CA2800247A1 - Unitised building system - Google Patents

Abstract

A structural connection for connecting four building units (2). The building units include two building units in a lower layer and two building units in an upper layer. Each building unit includes self supporting structure defining an internal volume and has at least one mounting member (206, 218). The connection includes the mounting members. Each mounting member of the lower building units includes at least one engagement point (223).The connection further includes interlocking structure (305) by which the mounting members of the lower building units are relatively locatable to relatively locate the engagement points. The mounting member of a first of the upper building units is cooperable with the mounting member of a first of the lower building units to transmit load thereto. The mounting member of a second of the upper building units is co operable with the mounting member of a second of the lower building units to transmit load thereto and engageable with the relatively located engagement points of the mounting members of the lower building units to fasten the lower building units and the second upper building units.

Description

Unitised Building System Field of the invention This invention relates to a building system. The invention will be described in connection with construction of high rise buildings, however aspects of the invention will find application outside this field and the invention should not be considered as being limited to that exemplary field of use.

Background of the invention There have been many proposals to utilise prefabricated building methodologies in order to enable inexpensive and fast construction of buildings. Examples of prefabricated modular systems include those disclosed in the following prior art documents: US 6,625,937; US 5,706,614; US
4,120,133; US
6,826,879; US 4,045,937; US 5,402,608; US 4,807,401; US 4,545,159 and WO
2005/038155.

Generally speaking, however, the prefabricated systems which have been proposed are suitable only for single storey or low rise buildings and are generally modular in their approach so that there is an inherent inflexibility that limits their application.

The applicant has developed a new method of building a building having a plurality of levels using a plurality of building unit assemblies wherein each building unit assembly is structurally self supporting and has at least one sidewall, a floor and a roof. The method is described and claimed in the applicant's co-pending international patent application no. PCT/AU2009/01236, certain figures of which are reproduced herein as figures. 1 to 15. The method includes the steps of lifting the building unit assemblies into position in the building so that each level of the building includes a predetermined number of units;
connecting adjacent units to one another in each level; and connecting units in one level to corresponding units in at least one adjacent level that is vertically above or below the one level. This patent application .concerns improvements in the applicant's approach to building buildings.
However the approaches described herein may find use in other types of construction.

Objects of various aspects of the invention include providing improved structural connections for buildings and improved load bearing columns or at least to provide alternatives for those concerned with building buildings.

Summary of the invention Accordingly in its various aspects the invention provides buildings, building units, various components and assemblies therefor, including structural connections and load bearing members, and methods of building and methods of interconnecting building units.

In one aspect, the invention provides a structural connection for connecting four building units, each building unit including self supporting structure defining an internal volume and having at least one mounting member; the building units being mutually arranged such that there are two building units in a lower layer and two building units in an upper layer, the structural connection including:

one mounting member corresponding with each building unit; each said mounting member of the, lower building units including at least one engagement point;

interlocking structure by which the mounting members of the lower building units are relatively locatable to relatively locate the engagement points;

the mounting member of a first of the upper building units being co operable with the mounting member of a first of the lower building units to transmit load thereto;

the mounting member of a second of the upper building units being co operable with the mounting member of a second of the lower building units to transmit load thereto and engageable with the relatively located engagement points of the mounting members of the lower building units to fasten the lower building units and the second upper building unit.

In preferred forms of the connection, the interlocking structure includes one or more portions tapered in the vertical plane providing a lead in whereby vertical movement along the tapered portion horizontally drives the engagement points towards said relative location. The interlocking structure may be configured to vertically drive the engagement points towards said relative location. Most preferably the interlocking structure is configured to locate the engagement points to within 3mm of a desired relative location.

The interlocking structure is preferably configured to engage the mounting members of the lower building units to positively relatively locate the engagement points in at least two opposed directions and most preferably to fully relatively restrain the engagement points. The interlocking structure may include a biscuit engageable with each of said mounting members of the lower building units. The biscuit may be fastened to one or both of said mounting members of the lower building units.

Preferably each mounting member is predominantly formed of plate material. One or more of the engagement points may be a bolting aperture, or more preferably a threaded bore.

The connection may include a respective load bearing column associated with each building unit, which column includes at one end the building unit's respective mounting member, and at the other end another mounting member for forming a like connection with other building units.
Preferably columns of the first lower building unit and the first upper building unit are substantially identical.

According to preferred forms of the connection, each first unit column carries an elongate rod by which a locking mechanism may be actuated from an upper end of said first unit column to lock a lower end of said first unit column to an upper end on an underlying column.

The locking mechanism optionally includes a member carried by a lower portion of the rod shaped to pass through an aperture formed in the mounting member of the first building unit when in a first orientation. In this case, said actuation may include rotating the shaped member about an axis of the rod to a second orientation. Preferably the shaped member engages an underside of the mounting member of the first building unit when in the second orientation.

Optionally an upper portion of the rod is engaged with a threaded fastener bearing against a mounting point fixed relative to the upper end of the first unit column.

Preferably the columns of the second lower building unit and the second upper building unit are substantially identical. Desirably each building unit may include four load bearing columns each including mounting members at each end for forming like respective connections with building units.

In another aspect, the invention provides a load bearing column for a building including an elongate rod by which a locking mechanism may be actuated from an upper end of said column to lock a lower end of said column to. an upper end of a like underlying column;

the locking mechanism including a member carried by a lower portion of the rod, shaped to pass through an aperture formed in the upper end of the underlying column when in a first orientation; wherein actuation of the locking mechanism includes rotating the shaped member about an axis of the rod; and wherein the column includes one or more stops or detents defining a second orientation of the member.
The lock mechanism may further include one or more stops or detents defining the first orientation. The stops or detests may take the form of projections which in use abut the shaped member. Preferably the stops and/or detents are formed at a lower end portion of the column.

According to preferred forms of the locking mechanism, the shaped member is positioned to engage an underside about the aperture when in the second orientation.

An upper portion of the rod may be engaged with a threaded fastener bearing against a mounting point fixed relative to the upper end of the first unit column.

In another aspect the invention provides a mounting member for a structural connection, the member including at least two inclined peripheral guiding surfaces along which another mounting member is relatively slidable to a desired relative location.

Brief description of the drawings Embodiments of the presentation will be detailed by way of example with reference to the accompanying drawings. The illustrated dimensions and tolerances are for the aid of the reader. The figures, particularly the dimensions and tolerances, are only exemplary. In the drawings;

Figure 1 is a schematic perspective view of a building unit;
Figures 2 is a perspective view of a building unit assembly;
Figures 3 to 8 illustrate the interconnection of building units;

Figure 9 is a perspective view of an alternative mounting plate usable in an embodiment of the present invention;

Figure 10 is a plan view of the mounting plate of figure 9;

Figure 11 illustrates three building unit assemblies which are to be mounted together using the mounting plate of figure 9;

Figures 12 to 14 illustrate the manner in which horizontally neighbouring building unit assemblies come together using a mounting plate of figure 9;

Figure 15 is a perspective view of an upper portion of a load bearing column;
Figure 16 is a plan view of a pair of upper connecting plates;

Figure 17 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 16;

Figure 18 is a plan view of a pair of upper connecting plates;

Figure 19 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 18;

Figure 20 is a plan view of a pair of upper connecting plates;

Figure 21 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 20;

Figure 22 is a plan view of a pair of upper connecting plates;

5 Figure 23 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 22;

Figure 24 is a plan view of a pair of upper connecting plates;

Figure 25 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 24;

Figure 26 is a plan view of a pair of upper connecting plates;

Figure 27 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 26;

Figure 28 is a plan view of a pair of upper connecting plates and an associated biscuit;
Figure 29 is a plan view of the biscuit of figure 28;

Figure 30 is a cross-section view of the biscuit of figure 29;
Figure 31 is a cross-section view of the biscuit of figure 29;

Figures 32 and 33 illustrate alternate arrangements of the upper connecting plates of figure 28;
Figure 34 is a plan view of a pair of upper connecting plates and an associated biscuit;

Figure 35 is a cross-section view of one of the upper connecting plates of figure 34;

Figure 36 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 34 and an associated temporary plate;

Figure 37 is a cross-section view of the lower connecting plates of figure36;

Figure 38 is a plan view illustrating one of the upper connecting plates of figure 34 in more detail;
Figure 39 is a cross-section view of a portion of the upper connecting plate of figure 38;

Figure 40 is a cross-section view of the upper connecting plate of figure 38;
Figure 41 is a plan view of the other of the upper connecting plates of figure 34;
Figure 42 is a cross-section. view of the upper connecting plate of figure 41;

Figure 43 is a plan view showing the biscuit of figure 34 in more detail;
Figure 44 is a cross-section view of the biscuit of figure 43, Figure 45 is a cross-section view of the biscuit of figure 43;

Figure 46 is a plan view of one of the lower connecting plates of figure 36;

Figures 47 and 48 are cross-section views of the lower connecting plate of figure 46;
Figure 49 is a plan view of the other lower connecting plate of figure 36;

Figures 50 and 51 are cross-section views of the lower connecting plate of figure 49;
Figure 52 is a plan view of a packing shim;

Figure 53 is a cross-section view of the packing shim of figure 52;
Figure 54 is a plan view of the temporary plate of figure 36;

Figure 55 is a cross-section view of the temporary plate of figure 54;

Figure 56 is a plan view of a lower connecting plate and an associated locking member;
Figure 57 is a cross-section view of the lower connecting plate of figure 56;

Figure 58 is a cross-section view of the locking plate of figure 56;
Figure 59 is a plan view of the locking plate of figure 56;

Figure 60 is a cross-section view of the locking plate of figure 59;

Figure 61 is. a view of an underside of the lower connecting plate and locking member of figure 56;

Figure 62 is a plan view of the lower connecting plate and locking member of figure 56 and another lower connecting plate and fasteners;

Figure 63 is a plan view of a pair of upper connecting plates and an associated biscuit;

Figure 64 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 63;

Figure 65 is a plan view of a pair of upper connecting plates and an associated biscuit;

Figure 66 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 65;

Figure 67 is a plan view of a pair of upper connecting plates and an associated biscuit;

Figure 68 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 67;

Figure 69 is a plan view of a pair of upper connecting plates and an associated biscuit;
Figure 70 is a plan view of a pair of upper connecting plates and an associated biscuit;

Figure 71 is a plan view of a pair of lower connecting plates configured to form a connection with the plates of figure 70;

Figure 72 is a plan view illustrating one of the upper connecting plates of figure 70 in more detail;
Figures 73 and 74 are cross-section views of the upper connecting plate of figure 72;

Figure 75 is a plan view illustrating the other of the upper connecting plates of figure 70 in more detail;
Figure 76 is a cross-section-view of the upper connecting plate of figure 75;

Figure 77 is a plan view of the biscuit of figure 70;

Figures 78 and 79 are cross-section views of the biscuit of figure 77;

Figure 80 is a plan view illustrating one of the lower connecting plates of figure 71 in more detail;
Figures 81 and 82 are cross-section views of the lower connecting plate of figure 80;

Figure 83 is a plan view illustrating the other of the connecting plates of figure 71 in more detail;
Figures 84 and 85 are cross-section views of the lower connecting plate of figure 83;

Figure 86 is a plan view of a locking member;

Figures 87 and 88 are cross-section views of the locking member of figure 86;
Figure 89 is a plan view of an upper connecting member;

Figures 90 and 91 are cross-section views of the upper connecting member of figure 89;
Figure 92 is a plan view of a bridge member;

Figure 93 is a cross-section view of the bridge member of figure 92;
Figure 94 is a plan view of a biscuit;

Figures 95 and 96 are cross-section views of the biscuit of figure 94;
Figure 97 is a plan view of a lower connecting plate;

Figures 98 and 99 are cross-section views of the lower connecting plate of figure 97;
Figure 100 is a plan view of a lower connecting plate;

Figures 101 and 102 are cross-section views of the lower connecting plate of figure 100;
Figure 103A is a cross-section view of a rod;

Figure 103E is an end view of the rod of figure 103A;

Figure 104 is a plan view of a pair of lower connecting plates and their respective columns and fasteners;

Figure 105 is a plan view of a pair of upper connecting plates configured to form a connection with the plates of figure 106, their associated biscuit and columns, and fasteners;

Figure 106 is a plan view of a pair of lower connecting plates and their respective columns and fasteners;
Figure 107 is a plan view of a pair of upper connecting plates, their associated biscuit and columns, and fasteners;

Figure 108 is a cross-section view of a structural connection incorporating the components of figures 104 to 105;

Figure 109 is a plan view illustrating one of the like upper connecting plates of figure 108 in more detail;
Figures 110 and 111 are cross-section views of the connecting plate of figure 109;

Figure 112 is a plan view illustrating one of the upper connecting plates of figure 107 in more detail;
Figures 113 and 114 are cross-section views of the upper connecting plate of figure 112;

Figure 115 is a plan view of the biscuit of figure 108;

Figures 116 and 117 are cross-section views of the biscuit of figure 115;

Figure 118 is a plan view illustrating one of the lower connecting plates of figure 108 in more detail;
Figures 119 and 120 are cross-section views of the lower connecting plate of figure 118;

Figure 121 is a plan view of a bar forming a mounting point;

Figures 122 and 123 are cross-section views of the bar of figure 121;

Figure 124 is a plan view of the other of the lower connecting plates of figure 108 (certain details are omitted);

Figure 125 is a cross-section view of the lower connecting plate of figure 124;

Figure 126 is a plan view of the locking-member of the structural connection of figure 108;
Figure 127 is a cross-section view of the locking member of figure 126;

Figure 128 is a plan view of the lower connecting plate of figure 124;

Figure 129 is a cross-section view of the lower connecting plate of figures 124 and 128;
Figure 130 is a plan view of an upper connecting plate:

Figure 131 is an enlargement of detail 131 of figure 130;

5 Figure 132 is a side view of the upper connecting plate of figure 130;
Figure 133 is an end view of the upper connecting plate of figure 130;

Figures 134 and 135 are cross-section-views of the upper connecting plate of figure 130:
Figure 136 is a perspective view of the upper connecting plate of figure 130;

Figure 137 is a plan view of a lower connecting plate;

10 Figure 138 is a side view of the lower connecting plate of figure 137;
Figure 139 is an end view of the lower connecting plate of figure 137;

Figure 140 is a cross-section-view of the lower connecting plate of figure 137;
Figure 141 is an enlargement of detail 141 of figure 140;

Figure 142 is a view of the underside of the lower connecting plate of figure 137;
Figure 143 is a cross-section-view of the lower connecting plate of figure 137;
Figure 144 is a perspective view of the lower connecting plate of figure 137;
Figure 145 is a plan view of a lower connecting plate;

Figure 146 is a side view of the lower connecting plate of figure 145;
Figure 147 is an end view of the lower connecting plate of figure 145;

Figure 148 is a cross-section-view of the lower connecting plate of figure 145;

11.
Figure 149 is an enlargement of detail 149 of figure 148;

Figure 150 is a view of the underside of the lower connecting plate of figure 145;
Figure 151 is a cross-section-view of the lower connecting plate of figure 145;
Figure 152 is a perspective view of the lower connecting plate of figure 145;

Detailed description of the embodiments In broad concept the applicant has realised that the building units per se (which delineates the interior space of the unit) can be considered separately from the structural frame of the unit, when this is implemented, in a preferred form, this can allow both flexibility of design an improved ease of manufacture.

In terms of ease of manufacture the building units can be manufactured to relatively relaxed tolerances, say 20mm, which is relatively easy to achieve. The structural frame segments can be manufactured to much tighter tolerances, say within 1 mm so as to provide an accurate framework for the building. The building unit and associated structural frame segments assemblies can then be attached together in a manner that accounts for any inaccuracy in the building unit to form a building.unit assembly for assembly into the building.

The preferred variants provide an independent column system that sets up an accurate dimensional grid from which to dimensionally reference all other building elements.

In alternative systems where the structural frame for the building forms part of its framework for the building the whole unit needs to be manufactured to meet the tighter tolerances required by the frame, which is expensive and complicated.

In terms of design and flexibility, de-coupling the design and manufacture of the structural frame segments from the units gives a designer flexibility to position the structural frame segments at a broad range of positions relative to the building unit. This allows flexibility of design that is not practically possible if the structural frame of the building unit is built into the walls of the unit.

The applicant's unitised building system can be used for constructing buildings to be used for any purpose including, but- not limited to, residential, hotel and office use.
Preferred embodiments are also suitable for high rise use, that is to say for buildings which have four levels or more above ground level.

As will be explained in more detail below, variants of the system can have the following features: the building unit's length, width and height can vary from project to project; the building units can incorporate all components of a building including stairs, corridors and services; the building unit assemblies are constructed in a production facility; the completed building unit assemblies are transported to site for assembly; the building unit assemblies are lifted into position by construction cranes; there is minimal work on site to complete the buildings as the facade and interiors can be connected to or fitted in the building unit assemblies before delivery; special bolted connections can be used to connect the building unit assemblies together; and each building unit is structurally self-supporting and can have structural frame segments connected thereto so that when connected together the building unit assemblies including structural frame segments form the vertical and lateral support of the building.

Each building unit can be regarded as a rectilinear box frame which is structurally independent and self-supporting in terms of its own weight and the live loads it will carry.

The units can be constructed from a variety of materials including: timber framed construction with plywood bracing to walls, floor and roof plates; steel framed truss construction, using steel sections and profiled sheet steel to walls and roof and rolled steel channels and profiled sheet steel or purlins to floor, and profiled sheet steel construction constituting diaphragm wall and roof sections, the wall and roof sections being sufficiently rigid so as not to require additional cross bracing and therefore the sheet steel walls constitute a major part of the strength of the unit in the manner of monocoque or systems used in the automotive and aerospace industries.

The building units may have four or more structural frame segments in the form of load bearing columns including structural steel or concrete column elements fixed to their exterior to carry the total loads and form, in combination with the building units, the building structure. The column elements are designed to take the load .that its position within the structure imposes. Additional structural support can be included, if required, to spread load or increase rigidity. This can be regarded as forming an exo-structure for the building units that will be connected together with the exo-structure of neighbouring units to form the load bearing structure of the building.

The exo-structure occupies a zone outside the building unit's occupiable interior space so that there is no conflict between the two in terms of constructability and assembly. The structural zone between the building units typically ranges from 100mm to 150mm. This zone is where all structural frame segments are located and where all connections that lock together the entire building, are made.

The advantage of this in constructability terms is that the building units, the exo-structure comprising the structural frame segments of the building unit assemblies and the facade elements can, after fabrication, be temporarily aligned and even locked together at the production facility, in the exact positions they will occupy in the multi story structure due to the accuracy of the placement of the structural frame segments.

This process facilitates checking of tolerances to ensure ease of assembly on-site and quality control. It also allows finishing at ground. level, which is far more cost effective and less dangerous than doing so in an elevated position on site, as would be the alternative in a high-rise building. This makes building and facade tolerances much easier to check, manage and achieve during the manufacturing stage rather than in the assembly stage.

The structural frame segment or column elements thereof may increase in size with the increase in building height and/or load bearing requirements. The elements are sized to suit their position within the structure so that the building unit assemblies at the base of the building may have larger column elements connected to them compared to those at the top. The building units can, however, remain unchanged as they are designed to support only themselves.

The building units transmit lateral loads through the walls, roof and floor plates to the stability or bracing elements. These stability elements can be in the form of other units placed in the opposing direction to the main bulk of the units. They can be framed cores within selected units or a conventional concrete or steel framed core system, subject to the height of the building. Vertical loads within the building units are transferred through their sidewalls to the structural frame segments, which are connected thereto.

The building unit in its most basic form can be regarded as a box frame supported at four points with open ends. The structure is light and highly resistant to wind and earthquake loads. It is also sufficiently weather proof to allow it to be transported and erected without the possibility of water damage to the interior elements.

The building unit's interiors are unaffected by structural elements as all columns are outside the skin of the units in a column zone of 100mm to 150mm. This zone remains the same regardless of the building height of up to 50 stories. This is achieved by maintaining the column width while increasing the column depth and strength.

For some structures, usually low to medium rise structures, the lateral load can be taken out by turning some of the building units perpendicular to the general direction of the other building units. This will be determined by the layout of the building. Alternatively, the ends of the units can be stiffened by using heavier frames and/or bracing additional walls, or introducing additional elements to suit the loading conditions of each particular building or site. The lifts and stairs can also be framed to take the lateral loads. The lifts and stairs can be incorporated within a building unit assembly or be constructed separately.

For taller structures beyond 12 to 15 levels, a more conventional bracing system utilizing an in situ concrete core can be advantageous. Where an in situ concrete core is utilised as the main bracing element, the core would be partially or fully constructed prior to installation of the fabricated building unit assemblies.

For very tall buildings it may be necessary to introduce concrete or steel transfer structures where the requirements of practicality and economy are required or to suit altered loading or bracing requirements dictated by the building design and site conditions.

This effectively breaks up a tall building into two or more stacks of units carried by a concrete or a. steel core structure. Where a concrete core is utilised, it can also b.e used as a supporting element through the use of transfer structures which transfer the vertical loads back to the core, thus reducing the sizes of the structural frame segments connected to the building units, thereby effectively reducing the building to a series of smaller structures. For example, a 20 level building could incorporate three transfer structures, thereby reducing the effective height for the structural frame segments to what would be required for a five level building.

The transfer structures could be connected to the structure of the building unit assemblies themselves so that the transfer structures would be assembled with the building unit assemblies.

Alternatively, the transfer structures could be provided as a separate steel or concrete structure, depending on the circumstances.

As indicated above, the building unit assemblies can be of a size which is varied according to requirements and transport limitations. Typically, however, each building unit assembly would have a width of say 2m to 5m, a length from 1 Om to 28m and a height from 2.7m to 3.3m.

It will further be appreciated that in a building, building unit assemblies of different sizes and shapes can be arranged so as to produce required floor plan areas for the useful space of the building. The sidewalls of a building unit can have openings formed therein for doors, windows etc.
Corridors and balconies, etc., can also be added.

Figure 1 shows a schematic view of a building unit assembly 2 constructed in accordance with an embodiment of the invention. The building unit assembly 2 includes a building unit including two sidewalls 4 and 6, floor 8 and roof 10, with structural frame segments, in the form of column elements 16, 18, 20 and 22 attached thereto.

In the illustrated arrangement, the ends 12 and 14 are open but these could be closed in accordance with requirements. As will be described in more detail below, the sidewalls 4 and 6, floor 8 and roof 10 are of robust construction so that the building unit assembly 2 is capable of being self supporting during transport and lifting. It is also capable of withstanding loads which are applied to it in use such as the internal fit-out and live loads. As will be described in more detail below, the building unit assemblies 2 can be manufactured in a factory remote from where a building using the units 2 is to be erected (e.g. in a factory or other production facility), Manufacturing building unit assemblies in the manner of industrial products lends itself to cost and time savings and achievement of better manufacturing tolerances in the 5 finished units.

In the illustrated arrangement, the building unit assembly 2 has four column elements 16, 18, 20 and 22 connected to the sidewalls, the elements 16 and 18 being connected to the sidewall 4 and the elements and 22 being connected to the sidewall 6. As will be described below, the function of the structural frame segments is to provide mounting points for the building unit assemblies 2 and also to bear vertical 10 loading when the building unit assemblies are stacked on top of each other.
The elements 16, 18, 20 and 22 include respective lower mounting means 24 and respective upper mounting means 26. The upper mounting means 26 can form the attachment point for lifting cables during transport and construction stages. Also the members 24 and 26 can be used for coupling adjacent building unit assemblies 2 to each other in a completed building, as will be described in more detail below.

15 Figures 3 to 8 illustrate the interconnection of 4 building units. Figure 3 shows an isometric view of a building unit assembly 28 which has a load bearing column 18B the upper end of which terminates in a mounting member in the form of upper connecting plate 2188. The column 18B is connected to the sidewall 4B of the building unit assembly 2B. The length of the structural frame segment 188 is chosen so that the top of the upper connecting plate 218B is located about 100mm above the plane of roof 108.

20 The upper connecting plate 218B defines a rearwardly projecting horizontal flange carrying a bore 2228, and forwardly projecting tab 220B carry a bore 2238. Tab 220B defines a stepped profile. An elongate connecting rod 207B having threaded ends is passed through the bore 222B and its lower end engages a threaded coupling member (not shown) located adjacent to the bottom of the structural frame segment 188, as will be described in more detail below. A nut 209B is tightened on the threaded end of the connecting rod 207B to lock the unit 2B to an underlying building unit (not shown).

Figure 4 shows a building unit assembly 2A positioned along side building unit assembly 2B. The load bearing column 20A of building unit assembly 2A sits in front of and adjacent to the load bearing column 18B of the building unit 2B.

The upper end of the load bearing column 20A terminates in a upper connecting plate 218A. The upper connecting plate 218A includes a forwardly projecting horizontal flange carrying a bore, and a rearwardly projecting tab 220A carrying another bore. The tab 220A defines a stepped profile complementary to the stepped profile of upper connecting plate 218B so the tabs 220A and 220B are interleaved so that their bores sit side by side. According the described variant there is a spacing of about 5mm between to stepped profiles to allow for production variations.

Towards the other end of the building unit assemblies 2A and 2B (not shown), the structural frame segments 22A and 16B are similarly disposed.

After alignment of the building unit assemblies 2A and 2B, a further building unit assembly 2C is lowered on top of the building unit assembly 2B. The building unit assembly 2C carries a structural frame segment 20C the lowered end of which terminates in a lower connecting plate 206C. The lower connecting plate 206C includes a forwardly projecting horizontal flange carrying a bore, and a rearwardly projecting horizontal flange carry two bores. As building unit assembly 2C is lowered it is aligned so that the bores of its rearwardly projecting flange align with the bores of tabs 220A and 2208.

A coupling member 233B is subsequently connected to the projecting end of the connecting rod 207B.
The coupling member 233B is essentially an elongate nut which can receive the threaded lower end of an upwardly adjacent elongate connecting rod 207D (as shown in Figure 6).

The lower connecting plate 206C includes tapered projection 211C for mating with a complementary recess 221A formed in the upper connecting plate 218A. As the building unit assembly 2C is lowered it is aligned such that the projection 211C enters the recess 221A and because of their complementary tapering shapes, this will tend to automatically correctly align the building unit assemblies 2C and 2A. As the building unit assembly 2C is lowered, all of its projections 211 and 217 will enter corresponding recesses 221 of the building unit assembly 2B. Bolts 224, 225 and 226 can then be introduced through the aligned bores in the plates 206C and 218A, 218B. More particularly, the bolt 224 passes through the bores 212C and 222A; the bolt 225 passes through the bores 214C and 223A and the bolt 226 passes through the bores 213C and 223B. Nuts 227, 228 and 229 can be tightened on the respective bolts to securely couple the plates together, as shown in Figure 6.

After all of the nuts have been tightened, a fourth building unit assembly 2D
can then be lowered into position above the building unit assembly 2A. For clarity of illustration in Figures 6 and 7, only the structural frame segment 20D of the building unit assembly 2D is shown. The lower end structural frame segment 20D terminates in a lower connecting plate 215. The lower connecting plate includes a tapered projection 217D for mating with a complementary recess 221B formed in the upper connecting plate 2188.

The fourth building unit is lowered into position such that its projections 217D enter the recess 221 B of the building unit assembly 28. The four tapering projections of the building unit assembly 2D will assist in correct alignment of the building unit assembly 2D above the building unit assembly 2A.

Figure 7 shows the final position of the various plates. Figure 8 shows the a partially exploded view of the various components. It will be seen that the plate 215D bears against the plate 218B and is held in position by means of the elongate connecting rod 207D, as shown. The elongate connecting rod 207 is preferably made from 30mm diameter steel rod and is threaded at its ends or along its entire length.

It will be appreciated that the nuts 227, 228 and 229 can be tightened before the fourth building unit assembly 2D is lowered into position. Once this occurs, there is no access to the connecting plates and the use of the elongate connecting rod 207D enables the final connection to be made by assemblers working from the roofs of the upper building unit assemblies 2C and 2D. The normal procedure for fitting the elongate connecting rod 207D would be to screw its lower end into the coupling member 2338 prior to positioning of the fourth building unit assembly 2D. The building unit assembly 2D is then positioned above the building unit assembly 2A and the upper end of the rod 207D is aligned with the bore 222 of . the top plate (not shown) of the structural frame segment 18D. The building unit assembly 2D can then be lowered so that the upper end of the rod 207D passes through the bore. A
similar sequence occurs for all of the structural frame segments of the building unit assembly 2D.

It will be appreciated that the describe plates constitute mounting members predominantly formed of plate material, that the bores of tabs 220A and 2208 constitute engagement points, and that the plate 206C is engaged with the bores via bolts 225 and 226.

The illustrated arrangement provides a very robust connection both vertically and laterally for the connecting plates and hence for the structural frame segments. This imparts rigidity and stability to the building.

Figure 9 shows a perspective view of an alternative connecting plate. In general terms the structural frame segment 800 illustrated is substantially similar to those structural frame segments already described herein and accordingly only one end thereof is illustrated in this figure. In this regard, the structural frame segment 800 includes a support column 802 and a connecting plate 804. In this example, the connecting plate 804 has a first end which Is generally rectangular 806 and a second end 808 which is tapered. Thus, in plan view the connecting plate 804 is generally trapezoidal in shape as best illustrated in figure 10. As with the previous embodiments, the connecting plate has a central recess 810 for receiving an engagement means from a similar connecting plate of a vertically adjacent structural frame segment and a number of bolt holes 812 and 814 for fastening to other connecting plates of adjacent structural frame segments. The structural frame segment 800 in use is mounted to a building unit with the wider side of the trapezoidal connecting plate 804 nearest the building unit.
Accordingly, face 816 of the connecting plate 804 tapers towards the wall of the building unit to which it is attached. As will be described this arrangement provides a lead in to assist with aligning laterally adjacent building units.
Figure 10 illustrates a plan view of the connecting plate 804 to better show its shape. In preferred forms of this structural frame segment 800 the column element 802 is mounted such that one of its surfaces is substantially aligned with surface 818 of the connecting plate and more preferably that it has an edge 820 which is substantially vertically aligned with the vertex 822 of the trapezoidal connecting plate 804. The reason for this preferred alignment will be described below.

Figure 11 illustrates three building unit assemblies 828, 830 and 832 which are to be positioned side-by-side to construct a level of a building. Each of the building unit assemblies 828, 830 and 832 comprise a rectangular building unit with four structural frame segments attached thereto. As can be seen in building unit assembly 828 the structural frame segments 834 and 836 are mounted such that their tapered sides 834A and 836A face inwardly, towards each other. On the other side of the building unit the structural frame segments 838 and 840 are mounted in the opposite sense so that their tapered faces 838A and 840A taper away from each other. In this manner, the tapered faces of the connecting plates operate like a tapered guide assembly with respect to a horizontally adjacent building unit assembly. This gradius effect between neighbouring building unit assemblies allows accurate and easy positioning of the building unit assemblies with respect to each other on site.

Figures 12 to 14 illustrate a manner in which neighbouring building unit assemblies come together using this guiding effect. In figure 84A two building unit assemblies 844 and 846 are positioned side by side and spaced apart. In this position their oppositely directed connecting plates 844A and 844B are aligned. In figure 84B as the building unit assemblies 844 and 846 come together, the tapered faces of the connecting plates 844A and 846A of their respective structural frame segments come together such that they engage. The tapered faces provide guiding surface which is angled and as the units move together is used to guide the building unit assemblies 844 and 846 into the correct relative alignment. To illustrate the misalignment, in figure 84B the building unit assemblies 844 and 846 are out of alignment by distance X. In this case when correctly aligned, the Z purlins 850 and 852 will be in alignment - although alignment of the structural frame segments is the key for structural integrity reference to the purlins is made for convenience in illustrating the alignment distance.

Turning now to figure 14 which shows the final accurately positioned locations of the building units 844 and 846. As can be seen the building unit assemblies are in position such that the structural frame segment 844A and 846A are aligned along the column gap 854 between the building units and they are substantially in contact along their tapered faces. They can now be joined together as described elsewhere herein, by bolting, welding or other means.

As can be seen from figures 12 to 14 the tapered faces of the connecting plates operate as guiding surfaces to allow for easy alignment of building units in the horizontal direction. However, the outermost face of the columns of the structural frame segments and particularly the horizontally extending edge of the column element which substantially aligns with the obtuse vertex of the trapezoidal connecting plate also acts as guiding surface in the event that there is poor vertical alignment between building unit assemblies during positioning. This vertical guiding will almost always be needed as the building unit assemblies will typically be lowered into position using a crane. To further explain this, figure 85 shows the same portion of a structural frame segment as shown in figure 81 but has cross-hatching to illustrate those portions of the structural frame segment 800 which may be used as guiding surfaces during assembly of a building.

In order to facilitate smooth guiding of the building unit assemblies into position the guiding surfaces of the column element 802 are substantially aligned with the guiding surfaces of the connecting plate 804.
As will be appreciated, perfect alignment need not be necessary particularly where only a small discontinuity in the guiding surface exists, such as at a welded joint between the column element 802 and the connecting plate 804. In this case, the weld itself will tend to provide an angled surface which acts as part of the guiding surface to relatively smoothly bridge the discontinuity in alignment. As will be appreciated, with this preferred alignment even if two building units are brought into contact such that their connecting plates are not horizontally aligned the guiding surface 860 of the column element 802 will contact a guiding surface of the corresponding connecting plate of the adjacent building unit and allow smooth guiding of the building unit element into place in correct alignment as described above.

Whilst the arrangements of figures 1 to 15 represents a significant advance over the prior art, the applicant has developed a range of further improvements.

It has been realised that the insertion of bolts 225 and 226 can be difficult and that this might be improved by relatively locating the bores of the tabs 220A and 220B prior to the placement of the upper building unit assemblies. It has. been found that this is best achieved with some form of interlocking structure. In its simplest form this might involve simply reducing the design spacing between the interleared tabs 220A
and 220B whereby the tabs 220A and 220B engage when units 2A and 2B are placed alongside each other so that their bolting apertures are relatively located.

Figures 16 and 17 illustrate a complementary set of upper and lower connecting plates. The upper connecting plates 218 of figure 16 are similar to the connecting plates 804 of figures 9 to 15 in that they present an inclined face forming a lead-in which assists to relatively align laterally adjacent building unit assemblies. The connecting plates 218 each include at a mid-point along their inclined face a short step 300. Step 300 extends about 10 millimetres or so in the fore-aft direction.
The plates 218 are dimensioned to define a continuous 1 millimetre wide cap between their inclined-stepped faces when "ideally" aligned. As such an adjacent building unit assembly can be moved into position and its column and the inclined-stepped face of its upper connecting plate 218 will co-operate with the inclined-stepped face of the upper connecting plate 218 already in place to assist with the relative alignment of the building unit assemblies. With further relative movement of the building unit assemblies the respective steps 300 of the upper connecting plates 218 bear against each other. As such the steps 300 define a positive stop for restraining the building units in one direction (ie. from moving towards each other) to relatively locate the plates 218 and in turn relatively locate their bolting apertures 223.

The upper connecting plates 218 of figure 16 also differ from the previously described upper connecting plates by the bores 214 and 223 being tapped, in this case with an M24 thread.
This allows the lower connecting plates 206 of an upwardly adjacent building unit assembly to be bolted to the upper connecting plates 218 of figure 16 without underlying nuts. It will also be observed that in this 5 embodiment each upper connecting plate of figure 16 is substantially identical. Of course, using common components is desirable in terms of reducing inventory costs and improved economies of scale.

The lower connecting plates 206 of figure 17 include three bores each being tapped with an M30 thread.
These bores are sufficiently large for an M24 bolt to pass through to engage with the upper connecting plate 218 of the underlying building unit, but being tapped leaves the option of an M30 threaded structure 10 being engaged therewith (e.g. one of the M30 bores could replace the connector 233B of figure 8).

Figure 18 illustrates an alternative pair of upper connecting plates 218.
These plates also include a surface inclined in the horizontal plane to provide a lead-in, but rather than a central longitudinal step 300 include short lateral steps towards each side. The short lateral steps provide positive stops to restrain relative movement of adjacent building units in one of the fore and aft directions.

15 Figure 19 illustrates a proposed form of lower connecting plate 206 wherein the plates include a complementary curved profile which engages to relatively locate the plates. A
spacing of about 2 millimetres between the plates is thought to be a desirable tolerance.

Figure 20 illustrates a further development of the upper connecting plates 218 illustrated in figure 18. The plates. of figure 18 include vertical interfaces defining the steps 300. The plates of figure 20, in contrast, 20 include inclined faces (ie faces tapered in the vertical plane). The tapered faces 300A and 300B are arranged whereby a first of the upper connecting plates may be positioned and a second may be aligned whereby it contacts the fixed upper connecting plate 218 but is slightly higher so that it can be lowered into position and as it does so, the inclined faces 300A and 300B co-operate to drive the upper connecting plate 218 which is yet to be fixed (and the building unit assembly to which it is attached) into an appropriate alignment wherein the bores 223 are relatively located.

Figure 21 illustrates a pair of lower connecting plates 206 which similarly (to the upper connecting plates described in figure 20) includes mating faces 302A and 302B which are tapered in the vertical plane so that as one of the plates 206 is lowered into position relative to the other plate 206 it is driven towards its correct location. The complementary mating faces 302A, 302B define a key arrangement. One of the plates 206 includes a triangular projection and the other includes a complementary triangular recess. The surfaces of the key formation 303 are also tapered in the vertical plane such that as the plates 206 lowered into position adjacent the other plate 206 it slides down inclined faces to be driven towards its correct location both in the longitudinal (ie fore and aft) and lateral directions.

Figures 22 and 23 illustrate a set of upper connecting plates 218 and lower connecting plates 206. One of the upper connecting plates 218 of figure 22 includes a truncated wedge-shaped projection 2200 which mates with a complementary recess 2202 formed within the other connecting plate 218 of figure 22 to form key arrangements 304. In this embodiment the faces of the truncated wedge-shaped projection, and the complementary faces of the recess, are tapered in the vertical direction.
The lower connecting plates 206 of figure 23 are relevantly similar to the lower connecting plates 206 of figure 21.

Figures 24 and 25 illustrate a set of upper connecting plates 218 and lower connecting plates 206. One of the connecting plates 218 of figure 24 includes a splayed projection 2400. The other connecting plate 218 includes a recess 2402 complementary. to the splayed projection 2400. When the projection 2400 and the recess 2402 are interlocked, relative movement of the plates 218 in both lateral and both longitudinal directions is prevented. As such relative movement of the bores 223 in the horizontal plane is prevented.
The peripheral faces of the splayed projection 2400 and the complementary recess 2402 are tapered in the vertical plane. The lower connecting plates 206 of figure 25 are relevantly similar to the lower connecting plates 206 of figure 17.

Figures 26 and 27 illustrate another set of upper connecting plates 218 and lower connecting plates 206.
Again, the upper connecting plates 218 incorporate interlocking structure 2600 in the form of an integrally formed truncated wedge like projection 2602 and a complementary recess 2604.

Figures 28 to 33 illustrate a pair of upper connecting plates 218 and an associated biscuit 305, unlike the previously described embodiments which included integrally formed key formations. According to this embodiment, each of the upper connecting plates 218 includes a shaped recess 2800 along its inclined face 2802 in which the biscuit 305 is receivable to relatively locate the upper connecting plates 218.

In this embodiment the biscuit or key 305 is generally bow-tie or butterfly shaped in that it has a central portion narrower than its end portions 2808. The recesses 2800 within the upper connecting plates 218 each have a shape complementary. to a respective half of the biscuit 305 and as such define a socket into which the biscuit 305 is received. The upper connecting plates 218 and are positively keyed together to prevent relative motion in both lateral and both longitudinal directions.
In this embodiment the plates 218 are about 40 millimetres thick. The complementary recesses are about 25 millimetres deep. The biscuit 305 is 25 millimetres thick and has a taper 2900 of 5 millimetres per side about its periphery. The biscuit 305 includes two apertures 2902, 2904 each positioned to overlie a respective bore within a respective complementary recess 2800. The arrangement is configured whereby the plates 218 can be aligned to within 5 millimetres of their desired position, the biscuit at least partly inserted into the complementary recesses and then bolted into position via the bolting apertures. As the biscuit 305 is driven downwardly by the bolting action its tapered sides 2900 drive the plates 218 toward the true location.

Figures 34 to 37 illustrate a further set of upper and lower connecting plates. Like the previously described embodiment, the upper connecting plates are keyed together by a 25 millimetre thick bow-tie shaped biscuit 305. The plates and biscuit of figures 34 to 37 are illustrated in more detail in figures 38 to 55. This variant of the invention incorporates an upwardly projecting stub 306, extending from an edge of one of the lower connecting plates 206, and a temporary plate 307. The temporary plate 307 is an L-shaped piece with two bolting apertures along its longer arm. During assembly of a building unit (eg within the factory environment) the temporary plate 307 is bolted to the other of the lower connecting plates 206 such that its shorter arm projects beyond the edge of the plate 206 to which it is bolted to engage a side of the stub 306. Thus the temporary plate 307 provides an alignment aid. Once the building unit is assembled the temporary plate is removed prior to the building unit assembly being shipped to the building site.

As illustrated the bow-tie shaped biscuit 305 is symmetrical and advantageously the upper connecting plates 218 of figure 34 are common.

Figures 38 to 55 illustrate top and bottom mounting plates for use within an embodiment of the present invention. The top mounting plate 218 is illustrated in Figures 38 to 40. In plan view, the top mounting plate 218 is generally trapezoidal and includes a series of mounting apertures 3802 through which the mounting plate is fastened to an overlying, lower connecting plate of a unit mounted above it. The mounting plates 218 additionally includes a central aperture 3804 for receiving a projecting portion of an overlying bottom mounting plate of a building unit above it. The aperture 3804 has a 5mm taper on it. At one end of the mounting plate 218, there is also located a receiving recess 3806 that is adapted to receive a biscuit 305 as described in connection with the previous embodiment.
In use, when two building units are brought into position such that the mounting plate 218 is positioned next to a neighbouring, like mounting plate, the recess 3806 provides a bow-tie, or butterfly shaped recess into which the biscuit 305 can be received. Bolting apertures 3808 are also provided in the recess 3806 to receive the bolts through the bow-tie 305.

An exemplary biscuit is illustrated in Figure 43 to 45. As can be seen, the biscuit is generally bow-tie shaped and includes a pair of bolting apertures 4302. The peripheral edges of the biscuit 305 have a taper 4304 to aid in insertion of the bow-tie into the aperture 3806 and also to enable the bow-tie be urged into the aperture 3806 to thereby drag the neighbouring mounting plates 218 into alignment with each other.

Figures 46 to 51 illustrate a pair of bottom mounting plates. A first mounting plate illustrated in Figured 46 to 48 is generally rectangular in shape and made of 25mm thick plate material.
The mounting plate 4600 includes a projection 211 on its underside which is shaped to be received into a corresponding recess in an upper mounting plate of a building unit mounted below it. The plate 4600 includes four bolting apertures 4602 for receiving fasteners. The second mounting plate 4900 illustrated in Figures 49 to 51 is similar in construction to the embodiment of Figures 46 to 48, in that it is generally rectangular shaped and includes a projection 211 on its underside. At one end the mounting plate 206 includes a pair of mounting apertures 4902 for receiving fasteners. Mounting plate 206 additionally includes a generally rectangular projecting stud 306, whose faces, or one point on it can be used as a datum point for the placement of other structures, or fittings forming part of the building unit to which the mounting plate 206 is fitted.

Figures 57 to 61 illustrate a lower connecting plate 206, rod 310 and locking member 308. The lower connecting plate 206 includes a tapered, generally rectangular, projection 5700 extending downwardly to perform. a function analogous to the projection 217D of figure 8. A central aperture 5702 through the tapered projection 5100 of the plate 206 carries the elongate rod 310. A lower end of the elongate rod 310 is fastened to a locking member 308. The locking member 308 is a broadly rectangular sheet of material about 20 millimetres thick which lies in a horizontal plane. It includes a central aperture 5704 by which it is fastened to an end of the rod 310. A lower-end face 5708 of the tapered projection 5700 of lower connecting plate 206 terminates in two spigots 309 which engage with complementary curves 5710 in the periphery of the locking plate 308 to define an orientation wherein the locking plate 308 lies within the footprint of the tapered projection. Figure 61 illustrates this orientation. As will be described in more detail in respect of other embodiments, when locking units together, the locking plate 308 is carried on the end of the tapered projection 5700 of plate 206 and inserted through an aperture formed in an upper connecting plate of an underlying unit and then rotated about the axis of the rod 310 by about 90 degrees into a second orientation so that its ends 5712 project outwardly beyond the sides of the tapered projection 5700. An upper end of the rod 310 is then engaged with a threaded fastener to draw the rod 310, and in turn the locking member 308 upwardly so that its projecting end portions 5712 engage with an underside of the upper connecting plate of the underlying building unit.

As illustrated the plate 206 of figures 57 to 62 includes a stepped interface surface 302 which is tapered in the vertical plain.

Figures 63 to 69 illustrate various alternative forms of plates. The upper connecting plate 218 at figure 63 cooperating with a large rectangular biscuit 305. The biscuit is bolted to the plates 218. One of the lower connecting plates 206 includes rebates 313 to receive the bolt head that is used to fasten the biscuit 305.
The upper plates 218 of Figure 65 are trapezoidal in form and use a butterfly shaped biscuit 305. The lower plates 206 include recesses 313 for receiving the biscuit retaining bolts (not shown). Figures 67 and 69 show upper connecting plates 218 cooperating with a butterfly shaped biscuits 305 arranged diagonally across the plates 218, transverse to the inclined faces 6700 of the plates. Plates 206, of Figure 69 are similar to those of Figure 64.

Figures 70 to 88 illustrate plates including various features of the previously described embodiments. The upper connecting plate 218 includes a recess 221 for receiving the tapered projection of a lower connecting plate of an overlying building unit. The upper connecting plate 218 of figure 72 to.76 is adapted to cooperate with a locking mechanism incorporating a locking member similar to the locking member 308 of figures 57 to 62. For this purpose the plate 218 includes downwardly projecting spigots 309 which abut the locking member 308 to define its outwardly projecting locked position.

The aperture 221 is spanned by a bridge structure 311. The bridge structure 311 projects sufficiently deep so as not to interfere with the locking member that is inserted into aperture 221. At its lower extent the bridge structure 311 carries a bolting aperture 312. The bolting aperture 312 constitutes a mounting point for carrying a threaded fastener to activate a locking mechanism. In use, the upper connecting plate 218 is fixed to an upper-end of a column that carries, at its bottom-end, a lower connecting plate 206 similar to the connecting plate of figures 57 to 62. An upper end of the rod 310 projects upwardly through the aperture 312 and is engaged by a nut. To connect the column to an upper connecting plate of an underlying building unit, the nut is initially tightened so that the locking plate 308 is retained in its aligned, insertion, position against an end face of the tapered projection of lower connecting plate 206. The locking member 308 and the tapered projection of lower connecting plate 206 is then received in the aperture 221 of the underlying upper-connection plate. Next the nut is partly released to allow the rod, and in turn the locking member 308, to drop below the spigots 311 so that the locking member 308 can be rotated by 90 degrees to its outwardly projecting, locking, second position. The nut is then tightened to draw the rod 310 upwardly so the locking member 308 whereby the locking member 308 is engaged with an underside of the upper connecting member of the underlying building unit.

The biscuit 7800 of this' embodiment is that illustrated in Figures 77 to 79.
It is generally bow-tie shaped and has a 5mm chamfer 7802 around its lower periphery 7804.

Figures 83 to 88 illustrate an alternative form of locking member 308 and lower connecting plate 206. This form of lower connecting plate 206 includes a groove 309 in place of the spigots 309 of the embodiment of figures 57 to 62. The locking member 308. includes a ridge 308A
complementary to the groove 309.
The ridge 308A and the groove 309 together constitute a detent. The lower connecting plate 206 also includes a tranverse groove 309A which in use aligns with transverse grooves 3096 formed in an underside of the upper connecting plate 218 of figure 72. Grooves 309A and 3096 cooperate with the ridge 308A of the locking member 308 to define the outwardly projecting, locking, position of the locking member 308.

Figures 89 to 103 illustrate a further set of plates and locking components.
The upper connecting plate 218 of figures 89 to 93 are adapted to receive a bridge structure 311 (see figs 92 and 93) in the form of a separate component. Preferably the bridge 311 is a separate integrally formed piece. The bridge 311, shown in cross-section in Figure 93, is generally U shaped, and has a hole 9300 at its centre for receiving a fastening member. The upper outer edges 9302, 9304 of the bridge 311 have an outwardly extending tab that is used to support the bridge 311 in use. The tabs 9302, 9304 are received into indentations 9002 and 9004 (best shown in Figure 90) to support the bridge 311 therein, within aperture 9006. The plates 208 includes a recess 8902 for receiving a biscuit 305 (shown in Figures 94 to 96) in a manner analogous to the previous embodiments.

The lower connecting plate 10000 of Figure 100 to 102 is adapted to operate in a manner similar to that 5 of Figure 80 to 85. The plate 10000 includes a control aperture 10002 at the tower end of rod 10300 in use.

Again, and as best illustrated in figure 97 one of the lower connecting plates 206 includes a pair of rebates 313 on its underside. The rebates 313 provide clearance for bolt heads which in use retain the biscuit 305. Figures 94 to 96 illustrate a further embodiment of locking biscuit 305. According to this 10 embodiment the biscuit is about 18 millimetres thick, but rather than having continuously tapering edge surfaces it includes a 5 millimetre by 5 millimetre chamfer all about its lower peripheral edge. Figures 104 to 129 illustrate a preferred form of a structural connection and various components therefor.

Figure 108 is a vertical cross-sectioning view through the structural connection of figure 105. The structural connection illustrated in figures 106 and 107 is a 'mirror image' of the structural connections 15 104, 105 and 108 for connection on the other side of a building unit.

With reference to figure 108, two like columns 18 and two like columns 20 cooperate to form a structural connection between four building units including two building units in a lower layer and two building units in an upper layer.

Each column is formed from square profiled rectangular hollow section (RHS) having a wall thickness of 20 about 10mm and an external dimension of 150mm capped at its lower extent by a lower connecting plate 206 at its upper extent by an upper connecting plate 218.

A building unit of the lower layer carrying a column 20 is first to be placed.
The upper connecting plate 218A at the upper end of column 20 is a broadly symmetrical elongate trapezoidal form which presents an inclined surface at each end. The upper connecting plate 2186 of column 18 is a like component but in 25 use rotated to an orientation 180 degrees from that of the upper connecting plate 218A.

The second of the building units of the lower level, which carries one of the columns 18 of figure 108, is next to be placed. An exterior of the column 18's rectangular hollow section and the inclined surface of its upper connecting plate 218B cooperate with the inclined face 302 of the upper connecting plate 218A to locate the second lower building unit relative to the first lower building unit and to locate the upper connecting plates 218A and 218B to within about 5mm or so of the desired location.

The plates 218A and 2188 are keyed together by bow tie shaped biscuit 305.
which is received within complementary recesses 10802 formed in the upper surface of each of the upper connecting plates 218A, 218B. Bolts 314 are each passed through a respective aperture formed in the bow be shaped biscuit 305 to engage with threaded bores formed in the base of the complementary recesses. As best illustrated in figure 115 to 117 the biscuit 305 has upright perpendicular side walls. The complementary recesses are shaped to receive the biscuit 305 with a nominal clearance of 0.5mm per side. A 5mm by 5mm chamfer is formed about the upper edge about the periphery of each complementary recess.

As mentioned above, the building units of the lower layer are initially positioned side by side so that their respective upper connecting plates 218A and 218B are relatively positioned to within a tolerance of about 5mm or so. The biscuit 305 is initially placed in its approximate position (at least to within the outer extent of the chamfer about the complementary recesses), Bolts 314 are then passed through a respective bore in each half of the biscuit 305 to engage with bores formed in the base of the complementary recesses.
The bolts 314 are then tightened to drive the biscuit downwardly along the chamfered edges of the complementary recesses and thus drive the upper connecting plates 218A, 218B
towards a desired relative location whereby the thread bores 223 formed in each connecting plate are located relative to the threaded bores 223 in the other connecting plate. Once the bolts 314 are fully tightened the plate 218A
and 218B are fully restrained, ie they cannot move relatively in any direction.

Next to be installed is the building unit of the upper layer bearing one of the columns 18 of figure 108 (hereinafter the second upper building unit).

As illustrated the lower end of column 18 terminates in a lower connecting plate 206B which is illustrated in more detail in figures 118 to 120. The plate 206 of figure 118 is formed of plate material in which a central rectangular aperture 11900 is formed. This aperture 11900 is plugged by a block of material forming the tapered projection 211. The block of material forming the tapered projection 211 includes a stepped location groove 11902 about its upper most periphery by which it is seated into the rectangular recess of the plate material. A fillet weld 11909 between a rearward face of the block of material and a mid point of the face defining the rectangular aperture connects the block of material and the plate of material.

The tapered projection 211 is shaped to be received within and mate with the recess 221 of the upper connecting plate 2186 to relatively align the columns 18. As the upper building unit is lowered the heads of bolts 314 retaining the biscuit 305 are received within through holes 313 formed in the lower connecting plate 206 so that the plate 206 lies flush against the upper connecting plate 2188.

Of course the plates 206B and 218B need not bear directly against each other.
By way of example a packing material might be placed therebetween to adjust the relative spacing of the plates. As best illustrated in figure 118 the plate 2068 includes a rectangular array of bolting apertures 212. When the plate 206B is positioned over the plate 218B the bolting apertures 212 align with the relatively located threaded bores 223. Bolts 225 are passed through the bores 212 to engage with threaded bores 223 thus the first lower building unit, second lower building unit and second upper building unit are fastened together.

A further upper building unit which carries one of the columns 20 illustrated in figure 108, hereinafter the first upper building unit, is then moved into position.

The column 20 includes at a lower end a lower connecting plate 206A
illustrated in figures 124 and 128.
Like the lower connecting plate 206B, the lower connecting plate 206A is predominantly formed from plate material and includes a tapered projection 217 formed by a plug of material welded into an aperture 12404 formed in the plate material.

The tapered projection 217 mates with the recess 221 in the upper connecting plate 218A to relatively align the columns 20.

The first upper building unit is locked to the first lower building unit with the aid of a locking mechanism including rod 310, member 311, contoured washer 314, nut 315 and locking member 308.

As best shown in figures 126 and 127 the locking member 308 is a more or less rectangular plate and includes a central threaded bore by which it is engaged with a lower end of the rod 310 (see figure 108).
The locking plate 308 is subsequently welded to the rod 310 and is thus fixed relative thereto.

The lower connecting plate 206A includes a bore passing centrally through the tapered projection 217 for carrying the rod 310. A rectangular array of four. downwardly projecting spigots 309 is positioned on an underside of the tapered portion 317. A diagonal pair of the spigots 309 projects downwardly by about 3mm. The pair of spigots on the other diagonal projects downwardly by about 10mm.

The locking member 308 includes four recesses 12600 about its periphery shaped to Cooperate with the spigots 309. The locking member 308 initially overlies the end of the tapered projection 217 to lie within its footprint. The side recesses 12600 on locking member 208 cooperate with the 3mm high spigots to retain this orientation (hereinafter the first orientation). As will be described the locking member 308 is subsequently released from the 3mm spigots and the locking member is rotated such that it cooperates with the 10mm spigots to assume a second locking position.

As illustrated in Figured 121 to 123, at an upper end of the Column 20 a solid cylindrical member 311 is passed through aligned holes in opposed walls of the column 20, which in this case is a rectangular hollow section. The member 311 is retained in place by fillet welds 12100 between the circumferential exterior of the cylindrical member 311 and an exterior of the column wall.

The member 311 carries a vertical through hole 312 central to the rectangular hollow section. The through hole 312 receives an upper end of the rod 310. The rod 310 is configured so that a short externally threaded end portion projects upwardly from the member 311. The contoured washer 314 is passed over the projecting rod portion followed by the nut 215 which threadingly engages with the rod.
The contoured washer 314 and member 311 thus constitute a mounting point which the nut 315 may bear against to upwardly draw the rod 310 and in turn the locking member 308 carried thereby.

This embodiment differs from others in that the mounting point of the locking mechanism is a separate structure rather than being a portion of a mounting plate.

In a factory environment before the first upper building unit is moved to the construction site, the locking mechanism is positioned in a first orientation wherein the locking member 208 bears against the 3mm spigots 309 and is retained against an underside of the tapered port projection 217 by an initial preload on the nut 315 so that it lies within a rectangular footprint of the projection 217.

On site once the first upper building unit has positioned the preload on nut 315 is released and the nut is loosened to allow the rod 310 and locking member 308 to sink by slightly more than 3mm whereby the locking plate 308 clears the 3mm spigots 309 and can rotate about an axis of the rod to engage with the 10mm spigots 309. In this embodiment a transverse slot is formed in an upper end of the rod 310 whereby a screwdriver or like tool may be engaged to rotate the rod about its axis.

Similar to the variant described in respect of figures 57 to 62, the 10mm spigots 309 define a second, locking, orientation where end portions of the locking member 308 project beyond the sides of the tapered portion 217. The nut 315 may then be tightened to draw the rod 310 upward and in turn the locking member 308 so that the projecting ends of the locking member 308 engage an underside of the upper connecting plate 218A of the unit below it about the periphery of the aperture 221. Tightening the nut 315 thus completes the actuation of the locking mechanism.

Figures 130 to 136 illustrate an upper connecting plate in accordance with a further embodiment of the invention. This plate 218 is broadly rectangular in shape. The upper and lower edges at one end of the plate include a 5mm x 5mm chamfer 300'. The chamfer 300' functions as a lead in to guide a like plate 218 of a horizontally adjacent building unit during installation, to assist with alignment as horizontally adjacent units are positioned relative to each other. The plate 218 also includes a central alignment hole 221, by which a complimentary projection of a cooperating lower connecting plate of an overlying module aligns with the plate 218 is formed of 3 sections:

an upper section 221A, an intermediate section 221 B and a lower section 221 C.

The lower section 221C has a vertical side, The intermediate section 221B has a slight taper diverging outwardly in an upward direction to receive the complimentary alignment projection of a lower connecting plate of an overlying building unit, to form a precise alignment therewith.
The upper section 221A has a 5mm x 5mm chamfer all about the edge of the aperture 221. The upper portion 221A acts as a guide to assist with the movement and alignment of the upwardly adjacent module from a rough initial alignment toward the true location.

The plate 218 includes a biscuit receiving recess 12800 which, like the plate 218 of figure 38 is adapted to cooperate with a biscuit 305, that is similar to that of figure 43. Unlike the previous embodiments, the biscuit receiving recess 12800 includes parallel side portions 12802 opening outwardly towards the end of the plate. Elsewhere the shape of the recess 12802 closely matches the outer periphery of the biscuit 305. The parallel side portions 12802 create a small triangular clearance on either side of the centre of the biscuit when the biscuit is installed. This clearance makes inserting the biscuit easier if the adjacent, plates 218 are misaligned.

'Figures 137 to 151 illustrate two further variants of bottom plate 206. The bottom plate 206 of figures 137 to 143 is similar to the plate of figure 118, except that its alignment projection 211 is formed into portions 211A, 21i B and is. surrounded by a machined recess 13000 formed in the underside of the plate body.
The upper, portion 211A of the alignment projection 211 is tapered and precisely dimensioned to cooperate with the hole 221B in the plate of figure 132 so that the upper and lower plates (and in turn their respective building units) are precisely aligned. The lower portion 211B
is tapered at a slightly greater angle, to create an additional clearance of about 0.1mm to 0.2mm per side. The peripheral edge of the free end of alignment projection 211 includes a 5mm x 5mm chamfer, The additional clearance and the chamfer together aid in alignment and insertion of the alignment projection 211 into the complementary aperture 221.

The machined recess 13000 is, in this embodiment, formed by a 20mm diameter cutter acting on the underside of the plate after the alignment projection 211 has been welded in place. Typically the recess is about 0.5mm deep. The machined recess 13000 allows for small misalignment between the alignment projection 211 and the plate body and ensures that the lower surface of the plate main body does not have any projections so that is mates neatly with the upper surface of a complementary upper plate 218.

Figures 146 to 152 show a lower connecting plate similar to the connecting plate of figure 124 which includes a machined recess 14000, which is similar to the machined recess 13000, encircling its alignment projection 217.

Throughout the present specification various connections formed by certain combinations of upper and lower plates have been described. Of course upper and lower mounting plates can be interchanged and fitted together in variations other than those made explicit are possible, with or without minor changes to dimensions or tolerances. By way of example, a connection may be formed using upper plates of the type 5 illustrated in figure 16 and the lower plates of figure 19, other combinations are readily able to be made..

Claims (29)

1. A structural connection for connecting four building units, each building unit including self supporting structure defining an internal volume and having at least one mounting member; the building units being mutually arranged such that there are two building units in a lower layer and two building units in an upper layer, the structural connection including.

one mounting member corresponding with each building unit; each said mounting member of the lower building units including at least one engagement point;

interlocking structure by which the mounting members of the lower building units are relatively locatable to relatively locate the engagement points;

the mounting member of a first of the upper building units being co operable with the mounting member of a first of the lower building units to transmit load thereto;

the mounting member of a second of the upper building units being co operable with the mounting member of a second of the lower building units to transmit load thereto and engageable with the relatively located engagement points of the mounting members of the lower building units to fasten the lower building units and the second upper building unit.

2. The connection of the claim 1 wherein the interlocking structure includes one or more portions tapered in the vertical plane providing a lead-in whereby vertical movement along the tapered portion horizontally drives the engagement points towards said relative location

3. The connection of claim 1 or 2 wherein the interlocking structure is configured to vertically drive the engagement points towards said relative location.

4. The connection of claim 1, 2 or 3 wherein the interlocking structure is configured to locate the engagement points to within 3mm of a desired relative location.

5. The connection of any one of claims 1 to 4 wherein the interlocking structure is configured to engage the mounting members of the lower building units to positively relatively locate the engagement points in at least two opposed directions

6. The connection of any one of claims 1 to 4 wherein the interlocking structure is configured to engage the mounting members of the lower building units to fully relatively restrain the engagement points.

7. The connection of any one of claim 1 to 6 wherein the interlocking structure includes a biscuit engageable with each of said mounting members of the lower building units.

8. The connection of claim 7 wherein the biscuit is fastened to one or both of said mounting members of the lower building units.

9. The connection of any one of claims 1 to 8 wherein each mounting member is predominantly formed of plate material.

10. The connection of any one of claims 1 to 9 wherein one or more of engagement points is a bolting aperture.

11. The connection of claim 10 wherein one or more of the engagement points is a threaded bore.

12. The connection of any one of claim 1 to 11 wherein each building unit further includes a respective load bearing column associated with each building unit and including at one end a respective one of said mounting members associated with the building unit, and at the other end another mounting member for forming a like connection with other building units.

13. The connection of claim 12 wherein the respective columns of the first lower building unit and the first upper building unit are substantially identical columns of a first type.

14. The connection of claim 13 wherein each first type of column carries an elongate rod by which a locking mechanism may be actuated from an upper end of said column to lock a lower end of said column to an upper end on an underlying column.

15. The connection of claim 14 wherein the locking mechanism includes a member carried by a lower portion of the rod that is shaped to pass through an aperture formed in the upper mounting member of the first lower building unit when in a first orientation; said actuation including rotating the shaped member about an axis of the rod to a second orientation.

16. The connection of claim 15 wherein the shaped member engages an underside of the mounting member of the first lower building unit when in the second orientation.

17. The connection of claim 14, 15 or 16 wherein an upper portion of the rod is engaged with a threaded fastener bearing against a mounting point fixed relative to an upper end of the unit column.

18. The connection of any one of claims 12 to 17 wherein the respective said columns of the second lower building unit and the second upper building unit are substantially identical.

19 A load bearing column for a building including an elongate rod by which a locking mechanism may be actuated from an upper end of said column to lock a lower end of said column to an upper end of a like underlying column; A building unit including self supporting structure defining an -internal volume and having at least one mounting member the locking mechanism including a member carried by a lower portion of the rod shaped to when -n a first orientation pass through an aperture formed in the upper end of the underlying column; said actuation including rotating the shaped member about an axis of the rod to a second orientation; the column -inlcuding one or more stops or detents defining the second orientation.

20 The column of claim 19 including one or more stops or detents defining the first orientation.

21. The column of claim 20 wherein the stops or detents take the form of projections which in use abut the shaped member

22. The column of claim 19, 20 or 21 wherein the stops and/or detents are formed at a lower end portion of the column.

23 The column of any one of claims 19 to 22 wherein the shaped member is positioned to engage an underside about the aperture when in the second orientation.

24. The column of any one of claims 20 to 23 wherein an upper portion of the rod is engaged with a threaded fastener bearing against a mounting point fixed relative to the upper end of the first unit column..

25. A mounting member for a structural connect-on; the member including at least two inclined peripheral guiding surfaces along which another mounting member is relatively slidable to a desired relative location

26. A building unit Including self supporting structure defining an internal volume and having at least one mounting member configured to be used to connect the building unit to three other building units using a connection as claimed -n any one of claims 1 to 18

27. A building unit including self supporting structure defining an internal volume and having at least one load bearing column as claimed -n any one of claims 19 to 24.

28 A building unit including self supporting structure defining an -internal volume and having at least one mounting member as claimed in claim 25

29. A building including at least one building unit as claimed in any one of claims 26 to 28.