ergonomic design of the handles ensures that minimal physical effort is required, further increasing the efficiency of the installation process and reducing operator fatigue.

[0289] Fig. 43 shows another view of the alternative embodiment. The handles 1100 are positioned to optimise ergonomic access, allowing the operator to securely fasten or adjust the components with minimal effort. This design further ensures that the assembly process remains straightforward and efficient. The orientation of the handles 1100 also minimises the risk of slippage during use, enhancing both safety and reliability in operation. The bearer plate 120A is also shown.

[0290] Fig. 44 shows a top-down view of a screw pile cap with integrated handles for manual adjustment of the housing according to an embodiment. The figure also shows the upper bearer plate 120A upon which a composite flooring cassette or other flooring or building component may be attached. This configuration may be particularly advantageous in modular construction systems where prefabricated components are assembled on-site. The screw pile cap ensures that the flooring elements are securely attached while allowing for adjustments to accommodate variations in alignment or positioning. The integration of the handles provides further adaptability, enabling the system to be used effectively in uneven or irregular site conditions without the need for extensive preparatory work.Fig. 45 shows an embodiment wherein a pile cap may comprise an upper housing 1200 and a lower housing 1201 , wherein both housings 1200,1201 may be secured to an upper plate 150 of a pile or flooring support 110 using a dedicated tool having two projections. This embodiment provides a robust and reliable connection between the pile cap and the pile or flooring support 110 making it particularly suitable for heavy-duty applications. The design of the housings 1200,1201 ensures a precise fit, thereby reducing the risk of misalignment or instability during use. The configuration also facilitates quick disassembly, allowing for maintenance or repositioning of components without significant disruption to the overall structure.

[0291] Fig. 46 shows a tool 1300 having two projections 1301 for tightening the upper housing 1200 shown in Fig. 45 so as to secure a screw pile cap according to various embodiments to an upper plate 150 of a pile or flooring support 110. The tool 1300 is designed to be simple and intuitive, allowing precise and secure assembly even in challenging site conditions. The two projections 1301 may be configured to engage corresponding slots or recesses in the upper housing 1200 thereby enabling a firm and reliable connection. Further embodiments are contemplated wherein the tool 1300 may comprise additional features, such as adjustable handles or interchangeable projections, to accommodate a wider range of housing designs and sizes. The intuitive operation of the tool 1300 ensures that it can be used effectively by operators with varying levels of expertise, further enhancing its versatility and utility on construction sites. The tool 1300 may also be constructed from lightweight materials to improve portability, while maintaining sufficient strength to handle the demands of heavy-duty applications.

[0292] Additionally, provisions for ergonomic grips may be incorporated to ensure comfortable and prolonged use during extended assembly tasks.

[0293] Various further embodiments are contemplated. For example, according to further embodiments single-motion tightening may be achieved by upper and lower housings defining a socket around the articulated element and incorporating complementary annular threads. Rotation of one housing relative to the other advances the threaded engagement and uniformly compresses the socket around the articulated element to lock its orientation in a single tightening motion. The annular thread profile may be selected to withstand radial clamp forces while providing smooth engagement, for example a trapezoidal or buttress thread. Integrated handles may be provided on one or both housings to enable manual tightening in constrained conditions where tool access is limited. Additionally, one or more recesses or apertures may be formed in the housing to receive a dedicated tool such as a two-projection tool configured to apply torque for tightening or release. Low-friction liners or bushes may be included within the socket to reduce wear and to facilitate controlled clamp force application.In alternative locking arrangements the housings may be clamped around the articulated element using three, four, five, six or more bolts arranged preferably symmetrically. Prototyping indicates that three bolts comprise a useful minimum, with four bolts suitable for medium sizes and higher counts for larger units. Even tightening applied in a cross-pattern may be used to maintain levelness of the support portion and to avoid rotational creep of the joint.

[0294] The support portion may be configured to provide horizontal positional adjustment. In particular, the support portion may include one or more arcuate slots adapted to receive a pin or threaded stud extending from the articulated joint, permitting rotation of the support portion about the stud within the arcuate slot to correct for angular and lateral offsets. One or more orthogonal slots may be provided to permit translation along x- and / or y-axes prior to locking. The combined slot geometry affords a spin-and-slide adjustment protocolthat reduces sensitivity to pile installation tolerances by enabling controlled rotation and translation of the support portion relative to the joint output.

[0295] Interfaces for traditional systems may be provided. In one embodiment the support portion may be configured as an L-shaped bracket adapted for side fixing to a bearer or joist, wherein one limb provides vertical support and the orthogonal limb includes apertures for side attachment. In another embodiment the support portion may configured as a Y-shaped bracket adapted to receive a hinge pin, the bifurcated arms receiving a pin to allow limited pivoting whilst transmitting vertical loads into the articulated joint and connection portion.

[0296] Height-differential blocks may be mounted on, or integrated with, the support portion beneath one or more adjacent cassettes or building components to produce intentional elevation differences such as patio step-downs. The blocks may be removable modules keyed to the support portion to resist slip and may include elastomeric shims to accommodate tolerances and damp vibration.

[0297] One or more components of the pile cap may be formed from steel,

[0298] fibre-reinforced polymer, thermoplastics, fibre-reinforced thermoplastics, concrete or ceramics. Hybrid constructions may be employed. For example, a steel lower housing may be utilised with an FRP support portion and polymer wear liners within the socket. Corrosion-resistant coatings may be applied to metallic components and resin systems may be selected for outdoor durability in composite components.

[0299] In further embodiments the articulated element may comprises a semi-dome having a convex curved bearing surface corresponding to a spherical cap co-operating with a complementary concave socket. The semi-dome may be oriented dome-up or dome-down. The spherical cap may subtend a half-angle in the range 20-45 degrees,concentrating bearing contact in regions of near-horizontal curvature that carry load efficiently. The semi-dome may be moulded in fibre-reinforced polymer or thermoplastics by compression moulding, resin transfer moulding, vacuum infusion or injection moulding. Optional low-friction wear liners or bushings may be bonded to the concave socket. The semi-dome provides sufficient angular adjustment for inclination correction within a defined envelope while reducing material usage and weight. A retainer ring may be employed to limit travel, provide end-stop protection and maintain component alignment during service.

[0300] While particular embodiments have been illustrated and described, it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the scope of the present invention.

Claims

Claims1. A pile cap configured to interface between a pile or flooring support and a flooring or building component, wherein the pile cap comprises:a connection portion configured to connect the pile cap to a pile or flooring support;a support portion configured to support one or more flooring or building components; andone or more articulated joints configured to enable an angle of inclination of the support portion to be varied.

2. A pile cap as claimed in claim 1 , wherein the connection portion comprises a first threaded portion configured to engage, in use, with a corresponding second threaded portion formed on or within a pile or flooring support.

3. A pile cap as claimed in claim 2, wherein the pile cap is configured to be screwable, in use, towards and / or away from a pile or flooring support so as to adjust the relative height of the support portion relative to the pile or flooring support.

4. A pile cap as claimed in claim 1 , 2 or 3, wherein the support portion comprises a first bearer plate.

5. A pile cap as claimed in any preceding claim, wherein the support portion comprises one or more support fins configured to strengthen the support portion.

6. A pile cap as claimed in claim 5, wherein the pile cap has a longitudinal axis and wherein the one or more of the support fins extend radially outwards relative to the longitudinal axis.

7. A pile cap as claimed in any preceding claim, wherein the one or more articulated joints comprise one or more ball joints.

8. A pile cap as claimed in claim 7, wherein the one or more ball joints comprise a ball connector and a ball joint thread, wherein in use either the ball joint thread is received in a complementary thread provided on or in the support portion and / or on or in a pile or flooring support.

9. A pile cap as claimed in any preceding claim, wherein the one or more articulated joints comprise one or more pin joints, one or more universal joints or one or more swivel connections.

10. A pile cap as claimed in any preceding claim, further comprising a locking mechanism configured to lock the one or more articulated joints in position so as to substantially prevent or restrict movement or rotation of the one or more articulated joints.

11. A pile cap as claimed in claim 10, wherein the locking mechanism is unlockable to allow movement or rotation of the one or more articulated joints.

12. A pile cap as claimed in claim 10 or 11, wherein the locking mechanism comprises one or more fasteners.

13. A pile cap as claimed in claim 12, wherein the one or more fasteners comprises one or more bolts, one or more screws, one or more clamps, one or more magnets, one or more pins, one or more locks, one or more fixings, or one or more cam locks.

14. Apparatus comprising:one or more piles or flooring supports configured to form a foundation for a building structure; andone or more pile caps as claimed in any of claims 1-13, wherein the one or more pile caps are secured, in use, to the one or more piles or flooring supports.

15. Apparatus as claimed in claim 14, wherein the one or more piles or flooring supports comprise screw piles configured to be screwed, in use, into the ground in order to form a foundation fora building structure.

16. Apparatus as claimed in claim 14, wherein the one or more piles or flooring supports comprise one or more posts, one or more anchors, one or more stumps or one or more foundation structures.

17. Apparatus comprising:one or more pile caps as claimed in any of claims 1-13; andone or more flooring or building components configured to be secured, in use, to the one or more pile caps.

18. Apparatus as claimed in claim 17, wherein the one or more flooring or building components comprise one or more composite flooring cassettes or one or more flooring components fabricated from fibre reinforced polymer (“FRP”).

19. Apparatus as claimed in claim 18, wherein one or more of the flooring or building components comprise a plurality of reinforcing members arranged in a grid, array or other format.

20. Apparatus as claimed in claim 17, wherein the one or more flooring or building components comprise one or more bearers or joists, one or more precast concrete flooring panels or sections, one or more timber beams or panels, or one or more metal flooring cassettes.

21. A building system comprising:one or more piles or flooring supports;one or more pile caps as claimed in any of claims 1-13, wherein the one or more pile caps are configured to be secured in use to the one or more piles or flooring supports; andone or more flooring or building components configured to be secured to the one or more pile caps.

22. A method of construction comprising:installing one or more piles or flooring supports; andsecuring one or more piles caps as claimed in any of claims 1-3 on to the one or more piles or flooring supports.

23. A method as claimed in claim 22, further comprising varying the angle of inclination of a support portion of one or more of the pile caps in order to incline an upper portion of a support portion either substantially horizontally or otherwise at a desired angle to the horizontal.

24. A method as claimed in claim 22 or 23, further comprising locking the angle of inclination of the support portion in order to substantially prevent movement or rotation of the support portion.

25. A method as claimed in claim 24, further comprising unlocking the angle of inclination of the support portion in order to allow further adjustment of the support portion.

26. A method as claimed in any of claims 22-25, further comprising reversibly locking or fixing the horizontal and / or vertical position of a support portion of one or more pile caps.

27. A pile cap as claimed in any of claims 1-13, wherein the one or more articulated joints comprise a ball-and-socket joint.

28. A pile cap as claimed in claim 27, wherein the ball-and-socket joint comprises a spherical or semi-spherical ball received within a cup-like socket portion.

29. A pile cap as claimed in claim 28, wherein the ball-and-socket joint further comprises a shaft or shank portion, wherein the shaft or shank portion is either integrally formed with the spherical or semi-spherical ball or attached thereto.

30. A pile cap as claimed in claim 29, wherein in use the cup-like socket portion is attached to the support portion with the shaft or shank portion extending downwards from the spherical or semi-spherical ball.

31. A pile cap as claimed in claim 29, wherein in use the cup-like socket portion is attached to the connection portion with the shaft or shank portion extending upwards from the spherical or semi-spherical ball.

32. A pile cap as claimed in any of claims 28-31 , wherein the cup-like socket portion comprises a first portion and a second portion, wherein in use the spherical or semi-spherical ball is received within the first portion and wherein the second portion is secured to the first portion using one or more fasteners.

30. A pile cap as claimed in claim 28, further comprising a locking mechanism, wherein the locking mechanism comprises an upper housing and a lower housing having complementary annular threads, wherein rotation of the upper housing relative to the lower house tightens or secures the ball-and-socket joint.

31. A pile cap as claimed in claim 30, wherein the upper housing and / or the lower housing comprise integrated handles configured for manual tightening.

32. A pile cap as claimed in claim 30 or 31 , wherein the upper housing and / or the lower housing comprise comprise a tool-engageable interface adapted to receive a two-projection tool to apply torque to tighten or release the housings.

33. A pile cap as claimed in any of claims 1-12, wherein the support portion comprises one or more arcuate slots adapted to receive a pin or threaded stud from the articulated joint, whereby rotation of the support portion about the stud within the arcuate slot permits horizontal positional adjustment prior to locking.

34. A pile cap as claimed in any of claims 1-12, wherein the support portion comprises one or more orthogonal slots permitting translation along x- and / or y-axes prior to locking.

35. A pile cap as claimed in any of claims 1-12, further comprising a locking mechanism comprising 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more than 10 bolts arranged symmetrically around the articulated joint.

36. A pile cap as claimed in any of claims 1-12, wherein the support portion is configured as an L-shaped bracket adapted for side fixing to a bearer or joist.

37. A pile cap as claimed in any of claims 1-12, wherein the support portion is configured as a Y-shaped bracket adapted to receive a hinge pin.

38. A pile cap as claimed in any of claims 1-12, wherein one or more components of the pile cap are formed from steel, fibre-reinforced polymer (“FRP”), thermoplastic, fibre-reinforced thermoplastics, concrete, ceramic or combinations thereof.

39. Apparatus as claimed in any of claims 14-20, further comprising a set of interchangeable height blocks configured to be mounted on or integrated with the support portion to produce a step-down or elevation difference between adjacent flooring or building components.

40. A method as claimed in any of claims 22-26, comprising tightening a locking mechanism by rotating complementary annular threads of upper and lower housings in a single motion, optionally using integrated handles ora two-projection tool.

41. A method as claimed in any of claims 22-26, comprising performing horizontal correction by rotating and / or sliding the support portion within one or more arcuate and / or orthogonal slots prior to locking.

42. A method as claimed in any of claims 22-26, comprising installing one or more height blocks on the support portion to produce a step-down between adjacent flooring or building components.

43. A pile cap as claimed in any of claims 1-12, wherein the articulated joint comprises a semi-dome articulated element having a convex curved bearing surface corresponding to a spherical cap and a complementary concave socket, the semi-dome being oriented dome-up or dome-down.

44. A pile cap as claimed in claim 43, wherein the spherical cap subtends a half-angle in the range 20-45°.

45. A pile cap as claimed in claim 43 or 44, wherein the semi-dome articulated element is manufactured from fibre-reinforced polymer or thermoplastics and optionally comprises a wear liner or bushing within the complementary socket.

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