GB2251006A - Modular building assembly - Google Patents

Abstract

A modular building set comprises a plurality of wall modules (12) to be arranged vertically on a site, each of said wall modules having a substantially horizontal open box-section structure (60) disposed between the top and bottom ends of the wall module at a predetermined height and which, when the building is assembled, communicates with the horizontal open box-section structure of the adjacent wall module or modules whereby a continuous recess is formed to receive wiring and/or plumbing. Each wall module is provided with wiring and/or plumbing prior to assembly of the building, and connecting means for the connection of the wiring or plumbing as each wall module is placed in position to form the building assembly. <IMAGE>

Description

MODULAR BUILDING ASSEMBLY This invention relates to a modular building assembly particulary for use as a dwelling or office accommodation.

Many constructions are known which enable a building to be erected on site from modules which have been factory assembled. An example of such a construction is described in the specification of Patent No An object of the present invention is to provide a modular building assembly designed to enable each module to be pre-assembled off-site to a greater extent than has hitherto been achieved. For example it is particularly desirable to provide a module with services such as electrical wiring and plumbing in order to reduce the amount of work when assembling the building on-site.

According to the invention there is provided a modular building set comprising a plurality of wall modules to be arranged vertically on a site, each of said wall modules having a substantially horizontal open box-section structure disposed between the top and bottom ends of the wall module at a predetermined height and which, when the building is assembled, communicates with the horizontal open box-section structure of the adjacent wall module or modules whereby a continuous recess is formed to receive wiring and/or plumbing.

Each wall module may be provided with wiring and/or plumbing prior to assembly of the building, with suitable connecting means for the connection of the wiring or plumbing as each wall module is placed in position on a respective base module. To achieve a continuous recess the open boxstructure, preferably a cold-rolled steel channel, extends across the entire width of the wall module which wall module is preferably a frame-like construction having upper and lower end box-section pieces and vertical box-section side members. For the sake of minimizing the wall thickness the channel lies within the overall thickness of the wall module.

In order to compensate for the loss of strength in the vertical side members and in order also to permit access to the inside of the vertical side members for the purpose of interconnection, each of the vertical side members is constructed from two cold-rolled box-section channels, each being substantially of U-section, the two channels being secured together, e.g. by welding, with their open sides facing inwardly of the wall module.

When the vertical side member of one wall module is locked to the vertical side piece of an adjacent wall module there results a support column of cruciform section with each limb being a double thickness of steel.

The invention will now be described by way of example with reference to the accompanying drawings in which: FIGURE 1 is a side elevation of a Dart of a bullo-nq assembly showing a single wall module at right angles adjacent wall modules, FIGURE 2 is a plan view of part of the arrangement shown in Figure 1, FIGURES 3, 4 and 5 are respectively elevation, plan, and underplan views of a base module, FIGURE 6 is a section taken along the line VI-VI of Figure 3, FIGURES 7 and 8 are an elevation and plan respectively of a floor module with wood cladding, FIGURE 9 is a section taken along the line IX-IX of Figure 7, FIGURES 10, 11 and 12 are respectively front elevation, side elevation and plan of a wall module, FIGURE 13 is a cross-section taken along the line XIII-XIII of Figure 10, FIGURE 14 is a part elevation showing a base module, a floor module and a wall module in an exploded view, FIGURE 15 7s a part elevation, with the modules in the assembled state, FIGURE 16 is a section of a quarter turn fastener suitable for connecting the modules together, and FIGURE 17 is an isometric view of the stud portion of the fastener of Figure 16.

A corner portion of the building assembly is shown in Figures 1 and 2 which is assembled from a plurality of each of three main modules, a base module 10, a floor module 11 and a wall module 12. The modules of each class of module are constructed so as to have the same standard dimensions of height, width and length.

The base module 10 comprises a cold-rolled steel open box-section structure of generally overall L-shape comprising a horizontal base portion 13, a vertical wall 14, a lower horizontal supporting wall 15, a vertical abutment wall 16, and an upper horizontal supporting wall 17. For the purpose of strengthening the structure the upper supporting wall 17 and the base portion 13 are provided with mutually aligned flanges 18 and 19 respectively which extend towards each other, their edges defining an aperture providing access to the interior of the structure for the purpose of interconnection of the modules.

The profile of the base module is therefore such as to provide a rebate defined by the horizontal support wall 15 and the adjacent vertical abutment wall 16.

The base module 10 is enclosed at each end by plates 20 of L-shape conforming to the overall section. As shown in Figure 6 the end plates 20 are provided with a pair of slotlike connecting apertures 21. Apertures of the same dimension to receive a quarter-turn fastener described below are provided in the vertical wall 14 and in the abutment wall 16. The connecting apertures are provided at various positions i the floor and wall modules and also in subsidiary modules and all bear the reference numeral 21.

For securing the floor module 11 against lateral movement relative to the base module 10 a pair of locating pins 22 are provided close to the ends 0 the module respectively which ch project upwards from said horizontal supporting wall 15.

Apertures 24 are provided in the base portion 13 for securing the base module to the foundation of the building.

The floor module 11 has a square overall profile in plan view (see Figure 8) and is constructed from two side channels 25, 26 and between them two pairs of channels 27, 28 and 29, 30 arranged back-to-back; all the channels being arranged parallel to each other. The ends of the channels are secured to end plates 31, 32 above which are provided edging strips 33, 34. A suitable cladding 35 is provided which may be floorboards traversing the channels and secured thereto by means not shown.

Circular apertures 36 are provided at the corners of the floor module on both sides to receive the locating pins 22.

The wall module 12 is a welded frame structure having lower and upper horizontal transverse members 40, 41 and vertical side members 42, 43, each member being formed of open box-section cold-rolled steel.

The lower and upper transverse members 40, 41 have the same profile and dimensions (see Figure 11) but are arranged as LI mirror image. Each transverse member 40, 41 comprises a first horizontal support wall 45, a first vertical abutment wall 46, and a second horizontal support wall 47. The first and second horizontal abutment walls 45, 47 are provided respectively with strengthening flanges 48, 49.

The profile of the transverse members is therefore such as to provide a rebate defined by the horizontal support wall 47 and the adjacent vertical abutment wall 46.

The vertical side members 42, 43 are each composite structures of the same profile and dimensions as each other but arranged in mirror image. The profile is shown in Figure 13 and comprises two cold-rolled box-section channels 50, 51 each of U-section, the two channels being secured together by welding with their open sides facing inwardly of the wall module. The channel 50 is provided with flanges 52, 53 which turn in towards each other whereas the channel 51 has flanges one, 54, of which turns inwardly and the other, 55, turns outwardly and lies against the flange 53.

Extending across the entire width of the wall module conveniently at dado level between and parallel to the upper and lower transverse members 40, 41 there is provided an open box-section channel 60 which as shown in Figure 10 communicates with the channel of the adjacent wall module so that a continuous recess is formed to receive services such as wiring or power or telephones and plumbing.

The channel 60 which has a profile substantially Ushaped having outwardly turned flanges 61, 62, lies within the thickness of the wall module. This necessitates the provision of suitable gaps in the vertical members 42, 43.

However, as seen from Figure 13 when the vertical member of one wall module is secured to the vertical member cf an adjacent wall module a substantially cruciform central support column results with each limb being a double thickness of steel plate.

By providing both channels of the vertical member in U-shaped form the interiors are accessible for connection purposes.

Slots 21 for connection are provided in the walls of the upper and lower transverse members and in the vertical members for securing adjacent modules to each other.

Locating pins 63 and 64 extending from the abutment walls 47 are engageable with apertures 36 in the floor module and serve to secure the wall module against movement relative to said floor module.

The procedure for assembly will now be described with reference especially to Figures 14 and 15.

The required number of base modules 10 are laid out to define the perimeter of the building assembly specified and secured to the foundation by bolts set into the foundations and which pass through the apertures 24 in the base modules. The base modules are levelled, using packing material where necessary, and aligned. The modules are fastened together by quarter-turn connectors of the kind having a head portion which passes through aligned slits in the adjacent base modules only from one side, the connector being movable by manipulation at said one side to a position so that the head can enrage the module whereby on tightening the connector the adjacent modules are drawn into close engagement. The connectors are applied from what is effectively the exterior of the building assembly.

The floor modules 11 are lowered in position on the base modules 10. Where say four floor modules are yrouped together the sides of the floor modules not being supported by base modules are secured together by the connectors. The four adjacent corners of floor modules not supported by base modules may be supported on a supplementary column (not shown) mounted on the foundation.

As shown in Figure 15, the circular apertures of the floor module are engaged by the locating pins 22, a lower marginal portion of the floor module seating within the rebate formed by the support wall 15 and the abutment wall 16. Wall modules 12 are then lowered into engagement with the base module 10 and the floor module 11, the locating pins 53 engaging the circular apertures 36 in the floor module.

The wall module is secured to the floor module by quarter-turn connectors inserted from the open side of the lower transverse member 40. Adjacent wall modules are also secured together by such connectors.

As can be seen in Figure 15 an upper marginal portion of the floor module seats within the rebate formed by the horizontal support wall 47 and the adjacent vertical wall 46.

The wall modules are supported by the engagement of the horizontal walls 17 and 45 of the respective base module and wall module. The walls are also supported through the marginal portion of the floor module which is engaged on each side by the horizontal support walls 15 and 47. Thus the floor module is held by compression which obviates the need for brackets or other supporting structures which are subject to shear forces.

The wall modules which are adjacent each other and extend both in the same direction may be secured to each other by connectors passing through adjacent walls of the vertical members. At the corners of the building where two wall modules are at right angles to each other a corner piece (not shown) may be provided. The corner piece is also of an open box-section accessible from the exterior of the building assembly and may have a suitable channel at dado level serving to effect communication between the service channels of the adjacent wall modules.

The upper ends of the wall modules are provided with rebates of similar dimensions to those of the base portion.

Therefore further floor modules may be lowered onto the wall modules and further floor modules to assemble another storey from replica modules. Where these further floor modules are not supported by a wall portion, a column may be provided particularly where the span is such that four adjacent corners would otherwise remain unsupported.

If no second storey is required the upper ends of the wall portions may support a number of beam units (not shown) to form a ceiling or roof support structure. When the roof level is reached, roof modules (not shown) incorporating guttering may be assembled.

Final sealing of the roof is completed from the roof surface using sealing strips and capping strips.

The above described modular construction enables all the.modules to be constructed and fitted out at the factory with services such as wiring, plumbing for gas and water, air conditioning ducts; the finished modules being positioned in the building assembly as substantially complete items (other modules, so-called module pods, not so far described, being in the form of toilet module, stair modules, input supply room modules, and kitchen modules).

The method of connecting the modules allows for a multi-storey building to be erected from single storey module items. Common frame units lock together to produce integrated jointed assemblies which both absorb and dissipate all the imposed, dead and wind loads throughout the structure. The joints are produced by locking the individual units together with the combined effect of both location pins and connectors. The joint system operates the same whether individual units are locked together or module pods are locked into the assembly.

Various plan shapes of the building may be selected by arranging the base modules into a predetermined boundary arranged on a grid matrix which may range from a single square floor module to square, rectangular or T-shape made up of many basic floor squares.

The building can be assembled without the use of scaffolding.

Module pods may be inserted after completion of a level and services made available to assist operators as successive levels are added.

The use of quarter-turn connectors facilitates rapid assembly and dismantling.

The quarter-turn connection is preferably that designed by Camloc (UK) Limited of Leicester LE4 7JD (see Figures 16 and 17). A stud 70 is provided with a head 71 having a threaded shank 72 on which is located a washer 73 and a self-locking nut 74.

Claims (11)

CLAIMS:

1. A modular building set comprising a plurality of wall modules (12) to be arranged vertically on a site, each of said wall modules having a substantially horizontal open box-section structure (60) disposed between the top and bottom ends of the wall module at a predetermined height and which, when the building is assembled, communicates with the horizontal open box-section structure of the adjacent wall module or modules whereby a continuous recess is formed to receive wiring and/or plumbing.

2. A building set as claimed in claim 1, wherein each wall module is provided with wiring and/or plumbing prior to assembly of the building, and connecting means for the connection of the wiring or plumbing as each wall module is placed in position to form the building assembly.

3. A building set as claimed in claim 1 or 2, wherein the horizontal open box-structure comprises a coldrolled steel channel extending across the entire width of the wall module

4. A building set as claimed in claim 3, whrr-en the wall module is a frame-like construction having upper and lower end bcx-section members (40, 41) and vertical boxsection side members (42, 43).

5. A building set as claimed in claim 4, wherein the channel (60) lies within the overall thickness ot the wall module.

6. A building set as claimed in claim 4 or 5, wherein each of the vertical side members (42, 43) is constructed from two cold-rolled box-section channels, each being substantially of U-section, the two channels being secured together with their open sides facing inwardly of the wall module.

7. A building set as claimed in any one of claims 1 to 6, including a plurality of base modules (10) arranged to define the building perimeter serving to support said wall modules, said base modules being connectible to each other and respectively to said wall modules.

8. A building set as claimed in claim 7, wherein the base module (10) comprises a cold-rolled steel open boxsection structure of generally overall L-shape comprising a horizontal base portion (13), a vertical wall (14), a lower horizontal supporting wall (15), a vertical abutment wall (16), and an upper horizontal supporting wall (17), a rebate being defined by the lower horizontal support wall (15) and the adjacent vertical abutment wall (16).

9. A building set as claimed in any one of claims 1 to 8, wherein for securing the floor module (11) against lateral movement relative to the base module (10) locating pins (22) are provided close to the ends of the base module respectively which project upwards therefrom for engaging apertures (36) provided at the corners of the floor module.

AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS

10. A modular building set as claimed in claim 1, substantially as described with reference to the accompanying drawings.

11. A modular building assembled from a set as claimed in any one of claims 1 to 9.