GB2420126A

GB2420126A - A prefabricated unit for a building

Info

Publication number: GB2420126A
Application number: GB0425078A
Authority: GB
Inventors: Dr Mihajlo Kazic; William John Hewlett; Scott Lawrie
Original assignee: LAING O ROURKE GROUP SERVICES
Current assignee: LAING O ROURKE GROUP SERVICES
Priority date: 2004-11-12
Filing date: 2004-11-12
Publication date: 2006-05-17
Also published as: GB0425078D0

Abstract

A prefabricated unit 5 for constructing a building comprising adjacent units, has at least a part of walls 8 facing other units being omitted or removable, to define a space extending between the units. The prefabricated units are preferably of a standard design and are preferably of the size of shipping containers. A prefabricated unit and method of construction are also claimed. Independent claims relate to: a building having a main face and multiple storeys; a building comprising a plurality of occupancy units 1, that unit having service connections provided in less prefabricated units than the number which comprise the occupancy unit; a prefabricated unit for an occupancy unit having all service connections required for the occupancy unit, and a surface unit comprising metal or polymer sandwiched between two wood-based layers.

Description

I

A PREFABRICATED UNIT FOR A BUILDING

The present invention relates to a building comprising prefabricated units, a prefabricated unit for constructing a building, a method of constructing a building using prefabricated units and a surface unit for prefabricated units of a building.

The use of prefabricated units in the construction of buildings has been known for a very long time. It is considered that prefabricated units can shorten building times, simplify constructions methods and reduce expenditure. However, there have been problems with the use of prefabricated units, particularly when prefabricated units comprise a closed structure having wall, ceiling and floor. This kind of unit is limited in size by the practicalities of transportation. However, when a building is constructed for a particular use, for example as a residence, the size and internal design of such units may not match the requirements of the building being constructed. Larger structural areas than can be provided by the units may be required.

For this reason, prefabricated units have most commonly been used in the construction of buildings which themselves comprise just one prefabricated unit or in the construction of temporary buildings particularly on work sites where temporary aesthetically unpleasing connections and access ways are not a problem.

The present inventors have sought a system for constructing a building from prefabricated units in which the benefits of simplicity of construction, and reduction of assembly time inherent to these prefabricated units can be retained at the same time as overcoming the disadvantages.

The present inventors have realised that prefabricated units having side walls can be constructed into a building in such a way that at least some of the prefabricated units are placed with walls facing each other, at least parts of the walls facing each other being removed or absent to define habitation spaces extending between the prefabricated units. In this way, the structural rigidity and integrity of the prefabricated units can be exploited at the same time as incorporating into the design flexible design spaces which can extend between the prefabricated units, allowing spaces of dimension larger than the prefabricated units themselves to be easily constructed into the building.

Accordingly, in a first aspect, the present invention provides a building constructed from pre-fabricated units placed adjacent to one another, parts of walls of at least some prefabricated units facing other prefabricated units being removed, to define habitation spaces extending between the prefabricated units.

The first aspect of the invention further provides a prefabricated unit for use in the construction of a building, the prefabricated unit being designed so that, when constructed into a building so that it is placed facing another prefabricated unit, at least a part of a wall of the prefabricated unit for facing the other prefabricated unit being removable to define habitation spaces extending between the prefabricated units.

The first aspect of invention further provides a method of constructing a building, comprising placing prefabricated units adjacent to one another and removing parts of the walls of at least some prefabricated units facing one another to define habitation spaces extending between the prefabricated units.

The present inventors have further realised that whereas it has been the practice to construct prefabricated units into buildings so that the short sides of the prefabricated units are aligned with the main face of the building, it is possible to construct a building of several storeys with long faces of the prefabricated units in each storey aligned with the main face of the building.

Accordingly, in a second aspect, the present invention provides a building, having a main face, the building being constructed of a plurality of prefabricated units, the building having at least two storeys, each storey being constructed of at least two prefabricated units of the type having long sides, short sides, ceiling and floor, the prefabricated units being assembled into each storey of the building such that the long faces of selected prefabricated units are aligned with the main face of the building.

The present inventors have further realised that, where a building is constructed having a plurality of individual occupation units, each of which is formed from at least parts of separate prefabricated units, the service connections for providing services such as water and electricity may be all supplied in just one prefabricated unit. As only one prefabricated unit out of a plurality which are used to assemble a single occupation unit requires connection in this way, the time required to assemble the prefabricated units is much quicker.

Accordingly, in a third aspect, the present invention provides a building comprising a plurality of occupancy units, each occupancy unit being constructed from at least parts of a number of prefabricated units, service connections for the occupancy unit being provided in less prefabricated units than the said number.

The third aspect of the invention further provides a method of constructing a building, comprising assembling the building so that it has a plurality of occupancy units, each occupancy unit being constructed from at least parts of a number of prefabricated units, the service connections for at least one occupancy unit being contained in less prefabricated units than the said number, further including the step connecting the service connections of the occupancy unit to service supplies.

The third aspect of the invention further provides a prefabricated unit for constructing a building, the prefabricated unit being configured so that, when it is assembled with at least parts of a plurality of other prefabricated units for constructing a prefabricated unit, the prefabricated unit comprises all of the service connections required for the occupancy unit.

The present inventors have also sought a design of surface component which may be suitable for use in buildings, including prefabricated buildings.

Accordingly, in a fourth aspect of the invention, the present invention provides a surface unit for a prefabricated building, comprising, in sequence, at least a first layer constructed of wood or wood based material, a second layer comprising a corrugated material selected from metal or polymer composite, and a third layer of wood or wood based material. This structure is found to give a very good combination of lightness and strength which is suitable use in prefabricated units and other structures.

Optionally, the prefabricated units and the building of the first, second or third aspect of the invention are formed in accordance with the features of the other first aspects of the invention, as appropriate.

Optionally, prefabricated units and the building of the first, second or third aspect of the invention may incorporate surface units in accordance with the fourth aspect of the invention.

Preferred or optional features of the invention are described further below.

PREFABRICATED UNITS

By "prefabricated unit" is meant a structural unit having a threedimensional structure which is constructed other than in situ in the building being constructed.

The prefabricated unit may be constructed on a separate part of the building site, but it is particularly preferred that the prefabricated units are constructed at a different location from the building site. This means that the building site does not need to be excessively large and it means that the prefabricated units can be constructed at any suitable time up to the point at which they are required. Construction of prefabricated units can be carried out even before the building site is ready to receive them, allowing substantial savings in time.

The prefabricated units are preferably constructed to at least one standard design. The number of standard designs will depend upon the number of design features which it is desired to make available for the finished building. However, a balance has to be sought between flexibility of design and savings to be achieved by minimising the number of standard designs.

If standard designs are used, they can be constructed and stored for use, allowing further savings in construction time of the building.

In a preferred embodiment, at least one standard design of prefabricated unit comprises a prefabricated unit according to the third aspect of the invention, which includes the service connections for an occupancy unit.

The prefabricated units preferably comprise walls, floor and ceiling. That is, they are preferably substantially complete blocks.

The prefabricated units may be constructed in any suitable fashion. The structural rigidity may be obtained by any combination of frames and wall structures. For example, the prefabricated units could be of a monocoque construction. However, it is particularly preferred that the prefabricated units should be defined by a frame work with wall surfaces extending between the frames of the framework. Preferably, the frames provide substantially all of the structural rigidity of the prefabricated unit. This allows the wall surfaces to be designed with a particular reference to factors such as thermal and acoustic insulation, aesthetic finish, removability etc. In a particularly preferred embodiment, the prefabricated units are constructed to the dimensions of shipping containers as defined by international standard, preferably as defined in Iso 668-1995 (relating to freight containers) Further, the prefabricated units may be provided with handling structures of the type provided for shipping containers according to international standard, preferably as defined in ISO 1161-1984 (relating to corner fittings). The prefabricated units may be connected to one another through corner fittings of this type.

In this way, the prefabricated units may be constructed in any suitable location and then transported using the transport network established for containers, for example by road, rail or sea, without any special modification.

For transport, the prefabricated units may be supplied with protective cladding which may be at least partially removed in construction.

For example, corrugated steel surfaces resembling outer walls of standard shipping containers may be used.

Preferably, the prefabricated units of the present invention are constructed to shipping container dimensions but do not themselves comprise shipping containers which have been reused.

The prefabricated units may be finished to any desired level of internal or external completion. For example, the prefabricated units may simply comprise structural units having wall structures, ceiling structures and floor structures to which decorative, weather resistant or insulative surfaces may subsequently be applied. However, in a preferred embodiment, the prefabricated units comprise walls, ceilings and floors provided with finished surfaces including an aesthetic coating and, optionally, weather proofing or thermal or acoustic insulation as appropriate.

The prefabricated units preferably comprise internal dividing walls.

OCCUPANCY UNITS

Prefabricated units according to the aspects of the invention may be combined together in a suitable way to form occupancy units. Occupancy units may for example may comprise individual apartments in an apartment block, working spaces, retail units or any other suitable type of occupancy unit.

An occupancy unit may be constructed from an integer number of prefabricated units.

However, occupancy units according to the present invention can be constructed from at least parts of a plurality of prefabricated units. For example, at least two prefabricated units could be placed next to one another, removable walls and internal divisions of the prefabricated units being configured so that at least two occupancy units are defined, each extending across parts of the two prefabricated units. For example, each occupancy unit could be made from two halves of respective prefabricated units.

In one optional embodiment, a pre-determined number of prefabricated units are designed to be assembled together, optionally with first and second prefabricated units placed next to one another as required by the first aspect of invention, the predetermined number of prefabricated units defining together a single occupation unit.

Prefabricated units which are designed to be constructed together to form an occupation unit are constructed so that when at least one wall of a first prefabricated unit facing a second prefabricated unit is removed, occupation spaces are formed within the constructed unit which are of greater dimension than the respective dimension of the prefabricated unit.

In a preferred embodiment, the prefabricated units are of a rectangular prismatic shape, as they can be readily stacked together to form buildings of conventional shape.

Prefabricated units according to the invention can be constructed by any suitable technique. Preferably, the process of constructing the prefabricated units comprises the steps of: a) constructing a framework, b) constructing a floor structure, c) constructing a ceiling structure on the framework and, d) constructing wall structures on the frame work, e) inserting internal fitting as required, for example kitchen, bathroom, wallpaper, electrical and other services, carpets etc. f) optionally, adding protective cladding to the outside of the prefabricated unit.

Of course, where prefabricated units are to be placed immediately adjacent one another, corresponding wall sections of the prefabricated units are both removable to define a habitation space extending between the prefabricated units.

According to the invention, "habitation space" signifies spaces which, in normal use, are substantially continuous not being subdivided by any permanent structure, such as a partition wall or door.

In a particularly preferred embodiment, prefabricated units are assembled into the building so that they are spaced apart from one another by a predetermined distance, the space between the prefabricated units being subsequently provided with at least one of a floor, ceiling or wall. For example, prefabricated units may be placed with faces facing one another but spaced apart from one another, parts of the faces which face one another being removable, in accordance with the first aspect of the invention.

This allows particularly large occupancy spaces to be assembled in a simple and straightforward manner.

Wall, floor or ceiling surfaces may be present between the prefabricated units which face one another, to enclose the space between the prefabricated units. The wall, floor or ceiling surfaces may themselves comprise prefabricated surfaces which can be inserted into position during construction of the building.

REMOVABLE WALLS

According to the first aspect of the invention, selected parts of walls of sides of prefabricated units are absent or removed.

Preferably the prefabricated units are placed with long or short sides adjacent to one another, selected parts of the walls of sides of the prefabricated units being absent or removed. Preferably, the prefabricated units are assembled so that their sides are substantially coextensive with one another.

For example, a prefabricated unit may be constructed so that the respective wall surface is not complete. If the prefabricated unit is to be transported, the absent wall surface may be enclosed in protective cladding which may be subsequently removed.

The selected part of the wall may be constructed so that it is present in the prefabricated units as constructed and subsequently removed. It may be removed when the prefabricated unit is in position in the building or before it is placed in position in the building.

In a particularly preferred embodiment, a selected part of the wall of the long side of a prefabricated unit which, when constructed, will be absent from the long side, is configured to be repositionable so that it defines a floor surface or ceiling surface extending between a prefabricated unit and a second prefabricated unit spaced apart from it.

In a particularly preferred embodiment, a first prefabricated unit is provided with a wall surface which is rotatable between a first position in which it closes the long side of a prefabricated unit and a second position in which it defines a floor or ceiling between the first prefabricated unit and a second prefabricated unit. Preferably, a first prefabricated unit has a first wall surface for forming a floor surface and a second prefabricated unit is designed with a wall surface which is rotatable upwards to define a ceiling surface.

There may be a plurality of movable wall sections at different positions along the long side of a prefabricated unit.

THE BUILDING

The building of the present invention preferably comprises at least two storeys.

Prefabricated units according to the present invention can be used to form at least one and preferably at least two storeys of a multi-storey building.

In an optional embodiment, the present invention provides a building, comprising at least two storeys, each storey being constructed with prefabricated units having long sides, short sides, ceiling and floor, each storey comprising at least first and second prefabricated units placed with long sides facing one another and spaced apart from one another, and at least third and fourth prefabricated units placed adjacent to the short sides of the first and second prefabricated units, selected parts of the walls of the selected sides of at least one of the first and second units being absent.

The inventors have found that a building constructed as several storeys of pre-fabricated units spaced apart in this way can have structural rigidity.

Other storeys of the building may be constructed in different ways. For example, a building may comprise one or both of a basement and a ground floor constructed in a manner which will be known to the person skilled in the art, with the prefabricated storeys assembled on top of the basement or ground floor. Preferably, more than two storeys are constructed from prefabricated units. Preferably, in a building comprising up to four or five storeys of prefabricated units, prefabricated units of the storeys are of the same design or the same range of designs. However, for a number of storeys in excess of four or five, lower storeys may be constructed of prefabricated units built with stronger frames and the upper storeys may be made with prefabricated units with less strong frames.

It may be necessary to include auxiliary-strengthening frames particularly where a very large number of storeys are assembled. Preferably, additional frames are used where the number of storeys exceeds from 8 to 10 storeys.

The building may comprise any suitable auxiliary structural units selected from: Stairways; Lifi units; Roof units.

These may be constructed in any suitable fashion as will be known to the person skilled in the art.

During construction of the building, an additional wall surface may be inserted relatively simply between each side wall of the facing prefabricated units to complete the enclosure of the space between them.

The building may be constructed for any suitable purpose. However, the present invention is particularly suitable for multi-occupancy buildings, for example buildings having small industrial units or dwellings. It is particularly preferred that the present invention provides a building comprising a plurality of apartments.

Internal corridors can be formed from prefabricated corridor units. Alternatively, floor and ceiling units may be constructed between adjacent prefabricated units.

In the method of constructing the building according to the invention, prefabricated units are preferably placed with their long sides facing one another. A plurality of prefabricated units may be placed one after the other in any pattern required to construct the building. The prefabricated units may be connected to one another by any suitable means.

The prefabricated units may be connected to a building frame work for additional strength if necessary.

Faces of prefabricated units which, in the completed building will face towards the outside may comprise an outside surface finish. For example, they may be tiled, painted, metallic or any suitable finish.

According to the second aspect of the invention, the faces of the prefabricated units which in use form the outside surface of the building or form surfaces which will be adjacent to the outside of the building (having exterior cladding fixed thereto) comprise the long faces of prefabricated units.

When the prefabricated units are assembled into a building, the external face of the building will be at least partially defined by or will be constructed adjacent to outwardly facing walls of respective prefabricated units. These walls may be designed so that they abut one another with a very small gap between. Closure members may be provided for closing or sealing the gap between adjacent prefabricated units. A closure member may be configured to allow air to pass into the building but exclude water falling down the face of the building.

During the finishing of the building, additional exterior surfaces may be provided, if required.

The method of constructing the building suitably comprises at least one of the following optional steps: a) preparing the site to receive prefabricated units, b) constructing at least one of a foundation, a basement, and at least one lower storey, the top most structure of which has a top surface which is prepared to receive prefabricated units.

c) assembling prefabricated units to define the structure of the building, d) adding finishing the structure selected from closure members, roof structures, stairways, and lift shaft.

Structures such as lift shafts, stairs, stability structures, roofing structures or other structures may themselves comprise modular units or they may be constructed as parts of prefabricated units.

In a preferred embodiment, where a plurality of prefabricated units having removable walls section are assembled together with spaces between them, wall sections are not removed until the spaces between the prefabricated units have been sealed against the outside environment, so that any internal furnishing of the prefabricated units can be protected. For example, the prefabricated units could be assembled spaced apart from one another and at least one of a wall, ceiling or floor can be inserted between them.

In a particularly preferred embodiment, a plurality of prefabricated units are constructed into a building, spaced apart from one another, the building being sealed by insertion of exterior walls and a roof, removable walls between units being subsequently removed, or moved into position as floor and ceiling units.

The method of constructing the building preferably includes the steps of designing the building comprising: (1) designing a building, (2) preparing the ground to receive the building, (3) in a time period overlapping with two, determining the number and type of prefabricated units required and commencing construction of the prefabricated units, (4) delivering prefabricated units to the site, and (5) constructing the prefabricated units into a building.

Connections between prefabricated units and between prefabricated units and structural elements may be provided by any suitable design of connector, which will be available to the person skilled in the art. For example, welding, bolting, grouting or any other method may be used. Connections may be formed using the corner fittings as defined in ISO 1161-1984 and provided on the prefabricated units.

SERVICES

Occupancy units of the building according to the present invention will typically require supplies of fresh water, electricity, telecommunications, gas (where appropriate), air conditioning, (where appropriate) and sewerage. According to the third aspect of the invention, connections for all of the services are constructed into a smaller number of prefabricated units than the number of units joined together. Any system may be used for distributing the services from the connection throughout an occupancy unit constructed from prefabricated units.

In the third aspect of the invention, "service connection" signifies connection to services outside the prefabricated unit. However, it is particularly preferred that some of the services are concentrated into the unit having the service connection.

According to the third aspect of the invention, services comprising any or all of fresh water supply, sewerage, air conditioning or gas and the units which consume the services are all built into a restricted number of prefabricated units. Preferably, the service connections are all formed in one prefabricated unit of an occupancy unit. This means that during the assembly of the building, it is not necessary to form connections for these services between prefabricated units. In practice, it may be necessary to form connections for electricity and telecommunications between prefabricated units of an occupancy unit, but this is relatively straightforward.

In particular, a prefabricated unit comprising connections for the services may also include units selected from kitchens, bathroom, WC facilities etc. The service connections themselves may be of any suitable form, as will be known to the person skilled in the art.

A service connection may be formed in any face of a prefabricated unit.

Preferably, the service connections are located both in a top surface and a bottom surface of a prefabricated unit. Preferably, in this case, prefabricated units of the design incorporating the service connections are configured so that they can be assembled with their connections adjacent to one another and ready for connection, so that a continuous connection of services can be provided throughout the building.

Higher level service distribution, for example switch boards, water main connections, gas connections etc. may be provided in other structures of the building, for example modular structures, prefabricated units or from kits of parts.

Where appropriate, metering facilities may be constructed for measuring consumption of the services within a prefabricated unit.

SURFACE UNITS FOR WALLS, FLOORS AND CEILINGS The surface unit of the fourth aspect of the invention provides a particularly light and strong component which is highly suitable for construction of prefabricated units.

Surface units of standard size may be provided which can be subsequently inserted into the structure of a prefabricated units andlor between prefabricated units in accordance with the first, second, third aspect of the invention.

The first and second layers may comprise for example plank wood, ply wood or reconstituted wood material, such as MDF. The layer may be of thickness in the rangelOmm-5Omm, preferably l2mm-2Omm, preferably around 18mm.

The metal or composite layer suitably comprises a corrugated or wavy structure, for lightness and strength. The corrugated or wavy structure is suitably connected to the first and second wood based layers at peaks and troughs of the waves. Connections may be formed by example by screws, nails or adhesive.

The space between the metal or composite layer and either or both of the wood or wood based layers may be empty or filled with material, for example insulation.

The metal layer preferably comprises steel, for example steel decking. The steel maybe of thickness in the range 0.5 mm-5.0mm, preferably 0.8mm2.OOmm, preferably around 1.2mm.

The present invention will be described further below by way of example only with reference to the accompanying drawings in which:

BRIEF DESCRIPTION OF THE DRAWiNGS

Figure 1 is schematic isometric drawing showing how a component of abuilding can be notionally split into three ISO container sized prefabricated units.

Figure 2 is a sketch plan view of the unit of figure 1, showing a floor plan.

Figure 3 is a sketch isometric view of a second embodiment showing how a component of the building can be notionally split into two ISO sized container units.

Figure 4 is a sketch isometric view showing how a plurality of components as shown in figure 1 or figure 3 can be assembled into a building.

Figure 5 is a sketch isometric view showing how a prefabricated unit can be assembled.

Figure 6 is a sketch isometric view of the frame work of a first embodiment of prefabricated unit.

Figure 7 is a sketch isometric view of the frame work of a prefabricated unit of a second embodiment.

Figure 8 is sketch perspective view showing how a floor and ceiling panel can be assembled according to the method of the invention.

Figure 9 shows a sketch perspective view showing how ceiling and floor panels can be assembled according to a second embodiment.

Figure 10 shows a sketch isometric view of a building constructed according to the invention, with additional structures.

Figure 11 shows a sketch isometric view of the construction of a building according to the present invention.

Figure 12 shows a sketch isometric view of a surface unit according to a fourth aspect of the present invention.

DETAILED DESCRIPTION OF THE DRAWING

Figure 1 shows a sketch plan of a component of a building. In this case, the component 1 comprises a self-contained occupancy unit, for example an apartment. Figure 2 shows a sketch plan view of the component of figure 1. It can be seen that it includes external walls 2, internal walls for example 3 and window units 4. The complete component 1 can be notionally split along the dotted lines into three prefabricated units, 5. These prefabricated units can be constructed to the standard dimensions specified by international standards for shipping containers (hereinafter referred to as ISO size containers'). It can be seen that the prefabricated units 5 each comprise wall sections 6 which will form external walls of the complete component 1 and internal walls 7 which form internal walls of the complete component as well as removable wall sections 8 which, during assembly, are removed. When the removable walls 8 are removed, habitation spaces are formed within the component 1 which are of width greater than the width of the standard ISO container.

In this way, three prefabricated units can be used to assemble component, whilst being able to obtain dwelling spaces within the component which are larger than the ISO width of a container, thus allowing large, comfortable spaces to be formed.

The prefabricated units 5 will each comprise ceiling components, which are not shown so that the internal structures can be revealed.

Figure 2 shows how the component 1 can be completed and furnished. Some components, such as doors, windows, bathroom fittings, kitchen fittings and services can be built into the respective prefabricated units before they are assembled to form a component 1. Others, such as furniture, can be installed afterwards.

Figure 3 shows a sketch isometric view of a second embodiment. In this embodiment, a component 10 which is of the same design as the component 1 is notionally split along the dotted lines into two prefabricated units 11. These prefabricated units 11 comprise walls 6 which will form external walls of the component 10 and movable walls 12.

Removable walls 12 are designed so that they can be moved, for example by being rotated, from sides of the prefabricated unit 11 which face one another when placed in position, to positions in which they define ceiling or floor components.

End wall units 13 which may comprise prefabricated panels can be assembled between the end walls of the prefabricated units 11 so that the component 10 is substantially completely defined.

Prefabricated units 11 will comprise ceiling structures which are not shown, so that the internal structures can be seen.

The prefabricated units 5 and 11 may each be constructed to a size corresponding to the standard ISO container size.

Figure 4 shows that a plurality of components, for example 10, can be assembled in a predetermined array to define a complete building comprising a plurality of components 10.

The construction of prefabricated units will described further below.

Figure 5 shows a sketch isometric view showing the construction of a prefabricated unit or 11.

The prefabricated unit 5 or 11 comprises a steel framework constructed of structural sections. The frame work will be constructed in a maimer which will be known to the person skilled in the art so that it can bear the weight of other prefabricated units stacked on top of it.

In particular, a first type of prefabricated unit is designed to bear the weight of four other prefabricated units stacked on top. A second type is designed to bear the weight of 5 to 10 prefabricated units stacked on top of it.

The frame work may comprises cross braces for added strength.

During the construction of the prefabricated unit, a floor structure is inserted into the frame work. The floor structure comprises a corrugated sheet metal structural member 16 designed to bear the weight of equipment and occupancy loads placed in the prefabricated unit. This surface unit will be described further below. There may be additional layers 17, 18 which may provide or any or all of thermal insulation, acoustic insulation, under floor heating and suitable types of decorative finish. Once the floor structure is in place, other fittings can be inserted into the prefabricated unit. For example, fitted units such as a sink unit 19 or internal walls 20 can be inserted into the frame work. These fittings can be placed in the frame work before or after side walls are inserted and before or after ceiling units are inserted, in a maimer defined by ergonomic considerations.

Wall units and ceiling units will correspond in design to the floor units, comprising structural units 16 and other layers 17, 18 which may provide acoustic insulation, thermal insulation, aesthetic finish etc. A removable wall unit 21 is provided. The removable wall unit 21 may comprise a structural unit suitable for forming sections of floor or ceiling, if the prefabricated unit is of the type shown in figure 3. However, if the prefabricated unit is as shown in figure 1, the removable wall units 21 may simply comprise units of adequate strength to close the sides of the prefabricated units during transport.

Finally, cladding units 22 may be fixed to sides, ends, bottom and top of the prefabricated units to protect it during transport. This cladding may, for example, comprise corrugated steel section which may be reused.

Figure 6 shows a sketch isometric view of prefabricated unit 11, showing the structural frame work. A movable wall 21 is provided. It can be seen that it is constructed with a structural layer 16 and other layers 17, 18 as described in relation to figure 5. The movable wall 21 is mounted on pivots 23 at its bottom edge allowing the wall to be rotated downwards until its underside comes to rest against a ledge 24, in which position it is configured to define a part of the floor between two prefabricated units 11 as shown in figure 3.

Figure 7 shows another embodiment of prefabricated unit 11. In this case, the movable wall section 21 is mounted on pivots 25 located at the top so that it can be rotated upwards to define part of the ceiling of a space between two prefabricated units 11 as shown in figure 3.

It should be noted that, in this embodiment, a part of the frame work of the prefabricated unit 26 is set back, to define a space within which the movable wall is located in the folded position in each case so that the overall width of the prefabricated unit does not exceed that of the standard ISO container width.

Figure 8 shows a sketch perspective view showing how two prefabricated units 11 can be placed spaced apart from one another by a distance L determined by the dimension of the movable walls 21 which are subsequently moved into position defining sections of the floor and ceiling as shown.

Figure 9 shows an alternative embodiment of prefabricated units 11 in which floor and ceiling sections are constructed from floor and ceiling units 27 and 28 respectively.

During manufacture and transport of the prefabricated units 11, floor and ceiling units 27 and 28 are stored within spaces inside the prefabricated units. The system shown in figure 9 is particularly suitable for forming ceiling and floor units of corridors between occupancy units, which may be of smaller dimensions than the dimensions of the prefabricated units.

Figure 10 shows a sketch isometric view in which a plurality of components assembled as shown in figure 4 can be included into a complete building 29. In this complete building, the prefabricated units are assembled on to a preconstructed basement structure 30 which may be constructed in a conventional manner for example using masonry, or different prefabricated structures.

The building may further comprise a stair or lift unit 31 which may be formed of prefabricated units or it may be constructed in a conventional manner.

An access unit 32 comprising for example corridors, vertical passageways for surfaces etc. may be constructed along one face comprising the narrow sides of the prefabricated units. Finally, a roof structure of any suitable design may be constructed on top of the prefabricated units 33 It can be seen that the long faces of the prefabricated units 33 are aligned with the major face 34 of the building 29, in accordance with the second aspect of the invention, presenting a pleasing aesthetic appearance whilst still obtaining a rigid secure structure.

Figure 11 is a sketch isometric view of a construction of a building according to the present invention.

In this embodiment, a preconstructecl basement 35 is provided, which may be constructed in a conventional manner, for example using masonry or different prefabricated structures.

A plurality of prefabricated units 36 are then assembled in stacks, spaced apart from one another, on top of the basement 35.

In a further step, a roof structure 37, shown in dotted lines, is constructed on top of the stacks of prefabricated units 36. A side wall closure is inserted into the space 38 between the stacks of prefabricated units 36. As a result, the space between the stacks becomes enclosed and sealed from the outside environment. At this stage, removable walls of faces 39 of the prefabricated units 36 which face into the space between the stacks can be removed and, optionally, used to assemble units such as floors and ceilings. Because the space between the stacks is sealed from the weather, the internal fittings of the prefabricated units 36 will not be adversely affected by the weather.

Figure 12 is a sketch isometric view of a surface structure 40 according to the fourth aspect of the invention. It comprises a first wood or wood based layer 41, a corrugated metal structure 42 having an angular profile, and a second wood or wood based layer 43. The corrugated metal layer 42 is bonded at the peaks and troughs of the corrugations to the wood or wood derived layers 41 and 43. The bonding may be by screws or adhesive.

The present invention has been described above by way of example only and modification can be made within the spirit of the invention which extends to equivalents of the features described. The invention also consist in any individual features described or implicit herein or shown or implicit in the drawings or any combination of any such features or generalisation of any such features or combination.

Claims

CLAIMS: I. A building constructed from pre-fabricated units placed

adjacent to one another, parts of walls of at least some prefabricated units facing other prefabricated units being removed, to define habitation spaces extending between the prefabricated units.
2. A building, having a main face, the building being constructed of a plurality of prefabricated units, the building having at least two storeys, each storey being constructed of at least two prefabricated units of the type having long sides, short sides, ceiling and floor, the prefabricated units being assembled into each storey of the building such that the long faces of selected prefabricated units are aligned with the main face of the building.
3. A building comprising a plurality of occupancy units, each occupancy unit being constructed from at least parts of a number of prefabricated units, service connections for the occupancy unit being provided in less prefabricated units than the said number.
4. A building according to any of claims 1 to 3, wherein the prefabricated units are constructed to at least one standard design.
5. A building according to any of claims 1 to 4, wherein the prefabricated units are constructed to the dimensions of shipping containers as defined by the international standard.
6. A building according to any of claims I to 5, wherein a selected part of the wall of a prefabricated unit which is absent from the long side, is repositioned so that it defines a floor surface or ceiling surface extending between a prefabricated unit and a second prefabricated unit spaced apart from it.
7. A prefabricated unit for use in the construction of a building, the prefabricated unit being designed so that, when constructed into a building so that it is placed facing another prefabricated unit, at least a part of a wall of the prefabricated unit for facing the other prefabricated units being removable to define habitation spaces extending between the prefabricated units.
8. A prefabricated unit for constructing a building, the prefabricated unit being configured so that, when it is assembled with at least parts of a plurality of other prefabricated units for constructing a prefabricated unit, the prefabricated unit comprises all of the service connections required for the occupancy unit.
9. A prefabricated unit according to claim 7 or 8, constructed to the dimensions of shipping containers as defined by the international standard.
10. A prefabricated unit according to any of claims 7 to 9, wherein a selected part of the wall of a prefabricated unit which, when constructed, will be absent from the long side, is repositionable so that it defines a floor surface or ceiling surface extending between a prefabricated unit and a second prefabricated unit spaced apart from it.
11. A method of constructing a building, comprising placing prefabricated units adjacent to one another and removing parts of the walls of at least some prefabricated units facing one another to define habitation spaces extending between the prefabricated units.
12. A method of constructing a building, comprising assembling the building so that it has a plurality of occupancy units, each occupancy unit being constructed from at least parts of a number of prefabricated units, the service connections for at least one occupancy unit being contained in less prefabricated units than the said number, further including the step of connecting the service connections of the occupancy unit to service supplies.
13. A method according to claims 11 or 12, wherein the prefabricated units are constructed to at least one standard design.
14. A method according to any of claims 11 to 13, wherein the prefabricated units are constructed to the dimensions of shipping containers as defined by the international standard.
15. A method according to any of claims 11 to 14, wherein a selected part of the wall of a prefabricated unit which, when constructed, will be absent from the long side, is repositioned so that it defines a floor surface or ceiling surface extending between a prefabricated unit and a second prefabricated unit spaced apart from it.
16. A surface unit for a prefabricated building, comprising, in sequence, at least a first layer constructed of wood or wood based material, a second layer comprising a corrugated material selected from metal or polymer composite, and a third layer of wood or wood based material.