GB2545501A

GB2545501A - Modular building

Info

Publication number: GB2545501A
Application number: GB1522444.7A
Authority: GB
Inventors: Donald Foster Pierce Richard; Goss Martin
Original assignee: Pierce Dev (holdings) Ltd
Current assignee: Pierce Dev (holdings) Ltd
Priority date: 2015-12-18
Filing date: 2015-12-18
Publication date: 2017-06-21
Anticipated expiration: 2035-12-18
Also published as: GB2545501B; GB201522444D0

Abstract

The building comprises first and second modules 3a, 3b formed from frames 5a, 5b and arranged adjacent each other with one or more connections 15 between them, the connections having location and alignment portions for locating and aligning the frames relative to each other. The connection may include a guide member 17 fixed to one of the first and second frames, and an aperture 27 on the other. The guide member may be fit loosely in the aperture. The alignment portion may include an adjustment member 21 which fits over the guide member and at least partially in the aperture. The connection may have a nut 23 for applying force to the adjustment member. The adjustment member may be a tapered washer. The guide member may be a threaded stud. The modules may be connected vertically or horizontally. Also claimed is a method of assembling the building.

Description

MODULAR BUILDING

The present invention relates to a modular building. A modular building is constructed from preformed modules which are made off site, and joined together on site. To join the modules together, they must first be positioned, and then the frames of adjacent modules are joined together to form the complete structural building frame. Positioning the modules requires use of a crane, which is expensive, and disruptive, for example requiring road closures. The longer the crane is used for, the more expensive and disruptive its use is. Building Regulations and structural codes require a high degree of alignment between the frames of adjacent modules to meet the current codes for accepted structural connections, and therefore positioning the frames can be difficult and time consuming.

According to a first aspect of the invention, there is provided a modular building having a first module formed from a first frame; a second module, arranged adjacent to the first module, formed from a second frame; and one or more connections formed between the first frame and the second frame, each connection including: a location portion arranged to locate the second frame relative to the first frame; and an alignment portion arranged to align the first frame and the second frame.

The location portion may align the first frame and the second frame to a first accuracy, and the alignment portion may align the first frame and the second frame to a second, higher, accuracy. The first accuracy may correspond to a safe position for initial assembly and the second accuracy may correspond to a secured position for final assembly. In this way, initial assembly may be facilitated by reducing the tolerance difficulty for assembly of large building modules.

The location portion may be arranged to locate the first frame relative to the second frame whilst the second module is positioned adjacent to the first module.

The alignment portion may be arranged to align the first frame and the second frame after the second module has been positioned adjacent the first module.

The connection may include a means for securing the first frame to the second frame.

The connection may include a guide member fixed to one of the first frame and the second frame, the guide member forming a part of both the location portion and the alignment portion.

The location portion may include an aperture for receiving the guide member formed in the other of the first frame and the second frame. The aperture may have a larger diameter than the guide member, such that the guide member forms a loose fit in the aperture.

The alignment portion may include an adjustment member arranged to fit over the guide member, and arranged to at least partially fit in the aperture, such that the effective diameter of the aperture is reduced.

The adjustment member may include a region having a tapered surface, such that the adjustment member encourages the first frame and second frame into alignment as it is engaged.

The region having a tapered surface may include a first end having a first diameter larger than the aperture, and a second end having a smaller diameter, the second end arranged to be received in the aperture, and the alignment adjustment member tapering from the first end to the second end.

The connection may include means for applying a force to the adjustment member to at least partially urge the adjustment member into the aperture.

The guide member may comprise a threaded stud, fixed to one of the first frame and the second frame.

The adjustment member may comprise a tapered washer. The means for applying a force to the adjustment member may comprise a nut having a thread arranged to cooperate with the thread of the stud such that tightening the nut urges the washer into the aperture.

The other of the first frame and second frame may include an access opening for adjustment of the alignment portion of the connection, to align the first frame and the second frame.

Each frame may be formed of elongate frame members joined together, and may include horizontal frame members and vertical frame members. The horizontal frame members extend along the sides and ends of the frame. The vertical frame members may extend between upper and lower horizontal frame members. The vertical frame members may be provided at least at the corners of the frame.

The connection may connect modules arranged one on top of the other, i.e. in a vertical direction. Alternatively or additionally, the connection may connect modules arranged side by side, i.e. in a horizontal direction.

The modular building may include modules arranged in a vertical direction and/or in a horizontal direction with each module connected to the adjacent module in a vertical and/or horizontal direction by at least one of the one or more connections.

The connection may facilitate location of the modules so that a safe position can be achieved quickly during initial assembly of the modules and fine adjustments can then be made to the connection to achieve a secured position during final assembly of the modules.

According to a second aspect of the invention, there is provided a method including the steps of: providing a first module formed from a first frame; positioning a second module formed from a second frame adjacent to the first module, wherein positioning the second module comprising locating the second frame relative to the first frame using a location portion of a connection; and after positioning of the second module, aligning the second frame to the first frame using an alignment portion of the connection.

Positioning the second module using the location portion may align the first frame and the second frame to a first accuracy, and aligning the second frame to the first frame using an alignment portion may align the first frame and the second frame to a second, higher, accuracy. The first accuracy may correspond to a safe position for initial assembly and the second accuracy may correspond to a secured position for final assembly. In this way, initial assembly may be facilitated by reducing the tolerance difficulty for assembly of large building modules.

Aligning the second frame to the first frame using an alignment portion may include securing the first frame to the second frame.

The connection in the second aspect may include the optional features of the connection according to the first aspect.

Other features, benefits and advantages of the modular building will be more readily understood from the following description of embodiments of the invention which is provided by way of example only with reference to the accompanying drawings wherein:

Figure 1 shows the frame of an example modular building;

Figure 2 shows an exploded view of a connection between two modules of the modular building of Figure 1;

Figure 3 shows a sectional view of the assembled connection; and

Figure 4 shows a side view of the assembled connection.

Figure 1 shows an example of a frame 5 of a building 1 having three floors (storeys). The building 1 is constructed by assembling the frame 5, and then filling in the walls, floors, ceilings and the like (not shown) using, for example, concrete.

The frame 5 is modular, meaning that it is formed of several preformed sections (modules 3). The modules 3 are formed in advance, off site from where the building 1 is being constructed, and later transported to the site. The walls, floors, ceilings and the like may either be preformed off site, or alternatively, formed on site.

The ground floor of the building 1 is formed by a first module 3a, the first floor by a second module 3b, and the second floor by a third module 3c. Each module 3a, 3b, 3c has a respective frame 5a, 5b, 5c.

The first frame 5a, which forms the first module 3a, is cuboid in shape, with vertical frame members 7 extending between upper and lower horizontal frame members 9, 11. The horizontal frame members 9, 11 extend along the sides and ends of the frame 5a and the vertical frame members 7 extend between the upper and lower horizontal frame members 9,11 at the corners of the frame 5a. The floor plan and side profile of the first frame 5a are rectangular, while the end profile is substantially square. The frame members 7, 9, 11 may be of any suitable material. For example, the frame members may be made of steel. The frame members 7, 9, 11 may be of any suitable shape. For example the frame members may be of I-section or hollow box section or any other suitable section for the intended application and load bearing requirements. In the example shown, the horizontal frame members 9 extending along the sides of the frame 5a may have a larger cross-section than the horizontal frame members 11 extending along the ends of the frame 5a. This is because these frame members 9 are usually greater in terms of span and so must carry increased weight.

Further transverse support members 13 or alternatively continuous structural decking may be provided if required across the top of the frame 5a, between the upper frame members 9. The transverse support members 13 form the base of the floor for the first storey of the building.

The second frame 5b, which forms the second module 3b is generally the same as the first frame 5a, although the horizontal lower frame members 9 are omitted along the sides of the frame 5b.

The third frame 5c, which forms the third module 3c is generally the same as the second frame 5b. In this case, the transverse support members 13 form the base for the roof of the building 1.

To form the complete frame 5, the second frame 5b is positioned on top of the first frame 5a by a crane. The second frame 5b is then joined to the first frame 5a by connections 15 provided at the corners. The connections 15 are formed by the top of each of the vertical frame members 7 of the first frame 5a, and the base of each of the vertical frame members 7 of the second frame 5b. The third frame 5c is then positioned above, and joined to, the second frame 5b in a similar manner.

The connections 15 will now be described in more detail, with reference to Figures 2 to 4.

Figure 2 shows an exploded perspective view of one example connection 15 formed between the first module 3a and the second module 3b. Figure 3 shows a sectional view of the connection 15 when it is assembled, and Figure 4 shows the side view of the assembled connection 15. A threaded stud 17 extends through a first aperture 27 in the base of the vertical frame member 7 of the second frame 5b, and through a second aperture 29 in the top of the vertical frame member 7 of the first frame 5a. The stud 17 is fixed to the first frame 5a by a captive nut 25 welded to the first frame 5a. Therefore, prior to assembly of the frame 5, the stud 17 extends upwardly from the vertical frame member 7 of the first frame 5a.

The stud 17 is a clearance fit in the first and second apertures 27, 29 and the first aperture 27 in the bottom of the vertical frame member 7 of the second frame 5b is preferably of larger diameter than the second aperture 29 in the top of the frame 5a to receive the tapered washer 21 so that the frames 5 of the modules can be accurately aligned to meet the structural requirements of building codes and structurally interconnected when the building is assembled as described later..

During positioning, the second module 5b is located on top of the first module 5a so that the stud 17 extends through the first aperture 27 in the base of the vertical frame member 7 of the second frame 5b. The first aperture 27 is significantly larger than the stud 17. For example, the stud may have a 30mm diameter, and the first aperture 27 a 50mm diameter.

The size difference between the stud 17 and the first aperture 27 means that the second module 5b does not have to be exactly aligned to the first module 5a to position the second module 5b. Instead, a loose fit is formed by using the stud 17 as a guide member. This means it can be relatively quick to position the second module 5b, compared to having to get exact alignment, meaning that the crane is required for less time.

The first module 5a and second module 5b can be secured together by fitting a nut 23 onto the thread 19 of the stud 17, and tightening. The stud 17 and nut 23 can be accessed through an opening 31 formed in the base of the side of the vertical frame member 7, where the long horizontal frame member 9 would be positioned in the first module 5a.

However, the accuracy of the alignment provided using the stud 17 as a guide member is not sufficient to satisfy the building codes and current national and EU standards. Therefore, the connection 15 also includes a tapered washer 21, which can be used to align the first 5a and second module 5b as the nut 23 is tightened.

The tapered washer 21 is an annular washer extending from a first end 35 to a second end 37. The first end 35 has a diameter that is wider than the first aperture 27 in the base of the vertical frame member 7 of the second module 3b. The second end 37 has a diameter that is smaller than the first aperture 27 in the base of the vertical frame member 7 of the second frame 5b, but slightly larger than the second aperture 29 in the top of the vertical frame member 7 of the first frame 5a. The outer surface 39 tapers from the first or wide end 35 to the second or narrow end 37.

In use, if the first frame 5a and second frame 5b are exactly aligned, then the stud 17 will be centrally located in both apertures 27, 29 so that, when the washer 21 is placed (sliding fit) over the stud 17 narrow end 37 first, the narrow end 37 is received in the aperture 27 and the outer surface 39 of the washer 21 rests on the base of the vertical frame member 7 of the frame 5b and engages the base around substantially the entire circumference of the aperture 27 with the narrow end 37 of the washer spaced from the aperture 2 in the top of the vertical frame member 7 of the first frame 5a. The frames 5a, 5b can then be fully secured by tightening the nut 23 to provide a downward force on the washer 21 that urges the washer 21 further into the aperture 27. It is desirable that the narrow end 37 of the washer 21 does not contact the top of the vertical frame member 7 of the frame 5a before the frames 5a, 5b are fully secured. It may be that the narrow end of the washer 21 is spaced from the top of the vertical frame member 7 of the frame 5a when the frames 5a, 5b are fully secured.

However, if the first frame 5a and second frame 5b are not exactly aligned, then the stud 17 will not be centrally located in the aperture 27 in the base of the vertical frame member 7 of the frame 5b so that, when the washer 21 is placed (sliding fit) over the stud 17 narrow end 37 first, the narrow end 37 is again received in the aperture 27 but is offset to one side and the outer surface 39 of the washer 21 rests on the base of the vertical frame member 7 of the frame 5b and engages the base around part only of the circumference of the aperture 27 with the narrow end 37 of the washer spaced from the aperture 2 in the top of the vertical frame member 7 of the first frame 5a. Tightening of the nut 23 again provides a downward force on the washer 17 that is translated through the engagement of the tapered outer surface 39 of the washer 21 with the aperture 27 to force the second frame 5b into sufficient alignment with the first module 5a to satisfy the building codes and structural requirements. Therefore, the washer 17 can be considered an alignment element.

The stud 17 also includes a hole 33 to receive a tommy bar or the like (not shown) to prevent the stud rotating when tightening the nut 23 and/or to adjust the axial position of the stud 17 relative to the frames 5a, 5b during installation. To

At least the top of the vertical frame members 7 in the first frame 5a and second frame 5b, and the bottoms of the vertical frame members 7 in the second frame 5b and third frame 5c are formed as discussed above, in order to form connections between the modules 3. Connections are formed at all four corners of the frame 5.

The use of the tapered washer 21 provides a higher accuracy alignment, but does not require prolonged use of a crane, since the first aperture 27 and the stud 17 can be used as a locating portion of the connection 1, while the stud 17, washer 21 and nut 23 can be used as an alignment portion and securing means. The accuracy of the alignment provided by the washer 21 means the frames are substantially exactly aligned, such that the alignment satisfies the building codes. The alignment is achieved by reducing the effective size of the first aperture 27 in the bottom of the vertical frame member 7, such that exact alignment is achieved.

In one example, the captive nut 25, nut 23 and stud 17 are formed of grade 8,8 steel. However, it will be appreciated that any material that provides suitable strength may be used. Furthermore, the captive nut 25 may be fixed by any suitable means.

In addition, the washer 21 may be any suitable type of washer, such as a split ring washer. Furthermore, although in the above example, the washer 21 and nut 23 are separate, they may be provided in a single unitary element.

It will also be appreciated, that although the connection 15 shown, only one stud 15 is provided for alignment, multiple studs may also be provided.

Instead of using the nut 23 to apply a force to the washer 21, any suitable means of applying the force may be used. Furthermore, the connection means may be separate to the locating portion and alignment portion. For example, connection may be achieved through different nuts and bolts, or through welding, and the like.

The frame 5 of the modules is shown by way of example only. In the example show, vertical frame members 7 are provided at the vertical edges of the frame 5, and connections are provided at the top/bottom of each vertical frame member 7. It will be appreciated that additional vertical frame members 7 may be provided along the sides and ends of the modules 3. It will be further appreciated that some or all of the vertical frame members may be configured to form connections 15 as described above.

In addition, it will be appreciated that the connections may be formed in the horizontal frame members 9, 11 instead of or as well as in the vertical frame members 7, and the connections may be provided at any point around the frame 5.

In the example, shown, the module 3 includes only the frame 5, and none of the panels used to fill in the frame. It will be appreciated that the modules 3 may include part or all of the walls, floors and other fittings of the building 1.

Furthermore, although the example building shown in Figure 1 includes three floors, each floor made of a single module 5, it will be appreciated that a building may include any number of floors, and each floor may include one or more modules side by side. The connections 15 described above may be used to connect modules 3 laterally as well as vertically.

It will be understood that the invention is not limited to the embodiment described herein and that features of the apparatus may be altered, omitted or adapted according to the requirements of the unit. It will also be understood that the invention includes any novel feature described herein as well as combinations and sub-combinations of any of the features and equivalents thereof.

Claims

1. A modular building having a first module formed from a first frame; a second module, arranged adjacent to the first module, formed from a second frame; and one or more connections formed between the first frame and the second frame, each connection including: a location portion arranged to locate the second frame relative to the first frame; and an alignment portion arranged to align the first frame and the second frame.

2. The building of claim 1 wherein the location portion is arranged to locate the first frame relative to the second frame whilst the second module is positioned adjacent to the first module.

3. The building of claim 1 or claim 2 wherein the alignment portion is arranged to align the first frame and the second frame after the second module has been positioned adjacent the first module.

4. The building of any preceding claim wherein the connection includes means for securing the first frame to the second frame.

5. The building of any preceding claim wherein the connection includes a guide member fixed to one of the first frame and the second frame, the guide member forming a part of both the location portion and the alignment portion.

6. The building of claim 5 wherein the location portion includes an aperture for receiving the guide member formed in the other of the first frame and the second frame.

7. The building of claim 6 wherein the aperture has a larger diameter than the guide member, such that the guide member forms a loose fit in the aperture.

8. The building of any of claims 5 to 7 wherein the alignment portion includes an adjustment member arranged to fit over the guide member, and arranged to at least partially fit in the aperture.

9. The building of claim 8 wherein the adjustment member includes a region having a tapered surface such that the adjustment member encourages the first frame and second frame into alignment.

10. The building of claim 9 wherein the region having a tapered surface includes a first end having a first diameter larger than the aperture, and a second end having a smaller diameter, the second end arranged to be received in the aperture, and the alignment adjustment member tapering from the first end to the second end.

11. The building of any of claims 8 to 10 wherein the adjustment member comprises a tapered washer.

12. The building of any of claims 8 to 11 wherein the connection includes means for applying a force to the adjustment member to at least partially urge the adjustment member into the aperture.

13. The building of claim 12 wherein the guide member comprises a threaded stud, fixed to one of the first frame and the second frame, and the means for applying a force to the adjustment member comprises a nut having a thread arranged to cooperate with the thread of the stud such that tightening the nut urges the adjustment member into the aperture.

14. The building of any preceding claim wherein the other of the first frame and second frame includes an access opening for adjustment of the alignment portion of the connection, to align the first frame and the second frame.

15. The building of any preceding claim wherein each frame is formed of elongate frame members joined together, and includes horizontal frame members and vertical frame members.

16. The building of claim 15 wherein the horizontal frame members extend along the sides and ends of the frame and the vertical frame members extend between upper and lower horizontal frame members.

17. The building of claim 16 wherein the vertical frame members are provided at least at the corners of the frame.

18. The building of any preceding claim wherein the connections connects modules arranged one on top of the other, i.e. in a vertical direction.

19. The building of any preceding claim wherein the connection connects modules arranged side by side, i.e. in a horizontal direction.

20. The building of any preceding claim including modules arranged in a vertical direction and/or in a horizontal direction with each module connected to the adjacent module in a vertical and/or horizontal direction by at least one of the one or more connections.

21. A method of assembling a modular building including the steps of: providing a first module formed from a first frame; positioning a second module formed from a second frame adjacent to the first module, wherein positioning the second module comprising locating the second frame relative to the first frame using a location portion of a connection; and after positioning of the second module, aligning the second frame to the first frame using an alignment portion of the connection.

22. A modular building substantially as hereinbefore described with reference to the accompanying drawings.

23. A method of assembling a modular building substantially as hereinbefore described with reference to the accompanying drawings.