AU2013205214B2

AU2013205214B2 - Modular Buildings

Info

Publication number: AU2013205214B2
Application number: AU2013205214A
Authority: AU
Inventors: Susan Unger
Original assignee: 1SPACE Pty Ltd
Current assignee: 1SPACE Pty Ltd
Priority date: 2012-07-11
Filing date: 2013-04-14
Publication date: 2017-05-04
Anticipated expiration: 2033-04-14
Also published as: AU2021203202B2; AU2013205214A1; AU2019100006A4; AU2019200056B2; AU2017200285A1; AU2019200056A1; AU2021203202A1

Abstract

- 27 A building structure formed of one or more elongate clusters, each cluster comprising a plurality of side by side module banks, each module bank formed of end to end 5 modular building units. 36' 14D 14E 14F 12G 12D 12E 12F -- ------ FIG. 12A FIG. 12B FIG. 12C FIG. 12D 0 1 2 3 4 5 6 7 8 9 10 11 12 -------------- ---------------------------------- ------ --------- -- i b FIG. 14A

Description

- 1 - 2013205214 14 Apr 2013

Modular Buildings

The present invention relates to modular buildings. 5 Background

Known modular buildings comprise buildings formed of custom modified intermodal shipping containers, also known as sea containers. However shipping containers are of a fixed width - 2.4m (8ft) - and of a limited number of lengths - 6.1m (20ft) or 10 12.2m (40ft). Accordingly areas or rooms inside building constructed of these containers are limited in their dimensions, according to the dimensions of the container. Making an area wider than the width of the container requires extensive structural modification of the containers, such as cutting through walls of the containers, which is undesirable and defeats the purpose of modularisation. 15 Furthermore each container is individually customised to its particular application, which is counter to the concept of modularisation.

Reference to prior art documents is not an admission that they form part of the common general knowledge of a skilled person in any jurisdiction. 20

Summary of the Invention

In this specification the terms “comprising” or “comprises” are used inclusively and not exclusively or exhaustively. 25

According to the present invention there is provided a building structure formed of one or more elongate clusters, each cluster comprising a plurality of side by side module banks, each module bank formed of a plurality of end to end modular building units. 30 In an embodiment each of the units has the same dimensions.

In an embodiment a clear area within the building has a Cartesian dimension larger than an equivalent dimension of the modular units. For example a clear room width is larger than the width of the modular unit. 35 PCT/AU2013/000768 Received 10/04/20 ί 4 -2

Summary of the Invention

According to the present invention there is provided a modular building unit for construction of a building, said modular building unit comprising: a structural frame suitable for interconnection to another modular building unit in construction of the building; wherein the modular building unit is suitable for handling as a shipping container for transport,

In an embodiment the building unit further comprises a stud frame panel internal to and f ixed to the frame, wherein the frame and panel in combination are load bearing and the stud frame panel is inwardly spaced from a parallel adjacent external face of the frame.

In an embodiment the structural frame is a parallelepiped shape or in the form of a rectangular prism, in an embodiment the structural frame is in the form of a rectangular table shape, comprising a rectangle and four legs, each leg extending from one of the corners of the rectangle. Typically the rectangle will be at the base of the building unit and the legs will extend vertically. In such a case it will be typical to have another rectangle a Structural frame of another building unit joined at the corners to ends of the legs such that the other rectangle and the structural frame form a rectangular prism.

In an embodiment the panel contributes to the structural capacity of the modular building unit to withstand forces applied to the modular building unit.

In an embodiment the panel coincides with a face of the frame. In an embodiment the panel is set back from a face of the frame.

In an embodiment the panel is or forms part of a wall partly defining a room at least in part within the modular building unit. in an embodiment the building unit comprises a plurality of structural stud frame wall panels internal to and fixed to the frame, the walls defining a room within the modular building unit, the plurality of panels contributing to the structural capacity of the

AMENDED SHEETS IPEA/AU PCT/AU2013/000768 Received 10/04/2014 modular building unit to withstand forces applies to the modular building unit, in an embodiment the forces include static forces, such as from other building units stacked on top of the building unit, and from dynamic forces, such as those experienced in cyclonic weather conditions, in an embodiment the modular building unit comprises a non-struetural wail panel for forming a partition to a room in the modular building unit.

In an embodiment the building unit comprises a veranda deck internal to the frame, but able to be opened to the exterior of the frame. In an embodiment the veranda deck is open to the exterior of the building through one of the faces of the building unit. in an embodiment the veranda deck comprises shutters for closing the veranda deck during inclement weather conditions. In an embodiment the veranda deck comprises a rail or balustrade along one of the faces of the building unit,

In an embodiment the veranda deck is open to a veranda deck of an adjacent building unit in use.

In an embodiment a wall partitioning the veranda deck from a room in the building is insulated. In an embodiment an enclosure of the veranda deck is uninsulated.

In an embodiment the veranda deck comprises a cyclone resistant shutter able to close the veranda deck from the exterior of the frame, wherein the veranda deck is able to be connected to an adjacent veranda deck of an adjacent other building unit so as to allow passage between the adjacent veranda decks.

In an embodiment the building unit further comprises a portion of a building-internal vertically extending service access-way portion that is internal to the frame, exposed to the exterior of the building unit and configured to cooperate with another a building-internal vertically extending service access-way portion that is internal to a frame of an adjacent other modular building unit so as to form a building-internal service access-way comprised of at least the two building-internal service access-way portions, in an embodiment the building-internal service access-way is covered by a removable panel for transport. In an embodiment the building-internal service

AMENDED SHEETS 1PEA/AU PCT/AU2013/000768 Received 10/04/20 ί 4 -4- access-way is open to the exterior of the frame when the removable panel is removed.

In an embodiment the building-internal service access-way is accessible from 5 underneath the building module, wherein the building-internal service access-way extends across and is open on either side of the modular building unit.

In an embodiment the building unit further comprises a first portion of a building-internal service access-way able to be externally open on the modular building unit ID and arranged so that when another building module with a complementary second portion of a building-internal service access-way is placed adjacent the first portion they define a combined portion of a building-internal service access-way.

In an embodiment the building-internal service access-way is in the form of a recess 15 in a face of the building unit.

In an embodiment the building unit further comprises a weather resistant external panel affixed to each side and end face of the frame and is in-line with the corresponding side or end face of the frame, wherein the external panel covers the 20 stud frame panel when In place. In an embodiment the external panels are removable.

In an embodiment the building unit further comprises a removable panel affixed to a side and/or end face for transport, wherein the panel is formed of FRP. 25 in an embodiment an air gap is provided between the external panel and a wall internal to the frame. In an embodiment the wall internal to the frame is the stud frame panel. 30 In an embodiment in the building unit comprises a stud frame panel wall and ceiling system internal to and fixed to the frame, wherein the stud frame panel wall and ceiling system provides a load bearing system independent from the frame.

In an emebodiment the structural frame comprises vertical corner posts and a 35 structural wall inside the frame comprises a vertical corner post adjacent to and fixed to one of the vertical corner posts of the frame.

AMENDED SHEETS 1PEA/AU PCT/AU2013/000768 Received 10/04/2014 (π an embodiment the external panel provides load bearing support to the frame.

In an embodiment the building unit further comprises a plurality of beams extending transversely across the bottom of the frame and inwardly spaced from the ends of the frame, each of the plurality of beams providing at least one fastener mounting means inwardly spaced from the sides of the frame for attachment to ground supports or another building unit.

In an embodiment one or more of the frame or transverse beams are formed of Fibre Reinforced Polymer (FRP).

In an embodiment the building unit further comprises one or more removable vertical supports on side faces of the frame and located underneath a removable weather resistant external pane],

In an embodiment the unit further comprises one or more removable vertical supports on side faces of the frame, wherein the vertical supports are formed of a FRP beam.

In an embodiment the internal walls are formed of a stud frame with an insulating material inside the stud frame.

In an embodiment the building unit further comprises a structural panel affixed to, but inwardly spaced from, a top face of the frame. in an embodiment the unit further comprises a panel affixed to a top face of the frame, wherein top panel is formed of FRP.

In an embodiment the building unit further comprises an opening in a side or end face when the removable panel is removed from the respective side or face for allowing movement to another building unit in the building. in an embodiment an external finish is applied to the panels on a side/end of the building unit or ceiling of the unit

In an embodiment the frame has attachment points at each corner.

A MENDED SHEETS IPEA/AU PCT/AU2013/000768 Received 10/04/20 ί 4 -ό- Ιη an embodiment the frame has attachment points at each corner formed of FRF. in an embodiment the building unit is of a width between 2.4m and 6m and preferably between 2.6 and 4.2m. In a preferred embodiment each container is of a width of about 3.3m (1 Τ’) to 3.5m, in an embodiment the building unit is of a length of 6m (20% In other embodiments the container is of a length of one of 6.8m, 7.2m, 12m. 14.4m, 18m, or 36m.

In an embodiment the building unit is of a height of 2,9m (9’6") to 3.2m. In an embodiment each container is of a height of about 3.48m. In an embodiment each tall container is of a height of 5,8m (19') to 6.2m. in an embodiment the building unit is a tali container, where the tall container has a height of two other unit stacked one on another and a length of half the length of other building units, in an embodiment length is about 3m. in an embodiment each tail container is of a height of 8.7m.

In an embodiment the building unit comprises a longitudinally extending stair well, such that when formed as part of the building the modular building unit extends lengthways in a vertical orientation. in an embodiment the frame of the container forms a structural element of a building formed of a plurality of such building units.

In an embodiment the end and or side panels of the container form a structural element of a building formed of a plurality of such building units.

In an embodiment the building unit is configured such that it can be assembled into the building without structural modification.

In an embodiment the building unit is stackable for transport and is able to be stacked in the building.

AMENDED SHEETS IPEA/AU PCT/AU2013/000768 Received 10/04/2014 -7 -

In an embodiment the building unit comprises a portion of a roof locatable inside the modular building unit and able to be placed above the building unit to form part of a roof of the building when the building unit is formed into a building.

In an embodiment the frame is formed of hot formed steel and is provide with comer castings.

In an embodiment a truss of the roof portion is formed of FRP. In an embodiment a roof cladding sheet of the roof portion is formed of FRP. In an embodiment the roof portion comprises lifting points.

In an embodiment an opening for receiving a forklift tine comprises a casing form of FRP.

According to the present invention there is provided a modular building unit for construction of a building, said modular building unit comprising a structural frame suitable for interconnection to another modular building unit in construction of the building and a wall of the building unit comprises; a first structural panel in line with and fixed to the frame; and a second structural panel interneai to and fixed to the frame so as to be parallel to and spaced from the first structural panel so as to provide an air gap therebetween; wherein the modular building unit is transportable.

Also according to the present invention there is provided a building module comprising a roof portion to be placed above the building unit when the building unit is formed into a building.

In an embodiment the roof portion comprises a truss formed of FRP.

According to the present invention there Is provided a modular building unit for construction of a building, said modular building unit comprising: a rectangular frame; and a plurality of beams extending transversely across the bottom of the frame and inwardly spaced from ends of the frame, each of the plurality of beams providing at

AMENDED SHEETS IPEA/AU PCT/AU2013/000768 Received 10/04/2014 - 7A- least one fastener mounting means inwardly spaced from the sides of the frame for attachment to footings or another building unit.

According to the present invention there Is provided a modular building unit for 5 construction of a building along with a plurality of similar modular building units, said modular building unit comprising: a rectangular frame: a removable skin affixed to a side and/or end face for transport, and one or more removable vertical supports on side faces of the frame and located 10 underneath the removable weather resistant skin.

According to the present invention there is provided a modular building unit for construction of a building, said modular building unit comprising: a rectangular structural frame; 15 a skin affixed to a top face of the frame; and an internal insulated ceiling underneath the skin, wherein the ceiling provides structural support to an internal structural sidewall.

According to the present invention there is provided a modular building unit for 20 construction of a building, said modular building unit comprising: a rectangular structural frame, wherein the width of the frame Is of at least 2,6m; a skin affixed to each face of the frame; and a structural wall panel behind at least one of the skins and is fixed to the inside of the frame, 25

According to the present invention there is provided a modular building unit according to claim 29. wherein the frame, panel and or skin configure the building unit to have other building unit stacked thereon and the frame is suitable for handling as an oversized shipping container 30

According to the present invention there is provided a modular building unit comprising a structural frame for interconnection to another building unit in construction of a building, a structural panel affixed to, but inwardly spaced from, a top face of the frame. 35

AMENDED SHEETS IPEA/AU PCT/AU2013/000768 Recei ved 10/04/20 ί 4 -7B-

According to the present invention there is provided a modular building unit comprising a structural frame for interconnection to another building unit in construction of a building, wherein the frame is of a width between 2.6m and 3.5m. 5 According to the present invention there is provided a modular building unit comprising a structural frame for interconnection to another building unit in construction of a building, wherein the building unit is of a height of about 3.5m,

According to the present invention there is provided a modular building unit 10 comprising a structural frame comprising vertical posts, a structural wall inside the frame comprising a vertical post adjacent to and fixed to one of the vertical posts of the frame.

According to the present invention there is provided a modular building unit for 15 construction of a building, said modular building unit comprising: a structural frame suitable for interconnection to another modular building unit in construction of the building, wherein the frame is at least 2,6m in width: and a stud frame panel internal to and fixed to the frame. 20 According to the present invention there is provided a modular building unit according to claim 35, wherein the structural frame comprises vertical corner posts and the stud frame comprises a vertical corner post adjacent to and fixed to one of the vertical corner posts of the frame. 25 According to the present invention there is provided a building comprising a plurality of modular building units, each modular building unit comprising a rectangular frame; a plurality of beams extending transversely across the bottom of the frame between the ends of the frame for attachment to footings or another building unit; 30 a removable weather resistant skin affixed to a side and/or end face for transport, wherein the skin provides structural rigidity to the frame; one or more removable vertical structural supports on side faces of the frame; an interna] structural support wall on one or more corresponding faces and fixed to the frame; 35 a weather resistant skin affixed to a top face of the frame, and an internal insulated ceiling underneath the skin; and

AMENDED SHEETS

IPEA/AU PCT/AU2013/000768 Received 10/04/2014 -7 C- wherein the width of the frame is of at least 2.8m.

Also according to the present invention there is provided a building comprising a plurality of modular building units, each modular building unit according to one or 5 more of the descriptions above. in an embodiment the building comprises longitudinally side by side frames and parallel adjacent back to back internal walls of each building unit.

If) in an embodiment the building comprises building-internal service access-way formed on at least two building-internal service access-way portions of at least two adjacent building units. In one embodiment the building-internal service access-way portions are formed by the building units being end to end. in one embodiment the building-internal service access-way portions are formed by the building units are 15 side by side. In one embodiment the building-internal service access-way portions are formed by the building units are end to end and side to side.

Also according to the present invention there is provided a method of constructing a building comprising providing a plurality of building units as defined above and 20 placing the building units next to one another and connecting the units together into a single structure.

In an embodiment at least two of the building units are placed end to end. in an embodiment at least two of the building units are placed side by side. 25

In an embodiment at least two of the building units are stacked.

According to the present invention there is provided a building comprising a plurality of modular building units, each modular building unit comprising: 30 a rectangular frame;: a plurality of beams extending transversely across the bottom of the frame for attachment to ground supports or another building unit; and wherein one or more of the frame or transverse beams are formed of Fibre Reinforced Polymer (FRP). 35 AMENDED SHEETS IPEA/Ali PCT/AU2013/000768 Received 10/04/2014 - 7D -

Also according to the present invention there is provided a panel for use in a building comprising a sheet of FRP having mounting points for fixing the sheet to a structure. in an embodiment a first surface of the sheet is finished in a manner suitable for decorative use prior to fixing to a structure.

In this specification the terms “comprising" or “comprises” are used inclusively and not exclusively or exhaustively.

Description of Drawings

In order to provide a better understanding of the present invention preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic set of plan views showing a building unit and a building according to an embodiment of the present invention:

Figure 2A is an upper isometric view of a bank of modular building units of the building of Figure 1.,. with a roof removed;

AMENDED SHEETS IPEA/AU -8- 2013205214 14 Apr 2013 floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.

In an embodiment the determined composition comprises determining a configuration 5 such that the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.

In an embodiment the determined space requirements comprises determining a configuration such that an area is smaller than or the same size as a modular building 10 unit, with multiples of the area repeating with end to end or side to side modular building units.

In an embodiment the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal corridor therein and 15 an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor.

In an embodiment the determined composition comprises determining a configuration 20 such that a modular building unit type has a portion of an internal service corridor therein, where there are a plurality of such modular building units adjacent one another so as to connect the service corridor portions to form the service corridor.

In an embodiment the determined composition comprises determining a configuration 25 such that the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored.

In an embodiment the determined space requirements comprises determining a configuration such that an internal portion of the building has repeated use areas, with 30 an outer portion providing an entrance to the internal portion, the entrance being an area provided for in one type of modular building unit.

In an embodiment the determined composition comprises determining a configuration such that an outer portion of the building has a different use to the internal portion. 35 -9- 2013205214 14 Apr 2013 ln an embodiment the determined composition comprises determining a configuration such that the building comprises a plurality of banks of usage areas.

In an embodiment the determined composition comprises determining a configuration 5 such that a joining portion of the building joins one bank of connected building units to another bank of building units, such that there is internal, or covered access-way between banks

According to the present invention there is provided a building formed by performing 10 the above method.

Also according to the present invention there is a building structure formed of one or more elongate clusters, each cluster comprising a plurality of end to end module banks, each module bank formed of a plurality of side to side modular building units. 15

Description of Drawings

In order to provide a better understanding of the present invention example embodiments will now be described in reference to the accompanying drawings, in 20 which:

Figure 1 is a schematic set of plan views showing a building according to an embodiment of the present invention;

Figure 2 is an upper isometric view of a bank of modular building units of the building of Figure 1; 25 Figure 3 is a lower isometric view of the bank of Figure 2;

Figure 4 is an upper isometric view of a modular building unit of the building of Figure 1, with a top face removed;

Figure 5 is an upper isometric view of a frame of the modular building unit of Figure 4; Figure 6 is an end view of a cluster of the building of Figure 1; 30 Figure 7 is a side elevation of the cluster of the building of Figure 6;

Figure 8 is a plan view of a connecting portion of the building of Figure 1;

Figure 9 is a side elevation of the bank of Figure 3 in a transportation configuration; Figure 10A is an end view of the bank of Figure 3 in a transportation configuration; Figure 10B is an end view of an inside end of the unit of Figure 4 in a transportation 35 configuration;

Figure 11 is a plan view of a village comprising the building of Figure 1; - 10- 2013205214 14 Apr 2013

Figure 12A is a plan view of an embodiment of a bank of modular units and a cluster according to the present invention;

Figure 12B is a plan view of an alternative embodiment of a bank of modular units and a cluster according to the present invention; 5 Figure 12C is a plan view of an alternative embodiment of a bank of modular units and a cluster according to the present invention;

Figure 12D is a plan view of an alternative embodiment of a bank of modular units and a cluster according to the present invention;

Figure 13 is a plan view of a selection palette of modular building units according to 10 the present invention;

Figure 14A is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12A;

Figure 14B is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12B; 15 Figure 14C is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12C;

Figure 14D is a plan view of an embodiment of a cluster according to the present invention;

Figure 15 is a schematic set of plan views showing a building according to an 20 embodiment of the present invention;

Figure 16 is an exploded upper isometric view of an embodiment of an apartment building according to the present invention;

Figure 17A is a plan view of a ground storey of the apartment building of Figure 16; Figure 17B is a plan view of a first storey of the apartment building of Figure 16; 25 Figure 17C is a plan view of a second storey of the apartment building of Figure 16; Figure 18 is a schematic set of isometric views showing examples of configurations of banks of modular units of Figure 16;

Figure 19 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention; 30 Figure 20 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention;

Figure 21 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention;

Figure 22 is a plan view of a fitted out and furnished building according to Figure 19; 35 Figure 23 is a plan view of a fitted out and furnished building according to Figure 20;

Figure 24 is a plan view of a fitted out and furnished building according to Figure 21; -11 - 2013205214 14 Apr 2013

Figure 25 is a schematic plan view of a complex which includes three buildings according to an embodiment of the present invention;

Figure 26 is a plan view of one of the buildings of Figure 25;

Figure 27 is a plan view of a building according to an embodiment of the present 5 invention;

Figure 28 is a plan view of a building according to an embodiment of the present invention; and

Figure 29 is a plan view of a building according to an embodiment of the present invention. 10

Description of Preferred Embodiments

Referring to Figures 1 and 11 there is shown a building 10 according to an embodiment of the present invention. In this case the building 10 is a precinct in a 15 village 100. The village 100 comprises a number of buildings 10. For example the precinct may be a mine site accommodation complex, a hotel, hospice or offices.

The building 10 comprises one or more clusters 12. In this embodiment a cluster comprises a plurality of similar usage areas. For example in an accommodation 20 complex a living quarters may comprise usage areas that may be bed and bath rooms. The cluster comprises a plurality of banks 14,14’, 14”, 14’” of modules. A bank 14 of modules comprises a plurality of modular building units 16. Every unit in the bank, and preferably in the cluster has the same dimensions. In this embodiment each bank 14 comprises three units 16 positioned end to end. Thus each bank has 25 the same dimensions. Further in this embodiment each bank 14 comprises a mirrored usage area on each side of a corridor, which will be described further below. For example each bank may comprise living quarters on each side of a corridor. In this embodiment each cluster comprises a plurality (in this case ten) of banks 14 in a side by side arrangement. Further the cluster 12 comprises a bank 14’” on one side of the 30 banks 14 and a bank 14” on either side of the banks 14”’/14. Further still the cluster 12 comprises a different usage type of bank 14’ on either side of the plurality of banks 14”. In this embodiment the banks 14’ comprises a vertical access unit, such as a stair way or elevator. In this embodiment the clusters are offset and connected to each other by a cluster connection portion 20. In this embodiment cluster 12’ is 35 substantially a mirror of cluster 12. The mirroring need not be identical as described more in relation to Figure 8. - 12- 2013205214 14 Apr 2013 ln an alternative or in addition a bank 14 may comprise a plurality of units 16 side by side as will be described in more detail below in relation to Figure 15. 5 In an embodiment each unit is of a unit type and each unit is configured according to its unit type. In an embodiment the configuration comprises one or both of internal wall configuration and external (permitter of the unit) wall configuration. In an embodiment each bank is of a bank type, where each bank type is defined according to the unit types of its units. 10 A bank 14 is shown in more detail in Figures 2 and 3. In this embodiment the bank 14 comprises unit 16A, which comprises a corridor 30 and entries 32 and 32’. On either end of unit 16A are units 16B and 16C, each of these comprises a bedroom 34/34’ and bathroom 36/36’. In an alternative the corridor may be a service corridor and 15 rooms 32 and 32’ are the bathroom and room 36 and 36’ are the entries. Also referring to Figures 4 and 5, each unit 16 comprises a structural frame 40 in the shape of a rectangular prism. Longitudinally disposed end faces of the frame have vertically extending support members 44. Such a suitable frame is of the type used in a shipping container. The longitudinal frame members have removable supports 52 20 extending vertically between them, which are used during transport of the unit and may be retained to provide additional support strength to the structure. However these supports 52 may also be removed leaving open the space 46 between the top and bottom longitudinal frame members. When the walls are removed leaving open space 46, this enables an area in the building to be larger than would otherwise be 25 available. A bottom face of the frame has transverse support members 42. The top face of the frame may also have transverse support members. These support members 42 allow the floor of the unit to support sufficient weight and can also be used to mount a bottom level to a ground mounting system or to a level of units beneath. 30

For transport, and if desired to be used in the assembled building, the faces of the prism may have walls as shown in Figures 9, 10A and 10B. In one embodiment an internal wall is provided inside of an outer wall. The outer wall is preferably suitable for transport of the unit in a weather exposed condition. In an embodiment the wall is 35 formed of weathering steel, such as Cor-ten™. In an embodiment the wall is formed - 13- 2013205214 14 Apr 2013 of a fibre reinforced polymer. In an embodiment the outer wall is removable after transport or retained as a weather resistant outer wall in the building.

Also for transport the corners 50 of the unit 16 may have attachment points for lifting 5 the unit to and from a transport vehicle, such as a truck, rail car, or ship, and for positioning in place in the building 10. The attachment points are in the normal form of “castings” using for shipping containers. In the sides of the longitudinal frame members 40 there are fork pockets for receiving tines of a forklift, the same as is a normal shipping container. The attachment points may also be used to secure 10 adjacent units together in the building.

In an embodiment a portion of or the whole of the building is multistorey. In the embodiment shown in Figures 6 and 7 there are two stories. There may be more stories if desired. As shown, banks 14A, 14B and 14C each have respective banks 15 14AA, 14BB and 14CC on top so that there are two storeys. Bank 14A has end corridor unit 16A with a door to the exterior of the building, and lower stair well units 16BA and 16BA’. Above unit 16A in bank 14AA is an end corridor unit 16AB with a door to the exterior of the building and a hand rail. A top part of the stair well units 16BA and 16BA’ is in bank 14AA. A unit may be two storeys high to span two stories 20 with a stair well or elevator shaft between the stories. An embodiment of a roof 60 is in two parts and spans bank 14AA. Each part is longer than the respective end building unit and partly covers unit 16AB.

Referring to Figure 8 a cluster connection portion 20 is shown in more detail. It can be 25 seen that the end banks 14A are spaced apart, both axially and longitudinally.

Opposite longitudinal walls of the respective clusters are aligned in this embodiment. A bridging bank 22 of units is provided to connect the banks 14A together. Each bank 14A abuts a respective half of the bank 22. The clusters are generally mirrored. However one of the clusters (or both if desired) may be provided with an overlapping 30 bank 24 that overlaps the lower bank 14A. In this case the overlapping bank may provide a usage not required internally of the cluster or not required in each cluster. For example a laundry or lockers may be provided in the bank 24. Other variations include services (such as plumbing, electrical, air conditioning) or if made larger common access rooms can be provided, or universal access rooms or suites. 35 - 14- 2013205214 14 Apr 2013

Banks may be wider than one unit. For example in Fig 12A the bank 14D is one unit wide for a first use. In Figure 12B the bank 14E is two units wide for a second type of use. In Figure 12C the bank is three units wide for a third type of use. It can be seen that the banks of whichever type are repeated within the cluster and at the end of 5 each cluster there are different banks.

Wider banks or areas spread over a plurality of banks can allow for a greater range of usages or areas not constrained by container size, which is the case with standard shipping containers, without structural modification of the container(s) particularly 10 when the side walls are removed to produce open areas 46 between the banks of a larger dimension than the width of the unit. In other words a room can span two or more units.

Clusters may have more than one type of bank. For example in Figure 12D, the 15 cluster 12G comprises types 14D, 14E and 14F. In these examples the end banks can be verandas in a single story building or can be stair wells in a multistory building. Alternatively they can be common areas. If secured during a storm or cyclone secured accessways will still allow movement within the building. In an embodiment a bank in the building may be a cyclone / hurricane shelter. 20

Referring to Figure 13 a plurality, in this example, 13 different types of unit can be available as stock units. This allows the building to be modularly design the building and for it to be built by following the following process: determining the usage requirements of the building in terms of types of areas within 25 the building, from a plurality of available types; determining the space requirements of the building in terms of the number of each type of area within the building and size of each area of each type, where each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit; 30 determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements, where the composition is selected form a plurality of stock types; obtaining the modular building units according to the determined type and number; 35 transporting the modular building units to a building site; and assembling the modular units into the building. - 15- 2013205214 14 Apr 2013 ln Figure 13 each of the types of unit is, by way of example: 0 - service corridor, with a ‘wet area’, for example a bathroom, on either side of the service corridor; 5 1 - carport; 2 - alfresco area; 3 - living room; 4 - dining room with kitchen bench; 5 - study or bedroom with veranda; 10 6 - bathroom/laundry with veranda; 7 - bathroom/laundry with passage ; 8 - bedroom with bathroom; 9 - meals room with kitchen; 10 - alfresco with barbeque area; 15 11 - entry veranda with stairs; and 12 - stairs entry and living area.

In this example, plain white areas may have a concrete floor, vertical shading may be a timber or similar floor, dotted areas are “dry areas” floors and square pattern is a 20 “wet area” floor, with appropriate services.

In Figure 12A, the bank 14D has type 5 units on either side of a type 0 unit.

Alternatively if a unit of non stock type is required the required number of units can be 25 mass manufactured according to the requirements and then transported to the building site for assembly.

In an embodiment prior to transport one or more of the modular building units are packed into a container form for transport. In an embodiment prior to assembly the 30 modular building units, one or more of the modular building units are unpacked from container form to an assemble-able form, without need for structural modification.

In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit. In an embodiment 35 the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit, or standard fractions thereof. - 16- 2013205214 14 Apr 2013 A standard fraction may comprise 1A 1/3, or 1/2. In an embodiment the grid is based on a unit size suitable for transport.

In an embodiment determining a configuration of the building comprises selecting a 5 type of unit, wherein the unit type determines one or both of internal wall configuration and external (perimeter of the unit) wall configuration. In an embodiment determining the configuration comprises selecting a type of unit, wherein each bank type is determined according to the unit types of its units. 10 In an embodiment determining the configuration comprises selecting units such that selection of the unit designate whether a room in the building is a “wet area”, such as for example a bathroom, including the wall and floor treatments and furnishings in the room. 15 In an embodiment determining the configuration comprises selecting units such that there is an area within the building larger than a dimension of the modular units.

In an embodiment the determined space requirements comprise determining that the units are to be stacked in the building. 20

Preferably the determined composition comprises determining a configuration such that the outer units of the bank are mirrored. In an embodiment the determined composition comprises determining a configuration such that each cluster comprises at least two banks of the same type. 25

In an embodiment the determined composition comprises determining a configuration such that a room in a cluster is defined by one of: a portion of a modular unit; a bank; 30 a plurality of banks; a plurality of portions of modular units spaning a plurality of banks.

In an embodiment the determined space requirements comprises determining a configuration such that internal spaces with a dimension longer than the length of a 35 modular building unit are constrained to a maximum dimension without an internal - 17- 2013205214 14 Apr 2013 floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.

In an embodiment designing a building comprises: determining the area of the building which is a multiple of a floor area of a modular 15 building unit, where the floor area may span a plurality of levels; determining the types of uses of rooms in the building, subject to a constraint of the determined area of the building; i) selecting a module type according to one or more of the determined types of room usage from a plurality of available module types; 20 ii) selecting a number of the selected module type to accommodate a desired area of the room usage or usages for which the module type was selected; and iii) repeating the selection steps i) and ii)) so that each of the types of use of the rooms is accommodated in the area available within the building. 25 The modular building units used may be manufactured ready for assembly into the building, transported to the building site in a stackable manner and may be assembled into the building in a stackable manner.

Figures 14A to 14C show alternative lay outs of a dwelling. Figure 14A comprises one 30 modular building unit fitted out with an entry, bedroom and bathroom. It might be for example a hotel room or a single worker’s quarters in an accommodation village. Figure 14B comprises of two side by side modular building units in a bank and is fitted out with an entry, bedroom, bathroom kitchen, living room and study. It might be a hotel suite or a supervisor’s quarters in an accommodation village. Figure 14C 35 comprises of three modular building units in a bank fitted out with an entry, bedroom, bathroom, kitchen, laundry, dinning theatre, study and living room. It might be a hotel - 18- 2013205214 14 Apr 2013 penthouse suite or a manger’s quarters in an accommodation village. As shown in Figure 14D, in an embodiment, banks of these dwellings 102 may be arranged into buildings in an accommodation precinct building or hotel building 100, with connecting pathways/corridors 104. This floor plan may be repeated with stacked banks of 5 building units many levels high.

Referring to Figure 15 there is shown a set of buildings 10A, 10B, 10C and 10D, each of which comprise an end to end bank 14 or an alternative side to side bank 14A. In an alternative bank 14A, the plurality of units 16 are side by side and the banks abut 10 end to end.

Building 10A is one building in a cluster of buildings that have a dwelling density of R60, that is 60 dwellings are permitted in a 1 hectare (10000m2) area of land. 15 Building 10B is one building in a cluster of buildings that have a dwelling density of R40, that is 40 dwellings are permitted in a 1 hectare area of land. This building has two alternate banks 14A of three units side by side on a first level and one alternate bank of three units on a second level and one alternate bank of three units on a third level. 20

Building 10C is one building in a cluster of buildings that have a dwelling density of R30, that is 30 dwellings are permitted in a 1 hectare area of land.

Building 10D is one building in a cluster of buildings that have a dwelling density of 25 R20, that is 20 dwellings are permitted in a 1 hectare area of land.

Figure 25 is another example of a complex 200 with three buildings of R40 density. Figure 26 shows the make up of each building from the unit types 3, 4, 2 (in the first alternative bank of 3 units) and unit types 8, 3, and 8 (in the second alternative bank 30 of units). It can be seen the areas of units 3 and 4 are combined to form a large room and unit 4 and 3 have a joining doorway and that both of units 8 have joining door ways with unit 3. It can also be seen that the right side unit 8 is a mirror of left side unit 8. 35 Referring to Figure 16 to 18, a three story apartment building 110 is shown. In this embodiment the banks are formed of side by side modular units. In this case the - 19- 2013205214 14 Apr 2013 widths of bank are the same, but in an alternative embodiment the width need not be the same in each bank.

The ground level is 112, the first level is 114 and the second level is 116. Figure 18 5 shows the removal of side/end panels used in transport in each back of the ground 112, first 114 and second 116 levels. This allows for larger internal areas or in the case of the units in the ground level side access to the units, such as for car parking spaces. Figure 17 A shows the floor plan of the ground level 112 using the types of modular units in Figure 13. Figure 17B shows the floor plan of the first level 114 and 10 Figure 17C shows the floor plan of the second level 116.

Figure 19 shows an alternative building comprising a bank of units in a side by side arrangement. In this building, notional unit types are 5, 8 and 9, with 2 of type 5 and type 8 being used, along with the removal of external walls between types 5 and 9, so 15 as to produce a larger area internal to units 5 and 9. The external wall units are surplus to the units transported. In an embodiment this building can be transported on a single move using a single vehicle (truck / road train). Figure 22 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport. 20

Figure 20 shows an alternative building comprising two banks of units in a side by side arrangement, with the banks being offset by a unit width and with the units end to end. In this building, notional unit types are 1,2, 3, 4, 7, and 8, with 1 of type 1,2 of type 2, 2 of type 3, 1 of type 4, 3 of type 7 and 1 of type 8 being used, along with the removal 25 of external walls between the 2 type 2 units and the type 4 and 8 units, so as to produce a larger area internal to units 2-2 and 4-8. The external wall units are surplus to the units transported. In an embodiment this building can be transported on a single move using two vehicles (truck / road train). Figure 23 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, 30 optionally, also packaged in the containers for transport.

Figure 21 shows an alternative building comprising three banks of units in a side by side arrangement. In this embodiment two banks are perpendicular and a shorter bank is end to end with one bank and offset from the other bank by a unit width. In 35 this building, notional unit types are 1,2, 3, 4, 5, 7, 8 and 9, with 2 of type 1,2 of type 2, 3 of type 3, 1 of type 4, 2 of type 5, 1 of type 7, 2 of type 8 and 1 of type 9 being -20- 2013205214 14 Apr 2013 used, along with the removal of external walls between types 1 and 1,2 and 2, 3 and 3 and 3 and 4, so as to produce a larger area internal to units 1-1 2-2, 3-3, 3-4. The external wall units are surplus to the units transported. In an embodiment this building can be transported on a single move using three vehicles (truck / road train). Figure 5 24 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport.

Figure 27 is another example building of R20 density and is assembled from four alternative banks of three side by side units. The first bank is assembled from unit 10 types 1, 1 and 0. The next bank is assembled from unit types 4, 3, and 5’. The next bank is assembled from unit types 2, 2, and 0. The final bank is assembled from unit types 5’, 5’, and 5’.

Figure 28 is another example building of R30 density where each level has a common 15 area 202 and two individual bedrooms adjacent to each staircase.

Figure 29 is a further example building of R30 density similar to Figure 28 with a different floor plan. 20 The transportability of the units may also be useful not just to construct a build, but also to move the building to a different location, or to break up the building and reuse the modular units on one or more other buildings of different design.

The modular building unit are suitable for transport by road, rail and ship. The 25 dimensions of each unit may be for example 3.3m x 6m, 3.4m x 6m, 3.6m x 7.2m, 3.7m x 7.3m, or otherwise.

Modifications may be made to the present invention with the context of that described and shown in the drawings. Such modifications are intended to form part of the 30 invention described in this specification.

Claims

Claims

1. A method of forming a building comprising: specifying a palette of predetermined modular building unit types, wherein at least one of the types of modular building units is a perimeter type which comprises an internal wall adjacent to and inward of an external wall, wherein each of the modular building unit types has a different internal configuration, wherein each internal configuration comprises one or more different types of construction; determining the usage requirements of the building in terms of types of areas within the building from a plurality of predetermined available types of areas, such that the types of areas able to be built in the building are constrained by the types of construction in the respective modular building units in the palette of predetermined modular building unit types; determining the space requirements of the building in terms of the number of each type of the determined types of areas within the building and size of each type of area, where the size of each type of area is constrained by the internal configuration of the modular building units having the corresponding type of construction for that type of area, wherein the size of the area of each type is able to be configured to have a plurality of predetermined available sizes, the sizes available being smaller than the size of a modular building unit where that type of area is constrained to be within a modular building unit, the same as a modular building unit where that type of area is constrained to take all of the interior of a modular building unit or larger than a modular building unit where that type of area is within more than one modular building unit but is constrained to be of a size limited by combining adjoining modular building unit of a type that has an internal configuration that permits adjoining modular building units to have a room spanning more than one modular building unit; determining a composition of each of the predetermined types of modular building units and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements; obtaining the modular building units according to the determined type and number; transporting the modular building units to a building site; and assembling the modular units into the building which comprises a continuous external wall and a continuous internal wall adjacent to and inward of the external wall; wherein the external wall and internal wall of the building is formed by adjoining perimeter type of modular building units which are positioned in the building around the perimeter of the building so as to make the external wall and internal wall continuous; wherein the modular building units are positioned within the building so as to create the determined types of areas; wherein the modular building units used to create the determined areas which span adjacent building units are positioned to be adjacent to each other within the assembled building; wherein each modular building unit comprises a frame for handling of the modular building unit during transport and for connection to adjacent modular building units during assembly of the building, wherein the external wall is situated inside of the perimeter of the frame.
2. A method according to claim 1, wherein the modular building units are of the same size and are stackable for transport and stackable for assembly into the building.
3. A method according to any one of claims 1 or 2, wherein the modular building units of each type have one or more of the following predetermined: room size, room position, room orientation, internal walls, entrance/exit, windows, electrical services, plumbing services, and covered areas, before the determining steps occur.
4. A method according to any one of claims 1 to 3, wherein the predetermined available sizes comprise sizes that are larger in at least one dimension than a modular building unit, wherein the type of area is a room that spans more than one modular building unit, wherein the units are obtained to provide a part of the area in one building unit and another part of the area in another building unit, and the units are assembled with the building units adjacent so as to form the unit spanning area, such that a room dividing internal wall of the one building unit continues with a room dividing internal wall of the other building unit, wherein there are rooms on either side of the room dividing internal wall when the building is assembled.
5. A method according to any one of claims 1 to 4, wherein obtaining the modular building units according to the determined type and number comprises manufacturing the modular building units according to the determined type and number.
6. A method according to any one of claims 1 to 5, wherein the method further comprises specifying internal spaces defined by an internal wall to conform to a grid dimensioned to a fraction of the length and / or a fraction of the width of the modular building unit.
7. A method according to any one of claims 1 to 6, wherein determining a configuration of the building comprises selecting a type of unit, wherein the unit type determines the internal wall configuration, where spaced apart ends of internal walls define an opening in a side or end of the modular building unit, which will be internal to the building when the building is assembled, wherein the opening spans the entire side or end within the frame of the modular building unit, wherein the opening is bordered by flooring, ceiling and the internal walls.
8. A method according to any one of claims 1 to 7, wherein the external wall of a building unit where a wall face internal to the frame of the building is removed prior to assembly of the building unit into the building so as to leave an open space to connect the inside of adjacent building units.
9. A method according to any one of claims 1 to 8, wherein the determined composition comprises determining a configuration such that there are least three banks of only three end to end building units in the same level of the building when the building is assembled, wherein the banks are connected side to side.
10. A method according to claim 9, wherein each bank comprises more than one modular building unit in width and there are at least two banks side by side in the assembled building.
11. A method according to claim 10, wherein there is an opening between each of the end to end modular building units in each bank and there is an opening between each of the side by side modular building units in each bank.
12. A method according to claim 10, wherein each bank comprises only two dwellings, with a corridor in a middle modular building unit separating the dwellings, wherein each dwelling comprises an open room spanning the adjacent side by side modular building units forming each dwelling.
13. A method according to any one of claims 1 to 12, wherein the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where the spaces on either side of the corridor are part of the modular building unit, where there are a plurality of such modular building units adjacent to one another so as to connect the corridor portions to form the corridor, wherein each of the spaces on either side of the corridor are connected to an end of part of another modular building unit.
14. A method according to any one of claims 1 to 13, wherein the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal service corridor therein, wherein when the building is assembled there are a plurality of such modular building units adjacent to one another so as to connect the service corridor portions to form the service corridor.
15. A method according to claim 13 or 14, wherein the determined composition comprises determining a configuration such that the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored within the modular building unit.
16. A method according to any one of claims 1 to 15, wherein modules in the palette comprise: a dry use unit; a wet use unit; a partly wet and partly dry use unit, separated along the length; a part inside use area and a part outside environment use area unit, separated along the length; a corridor unit with rooms on either side of the corridor and entry doors to each room; and a corridor unit with service accesses to wet use areas on either side of the corridor.
17. A building formed by performing the method according to any one of claims 1 to 16.
18. A building substantially according to each embodiment hereinbefore described with reference to any one or more of the accompanying drawings.
19. A method of building a building substantially according to each embodiment hereinbefore described with reference to any one or more of the accompanying drawings.