GB2586619A

GB2586619A - Structural module for a frameless building

Info

Publication number: GB2586619A
Application number: GB1912392.6A
Authority: GB
Inventors: Braddon Parnall Robert; Belcher Matthew; Roger Braddon Parnall Adam; George Lambton Nicholson Robin
Original assignee: Parnall Bio Engineering Ltd
Current assignee: Parnall Bio Engineering Ltd
Priority date: 2019-08-29
Filing date: 2019-08-29
Publication date: 2021-03-03
Anticipated expiration: 2039-08-29
Also published as: GB201912392D0; GB2586619B

Abstract

A monocoque structural module for the superstructure of a frameless building is provided. The module may comprise three or four separate pre-fabricated elements configured for onsite assembly to form the module. Each element comprises a box-beam structural insulated panel, with integrated service conduits, insulation material, and finished inner and outer surfaces. The ends of the elements abut and are attached together by bolts. Four elements may together provide a floor, two uprights, and a roof or ceiling member of the module with closed contiguous outer and inner surfaces. The inner surfaces of the elements combine to provide a portion of a room of the building. The edges of the elements of the module abut the edges of another similar structural module, placed next to the module. The outer surfaces of the two adjacent structural modules are contiguous. A module with four elements may form a rectangle cross section or an unequal trapezoid cross section. The panel element may be formed from glue-laminate timber members and may have hempcrete and lime plaster layers. Heating, cooling and solar panels may be incorporated.

Description

Structural module for a frameless building

Technical Field

The present invention is in the field of building structures. In particular, the invention relates to a structural module that may be pre-fabricated off-site.

Background

Traditional approaches to building involved bringing simple materials to a construction site. Skilled tradespeople then assemble the building, for example by constructing block walls by hand. Tradespeople require skill to ensure the provision of openings in walls for doors and windows. Services need to pass through smaller openings in walls, for example to allow water pipes and electric cables to pass from outside the building to its inside.

Some modern buildings use 'Structural Insulated Panels', henceforth SIPs. Typically, foundations are laid for a building, and a frame will be constructed on the foundations. The frame will provide structural support to the building. Then, SIPs will be inserted into the frame. Each SIP provides some functions of a traditional building's walls. For example, a SIP contains insulation. The SIP is also opaque, so provides privacy and prevents excessive solar insolation, and provides sound insulation.

Figure 1 provides a drawing of a known building 100. Frame 110 provides structural strength to the building 100. In domestic buildings, frame 110 may be timber or steel, for example. Although frame 110 is made of three dimensional structural members, those members are shown as simple one-dimensional lines in figure 1 for ease of illustration. In industrial buildings, frame 100 is most likely to be made of steel, for example in the form of I-beams. A first SIP 120 and a second SIP 130 are also shown. First SIP 120 and second SIP 130 are shown separately from frame 110. Arrow 112 shows where first SIP 120 will be inserted into frame 110, and arrow 114 shows where second SIP 130 will be inserted into frame 110. The shape and dimensions of frame 110 determine the location and placement angle of each SIP, and the overall size and shape of the building.

Figure 2 shows the frame 110 of figure 1. First SIP 120 and second SIP 130 have been inserted where they are to be located in the finished building 200. More SIPs, or other forms of panel, not shown in figures 1 and 2, will be inserted into some of the remaining openings in the frame. Some portions of the frame 110 will not contain SIPs or other panels, and may form openings for vehicle entrances, pedestrian doorways or windows. -2 -

Once the SIPs have been inserted, skilled tradesmen will carry out finishing works that are known in the construction industry as 'wet trades'. Typically, plaster or other surface finishes will be applied to the insides and/or outsides of the SIPs. Disadvantages of such approaches include the fact that the building may not be weatherproof until the building has received an outside plaster coating.

The construction of a building 200 as shown in figure 2 requires a particular construction method. Figure 3 shows the method 300 of construction of the building 200. In step 310, the foundations are laid. In step 320, the frame is built. In step 330, the SIP panels are installed into the frame. In step 340, the wet trades complete the interior and exterior of the building. A disadvantage of method 300 is the need to schedule each item of work in succession, which extends construction time. A project manager typically needs to include contingency time for each activity.

Some small buildings may occasionally be built without a frame. However, the SIPs for such buildings have to be re-designed to allow them to mate with each other. In addition, they have to be scaled to support the weight of the building and to resist such forces as wind-loading, in the absence of a frame. There are only limited designs of SIPs for truly frameless buildings. The SIPs for such buildings tend to be designed as 'building blocks', which can be stacked on each other. Thus such SIPs are thus comparable to large concrete blocks, at least in how they are used to construct a wall, although they are considerably lighter than concrete. These designs of SIP typically still need wet trades to finish their surfaces, after construction of the building. They tend to have synthetic insulation materials. Known SIPs tend to have a high percentage of synthetic materials, and may often have a high plastic content.

In summary, the known approaches tend to have addressed the need to provide good insulation performance, or the need to provide large enclosures, by resorting to structural frames into which the SIPs are then inserted. The applicant has identified a need for improved, pre-fabricated SIPS. The applicant has also identified a need to improve the sustainability of buildings. Specifically, the applicant has identified a need to reduce the amount of highly refined materials used, such as structural steel and the typical insulation materials used in known designs of SIP.

Summary of the Invention

In accordance with a first aspect of the present invention, there is provided a monocoque structural module in accordance with appended independent claim 1. In accordance with a second aspect of the present invention, there is provided a monocoque structural module in accordance with appended independent claim 16. In accordance with a third aspect of the present invention, -3 -there is provided a method in accordance with independent claim 17. The dependent claims provide further details of embodiments.

Brief Description of the Drawings

Exemplary embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 illustrates a perspective, schematic view of a known building with a frame.

FIG. 2 illustrates a further perspective, schematic view of the building of figure 1, after insertion of SIPs.

FIG. 3 illustrates an example flowchart of a known method of construction of the building of figure 2.

FIG. 4 is a perspective view of a monocoque structural module for the superstructure of a frameless building.

FIG. 5 shows a module 400, after the elements have been attached to each other.

FIG. 6 shows an elevation view of a series of modules in accordance with the invention.

FIG. 7 shows an elevation view of a series of modules that provide a building and a room in accordance with the invention.

Fig. 8 shows an elevation view of a series of modules that provide a building and a closed room in accordance with the invention.

Fig. 9 shows an embodiment of a second building.

FIGs. 10A to 1OF illustrate alternative forms for the module, in side elevation view.

FIG. 11 shows an exploded axonometric view of an example of a SIP element of a module, in accordance with the invention.

FIG. 12 shows an axonometric view of the example of a SIP element of a module of FIG. 11. -4 -

FIG. 13 shows another axonometric view of the example of a SIP element of a module of FIG. 11.

FIG. 14 shows another axonometric view of the example of a SIP element of a module of FIG. 11.

FIG. 15 shows an axonometric view of another example of a SIP element of a module.

FIGs 16-19 illustrate a locking system to lock elements together, in accordance with the invention.

FIGs. 20A to 20D illustrate alternative forms for the module, in side elevation view, when comprised of only three elements.

FIG. 21 illustrates an example flowchart of a method of distributing the functional features of the building between elements and structural modules of the building.

Detailed description

The present invention will now be described in terms of the examples shown in figures 4-21 and the accompanying description of those figures. In the broadest terms, the invention relates to prefabricated building products, natural building materials and integrated green energy technology. The invention allows the delivery of large, clear, open-plan environments. The invention achieves the construction of such large spaces with a rapid assembly SIP panel system.

In order to make the finished building more sustainable, individual SI Ps may be constructed with 'HEMPOSITE'RTm, which is a natural structural insulated panel system. Hemposite is overwhelmingly a natural material, with limited man-made elements where performance requirements make natural materials unacceptable.

The invention disrupts conventional construction patterns, through the use of a novel bio composite SIP. The SIP of the invention is precision fabricated offsite, with fully integrated services. The SIP of the invention offers a complete building superstructure that can be rapidly assembled. The overall result is the revolutionising and simplifying of conventional construction methods. The number of different trades and materials involved in the construction process is reduced, with a particular reduction of the need for skilled trades on site towards the end of the construction process. This may reduce time and the wastage of materials. In addition, through -5 -the use of Hemposite as a construction material, the proportion of natural materials in the finished building will be increased, in comparison to traditional buildings.

Known construction approaches do not allow the structural spanning capabilities of the invention. Nor do they produce large interior spaces in buildings with such a high natural material content as is achieved by the present invention. Relative to known construction approaches, the invention may provide some or all of: a) A natural material solution to rival conventional build methods.

b) A better space for users of the building -The Hemposite SI Ps offer the potential for vast clear spans thanks to the loading capacity of 'glulam' timber beams. Glulam beams use laminated layers with high strength glues. The SIPs of the invention facilitate large open plan areas within either residential or commercial/industrial spaces.

c) Lower environmental impacts -reduced waste, and enhanced carbon sequestration.

d) Green energy generation-energy generation may be achieved by in-built solar photovoltaic elements on the outer surfaces of the panels.

Thus the invention helps to solve multiple problems. The Hemposite SIPs of the invention deliver very high structural capability, with outstanding thermal performance and/or integrated green energy production.

Figure 4 is a perspective view of a monocoque structural module 400 for the superstructure of a frameless building. The view in figure 4 is an 'exploded' view of the module, with the elements of the module shown prior to their assembly into the module. The module of figure 4 comprises four separate elements. However, the module of figure 4 can also be constructed with more than four separate elements.

In figure 4, the four elements are pre-fabricated, and are configured for on-site assembly. The four elements form the structural module when the elements have been attached to each other. Each element comprises a box-beam SIP, with integrated service conduits, insulation material, a finished inner surface, and a finished outer surface. Each end of each element is configured to abut, and to be attached by bolts to, one end of another of the elements.

The illustrative example in figure 4 shows a first element 410. First element 410 is configured to provide a horizontal floor. First element 410 has first end 412 and second end 414.

A second element 420 is configured to provide an upright wall member. The second element 420 has a first end 422 for attachment to the first end 412 of the first element 410. The second element 420 also has a second end 424. -6 -

A third element 430 is configured to provide an upright wall member. The third element 430 has a first end 432 for attachment to the second end 414 of the first element 410. The third element 430 also has a second end 434.

A fourth element 440 is configured to provide a roof or ceiling member. The fourth element 440 has a first end 442 for attachment to the second end 424 of the second element 420. The fourth element 440 also has a second end 444 for attachment to the second end 434 of the third element 430.

Figure 5 shows the module 400, after the first 410 to fourth 440 elements have been attached to each other. The module shown in figure 5 is designed to be used together with another module, placed next to the module shown in figure 5. Thus the first edges of the first 410 to fourth 440 elements of the module 400 are configured such that: (i) a first edge 450 of the structural module, when assembled, is configured to abut and to attach to an edge of a second structural module placed next to the first edge 450 of the structural module; and (ii) an outer surface of each of the first to fourth elements is contiguous with an outer surface of an adjacent abutting portion of the second structural module. The outer surface 416 of first element 410 faces downwards, so is not completely visible in figure 5. The outer surface 426 of second element 412 faces towards the right of figure 5, so is also not completely visible in figure 5. The outer surface 436 of third element 430 faces towards the left of figure 5. The outer surface 446 of fourth element 440 faces upwards in figure 5.

The inner surfaces of each of the first 410 to fourth 440 elements combine to provide a portion of a room of the building. The inner surfaces of first element 410 and second element 420 are the surfaces onto which each of the reference lines to those elements connect in figure 5.

Figure 6 shows an elevation view of a series of modules in accordance with the invention.

The module 400 of figures 4-6 is shown generally towards the right in figure 6. The first edge 450 of module 400 is exposed and faces towards the right in figure 6.

Towards the left in figure 6, second module 660, third module 670 and fourth module 680 are shown in an assembled configuration. The edges of each of second module 660 and third module 670 have met and have mated together. The other edge of third module 670 has met and mated with a first edge of fourth module 680. The second edge 650 of fourth module 680 remains exposed in figure 7. -7 -

The four modules shown in figure 6 can be seen to generally create an inner space 685. The inner space 685 is a portion of a room of the building.

Figure 7 shows an elevation view of a series of modules that provide a building and a room in accordance with the invention.

Figure 7 shows a long sequence of modules in accordance with the invention. Together, the modules provide a building 700. In order to allow the reader to relate the building 700 back to figures 4-6 more easily, the module 400 is illustrated towards the right in figure 7. However, module 400 could equally well be located anywhere in the series of attached modules stretching towards the left in figure 7.

Interior space 785 of the room created by the modules is shown. In order to demonstrate the potential for large spans, the dimensions of the building 700 are marked. The marked dimensions are purely numerical illustrations of buildings that can be built with the modules. The building's length is shown as 30 metres and its height as 5.5 metres. The width of the building is shown as 18 metres. The width of the building is the separation between the outer edges of each of second element 420 and third element 430 shown in figure 4.

Figure 8 shows an elevation view of a series of modules that provide a building and a closed room in accordance with the invention.

Building 700 in figure 8 corresponds to building 700 of figure 7. However, the end of the building 700 towards the right in figure 8 has now been closed off. A series of SIPs provide an end wall 790, in order to close off the interior space 785 of the room that was shown in figure 7. The end wall 790 in figure 8 comprises at least a first SIP 792, a second SIP 794, and a third SIP 796.

Figure 9 shows an elevation view of a series of modules that provide another embodiment of a building and a room in accordance with the invention.

Figure 9 shows an embodiment of a second building 910. Second building 910 comprises an interior space 920. In contrast to the walls of building 700, the second building 910 has been constructed of SIPs that do not fully enclose the interior space 920. Instead, at least one opening 930 is provided in the walls of the building 910.

The openings in the second building 910, such as opening 930, may be achieved in one of several ways. A first SIP 940 and a second SIP 950 are shown in figure 9. The first SIP 940 and -8 -the second SIP 950 are closest to the end of second building 910 that is towards the right in figure 9. A first opening 960 is shown in the first SIP 940. A second opening 970 is shown in the second SIP 950. When the first SIP 940 and the second SIP 950 have been assembled adjacent to one another and abutting, the first opening 960 and the second opening 970 align, adjacent to one another. The dividing line between the first opening 960 and the second opening 970 has been shown as a dotted vertical line between the first opening 960 and the second opening 970.

The opening 930, or the opening created by the first opening 960 and the second opening 970, might for example provide a window opening.

The modules shown in figures 4-9 each comprise four elements. In Fig. 4, module 400 is shown as comprising: (i) The second element 420, which is configured to provide an upright wall member.

(ii) The third element 430, which is configured to provide an upright wall member. Op The fourth element 440, which is configured to provide a roof or ceiling member.

However, the modules of the invention may take other forms. Each of figures 10A to 1OF illustrates one alternative form for the module, seen in side elevation view.

In Figure 10A, second element 1020 is inclined towards third element 1030. Thus the structural module, seen in side elevation, is a trapezium. All of fourth element 1040 overlies first element 1010.

In Figure 10B, second element 1122 is inclined away from third element 1132. Thus the structural module, see in side elevation, is a trapezium. A portion of fourth element 1142 does not overlie first element 1112, but extends beyond it, above second element 1122.

In Figure 10C, second element 1220 and third element 1230 are inclined in the same direction. Thus the structural module, see in side elevation, is a trapezium. A portion of fourth element 1240 does not overlie first element 1210, but extends beyond it.

In Figure 10D, second element 1320 and third element 1330 are inclined towards each other. All of fourth element 1340 overlies first element 1310. -9 -

In Figure 10E, fourth element 1440 is convex. An outer curved surface of the fourth element 1440 faces upwards thereby forming a curved roof or ceiling member, when the elements of the module have been attached to each other. Second element 1420 is inclined towards third element 1430.

In Figure 10F, second element 1522 is convex. An outer curved surface of the second element 1522 faces away from the centre of the module, thereby forming a curved wall or window member. Second element 1522 curves towards third element 1532.

Considering figures 4-10 together, it is clear that the invention provides a novel and cutting-edge building design concept. The invention provides a pre-fabricated solution that provides a structural span capability, using natural materials, which exceeds that of known approaches. Structural components may be precision fabricated, offsite, in controlled factory environments. The precision of the off-site construction allows subsequent rapid onsite assembly. The resulting building substitutes conventional steel and cement for composite materials that deliver superior performance. Advantages may be some or all of phenomenal thermal regulation, acoustic insulation, and internal comfort levels. The building method of the invention minimises both waste and energy demand, whilst sequestering carbon within its material structure.

In one practical application, the applicant has designed a 'LARGE ALTERNATIVE REALITY AREA' (LARA) building. This structure takes advantage of the large frameless internal space that can be achieved for a building built in accordance with the invention, which lacks internal supports or columns that may clutter large internal spaces that are created with conventional construction techniques. The LARA building will contribute to the revolution of the Clean Growth construction industry, which in some areas lags behind rapid developments in sustainability that have been achieved in other sectors such as the automotive sector. LARA will use bio-composite structural insulated Panel (BSI P) HEMPOSITETm. The LARA space will itself be a demonstration structure, and hence a flagship of proof of concept that will be used as a research and development incubator for future innovation.

The aim for LARA is to provide a low carbon structure, self-powered through integrated renewable energy sources including Solar PV and GSH, that can exist 'off grid' irrespective of the local environment. Designed as a structural monocoque made up of bio-composite HEMPOSITE panels as shown in figures 4-9, the result is a long clear span capability and 'flat' roof solutions that maximise space. HEMPOSITE will be made from Glue Laminated timber, which provides structural strength. HEMPOSITE also employs natural fibre insulation material and hemp resin skin with very high energy performance, as explained further in the description of subsequent figures. -10 -

Hemposite panels are designed to have some or all of integrated Solar PV cells, built-in heating elements, and also fully integrated service conduits. HEMPOSITE has the potential to be pre-manufactured to be available as an 'off the shelf stock product that reduces time and waste. The invention offers whole-life benefits associated with enhanced energy performance and carbon sequestration. One basic design of panel allows the building of an appropriate superstructure.

The LARA building offers a light touch environmental solution utilising natural recyclable materials within HEMPOSITE. The building has the capability to be disassembled and reassembled, and for this to occur in the absence of 'wet trades'. The scalable design is further applicable to a wide number of commercial, light industrial and residential uses, where there is advantage in high performance standards with a large open plan space.

Subsequent Figures 11-15 illustrate how the HEMPOSITE panel of the invention is constructed. The basic principle is a closed glulam box beam design that is filled with a layer of hemperete and hemp fibre insulation. Hemperete or Hemplime is a bio-composite material, comprising a mixture of hemp hurds and lime used as a material for construction and insulation. On the external face of the panel is a breathable membrane, timber batten and a hemp resin rain screen. On specific panels that are destined for some parts of a building, solar cells will be embedded as part of the green energy tech solution. On the inside face of the panel is a service void, followed by wood insulation board and lime render. On specific panels, embedded heating/cooling panels are provided. Finally a protective inner hemp resin layer will protect the lime render.

Figures 16-19 onwards illustrate how the panels come together. The use of a locking bolt enables the future un-locking of the panel system. Hence a building can be dismantled, extended, or reduced in size. In the examples of figures 4-10, one roof panel, two wall panels and one floor panel come together to create a rectangular or trapezoidal structural module. Then, for example, rectangular panel sections are locked together to create a clear open plan space within the superstructure. As shown in figure 16 onwards, holes may be provided in a first panel, to allow access for tightening bolt heads that project into the Glulam structural elements of a second panel, to which the first panel is to be attached.

Figure 11 shows an exploded axonometric view of an example of a SIP element of a module, in accordance with the invention.

The SIP elements of the invention comprise a box-beam of glue-laminated igluelam' timber. This construction provides superior structural strength. The glulam timber box beam supports the structural loading of the building. The Glulam timber box beam construction of the SIP element as shown in figure 11 may offer a large clear span capability of up to 30m, for a flat roof.

The SIP element is pre-fabricated, and may use both natural materials and integrated renewable energy technology. The SIP element is a complete 'in to out' panel system. When assembled, the SIP elements of a module form the building superstructure, upon which all other elements such as glazing, doors and internal walls bolt into. The SIP element, by not requiring 'wet trades', leads to both a rapid assembly time, and a building envelope that has the potential to be disassembled and recycled. The use of natural rather than synthetic materials may enhance the options for recycling.

The SIP elements also use natural materials, in particular to provide superior insulation performance. The U value of a SIP constructed as shown in figure 11 may be, for example, 0.09W/m2K. This performance exceeds the standards that are commonly in use. As a comparison, the non-domestic UK Building Regulations specify an insulation value of 0.22W/m2K. The domestic UK Building Regulations specify 0.16W/m2K. For a 'Passivhaus' standard, the insulation value may be -0.10W/m2K.

The SIP element of the invention is referred to as a HEMPOSITETm panel. The SIP element uses a proprietary material HempereteTM and hemp fibre to make up the insulation portion within the SIP element In addition to offering thermal regulation with U values of 0.09 W/m2K, the SIP element offers superior acoustic insulation.

The outer part of the SIP element provides a development of a bio-composite in the form of a Hemp resin fibre cladding. The Hemp resin fibre cladding offers a waterproof outer skin. This arrangement provides a roof-grade specification. Weathering integrity may be reinforced by a Permavent ECO breather membrane. The need for an internal vapour barrier has been designed out, with the dew point occurring outside of the panel resulting in a fully breathable structure.

Within the outer skin of the SIP element, solar photovoltaic 'PV' cells may be embedded. The PV cells may link to a battery storage system. For example, a battery storage system may be constructed from re-purposed automotive batteries. The internal plaster finish of the SIP element may be provided with a microbore heating and cooling element. The heating and cooling element may be powered, for example, by a ground source heat pump 'GSHP'.

Each SIP element may have within in it three prefabricated service conduits. The service conduits may act as a ring main supply for Electrics, Data and Water. All drainage routes within the SIP element, when used as a floor panel, are pre-cast within the SIP element. -12 -

It is important to note that the full capabilities of the SIP element may not be needed in all of the first to fourth elements of figure 4. The first element 410 may require pre-cast drainage elements. However, where the SIP element is the floor member of just one of several modules as shown in figures 6 to 9, not every floor member will need pre-cast drainage elements. Similarly, some of the second to fourth elements 420, 430 and 440 may have solar photovoltaic 'PV' cells. Where the SIP elements are in one of several modules as shown in figures 6 to 9, some of the SIP elements may however not have solar photovoltaic 'PV' cells. It is important to note that in figures 6 to 9, each of the SIP elements will be designed such that the building as a whole will have a desired number of photovoltaic 'PV' cells, drainage conduits or other features. Thus a building as a whole may be planned in advance, with the capabilities of each SIP element then chosen to meet the overall performance required from the building.

SIP element 1100 in figure 11 is shown as an exploded view. The example of SIP element 1100 corresponds to a SIP element that forms the second element 420 or the third element 430 of figure 4, i.e. an upright wall panel member. The 'INNER' and 'OUTER' faces of the SIP element and hence the wall are marked on figure 11.

Four layers of SIP element 1100 are together designated by reference 1105. Reference 1105 shows elements that will be provided in each SIP element. The thicknesses provided below are non-limiting examples of the possible thicknesses. The four layers that are together designated by reference 1105 are: a) Glu-lam timber inner skin 1110. Glu-lam timber inner skin 1110 may have a thickness of 40mm.

b) 'Hemperete' insulation layer 1120. 'Hemperete' insulation layer 1120 may have a thickness of 270mm.

c) Hemp fibre insulation layer 1130. Hemp fibre insulation layer 1130 may have a thickness of 200mm.

d) Glu-lam timber outer skin 1140. Glu-lam timber outer skin 1140 may have a thickness of 40mm.

Towards the interior of SIP element 1110 are three further layers, as follows: e) A service void 1145, which may be 100mm thick.

f) A 'Pavatex Diffutherm' wood insulation board layer 1150, which may be 60mm thick.

g) A lime render layer 1155, which may comprise a microbore 20mm rapid heating/cooling panel. Lime render layer 1155 may be 20mm thick.

Towards the exterior of SIP element 1110 are four further layers, as follows: h) A permavent ECO breather membrane layer 1160.

i) A ventilation void 1165, which may be 25mm thick. -13 -

j) A hemp resin rainscreen 1170, which may be 20mm thick.

k) A layer of photovoltaic lenses 1175.

Most of the layers shown in figure 11 would be provided in the embodiments of the SIP element 1110 and in the elements of figures 4-10. However, in some SIP elements used to construct the structural module 400 of figure 4, for example, some layers may not be included. For example, when SIP element 1110 forms the first element 410 of figure 4, i.e. is used to provide a horizontal floor element 410 as shown in figure 4, the layer of photovoltaic lenses 1175 would not be included.

Figure 12 shows an axonometric view of the example of the SIP element 1100 of a module of FIG. 11.

Fig. 11 had shown an exploded, cut away view of SIP element 1110. FIG. 12 shows an axonometric view of the example of the SIP element 1100 of a module of FIG. 11, but without the layers being shown in an exploded view. The cut-away view in FIG. 12 also allows layers 1110 to 1170 to be seen. The layer of photovoltaic lenses 1175 of figure 11 would be on the reverse side of the SIP element 1110, so is not referenced in figure 12.

Figure 13 shows another axonometric view of the example of the SIP element 1100 of a module of FIG. 11.

FIG. 13 does not show a cut-away view, in contrast to FIG. 12, except for a cutaway at 'Pavatex Diffutherm' wood insulation board layer 1150. However, the reference numbers for the layers 1110 to 1175 are all shown on figure 13. The reference numbers for the layers 1110 to 1175 on figure 13 show the sequence of each layer within SIP element 1110, and indicate the general position within SIP element 1100 of each layer.

Figure 14 shows another axonometric view of the example of a SIP element 1110 of the module of FIG. 11. In Fig. 14, the SIP element 1110 is shown without any cut-away. Fig. 14 shows the SIP element as it might be seen prior to assembly of a structural module 400 on site.

The view of SIP element 1110 in figure 14 is taken after rotation by 180 degrees about the long axis of the SIP element 1110. Thus the layer of photovoltaic lenses 1175 is in the foreground, in the view of figure 14, and clearly visible.

Figure 15 shows an axonometric view of another example of a SIP element 1500 of a module. -14 -

SIP element 1500 generally corresponds to SIP element 1110 of figs 11-14. However, SIP element 1500 also includes a first fin 1510 and a second fin 1520. Mounted on first fin 1510 is a second layer of photovoltaic cells 1515. Mounted on second fin 1520 is a third layer of photovoltaic cells 1525.

Figures 16-19 illustrate a locking system to lock elements together, in accordance with the invention.

Figure 16 shows another axonometric view of the example of the module 400 of FIG. 4 coming together with a second module. In Fig. 16, the fourth element 440 of the first SIP module 400 and the corresponding fourth element 1610 of another, second SIP module are shown in 3D coming together with a locking bolt 1620. The fourth element 440 in figure 4 was the roof or ceiling element of the first SIP module 400. The locking bolt 1620 occurs at least every meter along the edges where the first SIP module 400 and the second SIP module 1610 meet. This ensures that the fourth element 440 of the first SIP module 400 and the corresponding fourth element 1610 of the second SIP module are securely locked together.

First timber element 1630, second timber element 1640 and third element 1650 illustrate timber joint details that provide structural support to bolt 1620. Fourth timber element 1660 illustrates a capping strip that maintains the continuous waterproof outer surface of the structure.

Figure 17 shows another view of the fourth element 440 of the first SIP module 400 and the corresponding fourth element 1610 of the second SIP module of Figure 16. The structures in figure 17 correspond to those in figure 16, and each has been given the same reference numerals in figure 17.

Figure 18 shows another axonometric view of the fourth element 440 of the first SIP module 400 and the corresponding fourth element 1610 of the second SIP module.

In order to understand figure 18, it is helpful to refer back to figure 4. In figure 4: (i) Third element 430 is configured to provide an upright wall member. The third element 430 has a second end 434.

(ii) Fourth element 440 is configured to provide a roof or ceiling member. The fourth element 440 has a second end 444 for attachment to the second end 434 of the third element 430.

In figure 18, the fourth element 440 is shown at the upper right. The second end 444 of the fourth element 440 is also shown. Third element 430 is shown at the lower right in figure 18. The second end 434 of the third element 430 is labelled immediately below second end 444 of the fourth element 440. The second end 434 of the third element 430 is connected to the second end 444 -15 -of the fourth element 440. The connection is achieved using a first joining bolt 450. First joining bolt 450 is accessed through a first access point 1850 near to the second end 434 of the third element 430.

The corresponding fourth element 1610 of the second SIP module is shown at the upper left of figure 18. The second end 1644 of the fourth element 1610 is also shown. Third element 1630 of the second SIP module is shown at the lower left in figure 18. The second end 1634 of the third element 1630 is labelled immediately below second end 1644 of the fourth element 1610. The second end 1634 of the third element 1630 is connected to the second end 1644 of the fourth element 1640. The connection is achieved using a second joining bolt 1865. Second joining bolt 1865 is accessed through a second access point 1860 near to the second end 1634 of the third element 1630.

Referring back to figure 4, the fourth element 440 has a first end 442, which is to be connected to second end 424 of second element 420. First end 442 of the fourth element 440 will be connected to second end 424 of second element 420 using joining bolts corresponding to first joining bolt 450 and second joining bolt 1865 of figure 18. The ends of the first element 410 in figure 4 may also be joined to the abutting ends of second element 420 and third element 430 in figure 4 using joining bolts corresponding to first joining bolt 450 and second joining bolt 1865 of figure 18.

Figure 19 shows a perspective view of the arrangement of figure 18, but with a part of a third structural module also shown.

The fourth element 440 and third element 430 of a first structural module are labelled towards the right in figure 19, as in figure 18. The fourth element 1610 and third element 1630 of a second structural module are labelled towards the lower edge in figure 19, as in figure 18. In addition, the fourth element 1940 and third element 1930 of a third structural module are labelled at the upper edge and lower left corner, respectively, of figure 19. The fourth element 1940 of the third structural module abuts the edge of the fourth element 1610 of the second structural module. The third element 1930 of the third structural module abuts the edge of the third element 1630 of the second structural module.

FIGs. 20A to 20D illustrate alternative forms for the monocoque structural module, in side elevation view. In this form, the structural module comprises only three elements, compared to the four elements shown in each of the views in figures 10A to 10F. The elements are again pre-fabricated, and are configured for on-site assembly to form the structural module when the elements have been attached to each other. Each element in figures 20A to 20D comprises a -16 -box-beam structural insulated panel, with integrated service conduits, insulation material, a finished inner surface, and a finished outer surface, as for example shown in figure 11. However, some of the elements in figures 20A to 20D are curved. Once again, each end of each element is configured to abut, and to be attached by bolts to, one end of another of the elements.

In Figs. 20A to 20D: (i) The first element is configured to provide a floor member; (ii) The second element and the third elements together fulfil the roles of upright wall member and roof/ceiling member, and meet to enclose the space within the three elements.

In Figure 20A, first element 2010 is configured to provide a horizontal floor member, second element 2020 is configured to provide a first upright wall member that leans over at approximately 45 degrees, and third element 2030 is configured to provide a second upright wall member that also leans over at approximately 45 degrees. The second element 2020 and the third element 2030, thereby together fulfil the functions of a combined wall and roof or ceiling element. Other lean angles are also envisaged.

The first edges of the first element 2010, the second element 2020 and the third element 2030 are configured such that: (i) a first edge of the structural module, when assembled, is configured to abut and to attach to an edge of a second structural module placed next to the first edge of the structural module; and (ii) an outer surface of each of the first to third elements is contiguous with an outer surface of an adjacent abutting portion of the second structural module; The inner surfaces of the first element 2010, the second element 2020 and the third element 2030 combine to provide a portion of a room of the building.

In Figure 20B, first element 2110 is configured to provide a horizontal floor member. Second element 2120 is configured to provide a first curved wall member that is generally upright at its lower portion and finished with a horizontal top end. Third element 2130 is configured to provide an upright wall member, which is generally vertical. The second element 2020 fulfils the functions of a combined wall and roof or ceiling element. Third element 2130 fulfils the function of a wall element.

In Figure 20C, first element 2210 is configured to provide a horizontal floor member. Second element 2220 is configured to provide a first wall member that leans at a significant angle to the vertical, such as 60 degrees. Third element 2230 is configured to provide an upright wall member, which is generally vertical. The second element 2220 can be considered to fulfil the functions of a combined wall and roof or ceiling element.

In Figure 20D, first element 2310 is configured to provide a horizontal floor member. Second element 2320 is configured to provide a first curved wall member that is generally upright at its lower portion and finishes with a horizontal top end. Third element 2330 is configured to provide a second curved wall member that is generally upright at its lower portion and finishes with a horizontal top end. The horizontal top end of the second element 2320 meets the horizontal top end of the third element 2330. The second element 2320 and the third element 2330 effectively fulfil the functions of a combined wall and roof or ceiling element.

Figure 21 illustrates an example flowchart of a method of pre-fabricating a set of Structural Insulated Panels, SIP, to construct a frameless building. With the method of figure 21, it becomes possible to distribute the functional features of a building between elements and structural modules of the building.

The method of pre-fabricating a set of Structural Insulated Panels, SIP, to construct a frameless building, comprises calculating operating parameters for a complete building. Those parameters may depend on many variables. For example, a large building has a proportionately smaller external area than a small building, so may have a lower need for heating but a greater need for cooling. The further south a building, the greater the need for cooling and the lower the need for heating, in most cases. A building designed to house many workers and IT equipment may have a greater cooling need than a building that has comparatively few occupants, such as a squash or tennis court.

The four separate elements of figure 4 combine to form one structural module. The heating capacity of the structural module will depend on the heating elements provided in any or all of the four separate elements, together with any photovoltaic cells mounted on the second to fourth elements. The cooling capability of the structural module may depend on the size of the cooling ducts in any or all of the four elements.

Once the operating parameters for the complete building have been calculated, then a set of SIP elements is designed that, when assembled, provide a frameless building that meets the operating parameters for the complete building. For this method, the individual SIP elements comprise: a) a glue-laminated timber inner skin; b) a hemperete insulation layer; -18 -c) a hemp fibre insulation layer; d) a glue-laminated timber outer skin.

The operating parameters for the complete building may entail relatively few active components, such as photovoltaic cells or heating elements. These components may be included in a small number of the SIP elements, and might conceivably be in just one bespoke structural module. However, the method will lead to at least a first and a second SIP element being designed as bespoke SIP elements for a specific location within the complete building. In many buildings, the remaining SIP elements of the building may just be 'off the shelf SIP elements that are not specifically equipped with bespoke heating or cooling components.

When at least a first and a second SIP element are designed as bespoke SIP elements for a specific location within the complete building, the first and the second SIP are different in design from each other, for example one may be first element 410 of figure 4 providing a floor element, and the second may be second element 420 of figure 4 providing a wall element. The bespoke elements may be in the same structural module of the building. However, the bespoke elements may be in different structural modules, such as fourth element 440 and adjacent fourth element 1610 in figure 19.

When at least a first and a second SIP element are designed as bespoke SIP elements for a specific location within the complete building, each of the first and second SIPs incorporates at least one selected from: e) a service void; f) a microbore heating/cooling panel within the lime render layer; g) an outer layer of photovoltaic lenses.

The first and the second SIP element are different in design from each other, with at least the first SIP comprising at least one of elements e) to g) that is not comprised in the second SIP.

The steps of the method are illustrated in figure 21 with an initial step 2110 of calculating the operating parameters for a complete building that is to be constructed. There may be excess functional capability designed into the building, i.e. the building will be designed with more capability than is anticipated for its first use.

In step 2120, a set of SIP elements is designed to provide the frameless building. When assembled into modules, the set of SIP elements will meet or exceed the operating parameters for the complete building. -19 -

In step 2130, the structural modules are assembled from the bespoke and 'off the shelf elements. In step 2140, the building is assembled from the structural modules, i.e. from bespoke and 'off the shelf SIP elements.

During the lifetime of a building, the demands on the building may change. Figures 16-18 showed the use of bolts to connect SIP elements of one structural module to the SIP elements of an adjacent structural module. Even after a building has been in use, possibly for years, these bolts can be accessed and undone. This allows the removal of one or more entire structural modules, or the removal of one or more SIP elements. Thus a building can be modified, for example if the use of the building changes and the operating parameters for the complete building then change. A building that is converted from industrial storage to domestic accommodation might need enhanced heating and additional water and electric supply, for example. Thus the method of figure 21 may extend to step 2150. In step 2150, a calculation of new operating parameters is made for the complete building.

Step 2160 uses the calculation of the new operating parameters to design new bespoke SIP elements to provide structural modules with the desired enhanced performance. In step 2170, existing parts of the building are removed. In place of the removed elements, the new bespoke SIP elements are incorporated, to enhance the building.

Three possible variations of the method of figure 21 can be considered, as follows: a) Firstly, figure 21 assumes that some bespoke elements will need to be designed. In an alternative arrangement, a range of standard 'off the shelf' SIP elements may be designed. For example, SIP elements corresponding to the fourth element 440 on figure 4 may have various standard sets of photovoltaic cells, such as 0.5KW, 1.0KW, 1.5KW, 2.0KW and 2.5 KW.

Instead of using bespoke SIP elements, the method may comprise step 2110 of calculating operating parameters for the complete building. Then the building can be designed with a particular selection of the various standard panels that are available.

b) Secondly, step 2170 describes the replacement of SIP elements with enhanced SIP elements, as a form of 'mid-life upgrade' of the building. Instead, it is possible to change the shape of a building, or the size of a building, by either: (i) adding SIP elements of a different shape to those that are being removed; 00 adding structural modules between structural modules of the existing building; (iii) simply removing structural modules, without adding any new ones, to make a building smaller. -20 -

Thus incorporation of the at least one further bespoke SIP elements into the complete frameless building in step 2170 may comprise extending the building, to change the overall size and/or shape of the building.

c) Thirdly, a building can be dismantled and the SIP elements or structural modules may simply be re-deployed on other sites. SIP elements may be re-conditioned as part of this process.

In summary:

The invention provides a new modular building concept, which the applicant refers to as HEMPOSITETM. This concept encompasses: a) A 'Glulam' box beam design for each structural element; b) A closed panel system c) A composite blend of natural materials d) An integrated solar PV skin and/or Integrated Ground Source heating cooling on some panels; e) The potential use of three forms of natural HEMP. These three forms of natural HEMP are Hemperete, Hemp Resin & Hemp Fibre insulation.

The elements of the invention can be factory-built, and can deliver scalable solutions in residential, leisure, office and industrial settings. A fuller list of possible building uses is: Private Residential; Community Housing; Light industrial; Office Buildings; Student Accomodation; Small Hotel buildings; Other leisure use, e.g pool, spa, health club; School Halls.

In some cases, elements of the invention will be bespoke elements designed for a particular location in just one building. However, many elements built in accordance with the invention may be standardised. So, for example, 'off the shelf floor elements may be manufactured in various standard lengths. Those floor elements may then be shipped to a site, together with other bespoke elements that are designed for just one building.

Once on site, the elements may be rapidly assembled to provide the structural module of the invention for the superstructure of a frameless building. Many buildings will have a resulting on-site construction time of for example 5 days, or less. The invention gives rise to a versatile building structure, which offers exceptional structural and energy performance, and environmental credentials. The building structure has the capacity to be self-powering, through integrated renewable energy generation. Thus the resulting building may demonstrate some or all of: a) Reduced whole life cost benefits; -21 -b) Superior thermal performance, with reduced thermal bridging and superior air tightness; c) Superior acoustic performance; d) A monocoque superstructure; e) A long clear span capability, without the need for a pitched roof to maximise internal space when height is restricted; f) Off-Grid heating & power provision.

End user costs for HEMPOSITETm buildings are comparable to costs of conventional construction. The invention represents positive environmental change within the building industry. In terms of time to build, the novel 'in-to-out' structural panel design concept, using precision offsite fabrication of the structural components of the invention, allows rapid onsite assembly. The building superstructure provided by the invention substitutes conventional steel and synthetic materials for a high-performance low carbon bio-composite material sandwich, which exceeds the performance of known approaches and exceeds current environmental obligations. The system provided by the invention involves the unique assembly of components which together form HEMPOSITETM, with these uniform components slotting together in turn to form a building envelope that offers exceptional performance. The resulting structure may be entirely self-powering and energy neutral, through building integrated renewable energy generation. The integrated renewable energy generation may include solar photovoltaics (SPV) and/or ground source heating (GSH). The structures provided by the invention may be 'off-grid', and exist independently, anywhere. Thus the resulting building can be designed not to rely on infrastructure services, which may be intermittent or even entirely unavailable at some points on earth.

The building method of the invention both minimises waste and energy demand, and sequesters carbon within its material structure. However, these advantages may be achieved whilst also being faster and more simple to construct than conventional approaches. The building method of the invention may deliver long life benefits, to thereby reduce whole life costs relative to conventional business methods. Looking just at environmental performance, the building may achieve some or all of the following: a) A high performance sustainable bio composite structure; b) Very extensive use of natural materials, with both Glulam and Hemp being natural and renewable materials; c) A fully recyclable building; d) High carbon sequestration within the building superstructure; e) Elements providing embedded renewable energy technology and second life battery technology, for example using batteries that have already had one life in vehicles; -22 -f) Elements that are adaptable to Screw Pile foundations, providing a highly desirable 'light earth touch'.

Whilst the specific and preferred implementations of the embodiments of the present invention are described above, it is clear that one skilled in the art could readily apply variations and modifications that would still employ the aforementioned inventive concepts. Thus, a structural module for improving the reliability and performance of the superstructure of a building has been described, where the aforementioned disadvantages with prior art arrangements have been substantially alleviated. -23 -

Claims

Claims 1. A monocoque structural module for the superstructure of a frameless building, the module comprising at least four separate elements, wherein: a) the elements are pre-fabricated, and are configured for on-site assembly to form the structural module when the elements have been attached to each other; b) each element comprises a box-beam structural insulated panel, with integrated service conduits, insulation material, a finished inner surface, and a finished outer surface; c) each end of each element is configured to abut, and to be attached by bolts to, one end of another of the elements; b) a first element is configured to provide a horizontal floor, the first element having first and second ends; c) a second element is configured to provide an upright wall member, the second element having a first end for attachment to the first end of the first element, and having a second end; d) a third element is configured to provide an upright wall member, the third element having a first end for attachment to the second end of the first element, and having a second end; e) a fourth element is configured to provide a roof or ceiling member, the fourth element having a first end for attachment to the second end of the second element, and a second end for attachment to the second end of the third element; f) first edges of the first to fourth elements of the structural module are configured such that: (i) a first edge of the structural module, when assembled, is configured to abut and to attach to an edge of a second structural module placed next to the first edge of the structural module; and (h) an outer surface of each of the first to fourth elements is contiguous with an outer surface of an adjacent abutting portion of the second structural module; g) inner surfaces of each of the first to fourth elements combine to provide a portion of a room of the building. -24 -
2. The monocoque structural module of claim 1, wherein: the second, third and fourth elements are configured to provide an unsupported frameless span of at least 10 metres.
3. The monocoque structural module of claim 1 or claim 2, wherein: (i) the second element and third element are configured to provide vertical wall members; and (H) the fourth element is the same length as the first element, thereby completing a structural module that is rectangular in shape and provides a structural module for a single storey flat-roofed single span building.
4. The monocoque structural module of claim 1 or claim 2, wherein: (i) the second element is configured to provide a vertical wall member; (H) the third element is configured to provide a wall member inclined towards the second element; and (hi) the fourth element is shorter than the first element, thereby completing a structural module that is trapezoidal in shape.
5. The monocoque structural module of claim 1 or claim 2, wherein: (i) the second element and the third element are configured to provide inclined wall members; and wherein either: (h) the second element and the third elements are inclined towards each other, thereby completing a trapezoid in which all of the fourth member overlies the first member; or (hi) the second element and the third elements are inclined in the same direction, thereby completing a trapezoid in which part of the fourth member extends beyond the first or the second end of the first member.
6. The monocoque structural module of any previous claim, wherein: the fourth element is convex, wherein an outer curved surface of the fourth element faces upwards, thereby forming a curved roof or ceiling member when the elements have been attached to each other.
7. The monocoque structural module of any of claims 1-5, wherein: the fourth element lies at an angle of less than 5 degrees to the horizontal, when the elements have been attached to each other. -25 -
8. The monocoque structural module of claim 3, wherein: the outer surfaces of each of the second and third element provide an exterior wall of the building; the outer surface of the fourth element provides an exterior roof surface of the building; the outer surface of each of the second to fourth elements is a rain-proof material.
9. The monocoque structural module of any previous claim, wherein: second edges of the first to fourth elements of the structural module are configured such that: (i) a second edge of the structural module, when assembled, is configured to abut and to attach to an edge of a third structural module placed next to the second edge of the structural module; and (ii) the outer surface of each of the first to fourth elements is contiguous with an outer surface of an adjacent abutting portion of the third structural module.
10. The monocoque structural module of any previous claim, wherein the first to fourth elements each comprise a box-beam of glue-laminated timber, and are pre-fabricated such that: (i) at least one of the first, second and third elements comprises a heating element; OD at least one of the second, third and fourth elements comprises a cooling element; OD at least one of the second, third and fourth elements comprises a solar photovoltaic module.
11. The monocoque structural module of any previous claim, wherein the first to fourth elements each comprise, successively from a surface of the structural module that will form an inner surface following assembly: a) a glue-laminated timber inner skin; b) a hemperete insulation layer; c) a hemp fibre insulation layer; d) a glue-laminated timber outer skin.
12. The monocoque structural module of claim 11, further comprising, successively from the glue-laminated timber inner skin towards the inner surface of the element: e) a service void; f) a wood insulation board layer; g) a lime render layer. -26 -
13. The monocoque structural module of claim 12, further comprising: a microbore heating/cooling panel within the lime render layer.
14. The monocoque structural module of any of claims 11-13, further comprising, successively from the glue-laminated timber outer skin towards a surface of the structural module that will form an outer surface following assembly: h) a breather membrane layer; i) a ventilation void; j) a hemp resin rainscreen; k) a layer of photovoltaic lenses.
15. The monocoque structural module of any previous claim, wherein the first to fourth elements each comprise: a section of box-beam of glue-laminated timber at the end of the element, the section of box-beam of glue-laminated timber configured to be held in place by a bolt to the end of another of the elements.
16. A monocoque structural module for the superstructure of a frameless building, the structural module comprising at least three separate elements, wherein: a) the elements are pre-fabricated, and are configured for on-site assembly to form the structural module when the elements have been attached to each other; b) each element comprises a box-beam structural insulated panel, with integrated service conduits, insulation material, a finished inner surface, and a finished outer surface; c) each end of each element is configured to abut, and to be attached by bolts to, one end of another of the elements; b) a first element is configured to provide a horizontal floor, the first element having first and second ends; c) a second element is configured to provide an upright wall member, the second element having a first end for attachment to the first end of the first element, and having a second end; -27 -d) a third element is configured to provide an upright wall member, the third element having a first end for attachment to the second end of the first element, and having a second end; e) the second end of the second element is configured for attachment to the second end of the third element, thereby forming a combined wall and roof element; f) first edges of the first to third elements of the structural module are configured such that: (i) a first edge of the structural module, when assembled, is configured to abut and to attach to an edge of a second structural module placed next to the first edge of the structural module; and (h) an outer surface of each of the first to third elements is contiguous with an outer surface of an adjacent abutting portion of the second structural module; g) inner surfaces of each of the first to third elements combine to provide a portion of a room of the building.
17. A method of pre-fabricating a set of Structural Insulated Panels, SIP, to construct a frameless building, the method comprising: calculate operating parameters for a complete building; design a set of SIPs that, when assembled, provide a frameless building that meets the operating parameters for the complete building, wherein: the SIPs comprise: a) a glue-laminated timber inner skin; b) a hemperete insulation layer; c) a hemp fibre insulation layer; d) a glue-laminated timber outer skin; at least a first and a second SIP are designed as bespoke SIPs for a specific location within the complete building, wherein: the first SIP and the second SIP are different in design from each other; and each of the first SIP and the second SIP incorporates at least one selected from: -28 -e) a service void; f) a microbore heating/cooling panel within the lime render layer.g) an outer layer of photovoltaic lenses; whereby the first SIP and the second SIP are different in design from each other, with at least the first SIP comprising at least one of elements e) to g) that is not comprised in the second SIP.
18. The method of claim 17, further comprising, subsequent to construction of the frameless building and as a mid-life upgrade to the frameless building: calculating new operating parameters for the complete frameless building; and designing at least one further bespoke SIP to contribute to the new operating parameters; and incorporating the at least one further bespoke SIP into the complete frameless building.
19. The method of claim 18, wherein: incorporating the at least one further bespoke SIP into the complete frameless building comprises extending the building to change the overall size and/or shape of the building.
20. The method of claim 17, further comprising, subsequent to construction of the frameless building and as a mid-life upgrade to the frameless building: calculating new operating parameters for the complete frameless building; and identifying at least one SIP to be removed from the building, whilst the remaining SIPS meet the new operating parameters; and removing the at least one identified SIP from the building and thereby reducing the size of the building.