GB2559966A - Modular system for constructing buildings - Google Patents

Modular system for constructing buildings Download PDF

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Publication number
GB2559966A
GB2559966A GB1702794.7A GB201702794A GB2559966A GB 2559966 A GB2559966 A GB 2559966A GB 201702794 A GB201702794 A GB 201702794A GB 2559966 A GB2559966 A GB 2559966A
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Prior art keywords
hexagon
slab
building
panel
roof
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GB1702794.7A
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GB201702794D0 (en
Inventor
William Bell Christopher
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Hexpodular Ltd
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Hexpodular Ltd
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Priority to GB1702794.7A priority Critical patent/GB2559966A/en
Publication of GB201702794D0 publication Critical patent/GB201702794D0/en
Publication of GB2559966A publication Critical patent/GB2559966A/en
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    • 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
    • E04B1/34815Elements not integrated in a skeleton
    • E04B1/34823Elements not integrated in a skeleton the supporting structure consisting of concrete
    • 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
    • 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
    • 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
    • E04B1/02Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/04Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
    • E04B1/043Connections 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
    • E04B2001/0053Buildings characterised by their shape or layout grid
    • E04B2001/0084Buildings with non right-angled horizontal layout grid, e.g. triangular or hexagonal
    • E04B2001/0092Small buildings with hexagonal or similar horizontal cross-section

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Joining Of Building Structures In Genera (AREA)

Abstract

The system 200 has multiple pre-formed elements, preferably casts concrete, including a floor slab and a plurality of wall panels, the slab having the form of a half or third of a hexagon, the wall panels having side regions which are vertical in use, and top and foot regions which are horizontal in use, each foot region having a bottom profile which matches a side edge region of the floor slab. The system may also comprise roof slabs matching the floor slabs. The slabs may be various shapes formed from sections of a hexagon. The wall panels have a central region which may include openings for windows, French doors etc. or may be filled in, and have bevelled side edges. There may be relatively short parapet panels 190 for location of an upper roof. Elements may include a passage communicating between element edges and recessed inserts for receiving threaded rods to fasten together adjacent building elements. Also claimed is a method of constructing the building.

Description

(54) Title of the Invention: Modular system for constructing buildings Abstract Title: Modular building system with hexagon shaped units (57) The system 200 has multiple pre-formed elements, preferably casts concrete, including a floor slab and a plurality of wall panels, the slab having the form of a half or third of a hexagon, the wall panels having side regions which are vertical in use, and top and foot regions which are horizontal in use, each foot region having a bottom profile which matches a side edge region of the floor slab. The system may also comprise roof slabs matching the floor slabs. The slabs may be various shapes formed from sections of a hexagon. The wall panels have a central region which may include openings for windows, French doors etc. or may be filled in, and have bevelled side edges. There may be relatively short parapet panels 190 for location of an upper roof. Elements may include a passage communicating between element edges and recessed inserts for receiving threaded rods to fasten together adjacent building elements. Also claimed is a method of constructing the building.
Figure GB2559966A_D0001
FIG.13
At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.
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Figure GB2559966A_D0007
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FIG.10D
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FIG.10G
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FIG.10F
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FIG.11
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FIG.13
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FIG.14
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FIG.15
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Figure GB2559966A_D0024
FIG.16
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FIG.17
Modular System for Constructing Buildings
The present invention concerns the construction of buildings for use in residential housing, office, storage, agricultural or industrial purposes. The invention relates in particular for a modular construction system which utilizes pre-formed constructional elements such as floor, roof and wall portions which represent sub-units of a prismatic hexagon.
Pre-fabricated building construction techniques are well known. In this methodology buildings are part assembled in a factory, and then transported to a building site for final assembly and fitting out. Modular constructional techniques use a limited number of constructional elements which can them be combined and arranged in a wide variety of ways to produce different building patterns. Known modular construction techniques tend to use a rectilinear pattern of floors, ceilings and walls.
US 2,886,855 discloses buildings having a ground plan based upon hexagonal units of two different basic sizes. US 5,560,151 discloses buildings based upon geodesic structures based upon hexagon and pentagon panel elements. US 6,173,538 discloses a modular construction system for building (amongst other things) residential structures based upon dodecahedral shapes. US 6,631,603 discloses sub-hexagonal construction elements made of foam sandwiched between concrete fibreboard.
None of the foregoing construction methods has been adopted in the construction trade at large. Modular construction techniques has to a certain extent beers restricted to niche builders, or are limited to temporary buildings for use in emergencies or for events.
The present inventors have sought to provide a modular construction technique which is capable of providing permanent, long-lasting buildings which are stable in a wide range of weather conditions and which can be used to make small buildings but which can be easily scaled-up to produce very large buildings, in terms of both footprint area occupied (lateral scaling) but also the ability to scale upwards into multiple stories high (vertical scaling).
The building system should permit rapid on-site assembly of a building shell, without the need for extensive and labour intensive groundworks, slab-pouring or blockwork. The buildings system elements should also be easy to transport in a stacked matter.
One or more of these objectives may be accomplished by aspects of the present invention as set out below. The base hexagon unit used in the building elements is a hexagonal prism and preferably a regular hexagonal prism as shown in figure 1.
In accordance with one aspect the present invention there is provided a modular building construction system comprising a plurality of pre-formed constructional elements for assembly at a construction site, the elements including at least one floor slab and a plurality of wall panels, wherein the floor slab has the plan form of a half-hexagon and the wall panels each have rectilinear front and rear elevations including vertical side regions and transversely extending fop and foot regions, each foot region having a span which matches, or substantially matches, a sub-hexagonal side portion of the floor slab.
The pre-formed constructional elements may further comprise at least one roof slab having the plan form of a half-hexagon. The top region of each wall panel is sized to match or substantially match, a sub-hexagonal side portion of the roof slab.
One or more half-hexagonal slab or slabs may have the form of a halfhexagon obtained by dividing along a maximal diameter of the hexagon.
One or more half-hexagonal slab or slabs may have the form of a halfhexagon obtained by dividing along a minimal diameter of the hexagon.
The constructional elements may further comprise one or more radial wall panels which are generally rectilinear and sized to span a radius of the halfhexagon. In some elements the radius may be a maximal radius. In others the radius is a minimal radius.
The constructional elements may further comprise one or more diametric wall panels which are generally rectilinear in elevation and sized to span a diameter of the half-hexagon, alone or as a pair. The span diameter may be a maximal hexagonal diameter or the minimal diameter.
The constructional elements may further comprise at least one floor or roof slab having the plan form of a sub-hexagonal parallelogram represented by two hexagonal maximal radii and two complete sidewalls of the half-hexagon, together representing a third of the base hexagon area.
The constructional elements may further comprise at least one roof or floor slab having the plan form of a sub-hexagonal rhombus having one side which represents a maximal radius, perpendicular side which represents a minimal radius, a further perpendicular side which represents half a side of the hexagon, and a side which represents a complete side of the hexagon, together representing a quadrant of the hexagon.
The constructional elements may further comprise a floor or roof slab which has the plan form of an equilateral triangle of sides equal in length to the maximal radius of the hexagon.
The constructional elements may further comprise one or more parapet panel having a foot region for placement on a roof slab side. A length of the parapet panel is typically greater than its width, and the width is typically less than 50% of the height of the wall panels.
The construction elements may further comprise one or more wall sub-panels each having a rectilinear side elevation and a foot region which is sized to substantially match a sub-hexagonal, half-side portion of the floor slab.
The wall panels and/or radial spans and/or diametric spans may each have one or more vertical edges which are bevelled to provide an edge face with an internal angle of 60 degrees.
Each construction element may be provided with a plurality of pre-formed fastening features for facilitating the attachment of one element to another. One fastening feature on one element may comprise a recessed inset into an edge region of the surface of the element, and a passage which communicates between the inset recess and an edge surface of the element. Another fastening feature on another element may comprises a passage for a rod, which passage communicates between upper and lower surface edge regions of the element. The arrangement may be such that when an element is offered-up to the other in a building configuration, the rod passage and recess passage can be aligned, or two recess passage can be aligned, so that at rod may be threaded through both passages. There may be provided a retaining feature at each end of the rod, at least one of which retaining features is translatable along the rod so as to hold one element in abutment with the other. Thus, the rod may be screw-threaded and at least one said retaining feature comprises a screw-threaded nut. The other retaining feature may comprise a screw-threaded nut or is a fixed rod end obstruction which cannot pass through the constriction provided by the rod passage, such as an annular head, or a domed head or a transverse bar, or bar return.
One or more of the constructional elements (typically a panel element) is provided one or more pre-formed window or door apertures. One or more of the constructional elements may be provided with apertures and/or grooves for the location of building service routes such as electrical or plumbing or air conditioning services. The roof or floor slabs may be provided with apertures, such as skylight ports or stairwell ports.
Each constructional element is preferably pre-formed by casting of concrete. The concrete may be provided with internal reinforcement, such as by reinforcing steel mesh, cage or rods.
The preformed constructional elements are each preferably unitary elements.
One or more side edge of each wall panel, or sub-panel, may be formed with a bevelled edge, the bevel preferably subtending an internal angle of 60a with respect to a front or rear elevation of the panel.
In accordance with a further aspect of the invention there is provided a method of constructing a building comprising providing a modular building system as hereinbefore described at a construction site and assembling the pre-formed construction elements into a building. Further steps may include fitting out the building, such as with insulation boarding, fitting windows and doors, providing electrical services, plumbing, water and waste water services, heating services, flooring etc. The method may also include the initial step of pre-forming the constructional elements at a location remote from the construction site and delivering the elements to the construction site. The pre-forming preferably comprises casting the elements from a concrete slurry in appropriately configured moulds. The method may include flat packing the elements for transport to the construction site, such as on a flatbed lorry or trailer.
Following is a description by way of example only of modes for putting the invention into effect, by way of example only and with reference to the drawings, in which:
Figure 1 show a hexagonal prism which forms the basis for configuring the constructional elements used in the present invention.
Figure 2 is a plan view from above of a first floor slab element in accordance with the construction system of the present invention.
Figure 3 is a plan view from above of a second floor slab element in accordance with the present invention.
Figure 4 is a plan view from above of a third floor slab element in accordance with the present invention.
Figure 5 is a top plan schematic representation of foundations for use in the present invention.
Figure 6 is a top plan schematic representation of alternative foundations for use in the present invention.
Figure 7A is a side elevation of a second wall panel in accordance with the present invention.
Figures 7B, 7C, 7D and 7E are top plan views showing the alternative wall panel edge profiles.
Figure 7F shows a third slab and portion of a first slab showing possible locations of wall the panels.
Figure 8A is a side elevation of a first wall panel in accordance with the present invention.
Figures 8B and 8G are top plan views showing alternative the wall panel edge profiles.
Figure 8D shows a portion of a first slab showing the location of wail panels.
Figure 9A is a side elevation of a third wall panel in accordance with the present invention.
Figures 9B and 9C are top plan views showing the alternative wall panel edge profiles.
Figure 9D and 9E are top plan views of corner portions of second slabs showing alternative configurations of the wall panels.
Figure 10A is a side elevation of a fourth wall panel in accordance with the present invention.
Figures 10B, 10C and 10D are top plan views showing alternative wall pane
Figure 10E is a top plan view of a comer portion of a second slab, showing wall panel dispositions.
Figure 10F is a top plan view of two abutting comer portions of second slabs, showing the disposition of wall panels.
Figure 10G is a top plan view of a corner portion of a second slab showing an alternative disposition of wall panels.
Figure 11 is a side elevation of the parapet element for use in the present invention.
Figure 12 is an internal fop plan view of a building made using the system of the present invention.
Figure 13 is a three quarter perspective view from above and one side of the building shown in figure 12.
Figure 14 is a schematic representation of various floorplan arrangements possible using the slab elements of the present invention.
Figure 15 is a perspective photographic view of a partially complete building made in accordance with the present invention.
Figure 16 is a perspective photographic view of the building of figure 15 with all slabs, panels and parapet elements in place and awaiting fit-out.
Figure 17 is a perspective photographic view of the building of figure 16 after fit out.
The embodiments of building elements for use in the building system are subhexagonal shapes which are derived from a regular prismatic hexagon 10, as shown in figure 1. The base hexagon 11 has a maximal radius R (bisecting the comer 120e angle Θ) and a minimal radius r (bisecting a sidewall at a perpendicular angle). The upstanding sides of the hexagon are generally rectilinear flat panels 12 which extend upwards to a first story roof height H. The panels have a width which corresponds to the length of each side S of the hexagon.
First floor slab or roof element
A top plan view of a slab element for use in the building system of the present invention is shown in figure 2. The slab is formed as a single planar concrete casting, having an upper face 13 and a lower face (obscured) and four sides. The slab has a plan shape which represents half of a regular hexagon (or a trilateral trapezoid), with the long side 15 having a length equal to the hexagon maximal diameter 2R. The two adjacent sides 16, 17 each form an internal acute angle of 60s with respect to the long side. The short side 18 has obtuse internal angles of 120s with respect to the adjacent sides. Each of the adjacent and short sides is of equal length S.
Each side region of the slab is formed with inset recessed pockets 19 which are each cuboid in configuration, with a rectilinear opening formed on one of the upper or lower faces. The pocket is spaced apart from the side edge, with a bore 20 extending in a perpendicular direction with respect to the side edge, transversely through the neck of material which separates the pocket from the side edge, so as to open info the pocket. Each adjacent and short side is provided with two of these pockets. The long side is provided with three pockets, one centrally disposed and two on either side of the centre.
Conveniently, roof slabs may be provided which are essentially the same as the slab element.
Two of these floor or roof slab elements may be disposed side by side with respective long sides juxtaposed, to make a complete hexagonal slab. The pocket/bore (19,20) combinations are arranged to be aligned so that a threaded bolt may extend between each pair of aligned bores, with opposite ends of the bolts protruding into the opposed pockets. A nut at each end (or head and single nut) may be used to connect the slabs together.
Second floor slab or roof element
A second slab configuration is shown in figure 3. This slab represents the base hexagon divided in half along the minimal diameter 2r.
The slab is formed as a single planar concrete casting, having an upper face 33 and a lower face (obscured) and five sides. The slab has a plan shape which represents a pentagon which is a bisected regular hexagon, with the long side 35 having a length equal to the hexagon minimal diameter 2r. The two adjacent short sides 36, 37 each form an internal right angle of 90s with respect to the long side. Each of these sides has a length equal to half the length (S/2) of a side of the hexagon. The two remaining sides 39,40 extend from each short side end and meet at an apex of the pentagon. These two sides correspond to two adjacent sides of the base hexagon.
As with the first slab, each side region of this slab is formed with inset recessed pockets 19 which are cuboid in configuration, with a rectilinear opening formed on one of the upper or lower faces. The pocket is spaced apart from the side edge, with a bore 20 extending in a perpendicular direction with respect to the side edge, transversely through the neck of material which separates the pocket from the side edge, so as to open into the pocket. Each side of the slab is provided with one, two or three of these pockets. The long side is provided with three pockets, one centrally disposed and two on either side of the centre. The short sides are provided with one each, and the other two sides are provided with two spaced apart pockets.
Conveniently, roof slabs may be provided which are essentially the same as the floor slab element.
Two of these rood/floor slab elements may be disposed side by side with respective long sides juxtaposed, to make a complete hexagonal slab. In this case, and in general, the pocket/bore combinations are arranged to be aligned so that a threaded bolt may extend between each pair of aligned bores, with opposite ends of the bolts protruding into the opposed pockets. A nut at each end (or head and single nut) may be used to connect the slabs together.
Third floor slab or roof element
A third slab configuration is shown in figure 4. This slab represents the base hexagon divided in into three along maximal radii R.
The slab is formed as a single planar concrete casting, having an upper face 43 and a lower face (obscured) and four sides 44, 45, 46 & 47. The slab has a plan shape which represents a regular parallelogram with internal opposite angels of 120s and 60s. Two of the sides 44, 47 occupy the position of sides of the base hexagon. The other two occupy maximal radius lines R of the base hexagon.
As with the first and second slabs, each side region of this slab is formed with inset recessed pockets 19 which are cuboid in configuration, with a rectilinear opening formed on one of the upper or lower faces. The pocket is spaced apart from the side edge, with a bore 20 extending in a perpendicular direction with respect to the side edge, transversely through the neck of material which separates the pocket from the side edge, so as to open into the pocket. Each side of the slab is provided with two these pockets spaced apart from one another.
Conveniently, flat roof slabs may be provided which are essentially the same as the third floor slab element.
Three of these slab elements may be arranged placed together to form a complete hexagon, or two may be joined to make a two thirds of a hexagon. A particular use is however the combination this slab with the first and/or second slab configurations (see figure 14).
Generally, there is a uniform lateral spacing between pairs of pockets 19. This ensures that when respective different slab configurations are to be joined, the pairs of pockets are aligned.
Examples of the wide range of combination possibilities are shown in figures 5 and 6, and each one could be a floor slab, ceiling or flat roof combination. The slabs can function as floor or roof units. Where a roof unit serves in a multistory building, is may be termed a ceiling slab.
Foundations
Foundations are required for the slabs. A first foundation system comprises a shallow area which extends beyond the intended footprint of the building which is excavated and filled with aggregate, which is compacted. A sand layer is placed on top and compacted and levelled. The excavated area corresponds to an enlarged footprint of the slabs to be laid. Drainage channels may be provided around the edges of the slab footprint to prevent erosion of the sand and associated fines over time.
A second foundation system is shown in figure 5. In this system discrete pad supports 65 are provided under corner regions of individual slabs. The pads may be supported on a pile (such as a screw pile). Where there is a join between slabs at the relevant corners, the pad should bridge and support both slabs. A rubber (elastomer) interface layer (or pair of layers) is provided on each pad upper surface.
A third foundation system is shown in figure 6. In this system, elongate foundation strips 50 are provided which are configured and oriented to underlay and follow one or more slab sides. Thus in figure there is one triplet 51 of radially disposed foundation strips, separated from each other by 120s.
There are two zig-zagging strips 52, 53 each corresponding to two adjacent hexagon side portions and one short side portion 56 corresponding to half a complete hexagonal side portion.
The foundation strips are typically cast in situ by forming trenches and pouring concrete. Elongate bearing pads of rubber (elastomer) are laid along top sides of the strip to provide a resilient interface for slabs laid on top.
First wall panel
A first wall panel 100 is shown in figure 7A. The panel is generally rectilinear in form and cast from concrete. The panel has an inner face 101 and an outer face (not visible in the figure). There is a large aperture 102 formed in the panel which is framed by upper and lower transverse panel portions 103, 104 and left and right upright portions 105, 106. The panel has perpendicular top and bottom edges 107,108.
The upper transverse portion is formed with two transversely spaced apart, inset recessed pockets 119 which are cuboid in configuration, with a rectilinear opening formed on one of the inner or outer faces (of the same configuration as item 19 described hereinbefore. Each pocket is spaced apart from the top edge 107, with a bore 120 extending in a perpendicular direction with respect to the top edge, transversely through the neck of material which separates the pocket from the tope edge, so as to open info the pocket. A similar arrangement exists in the lower region of the panel with two spaced apart pockets 119 formed in lower regions of the upright portions 105 and 106. This panel is of a width (span) which substantially matches the side length S of the base hexagon (i.e. the short sides of the first slab (figure 2), and two apex sides of the second slab (figure 3), etc.)
Left and right edges 109, 110 of the panel are defined by respective bevels which flare out from the inner face to the outer face, the bevels having an internal angle of 1209 with respect to the inner face (see figure 7B). Alternative bevel arrangements and panel widths are possible and are exemplified in the four top end views shown in figures 7G to 7E in which the top edges are labelled 107B to 107D. 107B shows a parallelogram profile, with a width slightly greater than 107. 107C shows a trapezoid profile but with reduced overall width (comparted to 107). 107D has trapezoid profile, but with further reduced width.
In figure 7F possible locations of the panels are shown on a third slab and an abutting portion of a first slab. The required width and profile for a panel will depend upon whether an abutment with a neighbouring panel is a mitred (two bevels facing) or a butt joint.
Second wall panel
The second wall panel 130 in figure 11a is of similar configuration to the first 100, with reduced transverse width, but the same height. There is an aperture 132 and pockets and bores 119,120. The left hand edge 139 has a perpendicular profile. The right hand side 140 has a bevelled profile (see top view in figure 8C), The top edge 137 has a rectilinear profile at one end and is bevelled at the other end. This panel has a width of about half of the maximal radius R of the base hexagon, so that when paired with another panel, the long side of a first slab may be spanned (see figure 8D). Precise width variations and bevel configurations will depend upon whether a mitred, overlapped or butt joint is formed with neighbouring panels. Hence the panel width for profile 137A (figure 8B) is less than 137. These panels are provided in a width and configuration so as to be mountable side by side to span the maximal diameter represented by the long side of the first slab (as shown in figure 8D),
Third wall panel
The third wall panel 150 in figure 9A is of similar configuration to the second panel 130, but of further reduced width. Both side edges 159 and 160 are perpendicular to the inner and outer faces. There are two spans of the panel (shown in tope edge profiles 157 and 157A in figures 9B and 9G). These are sized so that together they span the long side of the second slab (the minimal diameter of the base hexagon), with one end flush with the end of the slab (as shown in figure 9D, and the other inset to provide a butt joint with the adjacent panel (as shown in figure 9E).
Fourth wall panel
The fourth panel 170 in figure 10A is further reduced and only has one upper pocket 119, rather than two. This panel has one side 179 which is formed with a perpendicular edge and the other end 180 is bevelled. The panel top edge 177 reveals the profile shown in figure 10D. The panel comes in three different spans, and with alternate bevel profiles 107A and 107B (see figures 10B and 10C) to account for joint variants, as shown in figures 10E, 10F and 10G. These panels span the short sides of the second slab, in three different joint arrangements.
Variants
Variants of the wall panels may be precast with or without the apertures shown and with or without one or more window or door apertures. The wall panels and floor and roof slabs can be formed with one or more service apertures for the passage of, for example, plumbing, electrical or heating conduits, piping or cabling. Slabs may be pre-formed with orifices for skylights, vents or stairwells.
Parapet panel
A parapet panel 190 is shown in figure 11. This panel is for placing on a roof slab. The panel has a span to match the underlying roof slab side, about the side length S of the base hexagon. The precise span will depend upon whether there is a perpendicular edge or a bevelled edge for abutment with adjacent further parapet panels, and variants in line with those for the first panel (and other panels if required) are possible. So the span typically matches the edge length of the underlying roof slab, with variations which allow for the presence or absence of bevelled ends, or the location of the required butt joint, or overlapped joint. In the panel shown in the figure 11 the inner face 191 has two outwardly flaring bevelled side edges. The parapet has two transversely spaced apart pockets 119 (as previously described) with downwardly directed bores 120 for engagement with the upper face of an underlying roof portion.
Figure 12 is an internal fop plan view of an upper story of a building 200 made using the system of the present invention. There is an atrium 201 erected on a single first roof slab with a stairwell 208, and with wall panels on three sides. There is a bedroom 202 which is defined by two second roof slabs disposed with long sides abutting. Wall panels are provided on five sides, and an internal partition 203 and door between the atrium and bedroom. A French door insert 204 to one of the wall panels leads to a terrace 205 defined by two first roof slabs disposed side by side in abutment.
Figure 13 is a three quarter perspective view from above and one side of the entire building (detail of which is shown in figure 12). The building has first and second stories, with the terrace 205 defined by the roof of an underlying living room 207, The roof of the bedroom 202 and atrium 206 is provided by corresponding first or second slabs. This roof area is provided with a parapet perimeter using nine parapet elements 190.
Figure 14 is a schematic representation of various floorplan arrangements possible using the first, second and third slab elements of the present invention. Other slab shapes maybe provided, but the one shown are the basic units which provide a wide range of options, including making flat building sides if a more conventional appearance is desired.
Figure 15 is a perspective photographic view of a partially complete building made in accordance with the present invention. There are two second floor slabs abutted along their long sides and bolted together via aligned pockets
19. One blank first panel (without aperture) 100A is disposed next to an apertured (102) first panel 100B, and another first panel 100C (with vertical window aperture 210) is disposed next to it.
In Figure 18 all floor and roof slab pairs, and wall panels are In place and the building is awaiting fit-out.
Figure 17 is a perspective photographic view of the building of figure 16 after fit out, with window fitted and two sets of French doors 204.
The building construction system of the present invention provides for the rapid erection of buildings, which are easily vertically scaled to multiple stories or laterally to multiple rooms, by using pre-cast concrete construction elements. The hexagonal base pattern simplifies construction while providing a wide range of building variants. Unlike many pre-fabricated construction techniques these building are capable of having a lifetime comparable to conventional (brick/block and mortar) buildings.

Claims (30)

Claims
1. A modular building construction system comprising a plurality of pre-formed constructional elements for assembly at a construction site, the elements including at least one floor slab and a plurality of wall panels, wherein the floor slab has the plan form of a half-hexagon and the wall panels each have rectilinear front and rear elevations including vertical side regions and transversely extending top and foot regions, each foot region having a span which matches, or substantially matches, a sub-hexagonal side portion of the floor slab.
2. A system as claimed in claim 1 wherein the pre-formed constructional elements further comprise at least one roof slab having the plan form of a half-hexagon, and wherein the fop region of each wall panel is sized to match or substantially match, a sub-hexagonal side portion of the roof slab.
3. A system as claimed In claim 1 or claim 2 wherein one or more halfhexagonal slab or slabs have the form of a half-hexagon obtained by dividing along a maximal diameter of the hexagon.
4. A system as claimed in any of the preceding claims wherein one or more half-hexagonal slab or slabs have the form of a half-hexagon obtained by dividing along a minimal diameter of the hexagon.
5. A system as claimed in any of the preceding claims wherein the constructional elements further comprise one or more radial wall panels which are generally rectilinear and sized to span a radius of the half-hexagon,
6. A system as claimed in claim 4 or 5 wherein the radius is a maximal radius.
7. A system as claimed in claim 4 or 5 claim wherein the radius is a minimal radius.
8. A system as claimed in any of the preceding claims wherein the constructional elements further comprise one or more diametric wall panels which are generally rectilinear in elevation and sized to span a diameter of the half-hexagon.
9. A system as claimed in claim 8 wherein the span diameter is the maximal diameter,
10. A system as claimed in claim 9 wherein the span diameter is the minimal diameter.
11. A system as claimed in any of the preceding claims wherein the constructional elements further comprise at least one floor or roof slab having the plan form of a sub-hexagonal parallelogram represented by two maximal radii and two complete sidewalls of the half-hexagon, together representing a third of the hexagon area.
12, A system as claimed in any of the preceding claims wherein the constructional elements further comprise at least one roof or floor slab having the plan form of a sub-hexagonal rhombus having one side which represents a maximal radius, perpendicular side which represents a minimal radius, a further perpendicular side which represents half a side of the hexagon, and a side which represents a complete side of the hexagon, together representing a quadrant of the hexagon.
13, A system as claimed in any of the preceding claims wherein the constructional elements further comprise a floor or roof slab which has the plan form of an equilateral triangle of sides equal in length to the maximal radius of the hexagon.
14. A system as claimed in any of the preceding claims wherein the constructional elements further comprise one or more parapet panel having a foot region for placement on a roof slab side, wherein a length of the parapet panel is greater than its width, and the width is less than 50% of the height of the wall panels,
15. A system as claimed in any of the preceding claims wherein the construction elements further comprise one or more wall sub-panels each having a rectilinear side elevation and a foot region which is sized to match a sub-hexagonal, half-side portion of the floor slab.
16. A system as claimed in any of the preceding claims wherein the wall panels and/or radial spans and/or diametric spans each have one or more vertical edges which are bevelled to provide an edge face with an internal angle of 60 degrees.
17. A system as claimed in any of the preceding claims wherein each construction element is provided with a plurality of pre-formed fastening features for facilitating the attachment of one element to another.
18. A system as claimed in claim 17 wherein one fastening feature on one element comprises a recessed inset into an edge region of the surface of the element, and a passage which communicates between the inset recess and an edge surface of the element.
19. A system as claimed in claim 18 wherein another fastening feature on another element comprises a passage for a rod, which passage communicates between upper and lower surface edge regions of the element.
20. A system as claimed in claim 18 or claim 19 the arrangement being such that when an element is offered-up to the other in a building configuration, the rod passage and recess passage can be aligned, or two recess passage can be aligned, so that at rod may be threaded through both passages,
21. A system as claimed in claim 19 or claim 20 wherein there is provided a retaining feature at each end of the rod, at least one of which retaining features is translatable along the rod so as to hold one element in abutment with the other.
22. A system as claimed in claim 21 wherein the rod is screw-threaded and at least one said retaining feature comprises a screw threaded nut.
23. A system as claimed in claim 21 or claim 22 wherein the other retaining feature comprises a screw threaded nut or is a fixed rod end obstruction which cannot pass through the constriction provided by the rod passage, such as an annular head, or a domed head or a transverse bar, or bar return.
24. A system as claimed in any of the preceding claims wherein one or more of the constructional elements is provided one or more pre-formed window or door apertures.
25. A system as claimed in any of the preceding claims wherein one or more of the constructional elements is provided with apertures and/or grooves for the location of building service routes such as electrical or plumbing or heating or air-conditioning services.
25. A system as claimed in any of the preceding claims wherein each constructional element is pre-formed by casting of concrete.
26. A system as claimed in claim 25 wherein the concrete is provided with internal reinforcement, such as by reinforcing steel mesh, cage or rods.
27. A system as claimed in any of the preceding claims wherein the preformed constructional elements are each unitary elements.
28. A system as claimed in any of the preceding claims wherein one or more side edge of each wall panel, or sub-panel, is formed with a bevelled edge, the bevel preferably subtending an internal angle of 60s with respect to a front or rear elevation of the panel.
29. A system as claimed in any of the preceding claims wherein the roof and or slabs are pre-formed with one or more apertures suitable for providing a skylight or staircase access.
5
30. A method of constructing a building comprising providing a modular building system in accordance with any of the preceding claims at a construction site, assembling the pre-formed construction elements into a building.
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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB581193A (en) * 1944-04-17 1946-10-03 Leslie Sturmer Jacobson Hut construction
DE2423132A1 (en) * 1974-05-13 1975-11-27 Horst Ing Grad Ebert Standard- component trapezoid elem reinforced concrete building syst. - with hexagons formed from elements divisible into six equilateral triangles
US4480414A (en) * 1982-09-24 1984-11-06 Tschudy Donald B Building construction
US4523418A (en) * 1983-08-15 1985-06-18 Mclaughlin Jon R Modular construction system
JPH0949340A (en) * 1995-08-09 1997-02-18 Masayuki Nakaya Knockdown temporary toilet
US6295768B1 (en) * 2000-07-14 2001-10-02 Mario R. Romero Prefabricated structure
WO2003080965A1 (en) * 2002-03-25 2003-10-02 Meir Silber A prefabricated tower foundation comprising equipment shelters and a method for its deployment on site
US20110173899A1 (en) * 2010-01-20 2011-07-21 Lane Lythgoe Pre-cast polygonal shelter

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB581193A (en) * 1944-04-17 1946-10-03 Leslie Sturmer Jacobson Hut construction
DE2423132A1 (en) * 1974-05-13 1975-11-27 Horst Ing Grad Ebert Standard- component trapezoid elem reinforced concrete building syst. - with hexagons formed from elements divisible into six equilateral triangles
US4480414A (en) * 1982-09-24 1984-11-06 Tschudy Donald B Building construction
US4523418A (en) * 1983-08-15 1985-06-18 Mclaughlin Jon R Modular construction system
JPH0949340A (en) * 1995-08-09 1997-02-18 Masayuki Nakaya Knockdown temporary toilet
US6295768B1 (en) * 2000-07-14 2001-10-02 Mario R. Romero Prefabricated structure
WO2003080965A1 (en) * 2002-03-25 2003-10-02 Meir Silber A prefabricated tower foundation comprising equipment shelters and a method for its deployment on site
US20110173899A1 (en) * 2010-01-20 2011-07-21 Lane Lythgoe Pre-cast polygonal shelter

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