COMPONENTISED BUILDING AND METHOD OF ASSEMBLING A COMPONENTISED BUILDING

Description

The present invention relates to a componentised building and a method of assembling a componentised building. More preferably, the present invention relates to a componentised building system comprising wall structural panel units and associated components for forming at least a part of a building structure.

Often, buildings, outhouses and other commercial building structures are built directly onto a plot of land where the building structure is desired to be located. In general, very little of the structure of buildings is prefabricated and complete construction of the building structure from scratch is required. This, inevitably, increases transportation and labour costs due to the need to source independently materials and labour.

Further, the unpredictable effects of, for example, weather conditions can increase the lead time and cost to complete a building structure. Additionally, the need essentially to produce a building structure from basic components may lead to a lack of consistency of structural fitting from building to building.

An alternative approach to manufacture of a building (or part thereof), is to produce the building structure in a factory before the semi-completed unit is transported to a building site where final construction can be completed.

There are a number of advantages to off-site construction. Manufacturing costs are lower due to reduced labour and transportation. Further, more accurate construction is possible due to the controlled environment in which the components are assembled. However, this approach lacks flexibility and is limited to the types and sizes of buildings that can be easily transported.

A further alternative approach for the construction industry is the use of structural insulated panels (SIPs). SIPs are a composite building material and generally comprise an inner foam layer sandwiched between two structural outer layers. The outer layers may comprise any suitable structural material such as sheet metal, plywood or oriented strand board (OSB).

SIPs are available in relatively large sheets which can be used individually, or combined, to form the walls of a building. SIPs have the advantages of providing both structural and insulating properties whilst facilitating more straightforward construction of buildings when compared to conventional brick or concrete block construction.

However, in most cases, a significant amount of skill and labour is required to assemble a building on-site from basic SIP units, and a number of connectors and seals are still required which can add to construction time, complexity and cost.

Therefore, there is a need in the art to provide a partially prefabricated structure which can be quickly, reliably and easily assembled on-site and which requires less time and resources to assemble.

According to a first aspect of the present invention, there is provided a componentised building system for forming a building structure, the componentised building system comprising: an elongate base rail having a longitudinal axis and configured to be secured to a ground surface to define the location and orientation of a wall structure of the building structure, the base rail comprising an elongate rail guide extending parallel to the longitudinal axis; and a wall structural panel unit configured to form a part of the wall structure, the wall structural panel unit having a rail engagement portion arranged at a lower end thereof and configured to engage with the rail guide to enable the wall structural panel unit to slide along at least a part of the length of the base rail in a direction parallel to the longitudinal axis.

In one embodiment, the rail engagement portion is configured to receive at least a part of the elongate rail guide therein.

In one embodiment, the rail engagement portion comprises a channel formed in a base surface of the wall structural panel unit.

In one embodiment, the base rail comprises a planar base portion configured to engage with the ground surface and the rail guide comprises a projection raised with respect to the planar base portion.

In one embodiment, the projection has a triangular cross section.

In one embodiment, the planar base portion and the rail guide are formed from sheet material.

In one embodiment, the base rail further comprises a plurality of moveable connecting elements, wherein each connecting element is moveable between a first position in which the connecting element is flush with the planar base portion to enable one or more wall structural panel units to slide along the base rail and a second position in which the connecting element is substantially parallel to a side wall of a wall structural panel unit and configured to enable the wall structural panel unit to be secured to the base rail thereby.

In one embodiment, wherein each wall structural panel unit comprises first and second outer layers and at least one intermediate layer located therebetween.

In one embodiment, each wall structural panel unit comprises a structural insulated panel (SIP).

In one embodiment, the first and/or second outer layers are formed from metal.

In one embodiment, the at least one intermediate layer is formed from rockwool.

In one embodiment, the componentised building system further comprises a plurality of wall structural panel units and wherein each wall structural panel unit is configured to slide along the rail guide in use to a position adjacent another wall structural panel unit to form the wall structure.

In one embodiment, the wall structural panel unit comprises a flange portion extending from at least a portion of a side of the wall structural panel unit, each flange portion being configured to conformally abut a flange portion of an adjacent wall structural panel in use.

In one embodiment, the componentised building system further comprises a connector arranged to slidably engage with the flange portions of two adjacent wall structural panel units to secure the wall structural panel units together.

In one embodiment, the connector is arranged to slidably engage with the flange portions of two adjacent wall structural panel units in a friction fit.

In one embodiment, the componentised building system further comprises a roof structural panel unit configured to form a part of a roof structure of the building structure, the roof structural panel unit being connectable to at least one wall structural panel unit.

In one embodiment, each roof structural panel unit comprises first and second outer layers and at least one intermediate layer located therebetween.

In one embodiment, each roof structural panel unit comprises a structural insulated panel (SIP).

According to a second aspect of the present invention, there is provided a kit of parts for assembling a building structure, the kit of parts comprising: a plurality of base rails and a plurality of wall structural panel units according to the first aspect; a plurality of roof structural panels according to the first aspect; and a plurality of connectors according to the first aspect.

According to a third aspect of the present invention, there is provided a method of assembling a componentised building structure, the method comprising the steps of: a) securing a plurality of elongate base rails to a ground surface to define the location and orientation of a plurality of wall structures of the building structure, each elongate base rail having a longitudinal axis and comprising an elongate rail guide extending parallel to the longitudinal axis; b) positioning an assembly structure comprising at least one wall structural panel unit on at least one base rail, the or each wall structural panel unit having a rail engagement portion arranged at a lower end thereof and configured to engage with the rail guide to enable the assembly structure to slide thereon; c) sliding the assembly structure along at least a part of the length of the respective base rail in a direction parallel to the longitudinal axis of the base rail to a desired location of the assembly structure; and d) repeating steps b) and c) for further assembly structures to form the componentised building structure.

In one embodiment, the method further comprises: e) connecting one or more roof structural panel units to at least one wall structural panel unit.

In one embodiment, step e) is performed after step b) and prior to step c), or after step c), or after step d).

In one embodiment, the assembly structure comprises a portal structure comprising at least two opposing wall structural panel units and one or more roof structural panel units, and the method further comprises, either prior to or as part of step b): f) connecting one or more roof structural panel units across the two opposing wall structural panel units to form the assembly structure in the form of a portal structure.

In one embodiment, the base rail comprises a plurality of connection tabs and the method further comprises, subsequent to step c): g) moving one or more connecting element from a first position in which the connecting element is flush with a portion of the base rail and a second position in which the connecting element is substantially parallel to a side wall of a wall structural panel unit and configured to enable the wall structural panel unit to be secured to the base rail thereby; and h) securing the respective wall structural panel unit to the base rail utilising the connecting element.

In one embodiment, each wall structural panel unit comprises a flange portion extending from at least a portion of a side of the wall structural panel unit and configured to conformally abut a flange portion of an adjacent wall structural panel unit, and wherein the method further comprises: i) slidably engaging a connector onto the flange portions of a pair of adjacent wall structural panel units to secure the adjacent wall structural panel units to one another.

In one embodiment, each roof structural panel unit comprises a flange portion extending from at least a portion of a roof surface of the roof structural panel unit and configured to conformally abut a flange portion of an adjacent roof structural panel unit, and wherein the method further comprises: i) slidably engaging a connector onto the flange portions of a pair of adjacent roof structural panel units to secure the adjacent roof structural panel units to one another.

Embodiments of the present invention will now be described in detail with reference to the accompanying drawings, in which:

FIG. 1 is a schematic isometric view of a building structure formed according to an embodiment of the present invention;

FIG. 2 is a side view of the building structure shown in FIG. 1;

FIG. 3 is an end view of the building structure shown in FIGS. 1 and 2;

FIG. 4 is a schematic view showing the structural panels comprising the walls of the building structure of FIGS. 1 to 3;

FIG. 5a is an end view of a wall structural panel and rail according to an embodiment;

FIG. 5b shows a section view of a structural panel and rail in situ on a ground surface;

FIG. 6 is an isometric view of a plurality of structural panels in situ on a pair of orthogonal rails;

FIG. 7 is a further isometric view of the features shown in FIG. 6;

FIG. 8 is an isometric view of structural panels and connectors;

FIG. 9 is a view of roof structural panels during assembly;

FIG. 10 is a further view of roof structural panels once assembled to form a portal structure;

FIG. 10a shows the completed portal structure of FIG. 10 engaged with a pair of rails;

FIG. 11 is a view of roof connectors and wall connectors applied to roof and wall structural panels;

FIG. 12 is a view similar to FIG. 11 but showing additional features;

FIG. 13 is a flow chart of a method according to an embodiment;

FIG. 14 is a flow chart of a method according to a further embodiment; and

FIG. 15 shows a section view similar to FIG. 5b but showing a structural panel and rail for forming a building structure to cover an existing building.

FIGS. 1 to 3 show views of a building structure 10 formed according to the present invention. It is noted that the building structure 10 is exemplary and the structural form shown is non-limiting. In embodiments, a building structure 10 formed according to embodiments of the invention may take any suitable form achievable using the components herein described.

The building structure 10 is formed on a ground surface 50 and comprises a plurality of wall structures 12 and a roof structure 14. The roof structure 14 is sloped and has a peak in a longitudinal axis and comprises roof portions 14a, 14b. Within the wall structures 12 are formed a plurality of apertures 16. The apertures 16 are to allow ingress to and egress from the interior of the building structure 10. Doors (not shown) may be fitted in the apertures 16 as required.

The wall structures 12 are, in embodiments, formed from a plurality of discrete wall structural panels 20. Each wall structural panel 20 is connected to an adjacent wall structural panel 20 by a panel connector as described below.

FIG. 4 shows a schematic diagram of the panel construction of the building structure 10 shown in FIGS. 1 to 3. As shown, a plurality of wall structural panels 20 are arranged adjacent one another to form the wall structures 12.

In embodiments, the wall structural panels 20 may take a multiplicity of different forms as required for the end building structure. For example, panels 20A comprise plain wall structural panels. Panels 20B comprise full length air vents, panels 20C include a single upper air vent and panels 20D include further connectors. However, this is to be taken as non-limiting and any suitable configuration of panels 20 may be used with the present invention. The panels described above are purely exemplary and indicative of the kind of structure 10, that may be implemented in practice.

FIGS. 5 to 7 show more details of the wall structural panels 20 and associated features to enable fitment on-site. FIG. 5a is an end-on view of a part of a wall structural panel 20 and a part of an associated rail structure 22. FIG. 5b shows a section view of a rail 22 and structural panel 20 installed on a ground surface 50. FIG. 6 is an isometric view of a plurality of wall structural panels 20 in situ on a pair of orthogonal rails 22. FIG. 7 shows a further isometric view of the features shown in FIG. 5.

In embodiments, the wall structural panels 20 are supported and connected to the ground surface 50 by means of the rail structure 22. It is noted that in the present disclosure “rail structure” and “rail” may be used interchangeably as appropriate. In embodiments, the rail structure 22 may comprise one or more lengths of rail 22 which form the base of the wall structures 12. In other words, the rail structure 22 comprises one or more lengths of rail 22 which, when installed, define the location and arrangement of the walls 12 of the building structure 10 to be formed. In embodiments, a single length of rail 22 forms the base for a single wall structure 12.

Each rail structure 22 is elongate and comprises first and second portions 22A, 22B suitable for connection to the ground surface 22. The first and second portions 22A, 22B are substantially flat and, in use, arranged parallel to the ground surface 50. It may, in embodiments, be necessary to prepare the ground surface 50 so it is level to receive the rail structure 22, for example, by shimming or grouting. Alternatively, the rail structure 22 may be placed directly on an existing concrete hardstanding or slab if appropriate.

The first and/or second portions 22A, 22B of the rail structure 22 comprise apertures to enable the rail structure 22 to be secured to the ground surface 50. In the described embodiments, the apertures may be formed only on both portions 22A, 22B or only on one of the first portion 22A or the second portion 22B.

In embodiments, rows of apertures are provided on at least an inner side of the rail 22 (i.e. facing the inside of the wall structure 12) on section portion 22B through which appropriate fixing means can be placed to secure the rail structure 22 to the ground surface 50. In embodiments, the fixing means comprise screws or anchors. In embodiments, the fixing means comprise M12 anchors. However, this is to be taken as non-limiting and any suitable configuration of fixing means could be used.

An example of this is shown in FIG. 5b. FIG. 5b shows a section view of a rail 22 and structural panel 20 installed on a ground surface 50. The ground surface comprises a concrete hardstanding 50C and a levelled portion 50L created by shimming or grouting. Fixing means 50F in the form of M12 anchors are provided to secure both the first and second portions 22A, 22B of the rail 22 to the ground surface 50.

The rail structure 22 further comprises a rail guide 24. The rail guide 24 comprises an elongate projection extending longitudinally along the full length of the rail guide 24 and located centrally in a width direction of each rail structure 22. The rail guide 24 is configured to engage with a complementary portion of each structural panel 20 forming a wall structure to enable each structural panel 20 to be slid along the rail structure 22 using the rail guide 24, as described below.

As shown in FIGS. 5a and 5b, the rail guide 24 has a substantially triangular cross-section. This has the technical advantages of enabling a wall structural panel 20 to be located on the rail guide 24 easily and for the wall structural panel 20 to slide with a minimum of resistance. However, this is not intended to be limiting and other cross-sectional shapes may be used, for example square, tapered, or semi-circular. More complex shapes may also be used. However, simpler forms such as the triangular form shown in the described embodiments has advantages in terms of ease of manufacture of the rail which can be formed or pressed from a single piece of sheet material such as steel, aluminium or a suitable alloy.

The rail structure 22 further comprises a plurality of connection tabs 26 formed on the first portion 22A. The connection tabs 26 are configured to be movable between two positions. In use, the connection tabs 26 are configured to lie flush with the first and second portions 22A, 22B as shown in FIGS. 5 to 7 so that the wall structural panels 20 can be slid along the rail structure 22 without being impeded by the connection tabs 26.

However, once a wall structural panel 20 is installed in place, the relevant connection tabs 26 can be bent, folded or otherwise moved to lie substantially perpendicular to the plane of the first portion 22A and parallel and adjacent an outer wall of a structural panel 20. Each connection tab 26 comprises an aperture therethrough enabling suitable fixing means to be used to secure the respective connection tabs 26 to the structural panel 20, thereby securing the structural panel to the rail structure 22 and ground surface 50.

Wall structural panels 20 for use in the wall structure 12 are shown in FIGS. 5 to 7. Further, FIG. 8 shows a pair of wall structural panels 20 adjacent one another. The wall structural panels 20 for use as wall structures will now be described.

The wall structural panels 20 for use as wall structures comprise elongate sandwich structures. Each structural panel 20 has a height equal to the intended height of the wall structure formed therefrom. In other words, the wall structural panels 20 are not stacked vertically and a single structural panel 20 extends the full height of the wall structure for a single storey building.

In specific embodiments such as the building structure 10 of FIGS. 1 to 3, the panels may have a height in the range of 3.5-4 m. The wall structural panels 20 are elongate and narrow in width. In embodiments, for panels having heights of 3.5-4 m, the wall structural panels 20 may have a width in the range of 0.4-0.8 m. In embodiments, the structural panels have a width of 0.6 m. In embodiments, the wall structural panels 20 may have a maximum size of 12 m in any dimension. In embodiments, the wall structural panels 20 may have a maximum size of 6 m in any dimension.

In embodiments, each structural panel 20 takes the general structural form of a structural insulated panel (SIP) comprising an inner insulating core layer (not shown) sandwiched between two structural outer layers 28, 30. In embodiments, the outer layers 28, 30 are formed from aluminium and have a thickness in the range of 1-5 mm. In embodiments, the outer layers 28, 30 have a thickness of 2-3 mm. However, in embodiments, the outer layers may comprise any suitable structural material such as another sheet metal, for example, stainless steel or mild steel. In embodiment, the outer layers 28, 30 may comprise a plastics material or carbon composites.

The inner core layer comprises any suitable insulating material. In embodiments, the inner core layer comprises a stone wool fibre. In embodiments, the inner core layer comprises Rockwool™. Rockwool™ comprises a stone wool fibre core formed from basalt. It may be used in any suitable thickness, for example, 50-100 mm. In embodiments, the thickness may be up to 500 mm. It is also preferred that the inner core layer has moisture-resistant and fire-resistant properties to aid longevity and safety. Finally, it is desirable for the inner core layer to be formed from non-toxic materials to aid site safety and ultimate future disassembly. In embodiments, the inner core layer may also comprise multiple layers of material.

Each structural panel 20 has a pair of opposing end plates 32. The end plates are arranged perpendicular to the outer layers 28, 30 and cap the ends of each structural panel 20 in the length direction of the wall structure which the wall structural panel 20 is intended to form a part of. In embodiments, the end plates 32 may comprise upper connectors 34 (see FIGS. 6 and 7) for connection to roof structural panels. This will be described below. However, this may be optional and other panels (for example, panels 20 designed to fit against the end of a roof structure, such as those shown to the right of FIG. 6) may not include these features.

Each structural panel 20 has a shaped channel 36 formed in a lower surface thereof. This is shown best in FIGS. 5a, 5b and 8. The channel 36 (or cut out, groove or recess) extends across the full width of the wall structural panel 20 between cut outs in the end plates 32. The channel 36 has a cross-sectional shape and dimensions which are complementary to the rail guide 24 and arranged to receive the rail guide 24 therein. In other words, when a wall structural panel 20 is placed on the rail structure 22, the rail guide 24 extends fully into and inter-engages with the channel 36 of the wall structural panel 20 and the base of the wall structural panel 20 is fully supported on the first and second portions 22A, 22B of the rail structure 22.

Through this inter-engagement, each wall structural panel 20 can be easily slid along the rail structure 22 by a user (e.g. construction personnel) to the correct installation position. This is convenient for the user since accurate location and precise alignment of the wall structural panels 20 is achieved automatically through the use of the rail structure 22. In addition, the sliding of the wall structural panels 20 enables the wall structural panels 20 to be manoeuvred easily into position without the need for lifting by site personnel or the use of heavy lifting machinery.

For example, a lorry or other suitable container containing the wall structural panels 20 could be located at the end of a section of rail structure 22 and each wall structural panel 20 placed into inter-engagement with the rail 22 and then slid to the correct position in turn or assembled into other structures (see portals described later) as required. This avoids wall structural panels 20 having to be lifted or dragged to the correct location and position before being installed, and makes installation of the wall structure 12 easier, quicker and less likely to result in damage to the wall structural panels 20.

Alternatively or additionally, more complex structures can be formed which can then be slid into position as required. This is described in relation to FIGS. 9, 10 and 10a below. Once the wall structural panels 20 are slid into place along the track 22 so that they are adjacent (such as shown in FIGS. 6 and 7), it is necessary to connect them in a manner which is weather-tight and can prevent water ingress. Seals (usually formed from rubber or other resilient material) are commonly used when connecting panels. However, seals can be complex to install, and can perish over time, reducing the viable lifespan of the building structure and allowing water ingress and other environmental damage to occur. The present invention provides a unique solution to these issues. Referring to FIG. 8, each structural panel 20 has a pair of flange elements 38. The flange elements 38 extend the full height of the wall structural panel 20 and are arranged on one side of the wall structural panel 20 only. In embodiments, the flange elements 38 are arranged on the outer surface of the wall structure 12 only.

In embodiments, the flange elements 38 form perpendicular extensions of the end plates 32. When two wall structural panels 20 are in abutment, the flange elements 38 form T-shape therebetween. The only effective path for water ingress is therefore through the centre of the T between the two abutting wall structural panels 20.

In order to secure the wall structural panels 20 to one another, and to provide the necessary weather protection, a channel cover member 40 is provided (FIG. 8 shows two such members). The channel cover member 40 is shaped and arranged to slide onto the T-shape formed by two abutting flange elements 38. In embodiments, the channel cover member 40 may be shaped and arranged to be held in place by a friction fit. In embodiments, this may be supplemented by use of fixing means to secure the channel cover member 40 to the pair of abutting wall structural panels 20.

When the channel cover member 40 is in place, the channel cover member 40 extends across the gap between the two wall structural panels 20 and the side walls of the flange elements 38 and the side walls of the channel cover member 40 shield the gap from environmental ingress. The environmental protection is thus achieved in an efficient, easy to assemble approach which avoids the need for perishable seals. Consequently, the building structure 10 can have a longer lifespan than conventional arrangements.

With reference to FIGS. 9 to 10a, the roof construction will now be described. FIGS. 9 and 10 show four wall structure structural panels 20 arranged in opposing pairs. FIG. 10 a shows the resulting structure being manoeuvred using the rails 22.

The roof 14 of the building structure 10 is formed from multiple segments of two roof portions 14a, 14b arranged at an angle to one another. However, this is to be taken as non-limiting and any number of roof portions may be used for each segment. In embodiments, the roof portions 14a, 14b are also formed from structural panels 20R.

The use of SIP-type structural panels 20R for roof structures is a unique aspect of the present invention and enables an entire building structure 10 to be formed from panels 20, 20R having common properties and features. This makes assembly more straightforward and manufacturing of components more cost-effective.

In embodiments, the structural panels 20R have a generally similar construction to the wall structure structural panels 20, and each structural panel 20R comprises a structural insulated panel (SIP)-type structure comprising an inner insulating core layer (not shown) sandwiched between two structural outer layers 28, 30. Further, each roof structural panel 20R comprises a pair of opposing end plates 32 and flange elements 38 in common with the wall structural panels 20. It is noted that for brevity the same reference numerals are used for the same features on the roof structural panels 20R as for the wall structural panels 20 and these features will not be described further.

However, there are differences relating to the specific requirements of the roof structural panels 20R. For example, the dimensions are necessarily different from wall structural panels 20. In addition, the cut outs and channels 36 are not required since the roof structural panels 20R do not engage with the rail structure 22. Further, flashing and other elements (described below) are necessary to ensure visual appearance and enhance weather-proofing.

The connection between the roof structural panels 20R and the wall structural panels 20 are shown in FIGS. 9 and 10. The upper connectors 34 of each structural panel 20 engages with a complementary connector 42 arranged on each roof structural panel 20R. The connectors 34, 42 can then be connected via the apertures formed therein and secured by suitable fixing means such as Tec screws, screws, bolts or other fixings.

Once so connected, the roof structural panels 20R and wall structural panels 20 form a U-shaped structure known as a “portal” 20P. This is shown in FIGS. 10 and 10 a. The completed portal 20P is a single unit comprising a pair of opposing wall structural panels 20 and connecting roof structural panels 20R. In this embodiment, two roof structural panels 20R are provided but this is not intended to be limiting.

An advantage of the method and system of the present invention is that each portal 20P can be formed at a convenient location (e.g. adjacent a storage area or truck where facilities may make assembly more straightforward) before the entire portal 20P is slid into position using the rails 22. In addition, each portal 20P can be assembled in the same location and so tools and personnel can remain in the same location.

FIG. 10a shows an example of this. In FIG. 10a a portal 20P-1 is shown in situ at one end of a pair or rails 22. A further portal 20P-2, now assembled, can be slid on the rails 22 to be in conformal abutment with the portal 20P-1. This process can be repeated for further portals 20P.

Roof channel cover members 44 are also utilised in the same manner as the channel cover member 40 of the wall structural panels 20. These are shown in FIG. 11. In addition, lower roof flashings 46 (i.e. flashings underneath the roof structure on an internally-facing side) are added to and secured to the ends of the roof structural panels 20R to protect the join at the centre of the roof.

Turning to FIG. 12, once the lower flashings and roof channel cover members 44 are installed, additional flashings can be added to provide enhanced weather protection. For example, upper roof flashings 48 (i.e. flashings on an outwardly-facing side of the roof structural panels 20R) are added above the ends of the roof channel cover members 44. Finally, once the wall structural panels 20 and roof structural panels 20R are assembled, further flashings 48, 50 can be added between the wall and roof structural panels 20, 20R and at the base of the wall structural panels 20 adjacent the rail 22, respectively. Doors and doorframes (not shown) may also be included. The doorframes may comprise welded steel sections formed into “U” shapes at the manufacturing site and transported to the assembly site in a complete form. This aids assembly and reduces the parts required. The doorframes may engage with wall structural panels 20 which are of suitable dimensions to fit with the doorframes in a seamless assembly.

A method of assembly of the building structure 10 according to an embodiment will now be described.

Step 100: Prepare Foundation

At optional step 100, the ground surface 50 may be prepared to form a foundation for the building structure 10. For example, it may be necessary to prepare the ground surface 50 so it is level to receive the rail structure 22. In embodiments, this may comprise shimming or grouting.

Step 102: Mount Rail Structure

At step 102, it is determined where the walls of the building structure 10 should be placed. On this basis, the rail structure 22 is laid, with a plurality of rails 22 being arranged in a manner corresponding to the intended wall position of the building structure 10.

If the ground surface 50 has been prepared and levelled in step 100, then the rail structure 22 may be placed flat on the ground surface 50 and connected thereto. Alternatively, the rail structure 22 may be placed directly on an existing concrete hardstanding or slab if appropriate.

The rail structure 22 is connected to the ground surface 50 by means of the apertures in the first and/or second portions 22A, 22B of the rail structure 22. In the described embodiments, the apertures are formed only on the second portion 22B.

In embodiments, the rows of apertures are provided on an inner side of the rail 22 (i.e. facing the inside of the wall structure 12) through which appropriate fixing means are placed in use to secure the rail structure 22 to the ground surface 50 In embodiments, the fixing means comprise screws or anchors. In embodiments, the fixing means comprise M12 anchors. However, this is to be taken as non-limiting and any suitable configuration of fixing means could be used.

Step 104: Locate Assembly Structure

Once the rail structure 22 is correctly located and secured in step 102, an assembly structure comprising a wall structural panel 20 can be placed on the respective rail guide 24. In this embodiment, the assembly structure comprises a single wall structural panel 20.

The rail guide 24 engages with the complementary channel 36 of the wall structural panel 20 and the wall structural panel 20 can then be slid along the rail structure 22 to the desired location in step 106.

Step 106: Slide Assembly Structure

At step 106, the assembly structure in the form of a wall structural panel 20 can be slid along the rail 22 to a desired location.

Multiple assembly structures in the form of a multiplicity of individual wall structural panels 20 may be located in this manner. It is noted that each step is not sequential for the whole building construction and steps 104 and 106 (and subsequent steps) may be repeated for further assembly structures once an initial set of assembly structures have been secured in situ, for example.

Step 108: Secure Wall Structural Panel

At step 108, the wall structural panel 20 is secured using adjacent connection tabs 26 on the rail structure 22.

As noted, the rail structure 22 further comprises a plurality of connection tabs 26 formed on the first portion 22A. The connection tabs 26 are configured to be movable between two positions. In use, the connection tabs 26 are configured to lie flush with the first and second portions 22A, 22B as shown in FIGS. 5 to 7 so that the structural panels 20 can be slid along the rail structure 22 without being impeded by the connection tabs 26.

However, once a wall structural panel 20 is installed in place in step 104, in step 106 the relevant connection tab(s) 26 can be bent, folded or otherwise moved to lie substantially perpendicular to the plane of the first portion 22A and parallel and adjacent an outer wall of the structural panel 20.

Each connection tab 26 comprises an aperture therethrough enabling suitable fixing means to be used to secure the respective connection tabs 26 to the structural panel 20, thereby securing the structural panel to the rail structure 22 and ground surface 50.

Step 110: Install Roof Structural Panels

At step 110, the roof structural panels 20R are installed. An example of the connection between the roof structural panels 20R and the wall structural panels 20 is shown in FIGS. 9 and 10. In this step, the upper connectors 34 of each structural panel 20 are engaged with the complementary connector 42 arranged on each roof structural panel 20R. The connectors 34, 42 are then connected via the apertures formed therein and secured by suitable fixing means such as Tec screws, screws, bolts or other fixings.

In this embodiments, the roof structural panels 20R and two opposing wall structural panels 20 may be connected to form a U-shaped structure known as a “portal” 20P. This is shown in FIGS. 10 and 10 a. The completed portal 20P is a single unit comprising a pair of opposing wall structural panels 20 and connecting roof structural panels 20R. In this embodiment, two roof structural panels 20R are provided but this is not intended to be limiting.

By this approach, a portal 20P can be formed at step 110 in the desired final location. It is noted that step 110 may occur before step 108 so the portal 20P is formed before the respective wall structural panels 20 are secured in step 108.

The process may be repeated for additional roof structural panels 20R as required.

Step 112: Install Lower Roof Flashings

In this step, the lower roof flashings are connected and secured in situ. This may be performed once step 110 is completed for one or more roof structural panels 20R.

Step 114: Install Channel Cover Members

At step 114, the channel cover members can be installed. Once at least two structural panels 20 are slid into place along the track 22 in step 104 and secured in step 106 so that they are adjacent (such as shown in FIGS. 6 and 7), it is necessary to connect them in a manner which is weather-tight and can prevent water ingress.

In order to secure the structural panels 20 to one another, and to provide the necessary weather protection, a channel cover member 40 is slid onto the flange elements 38 of two abutting structural panels 20. The channel cover member 40 is shaped and arranged to slide onto the T-shape formed by two abutting flange elements 38. In embodiments, the channel cover member 40 may be shaped and arranged to be held in place by a friction fit. In embodiments, fixing means may additionally be used to secure the channel cover member 40 to the pair of abutting structural panels 20.

When the channel cover member 40 is in place, the channel cover member 40 extends across the gap between the two structural panels 20 and the side walls of the flange elements 38 and the side walls of the channel cover member 40 shield the gap from environmental ingress. The environmental protection is thus achieved in an efficient, easy to assemble approach which avoids the need for perishable seals.

Step 116: Install Further Flashings

At step 116, once the wall structural panels 20 and roof structural panels 20R are assembled, further flashings 48, 50 are added between the wall and roof structural panels 20, 20R and at the base of the wall structural panels 20 adjacent the rail 22, respectively.

A method of assembly of the building structure 10 according to a further embodiment will now be described with reference to FIG. 14.

Step 200: Prepare Foundation

At optional step 200, the ground surface 50 may be prepared to form a foundation for the building structure 10. For example, it may be necessary to prepare the ground surface 50 so it is level to receive the rail structure 22. In embodiments, this may comprise shimming or grouting.

Step 202: Mount Rail Structure

At step 202, it is determined where the walls of the building structure 10 should be placed. On this basis, the rail structure 22 is laid, with a plurality of rails 22 arranged in a manner corresponding to the intended wall position of the building structure 10.

If the ground surface 50 has been prepared and levelled in step 200, then the rail structure 22 may be placed flat on the ground surface 50 and connected thereto. Alternatively, the rail structure 22 may be placed directly on an existing concrete hardstanding or slabs if appropriate.

In embodiments, the rail structure 22 defines a building structure having at least two opposing walls, i.e. two rails 22 are located parallel to one another and spaced apart by a width or length of the building structure 10 to be formed.

The rail structure 22 is connected to the ground surface 50 by means of the apertures in the first and/or second portions 22A, 22B of the rail structure 22 through which appropriate fixing means are placed in use to secure the rail structure 22 to the ground surface 50.

In embodiments, the fixing means comprise screws or anchors. In embodiments, the fixing means comprise M12 anchors. However, this is to be taken as non-limiting and any suitable configuration of fixing means could be used.

Step 204: Form Assembly Structure

At step 204, the roof structural panels 20R and wall structural panels 20 can be connected to form a U-shaped assembly structure known as a “portal” 20P. This is shown in FIGS. 10 and 10a. The completed portal 20P is, in this embodiment, an assembly structure comprising a pair of opposing wall structural panels 20 and connecting roof structural panels 20R.

A portal 20P can be formed from two wall structural panels 20 and, in the described embodiments, two roof structural panels 20R. However, this is to be taken as non-limiting and in embodiments different numbers of such panels could be used. For example, any number of roof structural panels 20R could be utilised as required, e.g. one or three or more.

An example of the connection between the roof structural panels 20R and the wall structural panels 20 is shown in FIGS. 9 and 10. In this step, the upper connectors 34 of each structural panel 20 are engaged with the complementary connector 42 arranged on each roof structural panel 20R. The connectors 34, 42 are then connected via the apertures formed therein and secured by suitable fixing means such as Tec screws, screws, bolts or other fixings.

By this approach, a portal 20P can be formed at step 204 at a convenient location (e.g. adjacent a storage area or truck where facilities may make assembly more straightforward) before the entire portal 20P is slid into position using the rails 22 as set out in later steps. In addition, each portal 20P can be assembled in the same location and so tools and personnel can remain in the same location.

FIG. 10a shows an example of this. Portal 20P-2, assembled in step 204, can be slid on the rails 22 to be in conformal abutment with the portal 20P-1 in later steps. This process can be repeated for further portals 20P.

Step 206: Locate Assembly Structure

Once the rail structure 22 (comprising a plurality of rails 22 in situ) is correctly located and secured in step 202 and the assembly structure in the form of a portal 20P is formed in step 204, the assembly structure (in the form of the portal 20P) can be placed on the respective rail guides 24. Each rail guide 24 engages with a complementary channel 36 of the respective wall structural panel 20 of the assembly structure (portal 20P). The assembly structure can then be slid along the rail structure 22 to the desired location in later steps.

However, it is noted that each step is not sequential for the whole building construction. For example, step 206 may be performed before step 204 and the wall structural panels 20 forming each portal 20P may be located (step 206) before the roof structural panels 20R are attached to form the portal 20P. In other words, the assembly structure comprises the portal 20P but instead of the portal 20P being fully assembled before being located on the rails 22, the portal 20P is at least partly assembled whilst the wall structural panels 20 of the portal 20P are engaged with the track 24 of the rails 22.

Step 208: Slide Portal

At step 208, the assembly structure (in the form of the entire formed portal 20P) can be slid along the rail structure 22 to a desired location. Multiple assembly structures (e.g. portals 20P) may be located in this manner.

Step 210: Secure Wall Structural Panels

At step 210, the wall structural panels 20 of each portal 20P may be secured using adjacent connection tabs 26 on the rail structure 22.

As noted, the rail structure 22 further comprises a plurality of connection tabs 26 formed on the first portion 22A. The connection tabs 26 are configured to be movable between two positions. In use, the connection tabs 26 are configured to lie flush with the first and second portions 22A, 22B as shown in FIGS. 5 to 7 so that the wall structural panels 20 of each portal 20P can be slid along the rail structure 22 without being impeded by the connection tabs 26.

However, once a wall structural panel 20 forming part of a portal 20P is installed in place in step 208, in step 210 the relevant connection tab(s) 26 can be bent, folded or otherwise moved to lie substantially perpendicular to the plane of the first portion 22A and parallel and adjacent an outer wall of the structural panel 20.

Each connection tab 26 comprises an aperture therethrough enabling suitable fixing means to be used to secure the respective connection tabs 26 to the structural panel 20, thereby securing the structural panel to the rail structure 22 and ground surface 50.

Step 212: Install Lower Roof Flashings

In this step, the lower roof flashings are connected and secured in situ. This may be performed once step 210 is completed, although could be performed beforehand. In addition, this step is not dependent on whether a portal 20P has been slid into position as described above and the flashings could, in embodiments, be installed prior to steps 208 and 210.

Step 214: Install Channel Cover Members

At step 214, the channel cover members can be installed. Once at least two wall structural panels 20 of adjacent portals 20P are slid into place along the track 22 in step 208 and secured in step 210 so that they are adjacent and in abutment (such as shown in FIGS. 6 and 7), it is necessary to connect them in a manner which is weather-tight and can prevent water ingress.

In order to secure the wall structural panels 20 to one another, and to provide the necessary weather protection, a channel cover member 40 is slid onto the flange elements 38 of two abutting structural panels 20. The channel cover member 40 is shaped and arranged to slide onto the T-shape formed by two abutting flange elements 38. In embodiments, the channel cover member 40 may be shaped and arranged to be held in place by a friction fit. In embodiments, fixing means may additionally be used to secure the channel cover member 40 to the pair of abutting structural panels 20.

When the channel cover member 40 is in place, the channel cover member 40 extends across the gap between the two structural panels 20 and the side walls of the flange elements 38 and the side walls of the channel cover member 40 shield the gap from environmental ingress. The environmental protection is thus achieved in an efficient, easy to assemble approach which avoids the need for perishable seals.

Step 216: Install Further Flashings

At step 216, once the wall structural panels 20 and roof structural panels 20R are assembled, further flashings 48, 50 are added between the wall and roof structural panels 20, 20R and at the base of the wall structural panels 20 adjacent the rail 22, respectively.

The building structure 10 is designed specifically to provide a cost-effective structure which is much faster and more straightforward to assemble than known arrangements. The present invention utilises a componentised structure using structural panels 20, 20R for both the walls and roof of a structure. This enables the structural panels 20, 20R to be manufactured and built on a single site (such as a factory), and enables the structural panels 20, 20R to be manufactured in advance, quickly, efficiently and with a high standard of quality control.

Further, by providing the rail structure, assembly of the structural panels 20, 20R can be effected more easily than known arrangements. Finally, by enabling a unique manner for connecting the structural panels 20, 20R without seals, the longevity of the building structure 10 can be improved.

The present invention has wide applicability in terms of intended use. The building structure 10 and method can be utilised to provide a new building for commercial, business and/or industrial use. However, a further application for the technology of the present invention is in extending the lifespan of existing buildings. The method and structure of the present invention enables an existing building or infrastructure element to be surrounded with a protective shell in the form of the building structure 10.

An example of this is shown in FIG. 15. FIG. 15 is a view similar to FIG. 5b but showing a wall W of an existing building structure or infrastructure element which can be surrounded by a protective building structure 10. Other elements of FIG. 15 correspond to those shown and described with reference to FIG. 5b.

This is a unique application of the technology and facilitated by the construction methodology and structural elements used. By surrounding an existing building and so shielding the building from environmental factors such as wind and rain, the lifespan of the existing building can be extended dramatically. This may be a cost effective alternative to demolition and replacement, or even repair of the existing building structure or infrastructure element.

Variations of the above embodiments will be apparent to the skilled person. The precise configuration of hardware components may differ and still fall within the scope of the present invention. For example, whilst the above embodiments have been described and illustrated in the context of commercial or industrial building structures, other building structures or residences may fall within the scope of the present invention; for example, residential or business structures.

Embodiments of the present invention have been described with particular reference to the examples illustrated. While specific examples are shown in the drawings and are herein described in detail, it should be understood, however, that the drawings and detailed description are not intended to limit the invention to the particular form disclosed. It will be appreciated that variations and modifications may be made to the examples described within the scope of the present invention.