GB2282395A - Building system - Google Patents

Abstract

A modular building system which can be assembled in a variety of forms and easily relocated comprises a series of modular frameworks presenting rectangular apertures which are filled with side panels (36) locking into one or more of the apertures. The frameworks may comprise rectangular upper and lower frames formed from channel section beams, fixed by bolts and joined by corner posts formed from square section steel beams. The wall panels have integral locking means around their periphery. The locking means are key operated bolts (31). The wall panels have a weather resistant outer surface (36) and thermally insulating material (38) between the outer surface and an inner surface. The building modules may be linked together. <IMAGE>

Description

BUILDING SYSTEM This invention relates to a building system and particularly to a modular building system which can be assembled in a variety of forms and easily relocated.

Prefabricated buildings are known that can be transported to a site when required and subsequently removed for reuse.

Such buildings comprise a preformed shell and although they can often be divided into a number of small rooms they cannot be extended to form larger rooms. Furthermore the maximum size of room obtainable is restricted by the size of available transporting vehicles and width of highways.

Modular building systems have been proposed in GB-A-244 501 which use a plurality of prefabricated modules to assemble buildings such as school classrooms. The need for a series of different modules to assemble each building causes logistic and storage problems and requires highly skilled engineers for the erection process. The walls are fitted to the module on site using conventional techniques and and must be recreated if the modules are to be reused.

According to the present invention there is provided a modular building system characterised in that a series of building modules having a standard set of rectangular faces are assembled and thereafter fitted with side panels locking into one or more of the outwardly facing vertical faces. Preferably the modules comprise upper and lower rectangular frames joined by corner posts and. optionally vertical channels.

The preferred building modules comprise a series of frames having dimensions of approximately 6m X 3m. 3m X 3m. 6m X 1.5m and 1.5m X 1.5m joined by corner posts and vertical channels to provide aproximately 2.5 m height. The trade mark FLEXI-LINK is proposed for the building system.

The modules are constructed of as a rigid framework of channel section beams that may be transported as complete modules for rapid assembly on site. Alternatively. if the modules have to be transported for long distances and transport volume is at a premium they may be transported in so-called 'flat pack' form as a series of beams for assembly on site into building modules. In order to facilitate such transport the beams are preferably attached to each other by screw fixings such as bolts. Alternatively the system can be containerised for transportation.

The building modules may be linked together in any direction. e.g. end to end. side to side. side to end to form larger volume buildings. The building modules are linked together with link units which fill the space between the corners of each module. The link units are joined to the corner posts of the linked modules and include a weatherproof wall section. The modules may also be stacked vertically to form multistorey structures.

Individual cambered roof panels are fitted to the upper surface of each building module after assembly with communal drainage routes. The guttering around each module is arranged so that communal drainage paths may be used where the sides of the module meet.

Wall panels are fitted into the outer faces of the modules by integral locking means which permit rapid assembly disassembly and change. For reasons of security the locking means are preferably only accessible from the inside. The preferred wall panels have a high degree of thermal insulation and sealing strips which prevent the ingress of moisture. As well as solid wall panels altern ative versions may contain doors or windows. The wall panels are preformed and of uniform dimensions so that they are generally interchangeable. The narrow ends of the module may contain a single panel that fills the total area defined by the corner posts and the upper and lower frames.

Alternatively the narrow ends may include a vertical channel in their outer faces so that two wall panels may be used to form the outer surface. The latter arrangement enables a single series of standard panels to be used for all module arrangements.

The wall panels preferably contain a plurality of moveable bolts which allow them to be linked to the corner posts.

vertical channels and the frames by extending the bolts into cavities in the posts. channels and frames. Key operated bolts are the most preferred in which rotation of the key moves the bolt inwardly or outwardly by means of a rack and pinion drive.

The beams forming the lower frame of each module have sufficient strength to carry joists for a suspended floor enabling thermal insulating material to be located below the floor. Ceilings are preferably suspended from the beams forming the upper frame of the module allowing thermal insulation to be located between the roof and the ceiling. Ducting is preferably included in each module so that services. such as gas. electricity. water. telephone and other data lines may be installed rapidly within an assembled building.

Supplementary pitched roofing units may be fitted over an assembly of modules if erected in areas of high solid precipitation. e.g. snow or hail. to prevent the formation of ice slabs.

In a most preferred form the buiding modules comprise upper and lower frames constructed from swaged steel beams fixed by bolts and joined by corner posts formed from square section steel beams. The posts carry brackets so as to facilitate the formation of joints with the corners of the frames using bolt fixings.

In the preferred embodiment the wall panels comprise a rigid frame carrying bolt locking means around its periphery and enclosed with an outer and an inner surface covering. The outer surface covering comprises a weather resistant surface such as GRP sheet while the inner surface may comprise a conventional interior covering such as a melamine laminate. The space between the inner and outer surfaces is preferably filled with a thermally insulating material such as a synthetic polymer film. The panels may include a window. door. ventilator or other access means.

The edges of the wall panels may be provided with sealing means to prevent the ingress of moisture or wind. In a most preferred embodiment the edges of the outer surfaces of the panels are directed inwardly and cooperate with a resilient sealing strip on the outer surfaces of the supporting elements to form a watertight seal. In a preferred form the sealing strip comprises neoprene.

In order that the invention may be clearly understood it will now be described with reference to the accompanying drawings in which: Figure 1A is a perspective view of a module according to the invention shown in part cut-away form in Figure 1B.

Figure 2 shows a corner joint of the module of Figure 1 on an enlarged scale.

Figure 3 shows the joints between the vertical channel and the upper and lower frames of the module of Figure 1 on an enlarged scale.

Figure 4 shows the corner post. intermediate support and wall panel locking system of the module of Figure 1 on an enlarged scale.

Figure 5 shows the linking member used for end to end joining of modules.

Figure 6 shows the supplementary linking member used for side to end joining of modules. and Figure 7 is a front view of a multi-module two storey building constructed using modules according to the invention A module according to the invention. see Figure 1. consists of two rectangular frames 1 and 2 spaced and supported by corner posts 3 and vertical channels 4. The outer surfaces of the module are filled by means of panels 5 and 6 fitted between the corner posts 3 and/or the vertical channels 4. The panels 5 and 6 may contain windows 7 or a door 8. The end panel 5 is shown as a single panel however a vertical channel 4 may be fitted centrally and the single panel replaced by two panels 6. The rectangular frames 1 and 2 are constructed from swaged steel beams 9 which are joined together and to the corner posts at the corners of the module at corner joints A.

A lower corner joint A is shown in detail in Figure 2.

Figure 2A shows a plan view of the end of a corner post 3.

Figure 2B shows a plan view of a corner joint. Figure 2C is a side perspective view of the corner joint and Figure 2D is an exploded view of the joint. The corner post 3 comprises a square section metal beam carrying angle brackets 11 welded to adjacent faces of the beam at each end. The brackets 11 contain fixing holes 12. The ends of the beams 9 also contain fixing holes 13 which mate with the holes 11 allowing the beams 9 to be firmly attached to the post 3 by means of bolts 14. A similar arrangement is used for the upper corner joint B.

The spaces between the frames 1 and 2 in a vertical plane include vertical channels 4. The vertical channels 4 consist of swaged beams of the same type as the beams 9 used for the frames 1 and 2. The channels are rigidly joined to the frames 1 and 2 as shown at C and D. The point D is shown in detail in Figure 3. Figure 3A shows a cross-section of a vertical channel. Figure 3B shows a plan view of a channel joint. Figure 3C is a side perspective view of the channel joint and Figure 3D is an exploded view of the joint. The channel section 4 has an end plate 21 welded to each end. The plates 21 contain fixing holes 22. Side faces 23 of the beams 9 also contain fixing holes 24 at appropriate locations which mate with the holes 22 allowing the vertical channels 4 to be attached firmly to the beams 9 by means of bolts. not shown.A similar arrangement is used for the joint C.

The walls 5 and 6 are locked in position between the corner posts 3 and the vertical channels 4 at a series of locking points. A locking point E is shown in detail in Figure 4.

The wall 6. see Figure 4. is located between corner post 3 and vertical channel 4 by means of bolts 31. Bolts 31 extend through an aperture 32 in the side of the post 3 and an aperture 33 on the face of the channel 4. Each bolt 31 is moveable from a locked position. as shown. into an unlocked position by movement into a recess 34 within the wall 6. The movement of the bolt 31 is controlled by a key. not shown. which is inserted into a keyway 35 on the interior surface of the wall.

The wall has an outer surface 36 of a highly weather resistant material and an inner surface 37 of a suitably hard wearing material. The space between the surfaces 36 and 37 is filled with thermally insulating material 38 such as a foamed synthetic polymer The edges of the outer surface 36 are inverted and engage with sealing strips 39 attached the the corner post and the vertical channel. To ensure good thermal insulation the space enclosed by the channel 4 is filled with insulating material 40. Each wall panel may carry at least three bolts on each side to ensure stable and waterproof sealing with the corner post and vertical channel.

When joining two modules in an end to end or side to side configuation a linking member is fitted between the external pairs of corner posts to ensure a watertight and thermally insulated joint. The linking member. see Figure 5. consists of a metal outer cover sheet 41 and an inner cover sheet 42. The space between the sheets is filled with rigid thermally insulating material 43 of the same type as that used in the wall panels When joining two modules in a side to end configuation two different linking members are used. A linking member of the type described with reference to Figure 5 between the adjacent pair of corner posts and an angled linking member between the other corner posts of the end facing module and the side of the module.The angled linking member. see Figure 6. consists of a beam 44 of the type used for the vertical channel sections 4 attached to an angled metal outer cover sheet 45. A pair of inner cover sheets 46 and 47 form an L shaped enclosure containing the beam 44 in one arm and a filling of rigid thermally insulating material 48 in the other arm. The space enclosed by the beam 44 is also filled with insulation material. The thermally insulating material may be of the same type as that used in the wall panels.

The modules may be joined both in.a horizontal plane and a vertical plane. In one embodiment. see Figure 7. four modules are shown joined side by side to form a ground floor having an area of approximately 72 sq m and carrying a further set of four modules to provide a second storey with the same area. In a similar manner a third storey can be added.

Claims (18)

1. A modular building system characterised in that a series of building modules having a standard set of rectangular faces are assembled and thereafter fitted with side panels locking into one or more of the outwardly facing vertical faces.

2. The modular building system according to claim 1 characterised in that the modules comprise upper and lower rectangular frames joined by corner posts and, optionally, vertical channels.

3. The modular building system according to claim 2, characterised in that the modules comprise a series of frames having dimensions of approximately 6m X 3m, 3m X 3m, 6m X 1.5m and/or 1.5m X 1.5m joined by corner posts.

4. The modular building system according to claim 3, characterised in that the corner posts provide a vertical height of 2.5 m.

5. The modular building system according to claim 2, characterised in that the rectangular frames are formed from channel section beams.

6. The modular building system according to claim 5, characterised in that the rectangular frames are formed from swaged steel beams fixed by bolts and joined by corner posts formed from square section steel beams.

7. The modular building system according to claim 2, characterised in that the rectangular frames are fite with wall panels having integral locking means around their periphery.

8. The modular building system according to claim 7, characterised in that the locking means are key operated bolts.

9. The modular building system according to claims 7 or 8, characterised in that the edges of the wall panels are provided with sealing means to prevent ingress of moisture.

10. The modular building system according to any of the claims 7 to 9, characterised in that the wall panels have a weather resistant outer surface and thermally insulating material between the outer surface and an inner surface.

11. The modular building system according to claim 1, characterised in that the building modules are linked together with link units which fill the space between the corners of each module.

12. The modular building system according to claim 11, characterised in that the link units are joined to the corner posts of the linked modules and include a weatherproof wall section.

13. The modular building system according to claim 1 characterised in that the modules are stacked vortice11y to rorm a mullisborey structure.

14. The modular building system according to claim 1, characterised in that individual cambered roof panels are fitted to the upper surface of each building module after assembly with communal drainage routes.

15. The modular building system according to claim 14, characterised in that guttering is arranged around each module so that communal drainage paths may be used where the sides of the modules meet.

16. The modular building system according to claim 1, characterised in that the modules are in a 'flat pack' form as a series of beams and bolts for assembly on site into building modules.

17. Modular building systems according to claim 1 and as herein described.

18. Modular building systems as herein described with reference to and as shown in the accompanying drawings.