GB2594723A - Improvements in and relating to modular building support systems - Google Patents

Abstract

An adjustable height support (101) for a building and methods of its manufacture are disclosed. The adjustable height support (101) comprises a base section (102) which receives and supports a screw assembly (106). The screw assembly (106) comprises a stabilisation plate (110) which is slidably received in a channel of the base section (102). The stabilisation plate (110) is sized and shaped to cooperate with the channel so that the stabilisation plate (110) is able to move freely along the length of the axis of the channel. Lateral movement of the stabilisation plate (110) perpendicular to the length axis of the channel and rotation of the stabilisation plate (110) about the length axis of the channel are inhibited. Also disclosed is a modular building system supported by adjustable height supports and a method of constructing the same. The system comprises at least three cuboid modules supported by at least eight independent supports, each module defining an occupiable space.

Description

Improvements in and relating to modular building support systems

Field of the Invention

The present invention concerns support systems for buildings (especially modular buildings), and modular buildings comprising such support systems. More particularly, but not exclusively, this invention concerns an adjustable height support platform for a building, and a modular building support system that provides flexibility in locating building supports.

Background of the Invention

Modular buildings offer many advantages over traditional construction. Often, building modules can be manufactured at a central manufacturing facility, allowing modules to be fabricated in a controlled environment with an experienced, local workforce. Furthermore, modules can be constructed and fitted out in parallel with site preparatory works, reducing construction time. Yet further, modules can be standardised, allowing for more efficient use of materials and time.

Modern, high specification modular buildings are robust, substantial structures, and are typically provided with foundations similar to those used for traditional, stick-built buildings (i.e. buildings that are constructed from raw materials and/or basic components on-site). Such foundations are generally concrete raft or pile foundations that require significant intrusive excavations. Modular buildings are often deployed in close proximity to existing buildings, not least because they offer a convenient and cost-effective approach to increasing capacity of existing complexes. As a consequence, installers frequently find that the installation site features numerous existing services, such as below-ground pipework and cabling. Moving such existing services is usually not practicable, and building traditional foundations around such services is complicated, increasing costs and timescales. For example, groundworks need to be carefully planned to avoid damaging existing services during installation, and the foundations themselves need -2 -to be designed to avoid damage to those services once the building is installed (e.g. by installing bridging foundations to avoid placing load on underground services). Additionally, modular buildings are frequently installed on another structure, such as a framework (to carry the building above uneven ground) or existing building. In such installations, existing building systems that require evenly distributed building supports drive up the complexity and thus costs of construction.

Recognising the high cost of traditional foundations, platform foundations have been developed, often consisting of multiple adjustable height supports that can be attached to the underside of a modular building. Most systems are designed for use with relatively lightweight structures. Other systems utilise large numbers of platforms to support heavier building modules. While buildings made up of multiple modules may have fastenings between buildings to limit relative movement of the modules, existing designs rely on each module being supported independently on its own set of platforms. In such systems, especially for heavier modules, large numbers of regularly spaced platforms are required. Consequently, while the need for invasive groundworks can be reduced, installation remains complicated by the need to form bridging foundations where platform locations clash with existing services.

Various platform foundations are disclosed in US patent publication nos. US 2007/056227 Al, US 2008/263968 Al, US patent US 6,718,711 Bl, Chinese patent/utility model publications CN104120792A, CN103233512A, CN204418373U.

Adjustable height building supports are disclosed in US patent publication no. US 2007/006540 Al and International (PCT) Application publication WO 2015/127506 Al. Modular building systems are disclosed in US patent publication nos. US 2013/055671 Al, US 2010/058689 Al. Other building support systems are disclosed in US 6,035,590 A, US 5,359,821 A, US 6,381,907 Bl, US 4,761,924 A, US 4,914,875 A, CN203238841U, GB 2,360,300 A, US 2007/056226 Al, WO 2017/029395 Al, US 6,349,512 Bl, FR2724403A1, KR20140128478A, CN109386143A.

Traditionally, modular buildings have been utilised for temporary and semipermanent office/classroom/kitchen/bathroom-type facilities. While it is of course important to achieve reasonable levels of weatherproofing and rigidity, such buildings are unmistakably inferior to stick-built structures. -3 -

More recently, modular building systems have been developed for higher quality buildings, such as healthcare facilities, data centres and laboratories. Such buildings are highly regulated installations, and building quality and integrity is tightly controlled. Floors must have minimal deflection under load, and floor, wall and ceiling joins should be sealed, and remain sealed for the life of the building. In the UK, minimum requirements for various technical aspects of healthcare buildings are specified in Health Technical Memoranda (HTM). Such higher quality buildings are often filled with large amounts of equipment, and have stringent environmental controls, adding significant weight to the structure. The need to support significant building loads, and to ensure building integrity, places significant demands on design of foundations. Thus, even where such buildings are constructed from modular techniques, the buildings are supported on conventional, concrete footings.

There remains a need for a flexible, high capacity building support system.

Summary of the Invention

According to a first aspect, the present invention provides an adjustable height support for a building, the support comprising a base section and a screw assembly, the base section receiving and supporting the screw assembly. Preferably, the base section comprises a top plate mounted on top of an upstanding support structure. Optionally, the support structure defines an elongate straight channel extending downwards from the top plate, preferably wherein the channel has a constant internal cross-sectional size and shape along its length axis. Optionally, the cross-sectional shape of the channel is non-circular. The plate comprises a top opening (e.g. a circular top opening) communicating with one end of the channel.

The top opening is smaller in size than the internal cross-sectional size of the channel. The screw assembly comprises: a threaded rod extending through the top opening of the top plate of the base section, a load support plate secured to the upper end of the threaded rod disposed above the top plate of the base section, a stabilisation plate secured to the lower end of the threaded rod disposed below the top plate of the base section, and a height adjustment nut threaded onto the -4 -threaded rod above the top plate of the base section. The nut is configured to transfer load from the screw assembly to the base section and so that rotation of the height adjustment nut about the threaded rod allows the threaded rod to traverse through the top opening of the base section thereby moving the load support plate of the screw assembly towards or away from the top plate of the base section.

Preferably, a washer is disposed between the height adjustment nut and the top plate of the base section. Preferably, in use, the height adjustment nut and the washer (if present) bear against the top plate to transfer load from the screw assembly to the base section.. Preferably, the stabilisation plate of the screw assembly is slidably received in the channel of the base section. Preferably, the stabilisation plate is sized and shaped to cooperate with (e.g. match the cross-sectional shape of) the channel so that the stabilisation plate is able to move freely along the length axis of the channel, and 1) lateral movement of the stabilisation plate in all directions perpendicular to the length axis of the channel, and 2) rotation of the stabilisation plate about the length axis of the channel are inhibited. For example, the sides of the channel constrict such lateral movement and rotation. It will be appreciated that constricting movement of the stabilisation plate constricts movement of the screw assembly. Preferably, the top opening of the top plate of the base section is sized to cooperate with the threaded rod so that the threaded is able to move freely through the top opening and lateral movement of the threaded rod in all directions perpendicular to the length axis of the channel is inhibited. For example, the threaded rod may have a cylindrical shape and the top opening may have a circular shape and an inner diameter 0.5 to 2 mm, such as 0.8 to 1.5 mm, for example about 1 mm, larger than the outer diameter of the threaded rod. For example, the stabilisation plate may be sized to provide a spacing of 0.5 to 2 mm, such as 0.8 to 1.5 mm, for example about 1 mm, between the stabilisation plate and the channel of the base section.

Preferably, the adjustable height support is a building support. In such a configuration, the load support plate may be considered to be a building support plate, and is attachable to the underside of a building requiring support. It will be appreciated that the adjustable height support is well suited for use with other -5 -loads, including for example fairground rides, large boats out on dry dock, temporary bridges, performance stages and spectator stands. Weight borne by the load support plate is carried by the screw assembly, which rests on the base section. The height adjustment nut and the washer which together rest on the top plate of the base section transfer load from the screw assembly to the base section.

As used herein, a rigid fastening between components prevents relative movement of the fastened components. For example, a rigid fastening prevents one component changing position relative to the other component by rotating, bending, pivoting or sliding. Preferably, each rigid fastening is a permanent fastening. A permanent fastening is a fastening that cannot be undone without damage to the fastening and/or the components fastened together. An example of a suitable rigid fastening is a weld. It will be understood that a non-circular shape is any shape other than a circle, and no 2D shapes other than a circle have infinite rotational symmetry in the plane of the 2D shape. Suitable channel/stabilisation plate shapes that prevent rotation include ovals, triangles, rectangles, pentagons, hexagons, heptagons, octagons etc. As used herein, load and/or capacity specifications are determined according to Eurocode engineering standards. More particular, the following Eurocodes are suitable for determining structure specifications: BS EN 1990 2002 (structural design for load combinations), BS EN 1991-1-1-2002 (densities self-weight imposed loads for buildings, BS EN 1991-1-4-2005 (wind actions & and the UK national annex to this -for determining appropriate horizontal loads), BS EN 1993-1-1-2005 (general rules and rules for buildings -applicable to steel elements).

The stabilisation plate restricts unwanted movement of the load support plate of the screw assembly relative to the base section. For example, the snug fit between the stabilisation plate and the channel helps the screw assembly pivoting about the opening in the top plate. Furthermore, the stabilisation plate helps to avoid undue localised stresses on the threaded rod at the point that it passes through the opening in the top plate. This is especially important when the support is used with high specification, heavy building modules. Furthermore, when the building is rigidly fastened to the support (e.g. when the load support plate is bolted -6 -to the underside of the building), the stabilisation plate allows the building support to better resist horizontal displacement of the building, e.g. due to wind loading of building sides.

The top opening is smaller in size that the internal cross-sectional size of the channel. Thus, the top opening has a dimeter smaller than the maximum diameter of the channel. It will be understood that the top opening diameter is measured across the plane of the opening, which is across the plane of the top plate of the base section. It will be understood that the maximum cross-sectional diameter of the channel is measured in a plane parallel to the plane of the opening. The top opening also has a diameter smaller in size than the cross-sectional size of the stabilisation plate. Having a top opening smaller in size than that of the channel, and also smaller in size than that of the stabilisation plate, ensures that the lower end of the rod, and thus the screw assembly, is retained in the base section.

It has also been found that having a non-circular channel and a stabilisation plate sized so that the channel prevents rotation of the stabilisation plate (and thus the screw assembly) about the length axis of the panel (and thus relative to the base section) provides a particularly robust and stable building support. In particular, it has been found that such an arrangement improves rigidity of the building support, and thus reduces movement of the building when exposed to external forces. Again, this is especially effective when the building is rigidly fasted to the support and the support is rigidly fastened to the ground. Yet further, restricting rotation of the screw assembly relative to the base section facilitates smooth and controlled height adjustment of the building when the building support is loaded. It will be appreciated that when the support is loaded, the weight of the building resists movement of the height adjustment nut. When the screw assembly is unable to rotate relative to the base section, connections between the base section and the ground, as well as between the screw section and the building, act to hold the threaded bar in place while the adjustable nut is rotated.

Optionally, the cross-sectional shape of the channel (and thus that of the stabilisation plate) is quadrilateral, optionally rectangular, such as square. It may be that such shapes are especially convenient to manufacture. A square has higher -7 -symmetry than other rectangular shapes, thereby allowing more flexibility in orientation of the support under the building and making installation more straightforward. Preferably, when the shape is quadrilateral (e.g. rectangular or square), the stabilisation plate is sized to have a spacing of 0.5 to 2 mm, such as 0.8 to 1.5 mm, e.g. about 1 mm, between each side of the plate and each adjacent internal side of the channel.

Optionally, the interior sides of the channel are coated with a lubricant, e.g. to reduce friction between the stabilisation plate and the channel during movement of the plate along the channel.

It will be understood that the threaded rod is a cylindrical threaded rod.

Optionally, the threaded rod has an outer diameter of 20-80 mm, such as 30-50 mm, for example 40-44 mm. Optionally, the threaded rod is an M42 threaded bar.

Optionally, the channel has an internal diameter at least two times, optionally at least three times, such as at least four times the outer diameter of the threaded rod. Thus, the stabilisation plate optionally extends out from the threaded rod by a distance at least equal to, such as 1.5 times, for example two times, the diameter of the threaded rod. In other words, the stabilisation plate has a minimum diameter at least two times, such as at least three times, for example at least four times, the outer diameter of the threaded rod. It will be understood that diameter of the stabilisation plate is measured in a direction perpendicular to the longitudinal axis of the threaded rod when the stabilisation plate is rigidly fastened to the rod. Additionally or alternatively, the threaded rod has an outer diameter of 20-80 mm and the stabilisation plate has a minimum diameter of 80-400 mm, for example wherein the threaded rod has an outer diameter of 30-50 mm and the stabilisation plate has a minimum diameter of 100-300 mm, such as wherein the threaded rod has an outer diameter of 40-44 mm and the stabilisation plate has a minimum diameter of 180-220 mm. It may be that when the diameter of the stabilisation plate is significantly larger than the diameter of the threaded rod, the stabilising action of the stabilising plate is especially effective.

Optionally, the base section comprises a base plate upon which the upstanding support structure is mounted. A base plate may help to spread load -8 -across a wider area of underlying surface, such as ground surface. Optionally, the base plate comprises a bottom opening communicating with the channel of the base section, wherein the bottom opening is sized and shaped to allow passage of the screw stabilisation plate of the screw assembly therethrough, optionally wherein the bottom opening has a cross-sectional size and shape matching the cross-sectional size and shape of the channel. Such a bottom opening conveniently allows the stabilisation plate to be inserted into the channel during assembly of the support. Preferably, the base plate has a cross-sectional area greater than that of the load support plate. Optionally, the base plate has a cross-sectional area 3-6 times the cross-sectional area of the load support plate, for example about four times the cross-sectional area of the load support plate. It will be understood that the cross-sectional areas of the load support plate and the base plate are measured in the plane perpendicular to the longitudinal axis of the threaded rod.

Optionally, the screw assembly comprises a lower end nut threaded onto the bottom end of the threaded bar, wherein the stabilisation plate is rigidly fastened to the lower end nut and the lower end nut is rigidly fastened to the lower end of the threaded rod. It may be that a lower end nut provides a convenient surface for attachment of the stabilisation plate. Optionally, the lower end nut is welded to the threaded rod and to the stabilisation plate. It may be that such weld connections provide an especially rigid and robust fastening. Alternatively, no lower end nut is present. It may be that having no lower end nut increases the adjustable height of the support because it allows the stabilisation plate to travel along the whole length of the channel, for example allowing the threaded bar to travel upwards until the stabilisation plate is brought into contact with the underside of the top plate.

Optionally, the screw assembly comprises an upper end nut threaded onto the upper end of the threaded rod, wherein the load support plate is rigidly fastened to the upper end nut and the upper end nut is rigidly fastened to the upper end of the threaded rod. It may be that an upper end nut provides a convenient surface for attachment of the load support plate. Optionally the upper end nut is welded to the threaded rod and to the load support plate. Typically, the vertical range of the -9 -building support is equal to the length of the channel of the base section less the thickness of the stabilisation plate, and the height of the lower end nut if present. Optionally, the base section, including the top plate, the upstanding support, and the base plate if present, and the screw assembly, including the threaded rod, the load support plate, the stabilisation plate, the height adjustment nut and washer, and the upper and lower end nuts if present, are fabricated from steel. Steel components provide an especially strong and robust building support system. Optionally, components of the base section including the top plate, the upstanding support, and the base plate if present, are welded together. Optionally, the upstanding support, the top plate, and the base plate if present, of the base section is fabricated from steel sheet having a thickness of 10-60 mm, such as 20 to 40 mm. Optionally, the load support plate and the stabilisation plate are fabricated from steel sheet having a thickness of 10-60 mm, such as 20-40 mm.

Optionally, the building support has a load capacity of at least 8 tonnes, for example at least 10 tonnes. Such a high load capacity allows a relatively small number of supports to be used with even relatively heavy, high-specification buildings, thereby reducing the number of ground contact points required to support the building.

Optionally, the building support comprises an outrigger pad for placement between the base section and a ground surface. Preferably, the base section and the outrigger pad are configured for rigidly fastening together. Optionally, the outrigger pad is rigidly fastened to the base section (for example, the outrigger pad is bolted to the base section), optionally wherein the outrigger pad is rigidly fastened to the base plate if present. The outrigger pad may help spread the load of the support across a larger area. Additionally, the outrigger pad may help increase the area of contact between the ground surface and the building support, thus aiding resistance to horizontal displacement provided by the building support. Optionally, the outrigger pad has a cross-sectional area 20-50 times, such as 30-40 times, the cross-sectional area of the load support plate, for example about 36 times the cross-sectional area of the load support plate. It will be understood that the cross-sectional areas of the load support plate and the outrigger pad are measured in the plane perpendicular to -10 -the longitudinal axis of the threaded rod. Optionally, the building support comprises a grout containment frame sized to surround the periphery of the outrigger pad and configured for attachment to a ground surface. Optionally, the grout containment frame is sized to have a spacing between the periphery of the outrigger pad and the frame of 20 to 500 mm, such as 50 to 200 mm. Preferably, the grout containment frame is configured to contain fluid grout mixture suitable for levelling a ground surface. Preferably, the grout containment frame comprises a plurality of upstanding sides, each side having a lower edge arranged for contact with a ground surface. Preferably, the grout containment frame has a bottom opening having a cross sectional size equal to or larger than the cross-sectional area of the outrigger pad.

Optionally, the outrigger pad comprises at least one window opening positioned to allow a user to check that grout extends between the outrigger pad and the ground surface. Preferably, the base plate of the building support, if present, comprises a corresponding window opening positioned to overlie the window opening of the outrigger pad. Optionally, the building support comprises a plurality of shim spacers for spacing the outrigger pad from an underlying ground surface during installation, thereby forming a void between the lower surface of the outrigger pad and the upper surface of the ground. Preferably, the shim spacers are configured so that the void has a height of from 15 to 150 mm, such as 25 to 100 mm (the void height being the spacing between the ground and the outrigger pad). It will be appreciated that the void may have a variable height across the outrigger pad, and that the range refers to minimum and maximum void height. Preferably, the grout containment frame has a height of at least 150 mm, such as at least 200 mm. In use, the grout containment frame forms a continuous barrier around the periphery of the outrigger pad, and is securable to the ground surface (e.g. by a plurality of bolts optionally held in place by a bonding resin), thereby containing grout inserted (e.g. poured and/or injected) into the void between the outrigger pad and the grout surface for a time sufficient for the grout to harden and provide a level support surface for the building support. Such an arrangement may provide a particularly effective and efficient method of providing localised levelling of the ground surface. In particular, such an arrangement allows the outrigger pad to be used to help form a smooth and level surface on the top of the grout, and helps to ensure intimate contact between the outrigger pad and the ground surface via the grout. Those skilled in the art will understand that grout includes for example self-consolidating concrete (also known as self-compacting concrete). Typically, self-consolidating concrete is a concrete/aggregate mix comprising an additive package such as plasticizers and/or superplasticizers, especially superplasticizers. Superplasticizers are synthetic polymers. Any suitable grout may be used.

Optionally, the building support has a vertical range of 30-100 mm, such as 40-80 mm, for example 50-60 mm. The vertical range is the difference between the height of the load support plate in its highest position (maximum extension) and its height in its lowest position (maximum retraction). Accordingly, the building support is preferably a levelling support that provides modest height adjustment to fine-tune module positioning and support, and not to allow for large variations in height above ground.

According to a second aspect, also provided is a method of manufacturing an adjustable height support according to the first aspect of the invention. The method comprises assembling the base section, optionally by welding together a plurality of steel components to define the support structure and thus the channel and the top plate. The top opening in the top plate may for example be drilled before or after the top plate and support structure are secured together. Optionally, the method comprises rigidly fastening the stabilisation plate to the lower end of the threaded rod, passing the upper end of the threaded rod upwards through the opening in the top plate, mounting the washer on the threaded bar and threading the height adjustment nut onto the threaded bar, and rigidly fastening the load support plate to the upper end of the threaded rod. Alternatively, the method comprises rigidly fastening the load support plate to the upper end of the threaded rod, threading the height adjustment nut onto the threaded bar and mounting the washer on the threaded bar, passing the lower end of the threaded rod downwards through the opening in the top plate, and, rigidly fastening the stabilisation plate to the lower end of the threaded rod. Optionally, the components of the building support are permanently fastened together. Optionally, the step of rigidly fastening the -12 -stabilisation plate to the lower end of the rod comprises threading a lower end nut onto the lower end of the rod, and rigidly fastening the stabilisation plate to the lower end nut and rigidly fastening the lower end nut to the lower end of the threaded rod. Optionally, the step of rigidly fastening the load support plate to the upper end of the rod comprises threading an upper end nut onto the upper end of the rod, and rigidly fastening the load support plate to the upper end nut and rigidly fastening the upper end nut to the upper end of the threaded rod. Preferably, each rigid fastening is formed by welding.

According to a third aspect of the invention, also provided is a modular building system comprising at least three cuboid building modules supported above a surface (such as the ground, an underlying framework, or another building, preferably the surface is the ground surface) on at least eight independent adjustable height supports. Each building module comprises a rigid four-sided floor portion, a rigid four-sided ceiling portion, and at least four vertical support pillars supporting the ceiling portion above the floor portion to define an internal volume of 60-400 m3, such as 80-300 m3, for example 100-200 m3. Each floor portion comprises: a first floor side beam extending along a first side of the floor portion, a second floor side beam extending along a second opposite side, and a plurality of parallel spaced apart floor cross beams, each cross beam extending from the first floor side beam to the second floor side beam, wherein the plurality of floor cross beams comprises a first floor cross beam extending along a third side of the floor portion and a second floor cross beam extending along a fourth opposite side. Each ceiling portion comprises: a first ceiling side beam extending along a first side of the ceiling portion, a second ceiling side beam extending along a second opposite side, and a plurality of parallel spaced apart ceiling cross beams, each cross beam extending from the first ceiling side beam to the second ceiling side beam, wherein the plurality of ceiling cross beams comprises a first ceiling cross beam extending along a third side of the ceiling portion and a second ceiling cross beam extending along a fourth opposite side. Optionally, the at least four vertical support pillars include at least two first side support pillars fastened to the first floor side beam and to the first ceiling side beam, and at least two second side support pillars fastened to -13 -the second floor side beam and to the second ceiling side beam. The first floor side beam of each building module is securely fastened to a floor side beam of an adjacent building module by at least two independent load-bearing fastenings, and the first ceiling side beam of each building module is securely fastened to a ceiling side beam of an adjacent building module by at least two independent load-bearing fastenings, wherein the load-bearing fastenings are sized and configured so that each building module is capable of fully suspending an adjacent building module above the underlying surface. Each adjustable height support is fastened to a floor side beam or a floor cross beam, and fastened to the underlying surface, wherein each beam so fastened to an adjustable height support has a first supported length and a second unsupported length, the first supported length being the sum length of the beam in contact with an adjustable height support and the second unsupported length being the remaining length of the beam. The second unsupported length is at least 5 times, such as at least 10 times, for example at least 20 times, the first supported length. The adjustable height supports and at least the floor side beams of each module are configured so that the adjustable height supports are positionable at any location along at least 80%, for example at least 90%, such as at least 95%, of the length of each beam. Each of the aforementioned fastenings is a rigid fastening.

It will be understood that the supported length of a beam is a measure of the total length of the beam that rests on a support, while the unsupported length is the remaining length of a beam. While a beam may in effect be supported by attachment to an adjacent beam, such attachment is not taken into account when determining the supported/unsupported length. The supported length is only the sum length of the beam in direct contact with an adjustable height support. Further, it will be appreciated that supported length + unsupported length = total length.

Having a long unsupported length reduces the ground area used in supporting the building, since it is generally the case that the longer the unsupported length the larger the gap(s) between building supports.

It will be understood that a load-bearing fastening is a fastening sized and configured to have load bearing capacity. More particularly, load bearing fastenings are fastenings sized and configured so that together the plurality of fastenings are -14 -capable of supporting the full design load of the building module. Unless otherwise stated, 'design load' includes design dead load and design live load. Preferably, the fastenings along two opposed sides of a module are sized and configured to together be capable of supporting the full weight of the module. Optionally, the fastenings along one side of a module are sized and configured to together be capable of supporting the full weight of the module. Having such fastenings can allow the building to behave as a monolithic structure, resistant to internal movement and/or distortion should one or more modules be or become unsupported other than by its fastenings to one or more adjacent modules. Accordingly, the load bearing fastenings provide high flexibility in locating building supports.

It will be understood that having a building support positionable at any location along at least 80% of a beam means that the support can be attached to the beam at any point along that proportion of the beam's length, and still provide appropriate support for the beam and thus the building. For example, the beam may present a continuous planar surface to which the support can be attached.

Furthermore, the beam may have a strength and thickness that allows it to be supported at unevenly distributed points along its length. Such an arrangement provides yet further flexibility in building support location.

The arrangements of side and cross beams in the floor and ceiling portions provide especially rigid floor and ceiling structures, which help allow any module to support at least part of the weight of an adjacent module and/or to be at least partially supported by an adjacent module while reducing or eliminating distortion of module structure. Optionally, the cross beams are spaced apart by a distance of no more than 600 mm, for example no more than 500 mm.

Optionally, each building module has a length of 5-30 m, such as 8-20 m, for example 10-14 m. Optionally, each building module has a width of 1.5-10 m, such as 2-7 m, for example 2.5-5 m. Optionally, each building module has a height of 1.5-5 m, such as 2-4 m, for example 2.5-3.5 m.

Optionally a first building module of the at least three building modules is supported by x adjustable height supports and a second building module of the at least three building modules is supported by y adjustable height supports, where x is -15 -greater than y. Optionally, x is at least double y. Optionally, y = 0. Additionally or alternatively, the at least three building modules are entirely supported by n adjustable height supports, wherein at least one module is supported only by m adjustable height supports, and at least one module is supported only by p adjustable height supports, wherein m < n/z < p, where z is the total number of building modules. Optionally, m = 0. Accordingly, at least one building module is the first building module at least partially supports at least one of the other building modules. Optionally, n is 4z to 16z, such as 6z to 12z, for example 8z to 10z, where z is the total number of building modules.

Optionally, at least one of the at least three building modules is at least partially suspended from an adjacent building module by the load bearing fastenings attaching said module to the adjacent module. Optionally, at least one of the at least three building modules is entirely suspended from at least one adjacent building module by the load bearing fastenings attaching said module to the adjacent module.

Optionally, the floor side beams and ceiling side beams of each building module are each formed from a universal beam having a horizontal lower flange, a horizontal upper flange and a vertical web extending from the lower flange to the upper flange. Optionally, the vertical support posts are attached to the upper flanges of the floor side beams and to the lower flanges of the ceiling side beams.

Optionally, the load-bearing fastenings between building modules include a bracing plate assembly comprising a brace plate spanning a flange of a side beam of a first module and the adjoining side beam of the adjacent module, the bracing plate being secured to each flange by at least two bolts extending through the bracing plate and said flange. Additionally or alternatively, the load-bearing between building modules include a toe plate assembly comprising: a first toe plate welded to the upper and lower flanges at the outer edges of a side beam of a first module, a second toe plate welded to the upper and lower flanges at the outer edges of a side beam of the adjacent module, and a plurality of bolts, each bolt extending through the web of said beam of the first module, the first toe plate, the second toe plate and the web of said beam of the adjacent module. Such fastenings have been found to be -16 -especially effective. Preferably, at least the load-bearing fastening arrangements between the ceiling side beams of adjacent modules are toe plate assemblies, optionally wherein the load-bearing fastening arrangements between the ceiling beams of adjacent modules and the floor side beams of adjacent modules are toe plate assemblies. As compared to fastenings made up only of bolts extending through the webs of adjacent universal beams, the toe plate assembly improves rigidity of the fastening, and helps to reduce or eliminate shearing movement of one module relative to an adjacent module.

Optionally, each floor portion comprises a floor covering, each ceiling portion comprises a ceiling covering, and/or at least a portion of at least two sides comprise a wall covering. Preferably, at least a portion of at least one side of each module is open to provide personnel access between modules when the modules are assembled.

Optionally, the floor side beams and the ceiling side beams have a maximum vertical deflection of beam span/900, such as beam span/1000. Optionally, the floor side beams and the ceiling side beams have a maximum horizontal deflection of beam span/750, such as beam span/850. Such low deflections helps to avoid distortion of floor and ceiling portions.

Optionally, the building system is configured to withstand horizontal force of at least 2 kN per module under a dead load of 20 kN per module, optionally a horizontal force of 2-8 kN per module under a dead load of 20 kN per module. For example, resistance to horizontal force may be enhanced by rigid connections between the building modules and the building supports, and between the building supports and the ground.

Optionally, the floor portion has a loading capacity of at least 5 kN/m2, optionally wherein the floor portion has a localised loading capacity of at least 7.5 kN/m2, optionally wherein the floor portion has a maximum vertical load of at least 180 kN. Such high load capacities have been found to increase floor rigidity, allowing adjacent modules to more effectively support each other.

-17 -Preferably, the adjustable height supports are supports according to the first aspect of the invention, or supports made according to the method of the second aspect of the invention.

According to a fourth aspect of the invention, there is provided a modular building constructed from the modular building system of the third aspect of the invention.

According to a fifth aspect of the invention, there is provided a kit of parts for forming the adjustable height support of the first aspect of the invention, wherein the kit of parts comprises the base section, the screw assembly and the outrigger pad of the first aspect of the invention. Optionally, the base section is rigidly fastened to the outrigger pad. Optionally, the kit of parts additionally comprises a grout containment frame, and optionally a plurality of fixings for securing the grout containment frame to a ground surface. Optionally, the kit of parts comprises the shim spacers.

According to a sixth aspect of the invention, there is provided a method of constructing a support for a building, wherein the method comprises: providing a kit of parts according to the fifth aspect of the invention, placing a plurality of shim spacers on a ground surface, resting the outrigger pad of a building support on the shim spacers, wherein the shim spacers are arranged under the outrigger pad so that the outrigger pad is stable and level and spaced apart from the ground surface by a void, securing to the grout surface a grout containment frame around the periphery of the outrigger to a ground surface, inserting (e.g. pouring and/or injecting) grout into the void, allowing the grout to set, and optionally adjusting the height of the building support. It will be appreciated that the step of securing the grout containment frame to the ground surface may be performed before or after the step of resting the outrigger pad on the shim spacers. Optionally, the method comprises positioning the shim spacers so that the void has a height of from 15 to 150 mm, such as 25 to 100 mm. For example, the shim spacers may be positioned so that the void has a minimum height of 15 mm or 25 mm, and a maximum height of 150 or 100 mm. it will be appreciated that the height of the void may vary across the cross-sectional area of the outrigger pad. Optionally, the step of inserting grout may -18 -comprise using a window opening to check that grout has filled the void, for example by performing a visual check.

According to a seventh aspect of the invention, there is provided a method of constructing a modular building at a building location, the modular building having a design dead load and comprising at least three cuboid building modules supported on at least eight independent adjustable height supports, the method comprising: (1) specifying an initial building support layout in which locations of the at least eight adjustable height building supports are chosen based on a design dead load distribution in the modular building, (2) identifying existing services at the building location to map permitted support locations and forbidden support locations, (3) determining which of the at least eight adjustable height building supports are located in a forbidden support location when located according to the initial building support layout (4) determining a revised building support layout in which at least two of the adjustable height building supports are re-located so that all of the at least eight adjustable height building supports are located in a permitted support location, and, (5) assembling the modular building using the modular building system of the first aspect of the invention. Optionally, in step (1), the locations of the at least eight adjustable height building supports are chosen to evenly distribute the design dead load of each module across its respective supports, for example to evenly distribute the design dead load of the entire building across the at least eight adjustable height building supports. Additionally or alternatively, the locations are chosen to minimise the number of adjustable height building supports.

It will be understood that existing services include, for example, cables, ducts, pipes and conduits. Non-limiting examples include telecommunication and/or electrical services (e.g. cables and/or conduits), fluid services such as water supply and/or drainage and/or gas supply (e.g. pipes).

Optionally, the step of determining a revised building support layout comprises moving at least two building supports a distance of at least 1 m from an initial position to a revised position, optionally wherein at least four building supports are so moved. Optionally, the method comprises adding at least one, such as a plurality of, additional adjustable height building supports, wherein each -19 -additional adjustable height building support is located in a permitted support location. Optionally, the step of determining a revised building support layout comprises moving at least one support, such as at least two supports, from an initial position in which said support is positioned for attachment to a first module to a revised position in which said support is positioned for attachment to a second module different to the first module. Thus, in the revised support layout, the supports may be arranged so at least a first building module is supported by at least one fewer building support than supported said first module in the initial layout, and at least a second building module is supported by at least one more building support than supported said second module in the initial layout.

It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa.

Description of the Drawings

Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which: Figure 1 shows a perspective view of an adjustable height support according to a first embodiment of the invention; Figure lb shows an enlarged view of part of the support of Figure la; Figure lc shows another perspective view of the support of Figure la; Figure id shows a top plan view of the support 101 of Figure la; Figure 2a shows a side view of the support of Figure la additionally comprising an outrigger pad; Figure 2b shows an enlarged view of part of the support as shown in Figure 2a; Figure 3a shows a perspective view of the frames of thirteen modules making up a modular building structure framework; -20 -Figure 3b shows an enlarged view of part of the building structure framework of Figure 3a; Figure 4 shows a side view of a module frame of the building structure framework of Figure 3a; Figure 5 shows a perspective view of a section of the bottom of the module frame of Figure 4; Figure 6 shows a perspective view of another section of the bottom of the module frame of Figure 4; Figure 7a shows a cut-away perspective view of a toe plate assembly used to fasten together ceiling portion side beams of adjacent modules in the building structure framework of Figure 3a; Figure 7b shows a cross-sectional view of the toe plate assembly of Figure 7a; Figure 7c shows another a cut-away perspective view of a toe plate assembly similar to that shown in Figure 7a; Figure 8a shows a cut-away perspective view of a toe plate assembly used to fasten together floor portion side beams of adjacent modules in the building structure framework of Figure 3a; Figure 8b shows a cross-sectional view of the toe plate assembly of Figure 8a; Figure Sc shows another a cut-away perspective view of a toe plate assembly similar to that shown in Figure 8a; Figure 9 shows a perspective view of a bracing plate assembly used to fasten together floor portion side beams of adjacent modules in the building structure framework of Figure 3; Figure 10a shows a perspective view of an adjustable height support according to another embodiment of the invention; Figure 10b shows a perspective view of the adjustable height support of Figure 10a additionally comprising an outrigger pad; Figure 10c shows a side cross-sectional view of the adjustable height support of Figures 10a and 10b positioned on a ground surface; and, Figures 11a and 11b show plan views of a modular building having supports positioned in initial and revised layouts.

-21 -

Detailed Description

Figure la shows a perspective view of an adjustable height support 101 according to a first embodiment of the invention. The support 101 comprises a base section 102 having a top plate mounted on an upstanding support structure 104, which is mounted on a base plate 105. Attached to the base section 102 is a screw assembly 106 having a central threaded rod 107 (shown in dashed lines in Figure la as it is hidden from normal view by other components of the screw assembly 106 and the base section 102). A load support plate 108 is welded to an upper end nut 109, which is welded to the upper end of the threaded rod 107. A stabilising plate is welded to a lower end nut 111, which is welded to the lower end of the threaded rod. The stabilisation plate 110 and the lower end nut 111 are shown in dashed lines because they are hidden from normal view inside the base section 102. The stabilising plate has a square shape, and sits snugly inside a channel having a square cross-sectional shape that extends through the base section 102. For the sake of clarity, the sides of the channel are not represented in Figure la. The spacing between each side of the stabilisation plate 110 and the inner sides of the channel is 1 mm. The base plate 105 has an opening of the same cross-sectional size as the channel, thereby allowing passage of the stabilisation plate 110 during assembly of the support 101. Threaded onto the rod 107 above the top plate 103 is a height adjustment nut 112, which is separated from the top plate 103 by a washer 113. The height adjustment nut and the washer together transfer load from the screw assembly 106 to the base section 102. Rotation of the height adjustment nut 112 either pulls the rod 107 upwards, or allows it to move downwards. The rod 107 passes through a circular opening in the top plate 103 (not shown in Figure la). The inner diameter of the opening is 1 mm greater than the outer diameter of the threaded rod 107. The support 101 has a load capacity of about 11 tonnes. The rod 107 is an M42 threaded rod. The load support plate 108 has a 200 mm x 200 mm upper support surface. The base plate 105 has a 400 mm x 400 mm lower support surface. The maximum vertical range of the building support 101 is 50 mm. The base plate 105 comprises four through-holes 120 (three through-holes 120 are visible in -22 -Figure la) for bolting the base plate 105 to an outrigger pad (not shown in Figure la. The base plate also comprises two window openings 130 (one window opening 130 is visible in Figure la) positioned to overlie corresponding window openings in the outrigger pad.

Figure lb shows an enlarged view of part of the support 101 of Figure la, showing the arrangement of the stabilisation plate 110, rod 107 and lower end nut 111 inside the supporting structure 104 of the base section 102.

Figure lc shows another perspective view of the support 101 of Figure la, with part of the supporting structure 104 omitted to more clearly show the arrangement of the stabilisation plate 110, rod 107 and lower end nut 111 inside the supporting structure 104 of the base section 102. The bottom hole 114 in the base plate 105 is also visible in Figure lc.

Figure ld shows a top plan view of the support 101 of Figure la, and is labelled with the same reference numerals as used in Figures la-c.

Figure 2a shows a side view of the support 101 of Figure la additionally comprising an outrigger pad 201 under the base plate 105. Not shown in Figure 2a are window openings that align with the window openings of the base plate to provide continuous openings extending from the top of the base plate 105 to the bottom of the outrigger pad.

Figure 2b shows an enlarged view of part of the support 101 as shown in Figure 2a, showing the arrangement of the stabilisation plate 110, rod 107 and lower end nut 111 inside the supporting structure 104 of the base section 102.

Figure 3a shows a perspective view of the frames of thirteen modules 301a-m making up a modular building structure framework 302. Floor, ceiling and wall coverings are omitted for clarity. Each module sits on eight supports 101 of the type shown in Figure 2a. In Figure 3a, the supports are shown in idealised positions. When deployed, the supports can be repositioned to take account of positions of existing services.

Figure 3b shows an enlarged view of part of the building structure framework 302 of Figure 3a. Shown in Figure 3b is the framework of module 301a, having a ceiling portion 303 supported above a floor portion 304 by six vertical support pillars -23 - 305. The ceiling portion 303 is made up of first and second side beams 306 and cross beams 807. The floor portion 304 is made up of first and second side beams 308 and cross beams 309.

Figure 4 shows a side view of module frame 301a of the building structure framework 302 of Figure 3a, labelled with the same reference numerals used in Figures 3a and 3b.

Figure 5 shows a perspective view of a section of the bottom of module frame 301a of Figure 4, labelled with the same reference numerals used in Figure 4. Figure 6 shows a perspective view of another section of the bottom of module frame 301a of Figure 4, labelled with the same reference numerals used in Figure 4.

Figure 7a shows a cut-away perspective view of a toe plate assembly used to fasten together ceiling portion side beams of adjacent modules in the building structure framework 302 of Figure 3a. Ceiling side beams 306 are each universal beams having an upper flange 701 and a lower flange 702 joined by a web 703.

Welded to the outer edges of each beam 306 is a toe plate 704. Through-bolts 705 extend through each web 703 and the toe plates 704.

Figure 7b shows a cross-sectional view of the toe plate assembly of Figure 7a, labelled with the same reference numerals as in Figure 7a.

Figure 7c shows another a cut-away perspective view of a toe plate assembly similar to that shown in Figure 7a, labelled with the same reference numerals as in Figure 7a.

Figure 8a shows a cut-away perspective view of a toe plate assembly used to fasten together floor portion side beams of adjacent modules in the building structure framework 302 of Figure 3a. Floor side beams 308 are each universal beams having an upper flange 801 and a lower flange 802 joined by a web 803. Welded to the outer edges of each beam 308 is a toe plate 804. Through-bolts 805 extend through each web 803 and the toe plates 804.

Figure 8b shows a cross-sectional view of the toe plate assembly of Figure 8a, labelled with the same reference numerals as in Figure 8a.

-24 -Figure 8c shows another a cut-away perspective view of a toe plate assembly similar to that shown in Figure 8a, labelled with the same reference numerals as in Figure 8a.

Figure 9 shows a perspective view of a bracing plate assembly used to fasten together floor portion side beams of adjacent modules in the building structure framework 302 of Figure 3. Floor side beams 308 are each universal beams having an upper flange (not visible in Figure 9) and a lower flange 902 joined by a web 903. A bracing plate 910 spans the lower flanges 902 of the beams 308. Through-bolts 905 extend through the bracing plate 910 and each lower flange 902.

Figure 10a shows a perspective view of an adjustable height support 1010 according to another embodiment of the invention. The adjustable height support 1010 is substantially identical to the adjustable height support 101 of Figure la, except that there is no lower end nut, and the stabilising plate 1100 is welded directly to the threaded rod 1070.

Figure 10b shows a perspective view of the adjustable height support 1010 of Figure 10a additionally comprising an outrigger pad 2010. The base plate 1050 of the adjustable height support 1010 is bolted to the outrigger pad 2010 by bolts 1500 extending through through-holes 1200. Also visible in Figure 10b is the top of a window opening 1300 that extends through the base plate 1050 and the outrigger pad 2010.

Figure 10c shows a side cross-sectional view of the adjustable height support 1010 of Figures 10a and 10b positioned on a ground surface 901. A grout containment frame 902 extends around the periphery of the outrigger pad 2010 (only two of the sides of the frame are visible in Figure 10c, which frame 902 forms a continuous barrier around all sides of outrigger pad 2010. The grout containment frame 902 is secured to the ground surface 901 by bolts held in place by resin (not shown in Figure 10c), and optionally a resin sealing layer is positioned between the frame 902 and the ground 901 to provide a grout-proof seal. The outrigger pad 2010 is spaced apart from the ground surface 901 by a plurality of shim spacers 902, defining a void 904 having a height of 75mm. In Figure 10c, the void has a constant height, but it will be appreciated that the ground surface 901 may not be level or -25 -even, in which case void height would vary across the cross-sectional surface of the outrigger pad 2010.

Figure 11a shows a plan view of a modular building 3001 comprising three cuboid building modules 3002a, 3002b, 3002c supported on twenty four independent adjustable height supports 3003. In Figure 11a, the supports 3003 are shown in their initial building support layout, chosen to evenly distribute the design dead load of the building across the supports 3003. A review of the installation location has identified multiple pre-existing services, the positions of which have been used to map permitted support locations and forbidden support locations.

Supports 3003b are all positioned in forbidden support locations.

Figure 11b shows a plan view of the modular building 3001 of Figure 11a with the supports 3003 located in a revised building support layout (the locations of all supports 3003b previously positioned in forbidden support locations have been changed). Supports 3003b on module 3002a have been moved to new positions 3003c on the same module 3002a. Support 3003b on module 3002b has been moved to a new position 3003d on adjacent module 3002a. Support 3003b on module 3002c has been moved to a new position 3003c on the same module 3002c and an additional support has been provided at position 3003e on that module 3002c.

Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein.

Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or -26 -features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.

Claims (28)

1. -27 -Claims 1. An adjustable height support for a building comprising a base section and a screw assembly, the base section receiving and supporting the screw assembly; wherein the base section comprises a top plate mounted on top of an upstanding support structure, wherein the support structure defines an elongate straight channel extending downwards from the top plate, the channel having a constant internal cross-sectional size and shape along its length axis, wherein the cross-sectional shape of the channel is non-circular, and wherein the plate comprises a top opening communicating with one end of the channel, the top opening being smaller in size than the internal cross-sectional size of the channel; wherein the screw assembly comprises: a threaded rod extending through the top opening of the top plate of the base section, wherein an upper end of the rod is disposed above the top plate and a lower end of the rod is disposed below the top plate, a load support plate rigidly secured to the upper end of the threaded rod, a stabilisation plate rigidly secured to the lower end of the threaded rod, and a height adjustment nut threaded onto the threaded rod above the top plate of the base section, wherein the nut is configured to transfer load from the screw assembly to the base section and so that rotation of the height adjustment nut about the threaded rod allows the threaded rod to traverse through the top opening of the base section thereby moving the load support plate of the screw assembly towards or away from the top plate of the base section; -28 -wherein, the stabilisation plate of the screw assembly is slidably received in the channel of the base section and is sized and shaped to cooperate with the channel so that the stabilisation plate is able to move freely along the length axis of the channel and 1) lateral movement of the stabilisation plate in all directions perpendicular to the length axis of the channel and 2) rotation of the stabilisation plate about the length axis of the channel are inhibited; and wherein the top opening of the top plate of the base section is sized to cooperate with the threaded rod so that the threaded is able to move freely through the top opening and lateral movement of the threaded rod in all directions perpendicular to the length axis of the channel is inhibited.
2. 2. The adjustable height support of claim 1, wherein: the threaded rod has a cylindrical shape and the top opening has a circular shape, wherein the top opening has an inner diameter 0.5 to 2 mm larger than the outer diameter of the threaded rod, and the stabilisation plate is sized to provide a spacing of 0.5 to 2 mm between the stabilisation plate and each side of the channel of the base section; optionally wherein the cross-sectional shape of the channel of the base section is quadrilateral, optionally rectangular, such as square.
3. 3. The adjustable height support of claim 1, wherein the channel has an internal diameter at least two times, optionally at least three times, such as at least four times the outer diameter of the threaded rod.
4. 4. The adjustable height support of any preceding claim, wherein the base section comprises a base plate upon which the upstanding support structure is mounted, optionally wherein the base plate comprises a bottom opening communicating with the channel of the base section, wherein the bottom -29 -opening is sized and shaped to allow passage of the screw stabilisation plate of the screw assembly therethrough, optionally wherein the bottom opening has a cross-sectional size and shape matching the cross-sectional size and shape of the channel.
5. The adjustable height support of any preceding claim, wherein the screw assembly comprises a lower end nut threaded onto the bottom end of the threaded bar, and wherein the stabilisation plate is rigidly fastened to the lower end nut and the lower end nut is rigidly fastened to the lower end of the threaded rod, optionally wherein the lower end nut is welded to the threaded rod and to the stabilisation plate.
6. 6. The adjustable height support of any preceding claim, wherein the screw assembly comprises an upper end nut threaded onto the upper end of the threaded rod, and wherein the load support plate is rigidly fastened to the upper end nut and the upper end nut is rigidly fastened to the upper end of the threaded rod, optionally wherein the upper end nut is welded to the threaded rod and to the load support plate.
7. 7. The adjustable height support of any preceding claim, wherein the base section, including the top plate, the upstanding support, and the base plate if present, and the screw assembly, including the threaded rod, the load support plate, the stabilisation plate, the height adjustment nut and washer, and the upper and lower end nuts if present, are fabricated from steel, wherein components of the base section including the top plate, the upstanding support, and the base plate if present, are welded together.
8. 8. The adjustable height support of any preceding claim having a load capacity of at least 8 tonnes, for example at least 10 tonnes.
9. 9. The adjustable height support of any preceding claim, comprising an outrigger pad rigidly fastened to the base section, wherein the outrigger pad -30 -footing plate has a cross-sectional area 20-S0 times, such as 30-40 times, the cross-sectional area of the load support plate.
10. 10. The adjustable height support of claim 9, comprising a grout containment frame sized to surround the periphery of the outrigger pad, and a plurality of shim spacers for spacing the outrigger pad from an underlying ground surface by 15 to 150 mm, wherein the grout containment frame is configured for attachment to a ground surface and to contain a fluid grout mixture filling the space between the ground surface and the outrigger pad.
11. 11. A method of manufacturing an adjustable height support according to any one of claims 1-10, the method comprising: assembling the base section, and, either: rigidly fastening the stabilisation plate to the lower end of the threaded rod, passing the upper end of the threaded rod upwards through the opening in the top plate, mounting the washer on the threaded bar and threading the height adjustment nut onto the threaded bar, and rigidly fastening the load support plate to the upper end of the threaded rod, or: rigidly fastening the load support plate to the upper end of the threaded rod, threading the height adjustment nut onto the threaded bar and mounting the washer on the threaded bar, passing the lower end of the threaded rod downwards through the opening in the top plate, and, rigidly fastening the stabilisation plate to the lower end of the threaded rod.
12. 12. A modular building system comprising at least three cuboid building modules supported above a surface on at least eight independent adjustable height supports, -31 -wherein, each building module comprises a rigid four-sided floor portion, a rigid four-sided ceiling portion, and at least four vertical support pillars supporting the ceiling portion above the floor portion to define an internal volume; wherein, each floor portion comprises: a first floor side beam extending along a first side of the floor portion, a second floor side beam extending along a second opposite side, and a plurality of parallel spaced apart floor cross beams, each cross beam extending from the first floor side beam to the second floor side beam, wherein the plurality of floor cross beams comprises a first floor cross beam extending along a third side of the floor portion and a second floor cross beam extending along a fourth opposite side; wherein each ceiling portion comprises: a first ceiling side beam extending along a first side of the ceiling portion, a second ceiling side beam extending along a second opposite side, and a plurality of parallel spaced apart ceiling cross beams, each cross beam extending from the first ceiling side beam to the second ceiling side beam, wherein the plurality of ceiling cross beams comprises a first ceiling cross beam extending along a third side of the ceiling portion and a second ceiling cross beam extending along a fourth opposite side; optionally, the at least four vertical support pillars include at least two first side support pillars fastened to the first floor side beam and to the first ceiling side beam, and at least two second side support pillars fastened to the second floor side beam and to the second ceiling side beam; wherein the first floor side beam of each building module is securely fastened to a floor side beam of an adjacent building module by at least two independent load-bearing fastenings, and the first ceiling side beam of each building module is securely fastened to a ceiling side beam of an adjacent building module by at least two independent load-bearing fastenings, wherein the load-bearing fastenings are sized and configured so that each building module is capable of fully suspending an adjacent building module above the surface; -32 -wherein each adjustable height support is fastened to a floor side beam or a floor cross beam, wherein each beam so fastened to an adjustable height support has a first supported length and a second unsupported length, the first supported length being the sum length of the beam in contact with an adjustable height support and the second unsupported length being the remaining length of the beam, wherein the second unsupported length is at least 5 times the first supported length; and wherein the adjustable height supports and at least the floor side beams of each module are configured so that the adjustable height support are positionable at any location along at least 80% of the length of each beam.
13. 13. The modular building system of claim 12, the at least three building modules are entirely supported by n adjustable height supports, wherein at least one module is supported only by m adjustable height supports, and at least one module is supported only by p adjustable height supports, wherein m < n/z < p, where z is the total number of building modules, optionally wherein m = 0.
14. 14. The modular building system of claim 12 or claim 13, wherein at least one of the at least three building modules is at least partially suspended from an adjacent building module by the load bearing fastenings attaching said module to the adjacent module, optionally wherein at least one of the at least three building modules is entirely suspended from at least one adjacent building module by the load bearing fastenings attaching said module to the adjacent module.
15. 15. The modular building system of any one of claims 12-14, wherein the floor side beams and ceiling side beams of each building module are each formed from a universal beam having a horizontal lower flange, a horizontal upper flange and a vertical web extending from the lower flange to the upper flange, optionally wherein the vertical support posts are attached to the -33 -upper flanges of the floor side beams and to the lower flanges of the ceiling side beams; wherein, the load-bearing fastenings between building modules include at least one of the following fastening arrangements: 1) a bracing plate assembly comprising a brace plate spanning a flange of a side beam of a first module and the adjoining side beam of the adjacent module, the bracing plate being secured to each flange by at least two bolts extending through the bracing plate and said flange; and 2) a toe plate assembly comprising: a first toe plate welded to the upper and lower flanges at the outer edges of a side beam of a first module, a second toe plate welded to the upper and lower flanges at the outer edges of a side beam of the adjacent module, and a plurality of bolts, each bolt extending through the web of said beam of the first module, the first toe plate, the second toe plate and the web of said beam of the adjacent module.
16. 16. The modular building system of claim 15, wherein at least the fastening arrangements between the ceiling side beams of adjacent modules are toe plate assemblies, optionally wherein the fastening arrangements between the ceiling beams of adjacent modules and the floor side beams of adjacent modules are toe plate assemblies.
17. 17. The modular building system of any one of any one of claims 12-16, wherein the floor side beams and the ceiling side beams have a maximum vertical deflection of beam span/900, such as beam span/1000.
18. 18. The modular building system of any one of claims 12-17, wherein the floor side beams and the ceiling side beams have a maximum horizontal deflection of beam span/750, such as beam span/850.
19. 19. The modular building system of any one of claims 12-18, wherein the building system is configured to withstand horizontal force of at least 2 kN under a -34 -deadload of 20 kN when, optionally a horizontal force of 2-8 kN under a deadload of 20 kN.
20. 20. The modular building system of any one of claims 12-19, wherein the floor portion has a loading capacity of at least 5 kN/m2, optionally wherein the floor portion has a localised loading capacity of at least 7.5 kN/m2, optionally wherein the floor portion has a maximum vertical load of at least 180 kN.
21. 21. The modular building system of any one of claims 12 to 20, wherein adjustable height supports are according to any one of claims 1-10, or made according to the method of claim 11.
22. 22. A modular building constructed from the modular building system of any one of claims 12-21. 15
23. 23. A kit of parts for forming the adjustable height support of claim 10, wherein the kit of parts comprises the base section, the screw assembly, the outrigger pad, a plurality of shim spacers, the grout containment frame, and a plurality of fixings for securing the grout containment frame to a ground surface, wherein the base section is rigidly fastened to the outrigger pad.
24. 24. A method of constructing a support for a building, wherein the method comprises: providing a kit of parts according to claim 23; placing the plurality of shim spacers on a ground surface; resting the outrigger pad of a building support on the shim spacers, wherein the shim spacers are arranged under the outrigger pad so that the outrigger pad is stable and level and spaced apart from the ground surface by a void having a height of from 15 to 150 mm; securing to the ground surface a grout containment frame around the periphery of the outrigger to a ground surface; inserting grout into the void; and, -35 -allowing the grout to set; and optionally adjusting the height of the building support.
25. 25. A method of constructing a modular building at a building location, the modular building having a design dead load and comprising at least three cuboid building modules supported on at least eight independent adjustable height supports, the method comprising: specifying an initial building support layout in which locations of the at least eight adjustable height building supports are chosen based on a design dead load distribution in the modular building; identifying existing services at the building location and thus identifying permitted support locations and forbidden support locations; determining which of the at least eight adjustable height building supports are located in a forbidden support location when located according to the initial building support layout; determining a revised building support layout in which at least two of the adjustable height building supports are re-located so that all of the at least eight adjustable height building supports are located in a permitted support location; and, assembling the modular building using the modular building system of any one of claims 12-21.
26. 26. The method of constructing a modular building of claim 25, wherein the step of determining a revised building support layout comprises moving at least two building supports a distance of at least 1 m from an initial position to a revised position, optionally wherein at least four building supports are so moved.
27. 27. The method of claim 25 or claim 26, wherein the method comprises adding at least one, such as a plurality of, additional adjustable height building -36 -supports, wherein each additional adjustable height building support is located in a permitted support location.
28. 28. The method of any one of claims 25 to 27, wherein the step of determining a revised building support layout comprises moving at least one support, such as at least two supports, from an initial position in which said support is positioned for attachment to a first module to a revised position in which said support is positioned for attachment to a second module different to the first module.