GB2487650A - Building construction system comprising modules with dimensions and connectors compliant with ISO shipping container standards - Google Patents

Building construction system comprising modules with dimensions and connectors compliant with ISO shipping container standards Download PDF

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Publication number
GB2487650A
GB2487650A GB1201036.9A GB201201036A GB2487650A GB 2487650 A GB2487650 A GB 2487650A GB 201201036 A GB201201036 A GB 201201036A GB 2487650 A GB2487650 A GB 2487650A
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GB
United Kingdom
Prior art keywords
module according
module
members
modules
frame
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB1201036.9A
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GB2487650B (en
GB201201036D0 (en
Inventor
Narinder Assi
Nico Lenkeit
George Petirides
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
KEY HOUSING Ltd
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KEY HOUSING Ltd
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Filing date
Publication date
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Publication of GB201201036D0 publication Critical patent/GB201201036D0/en
Publication of GB2487650A publication Critical patent/GB2487650A/en
Application granted granted Critical
Publication of GB2487650B publication Critical patent/GB2487650B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815Elements not integrated in a skeleton
    • E04B1/3483Elements not integrated in a skeleton the supporting structure consisting of metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34336Structures movable as a whole, e.g. mobile home structures
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/0006Coupling devices between containers, e.g. ISO-containers
    • B65D90/0013Twist lock
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/0033Lifting means forming part of the container
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/12Supports
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/12Supports
    • B65D90/125Docking stations, i.e. for the temporary support of the container
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/12Supports
    • B65D90/14Legs, e.g. detachable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/12Supports
    • B65D90/14Legs, e.g. detachable
    • B65D90/143Detachable individual legs
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/20Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of concrete, e.g. reinforced concrete, or other stonelike material
    • E04B1/21Connections specially adapted therefor
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815Elements not integrated in a skeleton
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/66Sealings
    • E04B1/68Sealings of joints, e.g. expansion joints
    • E04B1/6813Compressable seals of hollow form
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/005Modulation co-ordination
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/12Small buildings or other erections for limited occupation, erected in the open air or arranged in buildings, e.g. kiosks, waiting shelters for bus stops or for filling stations, roofs for railway platforms, watchmen's huts or dressing cubicles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D88/00Large containers
    • B65D88/02Large containers rigid
    • B65D88/12Large containers rigid specially adapted for transport
    • B65D88/121ISO containers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/0006Coupling devices between containers, e.g. ISO-containers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/0026Corner fittings characterised by shape, configuration or number of openings
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
  • Floor Finish (AREA)

Abstract

The building system comprises at least one box shaped module 1 in which each module comprises a frame having a least four vertical members 41 and horizontal members 42, 43 linking the respective tops and bottoms of the vertical members. The module also has corner fittings 21 mounted to the vertical members in positions compliant with ISO international standards for shipping container fitting points. The module also has, preferably detachable, external bracing members 44, which in use may lie external to any cladding 413 and weatherproof sheathing 417. The system may have part of bayonet coupling mounted on the vertical columns, with additional external columns attached to and detachable for the vertical columns by the other part of the bayonet coupling. A locking mechanism for locking the modules together and to a ground fixing point may also be provided.

Description

MODULAR CONSTRUC11ON SYSTEM This invention in one aspect relates to building modules for use in a modular construction system.
Attempts to design transportable modular construction systems for permanent housing and buildings (by this is meant a building having a life expectancy of at least 60 years in which the major components are modular and assembled off site) have been unsuccessful because these buildings have had serious corrosion and/or condensation problems. As a result modular construction has largely been confined to short term temporary buHdings where these issues are less of a prob'em. Furthermore the modules have often been difficult and expensive to transport, and when transported as shipping containers become damaged.
A building module for use in a modular building characterised in that the module comprises a substantially box shaped open frame having a least four vertical members located at each end of the module, and top and bottom perimeter members linking the tops and bottoms of the vertical member, the frame having external bracing members between the top and bottom perimeter members and external standard shipping fittings, some at least of which are at positions on the frame compliant with ISO standard for shipping containers. This latter feature enables the modules to be used as shipping containers for parts of a buHding to be constructed using the modules.
For many applications the bracing members are detachable, but can be retained in some case is added strength is requires in the finished structure.
Some of the shipping fittings may be detachable. This can be achieved by members at the end of the frame have mounted thereon one half of a locking device, the other half of the locking device being mounted on a detachable outer column. Preferably the locking device is a bayonet coupling. The outer column may have shipping fittings fitted top and bottom for transport purposes, removal of the outer column detaches these shipping fittings from the module. From an aesthetic point of view this arrangement means that the shipping containers at the end of the module are not visible when the module is finally placed in position.
The modules may have floor joists installed to add strength and b rigidity, and also to support any flooring finishing. The floor joists may be mounted transversely between the members forming the bottom perimeter. Similarly the modules may have ceiling joists which may be mounted transversely between the members forming the top perimeter.
To add strength when the modules are constructed into buildings the modules may have additional intermediate vertical members within the sides of the frame. In this configuration intermediate fittings substantially identical to ISO container standard shipping fittings are provided top and bottom of intermediate members.
Modules can be locked together using a locking means to engage corner fittings and intermediate fittings. Particular features of the locking means which are useful in the current invention are set out
in the description below and the claims.
Slack between the locking means and the corner and intermediate flthngs may be taken up by use of an additional fitting having upstanding shaped portions towards either end, the wedge shaped portions increasing in depth towards each end, and a thinner portion between the wedge shaped portions to enable the fitting to be arranged around the longer sides of a rectangular aperture of a corner or intermediate fitting. These fittings are not tied to this invention, and can be applied to locking systems.
Another aspect of the invention provides a new locking means adapted to engage shipping tittings on the modules so that b modules can be firmly tixed to each other top and bottom and side by side. One embodiment of such a locking means is described below and in the claims.
A ground fixing point may also be provided to receive a locking means by which shipping fittings may be couplel to the ground fixing point by a locking means to firmly attach modules in respect of the ground.
In a further embodiment of the invention partitions within or between modules are isolated from floors or ceilings in a construction by flat resilient material with serrations on one side.
Although invented in connection with the modular construction system described herein the isolation strip is capablc of application to other building systems to insulate the building against sound transmission. Thus in another aspect of the invention a sound insulation strip is provided comprising a flat resilient materials with serrations on one flat side, to be engaged between one element of a building (such as a partition) and another (such as a floor of ceiling).
Sound transmission can be reduced by providing that floor joists have a reduced cross section at one or more places along their length. The reduced cross section can be provided by perforations.
Similarly members linking the bottoms of the vertical members have a reduced cross section at one or more places along their length.
b Gaskets may be provided to seal gaps between individual modules, the gasket comprise a deformable hollow portion between lateral blades to engage between adjacent modules, and a flat portion to seal the flat faces of adjacent modules against water ingress.
These gaskets may be used separately to seal other gaps and are not uniquely applied to this construction system. Features of the gaskets are described below and identified in the claims.
The walls of the modules may be fitted with a vapour control membrane. The modules themselves may be made and sold separately otherwise than as part of the construction system.
In another aspect of the invention a building comprises one of the modules as previously described.
Other features of the invention are described below and in the claims.
The invention will be illustrated, by way of example, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a building constructed using a modular construction system according to the invention; Figures 2 and 3 illustrate standard and extended units respectively; Figure 4 shows a partially cut-away module for use with the invention; Figure 5 illustrates a corner lock fitting for use with the invention; Figure 6 shows a twist lock fitting; Figure 7 shows the mounting means for fixing ground floor modules to the ground; Figures SA to SC show the use of bearing corner pieces to support a stack of modules; Figures 9A to 9E show in more detail the locking devices; Figure 10 shows sound proofing and insulation systems for use with the invention; and Figure 11 shows gaskets to seal gaps between individual modules to exclude wind and rainwater.
The modular construction, shown, uses shipping containers as modules to make braced steel framed buildings. These are constructed using International Standards Organisation (ISO) freight container unit sizes. Bespoke non-standard size modules and infill panels are also used.
The modules can be arranged and connected together to form budings of volumetric units fabricated industrially and fitted with finishes and equipment.
The containers can be fabricated anywhere and transported by sea and road to the destination country in the same manner as ISO freight containers.
In figure 1 the modules 1 are arranged and joined together with connections 2 to form buildings of a variety of shapes on foundations 3, with site fixed infill panels 4. The connection 2 is showing in more detail in figure 6; corner pieces are shown in figure 5. The modules may arrive with the exterior cladding fitted or will be clad on site with brickwork or some other cladding. The modules 1 can be used to transport adcfltional panels 4 which can be inserted between the modules 1 as part of a hybrid volumetric and flat pack system. The units may be offset with respect to one another (labellecU 5, which allows scope for angled or curved architectural aesthetic features. Other components such as external claddings 6, parapets, pitched roofs 7, corridor floor 8 and wall panels can all be remotely manufactured at a factory and transported within the modules 1. Partitions 9 may be included within and between modules; these are described more fully with referencc to figure 10.
The module 1 is a new type of container, what the inventor has called a Shipping Building Container (SBC), that has thc ability to initially transport freight, to be handled like standard shipping containers and can Later be assembled together in order to provide permanent building accommodaflon La flats, houses, cluster housing, hotel bedrooms as part of the modular construction system.
The modules 1 have the following characteristics They are able to carry heavy loads and support heavy loads when they are stacked in high columns. The modules can be located anywhere on a container vessel with other freight containers stacked up above or below and are also designed to satisfy structural requirements of a permanent building structure (wind, live and dead loads, seismic etc.).
* They resist harsh environments during transportation globally on ocean going vessels or transported on land. As part of the permanent Modular Construction System, the structural steef frame has a design life in excess of 60 years and a target fife of the structural steel protection system of 75 years, thus providing permanent building solutions.
They are made to standard measurements and as such provide modular elements that can be combined into larger structures. Modular sizes include all standard ISO freight container unit sizes (including High Cube) as well as bespoke nonstandard sizes. In all cases the modules 1 are fitted with standard ISO Container corner shipping fittings, at the same locations as standard containers, which conform to standard shipping sizes, loadings and loading positions.
Figure 2 shows modules 1 of standard sizes. One module, meeting ISO standards, is shown and is 40 feet long. A 20 feet kDng standard module is also shown. ln both cases the widths and heights are to ISO standards. The shipping fittings 21 are provided at the corner of these standard modules.
Figure 3 show examples of modules nonstandard sizes with the position of shipping fittings 21. In the case shown, the modules 1 are of standard length and height but wider than the norm ln each b case the shipping fittings locations 21 are separated from each other by the standard ISO lengths widths and heights, such that these non-standard size modules can still be joined to other modules.
The module I is shown in more detail in figure 4. It has a braced steel framed structure with vertical columns 41, with a perimeter top 42 comprising beams joined to the tops of vertical columns 41 and perimeter bottom 43 comprising beams joined to the bottom of vertical columns 41. The open frame formed between the vertical columns 41 and the perimeter top and bottom (42 and 43) is diagonally braced with bracing 44. ISO standard container corner fittings 21 are fitted at the same retive locations ason standard containers. Although these conform to standard shipping sizes, loadings and loading positions, they may but not necessarily be used to transmit loads in their permanent use in a building structure In longer modules intermediate columns 46 with intermediate fittings 47 of similar design to corner shipping fittings 21 (hereinafter both intermediate fittings and corner shipping fittings 21 are called shipping fittings) are introduced and these are capable of transferring loads in their permanent use in a building structure. Floor joists preferably but not exdusively, pressed metal 48 that span across and are attached to the beams forming the perimeter bottom 43. These are lined with a membrane 49 that provides the waterproof lining and structural bracing. internally are applied floor finishes 410 that can be varied depending on the final requirements.
Lightweight (for example steel, aluminium or timber) infill wall studwork 411 is covered internally with a decorative board 412 and externally with a sheathing board 413 that is faced with a waterproof lining 417 Roof joists preferably but not exclusively pressed metal 414 span perimeter top 42. These are lined internally with a decorative board 415 and externally with a sheathing board 418 and further faced with waterproof lining 419.
A pitched roof (7 in Figure 1) may be attached to the beams forming the perimeter top 42. The pitched roof can be built in situ or more usually supplied as a complete pre-fabricated self-supporting unit. The pitched roof (7 in figure 1) may be located above a single module 1, or may span a number of modules that are joined together as illustrated in figure 6 below.
The pitched roof can be attached to the tops of the vertical columns using the corner locking fittings as described below in figure 5, with the pitched roof having corner fittings similar to those described in figure 5 below.
Alternatively, a single preformed roof 420 may be attached above each modulel, or again span a number of modules. Such a roof can be formed as a single sheet from metal, or may be moulded from other suitable materials such a glass reinforced plastic.
Bracing is provided on all sides of the module through a mixture of metal cross bracing 44 or by the use of structural sheeting material such as plywood 49, 416. Metal cross bracing could be permanent or temporary and could be fitted anywhere along the plane of the wall fabric. The metal cross bracing 44 provides rigidity during transit but some or all can be removed when the module is finally positioned as part of a building.
It will be seen that in contrast to a normal shipping container the module does not have a shell skin structure and corrugated steel panels, but strength is given by and its replacement with a braced steel frame 41, 42, 43 and 44, with weatherproofed infill panels 413. Compared with conventional containers, this allows any moisture that is built up internally to escape through the wall.
Nevertheless a vapour control layer (such as a TyvekRTM vapour membrane), 418, is fitted behkid the internal decorative lining 412 which controls the amount of vapour moving through the wall fabric.
This vapour control layer 418 can be sealed around windows and doors as well as penetrations such as sockets, ducts, pipes, flues within a factory environment that can achieve high standards of installation. This enables the modular system of this invention to achieve hugely improved air permeability through the fabric that is essential in low energy consumption buildings.
This arrangement as well as the improving the fabric of the new modular construction according to the invention creates a better internal environment. lt also minimises the risk of damage to the b contents of modules during transportation.
In other systems of this kind which use steel shells, the shell prevents the wall from breathing and any moisture within the building moving out may condense where it meets the metal srell skin, with the potential long term risk of rust. With the risk of interstitial condensation leading to rust it would be difficult to demonstrate a target life of 75 years required for permanent construction. This invention enables that target to be met.
lt should be noted that the expression "corner fitting" means a device of a kind normally fitted at the corners of 1SO standard Ii compliant shipping containers, it will he appreciated by reference to figure 3 that these devices are not necessarily located at the corners of modules for use in this invention. The ISO standard container shipping fittings 21 are shown in more detail in figure 5.
These corner fittings are fitted top and bottom of vertical columns 41 and comprise a hollow metal casting 22 having a plurality of rectangular apertures 23 aligned with the module such that the longer side 24 of aperture 23 is aligned top or bottom of the module with the longest side of the module.
Twist lock fittings 51 designed to engage with the corner fittings comprise a frame 512 in which a lever 511 is mounted perpendicularly on an axle, which itself is pivotaUy mounted in the frame 512. The axle is attached through the frame to lugs 514 to each side of the frama The lugs have a generally rectangular cross section tapering from the end 515 closest to the frame to the other end 516, so that four sloping faces 517 are formed. Atop the frame 512 and below each lug an upstanding portion 518 is found. The dimensions of portion 518 are such that it will fit snugly within the rectangular apertures 23 of shipping fitting 21. The dimensions of lug 514 are such that it will pass through the rectangular portion 23 of casting 22, if offered to it, but when lever 511 and the axle is turned, the lugs will twist and catch on the periphery 25 of the aperture 23. The upstanding portions 518 will be drawn into a snug fit within aperture 23. ln use the twist fitting is mounted into the corner fitting of one module and as a second module is offered to it, the sloping surfaces 517 will act as guides for the final positioning of the module adjacent to the first. Once in position the two modules can be joined simply by turning lever 511, causing lugs 514 to engage corner fittings of both modules.
Modules 1 are connected during transportation with the twist lock 51 that enable containers to be easily locked together and have an inherent slack in order to accommodate varying tolerances.
These twist locks 51 or variations of these see figures 6 and 7 are also used to structurafly connect the modules in their permanent condition. These offer the benefit of speed in locking together.
ln order to remove the inherent slack when the twist lock 51 engages shipping fitting 21, an additional new fitting 53 is used which is inserted into casting 22 prior to assembly of the modules 1 in their permanent condition. Fitting 53 is flexible for ease of inserting into the casting 22. It is generally composed of, but not limited to a composite of profiled structural rubber and steel. It is of wedge form 55 on one side in order to positively engage the lugs 514 of the twist lock 51 and casting 22 to remove inherent slack. A thinner portion 57 aligns with a shorter side of aperture 23. A flat outer part profile 56 isolates and protects the paint on the shipping fittings 21 from the steel twist 51.
Figure 6 shows how a number of modules are fitted together side by side and top to bottom. lt will be seen that in such a configuration access to the locks is difficult. This is overcome by a twin lock 6i similar in principle to the twist lock 51 shown in figure 5. The twin lock 61 is used to enable four modules I to be locked together at fittings 47 on columns 46 (figure 4) and where access for locking is restricted.
S This twin lock 61 is fitted with an upstanding wedge shaped guide 63 and is generally used with an extended locking arm 64 for the intermediate fittings. A short arm 65 can also be used if access is not a problem.
The twin lock 61 is designed to maintain a specified separation 66 between two adjacent modules and easily to guide the modules into position. It comprises two twist locking portions 62 each portion similar to the locks 51 of figure 5 linked by a connecting part 67.
Once the modules are installed the locking arm 64 (or 65) can be removed and reused IS Pairs of opposing lugs 68 are pivotally mounted within each portion 62 and operate in a similar way to lugs 514 in figure 5.
In use modules are lowered onto each other but are separated by the depth of twin lock 61, adjacent modules are separated by the wedges 63. The lugs 68 are pivotauy mounted on axles operated by the locking arms 64 or 65, and engage through apertures 472 in the fittings 47. Once in place the locking arms are twisted to cause the lugs 68 to engage the periphery 471 of apertures 472. The overall shape and configuration of fittings 47 are similar to shipping fittings 21 described in figure 5.
Figure 7 shows how modules may be mounted on the ground. Here a base plate 71 has an upstanding east ground fixing 72 with a locking device 73 for transferring load from the modules 1 to the foundations 74. The modules have cast steel shipping fittings 21 as shown in figure 2 The twist lock 51 is shown in more detail in figureS. lt hasa pair of opposed wedge shape rectangular cross section lugs 514. The maximum cross section of the lugs 514 is proportionally the same as but slightly smaller than apertures 76 in the tops of ground fixing 72 and aperture 23 in the bottom of shipping fitting 21. The lugs 514 are pivotally connected to a locking arm 511. The locking device 51 is initially located in its unlocked condition with one of the lugs 514 located in aperture 76.
As module 1 is lowered into position, the wedge shape of the upper b lug 514 engages in aperture 23 and finally guides the shipping fitting 21 (and thus module 1) into place. The module 1 is locked into place by turning arm 511 so that the upper lug 514 engages the periphery 25 of aperture 23.
Inserts as described in figure 5 can be located into the ground fixing 72 and shipping fitting 21 to ensure that no movement of the module can take place.
Similar arrangements can be made to join fittings 47 (figure 6) to the ground.
IS
Figures 8A to 8C illustrate a locking device 81 used to temporarily or permanently fix two structural elements together in order to transfer load from one to the other.
Modules 1 are fitted with ISO container shipping fittings 21 at the same locations as standard containers conforming to standard shipping sizes, and are loaded as shown by 87 in figure 8A. These shipping fittings 21 always protrude beyond all other parts of a container.
Protrusion of the corner fittings imposes certain difficulties with some potential cladding solutions to the modular construction system of the present invention. It also limits the possibility of transporting modules, tully insulated and with the external cladding pre-titted prior to transportation.
In order to avoid these problems support columns can be designed so that they can be removed prior to final assembly, as shown in Figure 8B. This development utilises two columns for each corner of the module 1. The inner column 85 will transfer vertical loads in the permanent condition and the outer support column 86 will transfer loads during transportation. The outer cocumn is securely attached to the inner column using a new locking device 81.
The approach shown in Figure 8B is the one preferred where inner column 85 is the structural element to which the removable support column 86 can be fixed, however, the outer support column 86 may be fixed to its proposed interface located on any appropriate structural element A possible alternative arrangement is shown in figure 8B. Here the removable support column 86 may be located via the locking devices 81 to cross members 88 and 89 top and bottom respectively of container 1.
it will be appreciated that inner column 85 may also form the vertica' column 41 shown in Figure 4; likewise transverse members 88 and 89 may be part of the perimeter top 42 and bottom 43 shown in Figure 4.
This ocking device 81, shown in more detail in figure 9, has a bayonet type fitting and is made up of a number of parts. The cast steel fitting plate 91 securely fitted to the inner column 85 at the factory incorporates the fixed part of the bayonet fitting 93. The outer column fitting 86 acts as a sleeve 94 ready to accept the rotating bayonet fitting 95 which securely locks the outer and inner is columns together. A tool fitting 96 is inserted and is used to rotate fitting 95 and securely engage into fitting 93. The shipping fittings 21 are fitted to the outer column 85.
These fittings are made and assembled at the factory and can achieve the high precision and quality control necessary for such a crucial structural connection.
Prior to final assembly the outer columns 86 and shipping fittings 21 can be unlocked, removed and returned to the factory to be used for the next assembly.
The modules are then assembled without the protruding corner columns. The inner columns 86 are then equivalent to vertical members 41 shown in figure 4, and modules are locked together using fittings 47 (figures 4 and 6).
This novel locking device can also be used to structurally connect two independent structures together. One such other use is shown in figure 1 to connect bespoke site fixed infill 4 to the corner columns of the module 1.
The scope of such a device is not limited to the connection of modules and can be used to connect other structural modules and components. One such use would be to connect the removable corner columns to an object that can be transported without the need of being within a container. The corner columns can then be directly fitted to the object and removed once it has reached its final b destination.
Figure 10 shows a new sound proofing fitting 101 developed to be used in conjunction with a partition system 102 within a modular construction system according to the invention to allow flexible use of space within and between housing units. This allows room space within homes made from the modular construction system, and homes to be subdivided (see partitions 9 in figure 1) within a module.
The partition system 102 reduces airborne sound transmission as well as to improve the isolation from adjacent floor 103 and wall structures. The fitting 101 is a linear strip extrusion of a resilient material comprising a flat top 104 and a serrated underside 105.
Bottom tracks 106 of an internal partition wall are installed flush with the flat top of the strip fitting. To improve airborne sound performance, the bottom edge of any planking 107 (such as plasterboard) can be rested on the strip fitting in order to eliminate any cracks. Uneven floor decks and tolerances cause gaps between bottom tracks and floor, allowing airborne sound transmission. The serrated underside 105 of fitting 101 adapts to uneven surfaces and forms several linear sound barriers. It also decouples the partition system from any impact sound introduced through the floor.
The fitting 101 can be used in conjunction with existing sound proof lightweight steel stud (or timber stud) partitioning wall systems, b Modifications made to the chassis structure (beams forming the bottom perimeter 43 and joists 48 in figure 4) in order to suppress structural flanking transmission through it.
A series of perforations 109 made to steel floor joists 48 will reduce the joist cross-section at strategic locations. Flanking sound transmission along the floor joists is consequently reduced.
ln figure 11 gaskets that can be used externally to fill the gap between modules and deal with relevant demands of maintaining the inherent qualities of the exterior fabric of the permanent building. This push fit cover system deals with weathering demands like wind and rainwater.
The gaskets have a hollow interior 110 which will deform when inserted between modules and are made of a resilient material such as rubber, silicone or similar to allow for tight-fit due to compression. Rows of flexible blades 111 to either side of the gasket adapt to any tolerances and unevenness between modules.
Two types of linear gaskets are wed: * A first type 112 to seal horizontal gaps and comprising of a shaped top edge 114 to direct any water away from the gap to be sealed; a ovedapping down stand edge 115 protects from water ingress * A second type 113 to seal vertic& gaps and comprising of an overlapping edge 125 to either side to protect from water ingress The gasket system is completed with corner and intermediate sections, (internal corner pieces 116, external corner pieces 117, tT"-shaped pieces 118, "X"-shaped pieces 119, LL -shaped pieces 120) all of Wiich have extended ends 121 to overlap and seal straight gaskets 112 and 113.

Claims (26)

  1. CLAIMS1. A buflding module for use in a modular building characterised in that the module comprises a substantially box shaped open frame having a least four vertical members located at each end of the module, and top (42) and bottom (43) perimeter members linking the tops and bottoms of the vertical member, the frame having external bracing members (44) between the top and bottom perimeter members and external standard shipping fittings (21), some at least of which are at positions on the frame compliant with 1SO standard for shipping containers.
  2. 2. A module according to claim 1 characterised in that the external bracing members are detachable.
  3. 3. A module for use in a modular according to claim 1 or 2 characterised in that the frame has weatherproof cladding panels (413,416) attached thereto.
  4. 4. A module according to claim 3 characterised in that some portions of the frame have no cladding, said unclad portions to be access from the module to other modules in a finished structure.
  5. 5. A module according to claim 3 or 4 in which the cladding has apertures in which doors andfor windows may be fitted.
  6. 6. A module according to any one of claims 3 to 5 characterised in that the cladding (413, 416) is covered with waterproof lining (417, 419).
  7. 7. A module according to any one of claims 3 to 6 characterised in that the detachable bracing (44) is external to the cladding.
  8. 8. A module according to any preceding claim characterised in that it additionally comprises internal wall panels (412).
  9. 9. A module according to claim 8 characterised h that the internal wall panels (412) are attached to vertical stud work (411) extending from the top perimeter to the bottom perimeter.
  10. 10. A module according to claim 9 characterised in that it additionally compromises a vapour control member (418) between the wall panes (412) and the vertical studwork (411).
  11. 11. A module according to any preceding claim characterised in that it additionally comprises ceiling panels (415).
  12. 12. A module according to claim 7 characterised in that the ceiling panels (416) are attached to ceiling joists (414) mounted between top perimeter members.
  13. 13. A module according to any preceding claim characterised in that it additionally comprises floor panels (410) said panels mounted on floor joists (48) themselves mounted between members of the bottom perimeter (43).
  14. 14. A module according to claim 13 characterised in that one or more floor joists (48) have reduced cross section at one or more places along their length.
  15. 15. A modnle according any preceding claim in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.
  16. 16. A module according to claim 14 or 15 characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.
  17. 17. A module according any preceding claim characterised in that at least some of the shipping fittings are detachable.
  18. 18. A module according to claim 17 characterised in that members at the end of the frame (85, 88) have mounted thereon a plate (91) having mounted therein one half (93) of a locking device (81), the other half (95) of the locking device (81) being mounted on a detachable outer column (86).
  19. 19. A module according to claim 18 characterised that locking device (81) is a bayonet coupling.
  20. 20. A module according claim 18 or 19 characterised in that the outer column (86) has shipping fitted thereto to allow the module to be transported on a container vessel or container lorry.
  21. 21. A module according to any one of claims 18 to 20 characterised in that the member (85) at the end of the frame is a vertical corner member (41) of the frame.
  22. 22. A module according to any one of claims 18 to 23 characterised in that the member (88) at the end of the frame is a transverse member of the top perimeter (42).
  23. 23. A module according to any preceding claim in that it has a roof spanning the top perimeter (42).
  24. 24. A module according to any preceding claim characterised in that it has one or more additional intermediate vertical members (46) between vertical corner members (41).
  25. 25. A module according to any preceding claim characterised in that it contains additional materials to be applied to the exterior of a building constructed using the module.
  26. 26. A building module substantially as hereinbefore described with reference to the accompanying drawings.
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GB0921744A GB2476102A (en) 2009-12-14 2009-12-14 Transportable modular building construction system
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GB201021043D0 (en) 2011-01-26
GB2478373B (en) 2016-02-10
GB2476102A (en) 2011-06-15
GB2478373A (en) 2011-09-07
GB201201036D0 (en) 2012-03-07
GB0921744D0 (en) 2010-01-27

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