GB2569551A

GB2569551A - Lifting system

Info

Publication number: GB2569551A
Application number: GB1721315.8A
Authority: GB
Inventors: Christopher Moore Gary; Nicolas Walker James
Original assignee: Tophat Industries Ltd
Current assignee: Tophat Industries Ltd
Priority date: 2017-12-19
Filing date: 2017-12-19
Publication date: 2019-06-26
Also published as: GB201721315D0

Abstract

Disclosed is a lifting connector 10 suitable for use in lifting and aligning modules 1,2 of a modular building. The lifting connector 10 is attached to an upwardly facing surface 21 of a module 2 in use and comprises: a downwardly facing bearing surface 31 for engaging with a lifting device 16; and at least one tapered upwardly facing surface 32,33 for engaging with a downwardly facing surface 12 on a further module 1 to be mounted on top of the module 2 to which the lifting connector 10 is attached. Cooperation between the at least one tapered upwardly facing surface 32,33 and the downwardly facing surface 12 on the further module 1 aligns the horizontal position of the modules 1,2. The at least one tapered upwardly facing surface 32 may extend upwards and inwards from an outer edge 34 of the downwardly facing bearing surface 31, and/or downwards and outwards from an edge 35 provided below the downwardly facing bearing surface 31. The or each tapered upwardly facing surface 32,33 may have a frusto-conical or rounded shape. Also disclosed are kits comprising the disclosed lifting connector 10 and: a contact plate (40, figure 3) to be mounted on a downwardly facing surface 12 of a module; and/or an elongate element (50, figure 5).

Description

LIFTING SYSTEM

The present disclosure relates to a lifting system for lifting modules of a modular building.

A modular building may be formed from a plurality of modules that are formed offsite and then assembled onsite to form a building.

Such an arrangement may have a variety of benefits. For example, the time to assemble a building onsite may be greatly reduced. Alternatively or additionally, by manufacturing modules offsite, for example in a factory, improved manufacturing tolerances may be achieved. This is because relatively high precision manufacturing may be possible in a factory setting that is not available on a building site. The improved manufacturing precision may in turn yield further benefits, including the possibility to improve the thermal efficiency of buildings, which may be significantly affected by manufacturing errors leading to gaps in the insulation.

The benefits of a modular building system may increase with the size of the modules used to form the building, namely by reducing the total number of modules from which a building is formed. However, the larger the modules, the greater the difficulty in moving the modules and positioning one module relative to another module.

Known arrangements for lifting sections of buildings during construction include fixing eyes, straps or anchors to sections of building that can be engaged by lifting devices in order to lift the section of building. For example, it is known to embed an anchor in a pre-cast concrete section of building such that, once the concrete has set, the pre-cast concrete section of building may be lifted by the anchor.

However, even with such anchors provided, it remains difficult to lift and accurately place the pre-cast concrete section in a building that is being built.

It may be desirable to provide a lifting system for lifting modules of a modular building that facilitates lifting and accurate placement of modules within a modular building.

According to the present disclosure, there is provided a lifting connector, configured to be provided on an upwardly facing surface of a module of a modular building and to provide a connection to a lifting device for lifting the modules. The lifting connector comprises a downwardly facing bearing surface, configured to engage with the lifting device. It further includes a tapered upwardly facing surface, configured to engage with a downwardly facing surface of a module that is to be mounted on top of the module to which the lifting connector is attached. The tapered upwardly facing surface may be configured such that the engagement of the tapered upwardly facing surface of the lifting connector with the downwardly facing surface of the module above determines the relative horizontal position of the upper module when it is lowered onto the module to which the lifting connector is attached.

The lifting connector may include a tapered upwardly facing surface that extends upwards and inwards from an outer edge of the downwardly facing bearing surface.

Alternatively or additionally, the lifting connector may include a tapered upwardly facing surface that extends downwards and outwards from an edge provided below the downwardly facing bearing surface.

Either or both of the tapered upwardly facing surfaces discussed above may engage with the downwardly facing surface of the module to be mounted on top of the module to which the lifting connector is attached in order to determine the horizontal position of the upper module relative to the module to which the lifting connector is attached.

In an arrangement including a tapered upwardly facing surface that extends downwards and outwards from an edge provided below the downwardly facing bearing surface, a separation may be provided between that edge and the downwardly facing bearing surface such that a part of the lifting device can be received within the separation to engage with the downwardly facing bearing surface.

The or each of the tapered upwardly facing surfaces of the lifting connector may be frustoconical or have a rounded profile. In either arrangement, as well as being tapered such that the part of the lower surface of the upper module that engages with it will be guided to a desired horizontal position, the cross-section of the lifting connector in a horizontal plane may be circular. Other sections of the lifting connector may also have a circular cross-section in a horizontal plane. In an arrangement, the shape of the lifting connector may generally be described as a solid of revolution.

In an arrangement, there is provided a kit comprising a lifting connector as described above and a contact plate. The contact plate may be configured to be mounted on a downwardly facing surface of a module of a modular building. The contact plate may have an opening that is configured to engage with the tapered upwardly facing surface of the lifting connector such that, when the contact plate is lowered onto the lifting connector, the contact plate is centred on the lifting connector. With such an arrangement, when the contact plate and the lifting connector are mounted on respective modules of a modular building, the centring of the contact plate on the lifting connector determines the horizontal position of the module to which the contact plate is mounted relative to the module to which the lifting connector is mounted.

The contact plate may have a tapered downwardly facing surface that corresponds to a tapered upwardly facing surface of the lifting connector. For example, the tapered downwardly facing surface of the contact plate may be frusto-conical.

According to the present disclosure, there is provided a lifting system for lifting a module of a modular building including a lifting connector described above and an elongate element capable of resisting tensile forces corresponding to a portion of the weight of the module that is associated with the lifting connector. It will be appreciated that the required tensile strength of the elongate element used may be based on the weight of the module in which it is to be provided and the number of lifting connectors and corresponding elongate elements to be used in the lifting system for lifting the module. The elongate element may have a first end connected to the lifting connector and a second end that is configured to be connected to a structural component that supports a module, namely a component by which the module can be safely lifted, and is arranged on the lower side of the module. Accordingly, the elongate element may extend from a lower side of the module to an upper surface of the module at which the lifting connector is to be provided.

In an arrangement, the elongate element may be connected to the lifting connector by a threaded connection. The lifting connector may include a tool engagement portion that is configured to engage a tool that is used to rotate the lifting connector relative to the elongate element in order to secure the threaded connection.

In an arrangement, the lifting system discussed above may include a contact plate. The contact plate may be configured to be provided on a downwardly facing surface of the structural component that supports the module and the elongate element may be connected to the contact plate, for example by a threaded connection, welding or other known means. The contact plate may be configured such that it can engage with a tapered upwardly facing surface of a lifting connector as discussed above that is provided on another module such that, when the contact plate is lowered onto the lifting connector on the other module, the contact plate is centred on the lifting connector. This may determine the relative horizontal positon of the upper and lower modules.

According to an aspect of the disclosure, there is provided a module for a modular building comprising at least one lifting connector as discussed above and/or at least one lifting system as described above. A building is also provided that is formed from a plurality of modules including such a lifting connector and/or lifting system.

According to a further aspect of the present disclosure, there is provided a method of lifting a module for a modular building as discussed above, comprising engaging one or more lifting devices with a respective downwardly facing bearing surface of the one or more lifting connectors of the module and raising the one or more lifting devices.

According to a further aspect of the present disclosure, there is provided a method of assembling a building formed from a plurality of modules as discussed above. The method comprises lowering a first module onto a second module such that the downwardly facing surface of the first module engages with the tapered upwardly facing surface of at least one lifting connector mounted on the second module in order to determine the relative horizontal positions of the first and second modules.

The invention will now be described by way of non-limiting examples, with reference to the accompanying figures, in which:

Figure 1 depicts a module of a modular building being lifted into place on top of a second module;

Figure 2 depicts a lifting connector according to an aspect of the present disclosure;

Figure 3 depicts a contact plate according to an aspect of the present disclosure;

Figure 4 depicts an alternative arrangement of a lifting connector; and

Figure 5 depicts a lifting system according to an aspect of the present disclosure.

Figure 1 depicts an arrangement for lifting a first module 1 of a modular building for mounting on top of a second module 2 of a modular building. The first module has a plurality of lifting connectors 10 provided on the upper face 11 of the first module 1.

It will be appreciated that the number of lifting connectors 10 required to lift a module 1, 2 may depend on the size of the module 1, 2 to be lifted. In some arrangements, a single lifting connector 10 may be sufficient.

As is described in further detail below, the lifting connectors 10 are configured such that they can each engage with a respective lifting device 15. In the arrangement depicted in Figure 1, each of the lifting devices 15 may be suspended from a lifting frame 16 which in turn may be suspended from a coupling 17 that may be provided for connection to, for example, a crane. The frame 16 may be configured such that the plurality of lifting devices 15 are suspended in relative positions that correspond to the relative positions of the lifting connectors 10 on the module 1.

With such an arrangement, a module 1, 2 of a modular building may be lifted by engaging the plurality of lifting devices 15 with a respective lifting connector 10 provided on the upper surface 11 of the module 1. By lifting the lifting devices 15, for example by way of a frame 16, the module 1 may be lifted and moved to a desired position. Accordingly the lifting connectors 10 have a first function used in the lifting of a module 1, 2.

The lifting connectors 10 also have a second function. In particular, as depicted in Figure 1, the lifting connectors 10 may project from an upper surface 11,21 of the module 1, 2 to which they are mounted. The lifting connectors 10 are configured such that, when a first module 1 is lowered onto a second module 2, the lifting connectors 10 mounted on the upper surface 21 of the second module 2 engage with the lower surface 12 of the first module 1.

In more detail, the lifting connectors 10 may engage with the lower surface of the module to be mounted above in such a way that the engagement determines the relative horizontal position of the first module 1 relative to the second module 2. Accordingly, not only do the lifting connectors 10 provide points to which lifting devices may be engaged in order to lift a module 1, 2 and manoeuvre it, the lifting connectors 10 also provide a mechanism in order to ensure accurate positioning of a first module 1 relative to a second module 2 during the assembly of a modular building. Further details of this arrangement are discussed below.

It should be appreciated that, although as depicted in Figure 1, a first module 1 to be mounted on a second module 2 may have a similar shape to the second module 2, for example such that the lower surface 12 of the first module 1 may correspond to the upper surface 21 of the second module 2, this need not be the case. The modules may be different sizes. The position of one module may be offset relative to another module. A plurality of modules of a first type may be mounted on top of one module of a second type. Alternatively a module of a first type may be mounted on top of a plurality of modules of a second type. Other arrangements are also possible.

It should also be understood that references to the horizontal and vertical take their normal meaning. References to components having an upper surface, a lower surface, an upwardly facing surface and/or a downwardly facing surface, or similar, refer to the relevant surfaces when the component on which they are formed is in its normal orientation in use.

Figure 2 depicts a lifting connector 10 for use in a lifting system according to the present disclosure. The lifting connector 10 is arranged about a vertical axis 30. The lifting connector 10 includes an upper section that projects away from the central axis 30 to define a downwardly facing surface 31 and an upwardly facing tapered surface 32.

The downwardly facing surface 31 of the lifting connector 10 is provided to engage with the lifting device 15. In particular, a part of the lifting device 15 may be placed below the downwardly facing surface 31 of the lifting connector 10. When the lifting device 15 is subsequently raised, the part of the lifting device 15 below the downwardly facing surface 31 of the lifting connector 10 engages with the downwardly facing surface 31, transmitting a lifting force through the downwardly facing surface 31 to the lifting connector 10 in order to lift the module 1, 2. When the module 1, 2 is suspended by a plurality of lifting devices 15 engaged with a corresponding plurality of lifting connectors 10, the downwardly facing surfaces 31 of the lifting connectors 10 bear the weight of the module 1, 2. In the subsequent description, the downwardly facing surface 31 will be referred to as a downwardly facing bearing surface.

In the arrangement depicted in Figure 2, the lifting connector 10 has two tapered upwardly facing surfaces 32, 33. One tapered upwardly facing surface 32 extends inwardly from an outer edge 34 of the downwardly facing bearing surface 31. A second tapered upwardly facing surface 33 extends downwards and outwards from an edge 35 provided below the downwardly facing bearing surface 31. A space 36 is provided between the downwardly facing bearing surface 31 and the edge 35 from which the second tapered upwardly facing surface 33 extends downwards and outwards. The space 36 surrounds a central support 37 connecting the upper section of the lifting connector 10 to the remainder of the lifting connector. When a lifting device 15 is engaged with the lifting connector 10, parts of the lifting device 15 enter the space 36 to be able to engage with the downwardly facing bearing surface 31.

The tapered upwardly facing surfaces 32, 33 are provided to engage with a downwardly facing surface 12 of a module 1 to be mounted above the lower module 2 on which the lifting connector 10 is provided. The lower surface 12 of the upper module 1 may include an opening that is configured to engage with the tapered upwardly facing surfaces 32, 33 of the lifting connector 10 such that the tapered surfaces 32, 33 force the horizontal position of the upper module 1 to be adjusted to a desired position relative to the lifting connector 10 and therefore relative to the lower module 2.

As discussed above, the lifting connector 10 depicted in Figure 2 has a first tapered upwardly facing surface 32 and a second tapered upwardly facing surface 33. As shown, the first tapered upwardly facing surface 32 may be provided in an upper section of the lifting connector 10 while the second tapered upwardly facing surface 33 may be provided in a lower section of the lifting connector 10. Additionally, as shown in Figure 2, the second tapered upwardly facing surface 33 may be arranged at a greater distance from the central axis 30 in a horizontal direction than the first tapered upwardly facing surface 32.

In use of such an arrangement of a lifting connector 10, the first tapered upwardly facing surface 32 being provided in an upper section of the lifting connector 10 may result in its engagement with the opening in the downwardly facing surface 12 of a module 1 being lowered onto the lifting connector 10. This first tapered upwardly facing surface 32 may therefore function to guide the opening in the downwardly facing surface 12 of the module 1 being lowered to engage with the second tapered upwardly facing surface 33. The second tapered upwardly facing surface 33 may remain engaged with the opening in the downwardly facing surface of the upper module 1 once the module has been fully lowered onto the lower module 2 and determine the horizontal position of the module 1 relative to the lifting connector 10.

However, it should be appreciated that the lifting connector 10 may have alternative arrangements. For example, the lifting connector 10 may have a single tapered upwardly facing surface. Such an arrangement may be facilitated by selection of the shape of the opening in the downwardly facing surface of the module 1 to be lowered onto the lifting connector 10.

In an arrangement, a contact plate may be provided that is mounted to the downwardly facing surface 12 of a module 1 to be lowered onto a module 2 that is provided with lifting connectors 10 on its upper face 21. The contact plate 40 may include an opening provided to engage with the tapered upwardly facing surfaces 32, 33 of the lifting connector 10.

The contact plate may be formed from a material that is harder than the materials used to form the underside of a module 1, 2 in order to avoid damage to a module during the process of lowering the module onto another module provided with the lifting connectors 10 discussed above. For example, the lifting connectors 10 may be formed from steel whereas the lower side of the module may be formed from wood, which may be damaged by engagement with the steel lifting connectors 10. The contact plate may also be formed from steel such that it will not be damaged when engaging with a lifting connector 10.

Figure 3 schematically depicts a contact plate 40 that may be provided on a downwardly facing surface of a module and configured to engage with a lifting connector 10. As shown, the contact plate 40 may include an opening 41 to receive a lifting connector. The edge of the opening 41 may include a tapered surface 42 that is downwardly facing when the contact plate 40 is mounted to a downwardly facing surface of a module.

The tapered downwardly facing surface 42 of the contact plate 40 may have a shape that corresponds to the tapered upwardly facing surfaces 32, 33 of the lifting connector 10. In particular, a contact plate 40 to be used in conjunction with a lifting connector 10 such as that depicted in Figure 2 may have a tapered downwardly facing surface 42 that matches the shape of the second tapered upwardly facing surface 33 of the lifting connector 10. In such an arrangement, when the upper module 1 is lowered into place on a lower module 2, the tapered downwardly facing surface 42 of the contact plate 40 may rest against the second tapered upwardly facing surface 33 of the lifting connector 10, ensuring that the opening 41 of the contact plate 40 is precisely centred on the lifting connector 10, setting the horizontal position of the upper module 1 relative to the lower module 2.

As shown in Figure 2, the lifting connector 10 may be configured such that the first and/or second tapered upwardly facing surfaces 32, 33 have a frusto-conical shape.

Alternatively, as shown in Figure 4, the lifting connector 10 may be configured such that the first and/or second tapered upwardly facing surfaces 45, 46 have a curved profile when viewed in a vertical cross-section. The first surface 45 may form a bulbous end of the lifting connector 10, with a rounded top surface.

As shown in Figures 2 and 4, the parts of the lifting connector 10 forming the tapered surfaces may have a circular cross-section in a horizontal plane.

Arrangements such as those shown in Figures 2 and 4 may ensure that the lifting connector 10 can perform its function for locating the position of a module 1 lowered onto it regardless of the angular position of the lifting connector 10 about its central axis 30. This may facilitate the manufacturing process of a module 1, 2 including such a lifting connector 10 because a particular angular orientation of the lifting connector 10 may not be required. Similarly, it may be beneficial for other sections of the lifting connector 10 to have a circular cross-section in a horizontal plane. For example, this may also ensure that a lifting device 15 can be engaged with the lifting connector 10 regardless of the angular position of the lifting device 15 relative to a lifting connector 10. In general, therefore, the lifting connector 10 may have an external shape that is a volume of rotation.

In order to transfer the forces required to lift a module 1 from a lifting connector 10 to a module 1, the lifting connector 10 may be included as part of a lifting system, such as that depicted schematically in Figure 5. As shown, the lifting connector 10 may be attached to a first end 51 of an elongate element 50 that is selected to be capable of resisting tensile forces to be borne by the lifting connector 10. Accordingly, the elongate element 50 may be sufficiently strong to bear a portion of the weight of the module associated with the lifting connector 10. More generally, the elongate element 50 may be selected to be capable of bearing the weight for which the lifting connector 10 is designed to carry. The number of lifting connectors 10 and corresponding elongate elements 50 provided to each module may then be selected based on the load for which the lifting connector 10 and elongate element 50 are capable of carrying and the total weight of the module 1, 2.

The elongate element 50 may be configured to extend from the lifting connector 10, which may be mounted on an upper side of a module 1, 2 to a lower part of a module 1, 2. In particular, the second end 52 of the elongate element 50 may be connected to a structural component provided on the lower side of the module 1, 2 that supports the module, namely on which the remainder of the module may be built.

In an arrangement, the first end 51 of the elongate element 50 may be connected to a lower part 38 of the lifting connector 10 by means of a threaded connection. In such an arrangement, the lifting connector 10 may be connected to the elongate element 50 by rotating the lifting connector 10 relative to the elongate element 50.

A tool engagement portion 39 may be provided on an upper surface of the lifting connector

10. The tool engagement portion 39 may be configured such that a tool can be engaged with the lifting connector 10 in order to rotate it relative to the elongate element 50. The tool engagement portion 39 may, for example, be a hexagonal recess. Alternative configurations may be provided that enable engagement of a tool to rotate the lifting connector 10.

In an arrangement, the second end 52 of the elongate element may be directly connected to the structural component supporting the module. For example, the structural component may include a threaded section that may be engaged with a corresponding threaded section at the second end 52 of the elongate element 50, providing a threaded connection.

In an alternative arrangement, the elongate element may be connected to a plate 60, such as that depicted in Figure 5, for example by welding or a threaded connection. The plate 60 may then be connected to the structural component that is provided on the lower side of the module, for example by fixing such as bolts or screws. The plate may be connected above or below the structural component.

In an arrangement, the function of a plate 60 for connecting the elongate element 50 to the structural component supporting the module 1, 2 may be combined with a contact plate 40 that may be provided on the downwardly facing surface 12 of a module 1 for engagement with a lifting connector 10 on another module 2. In such an arrangement, a plate may be provided on a lower surface of the structural component of the module that includes the opening 41 for engagement with a lifting connector 10 of another module and a connection to the elongate element 50 that connects to a lifting connector 10 on an upwardly facing surface of the module to which the plate is mounted.

Claims

1. A lifting connector, configured to be provided on an upwardly facing surface of a module of a modular building and to provide a connection to a lifting device for lifting the module, the lifting connector comprising:

a downwardly facing bearing surface, configured to engage with the lifting device; and a tapered upwardly facing surface, configured to engage with a downwardly facing surface of a module to be mounted on top of the module to which the lifting connector is attached such that it sets the relative horizontal position of the upper module when it is lowered onto the module to which the lifting connector is attached.

2. A lifting connector according to claim 1, comprising a tapered upwardly facing surface extending upwards and inwards from an outer edge of the downwardly facing bearing surface.

3. A lifting connector according to claim 1 or 2, comprising a tapered upwardly facing surface, extending downwards and outwards from an edge provided below the downwardly facing bearing surface.

4. A lifting connector according to claim 3, configured such that a separation is provided between the downwardly facing bearing surface and the edge from which the tapered upwardly facing surface extends downwards and outwards, the separation configured to receive a part of the lifting device to engage with the downwardly facing bearing surface.

5. A lifting connector according to any one of the preceding claims, wherein the or each tapered upwardly facing surface is a frusto-conical shape.

6. A lifting connector according to any one of claims 1 to 4, wherein the or each tapered upwardly facing surface has a rounded profile.

7. A kit, comprising a lifting connector according to any one of the preceding claims and a contact plate;

wherein the contact plate is configured to be mounted on a downwardly facing surface of a module of a modular building; and the contact plate has an opening configured to engage with the tapered upwardly facing surface of the lifting connector such that, when the contact plate is lowered onto the lifting connector, the contact plate is centred on the lifting connector.

8. A kit according to claim 7, wherein the contact plate has a tapered downwardly facing surface that corresponds to the tapered upwardly facing surface of the lifting connector.

9. A lifting system for lifting a module of a modular building, comprising:

a lifting connector according to any one of claims 1 to 6 for mounting on an upper surface of the module; and an elongate element capable of resisting tensile forces corresponding to a portion of the weight of the module that is associated with the lifting connector, the elongate element having a first end connected to the lifting connector and a second end configured to be connected to a structural component on the lower side of the module that supports the module.

10. A lifting system according to claim 9, wherein the elongate element is connected to the lifting connector by a threaded connection.

11. A lifting system according to claim 10, wherein the lifting connector includes a tool engagement portion configured to engage a tool used to rotate the lifting connector relative to the elongate element.

12. A lifting system according to claim 9, 10 or 11, further comprising a contact plate, configured to be connected to a downwardly facing surface of the structural component that supports the module;

wherein the elongate element is connected to the contact plate; and the contact plate has an opening configured to engage with a tapered upwardly facing surface of a lifting connector according to any one of claims 1 to 6 provided on another module such that, when the contact plate is lowered onto the lifting connector, the contact plate is centred on the lifting connector.

13. A lifting system according to claim 12, wherein the contact plate has a tapered downwardly facing surface that corresponds to the tapered upwardly facing surface of the lifting connector.

14. A module for a modular building, comprising at least one lifting connector according to any one of claims 1 to 6.

15. A module for a modular building, comprising at least one lifting system according to any one of claims 9 to 13.

16. A building formed from a plurality of modules according to claim 14 and/or claim 15.

17. A method of lifting a module according to claim 14 or 15, comprising engaging one or more lifting devices with a respective downward facing bearing surfaces of the one or more lifting connectors of the module; and raising the one or more lifting devices.

18. A method of assembling a building formed from a plurality of modules according to claim 14 and/or claim 15, comprising lowering a first module onto a second module such that the downwardly facing surface of the first module engages with the tapered upwardly facing 5 surface of at least one lifting connector mounted on the second module in order to determine the relative horizontal positions of the first and second modules.