Composite flooring or building component

Abstract

A composite flooring or building component is disclosed comprising a first surface forming a floor or building element and a second surface supported on pile caps, beams or bearers with recessed compartments. Formed of fibre reinforced polymer, embodiments use a multilayer assembly with a tailored core of structural and / or insulating materials encapsulated by an FRP skin. Encapsulated beam forms provide beam-like strength; solid inserts create hardpoints for columns, fixings and penetrations. Penetration-ready regions accept sleeve liners for sealed service interfaces. Perimeter rebates receive flush-fitting door / window frames and fix wall panels with drainage geometries. Variants include balcony panels with integrated falls and outlets, and outdoor decking with moulded drainage beneath permeable top layers. Optional factory- applied outer skins deliver fire retardation, weather resistance, UV resistance or aesthetics. The system supports modular panel dimensions, side fixing interfaces compatible with dog-bone connectors, adjustable installation on pile caps, and fabrication by moulding, infusion, resin transfer or additive manufacturing for lightweight, durable, rapid construction.

Description

[0001] COMPOSITE FLOORING OR BUILDING COMPONENT

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a composite flooring or building component, apparatus, a method of construction and a method of fabricating a composite flooring or building component.

[0004] BACKGROUND

[0005] It is known to construct a flooring or building component for a building from concrete. Concrete has long been a preferred material due to its inherent strength, durability and ability to withstand significant loads making it suitable for a wide range of structural applications. Its versatility allows it to be cast into various shapes and sizes, enabling the creation of floors, walls and other structural elements that meet specific architectural and engineering requirements. Additionally, concrete’s fire resistance and low maintenance characteristics have resulted in it commonly being used as a building material.

[0006] Pre-fabricated concrete slabs, while widely used in construction due to their strength and durability, however present significant challenges related to their weight and manoeuvrability. The inherent density of concrete results in slabs that are exceedingly heavy even for relatively modest dimensions. This weight places substantial demands on transportation and on-site handling, requiring the use of specialised vehicles, cranes and lifting equipment which can increase construction costs and logistical complexity.

[0007] It will also be understood that the manoeuvrability of concrete slabs is also a significant issue. Due to their size and weight, pre-fabricated concrete slabs are difficult to position precisely during installation. The process often necessitates highly skilled labour and extensive coordination to ensure that the slabs are properly aligned and fitted. In constrained or awkward construction sites, manoeuvring large slabs can be particularly problematic, leading to delays and increased risks of damage to the components or surrounding structures.

[0008] In addition, the weight of pre-fabricated slabs contributes to other practical concerns, such as the structural load they impose on supporting elements. Buildings must be designed to accommodate these loads, often requiring additional reinforcement in foundations, beams and columns which further adds to the cost and complexity of the project.

[0009] In addition, there are increasing environmental concerns surrounding the high carbon footprint associated with cement production. These issues are compounded bythe environmental impact of transporting and installing such heavy materials. The fuel consumption associated with transporting concrete slabs and the energy required to operate lifting equipment contribute to the carbon footprint of the construction process.

[0010] It will be apparent, therefore, that there are a number of problems associated with conventional construction techniques.

[0011] SUMMARY

[0012] According to an aspect there is provided a composite flooring or building component for a building, wherein the flooring or building component comprises:

[0013] a first surface configured to form a flooring or building component of a building; and

[0014] a second surface configured to be supported on a pile cap, beam or bearer, wherein the second surface comprises one or more recessed compartments;

[0015] wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

[0016] It should be understood that the term fibre reinforced polymer (“FRP”) is intended to include thermoset resins such as polyester, vinyl ester and epoxy which are combined with reinforcing fibres such as glass, carbon or aramid fibres to produce strong and lightweight composites having excellent strength-to-weight properties.

[0017] In addition, the term fibre reinforced polymer (“FRP”) is also intended to include fibre reinforced thermoplastics such as long fibre thermoplastics (“LFTP”) such as nylon, polyethylene terephthalate (“PET”) or polypropylene (“PP”) which utilise thermoplastic resins that can be melted and reshaped. This contrasts with traditional thermoset systems which are typically non-recyclable. The use of LFTP provides additional strength and stiffness through the incorporation of longer reinforcing fibres making them suitable for applications where durability and flexibility are required.

[0018] In addition, according to an embodiment 3D printing techniques may be utilised to fabricate the composite flooring or building component as such techniques allow for the production of fibre reinforced polymers using both thermoset and thermoplastic matrices. These technologies enable the incorporation of short or continuous fibres into the polymer during the additive manufacturing process.

[0019] Accordingly, the term FRP should be understood as including thermoset resins, thermoplastic resins such as LFTP, and fibre reinforced polymers produced using 3D printing or other advanced techniques, including those incorporating recycled materials.The composite flooring or building component according to various embodiments offers significant advantages over traditional pre-fabricated concrete slabs. One key benefit is the use of fibre reinforced polymer (“FRP”) which offers significantly improved strength-to-weight properties. Unlike concrete, which is dense and heavy, FRP materials offer comparable structural strength while being significantly lighter. This reduction in weight addresses problems associated with the transportation, handling and installation of heavy concrete slabs. Furthermore, lighter components reduces the need for specialised lifting equipment, cranes and reinforced foundations thereby lowering construction costs and simplifying on-site manoeuvrability.

[0020] In addition to weight advantages, a composite flooring or building component according to various embodiments significantly improves manoeuvrability during installation. FRP components are easier to transport, position and align particularly in constrained or complex construction sites where access may be limited. This enhanced flexibility allows for faster and more efficient installation, reducing labour costs and project timelines.

[0021] The use of fibre reinforced thermoplastics (“LFTP”) according to various embodiments such as nylon, polyethylene terephthalate (“PET”) or polypropylene (“PP”) further enhances the component’s suitability for modern construction. These materials offer superior durability and flexibility while maintaining high stiffness and strength through the incorporation of long reinforcing fibres. In contrast to traditional thermoset systems, LFTP resins are recyclable, aligning with the increasing focus on sustainability in the construction industry.

[0022] Embodiments are also contemplated wherein advanced manufacturing techniques, such as 3D printing, may be utilised which allow for the production of fibre reinforced polymers with either short or continuous fibres. These techniques enable the creation of customised and optimised structures that combine strength, lightweight properties and design versatility. Additionally, 3D printing minimises material waste and supports the incorporation of recyclable properties further enhancing the environmental credential of a composite flooring or building component according to various embodiments.

[0023] According to various embodiments a flooring or building component is provided which is lightweight, durable, cost-effective and environmentally sustainable and which offers benefits in terms of construction efficiency, performance and long-term sustainability. Accordingly, it will be apparent that the present invention represents a significant advance in the art.According to various embodiments the fibre reinforced polymer may comprise a thermoset resin. For example, the thermoset resin may comprise polyester, vinyl ester or epoxy.

[0024] According to various embodiments the fibre reinforced polymer may comprise a thermoplastic resin. The thermoplastic resin may comprise a long fibre thermoplastic (“LFTP”). Embodiments are contemplated wherein the long fibre thermoplastic (“LFTP”) comprises nylon, polyethylene terephthalate (“PET”) or polypropylene (“PP”).

[0025] The fibre reinforce polymer (“FRP”) may comprise glass, carbon or aramid fibres.

[0026] According to various embodiments the composite flooring or building component may be formed by a moulding process or an additive or 3D printing process.

[0027] The one or more recessed compartments may have a trapezoidal, top-hat, rectangular, square, V-shaped, W-shaped or polygonal cross-sectional profile.

[0028] The composite flooring or building component may have a tensile strength in the range 600-1500 MPa.

[0029] According to various embodiments the composite flooring or building component may have a density in the range 1.5-2.0 g / cm3.

[0030] According to various embodiments the composite flooring or building component may have a strength-to-weight ratio in the range 300-750 MPa.cm3 / g.

[0031] The composite flooring or building component may comprise a thermal insulating material located in one or more of the recessed compartments.

[0032] The thermal insulating material may have a R-value of > 0.45 per cm of thickness.

[0033] The thermal insulating material may comprise fiberglass insulation, expanded polystyrene (“EPS”), mineral wool (rock wall), open-cell spray foam or closed-cell spray foam.

[0034] According to various embodiments the composite flooring or building component may further comprise an acoustic insulating material located in one or more of the recessed compartments. The acoustic insulating material may have a Noise Reduction Coefficient (“NRC”) > 0.50.The composite flooring or building component may further comprise acoustic insulating material comprises fiberglass insulation, mineral wool (rock wool), acoustic foam, one or more fabric-wrapped acoustic panels, open-cell spray foam, closed-cell spray foam or one or more acoustic tiles.

[0035] The composite flooring or building component may further comprise a fire retardant material located in one or more of the recessed compartments.

[0036] According to an embodiment the fire retardant material may comprise a Flame Spread Index (“FSI”) as determined by ASTM E84 (Standard Test Method for Surface Burning Characteristics of Building Materials) of < 75.

[0037] The fire retardant material may comprise mineral wool (rock wool), fire-rated gypsum board, cement board, concrete, brick, fire-retardant-treated plywood, fiberglass insulation, fibreglass insulation treated with one or more fire-resistant additives, glass-reinforced cement (“GRC”), aluminium, steel, calcium silicate board, ceramic tiles ora intumescent material.

[0038] The composite flooring or building component may comprise a composite flooring or building cassette.

[0039] The composite flooring or building component may be stackable so that, in use, a first composite flooring or building component may be stacked upon a second composite flooring or building component.

[0040] According to various embodiments the composite flooring or building component may comprise one or more projections, recesses, key features or interlocking features for engaging with a further composite flooring or building component so as to secure, in use, the composite flooring or building component to a further composite flooring or building component either horizontally and / or vertically.

[0041] The first surface may comprise a lid or recess portion, wherein the lid or recess portion is configured to receive a flooring component and / or one of more utilities.

[0042] The composite flooring or building component may further comprise a thermal insulating material, an acoustic insulating material ora fire retardant material located in the lid or recess provided in the first surface.

[0043] The composite flooring or building component may further comprise a reflecting material or foil located in the lid or recess provided in the first surface, wherein the reflecting material or foil is arranged to reflect heat.The lid or recess portion may include a utility component. For example, the utility component may comprise one or more water pipes, one or more gas pipes, one or more electrical cables, one or more underfloor heating pipes or cables, one or more drains, one or more air vents, one or more air conditioning components, one or more communication cables, one or more data transmission cables, one or more insulation layers, one or more acoustic dampening components, or one or more lighting fixtures.

[0044] The composite flooring or building component may further comprise one or more reinforcing structures.

[0045] The one or more reinforcing structures may comprise a beam, rod or support.

[0046] The one or more reinforcing structures may be integrally formed as part of the composite flooring or building component. Alternatively, the one or more reinforcing structures may comprise discrete components which are secured to the composite flooring or building component in order to provide reinforcement.

[0047] The composite flooring or building component may further comprise one or more fixing blocks, wherein in use one or more fixings are arranged to pass through the first surface, the one or more fixing blocks and the second surface in order to secure the composite flooring or building component to a bearer plate connected to a pile cap, beam or bearer.

[0048] According to another aspect there is provided apparatus comprising:

[0049] one or more pile caps, beams or bearers configured to be secured in use to a pile or flooring support; and

[0050] one or more composite flooring or building components as described above, wherein the one or more composite flooring or building components are configured to be secured to the one or more pile caps, beams or bearers.

[0051] According to another aspect there is provided a method of construction comprising:

[0052] installing one or more piles or flooring supports;

[0053] securing one or more pile caps, beams or bearers on or to the one or more piles or flooring supports; and

[0054] installing one or more composite flooring or building components as described above on to the one or more pile caps, beams or bearers.

[0055] According to various embodiments the step of installing one or more composite flooring or building components on to the one or more pile caps, beams or bearers may further comprise passing one or more fixings or fasteners through a first surface and a second opposed surface of the composite flooring or building component and securingthe one or more fixings or fasteners to a bearer plate connected to a pile cap, beam or bearer.

[0056] According to another aspect there is provided a method of fabricating a composite flooring or building component for a building comprising:

[0057] forming using a mould a composite flooring or building component having a first surface configured to form a flooring or building component of a building and a second surface configured to be supported on a pile cap, beam or bearer wherein the second surface comprises one or more recessed compartments;

[0058] wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

[0059] According to another aspect there is provided a method of fabricating a composite flooring or building component for a building comprising:

[0060] forming using an additive or 3D printing process a composite flooring or building component having a first surface configured to form a flooring or building component of a building and a second surface configured to be supported on a pile cap, beam or bearer wherein the second surface comprises one or more recessed compartments;

[0061] wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

[0062] According to an embodiment there is provided a composite flooring or building component comprising a multilayer assembly including a core of one or more structural or insulating materials and an outer fibre reinforced polymer skin encapsulating the core. It will be understood that this provides the advantage of combining a high strength-to-weight outer shell with tailored core functionality, thereby improving stiffness, durability and thermal or acoustic performance while reducing mass.

[0063] According to an embodiment there is provided a composite flooring or building component wherein the core comprises one or more of timber, engineered wood, polymer foam, aerogel, honeycomb structures, recycled plastic, cementitious boards, gypsum boards, cork or combinations thereof. It will be understood that this provides the advantage of material flexibility, enabling optimisation for cost, sustainability, fire performance, thermal resistance and structural stiffness for different use cases.

[0064] According to an embodiment there is provided a composite flooring or building component further comprising an additional outer skin over the fibre reinforced polymer skin, the additional outer skin selected to provide fire retardation, weather resistance, ultraviolet resistance or aesthetic styling. It will be understood that this provides the advantage of tunable surface performance, allowing compliance with building codes and environmental exposure requirements while offering design finishes without secondary trades.According to an embodiment there is provided a composite flooring or building component wherein the additional outer skin comprises a metal skin, a timber skin, a ceramic skin, a stone skin, a laminate skin or a paint or coating system formulated to provide one or more of the foregoing properties. It will be understood that this provides the advantage of delivering factory-applied finishes with enhanced durability and appearance and reduces on-site finishing time and variability.

[0065] According to an embodiment there is provided a composite flooring or building component wherein the multilayer assembly comprises one or more encapsulated beam forms integrated within the core and extending along a predefined path to provide beamlike strength and stiffness. It will be understood that this provides the advantage of selectively increasing load-carrying capacity and limiting deflection along critical lines without significantly increasing weight.

[0066] According to an embodiment there is provided a composite flooring or building component wherein the encapsulated beam forms comprise one or more of fibre reinforced polymer solid beams, pultruded composite profiles, laminated composite beams, timber beams, steel channels, rectangular hollow sections or parallel flange channels. It will be understood that this provides the advantage of allowing designers to select the most suitable reinforcement technology for performance, cost and supply chain considerations.

[0067] According to an embodiment there is provided a composite flooring or building component further comprising one or more encapsulated solid elements located at predetermined positions within the component and configured to provide localised reinforcement for a column support, a through-bolt penetration or a side fixing. It will be understood that this provides the advantage of creating robust hardpoints that resist crushing and pull-out, thereby enabling reliable connections and point load transfer.

[0068] According to an embodiment there is provided a composite flooring or building component wherein the one or more encapsulated solid elements comprise plates, blocks or inserts formed of steel, aluminium, fibre reinforced polymer solid laminate, cement board or hardwood. It will be understood that this provides the advantage of tailoring the local reinforcement to the expected mechanical, corrosion and fire environment while maintaining compatibility with standard fixings.

[0069] According to an embodiment there is provided a composite flooring or building component comprising one or more pre-formed penetrations or penetration-ready regions configured to be cut using a hole saw and to receive a sleeve insert lining a round hole for passage of a plumbing pipe or an electrical conduit. It will be understood that this provides the advantage of facilitating rapid, accurate service routing while preserving structural integrity and moisture barriers.According to an embodiment there is provided a composite flooring or building component wherein the sleeve insert comprises a tubular liner having an external flange or shoulder configured to engage with a first or second surface and to provide a sealed interface around the penetration. It will be understood that this provides the advantage of achieving air- and water-tight transitions with improved durability and simplified inspection.

[0070] According to an embodiment there is provided a composite flooring or building component wherein the sleeve insert is formed of a fire-retardant or intumescent material and / or comprises seals or grommets to provide water-tightness or air-tightness. It will be understood that this provides the advantage of enhancing fire separation and building envelope performance at service penetrations without additional site-applied sealing systems.

[0071] According to an embodiment there is provided a composite flooring or building component comprising one or more rebates at a perimeter edge configured to receive a flush-fitting door or window frame and / or to assist water drainage away from an interior of the building. It will be understood that this provides the advantage of enabling low-threshold openings with controlled drainage, improving accessibility and weatherproofing.

[0072] According to an embodiment there is provided a composite flooring or building component wherein the rebate is further configured to locate and fix a vertical external wall panel and optionally comprises drainage geometry that prevents water ingress into the building. It will be understood that this provides the advantage of integrating floor-to-wall interfaces with reliable fixing and moisture management, reducing flashing complexity.

[0073] According to an embodiment there is provided a composite flooring or building component configured as a balcony panel for an upper level, the second surface arranged for support on a beam or bearer and the first surface comprising a weatherresistant top skin and integrated drainage features. It will be understood that this provides the advantage of delivering a prefabricated, durable and drainable exterior floor that accelerates installation and reduces on-site waterproofing risk.

[0074] According to an embodiment there is provided a composite flooring or building component wherein the integrated drainage features comprise a sloped or contoured surface directing water towards one or more drainage outlets and / or towards an edge discharge. It will be understood that this provides the advantage of improved water management, reducing ponding and the likelihood of leakage or slip hazards.

[0075] According to an embodiment there is provided a composite flooring or building component configured for use as outdoor decking wherein the first surface comprisesmoulded drainage channels arranged beneath a permeable top layer so as to convey water towards a central penetration and / or towards an edge discharge. It will be understood that this provides the advantage of concealed, efficient drainage beneath various deck finishes, prolonging service life and improving user safety.

[0076] According to an embodiment there is provided a composite flooring or building component wherein the permeable top layer comprises decking boards with gaps, spaced ceramic tiles, synthetic turf or grating, and wherein the moulded drainage channels are covered by a removable or serviceable mesh or cover. It will be understood that this provides the advantage of compatibility with diverse finishes and ease of maintenance by allowing debris removal and inspection of channels.

[0077] According to an embodiment there is provided a composite flooring or building component comprising one or more side fixing features configured to interface with plates or dog-bone connectors to provide one-way, two-way, three-way or four-way connections between adjacent components. It will be understood that this provides the advantage of rapid modular assembly with precise alignment and improved lateral load transfer.

[0078] According to an embodiment there is provided a composite flooring or building component dimensioned as a modular panel selected from 2 m x 2 m, 2 m x 3 m or larger single-piece panels within maximum road transport limits enabling installation of a whole building floor in one operation. It will be understood that this provides the advantage of reduced installation time and site labour with fewer joints and enhanced dimensional control.

[0079] According to an embodiment there is provided apparatus comprising one or more pile caps, beams or bearers and one or more of the foregoing composite flooring or building components including multilayer assemblies and perimeter rebates for flushfitting door and / or window frames. It will be understood that this provides the advantage of a coordinated structural and architectural solution that simplifies interfaces and improves buildability.

[0080] According to an embodiment there is provided apparatus wherein at least one component configured as outdoor decking comprises moulded drainage channels beneath a permeable top layer and is connected to one or more pile caps or bearers so as to provide discharge towards a central outlet and / or towards an edge. It will be understood that this provides the advantage of a structurally supported, integrated drainage deck system requiring minimal secondary works.

[0081] According to an embodiment there is provided a method of construction further comprising forming one or more penetrations by cutting a round hole at a penetrationready region of a composite flooring or building component and inserting a sleeve liner toline the hole for passage of services. It will be understood that this provides the advantage of clean, fast service integration with predictable sealing performance.

[0082] According to an embodiment there is provided a method of construction further comprising installing a composite flooring or building component having a perimeter rebate so that a flush-fitting door and / or window frame is received in the rebate and a vertical external wall panel is fixed at the rebate with provision for water drainage away from the building interior. It will be understood that this provides the advantage of simplified threshold detailing and reliable water management at fagade interfaces.

[0083] According to an embodiment there is provided a method of construction wherein installing comprises securing one or more components configured as balcony panels to beams or bearers at an upper level and arranging integrated drainage features to discharge towards one or more drainage outlets and / or an edge discharge. It will be understood that this provides the advantage of off-site pre-formed drainage that reduces membrane work and speeds programme.

[0084] According to an embodiment there is provided a method of construction further comprising installing one or more components configured as outdoor decking wherein a permeable top layer overlies moulded drainage channels in the component and water is directed towards a central penetration and / or an edge discharge. It will be understood that this provides the advantage of achieving compliant, maintainable drainage without complex falls in the supporting structure.

[0085] According to an embodiment there is provided a method of fabricating a composite flooring or building component comprising forming a multilayer assembly by placing one or more encapsulated beam forms and one or more encapsulated solid elements at predetermined positions within a mould, encapsulating them within a core material and applying a fibre reinforced polymer skin to wrap the assembly. It will be understood that this provides the advantage of precise placement of reinforcements and hardpoints, ensuring repeatable structural performance in mass production.

[0086] According to an embodiment there is provided a method of fabrication further comprising applying an additional outer skin over the fibre reinforced polymer skin selected to provide fire retardation, weather resistance, ultraviolet resistance or aesthetic styling. It will be understood that this provides the advantage of factory-controlled application of performance layers, enhancing quality and reducing on-site finishing.

[0087] According to an embodiment there is provided a composite flooring or building component wherein the first surface comprises a top lid having removable access covers aligned with utilities or penetrations and the second surface comprises a grid or top-hat arrangement of recessed compartments with localised reinforcement proximate the encapsulated solid elements. It will be understood that this provides the advantage ofsafe, maintainable access to services while preserving structural efficiency and providing targeted strength where fixings occur.

[0088] According to an embodiment there is provided a composite flooring or building component wherein the rebates, drainage channels and penetrations are integrally moulded during fabrication and are operatively associated with sleeve inserts, gaskets or drains to provide weatherproof performance. It will be understood that this provides the advantage of reducing site workmanship risks and ensuring consistent envelope integrity.

[0089] According to an embodiment there is provided a composite flooring or building component configured to be stackable and comprising interlocking projections and recesses compatible with dog-bone connectors and perimeter rebates so as to enable both horizontal and vertical assembly. It will be understood that this provides the advantage of rapid modular stacking and secure interconnection, improving erection rates and seismic or wind performance.

[0090] According to an aspect there is provided use of a composite flooring or building component as a balcony panel or outdoor decking element in a building, wherein water management is provided by moulded drainage channels directing water to a central outlet and / or an edge discharge beneath a permeable top layer. It will be understood that this provides the advantage of delivering a lightweight, durable and drainable exterior platform with reduced maintenance.

[0091] According to an aspect there is provided a building comprising one or more composite flooring or building components wherein at least one perimeter edge comprises a rebate receiving a flush-fitting sliding door and at least one service penetration comprises a sleeve liner providing a sealed interface fora plumbing pipe and / or an electrical conduit. It will be understood that this provides the advantage of integrated architectural thresholds and service entries that enhance weatherproofing, acoustic performance and installation efficiency.

[0092] BRIEF DESCRIPTION OF THE DRAWINGS

[0093] Various embodiments of the present invention together with other arrangements given for illustrative purposes only, will now be described, by way of example only, and with reference to the accompanying drawings in which:

[0094] Fig. 1 shows a floor plan of a building featuring modular composite flooring or building panels supported on piles and associated adjustable pile caps, wherein the piles are arranged in a grid format;Fig. 2 shows a flooring system comprising modular composite flooring or building cassettes according to an embodiment supported by piles anchored into the ground and wherein a pile cap provides an interface between the pile and the composite flooring or building cassette;

[0095] Fig. 3A shows an upper view of a mould arranged to form a composite flooring or building cassette having a lid according to an embodiment and Fig. 3B shows a lower view of a composite flooring or building cassette according to an embodiment illustrating its structural design which may comprise a grid pattern;

[0096] Fig. 4 shows an upper view of a composite flooring or building cassette having a square profile configured for modular construction according to an embodiment;

[0097] Fig. 5 shows a testing arrangement for a composite flooring or building cassette wherein the composite flooring or building cassette is subjected to a uniform distributed load according to an embodiment;

[0098] Fig. 6 shows a testing set up together with the results of the test wherein a composite flooring or building cassette was subjected to increasing applied loads in order to measure the deflection of the composite flooring or building cassette according to an embodiment;

[0099] Fig. 7 shows a testing arrangement simulating a line load applied to a composite flooring or building cassette to replicate wall loading conditions according to an embodiment;

[0100] Fig. 8A shows a testing arrangement for evaluating a composite flooring or building cassette's performance wherein weights were applied to the composite flooring or building cassette via steel channels which were secured to the composite flooring or building cassette and Fig. 8B shows steel weights being applied to the composite flooring or building cassette via a steel channel in a testing environment;

[0101] Fig. 9 shows the results of a load test wherein weights were applied to a composite flooring or building cassette according to various embodiments via a steel batten and comparative data showing the results without a steel batten;

[0102] Fig. 10A shows a timber beam bolted on to a composite flooring or building 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 or building cassette is measured;Fig. 11 A shows two composite flooring or building 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 or building cassette according to an embodiment, Fig. 11 C shows the use of a bolt and associated washer secured to a composite flooring or building cassette according to an embodiment, Fig. 11 D shows how screws and associated washers may be secured to a composite flooring or building cassette according to an embodiment and Fig. 11 E also shows how a screw may be secured directly to a composite flooring or building cassette according to an embodiment;

[0103] Fig. 12 shows a pull test being conducted to assess tensile strength and failure behaviour of various fixing methods for composite flooring or building cassettes according to various embodiments;

[0104] Fig. 13 shows a side connection method for joining two composite flooring or building cassettes together according to an embodiment wherein an adhesive may be used to join two adjacent composite flooring or building cassettes together;

[0105] Fig. 14 shows a table summarising the thermal resistance R-values of various conventional building materials, composite flooring or building cassettes according to various embodiments and composite flooring or building cassettes according to various embodiments having compartments which were filled with different insulation materials according to various embodiments;

[0106] 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);

[0107] Fig. 16 shows a load test being conducted on a rectangular hollow section ("RHS") edge beam under a line load testing regime;

[0108] Fig. 17 shows a load test being conducted on a parallel flange channel ("PFC") edge beam under a line load testing regime;

[0109] Fig. 18 illustrates a vacuum infusion process for fabricating fibre-reinforced polymer ("FRP") solid edge beams according to an embodiment;

[0110] Fig. 19A shows a first relatively thick FRP solid edge and Fig. 19B shows a second relatively thinner FRP solid edge beam;Fig. 20A shows how a line load test may be conducted on a FRP solid edge beam 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;

[0111] Fig. 21 shows a point load test being conducted on an FRP solid edge beam in order to evaluate its response under concentrated forces;

[0112] 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;

[0113] 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;

[0114] Fig. 24 shows a test setup for assessing the structural performance of a FRP edge beam under load conditions;

[0115] Fig. 25 shows a table comparing the weight / m, cost / m and deflection of various perimeter edge beam configurations when subjected to a centre point load of 2283 kg;

[0116] Fig. 26A illustrates how the horizontal position of a screw pile cap may be adjusted and Fig. 26B illustrates how a plurality of screw pile caps may be integrated into a modular composite flooring system according to various embodiments;

[0117] Fig. 27 shows a screw pile cap 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;

[0118] Fig. 28A illustrates how the horizontal position of a screw pile cap may be adjusted and Fig. 28B shows a top view and side views of a screw pile cap together with a supporting plate which is secured to the thread of a ball joint;

[0119] Fig. 29 shows a cross-sectional schematic of a screw pile cap, 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 according to an embodiment;

[0120] Fig. 30 shows a screw pile cap showing a bearer plate supporting a composite flooring or building cassette according to an embodiment, wherein the composite flooring or building cassette includes fixing blocks through which screws or bolts may be utilisedin order to secure an upper portion of the composite flooring or building cassette to a bracing or bearer plate of the screw pile cap;

[0121] Fig. 31 shows a ball down configuration for a screw pile cap, wherein a supporting plate which includes 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;

[0122] Fig. 32 shows a ball down configuration for a screw pile 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;

[0123] Fig. 33A shows a plurality of composite flooring or building cassettes according to various embodiments wherein each composite flooring or building 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 or building cassette, Fig. 33C shows a rearview of two different formats of composite flooring or building cassettes according to various embodiments and Fig. 33D shows a side view of composite fixing blocks according to various embodiments;

[0124] Fig. 34A shows a standard format composite flooring or building cassette according to an embodiment comprising a uniform grid configuration and Fig. 34B shows a different format composite flooring or building cassette which is customisable and wherein the flooring cassette may comprise integral or discrete insertable reinforcements according to an embodiment;

[0125] Fig. 35A shows a perimeter edge beam wherein the perimeter edge beam is supported on an adjustable screw pile cap and Fig. 35B shows a cross-sectional view of a perimeter edge beam;

[0126] Fig. 36A shows for summary purposes a ball-down configuration for a screw pile cap, 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 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;

[0127] Fig. 37A shows a centre connection detail for a modular construction using screw piles and composite flooring or building panels according to an embodiment, Fig. 37B shows a patio step down detail for a modular construction using screw piles and composite flooring or building panels according to an embodiment and Fig. 37C showsan edge connection detail for a modular construction using screw piles and composite flooring or building panels according to an embodiment;

[0128] Fig. 38 shows various different adjustable support arrangements for composite flooring or building cassettes according to various embodiments;

[0129] Fig. 39 shows test data and a graph of deflection behaviour in steel plates under a line load;

[0130] Fig. 40 shows a comparative analysis of various different composite flooring or building cassette configurations in terms of weight, load limits and deflection characteristics;

[0131] 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;

[0132] Fig. 42 shows a screw pile cap having integrated handles allowing for manual adjustment of the housing;

[0133] Fig. 43 shows a screw pile cap with integrated handles for manual adjustment of the housing;

[0134] Fig. 44 shows top down view of a screw pile cap with integrated handles for manual adjustment of the housing and shows an upper bearing plate upon which a composite flooring or building cassette or other building component may be attached or otherwise secured;

[0135] Fig. 45 shows an alternative arrangement 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

[0136] 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 to an upper plate of a pile or flooring support.DESCRIPTION

[0137] Various embodiments will now be described with reference to the accompany drawings.

[0138] Fig. 1 shows a floor plan of a building according to various embodiments wherein seventy-two full-sized composite flooring or building panels 130 (each measuring 2m x 2m) and eight half-sized composite flooring or building panels 130 (each measuring 2m x 1m) are installed upon piles 110 arranged in a regular array. The composite flooring or building 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.

[0139] As is apparent, the majority of the composite flooring or building 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 composite flooring or building 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 composite flooring or building panels 130 allows for efficient manufacturing and installation whilst facilitating customisation to meet bespoke requirements.

[0140] According to various embodiments some of the composite flooring or building panels 130 may be configured to support wet areas such as bathrooms, kitchens or laundries. According to various embodiments composite flooring or building 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 composite flooring or building 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.

[0141] According to various embodiments one or more of the composite flooring or building panels 130 may be configured to support outdoor areas such as a porch, balcony or terrace. It will be understood that outdoor composite flooring or building panels 130 may be configured both for structural stability whilst also addressing environmental factors. For example, balcony composite flooring or building panels 130 may include integrated attachment points for railings or balustrades and may include a sloped surface to aid water run-off. Additionally, outdoor composite flooring or buildingpanels 130 according to various embodiments may incorporate weather-resistant finishes which are provided in order to enhance longevity and performance in outdoor conditions. Transitional spaces, such as porches which may connect indoor and outdoor spaces or areas may incorporate composite flooring or building panels 130 which integrate both environments thereby ensuring a cohesive aesthetic and functional layout.

[0142] A plurality of pile caps, such as screw pile caps (not shown), may be secured to the piles or flooring supports 110. The pile caps may include a bearer plate which is configured to support or provide support to the composite flooring or building panels 130 and ensure structural stability.

[0143] The flooring and building system according to various embodiments may comprise 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 composite flooring or building panels 130 or building components.

[0144] According to various embodiments the composite flooring or building panels may comprise one or more composite flooring or building cassettes 130 may be constructed from composite materials such as fibreglass which benefits from a high strength-to-weight ratio. Accordingly, a building system according to various embodiments is disclosed comprising a plurality of composite flooring or building cassettes 130. It will be understood that fabricating the composite flooring or building 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 or building 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 or building 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 experienceseismic 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).

[0145] According to various embodiments the composite flooring or building panels 130 may be pre-fabricated and may be lightweight, durable and can be fabricated according to various embodiments in a range of different shapes and sizes. In particular, composite flooring or building 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.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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 or building cassettes 130 or other flooring panels. It will be understood that whilst various arrangements relate to the use of a pile cap 120 or screw pile cap 120 which is adjustable and which may be deployed in conjunction with one or more composite flooring or building cassettes 130 that it is not essential that the pile cap 120 is utilised inconjunction with a composite flooring or building cassette 130. For example, a composite flooring or building cassette 130 according to various embodiments may be installed on a first or higher floor level of a building and hence the composite flooring or building cassette 130 may be supported by one or more beams or bearers.

[0150] The piles or screw piles 110 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 the flooring system (or building components) to the underlying ground and sub-surface supporting structures such as bedrock.

[0151] The piles or screw piles 110 may be arranged in a predetermined grid or other pattern. Other arrangements 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. The 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.

[0152] A plurality of modular composite flooring or building 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 composite flooring or building 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 composite flooring or building cassettes 130 according to various embodiments facilitates rapid installation as a composite flooring or building cassette 130 can be quickly aligned and secured e.g. to a pile 110 via a pile cap 120 using standardised connectors (e.g. bolts) or brackets.

[0153] The composite flooring or building cassette 130 may more generally comprise a flooring or building component 130 i.e. it is not essential that the composite cassette 130 forms the floor of a building and embodiments are contemplated wherein a floor may be installed on top of a composite cassette 130. The flooring or building component 130 comprises a first (e.g. upper) surface which may be configured to form a flooring or building component of a building and a second (e.g. lower) surface which is configured to be supported on a pile cap (if installed on the ground floor) or a beam or bearer (if installed on a first or higher floor level). The second surface may comprise one or more recessed compartments 130A and the flooring or building component 130 may be made from fibre reinforced polymer (“FRP”). The fibre reinforced polymer (“FRP”) may comprise a thermoset resin such as polyester, vinyl ester and epoxy which is combinedwith reinforcing fibres like glass, carbon or aramid fibres to produce a strong and lightweight composite having excellent strength-to-weight properties.

[0154] Alternatively, the fibre reinforced polymer (“FRP”) may comprise a fibre reinforced thermoplastic such as a long fibre thermoplastic (“LFTP”) e.g. nylon, polyethylene terephthalate (“PET”) or polypropylene (“PP”) which utilises a thermoplastic resin that can be melted and reshaped. This contrasts with traditional thermoset systems which are typically non-recyclable. The use of LFTP provides additional strength and stiffness through the incorporation of longer reinforcing fibres making them suitable for applications where durability and flexibility are required.

[0155] Embodiments are also contemplated wherein 3D printing techniques may be used to produce the fibre reinforced polymers using both thermoset and thermoplastic matrices. These technologies enable the incorporation of short or continuous fibres into the polymer during the additive manufacturing process. Accordingly the term FRP should be understood as including thermoset resins, thermoplastic resins such as LFTP, and fibre reinforced polymers produced using 3D printing or other advanced techniques, including those incorporating recyclable properties.

[0156] The composite flooring or building component 130 according to various embodiments offers significant advantages over traditional pre-fabricated concrete slabs. One key benefit is the use of fibre reinforced polymer (“FRP”) which offers significantly improved strength-to-weight properties. Unlike concrete, which is dense and heavy, FRP materials offer comparable structural strength while being significantly lighter. This reduction in weight addresses longstanding issues associated with the transportation, handling and installation of heavy concrete slabs. Furthermore, lighter components reduce the need for specialised lifting equipment, cranes and reinforced foundations thereby lowering construction costs and simplifying on-site manoeuvrability.

[0157] In addition to weight advantages, a composite flooring or building component 130 according to various embodiments significantly improves manoeuvrability during installation. FRP components are easier to transport, position and align particularly in constrained or complex construction sites where access may be limited. This enhanced flexibility allows for faster and more efficient installation, reducing labour costs and project timelines.

[0158] The use of fibre reinforced thermoplastics (“LFTP”) according to various embodiments including nylon, polyethylene terephthalate (“PET”) or polypropylene (“PP”) further enhances the flooring or building component’s suitability for modern construction. These materials offer superior durability and flexibility while maintaining high stiffness and strength through the incorporation of long reinforcing fibres. In contrast to traditionalthermoset systems, LFTP resins are recyclable, aligning with the increasing focus on sustainability in the construction industry.

[0159] Embodiments are also contemplated wherein advanced manufacturing techniques, such as 3D printing, may be utilised which allow for the production of fibre reinforced polymers with either short or continuous fibres. These techniques enable the creation of customised and optimised structures that combine strength, lightweight properties and design versatility. Additionally, 3D printing minimises material waste and supports the incorporation of recyclable properties further enhancing the environmental credential of a composite flooring or building component according to various embodiments.

[0160] According to various embodiments a flooring or building component 130 is provided which is lightweight, durable, cost-effective and environmentally sustainable and which offers benefits in terms of construction efficiency, performance and long-term sustainability. Accordingly, it will be apparent that the present invention represents a significant advance in the art.

[0161] The composite flooring or building component 130 may comprise a composite flooring or building cassette 130. The composite flooring or building component 130 may be stackable so that, in use, a first composite flooring or building component may be stacked upon a second composite flooring or building component. According to various embodiments the composite flooring or building component 130 may comprise one or more projections (not shown in Fig. 2), recesses, key features or interlocking features for engaging with a further composite flooring or building component so as to secure, in use, the composite flooring or building component to a further composite flooring or building component either horizontally and / or vertically.

[0162] The composite flooring or building component 130 may further comprise one or more reinforcing structures. The one or more reinforcing structures may comprise a beam, rod or support. The one or more reinforcing structures may be integrally formed as part of the composite flooring or building component 130.

[0163] The composite flooring or building component 130 may further comprise one or more fixing blocks, wherein in use one or more fixings are arranged to pass through the first surface, the one or more fixing blocks and the second surface in order to secure the composite flooring or building component to a bearer plate connected to a pile cap, beam or bearer.

[0164] A pile cap 120 may be provided which allows for an adjustable connection thereby enabling precise alignment of a composite flooring or building cassette 130 to ensure a level flooring system (or more generally a building component) even on uneventerrain or varying soil conditions. The ability to adjust the connection height and inclination contributes to the overall adaptability and stability of the system.

[0165] The one or more composite flooring or building cassettes 130 may be arranged contiguously to form a uniform and stable base for a building. According to various embodiments, each composite flooring or building 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 or building cassettes 130 may include specialised materials or treatments to enhance properties such as thermal or acoustic insulation, fire resistance or overall durability.

[0166] The one or more recessed compartments 130A may have a trapezoidal, top-hat, rectangular, square, V-shaped, W-shaped or polygonal cross-sectional profile. In particular, as shown in Fig. 2, the recessed compartments 130A may have a trapezoidal profile. However, according to other preferred embodiments the recessed compartments 130A may have a top-hat profile. The composite flooring or building component may have a tensile strength in the range 600-1500 MPa. The composite flooring or building component 130 may have a density in the range 1.5-2.0 g / cm3. According to various embodiments the composite flooring or building component 130 may have a strength-to-weight ratio in the range 300-750 MPa.cm3 / g. The composite flooring or building component 130 may comprise a thermal insulating material located in one or more of the recessed compartments 130A. The thermal insulating material may have a R-value of > 0.45 per cm of thickness. The thermal insulating material may comprise fiberglass insulation, expanded polystyrene (“EPS”), mineral wool (rock wall), open-cell spray foam or closed-cell spray foam.

[0167] According to various embodiments the composite flooring or building component 130 may further comprise an acoustic insulating material located in one or more of the recessed compartments 130A. The acoustic insulating material may have a Noise Reduction Coefficient (“NRC”) > 0.50. The composite flooring or building component 130 may further comprise acoustic insulating material comprises fiberglass insulation, mineral wool (rockwool), acoustic foam, one or more fabric-wrapped acoustic panels, open-cell spray foam, closed-cell spray foam or one or more acoustic tiles.

[0168] The composite flooring or building component 130 may further comprise a fire retardant material located in one or more of the recessed compartments 130A.

[0169] According to an embodiment the fire retardant material may comprise a Flame Spread Index (“FSI”) as determined by ASTM E84 (Standard Test Method for Surface Burning Characteristics of Building Materials) of < 75. The fire retardant material may comprise mineral wool (rockwool), fire-rated gypsum board, cement board, concrete, brick, fire-retardant-treated plywood, fiberglass insulation, fibreglass insulation treated with one ormore fire-resistant additives, glass-reinforced cement (“GRC”), aluminium, steel, calcium silicate board, ceramic tiles or an intumescent material.

[0170] Fig. 3A shows an upper view of a mould for forming a composite flooring or building cassette 130 having a lid according to various embodiments. According to various embodiments the first (i.e. upper) surface of a composite flooring or building component 130 may comprise a lid or recess portion. The lid or recess portion may be configured to receive a flooring component and / or one of more utilities. The composite flooring or building component 130 may comprise a thermal insulating material, an acoustic insulating material or a fire retardant material which is located in the lid or recess provided in the first surface of the composite flooring or building component 130. The composite flooring or building component 130 may further comprise a reflecting material or foil located in the lid or recess provided in the first surface, wherein the reflecting material or foil is arranged to reflect heat. The lid or recess portion may include a utility component. For example, the utility component may comprise one or more water pipes, one or more gas pipes, one or more electrical cables, one or more underfloor heating pipes or cables, one or more drains, one or more air vents, one or more air conditioning components, one or more communication cables, one or more data transmission cables, one or more insulation layers, one or more acoustic dampening components, or one or more lighting fixtures.

[0171] Fig. 3B shows a lower view of the same composite flooring or building cassette 130 and shows how the rear of the composite flooring or building cassette 130 may according to various embodiments incorporate a plurality of compartments 130A which may be defined by reinforcing members. According to various embodiments a modular, lightweight and structurally robust modular flooring or building cassette 130 may be provided. The composite flooring or building 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.

[0172] For example, with reference to Fig. 3B the rear portion of a composite flooring or building 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.

[0173] 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 systemthereby enhancing functionality and minimising the need for additional modifications during installation.

[0174] The lower portion of the composite flooring or building 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 or building cassette 130 is both durable and lightweight. According to various embodiments, the rear of the composite flooring or building 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 or building cassette 130 while also ensuring minimisation of material usage and an even distribution of loads across the composite flooring or building cassette 130. As a result, the composite flooring or building cassette 130 according to various embodiments may have an enhanced load-bearing capacity without adding unnecessary weight.

[0175] According to other embodiments, the lower portion of the composite flooring or building 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.

[0176] The composite flooring or building 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. Other embodiments are contemplated wherein the composite flooring or building cassette 130 or at least a portion of the composite flooring or building cassette 130 may be fabricated by an additive printing process such as 3D printing.

[0177] The composite flooring or building cassettes 130 according to various embodiments 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 composite flooring or building cassettes 130 for added strength. Insulating materials may also be incorporated into the composite flooring or building 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 composite flooring or building cassettes 130 according to various embodiments are particularly adaptable for various building applications including residential, commercial and industrial buildings.Fig. 4 shows an upper view of a composite flooring or building cassette 130 according to various embodiments. The particular composite flooring or building cassette 130 shown in Fig. 4 has dimensions of 2 m by 2 m. However, it will be understood that the composite flooring or building cassette 130 according to various embodiments may have different dimensions. The composite flooring or building 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 or building cassette 130 may comprise alternative geometries allowing for flexibility in design and application to suit different structural or architectural requirements.

[0178] According to embodiments the composite flooring or building 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 or building 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.

[0179] Further embodiments are contemplated wherein the composite flooring or building cassette 130 may comprise a circular or oval shape. For example, a circular flooring or building 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 or building 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.

[0180] According to other embodiments, the composite flooring or building 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 or building 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.

[0181] The versatility in shape and dimensions of composite flooring or building 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 or building cassette 130may be customised including the thickness, material composition or integrated features. As a result, composite flooring or building cassettes 130 according to various embodiments can be produced which may be optimised for specific load bearing, thermal or acoustic performance criteria.

[0182] Fig. 5 shows a testing arrangement according to various embodiments wherein a 2m x2m composite flooring or building 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 or building 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 or building cassette 130 under controlled conditions. The composite flooring or building cassette 130 was tested by loading the composite flooring or building 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 or building cassette 130 according to various embodiments might be expected to encounter in real-world scenarios.

[0183] The testing arrangement as shown in Fig. 5 allowed for precise measurements to be taken of the extent to which the composite flooring or building cassette 130 deformed in response to an applied load. Deformation was measured at multiple points across the surface of the composite flooring or building cassette 130 including at the centre and near the edges in order to determine how the load distributed and how effectively the composite flooring or building 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.

[0184] Further tests were conducted to assess the performance of the composite flooring or building cassette 130 under dynamic conditions such as when the composite flooring or building 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 or building cassette 130 and its ability to return to its original form after being subjected to repeated or temporary loads.

[0185] 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 or building cassette 130 on its performance. For example, the presence of a grid or honeycomb structure on therear surface of the composite flooring or building cassette 130 influences how a load is distributed and how effectively the composite flooring or building cassette 130 is able to resist deformation. 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.

[0186] The testing process was useful for validating the suitability of the composite flooring or building 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 or building 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.

[0187] Fig. 6 shows a prototype testing arrangement for a composite flooring or building cassette 130 according to various embodiments wherein the testing arrangement was configured to evaluate the load-bearing capacity of a composite flooring or building cassette 130 and to measure the deflection of the composite flooring or building cassette 130 under varying applied loads. The composite flooring or building cassette 130 may according to various embodiments comprise a square composite flooring or building cassette 130 having dimensions of 2m x 2m and wherein for testing purpose the composite flooring or building cassette 130 was supported at its four corners in order to simulate conditions wherein a composite flooring or building 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 or building cassette 130 with bricks in order to create a uniform distributed load representative of a real-world usage scenario.

[0188] The testing results detail the load applied to the composite flooring or building cassette 130 in terms of kg / m2and the corresponding total load per composite flooring or building cassette 130 (kg / cassette). Deflection measurements were recorded in mm and indicate the extent of deformation at the centre and edges of the composite flooring or building cassette 130 under specific loading condition.

[0189] According to the results, under an Australian standard load of 153 kg / m2, equivalent to 612 kg / flooring or building cassette 130, the deflection at the centre of the composite flooring or building cassette 130 was measured as being 2.56 mm. Under a USA standard load of 195 kg / m2, equivalent to 780 kg / flooring or building cassette 130, the deflection increased to 3.20 mm at the centre. Higher load testing namely applying 512 kg / m2or 2050 kg / flooring or building 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 or building cassette 130 led to a deflection of 10.10 mm at the centre.The deflection may be measured across multiple points on the composite flooring or building cassette 130 including the centre and edges thereby providing a comprehensive understanding of how the load is distributed and how the composite flooring or building 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.

[0190] This testing arrangement demonstrated the structural performance of the composite flooring or building cassette 130 according to various embodiments under both standard and extreme loading conditions.

[0191] Fig. 7 shows a testing arrangement according to various embodiments wherein a composite flooring or building 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 or building 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 or building cassette 130 in order to mimic the force exerted by a wall structure.

[0192] The total applied load was increased incrementally and the corresponding deflection was measured at the edge of the composite flooring or building 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.

[0193] This testing arrangement provided data related to the structural behaviour of the composite flooring or building cassette 130 under edge-loading conditions. The deflection values reflect the stiffness and load-bearing capacity of the composite flooring or building cassette 130 particularly when subjected to concentrated linear loads such as those produced by heavy wall structures.

[0194] The test demonstrates that the composite flooring or building 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 or building 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 or building cassette 130 in order to further enhance the resistance of the composite flooring orbuilding cassette 130 to line loads while maintaining a favourable strength-to-weight ratio.

[0195] Fig. 8A shows a testing arrangement for a composite flooring or building cassette 130 according to various embodiments wherein the composite flooring or building cassette 130 is subjected to loads due to steel weights being applied to the composite flooring or building cassette 130 via a steel rolled channel which was secured to the composite flooring or building cassette 130 using rivets. The arrangement demonstrates the structural response of a composite flooring or building cassette 130 according to various embodiments under concentrated loads distributed along the steel channel. The test replicates conditions wherein a composite flooring or building cassette 130 supports linear or point loads such as might be encountered in structural or industrial applications.

[0196] Fig. 8A shows the composite flooring or building cassette 130 positioned horizontally with two steel rolled channels placed on its surface. The channels are connected to the composite flooring or building 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 or building cassette 130 and in the process of being aligned.

[0197] Fig. 8B shows steel weights which were used to apply incremental weights to the composite flooring or building 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 or building cassette 130 was supported on brick stacks at its edges replicating typical installation conditions where the composite flooring or building cassette 130 may be arranged to be supported by one or more pile caps.

[0198] The test setup allows for the evaluation of load-bearing capacity, deflection and structural integrity of a composite flooring or building 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 or building 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 or building cassette 130 according to various embodiments.

[0199] Fig. 9 shows the results of testing a composite flooring or building cassette 130 according to various embodiments. The composite flooring or building 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 loaddistribution and wherein deflection measurements were taken to compare performance both with and without the steel batten.

[0200] 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 or building 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 or building cassette 130 with a steel batten and which was referred to as "Edge #2."

[0201] The results demonstrate the positive reinforcing effect of utilising a steel batten on the structural performance of a composite flooring or building cassette 130 according to various embodiments. 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.

[0202] 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 or building cassette 130.

[0203] The data which is presented shows that the inclusion of a steel reinforcing batten significantly improved the performance of the composite flooring or building 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 or building cassette 130 to maintain structural integrity while limiting deflection under high loads validates its suitability for demanding construction scenarios.

[0204] This testing arrangement and the corresponding results enable composite flooring or building 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 or building cassette 130 meets performance requirements in both residential and commercial construction environments.

[0205] Figs. 10A and 10B shows a testing arrangement which was used fortesting a composite flooring or building cassette 130 according to various embodiments. The composite flooring or building cassette 130 was subjected to a loading test utilising steel weights. According to this arrangement a timber beam 200 measuring 50 mm x 100 mmwas bolted on to the composite flooring or building cassette 130 utilising three bolts. The purpose of this configuration was to evaluate the load-bearing performance and deflection characteristics of the composite flooring or building cassette 130 according to various embodiments when reinforced with a timber beam 200 under loading conditions.

[0206] Fig. 10A shows the timber beam 200 securely attached to the surface of a composite flooring or building 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.

[0207] 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.

[0208] This test arrangement provides insights into the effectiveness of using a timber beam 200 as a reinforcement method for composite flooring or building 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.

[0209] Figs. 11 A-E illustrate various different fixing methods which may be utilised to secure or assemble different components of a composite flooring or building cassette 130 according to various embodiments. According to various embodiments composite flooring or building 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 or building 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.

[0210] Fig. 11 A shows how according to an embodiment one or more adhesives may be applied to the joints of the two composite flooring or building 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.

[0211] Fig. 11 B shows a packet of rivets and their application in securing metal components to a composite flooring or building cassette 130 according to variousembodiments. 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.

[0212] 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 or building 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.

[0213] Fig. 11 D shows how according to other embodiments one or more screws may be secured directly into the surface of a composite flooring or building 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 or building cassette 130 thereby maintaining a smooth upper surface and preventing any protrusions.

[0214] Fig. 11E shows how one or more screws may be inserted into the composite flooring or building 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.

[0215] Fig. 12 shows a pull test which was conducted on various fixing methods together with a composite flooring or building 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.

[0216] 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.

[0217] 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 failedbefore 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.

[0218] 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.

[0219] Fig. 13 shows a side connection method for composite flooring or building cassettes 130 according to various embodiments. In particular, adhesives may be utilised to secure adjacent composite flooring or building 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.

[0220] 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.

[0221] Both methods provide reliable options for securing composite flooring or building 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.

[0222] Fig. 14 shows a table summarises the thermal resistance (R-values) of composite flooring or building 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 helpful when assessing the thermal efficiency of composite flooring or building cassettes in building construction.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.

[0223] The R-values of composite flooring or building 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 or building cassette, tested with a 1°C temperature difference, exhibited a lower R-value of 0.05. By contrast, a composite flooring or building cassette tested with a 6°C temperature difference achieved a significantly higher R-value of 6.00 illustrating superior thermal performance under those conditions.

[0224] According to various embodiments various insulation materials may be used within one or more composite flooring or building cassettes and may be installed in one or more compartments formed within the rear of a composite flooring or building cassette 130 according to various embodiments. It will be understood that the insulation materials will influence the overall thermal resistance of the composite flooring or building 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.

[0225] 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 or building cassettes according to various embodiments.

[0226] 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.

[0227] Figs. 15A and 15B shows various factors influencing the use of composite flooring systems according to various embodiments in Australia and illustrate howpopulation density and environmental factors may impact construction costs and design considerations.

[0228] 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.

[0229] 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.

[0230] 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.

[0231] 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.

[0232] 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.

[0233] 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.

[0234] 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.

[0235] 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.

[0236] 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.

[0237] 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.

[0238] 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 layered within 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.

[0239] 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.

[0240] 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.

[0241] 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.

[0242] 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.

[0243] 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.

[0244] According to various embodiments a 90 mm thick beam 320 may be configured for applications requiring high load-bearing capacity and resistance to bending ortorsional 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.

[0245] 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.

[0246] 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.

[0247] 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.

[0248] 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.

[0249] 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.

[0250] 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 ofthe 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.

[0251] 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.

[0252] 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.

[0253] 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.

[0254] 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.

[0255] 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.

[0256] 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 15.7kg / 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.

[0257] Figs. 26A and 26B illustrate how screw pile caps may be integrated into a modular construction system. 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.

[0258] As shown in Fig. 26A, a screw pile cap 120 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 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. 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.

[0259] Fig. 26A illustrates a method of adjusting the position and angle of inclination of a screw pile cap 120. 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. 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.

[0260] Fig. 26A also shows a top-down view of a screw pile cap 120. 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 screw pile cap 120 may have a circular design which may be configured to slide and rotate to correct for minor misalignments.

[0261] 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.Fig. 27 shows a screw pile cap 120 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.

[0262] The ball joint 140 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 multidirectional 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.

[0263] 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.

[0264] Fig. 28A shows a screw pile cap 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.

[0265] 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.

[0266] Fig. 28B includes a plan view of the screw pile cap assembly 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 sufficientfreedom 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.

[0267] Fig. 29 shows a cross-sectional view of a screw pile cap. 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 or building cassette 130 or more generally a metallic flooring cassette or other building component.

[0268] According to various embodiments a composite flooring or building 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 or building 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.

[0269] The ball joint 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. 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 upon a 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.

[0270] 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.

[0271] The ball connector 140 may be configured to allow for rotational adjustment so that a composite flooring or building cassette 130 (or other flooring or buildingcomponent) secured to a bearer plate 120A connected to the ball connector 140 can be manipulated and in particular the 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.

[0272] 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.

[0273] 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 or building cassette 130. 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.

[0274] A composite flooring or building 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 or building 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 or building cassette 130 ensuring stability and alignment during and after installation.

[0275] 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.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.

[0276] 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.

[0277] Fig. 31 shows a ball joint connector system 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 order to 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.

[0278] Optional welded support fins 160 may extend laterally from the assembly enhancing resistance to lateral forces and providing additional stability to the structure.

[0279] 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. 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. An Allen key may be utilised to tighten the M12 bolts which advantageously simplifies the installation and adjustment process.

[0280] 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- M -accommodated, making this configuration particularly suitable for modular systems where precision and adaptability are important considerations.

[0281] Fig. 32 shows a ball joint assembly wherein the ball joint is provided in a downwards orientation. The ball joint 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 together to prevent rotation of the ball connector 140.

[0282] The ball connector 140 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.

[0283] 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 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.

[0284] According to various embodiments a mould may be provided to fabricate composite flooring or building cassettes 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.

[0285] Further embodiments are contemplated wherein one or more composite beams may be inserted into a composite flooring or building 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 or building cassette.According to further embodiments a composite flooring or building cassette may include a key joint to enable two composite flooring or building cassettes to be secured to each other. Other embodiments are contemplated wherein composite flooring or building cassettes may comprise one or more projections and / or one or more recesses enabling two composite flooring or building cassettes to be stacked on top of each other in a vertical connection. For example, a lower composite flooring or building 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 or building cassette. Alternatively, a lower composite flooring or building 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 or building cassette.

[0286] Figs. 33A shows composite flooring or building cassettes 130 configured for modular construction according to various embodiments. According to various embodiments a grid-like structure of composite flooring or building 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 or building cassette 130. The array of cavities provided in the composite flooring or building cassette 130 results in the formation of a composite flooring or building 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.

[0287] 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 or building cassette 130 and a hole, aperture or threaded aperture may be provided in the insert or connection block 170 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 or building 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 or building cassette assembly.

[0288] Fig. 33C shows a single 11 x 11 composite flooring or building cassette 130 together with a composite flooring or building 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.Fig. 33D shows in more detail some moulded inserts of connection blocks 170 according to various embodiments.

[0289] Figs. 34A and 34B show two different configurations of composite flooring or building cassettes 130 according to various embodiments. Fig. 34A shows a first type composite flooring or building cassette 130 having a uniform grid. Fig. 34B shows a second type of composite flooring or building cassette 130 wherein the grid may be customised and may include one or more reinforcement elements.

[0290] 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 or building cassette 130. The uniform grid simplifies manufacturing and is well-suited for general-purpose use in modular construction.

[0291] 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.

[0292] According to various arrangements one or more perimeter edge beams may be incorporated into a modular construction system. According to such arrangements, 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.

[0293] 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.

[0294] 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 or building cassette allowing for singlepiece installation. This design approach simplifies assembly and ensures a seamless connection between structural components.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.

[0295] Fig. 35A shows the application and design details of a perimeter edge beam for modular construction according to various arrangements. 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.

[0296] 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.

[0297] Figs. 36A and 36B summarise two different configurations for a screw pile cap 120, contrasting ball-down and ball-up flat arrangements.

[0298] 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.

[0299] Fig. 36B shows a ball-up configuration wherein the ball connector 140 directly supports a bearer plate 120A and a composite flooring or building cassette 130. This system provides flexibility in allowing adjustment of the height between the top of the screw pile 110 and the composite flooring or building cassette 130 wherein the height may be set between 100-200 mm. The composite flooring or building 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.Figs. 37A-C shows detailed connection designs for modular construction using screw piles and composite flooring or building panels 130 according to various embodiments.

[0300] Fig. 37A shows a centre connection detail showing two composite flooring or building 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 composite flooring or building 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 composite flooring or building panels 130 to the plate, maintaining alignment and preventing movement.

[0301] Fig. 37B shows a connection detail showing a configuration for securing composite flooring or building 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 composite flooring or building panel 130 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.

[0302] Fig. 37C shows a patio step-down detail and shows a configuration that incorporates a stepped transition between composite flooring or building 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.

[0303] Fig. 38 shows a variety of different support arrangements which may be utilised to support a composite flooring or building 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.

[0304] 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.

[0305] According to various embodiments the load distribution testing may commence with the addition of small incremental weights gradually increasing to a total load of 2257kg. 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.

[0306] 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.

[0307] Fig. 40 shows a comparative analysis of different composite flooring or building 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 or building 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.

[0308] 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.

[0309] 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.

[0310] 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.

[0311] Fig. 41 shows an alternative configuration for a screw pile cap 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 thestructural 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.

[0312] 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.

[0313] 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.

[0314] 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 or building 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.

[0315] Fig. 45 shows an arrangement 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 arrangement 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 alsofacilitates quick disassembly, allowing for maintenance or repositioning of components without significant disruption to the overall structure.

[0316] 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 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 arrangements 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. Additionally, provisions for ergonomic grips may be incorporated to ensure comfortable and prolonged use during extended assembly tasks.

[0317] Although various aspects have been described above which relate to a composite flooring or building component, according to other aspects an apparatus is provided comprising one or more pile caps, beams or bearers configured to be secured in use to a pile or flooring support in combination with one or more composite flooring or building components as described above, wherein the one or more composite flooring or building components are configured to be secured to the one or more pile caps, beams or bearers.

[0318] In addition, there is disclosed a method of construction comprising installing one or more piles or flooring supports, securing one or more pile caps, beams or bearers on or to the one or more piles or flooring supports and installing one or more composite flooring or building components as described above on to the one or more pile caps, beams or bearers. According to various embodiments the step of installing one or more composite flooring or building components on to the one or more pile caps, beams or bearers may further comprise passing one or more fixings or fasteners through a first surface and a second opposed surface of the composite flooring or building component and securing the one or more fixings or fasteners to a bearer plate connected to a pile cap, beam or bearer.

[0319] In addition there is disclosed a method of fabricating a composite flooring or building component for a building comprising forming using a mould a composite flooring or building component having a first surface configured to form a flooring or building component of a building and a second surface configured to be supported on a pile cap,beam or bearer wherein the second surface comprises one or more recessed compartments and wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

[0320] Furthermore, there is disclosed a method of fabricating a composite flooring or building component for a building comprising forming using an additive or 3D printing process a composite flooring or building component having a first surface configured to form a flooring or building component of a building and a second surface configured to be supported on a pile cap, beam or bearer wherein the second surface comprises one or more recessed compartments, wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

[0321] In further embodiments, the composite flooring or building component comprises a multilayer assembly in which a core formed of one or more structural or insulating materials is encapsulated within an outer fibre reinforced polymer skin. The outer skin may be continuous around the perimeter of the component so as to provide a closed shell that resists moisture ingress and enhances durability in aggressive environments. The core may be tailored locally so that regions corresponding to high load paths, fixing zones or service interfaces receive stiffer or tougher materials whilst lower demand regions are provided with lighter insulating media to optimise overall mass.

[0322] In further embodiments, the core comprises one or more materials selected from timber, engineered wood, polymer foams including closed-cell and open-cell types, aerogel sheets or granules, polymer or metal honeycomb structures, recycled plastics including reinforced recyclate boards, cementitious boards such as fibre cement and calcium silicate, gypsum boards and cork. The core materials may be used singly or in combination, and may be arranged in layers or blocks with differing orientations and thicknesses. Aerogel or honeycomb regions may be positioned beneath zones intended for thermal breaks, whilst timber or engineered wood strips may be located along edge regions to provide robust fixing substrates. Recycled plastic boards may be used in wet areas to reduce water absorption, and cementitious or gypsum boards may be incorporated at fire separation lines to increase fire resistance without excessive weight gain.

[0323] In further embodiments, an additional outer skin is applied over the fibre reinforced polymer skin so as to deliver performance features or aesthetic styling. The additional outer skin may be factory-applied and may comprise continuous sheet, panel or coating systems. Fire-retardant outer skins may include intumescent paints or laminates, mineral-based ceramic skins, or metal facings having a thermal barrier layer beneath. Weather-resistant skins may include metal sheet with bonded seal coats, UV-stabilised polymer laminates, or ceramic or stone veneers with compliant adhesive layers that accommodate thermal movement. Aesthetic skins may comprise timber veneers, textured laminates or architectural coatings matched to project finishes. The additionalouter skin may be selectively applied to the first surface, the second surface, or both, depending on exposure and performance requirements, with edge wraps to protect perimeter rebates and interfaces.

[0324] In further embodiments, the multilayer assembly integrates one or more encapsulated beam forms extending along predefined paths to provide beam-like strength and stiffness. The beam forms may be straight or curved, continuous across the component or discontinuous so as to terminate at predetermined end stops. Beam forms may be located beneath internal walls, along perimeter edges or in crossing patterns beneath concentrated load points. The beam forms may comprise fibre reinforced polymer solid beams produced by vacuum infusion, pultruded composite profiles inserted into channels, laminated composite beams fabricated by stacking pre-cured plates, timber beams, or metal sections including steel channels, rectangular hollow sections and parallel flange channels. The encapsulation process may include mechanical interlocks, adhesive bonding and over-wrapping with fibre fabrics to ensure composite action between the beam forms and the surrounding core and skins.

[0325] In further embodiments, one or more encapsulated solid elements are positioned at predetermined locations to create hardpoints. The solid elements may comprise plates, blocks or inserts formed of steel, aluminium, fibre reinforced polymer solid laminate, cement board or hardwood. Hardpoints may be aligned with column bases, through-bolt penetrations, side fixings, lifting points orfagade anchors. The local architecture around a hardpoint may include densified foam, thicker FRP skins and bearing pads to resist crushing, creep and pull-out. Through-bolt sleeves may be comoulded or post-fitted, with sealing grommets and compressible washers to maintain watertightness and air-tightness under service conditions.

[0326] In further embodiments, the component may be provided with one or more preformed penetrations or penetration-ready regions indicated by moulded guides or thin membranes designed to be cut using a hole saw. Sleeve inserts may be fitted into the round holes and may comprise tubular liners with external flanges or shoulders configured to engage with either the first surface or the second surface and to provide a sealed interface. Sleeve inserts may be formed of fire-retardant or intumescent materials, and may incorporate integral seals, gaskets or grommets to deliver watertightness and air-tightness. The sleeve system may be modular so that different bore sizes, flange geometries and seal materials can be selected according to the service type, for example potable water, gas, electrical conduits or data cables. Penetration regions may be structurally reinforced locally to manage stress concentrations and to maintain stiffness.

[0327] In further embodiments, the component includes one or more rebates at a perimeter edge configured to receive flush-fitting door or window frames. The rebate geometry may include inclined or stepped surfaces, drainage throats and drip edgesarranged to assist water drainage away from the interior. The rebate may further be configured to locate and fix vertical external wall panels, with integrated anchorage features and seal landings designed to reduce the complexity of flashing and to improve envelope performance. Rebate dimensions may be standardised to interface with common sliding door systems, and may be adjustable by removable infill strips to accommodate manufacturer-specific tolerances.

[0328] In further embodiments, the component may be configured as a balcony panel for an upper level, wherein the second surface is arranged for support on beams or bearers and the first surface comprises a weather-resistant top skin and integrated drainage features. The drainage features may include sloped or contoured surfaces directing water towards one or more drainage outlets and / or towards an edge discharge. Drain outlets may connect to downpipes or scuppers, and may incorporate leaf guards or removable strainers for maintenance. The balcony panel may integrate balustrade fixing points tied to encapsulated solid elements to ensure compliant load transfer under crowd loads and wind.

[0329] In further embodiments, the component may be configured for use as outdoor decking. The first surface comprises moulded drainage channels arranged beneath a permeable top layer so as to convey water towards a central penetration and / or towards an edge discharge. The permeable top layer may comprise decking boards with gaps, spaced ceramic tiles, synthetic turf or grating, and the moulded channels may be covered by removable or serviceable meshes or covers to allow debris removal and inspection. The channel network may include branch channels, sumps and inspection ports positioned to suit site drainage layouts, and may be dimensioned to maintain selfcleansing velocities under typical rainfall intensities.

[0330] In further embodiments, the component comprises side fixing features, for example moulded profiles, slots or bosses designed to interface with plates or dog-bone connectors. The features enable one-way, two-way, three-way or four-way connections between adjacent components with precise alignment. The connection geometry may include lead-ins, chamfers and captive nut pockets to speed assembly, and may be combined with adhesives, rivets or bolts to achieve a desired stiffness and damping in the joint. Tolerances and adjustability may be provided by slotted holes, shim spaces or wedge keys to accommodate site variability.

[0331] In further embodiments, the component may be dimensioned as a modular panel selected from 2 m * 2 m, 2 m * 3 mor larger single-piece panels within maximum road transport limits. Larger single-piece panels may incorporate lifting inserts, spreader plates and temporary bracing skins to enable safe cranage and handling. Edge geometries and connector layouts may be standardised so that a whole building floor can be installed in one operation, with progressive fixing completed from above to reduce work at height and improve programme certainty.In further embodiments, apparatus is provided comprising one or more pile caps, beams or bearers in combination with one or more of the foregoing components. The apparatus may incorporate adjustable pile caps with ball joints, slider plates and bearer plates, enabling vertical and horizontal alignment of the components on variable terrain. The apparatus may further include perimeter beams, balcony bearers, and drainage manifolds pre-aligned with the component outlets so as to deliver coordinated structural and architectural integration.

[0332] In further embodiments, methods of construction are provided in which one or more penetrations are formed by cutting round holes at penetration-ready regions of a component and inserting sleeve liners to line the holes for passage of services. Methods further include installing components having perimeter rebates so that flush-fitting door and / or window frames are received in the rebates and vertical external wall panels are fixed at the rebates with provision for water drainage away from the building interior. Methods for balcony installation include arranging integrated drainage features to discharge towards one or more drainage outlets and / or an edge discharge, and methods for decking installation include directing water within moulded drainage channels towards a central penetration and / or an edge discharge.

[0333] In further embodiments, methods of fabrication are provided comprising forming the multilayer assembly by placing encapsulated beam forms and encapsulated solid elements at predetermined positions within a mould, encapsulating them within a core material and applying a fibre reinforced polymer skin to wrap the assembly. The fabrication process may include vacuum infusion, resin transfer moulding, hand lay-up with consolidation, or additive manufacturing for selected features. Post-cure application of an additional outer skin may be undertaken to provide fire retardation, weather resistance, ultraviolet resistance or aesthetic styling, with controlled surface preparation and adhesion promotion to ensure long-term performance.

[0334] In further embodiments, the first surface may comprise a top lid having removable access covers aligned with utilities or penetrations and the second surface comprises a grid or top-hat arrangement of recessed compartments with localised reinforcement proximate the encapsulated solid elements. Access covers may be sealed by gaskets and retained by quarter-turn fasteners to permit routine inspection. The recessed compartment geometry may be tuned to provide stiffness against uniformly distributed loads whilst maintaining pathways for services and insulation placement.

[0335] In further embodiments, the rebates, drainage channels and penetrations are integrally moulded during fabrication and are operatively associated with sleeve inserts, gaskets or drains to provide weatherproof performance. Integrally moulded features reduce site workmanship risks, shorten installation time and improve repeatability. In further embodiments, the component is configured to be stackable and comprises interlocking projections and recesses compatible with dog-bone connectors andperimeter rebates so as to enable both horizontal and vertical assembly. Stackability allows rapid erection of multi-level structures with secure interconnection, improved lateral load transfer and enhanced seismic or wind performance.

[0336] In further embodiments, the component may be used as a balcony panel or outdoor decking element in a building wherein water management is provided by moulded drainage channels directing water to a central outlet and / or an edge discharge beneath a permeable top layer. In further embodiments, a building is provided comprising one or more of the foregoing components wherein at least one perimeter edge comprises a rebate receiving a flush-fitting sliding door and at least one service penetration comprises a sleeve liner providing a sealed interface for a plumbing pipe and / or an electrical conduit. The building-level integration of thresholds and service entries improves weatherproofing, acoustic performance and installation efficiency whilst maintaining the benefits of lightweight modular construction.

[0337] 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 composite flooring or building component for a building, wherein the flooring or building component comprises:a first surface configured to form a flooring or building component of a building; anda second surface configured to be supported on a pile cap, beam or bearer, wherein the second surface comprises one or more recessed compartments;wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

2. A composite flooring or building component as claimed in claim 1 , wherein the fibre reinforced polymer comprises a thermoset resin.

3. A composite flooring or building component as claimed in claim 2, wherein the thermoset resin comprises polyester, vinyl ester or epoxy.

4. A composite flooring or building component as claimed in claim 1 , wherein the fibre reinforced polymer comprises a thermoplastic resin.

5. A composite flooring or building component as claimed in claim 4, wherein the thermoplastic resin comprises a long fibre thermoplastic (“LFTP”).

6. A composite flooring or building component as claimed in claim 5, wherein the long fibre thermoplastic (“LFTP”) comprises nylon, polyethylene terephthalate (“PET”) or polypropylene (“PP”).

7. A composite flooring or building component as claimed in any preceding claim, wherein the fibre reinforce polymer (“FRP”) comprises glass, carbon or aramid fibres.

8. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component is formed by a moulding process or an additive or 3D printing process.

9. A composite flooring or building component as claimed in any preceding claim, wherein the one or more recessed compartments have a trapezoidal, top-hat, rectangular, square, V-shaped, W-shaped or polygonal cross-sectional profile.

10. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component has a tensile strength in the range 600-1500 MPa.

11. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component has a density in the range 1.5-2.0 g / cm3.

12. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component has a strength-to-weight ratio in the range 300-750 MPa.cm3 / g.

13. A composite flooring or building component as claimed in any preceding claim, further comprising a thermal insulating material located in one or more of the recessed compartments.

14. A composite flooring or building component as claimed in claim 13, wherein the thermal insulating material has an R-value > 0.45 per cm of thickness.

15. A composite flooring or building component as claimed in claim 13 or 14, wherein the thermal insulating material comprises fiberglass insulation, expanded polystyrene (“EPS”), mineral wool (rock wall), open-cell spray foam or closed-cell spray foam.

16. A composite flooring or building component as claimed in any preceding claim, further comprising an acoustic insulating material located in one or more of the recessed compartments.

17. A composite flooring or building component as claimed in claim 16, wherein the acoustic insulating material has a Noise Reduction Coefficient (“NRC”) > 0.50.

18. A composite flooring or building component as claimed in claim 16 or 17, wherein the acoustic insulating material comprises fiberglass insulation, mineral wool (rockwool), acoustic foam, one or more fabric-wrapped acoustic panels, open-cell spray foam, closed-cell spray foam or one or more acoustic tiles.

19. A composite flooring or building component as claimed in any preceding claim, further comprising a fire retardant material located in one or more of the recessed compartments.

20. A composite flooring or building component as claimed in claim 19, wherein the fire retardant material comprises a Flame Spread Index (“FSI”) as determined by ASTM E84 (Standard Test Method for Surface Burning Characteristics of Building Materials) of < 75.

21. A composite flooring or building component as claimed in claim 19 or 20, wherein the fire retardant material comprises mineral wool (rock wool), fire-rated gypsum board,cement board, concrete, brick, fire-retardant-treated plywood, fiberglass insulation, fibreglass insulation treated with one or more fire-resistant additives, glass-reinforced cement (“GRC”), aluminium, steel, calcium silicate board, ceramic tiles or a intumescent material.

22. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component comprises a composite flooring or building cassette.

23. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component is stackable so that, in use, a first composite flooring or building component may be stacked upon a second composite flooring or building component.

24. A composite flooring or building component as claimed in any preceding claim, wherein the composite flooring or building component comprises one or more projections, recesses, key features or interlocking features for engaging with a further composite flooring or building component so as to secure, in use, the composite flooring or building component to a further composite flooring or building component either horizontally and / or vertically.

25. A composite flooring or building component as claimed in any preceding claim, wherein the first surface comprises a lid or recess portion, wherein the lid or recess portion is configured to receive a flooring component and / or one of more utilities.

26. A composite flooring or building component as claimed in claim 25, further comprising a thermal insulating material, an acoustic insulating material or a fire retardant material located in the lid or recess provided in the first surface.

27. A composite flooring or building component as claimed in claim 25 or 26, further comprising a reflecting material or foil located in the lid or recess provided in the first surface, wherein the reflecting material or foil is arranged to reflect heat.

28. A composite flooring or building component as claimed in claim 25, 26 or 27, wherein the lid or recess portion includes a utility component.

29. A composite flooring or building component as claimed in claim 28, wherein the utility component comprises one or more water pipes, one or more gas pipes, one or more electrical cables, one or more underfloor heating pipes or cables, one or more drains, one or more air vents, one or more air conditioning components, one or more communication cables, one or more data transmission cables, one or more insulation layers, one or more acoustic dampening components, or one or more lighting fixtures.

30. A composite flooring or building component as claimed in any preceding claim, further comprising one or more reinforcing structures.

31. A composite flooring or building component as claimed in claim 30, wherein the one or more reinforcing structures comprise a beam, rod, support.

32. A composite flooring or building component as claimed in claim 30 or 31 , wherein the one or more reinforcing structures are integrally formed as part of the composite flooring or building component.

33. A composite flooring or building component as claimed in any preceding claim, further comprising one or more fixing blocks, wherein in use one or more fixings are arranged to pass through the first surface, the one or more fixing blocks and the second surface in order to secure the composite flooring or building component to a bearer plate connected to a pile cap, beam or bearer.

34. Apparatus comprising:one or more pile caps, beams or bearers configured to be secured in use to a pile or flooring support; andone or more composite flooring or building components as claimed in any of claims 1-33, wherein the one or more composite flooring or building components are configured to be secured to the one or more pile caps, beams or bearers.

35. A method of construction comprising:installing one or more piles or flooring supports;securing one or more pile caps, beams or bearers on or to the one or more piles or flooring supports; andinstalling one or more composite flooring or building components as claimed in any of claims 1 -33 on to the one or more pile caps, beams or bearers.

36. A method as claimed in claim 35, wherein the step of installing one or more composite flooring or building components on to the one or more pile caps, beams or bearers further comprises passing one or more fixings or fasteners through a first surface and a second opposed surface of the composite flooring or building component and securing the one or more fixings or fasteners to a bearer plate connected to a pile cap, beam or bearer.

37. A method of fabricating a composite flooring or building component for a building comprising:forming using a mould a composite flooring or building component having a first surface configured to form a flooring or building component of a building and a secondsurface configured to be supported on a pile cap, beam or bearer wherein the second surface comprises one or more recessed compartments;wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

38. A method of fabricating a composite flooring or building component for a building comprising:forming using an additive or 3D printing process a composite flooring or building component having a first surface configured to form a flooring or building component of a building and a second surface configured to be supported on a pile cap, beam or bearer wherein the second surface comprises one or more recessed compartments;wherein the flooring or building component comprises fibre reinforced polymer (“FRP”).

39. A composite flooring or building component as claimed in any of claims 1-33, wherein the component comprises a multilayer assembly including a core comprising one or more structural or insulating materials and an outer fibre reinforced polymer skin encapsulating the core.

40. A composite flooring or building component as claimed in claim 39, wherein the core comprises one or more materials selected from timber, engineered wood, polymer foam, aerogel, honeycomb structures, recycled plastic, cementitious boards, gypsum boards, cork or combinations thereof.

41. A composite flooring or building component as claimed in claim 39 or 40, further comprising an additional outer skin over the fibre reinforced polymer skin, wherein the additional outer skin is selected to provide fire retardation, weather resistance, ultraviolet resistance or aesthetic styling.

42. A composite flooring or building component as claimed in claim 41 , wherein the additional outer skin comprises a metal skin, a timber skin, a ceramic skin, a stone skin, a laminate skin or a paint or coating system formulated to provide one or more of the properties recited in claim 41.

43. A composite flooring or building component as claimed in any of claims 39-42, wherein the multilayer assembly comprises one or more encapsulated beam forms integrated within the core and extending along a predefined path so as to provide beamlike strength and stiffness.

44. A composite flooring or building component as claimed in any of claims 39-43, wherein the encapsulated beam forms comprise one or more of fibre reinforced polymersolid beams, pultruded composite profiles, laminated composite beams, timber beams, steel channels, rectangular hollow sections or parallel flange channels.

45. A composite flooring or building component as claimed in any of claims 39-44, further comprising one or more encapsulated solid elements located at predetermined positions within the component and configured to provide localised reinforcement for a column support, a through-bolt penetration or a side fixing.

46. A composite flooring or building component as claimed in claim 45, wherein the one or more encapsulated solid elements comprise plates, blocks or inserts formed of steel, aluminium, fibre reinforced polymer solid laminate, cement board or hardwood.

47. A composite flooring or building component as claimed in any of claims 1 -33 or 39-46, wherein the component comprises one or more pre-formed penetrations or penetration-ready regions configured to be cut using a hole saw and to receive a sleeve insert lining a round hole for passage of a plumbing pipe or an electrical conduit.

48. A composite flooring or building component as claimed in claim 47, wherein the sleeve insert comprises a tubular liner having an external flange or shoulder configured to engage with the first surface or the second surface and to provide a sealed interface around the penetration.

49. A composite flooring or building component as claimed in claim 47 or 48, wherein the sleeve insert is formed of a fire-retardant or intumescent material and / or comprises seals or grommets to provide water-tightness or air-tightness.

50. A composite flooring or building component as claimed in any of claims 1 -33 or 39-49, wherein the component comprises one or more rebates provided at a perimeter edge configured to receive a flush-fitting door or window frame and / or to assist water drainage away from an interior of the building.

51. A composite flooring or building component as claimed in claim 50, wherein the rebate is further configured to locate and fix a vertical external wall panel and optionally comprises drainage geometry that prevents water ingress into the building.

52. A composite flooring or building component as claimed in any of claims 1 -33 or 39-51 , wherein the component is configured as a balcony panel for an upper level, the second surface being arranged for support on a beam or bearer and the first surface comprising a weather-resistant top skin and integrated drainage features.

53. A composite flooring or building component as claimed in claim 52, wherein the integrated drainage features comprise a sloped or contoured surface directing water towards one or more drainage outlets and / or towards an edge discharge.

54. A composite flooring or building component as claimed in any of claims 1 -33 or 39-53, wherein the component is configured for use as outdoor decking and the first surface comprises moulded drainage channels arranged beneath a permeable top layer so as to convey water towards a central penetration and / or towards an edge discharge.

55. A composite flooring or building component as claimed in claim 54, wherein the permeable top layer comprises decking boards with gaps, spaced ceramic tiles, synthetic turf or grating, and wherein the moulded drainage channels are covered by a removable or serviceable mesh or cover.

56. A composite flooring or building component as claimed in any of claims 1 -33 or 39-55, wherein the component comprises one or more side fixing features configured to interface with plates or dog-bone connectors to provide one-way, two-way, three-way or four-way connections between adjacent components.

57. A composite flooring or building component as claimed in any of claims 1 -33 or 39-56, wherein the component is dimensioned as a modular panel selected from 2 m x 2 m, 2 m x 3 m or larger single-piece panels within maximum road transport limits enabling installation of a whole building floor in one operation.

58. Apparatus as claimed in claim 34, wherein one or more composite flooring or building components comprise the multilayer assembly as recited in any of claims 39-57 and further wherein one or more of the components comprise rebates at perimeter edges for flush-fitting door and / or window frames.

59. Apparatus as claimed in claim 34 or 58, wherein at least one component configured as outdoor decking comprises moulded drainage channels beneath a permeable top layer and is connected to one or more pile caps or bearers so as to provide discharge towards a central outlet and / or towards an edge.

60. A method as claimed in claim 35, further comprising forming one or more penetrations by cutting a round hole using a hole saw at a penetration-ready region of a composite flooring or building component and inserting a sleeve liner to line the hole for passage of services.

61. A method as claimed in claim 35 or 60, further comprising installing a composite flooring or building component having a perimeter rebate so that a flush-fitting doorand / or window frame is received in the rebate and a vertical external wall panel is fixed at the rebate with provision for water drainage away from the building interior.

62. A method as claimed in claim 35, wherein installing comprises securing one or more components configured as balcony panels to beams or bearers at an upper level and arranging integrated drainage features to discharge towards one or more drainage outlets and / or an edge discharge.

63. A method as claimed in claim 35, further comprising installing one or more components configured as outdoor decking wherein a permeable top layer overlies moulded drainage channels in the component and water is directed towards a central penetration and / or an edge discharge.

64. A method of fabricating a composite flooring or building component as claimed in claim 37 or 38, comprising forming a multilayer assembly by placing one or more encapsulated beam forms and one or more encapsulated solid elements at predetermined positions within a mould, encapsulating them within a core material, and applying a fibre reinforced polymer skin to wrap the assembly.

65. A method as claimed in claim 64, further comprising applying an additional outer skin over the fibre reinforced polymer skin selected to provide fire retardation, weather resistance, ultraviolet resistance or aesthetic styling.

66. A composite flooring or building component as claimed in any of claims 39-57, wherein the first surface comprises a top lid having removable access covers aligned with utilities or penetrations and the second surface comprises a grid or top-hat arrangement of recessed compartments with localised reinforcement proximate the encapsulated solid elements.

67. A composite flooring or building component as claimed in any of claims 39-57, wherein the rebates, drainage channels and penetrations are integrally moulded during fabrication and are operatively associated with sleeve inserts, gaskets or drains to provide weatherproof performance.

68. A composite flooring or building component as claimed in any of claims 39-57, wherein the component is configured to be stackable and comprises interlocking projections and recesses compatible with dog-bone connectors and perimeter rebates so as to enable both horizontal and vertical assembly.

69. Use of a composite flooring or building component as claimed in any of claims 39-57 as a balcony panel or outdoor decking element in a building, wherein watermanagement is provided by moulded drainage channels directing water to a central outlet and / or an edge discharge beneath a permeable top layer.

70. A building comprising one or more composite flooring or building components as claimed in any of claims 39-57, wherein at least one perimeter edge comprises a rebate receiving a flush-fitting sliding door and at least one service penetration comprises a sleeve liner providing a sealed interface for a plumbing pipe and / or an electrical conduit.

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