BUILDING SYSTEM AND METHOD

Abstract

A system and method for construction of a building from components, supplies and tools which are transported to the desired building site in a shipping container. The building components loaded and transported in the shipping container include preassembled wall panels, ceiling panels, roof trusses, roof panels, roof cladding sheets and wall cladding sheets. Each preassembled component is sized so that no measuring or cutting of same is required during construction at the building site, and each component may be manually carried without the need for using a lifting device.

Description

REFERENCE TO PRIOR APPLICATION

This application claims the benefit and priority of U.S. Provisional Patent Application Ser. No. 61/367,143 filed on Jul. 23, 2010, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a system and method for construction of a building from components, supplies and tools which are transported to the desired construction site in a shipping container, thereby facilitating quick and efficient building construction, especially in remote areas.

BACKGROUND OF THE INVENTION

The present invention relates to a building system and method for construction and use in locations and environments where it is difficult, if not impossible, to procure adequate building materials and skilled labor. Such locations include, without limitation, areas which have been ravaged by war, storms and other disasters (hereinafter “disaster areas”). In such disaster areas, construction materials, tools and skilled labor are generally unavailable, yet it is precisely in such areas where at least some initial building is desperately needed so that the process of recovery can begin.

The building system and method of the present invention are a significant improvement over existing building systems used in disaster areas. For example, in war-ravaged areas, the standard military building system typically involves three stages or phases for establishing a progressively more substantial presence at the location. Phase 1 consists of a tent on natural dirt as a floor. In phase 2 a wooden floor is built under the existing tent. In phase 3 a wooden shell is built over the tent, resulting in a shelter which is prone to fire, rot, termites, decay and warpage. Such shelters have a limited life expectancy and are uncomfortable to inhabit. This staged process is due in part to the materials used, and the considerable time and effort required, for the above described standard military building.

By contrast, the building of the present invention can be completely erected in a single process within a fraction of the time, and resulting in a much more habitable and permanent building, than is the case with the above described, three-stage, standard military building. The present invention essentially replaces all 3 phases of the standard disaster-area building system with a semi-permanent structure which is fireproof, not subject to decay, insects or warpage, and is much more habitable than said standard system.

The preferred system of the present invention provides for the use of metal framing members, fiber cement wall boards, and metal wall and roof cladding, which are totally noncombustible and are not subject to rot, termites, decay or warpage. This provides significant advantages over traditional military building systems involving the use of wood and other building materials at disaster areas, which are prone to such problems. Moreover, the materials for such traditional military building systems, including plywood and wooden framing systems, are typically imported from North America and drain the eco-system, whereas the materials used in the present invention can be sourced worldwide without loss of timber or associated damage to the eco-system.

As an alternative to such traditional military building systems, the prior art includes so-called relocatable buildings (“RLBs”) which are typically shipped via flat pack containers. An advantage of the RLBs is that they can be shipped in a flat configuration of 4 units. However, there are many disadvantages associated with RLBs, including the following: they are limited in size to 8 feet by 20 feet, which is not the standard size used by the U S military; they are not rigid or semi-permanent; they are fragile to impact and wind; and they have an undesirable flat roof. Moreover, manufacturers of the RLBs are usually located outside the United States, such that the electrical wiring and related electrical components provided with RLBs must be replaced with 110/220v for use by U.S. customers such as the U.S. military. Additionally, a crane or other lifting device is required to help assemble RLBs, and the RLB components are not fireproof.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a building system and related method for rapid deployment via a shipping container to a disaster area where the building can be erected in minimal time with minimal labor. Packed within the shipping container are all of the necessary building components, including modular wall and ceiling panels, roof trusses, roof panels, and wall and roof cladding. Also packed within the shipping container are all of the building materials, tools, fasteners and supplies needed to erect the building. Upon arrival of the container at the disaster area, its contents can be expeditiously unloaded and the building can be constructed with a minimum of effort, time and labor, with minimal need for measuring or cutting of any materials, and without the need for a crane or other lifting device.

In the preferred embodiment of the present invention, the wall and ceiling panels are comprised of standard-sized, full width—full height sheets of cement fiber board, measuring 4 feet by 8 feet (1220 mm×2440 mm), so that there is no cutting or fitting required on site for said panels. By not having any panel waste materials, the net payload to be transported via the container to the disaster area can be kept to the bare minimum, and all the transported panel components can be incorporated into the work. Similarly, there is no cutting, fitting or waste material involved in connection with the roof trusses and roof panels. No waste material means no debris to dispose of, and site erection is eco-friendly. The present invention provides for a structure having the same standard size as existing building systems used by the U.S. military in disaster areas, i.e., 16 feet wide and 32 feet long, with an 8 foot ceiling (4870 mm×9756 mm×2440 mm). To simplify erection in disaster areas where the instant invention may be deployed, and where skilled craftsmen are likely unavailable, the major building components of the invention are preassembled and modularized, requiring no measuring or cutting.

The preassembled and modularized building components of the present invention include wall panels, ceiling panels, roof trusses and roof panels, each of which is light enough to be lifted manually and small enough to be fitted into a 20-foot shipping container. To further simplify erection of the building in accordance with the preferred system and method of the present invention, there are provided 6 identical-sized wall panels, 8 identical ceiling panels, 9 identical roof trusses and 8 identical roof panels.

The preassembled wall and ceiling panels of the present invention preferably have a finished inner surface which is faced with fiber cement wall board. The outer surface of the wall and ceiling panels may be equipped with electrical wiring, plumbing, telecommunication cables and other accessories, and are covered with insulation.

Upon arrival of the shipping container at the desired building site, the wall panels are removed from the container, stood erect at the building site and connected to one another. Ceiling panels that were also shipped in the container are then lifted in place, spanning and supported by the wall panels, thereby creating a building interior envelope within a matter of hours.

Roof trusses and roof panels, also shipped in the container, are then lifted in place, the roof trusses supported by the ceiling panels and the roof panels supported by the roof trusses. The roof panels and wall panels are then faced with pre-cut metal cladding, also shipped in the container, resulting in a walled building under roof in minimal time without the need for any measuring or any cutting, and without the need for any crane or other lifting device. The preferred building of the present invention, containing 512 square feet and having a standard military configuration 16 feet wide and 32 feet long, can be erected in approximately 10 hours by a 6-person team having minimal building skills. This is much less time, involving much fewer people with much less skill, than is required with existing building systems deployed in disaster areas.

The building of the present invention may be erected on and anchored to an existing concrete slab or other existing foundation at the building site. Alternatively, the shipping container of the present invention may include preassembled floor panels having a finished inner surface faced with fiber cement wall boards. The floor panels may be anchored to the ground at the desired building site, and the building may erected on the floor panels. The building may be fastened and secured on all 4 exterior and interior corners with metal “L” brackets which are through-bolted.

In summary, the preferred building system of the present invention provides the following features and benefits:

1. Simple erection of building components, including modular wall panels, ceiling panels, roof trusses and roof panels, facilitating work by soldiers and others who may have minimal construction training and/or experience.

2. Indefinite lifespan of the building.

3. The entire building system, including components, materials and tools, fits into one shipping container.

4. Rapid erection, multi-purpose use of building.

5. Snow, wind and earthquake resistant.

6. Made of all fire-resistant materials.

7. Will not rot, decay or warp, and is not subject to termites or other insects.

8. Building can be extended infinitely in length via additional containers.

9. Interior walls can easily be added.

10. Complete system uses the above structure and adds standing seam sheeting for exterior walls and root cement fire board for interior wall, 1 hour fire rated steel door.

11. Building site is without construction debris and is ecologically friendly.

12. The building can be rapidly erected at the desired site with minimal need for measuring or cutting materials, and without the use of cranes, forklifts or other lifting devices.

13. The building of the present invention has a universal flexibility in that it can be used as housing, offices, medical clinic, classroom, latrines, mess halls and so forth.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of the preferred building of the invention.

FIG. 2 is a perspective view of the preferred building of the invention next to the container in which all of its components, along with the necessary building materials and tools, were shipped.

FIG. 3 is a top view of the container, absent its top, showing the building components, materials and tools nested therein.

FIG. 4 is a partial, perspective view of the inside of the container depicted in FIG. 3.

FIG. 5 is a perspective view depicting the erection-in-progress of the building walls in accordance with the invention.

FIG. 6 is a side elevational view of the outer surface of a preassembled modular wall panel, covered with insulation.

FIG. 7 is a side elevational view of the finished inner surface of a preassembled modular wall panel.

FIG. 8 is a floor plan view of the building, i.e., a top view of the preferred building of the invention absent its ceiling panels, roof trusses, roof panels and roof cladding.

FIG. 9 is a partial, perspective view depicting the erection of ceiling panels placed on and supported by walls of the building.

FIG. 10 is a partial, perspective view depicting the erection of ceiling panels placed on and supported by building walls, with several roof trusses in place.

FIG. 11 is a partial, perspective view depicting the building walls in place, ceiling panels supported by the building walls, and roof trusses supported by the ceiling panels.

FIG. 12 is a side elevational view of a preassembled modular roof truss in accordance with the preferred embodiment of the invention.

FIG. 13 is a partial, perspective view depicting a preassembled, modular roof panel being lifted in place, after the building walls, ceiling panels and roof trusses have been erected.

FIG. 14 is a top view of a preassembled, modular roof panel in accordance with present invention.

FIG. 15 is a partial, perspective view depicting the placement-in-progress of roof cladding on a roof panel in accordance with the invention.

FIG. 16 is a perspective view of the building of the present invention, nearing completion, with the wall-cladding not yet fully complete.

FIG. 17 is a cross sectional view of the entire, completed building, taken along lines 17-17 of FIG. 8.

FIG. 18 is a plan view of the outer surface of a preassembled, modular ceiling panel without any insulation, showing its framing members.

FIG. 19 is a plan view of the finished inner surface of a preassembled, modular ceiling panel.

FIG. 20 is a perspective, fragmentary view of a building corner in accordance with the invention, showing a set of L-brackets in place, taken from FIG. 2 as shown.

FIG. 21 is a perspective view of a preassembled, modular floor panel is accordance with the invention, with a portion of its wall board cut away for purposes of illustration.

DETAILED DESCRIPTION

FIG. 1 generally depicts the finished building 10 of the present invention in its preferred embodiment. FIG. 2 depicts building 10 adjacent to shipping container 12 of the preferred embodiment of the present invention. Container 12 is large enough to accommodate, and is used to transport, all of the building components, supplies and tools needed to construct the finished building 10 at the desired building site.

Container 12 is preferably a 20-foot long metal container which complies with the specifications and standards set by the International Organization for Standardization, commonly referred to as a 20-foot ISO shipping container. Container 12 can be shipped by any number of transportation means, including truck, train, boat, and air transport.

FIGS. 3 and 4 generally depict the building components, supplies and tools loaded and nested inside container 12 in the preferred embodiment of the invention. Container doors 14 are closed during transport of the loaded container 12 to the desired building site. Doors 14 are reopened when the container 12 has reached the desired building location, so that the building components, supplies and tools can be unloaded and the building can be constructed.

The building components preferably include a plurality of preassembled, modular wall panels 20, as best depicted in FIGS. 5, 6 and 7. In the preferred embodiment of the invention, each wall panel 20 is approximately 16 feet long and 8 feet high, more preferably 16′2″ by 8′0″, and fits comfortably inside a 20-foot ISO container 12 as shown in FIGS. 3 and 4.

As depicted in FIG. 7, each wall panel 20 preferably includes 4 full sheets of fiber cement wall board 22, each sheet 22 preferably being 4 feet wide, 8 feet long and 0.236 inches thick. Each wall panel 20 is preferably preassembled, prior to being loaded and shipped in container 12, by affixing 4 adjacent sheets 22 to wall framing members 24, as depicted in FIG. 6. Wall framing members 24 are preferably comprised of metal studs having a channel-shaped profile, said studs preferably having the following dimensions: metal thickness of 0.75 mm; stud width of 1.61 inches (41 mm); and stud depth of 3.50 inches (89 mm)

In the preferred embodiment of the invention, each sheet of wall board 22 is attached to framing members 24 by using clips 100, commonly referred to as “omega clips.” Omega clips 100 have a profile somewhat similar to the Greek capital letter omega, said profile providing a channel which accommodates the insertion therein of an edge portion of sheet 22. Also known sometimes as “hat omega” clips because their profile resembles that of a top hat, omega clips 100 may be obtained through material suppliers such as BAATCO (Burj Al Aaj Building Materials) located in Dubai. The clip profile includes a flange which extends parallel to sheet 22. The flange can be provided with holes to accommodate screws passing therethrough, said screws being used to attach the omega clips 100 to their supporting frame members 24. As shown in FIG. 7, omega clips 100 are preferably used along the perimeter edges of sheets 22 which abut other sheets 22, but not along the perimeter edges which form an angle with other surfaces such as the floor, the ceiling or an intersecting wall.

As preassembled, each wall panel 20 has a finished inner surface 26 and an outer surface 28, as best depicted in FIGS. 7 and 6. Wall framing members 24 are preferably provided with openings 23 along their lengths, as depicted in FIG. 5, to accommodate the passage therethrough of electrical wiring, plumbing, telecommunication cables and other conduits that may be run along the outer surface 28 of the wall panel 20.

The outer surface 28 of preassembled wall panel 20 is preferably covered with wall insulation 30, as shown in FIG. 6. A preassembled wall panel 20 may also be provided with one or more openings through one or more sheets 22 of wall board, suitable to accommodate building accessories such as air conditioners, windows, doors and electrical outlets. For example, as best depicted in FIGS. 5-7, a wall panel 20 may have an opening 27 to accommodate an air conditioner, an opening 29 to accommodate a door, and openings 25 to accommodate electrical outlets.

Each preassembled wall panel 20 preferably has a total weight of approximately 300 pounds, sufficiently light to be carried by 6 workers without the need for using a crane or other lifting device, as such devices are generally unavailable in remote locations where the present invention may be deployed.

In the preferred embodiment of the invention, the loaded container 12 includes a total of 6 wall panels 20 which are used to form the walls of building 10, as shown in FIG. 5, as follows: one 16-foot long wall panel is used for the front wall 32 of the building; another 16-foot long wall panel is used for the rear wall 34 of the building; two other 16-foot long wall panels, placed side-by-side, are used for the left side wall 36 of the building; and two other 16-foot long wall panels, placed side-by-side, are used for the right side wall 38 of the building. As so configured in the preferred embodiment of the invention, building 10 has a rectangular footprint measuring 16 feet wide and 32 feet long, which is the standard size and configuration favored by the U.S. military, and can be used for buildings such as barracks, offices, latrines, and mess halls.

It is understood that building 10 of the present invention is not limited to a 16-foot by 32-foot rectangular configuration. For example, each of the front, rear and side walls of building 10 may include any number of wall panels 20, placed side-by-side so as to form a building having a desired width and length.

When the loaded container 12 arrives at the desired building site, the preassembled wall panels 20 may be unloaded from the container by soldiers or other workers, who carry the wall panels to the site where the building is to be erected. The bottom of each wall panel is placed on top of and is supported by a suitable foundation for the building, for example an existing concrete slab. Alternatively, as described in further detail later below, the wall panels 20 may be placed on and supported by preassembled modular floor panels 110, depicted in FIG. 21, which may be shipped in and with container 12.

FIG. 5 depicts a typical wall erection for the preferred building in accordance with the present invention. Wall panels 20 are erected by standing them up straight, with each of the inner surfaces 26 facing and forming the building interior. As shown in FIG. 5, rear wall 34 and right side wall 38 have already been stood upright. To keep them standing upright during the construction process, rear wall 34 and right side wall 38 are preferably fastened together along their adjoining edges by the use of suitable fastening means such as screws, which are sometimes referred to in the industry as “grabber” screws (hereinafter “screws”). Such fastening means are among the building components transported in container 12 of the present invention.

FIG. 5 also shows the left side wall 36 in the process of being stood up erect by workers. After the left side wall 36 is stood erect, the adjoining edges of the left side wall 36 and the rear wall 34 may be fastened together with suitable fastening means such as screws.

The front wall 32, shown in FIG. 5 in the supine position, is similarly stood up like the other walls. The adjoining edges of the erect front wall 32 and the erect side walls 36 and 38 may be fastened together with suitable fastening means such as screws, similar to the manner in which the adjoining edges of the rear wall 34 and the side walls 36 and 38 may be fastened together.

The perimeter of the building is established once all the wall panels shown in FIG. 5 have been stood erect. This can be accomplished in the preferred embodiment of the present invention in approximately 2 hours by 6 workers, without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device. If desired, interior wall panels may be loaded and shipped with container 12 to the building site, where they may be installed within the building interior to create interior spaces of various sizes and shapes. For example, an interior wall panel 8 feet high and 16 feet in length, with both sides finished with fiber cement wall board and with an opening to accommodate an inner door, may be used in the middle of the building to create 2 interior offices within the building, each office measuring 16 feet by 16 feet.

The building components of the preferred embodiment of the invention also include a plurality of preassembled, modular ceiling panels 40, as best depicted in FIGS. 9, 10, 18 and 19, for use in constructing a ceiling for building 10. In the preferred embodiment of the invention, each ceiling panel 40 measures approximately 16.75 feet long and 4 feet wide, more preferably 16′9.26″ by 4′0.55″, and fits comfortably inside a 20-foot ISO container 12 as shown in FIG. 4.

As best depicted in FIG. 9, each ceiling panel 40 preferably includes 2 full sheets of fiber cement wall board 42, each sheet 42 preferably being 4 feet wide, 8 feet long and 0.236 inches thick. Each ceiling panel 40 is preferably preassembled, prior to being loaded and shipped in container 12, by affixing 2 adjacent sheets 42 to ceiling framing members 44, depicted in FIG. 18. Ceiling framing members 44 are preferably comprised of metal studs having a channel-shaped profile, said studs preferably having the following dimensions: metal thickness of 0.75 mm; stud width of 1.61 inches (41 mm); and stud depth of 3.50 inches (89 mm)

In the preferred embodiment of the invention, each sheet of wall board 42 is attached to framing members 44 by use of omega clips 100, similar to the way that each sheet of wall board 22 is attached to framing members 22 as described above. Omega clips 100 are preferably used along the perimeter edges of sheets 42 which abut other sheets 42, but not along the perimeter edges which form an angle with other surfaces such as an intersecting wall.

As preassembled, each ceiling panel 40 has a finished inner surface 46 and an outer surface 48. Ceiling framing members 44 may be provided with openings along their lengths to accommodate the passage therethrough of electrical wiring, plumbing, telecommunication cables and other conduits that may be run along the outer surface 48 of ceiling panel 40. The outer surface 48 of preassembled ceiling panel 40 is preferably covered with ceiling insulation 50, as depicted in FIG. 11.

A preassembled ceiling panel 40 may also be provided with one or more openings through one or more sheets 42 of wall board, suitable to accommodate building accessories such as light fixtures and electrical outlets. Each preassembled ceiling panel 40 preferably has a total weight of approximately 165 pounds, sufficiently light to be carried by 4 workers without the need for using a crane or other lifting device, as such devices are generally unavailable in remote locations where the present invention may be deployed.

In the preferred embodiment of the invention, the loaded container 12 includes a total of 8 ceiling panels 40, each ceiling panel 40 measuring 4 feet wide by 16 feet long, which are used to form the ceiling of building 10 having a rectangular footprint measuring 16 feet wide and 32 feet long.

It is understood that building 10 of the present invention is not necessarily limited to a 16 foot wide by 32 foot long rectangular configuration. Accordingly, if building 10 for example has a width of 20 feet rather than 16 feet wide, the ceiling panels 40 will each have a corresponding length of at least approximately 20 feet, sufficient to span the distance between and rest upon the side walls 36 and 38 of the building.

The preassembled ceiling panels 40 may be unloaded from container 12 at the building site by soldiers or other workers who carry the ceiling panels 40 from container 12 to the building site. After the building walls have been erected, the ceiling panels 40 are then lifted in place by the workers, such that in the constructed building each ceiling panel 40 spans the distance between and is supported by the side walls 36 and 38, as depicted in FIGS. 9 and 10, with the finished inner surface 46 of each ceiling panel 40 facing downward and toward the inside of the building. In the preferred embodiment of the invention, wherein building 10 has a rectangular footprint measuring 16 feet wide and 32 feet long, 8 ceiling panels 40 placed side-by-side span the 32 foot distance between the front and rear walls 32 and 34 of the building.

Adjacent ceiling panels 40 are preferably fastened together along their adjoining edges by the use of suitable fastening means such as screws. The ceiling panels 40 are also preferably fastened to the side walls 36 and 38 and (for the ceiling panels adjacent to the front and rear walls) to the front and rear walls 32 and 34 by suitable fastening means such as screws. The fastening means for ceiling panels 40 are among the building components loaded and transported in container 12 of the present invention.

The 8 ceiling panels 40 in the preferred embodiment of the invention can be installed, i.e., placed and fastened in their proper position in the building as constructed, in approximately 1 hour by 6 workers without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device. The building components of the preferred embodiment of the invention also include a plurality of preassembled, modular roof trusses 60. Each roof truss 60 is triangular shaped in the preferred embodiment, having 2 ends 61 and an apex 63, as shown in FIGS. 11 and 12.

In the preferred embodiment of the invention, as depicted in FIG. 12, each roof truss 60 measures approximately 16.5 feet long, more preferably 16′9.26″, from one end to the other, and is approximately 2.25 feet high, more preferably 28.71″, and fits comfortably loaded inside a 20-foot ISO container 12, nested on top of the ceiling panels 40 as shown in FIGS. 3 and 4.

Each roof truss 60 is preferably preassembled, prior to being loaded and shipped in container 12, and is comprised a plurality of roof truss framing members 64. Roof truss framing members 64 are preferably comprised of metal studs having a channel-shaped profile, said studs preferably having the following dimensions: metal thickness of 0.75 mm; stud width of 1.61inches (41 mm);

and stud depth of 3.50 inches (89 mm)

Each preassembled roof truss 60 preferably has a total weight of approximately 42 pounds, sufficiently light to be carried by 2 workers without the need for using a crane or other lifting device, as such devices are generally unavailable in remote locations where the present invention may be deployed.

In the preferred embodiment of the invention, the loaded container 12 includes a total of 9 roof trusses 60. Roof trusses 60 may be unloaded from container 12 at the desired building site by soldiers or other workers who carry the roof trusses 60 from container 12 to the building site. After the building walls and ceiling panels have been erected, the roof trusses 60 are then lifted in place by the workers, such that the trusses rest upon and are supported by the ceiling panels 40, as shown in FIGS. 10 and 11.

When used in erecting the preferred building of the present invention, the roof trusses 60 are spaced 4 feet apart from each other so as to span the 32 foot distance between the front wall 32 and the rear wall 34 of building 10.

It is understood that building 10 of the present invention is not necessarily limited to a 16 foot wide by 32 foot long rectangular configuration. Accordingly, if building 10 for example has a width of 20 feet rather than 16 feet, the roof trusses 60 will have a corresponding length of 20 feet, sufficient to span the distance between side walls 36 and 38 of the building.

Similarly, it is understood that the building of the present invention is not limited to the preferred roof pitch shown in FIG. 17, which is approximately 1-rise-to-3.5-run, more preferably 14°. The desired roof pitch may be attained by providing each roof truss 60 with an apex 63 extending a desired distance above roof truss horizontal framing member 64h.

Roof trusses 60 are preferably fastened to supporting ceiling and wall panels by use of suitable fastening means such as screws, which are among the building components loaded and transported in container 12 of the present invention.

The 9 roof trusses 60 in the preferred embodiment of the invention can be installed, i.e., placed and fastened in their proper position in the building as constructed, in approximately 1 hour by 4 workers without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device.

The building components of the preferred embodiment of the invention also include a plurality of preassembled, modular roof panels 70, as depicted in FIGS. 13, 14 and 15. In the preferred embodiment of the invention, each roof panel 70 is approximately 8 feet wide and 9½ feet long, more preferably 8′1.16″ by 9′7.23″, and fits comfortably inside a 20-foot ISO container 12 as shown in FIGS. 3 and 4.

Each roof panel 70 is preferably preassembled prior to being loaded and shipped in container 12, and is comprised of a plurality of roof panel framing members 74. Roof panel framing members 74 are preferably comprised of metal studs having a channel-shaped profile, said studs preferably having the following dimensions: metal thickness of 0.75 mm; stud width of 1.61 inches (41 mm); and stud depth of 3.50 inches (89 mm)

Each preassembled roof panel 70 preferably has a total weight of approximately 68 pounds, sufficiently light to be carried by 2 workers without the need for using a crane or other lifting device, as such devices are generally unavailable in remote locations where the present invention may be deployed.

In the preferred embodiment of the invention, the loaded container 12 includes a total of 8 roof panels 70. Roof panels 70 may be unloaded from container 12 at the desired building site by soldiers or other workers who carry roof panels 70 from container 12 to the building site. After the wall panels 20, ceiling panels 40 and roof trusses 60 have been erected, the roof panels 70 are then lifted in place by the workers, such that the roof panels 70 rest upon and are supported by roof trusses 60. When used in erecting the preferred building of the present invention, each roof panel 70 rests upon and is supported by 3 roof trusses 60, as shown in FIGS. 13 and 15.

In the preferred embodiment of the invention, wherein building 10 has a rectangular footprint measuring 16 feet wide by 32 feet long, with a roof pitch of 14° as shown in FIG. 17, each roofing panel 70 is 8 feet and 1.16 inches wide, and 9 feet and 7.23 inches long.

It is understood that building 10 of the present invention is not necessarily limited to a 16 foot wide by 32 foot long rectangular configuration having the roof pitch shown in FIG. 17. Accordingly, if building 10 for example has a width other than 16 feet and/or a roof pitch other than as shown in FIG. 17, each of the roof panels 70 will have a corresponding length sufficient to extend from at least the apex 63 to an end 61 of a supporting roof truss 60.

Each roof panel 70 is preferably fastened to supporting roof trusses 60 by use of suitable fastening means such as screws, which are among the building components loaded and transported in container 12 of the present invention.

The 8 roof panels 70 in the preferred embodiment of the invention can be installed, i.e., placed and fastened in their proper position in the building as constructed, in approximately 0.50 hours by 4 workers without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device.

In the preferred embodiment of the invention, the preferred preassembly of metal studs used as framing member 24, 44, 64 and 74 and 114 includes the use of a profile-forming machine from the Frame Master Company of Auckland, New Zealand. A roll of flat metal stock material, preferably high tensile steel, is passed through the machine, said flat metal stock having a preferred width of 181 mm and a preferred thickness of 0.75 mm. The machine has a series of rollers and punches that form the flat metal stock passing therethrough into a framing member having a “c” or channel profile that is preferably 89 mm wide and 41 mm deep, with a 5 mm wide lip formed on the inside to each side of the channel. The machine also punches out holes in the framing members being formed, said holes accommodating screw connectors which can be passed therethrough to facilitate attachment of the framing members to each other and to other components of the building as it is being erected.

The machine is also used to punch holes, preferably 25 mm in size, out of the central 89 mm section of the stud, in appropriate locations to accommodate the passage therethrough of electrical wires, telecommunication cables and the like, as for example openings 23 as shown in FIG. 5. The 5 mm lips to the inside of the c-shaped channel are notched to permit the insertion and joining of channel sections.

The building components of the preferred embodiment of the invention further include roof cladding 80 and wall cladding 90 which are used, respectively, to face the roof and walls of building 10. In the preferred embodiment of the invention, the roof cladding 80 and wall cladding 90 are shipped in container 12 as pre-cut sheets, which can be off-loaded at the desired building site and rapidly attached to the building. As shown in FIGS. 3 and 4, the roof and wall cladding 80 and 90 is preferably shipped nested in sheets between roof panels 70 and ceiling panels 40.

In the preferred embodiment of the invention, the sheets of roof and wall cladding (sometimes referred to in the industry as “standing seam material”) are preassembled from flat galvanized metal stock prior to being loaded into container 12. The preferred preassembly of the roof and wall cladding includes the use of a profile-forming machine from New Tech Machinery Corp. of Denver, Colo. A roll of flat metal stock material is passed through the machine, which forms a “profile” running the length of the stock material, as for example the v-shaped profile 140 depicted in FIG. 20. The profile gives the material desired rigidity against bending, and the material is cut into desired sheet lengths. In addition, the profile-forming machine forms interlocking seams along both edges of the stock material, running along its length. Said interlocking seams provide a means for clipping or fastening together adjoining sheets of cladding.

As shown in FIG. 15, sheets of roof cladding 82 are placed on top of roof panels 70. In the preferred embodiment of the invention, where building 10 has a footprint measuring 16 feet wide and 32 feet long, with a roof pitch of approximately 1-rise-to-3.5-run, more preferably 14°, each sheet 82 of roof cladding 80 is preferably 500 mm wide and is 9′8″ feet long, and the loaded container 12 includes a total of 40 sheets 82 of roof cladding 80.

It is understood that building 10 of the present invention is not necessarily limited to a 16 foot wide by 32 foot long rectangular configuration having the roof pitch shown in FIG. 17. Accordingly, if building 10 for example has a width other than 16 feet and/or a roof pitch other than as shown in FIG. 17, each sheet 82 of roof cladding 80 will have a corresponding length sufficient to extend from at least the roof apex to an end of a supporting roof panel 70.

Adjacent sheets 82 of roof cladding 80 are preferably fastened together along their adjoining edges by the use of suitable fastening means such as interlocking seams running longitudinally along the edges of the sheets 82. The roof cladding is fastened to the roof panels 70 of building 10 by suitable fastening means such as screws. The fastening means for roof cladding 80 are among the building components loaded and transported in container 12 of the present invention.

Each pre-cut sheet 82 of roof cladding 80 in the preferred embodiment of the invention is manufactured from flat metal stock which is approximately 0.50 mm thick. Each sheet 82 has a weight of approximately 15 pounds, sufficiently light to be carried by 1 worker and placed on top its supporting roof panel 70 without the need for any crane or other lifting device.

In the preferred embodiment of the invention, the forty pre-cut sheets 82 of roof cladding 80 can be installed, i.e., placed and fastened in their proper position in the building as constructed, in approximately 1 hour by 2 workers without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device.

As shown in FIG. 16, wall cladding 90 is placed over the wall panels 20. Wall cladding 90 includes sheets of side wall cladding 92 and sheets of front and rear wall cladding 94. In the preferred embodiment of the invention, where building 10 is 32 feet long, with a side wall height of 8 feet, each sheet of side wall cladding 92 is approximately 500 mm wide and is 8 feet long, and the loaded container 12 includes a total of at least forty sheets of side wall cladding 92. The last sheets of side wall cladding 92, where the side walls meet the rear wall, are each precut longitudinally so as to provide a cladding sheet width of approximately 4 inches to fit the remaining portions of side wall to be covered in the preferred building of the invention. Some sheets of side wall cladding 92 are also precut as needed to accommodate wall openings for building accessories such as air conditioners 141, as shown in FIG. 1.

It is understood that building 10 of the present invention is not necessarily limited to a building length of 32 feet, or a side wall height of 8 feet. Accordingly, if building 10 for example has a length other than 32 feet and/or a side wall height other than as shown in FIG. 17, each sheet of side wall cladding 92 will have a corresponding length sufficient to cover the entire side wall, from top to bottom, with a sufficient number of side wall sheets to completely cover the side walls from the front to the rear of the building.

In the preferred embodiment of the invention, where building 10 is 16 feet wide with the roof pitch shown in FIG. 17, each sheet of front and rear wall cladding 94 will be in the shape of a trapezoid, as best shown in FIG. 16. Each sheet 94 is approximately 500 mm wide, with varying lengths sufficient to cover the front and rear walls from top to bottom, as shown in FIG. 16. The last sheets of front and rear wall cladding 94, where the front and rear walls meet the side walls, are precut longitudinally so as to provide a cladding sheet width of approximately 16 inches to fit the remaining portions of the front and back walls to be covered in the preferred building of the invention. Some sheets of front and rear wall cladding 94 are also precut as needed to accommodate wall openings for building accessories such as a door 143 and vent 145, as shown in FIG. 2.

It is understood that building 10 of the present invention is not necessarily limited to a 16 foot wide by 32 foot long rectangular configuration having the roof pitch shown in FIG. 17. Accordingly, if building 10 for example has a width other than 16 feet and/or a roof pitch other than as shown in FIG. 17, each sheet of front and rear wall cladding 94 will have a corresponding length sufficient to cover the front and rear walls from top to bottom, with enough such sheets 94 loaded into container 12 to completely cover the front and rear walls of the building. Adjacent sheets of wall cladding 90 are preferably fastened together along their adjoining edges by the use of suitable fastening means such as interlocking seams running longitudinally along the edges of sheets 92 and 94. The wall cladding is fastened to wall panels 20 of building 10 by suitable fastening means such as screws. The fastening means for the wall cladding 90 are among the building components loaded and transported in container 12 of the present invention.

Each pre-cut sheet of wall cladding 90 in the preferred embodiment of the invention is manufactured from flat metal stock which is approximately 0.5 mm thick. Each sheet of wall cladding 90 has a weight ranging from 15 to 20 pounds, sufficiently light to be carried by workers and placed over the wall panels 20 without the need for any crane or other lifting device.

All the wall cladding can be installed, i.e., placed and fastened in their proper position in the building as constructed, in approximately 2 hours by 4 workers, without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device.

Four pieces of corner flashing 147, shown in FIG. 20, are shipped in and with the container 12, each piece of corner flashing being long enough, approximately 8 feet in the preferred embodiment, to cover each of the building corners. The corner flashing pieces may be attached to the building via any suitable means, such as metal screws.

In the embodiment of the present invention wherein preassembled modular floor panels are shipped in and with container 12, each such floor panel 110 preferably includes 2 full sheets 112 of fiber cement wall board, as shown in FIG. 21. Each sheet 112 is preferably 4 feet wide, 8 feet long and 0.750 inches thick. As shown in FIG. 21, each floor panel 110 may be preassembled, prior to being loaded and shipped in container 12, by affixing 2 adjacent sheets 112 to floor framing members 114, such that each preassembled floor panel 110 is approximately 16 feet long by 4 feet wide. Floor framing members 114 are preferably comprised of metal studs having a channel-shaped profile, said studs preferably having the following dimensions: metal thickness of 0.75 mm; stud width of 1.61 inches (41 mm); and stud depth of 3.50 inches (89 mm) Sheets 112 are preferably attached to framing members 114 by fastening means such as screws, which are inserted through sheet 112 and into a supporting framing member 114 below.

In the alternative, the floor panels 110 may be loaded and shipped in container 12 without first attaching sheets 112 to floor framing members 114. This alternative may be especially desirable due to weight lifting considerations, as each sheet 112 weighs approximately 154 pounds. In said alternative, when the container arrives at the desired building site and is unloaded, the preassembled floor framing members 114 may be carried to and placed into a desired position at the building site, and then sheets 112 may be fastened to them as described above.

As preassembled, each floor panel 110 has a finished inner surface 116 and an outer surface 118. The finished inner surface 116 may be covered with vinyl, linoleum or some other suitable flooring material glued or otherwise attached to the fiber cement wall board. The outer surface 118 of preassembled floor panel 110 is preferably covered with floor insulation 120.

Each preassembled floor panel 110, with two adjacent sheets 112 fixed in place, has a total weight of approximately 373 pounds, sufficiently light to be carried by 6 workers without the need for using a crane or other lifting device, as such devices are generally unavailable in remote locations where the present invention may be deployed. If an embodiment is desired with lighter carrying components for floor panels 110, then the floor panel may be shipped and erected in accordance with the alternative described above, where each sheet 112 weighs approximately 154 pounds and can be carried by 4 workers, and the preassembled floor framing members of each floor panel 110 have a total weight of approximately 65 pounds and can be carried by 2 workers.

In the embodiment of the present invention wherein preassembled floor panels 110 are shipped in and with container 12, the loaded container 12 includes a total of 8 floor panels 110, each floor panel 110 measuring 4 feet wide by 16 feet long, which are used to form the floor of building 10 having a rectangular footprint measuring 16 feet wide and 32 feet long.

It is understood that building 10 of the present invention is not necessarily limited to a 16 foot wide by 32 foot long rectangular configuration. Accordingly, if building 10 for example has a width of 20 feet rather than 16 feet wide, the floor panels 110 will each have a corresponding length of 20 feet, sufficient to span the distance between the side walls 36 and 38 of the building.

The floor panels 110 or their component parts may be unloaded from container 12 at the building site by soldiers or other workers as described in the alternatives above, who carry them from container 12 to the building site. The floor panels 110 are erected at the desired building site by placing them into position on the ground, preferably on supporting ground beams which have already been positioned there, with the finished inner surface 116 of each floor panel 110 facing upward.

Ground beams may be 16 feet long, extending the length of the floor panel, with adjacent ground beams spaced 18 inches apart, from centerline to centerline. The ground beams sit directly on the ground at the desired building site, which has preferably been prepared by clearing away ground debris and otherwise leveling the ground.

The ground beams may be joined together by short, intermediate braces which preferably run perpendicular to the ground beams and prevent individual ground beams from overturning or otherwise moving with respect to each other. Each ground beam preferably has a cross section which is 89 mm wide and 250 mm high.

Ground beams may be assembled by fastening together a multitude of metal studs having the same channel-shaped profile, metal thickness, stud width and stud depth as floor framing members 114, with each stud preferably 250 mm long. Such studs, when stood on end and fastened together, can be used to form a ground beam which is 250 mm high and 89 mm wide, with a sufficient number of studs fastened together to form a ground beam 16 feet long. The open ends of the studs, top and bottom, may be faced with c-shaped metal covers, each preferably 16 feet long and 89 mm wide. Such ground beams may be shipped in and with the container.

Suitable ground anchors, preferably the ¾ inch by 30 inch “Iron Root” anchor with stabilizing disc available from Tie Down Engineering of Atlanta, Georgia, may be shipped in and with the container 12, said anchors being used to secure the floor panels and ground beams to the supporting ground below. In the preferred embodiment of the invention, wherein building 10 has a rectangular footprint measuring 16 feet wide and 32 feet long, 8 floor panels 110 placed side-by-side span the 32 foot distance between the front and rear walls 32 and 34 of the building, establishing the footprint of the building.

Adjacent floor panels 110 are preferably fastened together along their adjoining edges by the use of suitable fastening means such as screws. Side walls 36 and 38 and front and rear walls 32 and 34 are set in place on the 32 ft.×16 ft. perimeter edge of the supporting floor panels 110. The walls are preferably fastened to the floor panels by fastening means such as screws, which are among the building components loaded and transported in container 12 of the present invention.

In the preferred embodiment of the invention, the 8 floor panels 110 can be installed, i.e., fastened together and anchored to the ground at the desired building site, in approximately 0.50 hours by 6 workers without the need for any measuring or cutting of any materials, and without the need for any crane or other lifting device.

In the preferred embodiment of the invention, the building includes, on all four exterior and interior corners, upper and lower sets of metal “L” brackets 130. As shown in FIG. 20, each set 130 of “L” brackets includes an outside bracket 132 and a corresponding inside bracket 134. Each “L” bracket is preferably made of metal which is approximately 5 mm thick and 2.5 inches high, with each leg of the bracket extending horizontally about 8 inches. Outside bracket 132 and inside bracket 134 of each set 130 are fastened together, preferably through the use of carriage bolts 135. Carriage bolts 135 pass completely through the building wall, from wall cladding 90 to the finished inner surface 26 of wall panel 20, as shown in FIG. 20. An interior corner trim piece 136 may also be provided at each interior corner of the building. In the preferred embodiment of the invention, eight sets of “L” brackets, 16 carriage bolts, and 4 interior corner trim pieces are loaded and shipped in container 12.

The preferred embodiment of the present invention also includes additional building components, supplies and tools which are loaded in the container and transported to the desired building site, including the following: window air conditioners 141; building door 143; attic vent 145; lighting fixtures 149; roof ridge cap 151; soffit 153; and facia 155; box 157 of fabricating tools including screwdrivers and screws; boxes 159 containing electrical items including electric outlets, switches, wiring, wire nuts and electric tape; and rolls 161 of fiberglass insulation, all of which may be used for and with building 10 in accordance with well-established construction practice.

When the building of the present invention has been constructed at the desired building site, a local source of electric power may be used to power the building.

PARTS LIST
PART NO. DESCRIPTION
10       Finished building of the present invention
12       Shipping container
14       Doors of shipping container 12
20       Preassembled, modular wall panel
22       Sheet of wall board of wall panel
23       Opening in framing member 24
24       Wall framing member
25       Opening in wall panel 20 to accommodate an electrical
         outlet
26       Finished inner surface of wall panel 20
27       Opening in wall panel 20 to accommodate an air
         conditioner
28       Outer surface of wall panel 20
29       Opening in wall panel 20 to accommodate a door
30       Wall insulation
32       Front wall of building
34       Rear wall of building
36       Left side wall of building
38       Right side wall of building
40       Preassembled, modular ceiling panel
42       Sheet of wall board of ceiling panel 40
44       Ceiling framing member
46       Finished inner surface of ceiling panel 40
48       Outer surface of ceiling panel 40
50       Ceiling insulation
60       Preassembled, modular roof truss
61       End of roof truss
63       Apex of roof truss
64       Roof truss framing member
64h      Roof truss horizontal framing member
70       Preassembled, modular roof panel
74       Roof panel framing member
80       Roof cladding
82       Sheet of roof cladding
90       Wall cladding
92       Sheet of side wall cladding
94       Sheet of front and rear wall cladding
100      Omega clip
110      Preassembled modular floor panel
112      Sheet of wall board of floor panel 110
114      Floor framing member
116      Finished inner surface of floor panel 110
118      Outer surface of floor panel 110
120      Floor insulation
130      “L” bracket set
132      Outside “L” bracket
134      Inside “L” bracket
135      Carriage bolt
136      Interior corner trim
140      Profile in cladding
141      Air conditioner
143      Door
145      Vent
147      Corner flashing
149      Lighting fixture
151      Roof ridge cap
153      Soffit
155      Facia
157      Box of fabricating tools
159      Box of electrical items
161      Roll of insulation

Claims

1. A system for the shipment of building components to a desired building site, and the erection of a building at that site, the system comprising:

a. a shipping container housing all the components of the system during transit to the building site;

b. preassembled side, front and rear wall panels for use in constructing side, front and rear walls for the building, said wall panels configured to be fastened together along their adjoining edges when erected at the building site, wherein each wall panel has an inner and an outer surface, and wherein each wall panel when erected at the building site is configured to be supported by a suitable foundation;

c. preassembled ceiling panels for use in constructing a ceiling for the building, wherein each ceiling panel has an inner and an outer surface, and wherein each ceiling panel when erected at the building site is configured to span the distance between, and be supported by, the side walls of the building;

d. preassembled roof trusses configured to rest upon and be supported by the ceiling panels, said roof trusses when erected at the building site configured to extend the distance between the side walls of the building;

e. preassembled roof panels which, when erected at the building site, are configured to rest upon and be supported by roof trusses;

f. precut sheets of roof cladding which, when erected at the building site, are configured to be attached to and supported by roof panels; and

g. precut sheets of wall cladding which, when erected at the building site, are configured to be attached to and supported by wall panels.

2. The system of claim 1 wherein the preassembled wall panels, ceiling panels, roof trusses, roof panels, roof cladding sheets and wall cladding sheets are each sized so that no measuring or cutting of the same is required during the construction of the building at the desired site.

3. The system of claim 2 wherein:

a. the loaded container further comprises 6 wall panels and 8 ceiling panels;

b. each wall panel comprises four adjacent sheets of wall board, each wall board measuring 4 feet wide and 8 feet high, and wherein each wall panel is approximately 16 feet long and 8 feet high; and

c. each ceiling panel comprises 2 adjacent sheets of wall board, each wall board measuring 4 feet wide and 8 feet long, and wherein each ceiling panel is approximately 16.75 feet long and 4 feet wide.

4. The system of claim 2 wherein each building component as loaded in the container weighs no more than 380 pounds.

5. The system of claim 2 wherein each building component as loaded in the container can be carried by no more than 6 workers without the need for using a lifting device.

6. The system of claim 2 wherein the container is a 20 foot long metal container which complies with the specifications and standards set by the International Organization for Standardization.

7. The system of claim 2 wherein:

a. the building as erected has 4 corners;

b. each corner includes upper and lower sets of brackets; and

c. each set of brackets is comprised of an outside bracket and an inside bracket which are configured to be fastened together by bolts configured to pass through the building wall.

8. A system for the shipment of building components to a desired building site and the erection of a building at that site from those components without the need for any on-site measuring or cutting of components, the building having a rectangular footprint 16 feet wide and 32 feet long, the system comprising:

a. a 20-foot long shipping container housing the components of the system during transit to the site where the building is to be erected, wherein the components comprise the following:

b. preassembled, modular wall panels for use in constructing walls for the building, wherein the wall panels as shipped comprise a front wall panel and a rear wall panel, each measuring approximately 16 feet long and 8 feet high; 2 left side wall panels, each measuring approximately 16 feet long and 8 feet high; and 2 right side wall panels, each measuring approximately 16 feet long and 8 feet high; wherein each wall panel when erected at the building site is configured to be supported by a suitable foundation; wherein each wall panel as shipped is comprised of 4 full sheets of wall board, each sheet being 4 feet wide and 8 feet long, which are affixed to wall framing members; and wherein each wall panel as shipped has a finished inner surface, an outer surface and insulation covering said outer surface;

c. preassembled, modular ceiling panels for use in constructing a ceiling for the building, wherein each ceiling panel is approximately 16.75 feet in length such that in the constructed building each ceiling panel is configured to span the distance between and be supported by the left and right side walls; wherein each ceiling panel is approximately 4 feet wide such that 8 ceiling panels placed side-by-side will span the distance between the front and rear walls; wherein each ceiling panel as shipped is comprised of 2 full sheets of wall board, each sheet being 4 feet wide and 8 feet long, which are affixed to ceiling framing members; and wherein each ceiling panel as shipped has a finished inner surface, an outer surface, and insulation covering said outer surface;

d. preassembled, modular roof trusses for use in supporting roof panels for the building, wherein each roof truss is triangularly shaped and has 2 ends, a horizontal framing member extending between the 2 ends and an apex extending above said horizontal framing member; wherein each truss measures approximately 16.75 feet long from end to end such that when erected at the building site each truss is configured to extend the distance between the left and right side walls, said roof trusses configured to rest upon and be supported by ceiling panels; and wherein a total of 9 trusses spaced 4 feet apart from each other are configured to extend the distance between the front and rear walls when erected at the building site;

e. preassembled, modular roof panels configured to be supported by roof trusses when erected at the building site, wherein each erected roof panel has a length sufficient to extend from at least the apex to an end of its supporting roof trusses, and wherein 4 equal-sized roof panels placed side-by-side are configured to extend the distance between the front and rear walls;

f. pre-cut sheets of roof cladding configured to be attached to and supported by the roof panels when erected at the building site, wherein each sheet of roof cladding is at least as long as its supporting roof panel, and wherein adjacent sheets of roof cladding are configured to cover the entire roof of the building; and

g. pre-cut sheets of wall cladding configured to be attached to the outer surfaces of the wall panels when erected at the building site, and wherein adjacent sheets of wall cladding are configured to cover the entire walls except for door openings, air conditioner openings and other wall openings which accommodate other building accessories.

9. The system of claim 8 further comprising building tools and supplies necessary for assembling the building components into a finished building, said building tools and supplies loaded in and shipped with the container, said building tools and supplies comprising screws, screwdrivers, wiring, electrical outlets, switches, light fixtures and insulation.

10. The system of claim 8 wherein no other building components, tools and supplies are necessary to erect a finished building except those that are loaded in and shipped with the container.

11. A system for the shipment of building components to a desired building site, and the erection of a building at that site from those components, the system comprising:

a. a shipping container housing all the components of the system during transit to the building site;

b. preassembled side, front and rear wall panels for use in constructing side, front and rear walls for the building, said wall panels fastened together along their adjoining edges when erected at the building site; wherein each wall panel has an inner and an outer surface, and wherein each wall panel when erected at the building site is supported by a suitable foundation;

c. preassembled ceiling panels for use in constructing a ceiling for the building, wherein each ceiling panel has an inner and an outer surface, and wherein each ceiling panel when erected at the building site spans the distance between, and is supported by, the side walls of the building;

d. preassembled roof trusses which, when erected at the building site, rest upon and are supported by the ceiling panels and extend the distance between the side walls of the building;

e. preassembled roof panels which, when erected at the building site, rest upon and are supported by roof trusses;

f. precut sheets of roof cladding which, when erected at the building site, are attached to and supported by roof panels; and

g. precut sheets of wall cladding which, when erected at the building site, are attached to and supported by wall panels.

12. The system of claim 11 wherein:

a. the building as erected at the desired site has 4 corners;

b. each corner includes upper and lower sets of brackets; and

c. each set of brackets is fastened together by bolts passing through the building wall.

13. The system of claim 11 further comprising preassembled floor panels which, when erected at the building site, are anchored to the ground and provide support for the walls which are erected thereon.

14. The system of claim 13 wherein each floor panel comprises 2 adjacent sheets of wall board, each wall board measuring 4 feet wide and 8 feet long, and wherein each floor panel is at least 16 feet long and approximately 4 feet wide.

15. A method of constructing a building from components, supplies and tools shipped to a desired building site, comprising the steps of:

a. loading into a shipping container all the components, supplies and tools needed to construct the building, comprising preassembled wall panels, ceiling panels, roof trusses, roof panels, sheets of roof cladding and sheets of wall cladding;

b. transporting the loaded shipping container to the desired building site;

c. unloading the shipping container at the desired building site;

d. erecting front, rear and side walls for the building by standing the wall panels up on a suitable foundation at the building site, and fastening the wall panels together along their adjacent edges to form the building perimeter;

e. lifting the ceiling panels in place such that they span the distance between and are supported by the erect side walls of the building;

f. lifting the roof trusses in place such that they rest upon and are supported by ceiling panels;

g. lifting the roof panels in place such that they rest upon and are supported by roof trusses;

h. attaching the sheets of roof cladding to the roof panels; and

i. attaching the sheets of wall cladding to the wall panels.

16. The method of claim 15 wherein the preassembled wall panels, ceiling panels, roof trusses, roof panels, roof cladding sheets and wall cladding sheets are each sized so that no measuring or cutting of same is required during the construction of the building at the desired building site.

17. The method of claim 15 wherein the preassembled wall panels, ceiling panels, roof trusses, roof panels, roof cladding sheets and wall cladding sheets are each sufficiently light to be carried and installed by no more than 6 workers at the building site without the need for any lifting device.

18. The method of claim 15 further comprising the steps of:

a. loading into the shipping container, prior to transporting it, preassembled floor panels;

b. erecting a floor for the building, prior to erecting the building walls, by placing the floor panels on ground support at the desired building site; and

c. erecting the walls on the floor panels, said floor panels providing a suitable building foundation at the site.